108821-0202 ZEXEL 9 400 612 188 BOSCH INJECTION-PUMP ASSEMBLY 9400612188 1088210202 16801nd000

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 612 188 9400612188

ZEXEL 108821-0202 1088210202

NISSAN-DIESEL 16801ND000 16801nd000

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Service parts 108821-0202 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 108082-3860

3. GOVERNOR 105960-0320

4. SUPPLY PUMP 105237-5491

5. AUTOM. ADVANCE MECHANIS 105684-0190

6. COUPLING PLATE 105664-2400

7. COUPLING PLATE

8. _ 159640-0720

9. _

10. NOZZLE AND HOLDER ASSY 105110-7910

11. Nozzle and Holder 16600-97175

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/18.6{190}

13. NOZZLE-HOLDER 105041-4280

14. NOZZLE 105025-2740

15. NOZZLE SET 105019-2400

Include in #1:

108821-0202 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 188 9400612188

ZEXEL 108821-0202 1088210202

NISSAN-DIESEL 16801ND000 16801nd000

Zexel num

Bosch num

Firm num

Name

108821-0202

9 400 612 188

16801ND000 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
RG8 K 14CQ INJECTION PUMP ASSY TICS HD-TI8F TICS

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8250

Bosch type code 1 688 901 101

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 20.7

Opening pressure kgf/cm2 211

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600

Overflow valve 134424-4120

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

Tester oil delivery pressure kPa 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

RED4 control unit part number 407915-0 590

RED4 rack sensor specifications mm 19

PS/ACT control unit part no. 407980-2 24*

Digi switch no. 41

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 8-7-5-4- 3-6-2-1

Pre-stroke mm 6.4 6.37 6.43

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 8-7 deg. 45 44.75 45.25

Difference between angles 2
Cal 8-5 deg. 90 89.75 90.25

Difference between angles 3
Cal 8-4 deg. 135 134.75 135.25

Difference between angles 4
Cal 8-3 deg. 180 179.75 180.25

Difference between angles 5
Cal 8-6 deg. 225 224.75 225.25

Difference between angles 6
Cal 8-2 deg. 270 269.75 270.25

Difference between angles 7
Cal 8-1 deg. 315 314.75 315.25

Injection quantity adjustment

Rack position (11.9)

PWM % 55.2

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 126 124 128

Max. variation between cylinders % 0 -4 4

Basic *

PS407980-224* V 2.2+-0.0 1

PS407980-224* mm 4+-0.05

Injection quantity adjustment_02

Rack position (7.7)

PWM % 31.5+-2. 8

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 19 17 21

Max. variation between cylinders % 0 -10 10

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 6.3+-0.0 3

Remarks
Refer to items regarding the pre-stroke actuator

Governor adjustment

Pump speed r/min 750--

Advance angle deg. 0 0 0

Remarks
Start

Governor adjustment_02

Pump speed r/min 700

Advance angle deg. 0.5

Governor adjustment_03

Pump speed r/min 980

Advance angle deg. 3 2.5 3.5

Remarks
Finish

0000001201

Pre-stroke mm 6.4 6.37 6.43

Remarks
When the timing sleeve is pushed up

_02

Connector angle deg. 11.5 11 12

Remarks
When the eccentric pin is tightened

_03

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 2.4 2.35 2.45

Output voltage V 2.95 2.94 2.96

Adjustment *

_04

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 6.4 6.37 6.43

Output voltage V 1.2 1 1.4

Confirmation *

Remarks
Output voltage V1

_05

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Output voltage V 3.05 3.05

Confirmation of operating range *

Test data Ex:

Speed control lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
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aa=20mm bb=1mm
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a=27deg+-5deg b=37deg+-5deg

0000000901

(1)Pump vertical direction (2)Position of the coupling's key groove at the beginning of injection of the No. 8 cylinder. (3)Pre-stroke: aa (4)-
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aa=6.4+-0.03mm
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a=(80deg)

0000001501

A:Sealing position B:Pre-stroke actuator 1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully counterclockwise (viewed from the drive side). Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m) 2. Move the actuator in the clockwise direction when viewed from the drive side, and adjust so that it becomes the adjustment point of the adjustment value. Then tighten it. Tightening torque: 7^9 N.m (0.7^0.9 kgf.m) 3. After prestroke actuator installation adjustment, simultaneously stamp both the actuator side and housing side.
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0000001701

