104749-5471 ZEXEL test values diesel fuel-injection equipment 24/10/18 11:24:17 Page 1
ZEXEL Ass'y No. 104749-5471
Bosch Ass'y No. 9 460 611 847
Bosch Typecode
Engine Type C240
Manufacturer ISUZU
Edition date 07/06/02
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) L
Left
2 Adjustment specification
2.1 Full load delivery
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
S Average injection quantity mm3/st. 34.8 34.3 35.3
S Difference in delivery mm3/st. 2.5 2.5
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1375 1375 1375
C Average injection quantity mm3/st. 9.7 7.2 12.2
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1250 1250 1250
C Average injection quantity mm3/st. 34.6 32.5 36.7
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
C Average injection quantity mm3/st. 34.8 33.8 35.8
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 600 600 600
C Average injection quantity mm3/st. 35.2 33.2 37.2
2.2 Governing
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1375 1375 1375
S Average injection quantity mm3/st. 9.7 7.7 11.7
S Difference in delivery mm3/st. 2.5 2.5
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1425 1425 1425
C Average injection quantity mm3/st. 4 4
2.3 Idle
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 350 350 350
S Average injection quantity mm3/st. 8.3 6.3 10.3
S Difference in delivery mm3/st. 2.5 2.5
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
S = Setting value, C = Check value)
OT = Outside Tolerance (X is set)
104749-5471 ZEXEL test values diesel fuel-injection equipment 24/10/18 11:24:17 Page 2
P Pump speed r/min 400 400 400
C Average injection quantity mm3/st. 4 4
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 350 350 350
C Average injection quantity mm3/st. 8.3 6.3 10.3
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 288 288 288
C Average injection quantity mm3/st. 34.1 31.1 37.1
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. 48 45 51
P Basic *
2.5 Stop
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 350 350 350
C Average injection quantity mm3/st. 0 0 0
Remarks
Magnet OFF
2.6 Overflow
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
C Overflow quantity cm3/min 420 289.8 550.2
2.7 Pump chamber pressure
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
S Pressure kPa 402 382 422
S Pressure kgf/cm2 4.1 3.9 4.3
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
C Pressure kPa 402 382 422
C Pressure kgf/cm2 4.1 3.9 4.3
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1250 1250 1250
C Pressure kPa 460.5 431 490
C Pressure kgf/cm2 4.7 4.4 5
2.8 Timer
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
S Timer stroke mm 2.5 2.3 2.7
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 600 600 600
C Timer stroke mm 0.9 0.9
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
C Timer stroke mm 2.5 2.2 2.8
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1250 1250 1250
C Timer stroke mm 3.7 3.1 4.3
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1375 1375 1375
C Timer stroke mm 4.1 3.7 4.5
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 Additional device adjustment
S = Setting value, C = Check value)
OT = Outside Tolerance (X is set)
104749-5471 ZEXEL test values diesel fuel-injection equipment 24/10/18 11:24:17 Page 3
2.10.1 Additional device 1
Name STARTING I/Q ADJUSTMENT
L=2~8.5mm
Starting injection quantity adjustment
Adjust the adjusting bolt A so that the starting injection quantity adjustment is within the standar
ds. Fix using the nut B.
(C) Stop lever
L:Adjustment dimensions
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 5.8 5.7 5.9
S MS dimension mm 2 1.9 2.1
S Control lever angle alpha deg. 25 21 29
S Control lever angle beta deg. 38 33 43
S = Setting value, C = Check value)
OT = Outside Tolerance (X is set)
