101481-0153 ZEXEL test values diesel fuel-injection equipment 07/03/22 08:35:21 Page 1

ZEXEL Ass'y No. 101481-0153

Bosch Ass'y No.
Bosch Typecode
Engine Type 4BD2
Manufacturer ISUZU
Edition date 21/04/03 (5)

1 Adjustment conditions
CAT Designation Unit Set value min. max. Actual values OT
Test oil ISO4113 or {SAEJ96
7d}
1404 Test oil
P Test oil temperature degC 40 40 45
Nozzle and nozzle holder 105780-8140
Bosch type code EF8511/9A
Nozzle 105780-0000
Bosch type code DN12SD12T
Nozzle holder 105780-2080
Bosch type code EF8511/9
P Opening pressure MPa 17.2
P Opening pressure kgf/cm2 175
Injection pipe mm 6-2-600
Outer diameter - inner diameter - length (mm)
Overflow valve 131424-4920
P Overflow valve opening pressure kPa 127 107 147
P Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5
P Tester oil delivery pressure kPa 157 157 157
P Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6
Direction of rotation (viewed from drive side) R
Right

2 Adjustment specification
2.1 Injection timing adjustment
CAT Designation Unit Set value min. max. Actual values OT
P Direction of rotation (viewed from drive side) R
Right
P Injection order 1-3-4-2
S Pre-stroke mm 2.8 2.75 2.85
S Rack position R=A
Point A
P Beginning of injection position NO.1
Drive side
S Difference between angles 1 deg. 90 89.5 90.5
Cal 1-3
S Difference between angles 2 deg. 180 179.5 180.5
Cal 1-4
S Difference between angles 3 deg. 270 269.5 270.5
Cyl.1-2
2.2 Injection quantity adjustment
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point -
P Rack position 12.1
P Pump speed r/min 950 950 950
S Average injection quantity mm3/st. 76.8 75.2 78.4
S Max. variation between cylinders % 0 -4 4
P Basic *
P Fixing the rack *
P Standard for adjustment of the maximum vari *
ation between cylinders
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point H
P Rack position 9.5+-0.5
P Pump speed r/min 365 365 365
S Average injection quantity mm3/st. 9 7.7 10.3
S Max. variation between cylinders % 0 -14 14
P Fixing the rack *
P Standard for adjustment of the maximum vari *
ation between cylinders
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point A
P Rack position R1(12.1)
P Pump speed r/min 950 950 950
S Average injection quantity mm3/st. 76.8 75.8 77.8
P Basic *
S = Setting value, C = Check value)
OT = Outside Tolerance (X is set)
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P Fixing the lever *

P Boost pressure kPa 24 24
P Boost pressure mmHg 180 180
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point B
P Rack position R1-0.5
P Pump speed r/min 1500 1500 1500
S Average injection quantity mm3/st. 72.4 68.4 76.4
P Fixing the lever *
P Boost pressure kPa 24 24
P Boost pressure mmHg 180 180
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point C
P Rack position R2(R1-0.15)
P Pump speed r/min 650 650 650
S Average injection quantity mm3/st. 67.5 63.5 71.5
P Fixing the lever *
P Boost pressure kPa 24 24
P Boost pressure mmHg 180 180
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point D
P Rack position R2-0.3
P Pump speed r/min 650 650 650
S Average injection quantity mm3/st. 60.8 56.8 64.8
P Fixing the lever *
P Boost pressure kPa 0 0 0
P Boost pressure mmHg 0 0 0
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point I
P Rack position -
P Pump speed r/min 150 150 150
S Average injection quantity mm3/st. 93 93 109
P Fixing the lever *
P Boost pressure kPa 0 0 0
P Boost pressure mmHg 0 0 0

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
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2.3 Governor adjustment

