104740-6142 ZEXEL test values diesel fuel-injection equipment 13.04.

22 22:32:12 Page 1

ZEXEL Ass'y No. 104740-6142

Bosch Ass'y No. 9 460 620 023
Bosch Typecode
Engine Type 4EE1
Manufacturer ISUZU
Edition date 24.06.08 (1)

1 Adjustment conditions
CAT Designation Unit Set value min. max. Actual values OT
Test oil ISO4113orSAEJ967
d
1404 Test oil
P Test oil temperature degC 45 45 50
Nozzle 105780-0060
Bosch type code NP-DN0SD1510
Nozzle holder 105780-2150
P Opening pressure MPa 13 13 13.3
P Opening pressure kgf/cm2 133 133 136
Injection pipe 157805-7320
P Injection pipe mm 2-6-450
Inside diameter - outside diameter - length (mm)
Joint assembly 157641-4720
Tube assembly 157641-4020
P Transfer pump pressure kPa 20 20 20
P Transfer pump pressure kgf/cm2 0.2 0.2 0.2
Direction of rotation (viewed from drive side) R
Right

2 Adjustment specification
2.1 Full load delivery
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1325 1325 1325
S Average injection quantity mm3/st. 34.9 34.4 35.4
S Difference in delivery mm3/st. 3.5 3.5
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 400 400 400
C Average injection quantity mm3/st. 37.7 33.7 41.7
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 510 510 510
C Average injection quantity mm3/st. 34.3 31.5 37.1
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 600 600 600
C Average injection quantity mm3/st. 33.3 30.5 36.1
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1325 1325 1325
C Average injection quantity mm3/st. 34.9 33.9 35.9
C Difference in delivery mm3/st. 3.5 3.5
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1750 1750 1750
C Average injection quantity mm3/st. 35.6 33.6 37.6
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2200 2200 2200
C Average injection quantity mm3/st. 35.3 33.3 37.3
2.2 Governing
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2600 2600 2600
S Average injection quantity mm3/st. 17.1 14.1 20.1
S Difference in delivery mm3/st. 5 5
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2400 2400 2400
C Average injection quantity mm3/st. 34.3 28.8 37.8
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2600 2600 2600
C Average injection quantity mm3/st. 17.1 13.6 20.6
C Difference in delivery mm3/st. 5 5
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2800 2800 2800

C = Check value)
OT = Outside Tolerance (X is set)
104740-6142 ZEXEL test values diesel fuel-injection equipment 13.04.22 22:32:12 Page 2

C Average injection quantity mm3/st. 5 5

2.3 Idle
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 435 435 435
S Average injection quantity mm3/st. 12.5 10.5 14.5
S Difference in delivery mm3/st. 2 2
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 435 435 435
C Average injection quantity mm3/st. 12.5 10.5 14.5
C Difference in delivery mm3/st. 2 2
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 620 620 620
C Average injection quantity mm3/st. 5 5
2.4 Start
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 100 100 100
S Average injection quantity mm3/st. 51.5 41.5 61.5
P Basic *
Remarks
IDLE
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 100 100 100
C Average injection quantity mm3/st. 51.5 41.5 61.5
Remarks
IDLE
2.5 Stop
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 435 435 435
C Average injection quantity mm3/st. 0 0 0
Remarks
Magnet OFF at idling position
2.6 Overflow
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1250 1250 1250
C Overflow quantity cm3/min 600 470 730
2.7 Pump chamber pressure
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1250 1250 1250
S Pressure kPa 392 372 412
S Pressure kgf/cm2 4 3.8 4.2
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 850 850 850
C Pressure kPa 284 255 313
C Pressure kgf/cm2 2.9 2.6 3.2
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1250 1250 1250
C Pressure kPa 392 372 412
C Pressure kgf/cm2 4 3.8 4.2
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2100 2100 2100
C Pressure kPa 618 579 657
C Pressure kgf/cm2 6.3 5.9 6.7
2.8 Timer
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1250 1250 1250
S Timer stroke mm 2.6 2.4 2.8
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 850 850 850
C Timer stroke mm 0.5 0.1 1.5
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1250 1250 1250
C Timer stroke mm 2.6 2.3 2.9
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1750 1750 1750
C Timer stroke mm 5 4.4 5.6
C = Check value)
OT = Outside Tolerance (X is set)
104740-6142 ZEXEL test values diesel fuel-injection equipment 13.04.22 22:32:12 Page 3