(PWM) Pulse width modulation (%) (R) Rack position (mm) Rack sensor output characteristics 1. Rack limit adjustment (1)Measure the rack position R2 for PWM a2%. (2)Confirm that it is within the range R2 = 15+-1 mm. (3)Measure the rack position R1 at PWM a %. (4)Confirm that it is within the range R2 - R1 = 10+-0.1 mm. 2. Check the limp home operation. (1)Move the switch box's limp home switch to the limp home side. (2)Confirm rack position L1 (mm ) and L2 (mm) for PWM in the above table. 3. Check the pull down operation. (1)Confirm that the rack position is 19 mm at PWM B%. (2)In the conditions described in the above table, move the switch box's pull down switch to the pull down side and confirm that the rack position momentarily becomes 1 mm or less.
----------
a1=16.25 % a2=72.5 % L1=1-- mm L2=19++mm A=5 % B=95 %
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Information:

FEED ENGAGED
21. Slot. 22. Pin. 23. Knob. To set the feed mechanism into feed on later units, turn lever (A) up (the direction of arrow).
LATER FEED MECHANISM
A. Lever.Place adapter (24) into boring bar and tightening setscrew (25).
ADAPTER INSTALLED
24. 1P2364 Adapter. 25. Setscrew.Apply layout bluing to the bearing cap and bearing bore. Oil the centering rings. Do not use lubricant on the cutter. Use a one-half inch electric drill with universal joint (26) to feed tool through the bore. Service main bearings with .010 in. (0.25 mm) oversize outside diameter are available to permit the bore to be bored oversize. Bore the bore to 3.7175 .0005 in. (94.425 0.013 mm).
BORING BEARING BORE
26. 1P2363 Universal. If you use the later feed mechanism, the tool can be driven from either the boring bar or the feed mechanism.
DRIVING THROUGH FEED MECHANISM (Typical Example)
26. 1P2363 Universal.The bluing applied to the bearing bore indicates the condition of the bore at the corret bore size. If bluing shows an out of round condition, check the largest diameter (indicated by remaining bluing) in relation to the smallest diameter (indicated by lack of bluing). The difference of the two must not exceed .0010 in. (0.025 mm).If bluing indicates a step in the joint face, measure the diameter at the step in relation to the smallest diameter. A step of .0005 in. (0.013 mm) on one or both sides is permissible. A maximum of .0010 in. (0.025 mm) over the nominal finish bore diameter is permissible if within the described limits.To check the bore diameter, set the 1P3535 Dial Bore Gauge to 3.7175 in. (94.425 mm).
CHECKING BORE (Typical Example)Line Boring Main Bearing Bores
Line bore all main bearing bores if bearing caps or saddles are distorted.Clean bearing caps and saddles. Remove all nicks from pan rail. Plug oil holes in block with grease to prevent chips from entering oil passages.Place 1P2344 Centering Rings (1), with oiler (2) up, at each end of block. If an end bore is distorted, use the next good bore. There must be two good bores for locating centering rings.
CENTERING RINGS IN BLOCK
1. 1P2344 Centering Rings. 2. Oiler.Place original bearing caps (4) over the centering rings (1). Tighten bolts (3) hand tight.
CENTERING RINGS INSTALLED
1. 1P2344 Centering Rings. 3. Bolts (four). 4. Bearing caps.
BORING BAR INSTALLED
1. 1P2344 Centering Rings. 3. Bolts (four). 5. 1P2352 Boring Bar.Oil boring bar (5) and insert it through centering rings (1). Tighten bolts (3) to a minimum of 20 lb. ft. (25 N m) and a maximum of 50 lb. ft. (70 N m) while spinning bearing bar (5) to check for binding. Centering rings (1) must be seated in boring saddles after tightening.Slide boring bar (5) out of one end of block and install bearing assemblies (6) on boring bar (5). Slide boring bar (5) back through centering ring. Adjust bearing by tightening bolt (7) until bar begins to bind, then back off until boring bar (5) spins easily.
INSTALLING BEARING ASSEMBLIES
5. 1P2352 Boring Bar. 6. 1P2373 Bearing assembly