Information injection-pump assembly
BOSCH
9 400 612 189
9400612189
ZEXEL
108821-0224
1088210224
NISSAN-DIESEL
16801ND002
16801nd002
Rating:
Service parts 108821-0224 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
9.
_
11.
Nozzle and Holder
16600-97201
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/18.6{190}
14.
NOZZLE
Include in #1:
108821-0224
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 612 189
9400612189
ZEXEL
108821-0224
1088210224
NISSAN-DIESEL
16801ND002
16801nd002
Zexel num
Bosch num
Firm num
Name
108821-0224
9 400 612 189
16801ND002 NISSAN-DIESEL
INJECTION-PUMP ASSEMBLY
RH8F K 14CQ INJECTION PUMP ASSY TICS HD-TI8F TICS
RH8F K 14CQ INJECTION PUMP ASSY TICS HD-TI8F TICS
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
Governor side NO.1
Difference between angles 1
Cal 8-7 deg. 45 44.75 45.25
Cal 8-7 deg. 45 44.75 45.25
Difference between angles 2
Cal 8-5 deg. 90 89.75 90.25
Cal 8-5 deg. 90 89.75 90.25
Difference between angles 3
Cal 8-4 deg. 135 134.75 135.25
Cal 8-4 deg. 135 134.75 135.25
Difference between angles 4
Cal 8-3 deg. 180 179.75 180.25
Cal 8-3 deg. 180 179.75 180.25
Difference between angles 5
Cal 8-6 deg. 225 224.75 225.25
Cal 8-6 deg. 225 224.75 225.25
Difference between angles 6
Cal 8-2 deg. 270 269.75 270.25
Cal 8-2 deg. 270 269.75 270.25
Difference between angles 7
Cal 8-1 deg. 315 314.75 315.25
Cal 8-1 deg. 315 314.75 315.25
Injection quantity adjustment
Rack position
(12.5)
PWM
%
58.6
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
141
139
143
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
(7.5)
PWM
%
30.2+-2.
8
Pump speed
r/min
290
290
290
Average injection quantity
mm3/st.
13
11
15
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
Refer to items regarding the pre-stroke actuator
Governor adjustment
Pump speed
r/min
700--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Governor adjustment_02
Pump speed
r/min
650
Advance angle
deg.
0.5
Governor adjustment_03
Pump speed
r/min
960
Advance angle
deg.
3
2.5
3.5
Remarks
Finish
Finish
0000001201
Pre-stroke
mm
6.4
6.37
6.43
Remarks
When the timing sleeve is pushed up
When the timing sleeve is pushed up
_02
Connector angle
deg.
11.5
11
12
Remarks
When the eccentric pin is tightened
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
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
----------
aa=20mm bb=1mm
----------
a=27deg+-5deg b=37deg+-5deg
----------
aa=20mm bb=1mm
----------
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)-
----------
aa=6.4+-0.03mm
----------
a=(80deg)
----------
aa=6.4+-0.03mm
----------
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.
