104780-9122 ZEXEL 9 460 614 781 BOSCH INJECTION-PUMP ASSEMBLY 9460614781 1047809122 167006t082

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 460 614 781 9460614781

ZEXEL 104780-9122 1047809122

NISSAN-DIESEL 167006T082 167006t082

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Cross reference number

BOSCH 9 460 614 781 9460614781

ZEXEL 104780-9122 1047809122

NISSAN-DIESEL 167006T082 167006t082

Zexel num

Bosch num

Firm num

Name

104780-9122

9 460 614 781

167006T082 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
TD27 K 11CJ INJECTION PUMP ASSY VE4 VE

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 1100 1100 1100

Average injection quantity mm3/st. 44.8 44.3 45.3

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 41.8 39.3 44.3

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 44.8 43.8 45.8

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 2000 2000 2000

Average injection quantity mm3/st. 44.5 41.5 47.5

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2550 2550 2550

Average injection quantity mm3/st. 10.9 8.9 12.9

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2700 2700 2700

Average injection quantity mm3/st. 5

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2350 2350 2350

Average injection quantity mm3/st. 39.7 39.7 39.7

Oil temperature degC 52 50 54

Injection quantity adjustment_04

Pump speed r/min 2550 2550 2550

Average injection quantity mm3/st. 10.9 8.4 13.4

Basic *

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 7.7 5.7 9.7

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. 7.7 5.2 10.2

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 45 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 45 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 1100 1100 1100

Overflow quantity cm3/min 390 260 520

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1300 1300 1300

Pressure kPa 471 442 500

Pressure kgf/cm2 4.8 4.5 5.1

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1300 1300 1300

Pressure kPa 471 432 510

Pressure kgf/cm2 4.8 4.4 5.2

Basic *

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1700 1700 1700

Pressure kPa 559 520 598

Pressure kgf/cm2 5.7 5.3 6.1

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1300 1300 1300

Timer stroke mm 2.3 2.1 2.5

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1100 1100 1100

Timer stroke mm 1.4 0.9 1.9

Oil temperature degC 50 48 52

_03

Pump speed r/min 1300 1300 1300

Timer stroke mm 2.3 2 2.6

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 1700 1700 1700

Timer stroke mm 4.1 3.6 4.6

Oil temperature degC 50 48 52

_05

Pump speed r/min 2300 2300 2300

Timer stroke mm 6.2 5.7 6.6

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 1300 1300 1300

Average injection quantity mm3/st. 27.8 27.3 28.3

Timer stroke TA mm 1.7 1.5 1.9

Timer stroke variation dT mm 0.6 0.6 0.6

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 27.8 26.8 28.8

Timer stroke TA mm 1.7 1.4 2

Timer stroke variation dT mm 0.6 0.6 0.6

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 16.8 14.3 19.3

Timer stroke TA mm 1.1 0.6 1.6

Timer stroke variation dT mm 1.2 1.2 1.2

Oil temperature degC 50 48 52

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 5.8 5.7 5.9

MS dimension mm 0.9 0.8 1

Pre-stroke mm 0.1 0.08 0.12

Control lever angle alpha deg. 25 21 29

Control lever angle beta deg. 36 31 41

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Note: Potentiometer (P/M) adjustment method Substitute the actual measurement of the angle a of each I/P in the following formula and determine the P/M output adjustment y (V). When the angle a <= c: y = 7.23 When c < angle a < d: y = 7.23+( angle a -33) x 0.133 When d <alpha <e: y=7.97 Reference: Idle position and full speed position output voltages are V6 (idle) and V7 (full speed). The switch voltage specification is the value when the idle lever position is V8. A:Potentiometer standards B:ON, OFF switch standard G:ON-->OFF D:OFF-->ON E:Adjusting point F:Checking point P:Boost pressure Vi:Applied voltage C1:Full-speed C2:Idle Q:Injection quantity N:Pump speed V:Output voltage C:Control lever angle
----------
a=MEASURE c=33deg d=39deg e=-deg P1=-kPa P2=-mmHg V6=1.6+-0.6V V7=7.6+-0.4V V8=0V
----------
V1=y+-0.03V V2=1.6+-0.6V V3=-V V4=0.82+-0.8V V5=3.2+-0.8V C3=4.9+5.3-4.8deg C4=19.4+-5.0deg Vi=10V P1=-kPa P2=-mmHg

Information:

Introduction
The following procedures contain crucial information on correctly installing the new 162-2501 Hose As and the 258-8917 Protection Sleeve .Note: The 162-2501 Hose As replaces 107-7942 Tube As .Installation Procedure of the Hose Assembly
Illustration 1 g01230674
Remove old 162-2501 Hose As (1). Keep all of the manifold and pump fittings attached.Note: Step 2 is only for 3408E engines.
Remove the 7W-6492 Pipe Plug (2) from the aftercooler housing (3). Install the 8T-6762 Pipe Plug into the aftercooler housing.
Illustration 2 g01230678
Note: Always tighten the fittings with your hand before you use a wrench. Support the hose and the elbow while you tighten in order to avoid the following damage: twisting, kinking and side loading.
Loosen elbow (4) and jam nut (5) .
Hand tighten the nut on the hose (5) to the elbow (4) .
Install the other end of the hose (6) to the pump fitting. Tighten the nut to 125 15 N m (90 11 lb ft).
Hold the elbow (4) in position and torque the jam nut to 145 15 N m (105 11 lb ft).
Support the elbow (4). Tighten the nut (5) on the hose to 125 15 N m (90 11 lb ft).
Illustration 3 g01230687
Illustration 3 shows the routing of the 162-2501 Hose As (8). The hose is routed from the rail, around the rear of the fuel transfer pump (9), and into the 90 degree fitting (7) that is installed into the pump.
Illustration 4 g01230689
Some 3408 engines use an aftercooler that is mounted high. The mounting bracket (10) is located close to the 162-2501 Hose As (8). If there is not enough clearance to install the protective sleeve, the hose will need to be loosened and the hose will need to be repositioned. Refer to 5 for repositioning of the hose.
Illustration 5 g01230690
The hose must be realigned if any of the following conditions exist:
Not enough clearance against the fuel transfer pump
Not enough clearance against the support bracket
Loosen the end of the hose (12) .
Loosen the elbow and the jam nut (11). Note: Do not remove the hose.
Reposition the hose in order to acquire the desired clearance.
Hold the end of the hose (12). Tighten the jam nut (11) .Tighten the jam nut to the following torque. ... 143 15 N m (105 11 lb ft)Note: Locking pliers can be used on the crimped portion of the hose. Do not use the locking pliers on the braided portion of the hose. This will damage the hose which will cause a failure.
Tighten the end of the hose (12) .Tighten the end of the hose to the following torque. ... 125 15 N m (92 11 lb ft)Note: If adjustment of the hose is required, make sure that the hose is not bent. Also, ensure that the hose is not twisted. If these conditions exist the PTFE liner can be damaged.Installation of the Protective Sleeve Over the New Hose Assembly
Illustration 6 g01106118
Top viewInstallation of a protective sleeve for the hoses of the

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