104760-4560 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047604560 167000y713

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104760-4560 1047604560

NISSAN-DIESEL 167000Y713 167000y713

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Cross reference number

ZEXEL 104760-4560 1047604560

NISSAN-DIESEL 167000Y713 167000y713

Zexel num

Bosch num

Firm num

Name

104760-4560
104760-4561

167000Y713 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 105000-2010

Bosch type code NP-DN12SD12TT

Nozzle holder 105780-2080

Opening pressure MPa 14.7 14.7 15.19

Opening pressure kgf/cm2 150 150 155

Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-840

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) OFF

Injection timing adjustment

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 48.9 48.4 49.4

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 49.1 47.1 51.1

Oil temperature degC 50 48 52

Injection timing adjustment_03

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 48.9 47.9 49.9

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 50 50 50

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 47.1 47.1 47.1

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 2000 2000 2000

Average injection quantity mm3/st. 42.1 40 44.2

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2300 2300 2300

Average injection quantity mm3/st. 16.6 14.6 18.6

Difference in delivery mm3/st. 5

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_02

Pump speed r/min 2500 2500 2500

Average injection quantity mm3/st. 5

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2100 2100 2100

Average injection quantity mm3/st. 40 35.5 44.5

Oil temperature degC 52 50 54

Injection quantity adjustment_04

Pump speed r/min 2300 2300 2300

Average injection quantity mm3/st. 16.6 14.1 19.1

Basic *

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 8.8 6.8 10.8

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 8.8 6.3 11.3

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 48 46 50

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 60 50 80

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 60 50 80

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 1000 1000 1000

Overflow quantity with S/T ON cm3/min 400 270 530

Oil temperature degC 50 48 52

_02

Pump speed r/min 1000 1000 1000

Overflow quantity with S/T ON cm3/min 450 320 580

Oil temperature degC 50 48 52

Remarks
Without an O-ring

Stop lever angle

Pump speed r/min 1000 1000 1000

Pressure with S/T ON kPa 500 461 539

Pressure with S/T ON kgf/cm2 5.1 4.7 5.5

Pressure with S/T OFF kPa 324 304 344

Pressure with S/T OFF kgf/cm2 3.3 3.1 3.5

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1000 1000 1000

Pressure kPa 324 295 353

Pressure kgf/cm2 3.3 3 3.6

Basic *

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1800 1800 1800

Pressure kPa 569 530 608

Pressure kgf/cm2 5.8 5.4 6.2

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1000 1000 1000

Timer stroke with S/T ON mm 3.8 3.4 4.2

Timer stroke with S/T OFF mm 1.6 1.4 1.8

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 800 800 800

Timer stroke with S/T OFF mm 0.5 0 1

Oil temperature degC 50 48 52

_03

Pump speed r/min 1000 1000 1000

Timer stroke with S/T ON mm 3.8 3.3 4.3

Timer stroke with S/T OFF mm 1.6 1.3 1.9

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 1800 1800 1800

Timer stroke with S/T OFF mm 5.5 5 6

Oil temperature degC 50 48 52

_05

Pump speed r/min 2200 2200 2200

Timer stroke with S/T OFF mm 7.4 6.9 7.8

Oil temperature degC 52 50 54

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 22 21.5 22.5

Timer stroke TA mm 2.5 2.3 2.7

Timer stroke variation dT mm 0.1 0.1 0.1

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 22 21 23

Timer stroke TA mm 2.5 2.2 2.8

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 15 12.5 17.5

Timer stroke TA mm 2.1 1.4 2.8

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

Control lever angle alpha deg. 25 23 27

Control lever angle beta deg. 40 35 45

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer At pump speed N1 and a control lever position a from idle (gap L1), measure the injection quantity and convert it to a voltage value. Then adjust the potentiometer. Voltage conversion formula: V+-0.03 = 0.044Q+2.07 A:Potentiometer performance standards C:Position of the control lever C1:Idle C2:Full speed V:Potentiometer voltage E:Standards for the potentiometer's ON - OFF switch B:Conversion point B1:OFF-->ON B2:OFF-->ON D:Lever opening (from idle) Vi:Applied voltage F:Connecting diagram for the potentiometer G:Output when (2) and (3) connected. H:When (4) or (6) connected: switch OFF to ON. I:When (4) or (5) connected: switch ON to OFF. J:Output
----------
N1=700r/min a=7.5deg L1=4.9mm Vi=10V
----------
V1=1.6+-0.4V V2=8.0+-0.55V D1=6.0+-3.5deg D2=19.5+-3.5deg Vi=10V

Information:

Start By:a. remove radiatorb. remove hydraulic pumpc. remove crankshaft pulleyd. remove alternatore. remove intake manifoldf. remove starting motorg. remove oil filterh. remove transmission
All wires, hoses, lines and linkage that is disconnected must be tied or wired out of the way to prevent damage when removing engine.
1. Identify and disconnect all electrical connections to the engine. Disconnect hydraulic lines and cab heater hoses. Disconnect all fuel lines and throttle controls. Tie or wire all wires, hoses, lines and linkage out of the way for engine removal.2. Remove front and rear engine mount bolts (1). 3. With the forks of a lift truck positioned together, position forks centered over the engine as illustrated. Install tooling (A) and then run a chain through the existing engine lifting eyes and tooling (A) as illustrated. Raise engine up slightly and start to remove engine. 4. With the engine part of the way out, remove four bolts (2) and remove rear mount bracket (3). Repeat step for the other rear mount bracket. With both rear mount brackets removed, finish removing engine. Weight of the engine is 340 Kg (750 lbs.). At the time of installation, tighten front mount bolts to a torque of 370 50 N m (270 37 lb.ft.) and rear mount bolts to a torque of 100 15 N m (75 11 lb.ft.). Install in the reverse order.End By:a. install transmissionb. install oil filterc. install starting motord. install intake manifolde. install alternatorf. install crankshaft pulleyg. install hydraulic pumph. install radiator