104760-4461 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047604461 1670051n05

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104760-4461 1047604461

NISSAN-DIESEL 1670051N05 1670051n05

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Cross reference number

ZEXEL 104760-4461 1047604461

NISSAN-DIESEL 1670051N05 1670051n05

Zexel num

Bosch num

Firm num

Name

104760-4461
104760-4462

1670051N05 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
TD42 * 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

(Solenoid timer adjustment condition)
With S/T O-ring; S/T OFF. OFF

Injection timing adjustment

Pump speed r/min 500 500 500

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 46.3 45.8 46.8

Basic *

Oil temperature degC 48 46 50

Remarks
NA

Injection timing adjustment_02

Pump speed r/min 700 700 700

Boost pressure kPa 16 14.7 17.3

Boost pressure mmHg 120 110 130

Average injection quantity mm3/st. 53.7 53.2 54.2

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_03

Pump speed r/min 1000 1000 1000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 58.3 57.8 58.8

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 500 500 500

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 46.3 45.3 47.3

Basic *

Oil temperature degC 48 46 50

Injection timing adjustment_05

Pump speed r/min 700 700 700

Boost pressure kPa 16 14.7 17.3

Boost pressure mmHg 120 110 130

Average injection quantity mm3/st. 53.7 52.7 54.7

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_06

Pump speed r/min 1000 1000 1000

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 51.1 48.6 53.6

Oil temperature degC 50 48 52

Injection timing adjustment_07

Pump speed r/min 1000 1000 1000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 58.3 57.3 59.3

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_08

Pump speed r/min 2000 2000 2000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 61.1 58.6 63.6

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2300 2300 2300

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 18.3 16.3 20.3

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_02

Pump speed r/min 2500 2500 2500

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 5

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2100 2100 2100

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 55.2 50.7 59.7

Oil temperature degC 52 50 54

Injection quantity adjustment_04

Pump speed r/min 2300 2300 2300

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 18.3 15.8 20.8

Basic *

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 350 350 350

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 12.5 10.5 14.5

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 350 350 350

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 12.5 10 15

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 48 46 50

Timer adjustment

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 58 48 78

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 58 48 78

Oil temperature degC 48 46 50

Remarks
Full

Speed control lever angle

Pump speed r/min 350 350 350

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 48 46 50

Remarks
Magnet OFF at idling position

0000000901

Pump speed r/min 1000 1000 1000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Overflow quantity with S/T ON cm3/min 420 290 550

Oil temperature degC 50 48 52

Remarks
With an O-ring

_02

Pump speed r/min 1000 1000 1000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Overflow quantity with S/T ON cm3/min 564 434 694

Oil temperature degC 50 48 52

Remarks
Without an O-ring

Stop lever angle

Pump speed r/min 1000 1000 1000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Pressure with S/T ON kPa 431 392 470

Pressure with S/T ON kgf/cm2 4.4 4 4.8

Pressure with S/T OFF kPa 333 304 362

Pressure with S/T OFF kgf/cm2 3.4 3.1 3.7

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1000 1000 1000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Pressure with S/T OFF kPa 333 294 372

Pressure with S/T OFF kgf/cm2 3.4 3 3.8

Basic *

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1700 1700 1700

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Pressure with S/T OFF kPa 549 510 588

Pressure with S/T OFF kgf/cm2 5.6 5.2 6

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1000 1000 1000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Timer stroke with S/T ON mm 4.8 4.4 5.2

Timer stroke with S/T OFF mm 2.6 2.4 2.8

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 800 800 800

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Timer stroke with S/T OFF mm 1.1 0.6 1.6

Oil temperature degC 50 48 52

_03

Pump speed r/min 1000 1000 1000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Timer stroke with S/T ON mm 4.8 4.3 5.3

Timer stroke with S/T OFF mm 2.6 2.3 2.9

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 1700 1700 1700

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Timer stroke with S/T OFF mm 7 6.5 7.4

Oil temperature degC 50 48 52

_05

Pump speed r/min 2000 2000 2000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Timer stroke with S/T OFF mm 7 6.5 7.4

Oil temperature degC 50 48 52

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

Pump speed r/min 1000 1000 1000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 38 37.5 38.5

Timer stroke TA mm 2.3 2.3 2.3

Timer stroke variation dT mm 0.3 0.1 0.5

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1000 1000 1000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 38 37 39

Timer stroke variation dT mm 0.3 0 0.6

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1000 1000 1000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 26 23.5 28.5