Name

T1=F86 N:Pump speed

BCL=0.3+-0.1mm R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Boost compensator stroke: BCL
2.4 Boost compensator adjustment
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 650 650 650
P Rack position R2-0.3
S Boost pressure kPa 6.7 6.7 9.4
S Boost pressure mmHg 50 50 70
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 650 650 650
P Rack position R2(R1-0.15)
S Boost pressure kPa 10.7 10.7 10.7
About
S Boost pressure mmHg 80 80 80
About
2.5 Timer adjustment
CAT Designation Unit Set value min. max. Actual values OT
S Pump speed r/min 550--
P Advance angle deg. 0 0 0
Remarks
Start
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 500

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
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S Advance angle deg. 0.5 0.5

CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1500
S Advance angle deg. 3.9 3.4 4.4
Remarks
Finish
2.6 Speed control lever angle
Name
a=6.5deg+-5deg
b=32deg+-3deg

aa=0.1mm F:Full speed

bb=0.25mm I:Idle
(1)Stopper bolt setting
(2)At M/S adjustment, confirm that M/S turns ON when speed lever is returned from full to idle an
d gap between speed lever and idle side stopper bolt is aa. Confirm that M/S turns OFF when spe
ed lever is again returned from full to idle at gap bb.
2.7 Stop lever angle
Name
a=45deg+-5deg
b=29deg+-5deg

N:Pump normal
S:Stop the pump.
2.8 Additional device adjustment

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
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2.8.1 Additional device 1

Name ACS

L1=24+-0.5mm (A) Aneroid compensator

L2=1.5+-0.5mm (B) Set screw
(C) Boost pressure inlet
(D) Rack positioning screw
(E): Aneroid compensator main body
(F) Boost compensator spring
(G): Aneroid compensator spring
(H): Adjusting notch
(I) Push rod
1. Instructions for adjusting the boost compensator with the aneroid compensator
(1)Select a pushrod to obtain L1 at full boost.
(2)Remove the aneroid compensator main body.
(3)Adjust the booster compensator stroke by turning the screw at (D.
(4)Adjust the beginning of boost compensator operation by turning the notch at (H).
(5)Install the aneroid compensator at full boost state.
(6)Turn (B)'s set screw so that the distance between the snapring and the body is L2.
(7)Screw in the aneroid compensator main body and adjust the point where it comes into play.

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
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2.8.2 Additional device 2

Name ACS
Ra=R1(12.1)mm
Rb=R1-0.25mm
P1=74.6+-2.7kPa(560+-20mmHg)
P2=61.6+-0.7kPa(462+-5mmHg)
Q1=76.8+-1cm3/1000st
Q2=(70.7)+-2cm3/1000st

N1=950r/min (A) Set screw

L1=1.5+-0.5mm (B) Push rod 1
L2=24+-0.5mm (C) Push rod 2
h1=0.15mm 1. Adjustment of the aneroid compensator itself and the adjustment after mounting the governor
(1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position.
(2)Screw in (A) to obtain the performance shown in the graph (to obtain L1).
(3)Adjust the (D) spacer so that dimension L2 is obtained.
(4)As there is hysterisis, measure when the absolute pressure drops.
(5)Hysterisis must not exceed rack position = h1.
2.8.3 Additional device 3
Name FICD

L1=(3)mm (a) actuator

P1=53.3kPa(400mmHg) (B) Screw
P2=53.3kPa(400mmHg) (c) Nut
N1=450r/min 1. FICD adjustment
R1=9.3+-0.1mm (1)Set the clearance between the actuator rod and speed lever to approx. L1.
(2)Loosen nut (C) and fully screw in the actuator (A)'s screw (B).
(3)Apply negative pressure P1 to the actuator (A) and fully screw in screw (B).
(4)Set the pump speed at N1
(5)Set the rack position at R1.
(6)Tighten the actuator (A)'s screw (B) and fix using the nut (C).
(7)Apply P2 to negative pressure port A and confirm that the FICD operates normally.

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
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2.9 Timing setting

Name
a=(100deg)

aa=8deg (1)Pump vertical direction

(2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)