104742-4160 ZEXEL 9 460 614 492 BOSCH INJECTION-PUMP ASSEMBLY 9460614492 1047424160 167007t401

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 460 614 492 9460614492

ZEXEL 104742-4160 1047424160

NISSAN-DIESEL 167007T401 167007t401

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Cross reference number

BOSCH 9 460 614 492 9460614492

ZEXEL 104742-4160 1047424160

NISSAN-DIESEL 167007T401 167007t401

Zexel num

Bosch num

Firm num

Name

104742-4160

9 460 614 492

167007T401 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
* K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113orSAEJ967d

Test oil temperature degC 45 45 50

Nozzle 105780-0060

Bosch type code NP-DN0SD1510

Nozzle holder 105780-2150

Opening pressure MPa 13 13 13.3

Opening pressure kgf/cm2 133 133 136

Injection pipe 157805-7320

Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-450

Joint assembly 157641-4720

Tube assembly 157641-4020

Transfer pump pressure kPa 20 20 20

Transfer pump pressure kgf/cm2 0.2 0.2 0.2

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 61.4 60.9 61.9

Difference in delivery mm3/st. 5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 40 36 44

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 760 760 760

Average injection quantity mm3/st. 49 45.5 52.5

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 61.4 60.4 62.4

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1140 1140 1140

Average injection quantity mm3/st. 62 58.5 65.5

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 1520 1520 1520

Average injection quantity mm3/st. 74 70.5 77.5

Oil temperature degC 50 48 52

Injection timing adjustment_07

Pump speed r/min 1900 1900 1900

Average injection quantity mm3/st. 73 68.5 77.5

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2150 2150 2150

Average injection quantity mm3/st. 16.6 13.6 19.6

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_02

Pump speed r/min 2300 2300 2300

Average injection quantity mm3/st. 6

Oil temperature degC 52 50 54

Injection quantity adjustment_03

Pump speed r/min 2150 2150 2150

Average injection quantity mm3/st. 16.6 13.1 20.1

Difference in delivery mm3/st. 6

Basic *

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 5.8 3.8 7.8

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 70 50 90

Basic *

Oil temperature degC 48 46 50

Remarks
IDLE

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 70 50 90

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_03

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 70 50 90

Oil temperature degC 48 46 50

Remarks
Full

Speed control lever angle

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 48 46 50

Remarks
Magnet OFF at idling position

Speed control lever angle_02

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 5

Oil temperature degC 48 46 50

Remarks
Magnet OFF at full-load position

0000000901

Pump speed r/min 1140 1140 1140

Overflow quantity with S/T ON cm3/min 470 340 600

Oil temperature degC 50 48 52

Remarks
With an O-ring

_02

Pump speed r/min 1140 1140 1140

Overflow quantity with S/T ON cm3/min 470 340 600

Oil temperature degC 50 48 52

Remarks
Without an O-ring

Stop lever angle

Pump speed r/min 1140 1140 1140

Pressure with S/T OFF kPa 343 314 372

Pressure with S/T OFF kgf/cm2 3.5 3.2 3.8

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1140 1140 1140

Pressure with S/T OFF kPa 343 304 382

Pressure with S/T OFF kgf/cm2 3.5 3.1 3.9

Basic *

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1520 1520 1520

Pressure with S/T OFF kPa 412 334 471

Pressure with S/T OFF kgf/cm2 4.2 3.4 4.8

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1520 1520 1520

Timer stroke with S/T OFF mm 3.7 3.5 3.9

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1140 1140 1140

Timer stroke with S/T ON mm 2.5 2.5 2.5

Timer stroke with S/T OFF mm 1.3 0.9 1.9

Oil temperature degC 50 48 52

_03

Pump speed r/min 1520 1520 1520

Timer stroke with S/T OFF mm 3.7 3.3 4.1

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 2000 2000 2000

Timer stroke with S/T OFF mm 8.2 7.7 8.6

Oil temperature degC 50 48 52

0000001201

Max. applied voltage V 16 16 16

Test voltage V 25 24 26

Timing setting

K dimension mm 3.1 3 3.2

KF dimension mm 5.5 5.4 5.6

MS dimension mm 0.7 0.6 0.8

Pre-stroke mm 0.45 0.45 0.45

Control lever angle alpha deg. 25 21 29

Control lever angle beta deg. 36 31 41

Test data Ex:

0000001801 SUPPLY PUMP-TIMING DEVICE ADJ

Pump chamber pressure PT, timer stroke TA adjustment procedure Adjust the sequence in accordance with the procedure below. 1. At N = N1 set PT lower limit at P1. 2. At N = N2, set so that TA lower limit is TA1. 3. At N = N1 tap the regulating valve so that the timer's minimum specifications are obtained. 4. Reconfirm timer specifications for N = N2. (1)If as specified, confirm timer operation at N = N3. (2)If not as specified: 1) Readjust the timer at N = N2. (Adjust using the outer adjustable type). 2) Confirm timer operation at N = N1, N = N2. T:Tightening torque (A) = screw
----------
N1=1140r/min N2=1520r/min N3=2000r/min P1=314kPa(3.2kgf/cm2) TA1=3.5mm
----------
T=7~10N-m(0.7~1.0kgf-m)

0000001901 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer In the following condition, change the installation position of the potentiometer to adjust the output voltage to within the specified values. At pump speed N1 and with the control lever angle at a (corresponding to a shim thickness of L1), measure the injection quantity Q. Then, determine the voltage Vo from the voltage formula F and adjust the potentiometer. J:Vo+-0.03 A = potentiometer performance specifications C = control lever position Q = injection quantity Vo = output voltage D = idle E = full speed Vi = applied voltage M = potentiometer graph O = output P output at connecting harnesses 2 and 3
----------
N1=1140r/min a=13.4deg L1=8.65mm
----------
V1=(1.65+-0.4)V V2=(10.0)V J=Vo+-0.03=0.0245Q+4.5723

Information:

2. Remove pipe (1) and the gasket between aftercooler cover (2) and the turbocharger. If necessary, remove the O-ring seals from the pipe.3. Remove the bolts and clamps that hold tube assemblies (3) to each end of the aftercooler. Remove tube assemblies (3) from each end of the aftercooler. If necessary, remove the O-ring seals from the tube assemblies. An O-ring seal on each end of the aftercooler core holds the adapters in position.4. Remove adapters (4) and the gaskets from each end of the aftercooler.5. Remove all bolts (5) that hold aftercooler cover (2) in position. Remove the aftercooler cover and gasket from the engine. 6. Remove aftercooler core (6) and the gasket from the engine. If necessary, remove the O-ring seals from the aftercooler core. Two of the bolts that hold the aftercooler housing in position are on the inside of the aftercooler housing.7. Remove the bolts and spacers that hold aftercooler housing (7) to the engine. Make a note of the location of the spacers. Remove the aftercooler housing and gaskets from the engine.Install Aftercooler
Inspect all O-ring seals and gaskets, and make replacements if necessary. 1. Put the gaskets and aftercooler housing (1) in position on the engine. Install the bolts and spacers that hold the aftercooler housing.2. Install the O-ring seals on the aftercooler core, and put a thin layer of clean engine oil on them. Put the gasket and aftercooler core (2) in position on the engine. 3. Put the gasket and aftercooler cover (3) in position. Install the bolts that hold the aftercooler cover. Force may be required to push the adapters around the O-ring seals on the aftercooler core. Make sure the O-ring seals stay in position on the aftercooler core.4. Put a thin layer of clean engine oil in the bores of adapters (4). Install a gasket and adapter on each end of the aftercooler core. 5. Install the O-ring seals on tube assemblies (5), and put a thin layer of clean engine oil on them. Put the tube assemblies in position on each end of the aftercooler, and install the bolts and clamps that hold them.6. Install the O-ring seals on pipe (6), and put a thin layer of clean engine oil on them. Put the pipe and gasket in position between the aftercooler and the turbocharger. Install the bolts that hold it.7. Fill the radiator with coolant to the correct level. See the Operation & Maintenance Manual.