104742-2005 ZEXEL test values diesel fuel-injection equipment 03/04/19 17:49:15 Page 1

ZEXEL Ass'y No. 104742-2005

Bosch Ass'y No. 9 460 611 364
Bosch Typecode
Engine Type BD30TI
Manufacturer
Edition date 02/04/09 (8)

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
(Solenoid timer adjustment condition) OFF
With S/T O-ring; S/T OFF.
Timer measuring device installation position LOW PRESSURE SI
DE
Low pressure side

2 Adjustment specification
2.1 Full load delivery
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 900 900 900
P Boost pressure kPa 46 44.7 47.3
P Boost pressure kgf/cm2 0.47 0.456 0.484
P Boost pressure mmHg 345 335 355
S Average injection quantity mm3/st. 107.7 107.2 108.2
P Basic *
P Oil temperature degC 50 48 52
Remarks
CBS
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 900 900 900
P Boost pressure kPa 66.7 65.4 68
P Boost pressure kgf/cm2 0.68 0.666 0.694
P Boost pressure mmHg 500 490 510
S Average injection quantity mm3/st. 120.8 120.3 121.3
S Difference in delivery mm3/st. 10 10
P Basic *
P Oil temperature degC 50 48 52
Remarks
Full
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 600 600 600
P Boost pressure kPa 0 0 0
P Boost pressure kgf/cm2 0 0 0
P Boost pressure mmHg 0 0 0
C Average injection quantity mm3/st. 77.8 73.8 81.8
About
P Oil temperature degC 50 48 52

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
104742-2005 ZEXEL test values diesel fuel-injection equipment 03/04/19 17:49:15 Page 2

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

P Pump speed r/min 900 900 900
P Boost pressure kPa 46 44.7 47.3
P Boost pressure kgf/cm2 0.47 0.456 0.484
P Boost pressure mmHg 345 335 355
C Average injection quantity mm3/st. 107.7 105.7 109.7
P Basic *
P Oil temperature degC 50 48 52
Remarks
CBS
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 900 900 900
P Boost pressure kPa 66.7 65.4 68
P Boost pressure kgf/cm2 0.68 0.666 0.694
P Boost pressure mmHg 500 490 510
C Average injection quantity mm3/st. 120.8 118.8 122.8
C Difference in delivery mm3/st. 10.5 10.5
P Basic *
P Oil temperature degC 50 48 52
Remarks
Full
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1050 1050 1050
P Boost pressure kPa 66.7 65.4 68
P Boost pressure kgf/cm2 0.68 0.666 0.694
P Boost pressure mmHg 500 490 510
C Average injection quantity mm3/st. 115.8 111.3 120.3
About
P Oil temperature degC 50 48 52
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1200 1200 1200
P Boost pressure kPa 66.7 65.4 68
P Boost pressure kgf/cm2 0.68 0.666 0.694
P Boost pressure mmHg 500 490 510
C Average injection quantity mm3/st. 118.8 109.8 127.8
About
P Oil temperature degC 50 48 52
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1750 1750 1750
P Boost pressure kPa 66.7 65.4 68
P Boost pressure kgf/cm2 0.68 0.666 0.694
P Boost pressure mmHg 500 490 510
C Average injection quantity mm3/st. 133.3 128.3 138.3
About
P Oil temperature degC 50 48 52
2.2 Governing
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2100 2100 2100
P Boost pressure kPa 66.7 65.4 68
P Boost pressure kgf/cm2 0.68 0.666 0.694
P Boost pressure mmHg 500 490 510
S Average injection quantity mm3/st. 31.3 28.3 34.3
P Basic *
P Oil temperature degC 52 50 54
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2300 2300 2300
P Boost pressure kPa 66.7 65.4 68
P Boost pressure kgf/cm2 0.68 0.666 0.694
P Boost pressure mmHg 500 490 510
C Average injection quantity mm3/st. 5 5
P Oil temperature degC 52 50 54
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2100 2100 2100
P Boost pressure kPa 66.7 65.4 68
S = Setting value, C = Check value)
OT = Outside Tolerance (X is set)
104742-2005 ZEXEL test values diesel fuel-injection equipment 03/04/19 17:49:15 Page 3

P Boost pressure kgf/cm2 0.68 0.666 0.694

P Boost pressure mmHg 500 490 510
C Average injection quantity mm3/st. 31.3 26.3 36.3
P Basic *
P Oil temperature degC 52 50 54
2.3 Idle
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 350 350 350
P Boost pressure kPa 0 0 0
P Boost pressure kgf/cm2 0 0 0
P Boost pressure mmHg 0 0 0
S Average injection quantity mm3/st. 7.8 5.8 9.8
S Difference in delivery mm3/st. 2 2
P Basic *
P Oil temperature degC 48 46 50
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 350 350 350
P Boost pressure kPa 0 0 0
P Boost pressure kgf/cm2 0 0 0
P Boost pressure mmHg 0 0 0
C Average injection quantity mm3/st. 7.8 3.8 11.8
C Difference in delivery mm3/st. 2.5 2.5
P Basic *
P Oil temperature degC 48 46 50
2.4 Start
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 100 100 100
P Boost pressure kPa 0 0 0
P Boost pressure kgf/cm2 0 0 0
P Boost pressure mmHg 0 0 0
S Average injection quantity mm3/st. 124 94 154
About
P Basic *
P Oil temperature degC 48 46 50
Remarks
Full
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 100 100 100
P Boost pressure kPa 0 0 0
P Boost pressure kgf/cm2 0 0 0
P Boost pressure mmHg 0 0 0
C Average injection quantity mm3/st. 124 94 154
About
P Oil temperature degC 48 46 50
Remarks
Full
2.5 Stop
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 350 350 350
P Boost pressure kPa 0 0 0
P Boost pressure kgf/cm2 0 0 0
P Boost pressure mmHg 0 0 0
C Average injection quantity mm3/st. 0 0 0
P Oil temperature degC 48 46 50
Remarks
Magnet OFF at idling position
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 250 250 250
P Boost pressure kPa 0 0 0
P Boost pressure kgf/cm2 0 0 0
P Boost pressure mmHg 0 0 0
C Average injection quantity mm3/st. 5 5
P Oil temperature degC 48 46 50
Remarks

