4610

106675-4610
ZEXEL Ass'y No.

Bosch Ass'y No.
Bosch Typecode
Engine Type
Manufacturer
Edition date
P
P
P
P
P
P
Page 1
106675-4610
F 019 Z20 142
D2366T
DPICO
12.10.06 (5)
1 Adjustment conditions
CAT Designation
Test oil
07.01.15 16:00:54
ZEXEL test values diesel fuel-injection equipment
Test oil temperature

Nozzle and nozzle holder
Bosch type code
Nozzle
Bosch type code
Nozzle holder
Bosch type code
Opening pressure
Opening pressure
Injection pipe
Overflow valve
Overflow valve opening pressure
Overflow valve opening pressure
Tester oil delivery pressure
Tester oil delivery pressure
Direction of rotation (viewed from drive side)
Unit
Set value
min.
ISO4113 or {SAEJ96
7d}
1404 Test oil

degC
max.
40
40
105780-8140
EF8511/9A
105780-0000
DN12SD12T
105780-2080
EF8511/9
MPa
17.2
kgf/cm2
175
mm
8-3-600
Outer diameter - inner diameter - length (mm)
131424-4420
kPa
157
123
kgf/cm2
1.6
1.25
kPa
157
157
kgf/cm2
1.6
1.6
R
Right
45
Unit
min.
max.
1-5-3-6-2-4
4.3
NO.1
4.25
4.35
60
59.5
60.5
120
119.5
120.5
180
179.5
180.5
240
239.5
240.5
300
299.5
300.5
Set value
A
10.8
1100
145
0
*
*
80
600
min.
max.
1100
143
-2
1100
147
2
Set value
B
4.9+-0.5
400
15.5
0
*
0
0
min.
max.
400
14
-15
400
17
15
0
0
0
0
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
191
1.95
157
1.6
2 Adjustment specification
2.1 Injection timing adjustment
CAT Designation
P
Direction of rotation (viewed from drive side)
Set value
R
Right
P
S
P
Injection order
Pre-stroke
Beginning of injection position
Difference between angles 1
2.2 Injection quantity adjustment

CAT Designation
P
Adjusting point
P
Rack position
P
Pump speed
S
Average injection quantity
S
Max. variation between cylinders
P
Basic
P
Fixing the lever
P
Boost pressure
P
Boost pressure
CAT
P
P
P
S
S
P
P
P
Designation
Adjusting point
Rack position
Pump speed
Max. variation between cylinders
Fixing the rack
Boost pressure
Boost pressure
S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
mm
Governor side
deg.
Cal 1-5
deg.
Cal 1-3
deg.
Cal 1-6
deg.
Cyl.1-2
deg.
Cal 1-4
Unit
r/min
mm3/st.
%
kPa
mmHg
Unit
r/min
mm3/st.
%
kPa
mmHg
80
600
106675-4610
07.01.15 16:00:54
CAT Designation
P
Adjusting point
P
Rack position
P
Pump speed
S
P
Fixing the lever
P
Boost pressure
P
Boost pressure
P
Rack limit
2.3 Governor adjustment
Name
K=7
BCL=1.6+-0.1mm
2.4 Boost compensator adjustment

CAT Designation
P
Pump speed
P
Rack position
S
Boost pressure
S
Boost pressure
Unit
r/min
mm3/st.
kPa
mmHg
min.
max.
100
146
100
156
0
0
0
0
Set value
500
R1-1.6
13.3
100
min.
500
max.
500
11.3
85
15.3
115
Set value
500
R1-1
32
240
min.
500
max.
500
28
210
36
270
Set value
500
R1(10.8)
66.7
min.
500
max.
500
66.7
66.7
500
500
500
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Deliver without the torque control spring operating.
(4)RACK LIMIT
(5)Boost compensator stroke: BCL
(6)Set idle sub-spring
Unit
r/min
kPa
mmHg
CAT
P
P
S
S
Designation
Pump speed
Rack position
Boost pressure
Boost pressure
Unit
r/min
CAT
P
P
S
Designation
Pump speed
Rack position
Boost pressure
Unit
r/min
Boost pressure

Set value
E
100
146
*
0
0
*
Page 2
kPa
mmHg
kPa
About
mmHg
About
106675-4610
07.01.15 16:00:54
2.5 Speed control lever angle

Name
a=10deg+-5deg
b=27deg+-5deg
F:Full speed
I:Idle
(1)Stopper bolt setting
2.6 Stop lever angle
Name
a=32deg+-5deg
b=70deg+-5deg
aa=0r/min
bb=1-0.5mm
2.7 Additional device adjustment

N:Pump normal
S:Stop the pump.
(1)Pump speed aa and rack position bb (to be sealed at delivery)
Page 3
106675-4610
07.01.15 16:00:54
Page 4
2.7.1 Additional device 1

Name
TAMPER PROOF
T1=2.5N-m(0.25kgf-m)
T2=2.9~4.4N-m(0.3~0.45kgf-m)

Tamperproofing-equipped boost compensator cover installation procedure

(A) After adjusting the boost compensator, tighten the bolts to remove the heads.
(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)
106675-4610
07.01.15 16:00:54
2.8 Timing setting

Name
a=(70deg)
(1)Pump vertical direction

(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)(4)-

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106675-4610

ZEXEL Ass'y No.

ZEXEL test values diesel fuel-injection equipment

Test oil temperature

1404 Test oil

Difference between angles 1

Difference between angles 2

Difference between angles 3

Difference between angles 4

Difference between angles 5

2.2 Injection quantity adjustment

S = Setting value, C = Check value)

ZEXEL test values diesel fuel-injection equipment

2.4 Boost compensator adjustment

S = Setting value, C = Check value)

ZEXEL test values diesel fuel-injection equipment

2.5 Speed control lever angle

S = Setting value, C = Check value)

ZEXEL test values diesel fuel-injection equipment

2.7.1 Additional device 1

S = Setting value, C = Check value)

Tamperproofing-equipped boost compensator cover installation procedure

ZEXEL test values diesel fuel-injection equipment

2.8 Timing setting

(1)Pump vertical direction

S = Setting value, C = Check value)

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