107492-0000 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1074920000 1670029d00

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 107492-0000 1074920000

NISSAN-DIESEL 1670029D00 1670029d00

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Service parts 107492-0000 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 107049-3120

3. GOVERNOR 105923-3920

4. SUPPLY PUMP 105237-6450

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156639-8320

8. _ 159601-1520

9. _

10. NOZZLE AND HOLDER ASSY 105118-6544

11. Nozzle and Holder 16600-29D01

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105048-4130

14. NOZZLE 105017-9120

15. NOZZLE SET

Include in #1:

107492-0000 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 107492-0000 1074920000

NISSAN-DIESEL 1670029D00 1670029d00

Zexel num

Bosch num

Firm num

Name

107492-0000
107492-0001

1670029D00 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
FD46TI * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8250

Bosch type code 1 688 901 101

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 20.7

Opening pressure kgf/cm2 211

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600

Overflow valve 131425-0520

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

Tester oil delivery pressure kPa 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

PS/ACT control unit part no. 407910-3 03*

Selector switch no. 02

PS/ACT control unit part no. 407980-2 24*

Digi switch no. 01

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 5.6 5.57 5.63

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.75 90.25

Difference between angles 2
Cal 1-4 deg. 180 179.75 180.25

Difference between angles 3
Cyl.1-2 deg. 270 269.75 270.25

Injection quantity adjustment

Adjusting point -

Rack position 11.6

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 96.5 94.5 98.5

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the rack *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 5

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 5

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 7.5+-0.5

Pump speed r/min 510 510 510

Average injection quantity mm3/st. 13 11.2 14.8

Max. variation between cylinders % 0 -10 10

Fixing the rack *

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 5.5+-0.0 3

PS407910-303* V V1+0.05+ -0.01

PS407910-303* mm 5.5+-0.0 3

Standard for adjustment of the maximum variation between cylinders *

Remarks
Refer to items regarding the pre-stroke actuator

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.6)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 96.5 95.5 97.5

Basic *

Fixing the lever *

Boost pressure kPa 40 40

Boost pressure mmHg 300 300

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 5

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 5

Injection quantity adjustment_04

Adjusting point B

Rack position R1+2.25

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 111 107 115

Fixing the lever *

Boost pressure kPa 40 40

Boost pressure mmHg 300 300

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 5

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 5

Injection quantity adjustment_05

Adjusting point C

Rack position R2-1

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 69 65 73

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 5

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 5

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position R2-1

Boost pressure kPa 6.7 5.4 8

Boost pressure mmHg 50 40 60

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R2(R1-1)

Boost pressure kPa 26.7 26.7 26.7

Boost pressure mmHg 200 200 200

0000001601

CU407980-224* *

Actuator retarding type *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 2.5 2.45 2.55

Output voltage V 2.83 2.82 2.84

Adjustment *

_02

CU407980-224* *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 5.6 5.57 5.63

Output voltage V 1.2 1 1.4

Confirmation *

Remarks
Output voltage V1

_03

CU407980-224* *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Output voltage V 3.05 3.05

Confirmation of operating range *

_04

CU407910-303* *

Actuator retarding type *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 2.5 2.45 2.55

Output voltage V 2.83 2.82 2.84

Adjustment *

_05

CU407910-303* *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 5.6 5.57 5.63

Output voltage V 1.2 1 1.4

Confirmation *

Remarks
Output voltage V1

_06

CU407910-303* *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Output voltage V 3.05 3.05

Confirmation of operating range *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke: BCL
----------
T1=AF72 BCL=1+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=90.5mm
----------
a=22.5deg+-5deg b=40deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa (2)Stopper bolt setting (3)Rack position = bb (speed = cc)
----------
aa=34mm bb=1.5+-0.3mm cc=0r/min
----------
a=22.5deg+-5deg b=45deg+-5deg

0000001301

(1)Pump vertical direction (2)Positions of coupling's standard threaded holes at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)Pre-stroke: bb
----------
aa=3deg bb=5.6+-0.03mm
----------
a=(50deg)