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
104742-2005 ZEXEL test values diesel fuel-injection equipment 03/04/19 17:49:15 Page 4

Magnet OFF at full-load position

2.6 Overflow
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1500 1500 1500
P Boost pressure kPa 66.7 65.4 68
P Boost pressure kgf/cm2 0.68 0.666 0.694
P Boost pressure mmHg 500 490 510
C Overflow quantity with S/T ON cm3/min 450 300 600
P Oil temperature degC 50 48 52
Remarks
Without S/T O-ring; S/T ON.
2.7 Pump chamber pressure
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1500 1500 1500
P Boost pressure kPa 66.7 65.4 68
P Boost pressure kgf/cm2 0.68 0.666 0.694
P Boost pressure mmHg 500 490 510
S Pressure with S/T ON kPa 716 657 775
S Pressure with S/T ON kgf/cm2 7.3 6.7 7.9
S Pressure with S/T OFF kPa 569 540 598
S Pressure with S/T OFF kgf/cm2 5.8 5.5 6.1
P Basic *
P Oil temperature degC 50 48 52
Remarks
OFF
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1500 1500 1500
P Boost pressure kPa 66.7 65.4 68
P Boost pressure kgf/cm2 0.68 0.666 0.694
P Boost pressure mmHg 500 490 510
C Pressure with S/T OFF kPa 569 530 608
C Pressure with S/T OFF kgf/cm2 5.8 5.4 6.2
P Basic *
P Oil temperature degC 50 48 52
Remarks
OFF
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1750 1750 1750
P Boost pressure kPa 66.7 65.4 68
P Boost pressure kgf/cm2 0.68 0.666 0.694
P Boost pressure mmHg 500 490 510
C Pressure with S/T OFF kPa 647 608 686
About
C Pressure with S/T OFF kgf/cm2 6.6 6.2 7
About
P Oil temperature degC 50 48 52
2.8 Timer
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1500 1500 1500
P Boost pressure kPa 66.7 65.4 68
P Boost pressure kgf/cm2 0.68 0.666 0.694
P Boost pressure mmHg 500 490 510
S Timer stroke with S/T ON mm 5.9 5.5 6.3
About
S Timer stroke with S/T OFF mm 2.3 2.1 2.5
P Basic *
P Oil temperature degC 50 48 52
Remarks
OFF
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1250 1250 1250
P Boost pressure kPa 66.7 65.4 68
P Boost pressure kgf/cm2 0.68 0.666 0.694
P Boost pressure mmHg 500 490 510

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
104742-2005 ZEXEL test values diesel fuel-injection equipment 03/04/19 17:49:15 Page 5

C Timer stroke with S/T ON mm 4.3 3.6 5

About
C Timer stroke with S/T OFF mm 0.6 0 1.2
P Oil temperature degC 50 48 52
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1500 1500 1500
P Boost pressure kPa 66.7 65.4 68
P Boost pressure kgf/cm2 0.68 0.666 0.694
P Boost pressure mmHg 500 490 510
C Timer stroke with S/T ON mm 5.9 5.3 6.5
About
C Timer stroke with S/T OFF mm 2.3 1.9 2.7
P Basic *
P Oil temperature degC 50 48 52
Remarks
OFF
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1750 1750 1750
P Boost pressure kPa 66.7 65.4 68
P Boost pressure kgf/cm2 0.68 0.666 0.694
P Boost pressure mmHg 500 490 510
C Timer stroke with S/T OFF mm 4.2 3.6 4.8
About
P Oil temperature degC 50 48 52
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2000 2000 2000
P Boost pressure kPa 66.7 65.4 68
P Boost pressure kgf/cm2 0.68 0.666 0.694
P Boost pressure mmHg 500 490 510
C Timer stroke with S/T OFF mm 5.9 5.4 6.3
P Oil temperature degC 50 48 52
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

3 Assembly dimension
CAT Designation Unit Set value min. max. Actual values OT
S K dimension mm 3.6 3.5 3.7
S KF dimension mm 6.85 6.75 6.95
S MS dimension mm 0.4 0.3 0.5
S BCS stroke mm 5.8 5.7 5.9
S Pre-stroke mm 0.2 0.18 0.22
S Control lever angle alpha deg. 54 50 58
S Control lever angle beta deg. 37 32 42

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)