CAT Designation Unit Set value min. max. Actual values OT

P Pump speed r/min 2100 2100 2100
C Timer stroke mm 6.2 5.8 6.6
2.9 Magnet
CAT Designation Unit Set value min. max. Actual values OT
C Max. applied voltage V 8 8 8
P Test voltage V 13 12 14
2.10 Compensator
2.10.1 Load-timer adjustment
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1250 1250 1250
S Average injection quantity mm3/st. 22.7 21.7 23.7
S Timer stroke TA mm 2.3 2.3 2.3
About
S Timer stroke variation dT mm 0.3 0.1 0.5
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1250 1250 1250
C Timer stroke TA mm 2.6 2.3 2.9
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1250 1250 1250
C Average injection quantity mm3/st. 22.7 21.2 24.2
C Timer stroke TA mm 2.3 2.3 2.3
About
C Timer stroke variation dT mm 0.3 0 0.6
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1250 1250 1250
C Average injection quantity mm3/st. 10.8 9.3 12.3
C Timer stroke TA mm 1.5 1.5 1.5
About
C Timer stroke variation dT mm 1.1 0.6 1.6
2.11 Additional device adjustment

C = Check value)
OT = Outside Tolerance (X is set)
104740-6142 ZEXEL test values diesel fuel-injection equipment 13.04.22 22:32:12 Page 4

2.11.1 Additional device 1

Name POTENTIOMETER ADJUSTMENT
N1=1000r/min
Q1=17.3~19.3mm3/st
V1=4.95+-0.03V
V2=1.80+-0.45V
V3=9.13+-0.65V

N1=1000r/min Adjustment of the potentiometer

V1=4.95+-0.03V Adjustment method (supply voltage Vi, dummy bolt method)
Q1=17.3~19.3mm3/st 1. Hold the dummy bolt (A) against the control lever at position N = N1 and Q = Q1 and fix using t
he lock nut.
2. When adjusting the potentiometer, position the control lever against the dummy bolt (A) and ad
just so that the output voltage is V1.
3. After adjustment, remove the dummy bolt and confirm that the potentiometer output voltage at t
he control lever's idling and full positions is as specified in the table.
(A) Dummy bolt
N:Pump speed
V:Output voltage
Q:Injection quantity
C/L: control lever position
I:Idling lever position
F:Full speed lever position
B:Adjusting point
C:Checking point

C = Check value)
OT = Outside Tolerance (X is set)
104740-6142 ZEXEL test values diesel fuel-injection equipment 13.04.22 22:32:12 Page 5

2.11.2 Additional device 2

Name W-CSD ADJUSTMENT
N1=500r/min
a=20degC
b=-20degC
c=4.4+-1deg
d=6.9+-3deg
O1=0.9+-0.4mm
O2=1.8+-0.6mm
Q1=1.5+-0.3mm
Q2=2.3+-1mm

L1=1.0+-0.05mm Adjustment of the W-CSD

L2=L1+-0.05mm 1. Adjustment of the timer stroke
Adjust screw (A) so that the timer stroke is the value determined from the graph.
2. Adjustment of the position of the intermediate lever.
Insert the shim (L1) between the control lever (I) and the idle set screw (G).
Align the intermediate lever (F) with the aligning mark (J) and fix the intermediate lever screw (E)
so that it contacts the control lever.
3. Adjustment of the FICD
Insert the shim (L2) between the control lever (I) and the idle set screw (G).
Use adjusting screw to fix the CSD lever (C) in the position where it operates the intermediate lev
er via the rod (D).
(O) Timer stroke adjustment (mm) - (1):TA = -0.0235t+1.37 (-20 deg <= t <=60 deg C)
(P) Lever position (deg) 2:theta 1 = -0.0625t+5.65 (-20 deg C <= t <= 20 deg C)
Theta 2 = -0.1108t + 6.62 (20 deg C =< t =< 60 deg C)
(Q) lever position (mm) 3: L1 = -0.02075t+1.878 (-20 deg C <= t <= 20 deg C)
L2 = -0.03900t + 2.277 (20 deg C =< t =< 60 deg C)
The (Q) indicates the clearance between the control lever and the idle set screw.
(R) Cooling water temperature (deg C)
(S) Cooling water temperature: increase direction
N:Pump speed
X:Temperature t (deg C)
Y1:Timer stroke TA (mm)
Y2:Control lever position at theta L (deg, mm)
(T) Timer piston stroke (mm)
(U) Lever position (deg)
(W) Lever position (mm)

3 Assembly dimension
CAT Designation Unit Set value min. max. Actual values OT
S K dimension mm 3.3 3.2 3.4
S KF dimension mm 5.3 5.2 5.4
S MS dimension mm 0.8 0.7 0.9
S Pre-stroke mm 0.1 0.08 0.12
S Control lever angle alpha deg. 20 16 24
S Control lever angle beta deg. 44 40 48

C = Check value)
OT = Outside Tolerance (X is set)