108821-0224 ZEXEL 9 400 612 189 BOSCH INJECTION-PUMP ASSEMBLY 9400612189 1088210224 16801nd002

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 612 189 9400612189

ZEXEL 108821-0224 1088210224

NISSAN-DIESEL 16801ND002 16801nd002

Service parts 108821-0224 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 108082-3860

3. GOVERNOR 105960-0320

4. SUPPLY PUMP 105237-5491

5. AUTOM. ADVANCE MECHANIS 105684-0151

6. COUPLING PLATE 105664-2430

7. COUPLING PLATE

8. _ 159640-0720

9. _

10. NOZZLE AND HOLDER ASSY 105110-8071

11. Nozzle and Holder 16600-97201

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

13. NOZZLE-HOLDER 105041-3180

14. NOZZLE

15. NOZZLE SET 105019-2600

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

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 (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

Governor adjustment

Pump speed r/min 700--

Advance angle deg. 0 0 0

Remarks
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

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