101605-0321 ZEXEL test values diesel fuel-injection equipment 25/05/20 10:52:36 Page 1
ZEXEL Ass'y No. 101605-0321
Bosch Ass'y No. F 019 Z20 417
Bosch Typecode
Engine Type 6BG1-T
Manufacturer ISUZU
Edition date 27/09/05 (3)
1 Adjustment conditions
CAT Designation Unit Set value min. max. Actual values OT
Test oil ISO4113 or {SAEJ96
7d}
N=Measure the actual speed.
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 134424-4120
P Overflow valve opening pressure kPa 255 221 289
P Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95
P Tester oil delivery pressure kPa 255 255 255
P Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6
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 1-5-3-6-2-4
S Pre-stroke mm 4.2 4.15 4.25
P Beginning of injection position NO.1
Drive side
S Difference between angles 1 deg. 60 59.5 60.5
NA
S Difference between angles 2 deg. 120 119.5 120.5
Rack position at N = 900 is the same as in the reference point A for row L 103662-3125
S Difference between angles 3 deg. 180 179.5 180.5
OFF
S Difference between angles 4 deg. 240 239.5 240.5
Rack position at N = 900 is the same as in the reference point A for row L 103662-3123
S Difference between angles 5 deg. 300 299.5 300.5
Rack position at N = 900 is the same as in the reference point A for row L 103662-3344
2.2 Injection quantity adjustment
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point A
P Rack position 10.3
P Pump speed r/min 975 975 975
S Average injection quantity mm3/st. 92 90.5 93.5
S Max. variation between cylinders % 0 -2 2
P Basic *
P Fixing the lever *
P Boost pressure kPa 74.6 74.6
P Boost pressure mmHg 560 560
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point -
P Rack position 8+-0.5
P Pump speed r/min 450 450 450
S Average injection quantity mm3/st. 15 13.7 16.3
S Max. variation between cylinders % 0 -14 14
P Fixing the rack *
P Boost pressure kPa 0 0 0
P Boost pressure mmHg 0 0 0
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point E
S = Setting value, C = Check value)
OT = Outside Tolerance (X is set)
101605-0321 ZEXEL test values diesel fuel-injection equipment 25/05/20 10:52:36 Page 2
P Rack position 10.5++
P Pump speed r/min 100 100 100
S Average injection quantity mm3/st. 110 105 115
P Fixing the lever *
P Boost pressure kPa 0 0 0
P Boost pressure mmHg 0 0 0
P Rack limit *
2.3 Governor adjustment
Name
K=9 N:Pump speed
BCL=0.7+-0.1mm R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
(4)Set idle sub-spring
(5)Main spring setting
(6)Boost compensator stroke: BCL
2.4 Boost compensator adjustment
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 500 500 500
P Rack position R1-0.7
S Boost pressure kPa 37.3 33.3 41.3
S Boost pressure mmHg 280 250 310
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 500 500 500
P Rack position R1(10.3)
S Boost pressure kPa 61.3 54.6 68
S Boost pressure mmHg 460 410 510
S = Setting value, C = Check value)
OT = Outside Tolerance (X is set)
101605-0321 ZEXEL test values diesel fuel-injection equipment 25/05/20 10:52:36 Page 3
2.5 Speed control lever angle
Name
a=3deg+-5deg
b=18deg+-5deg
F:Full speed
I:Idle
(1)Stopper bolt setting
2.6 Stop lever angle
Name
a=32deg+-5deg
b=(55deg)
aa=0r/min N:Pump normal
bb=1-0.5mm S:Stop the pump.
(1)Pump speed aa and rack position bb (to be sealed at delivery)
(2)Normal
2.7 Additional device adjustment
S = Setting value, C = Check value)
OT = Outside Tolerance (X is set)
101605-0321 ZEXEL test values diesel fuel-injection equipment 25/05/20 10:52:36 Page 4
2.7.1 Additional device 1
Name TAMPER PROOF
T1=2.5N-m(0.25kgf-m) Tamperproofing-equipped boost compensator cover installation procedure
T2=2.9~4.4N-m(0.3~0.45kgf-m) (A): After adjusting the boost compensator, assemble then tighten the bolts to remove the heads.
(B): Specified torque
(1)Before adjusting the governor and the boost compensator, tighten the screw to the specified to
rque.
(Tightening torque T = T1 maximum)
(2)After adjusting the governor and the boost compensator, tighten to the specified torque to brea
k off the bolt heads.
(Tightening torque T = T2)
2.8 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)