Timer stroke variation dT mm 0.8 0.4 1.2

Oil temperature degC 50 48 52

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 6.64 6.54 6.74

MS dimension mm 1 0.9 1.1

BCS stroke mm 1.8 1.6 2

Control lever angle alpha deg. 10 6 14

Control lever angle beta deg. 40 35 45

Test data Ex:

0000001601 BOOST COMPENSATOR ADJUSTMENT

BCS adjustment procedure 1. At full boost pressure, set so that the full injection quantity is within the specifications (adjusting point). 2. Perform boost compensator intermediate operation point adjustment (pump speed N1, boost pressure P1). 3. When injection quantity at boost pressure P2 and pump speed N2 is not as specified, loosen nut (A) and adjust position of screw (B) so that injection quantity is as specified. The screw position should be within +-1 turn of initial position. 4. The nut tightening torque is T.
----------
N1=700r/min N2=500r/min P1=16.0kPa(120mmHg) P2=0kPa(0mmHg) T=6~9N-m(0.6~0.9kgf-m)
----------
SW=10mm T=6~9N-m(0.6~0.9kgf-m)

0000001801 POTENTIOMETER ADJUSTMENT

Potentiometer adjustment 1. Applied voltage: Vi 2. Boost pressure = P1 3. Set the control lever at the adjusting point. Position the dummy bolt against the lever and fix. 4. Assemble the potentiometer to obtain output voltage V1 at the fixed position. 5. After mounting the potentiometer, remove the dummy bolt. N:Pump speed Q:Injection quantity V:Output voltage C:Position of the control lever A:Adjusting point C1:Idle C2:Full-speed
----------
V1=5.52+-0.03V P1=0kPa(0mmHg) Vi=10V
----------
N1=850r/min Q1=13.8+-1.0mm3/st V1=5.52+-0.03V V2=2.42+-0.78V V3=(10V) a=-

Information:

Introduction
1. Type 2 fuel injector. 2. Two piece follower. 3. Nose cone. 4. Nozzle assembly.Tools are now available for the removal and installation of nose cone (3), on type 2 fuel injectors (1), when it is necessary to replace a nozzle assembly (4). Type 2 fuel injectors can be identified by the two piece follower (2).
5. 1U9395 Plate. 6. 1U8701 Socket.Use 1U9395 Plate (5) with the 6V4830 Fixture Group (not shown) and the procedure given in this instruction, for the removal and installation of nozzle assembly (4).Earlier type 2 injectors have a nose cone that has serrations on its exterior. These serrations will be damaged when the nose cone is removed. A damaged nose cone is not to be used again. A 7C9795 Nose Cone is available for use as a replacement for the original nose cone.The 7C9795 Nose Cone has a hexagon shape on its exterior. This nose cone can be installed and tightened using 1U8701 Socket (6). When the 7C9795 Nose Cone is installed, be sure to tighten it according to the procedure given in this instruction.Removal and Installation of Nose Cone and Nozzle Assembly
1. Remove the original plate from the 6V4830 Fixture Group and install 1U9395 Plate (1).2. Put injector (2) in position on the fixture group. If the exterior of the injector nose cone is a hexagon shape as shown at location (A), use the 1U8701 Socket for nose cone removal. 3. If the exterior of the nose cone has serrations as shown at location (B), use a pipe wrench, as shown, to remove the nose cone. Anytime a pipe wrench is used to remove a nose cone, the nose cone will be damaged. Never use or install a damaged nose cone on an injector. Always install a new 7C9795 Nose Cone as a replacement. 4. After the nose cone has been loosened, use a hammer and 6V4822 Tip Driver (3) to tap the nozzle assembly as shown. This is done to break the connection between the nozzle assembly and the nose cone. Be sure to use only the 6V4822 Tip Driver in this procedure, because use of a standard punch, or any other similar tool will cause damage to the nozzle tip.5. Remove the nose cone and nozzle assembly. 6. Inspect surface (C) in the injector. This is the sealing surface for the nozzle assembly. This surface must be clean and free of any scratches, nicks or burrs. Even a piece of lint from a shop towel can cause a leak and destroy nozzle performance. 7. Remove original O-ring seal (4). Install a new O-ring seal, refer to the Parts Book for the correct part number. Make sure the O-ring seal is not damaged during installation.Use a generous amount of 1P0808 Grease, or a good grade of multi-purpose lubricant, to lubricate the O-ring seal before the nose cone is installed.8. Install new nozzle assembly (5) on the injector. 9. Install and finger tighten the new 7C9795 Nose Cone on the injector. Using a