----------
----------
----------
----------
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%
----------
----------
a1=16.25% a2=72.5% L1=1--mm L2=19++mm A=5% B=95%
----------
Information:
33. Remove dowels (69) and flyweights (71) from the carrier.34. Remove shaft (70) from the carrier. Remove the dowel from shaft (70). 35. Remove races (72) and bearing (73) from the camshaft in the fuel injection pump housing.Assemble Governor
Put clean oil on all parts before assembly. Be sure all oil passages are clear. 1. Install one race (1), bearing (2) and the other race (1) on the camshaft in the fuel injection pump housing. 2. Put flyweights (3) in position on carrier (4) and install the dowels to hold the flyweights in place. The flyweights must move freely on the dowels and have 0.010 to 0.23 mm (0.0004 to 0.009 in. end play. 3. Install dowel (5) in governor shaft (6) and install the governor shaft in the carrier as shown. 4. Put the carrier in position on the camshaft and install the bolts that hold the carrier in place. Make a replacement of shield (7) any time it is removed.5. Install shield (7) on the carrier and use tool (A) to push the shield against its seat. Use a hammer and punch to move the metal (stake) two places on the side of the shield 180° 5° apart next to the holes in the shield. 6. Install one race (9), bearing (10), the other race (9) and use tool (B) to install the ring on riser (8) as shown. 7. Install riser (8) and spring (overfueling spring) on the governor shaft as shown. 8. Assemble the dashpot as follows:a) Install spring (12) on seat (11) and install seat (13) in spring (12).b) Put spool (14) and ring (15) in position on seat (13) and use tool (B) to install snap ring (16) to hold them in place. 9. Install dashpot assembly (17) on the governor shaft as shown. 10. Install ring (21) in the lower groove in the governor shaft. Install one sleeve (20), spring (19), the other sleeve (20) and bearing (18) on the governor shaft as shown. Spring (19) is used to put a preload on the thrust bearing on the camshaft in the fuel injection pump housing. 11. Use tool (C) to hold spring (19) in compression and install ring (22) in the groove in the governor shaft. Remove tool (C). 12. Put lever (27) in position on governor servo (23) and install pin (24) to hold the lever in place. Use a hammer and chisel to move the metal (stake) four places 90° apart on the outside surface on both legs of the governor servo to hold pin (24) in place.13. Install the O-ring seal on sleeve (25). Install piston (26) and sleeve (25) in the governor servo as shown. 14. Install valve (28) in the governor servo as shown. 15. Install one lockring (32) in the groove near the center of valve (28). Put sleeve (29), spring (broken link spring) (30) and seat (31) in position on valve (28) and install the other lockring (32) to hold them in place. 16.
Put clean oil on all parts before assembly. Be sure all oil passages are clear. 1. Install one race (1), bearing (2) and the other race (1) on the camshaft in the fuel injection pump housing. 2. Put flyweights (3) in position on carrier (4) and install the dowels to hold the flyweights in place. The flyweights must move freely on the dowels and have 0.010 to 0.23 mm (0.0004 to 0.009 in. end play. 3. Install dowel (5) in governor shaft (6) and install the governor shaft in the carrier as shown. 4. Put the carrier in position on the camshaft and install the bolts that hold the carrier in place. Make a replacement of shield (7) any time it is removed.5. Install shield (7) on the carrier and use tool (A) to push the shield against its seat. Use a hammer and punch to move the metal (stake) two places on the side of the shield 180° 5° apart next to the holes in the shield. 6. Install one race (9), bearing (10), the other race (9) and use tool (B) to install the ring on riser (8) as shown. 7. Install riser (8) and spring (overfueling spring) on the governor shaft as shown. 8. Assemble the dashpot as follows:a) Install spring (12) on seat (11) and install seat (13) in spring (12).b) Put spool (14) and ring (15) in position on seat (13) and use tool (B) to install snap ring (16) to hold them in place. 9. Install dashpot assembly (17) on the governor shaft as shown. 10. Install ring (21) in the lower groove in the governor shaft. Install one sleeve (20), spring (19), the other sleeve (20) and bearing (18) on the governor shaft as shown. Spring (19) is used to put a preload on the thrust bearing on the camshaft in the fuel injection pump housing. 11. Use tool (C) to hold spring (19) in compression and install ring (22) in the groove in the governor shaft. Remove tool (C). 12. Put lever (27) in position on governor servo (23) and install pin (24) to hold the lever in place. Use a hammer and chisel to move the metal (stake) four places 90° apart on the outside surface on both legs of the governor servo to hold pin (24) in place.13. Install the O-ring seal on sleeve (25). Install piston (26) and sleeve (25) in the governor servo as shown. 14. Install valve (28) in the governor servo as shown. 15. Install one lockring (32) in the groove near the center of valve (28). Put sleeve (29), spring (broken link spring) (30) and seat (31) in position on valve (28) and install the other lockring (32) to hold them in place. 16.
Have questions with 108821-0224?
Group cross 108821-0224 ZEXEL
Nissan-Diesel
108821-0224
9 400 612 189
16801ND002
INJECTION-PUMP ASSEMBLY
RH8F
RH8F