108921-0000 ZEXEL 9 400 619 381 BOSCH INJECTION-PUMP ASSEMBLY 9400619381 1089210000 1680197065

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 619 381 9400619381

ZEXEL 108921-0000 1089210000

NISSAN-DIESEL 1680197065 1680197065

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Cross reference number

BOSCH 9 400 619 381 9400619381

ZEXEL 108921-0000 1089210000

NISSAN-DIESEL 1680197065 1680197065

Zexel num

Bosch num

Firm num

Name

108921-0000
108921-0020

9 400 619 381

1680197065 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
RH10E K

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. 52

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 10-9-4-3 -6-5-8-7 -2-1

Pre-stroke mm 6.4 6.37 6.43

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 10-9 deg. 45 44.75 45.25

Difference between angles 2
Cal 10-4 deg. 72 71.75 72.25

Difference between angles 3
Cal 10-3 deg. 117 116.75 117.25

Difference between angles 4
Cal 10-6 deg. 144 143.75 144.25

Difference between angles 5
Cal 10-5 deg. 189 188.75 189.25

Difference between angles 6
Cal 10-8 deg. 216 215.75 216.25

Difference between angles 7
Cal 10-7 deg. 261 260.75 261.25

Difference between angles 8
Cal 10-2 deg. 288 287.75 288.25

Difference between angles 9
Cal 10-1 deg. 333 332.75 333.25

Injection quantity adjustment

Rack position (11.5)

PWM % 52.6

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 113.5 111.5 115.5

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 (7.8)

PWM % 31.7+-2. 8

Pump speed r/min 345 345 345

Average injection quantity mm3/st. 16 14 18

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 1000

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 start of injection for the No. 10 cylinder. (3)Pre-stroke: aa (4)-
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aa=6.4+-0.03mm
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a=(90deg)

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.
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a1=16.25% a2=72.5% L1=1--mm L2=19++mm A=5% B=95%
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Information:

Parts Required For 4C-8180 Timing Tool Group
Refer to Chart A for item identification.Assemble and Set the 4C-8180 Timing Tool Group
1. Obtain a 108-2104 Plunger and Barrel Assembly. This part can be new or used. If the part is used, make sure it is in good working condition. The plunger should move freely in the barrel.
4C-8181 Timing Tool Assembly
(9) 8J-3819 Spring. (10) 1N-3257 Retainer Ring. (11) Plunger and barrel from 108-2104 Plunger and Barrel Assembly. (12) 4C-8178 Indicator Mount Bonnet. (14) 4C-8179 Bonnet Nut. (16) 2W-3429 Gear Segment (part of 108-2104). (17) 8N-0669 Bolt (part of 108-2104). (18) 4P-8704 Spring (part of 108-2104). (19) 9Y-2088 Washer.2. Make a 4C-8181 Timing Tool Assembly out of the 108-2104 Plunger and Barrel Assembly. The 4C-8181 Timing Tool Assembly is not a serviceable part. a. Remove and discard 8N-0669 Bolt (17), 2W-3429 Gear Segment (16), and 4P-8704 Spring (18) from the 108-2104 Plunger and Barrel Assembly.b. Assemble 8J-3819 Spring (9) and 9Y-2088 Washer (19) onto plunger. The 9Y-2088 Washer is part of the 108-2104 Plunger and Barrel Assembly.c. Install the 4C-8178 Indicator Mount Bonnet (12) onto the barrel using a 1N-3257 Retainer Ring (10).d. Slip 4C-8179 Bonnet Nut (14) over indicator mount bonnet (12).e. This tool is now a 4C-8181 Timing Tool Assembly (11).3. Assemble knurled gauge collar (3) onto gauge (5) by threading them together. Hand tighten the two parts. Make sure the gauging surfaces are clean and free of all debris, nicks, etc.4. Install 4C-8181 Timing Tool Assembly (11) into gauge collar (3).5. Thread bonnet nut (14) into gauge collar (3) and hand tighten with 9U-5120 Spanner Wrench (13). This will secure timing tool assembly (11) into gauge collar (3).6. Spring (9) on the timing tool assembly should make the end of the plunger extend approximately 30 mm (1.2 in) past the end of gauge (5).7. Push on the end of the plunger and make sure it travels freely (under spring force) in and out of the gauge block bore. If there is binding, disassemble and correct the problem.8. Install either a 5P-4814 Collet (6) or 4C-2982 Collet Assembly (7) into indicator mount bonnet (12).9. Install an indicator with a 5P-7262 Contact Point into collet (6 or 7). Use either a 6V-6106 Dial Indicator or an 8T-1002 Probe connected to an 8T-1001 Electronic Position Indicator.
Do not over tighten collet (6 or 7) holding the indicator. Over-tightening can result in damage to the indicator or the electronic position indicator probe.
10. Tighten collet (6 or 7) just enough to make sure the indicator or electronic position indicator probe will not move in collet.11. Zero the indicator by following this procedure. a. Place the 4C-8183 Gauge Plate (8) onto a flat surface.b. Carefully hold the entire 4C-8180 Timing Tool Group and place it on the gauge plate, with the end of the plunger contacting the plate.c. Push down on the entire assembly, compressing the spring, until the bottom of gauge (5) is in complete contact with gauge plate (8).
Zero The Timing Tool Assembly With