0000001401

(1)Pointer (2)Injection timing aligning mark (3)Fly weight (4)The actual shape and direction may be different from this illustration. Operation sequence 1. Turn the prestroke actuator OFF. 2. Turn the camshaft as far as the No.1 cylinder's beginning of injection position. 3. Check that the pointer alignment mark of the injection pump and the alignment mark of the flywheel are matching. 4. If they are not matching, erase the alignment mark on the flywheel side, and stamp an alignment mark on the flywheel position that matches with the pointer side alignment mark. 5. Check again that the coupling's key groove position is in the No.1 cylinder's beginning of injection position.
----------

----------

0000001701

A : Stopper pin B: Connector
----------

----------

0000001801

C:Shim
----------

----------

0000001901

A:Sealing position B:Pre-stroke actuator 1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully counterclockwise (viewed from the drive side). Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m) 2. Move the actuator in the clockwise direction when viewed from the drive side, and adjust so that it becomes the adjustment point of the adjustment value. Then tighten it. Tightening torque: 7^9 N.m (0.7^0.9 kgf.m) 3. After prestroke actuator installation adjustment, simultaneously stamp both the actuator side and housing side.
----------

----------

0000002201 RACK SENSOR

(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack sensor adjustment (-0620) (1)Fix the speed control lever at the full position (2)Set the speed to N1 r/min. (If the boost compensator is provided, apply boost pressure.) (3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01. (4)At that time, rack position must be Ra. (5)Apply G at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the joint (B) and the end surface of the pump (H)
----------
N1=1400r/min Ra=R1(11.6)+2.25mm
----------

Information:

Illustration 9 g00293067
(5) Air shutoff solenoid that is mounted in the air intake pipe.
Illustration 10 g00281839
Air Shutoff (Typical Example)
Table 2
(1) Air transfer pipe. (5) Air shutoff solenoid.
(2) Valve assembly. (6) O-ring seal.
(3) Shutoff shaft. (7) Diode assembly.
(4) Governor control shaft. The air shutoff solenoid (5) is located in the air inlet system on the top of the engine. When the air shutoff solenoid (ASOS) is activated, the inlet air to the engine is mechanically shut off. The ASOS can be only activated in two ways:
The ASOS is activated by the overspeed switch (OS).
The ASOS is activated by the emergency stop switch (ES).Fuel Shutoff Solenoid (FSOS)
Illustration 11 g00281970
Fuel Solenoid (Typical Example) (1) Diode assembly. (2) Spring. (3) Governor drive. (4) Fuel solenoid. (5) Shaft.
Illustration 12 g00293070
(4) Fuel shutoff solenoid (FSOS) that is mounted on the governor.The fuel shutoff solenoid (FSOS) (4) is located on the governor or on the fuel injection pump of the engine.When the FSOS is energized, the spring (2) and the shaft (5) will cause the fuel rack to move directly or the fuel rack will move through governor drive (3) to the FUEL OFF position. The FSOS remains energized until the time delay relay causes the circuit of the FSOS to de-energize.Time Delay Relay (TD)
Illustration 13 g00281989
4W-8471 Time Delay Relay The time delay relay is an ON/OFF switch which has two controls. When the electric protection system is energized, one control will immediately activate the time delay relay. The other control will activate a relay after a delay of 9 seconds when a continuous signal is received. The time delay relay has a 70 second OFF delay after the signal is removed from both the input terminal (TD-1) and the input terminal (TD-2).The time delay relay is mounted in the junction box.2301AElectric Governor Control
Illustration 14 g00293071
(1) 2301A Electric Governor Speed Control
Illustration 15 g00293069
Electric governor actuator (EGA) (2) and fuel shutoff solenoid (FSOS) (3). These components are mounted on the top of the engine.The 2301A Electric Governor Control system consists of the following components:
2301A Control
Actuator (EGA)
Magnetic pickup (MPU)The 2301A Electric Governor Control system provides precision engine speed control. The 2301A Control constantly monitors the engine rpm. The control makes necessary corrections to the engine fuel setting through an actuator connected to the fuel system.The engine rpm is measured by the magnetic pickup (MU). The magnetic pickup makes an AC voltage that is sent to the 2301A Control. The 2301A Control then sends a DC voltage signal to the actuator in order to adjust the fuel flow.The actuator changes the electrical signal from the 2301A Control to a mechanical output. The mechanical output of the actuator causes the linkage from the actuator to move the fuel rack. This will increase the flow of fuel to the engine or this will decrease the flow of fuel to the engine. For example, if the engine speed is more than the speed setting, the 2301A Control will decrease the voltage output which