104760-4580 ZEXEL 9 460 614 742 BOSCH INJECTION-PUMP ASSEMBLY 9460614742 1047604580 167000y910

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 460 614 742 9460614742

ZEXEL 104760-4580 1047604580

NISSAN-DIESEL 167000Y910 167000y910

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Cross reference number

BOSCH 9 460 614 742 9460614742

ZEXEL 104760-4580 1047604580

NISSAN-DIESEL 167000Y910 167000y910

Zexel num

Bosch num

Firm num

Name

104760-4580

9 460 614 742

167000Y910 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

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

0000000901

Pump speed r/min 1000 1000 1000

Overflow quantity cm3/min 400 270 530

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1000 1000 1000

Pressure kPa 324 304 344

Pressure 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 608 569 647

Pressure kgf/cm2 6.2 5.8 6.6

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1000 1000 1000

Timer stroke mm 1.6 1.4 1.8

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 800 800 800

Timer stroke mm 0.5 0 1

Oil temperature degC 50 48 52

_03

Pump speed r/min 1000 1000 1000

Timer stroke mm 1.6 1.3 1.9

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 1800 1800 1800

Timer stroke mm 5.8 5.3 6.3

Oil temperature degC 50 48 52

_05

Pump speed r/min 2200 2200 2200

Timer stroke 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 21 29

Control lever angle beta deg. 40 35 45

Information:

Start By:a. remove exhaust manifoldb. remove inlet manifoldc. remove fuel injection nozzle assembliesd. remove fuel filtere. remove water temperature regulatorf. remove cylinder head assembly 1. Put cylinder head assembly (1) in position on tool group (A). 2. Put compression on valve spring (2) with tool (C). 3. Remove spring locks (3). 4. Remove tool (C). Remove valve spring cap (2) and valve springs (4). 5. Remove washer (5) and O-ring seal (8) from valve (7).6. Remove seal (6). Remove valve (7). 7. Check the valve spring tension with tool (B). The outer spring force must be 180 9 N (40 2 lb.). The length of the spring under test force must be 27.4 mm (1.08 in.). The free length after test must be 45.2 mm (1.78 in.). The inner spring force must be 68.5 9 N (15.4 2 lb.). The length of the spring under test force must be 23.88 mm (.940 in.). The length after test must be 39.6 mm (1.56 in.).8. Do Steps 1 through 8 again for the remainder of the valves. If the cylinder head is equipped with removable valve guides, refer to module SENB8082-06, System Operating Testing And Adjusting Specifications, 4.236 And 4.2482 Diesel Engines For Lift Trucks.Install Valves
1. Put clean engine oil on the valve stems.2. Install valve (3), washer (2) and seal (1).
The closed coil of the spring must be toward the cylinder head.
3. Install springs (5) and valve spring cap (4). 4. Use tool (A), and put springs under compression, and install O-ring seal on the valve. Exhaust valves have an extra O-ring seal on them.
Locks (6) can be thrown from the valve when tool (A) is released if they are not in their correct position on the valve stem.
5. Use tool (B), and install locks (6) that hold the springs in place.6. Remove tool (A), and hit the top of the valve with a plastic hammer to be sure the locks are in their correct position on the valve.7. Do Steps 1 through 6 again for the remainder of the valves.End By:a. install cylinder head assemblyb. install water temperature regulatorc. install fuel filterd. install fuel injection nozzle assembliese. install inlet manifold