1 Adjustment conditions CAT Designation Unit Set value min. max. Actual values OT

Transcription

1 ZEXEL test values diesel fuel-injection equipment 2009/12/04 23:17:48 Page 1 ZEXEL Ass'y No Bosch Ass'y No Bosch Typecode Engine Type 4BD2 Manufactures ISUZU Edition date 2003/04/21 (5) 1 Adjustment conditions Test oil ISO4113 or {SAEJ96 7d} N=Measure the actual speed. P Test oil temperature degc Nozzle and nozzle holder Bosch type code EF8511/9A Nozzle Bosch type code DN12SD12T Nozzle holder Bosch type code EF8511/9 P Opening pressure MPa 17.2 P Opening pressure kgf/cm2 175 Injection pipe mm Outer diameter - inner diameter - length (mm) Overflow valve P Overflow valve opening pressure kpa P Overflow valve opening pressure kgf/cm P Tester oil delivery pressure kpa P Tester oil delivery pressure kgf/cm Direction of rotation (viewed from drive side) R Right 2 Adjustment specification 2.1 Injection timing adjustment P Direction of rotation (viewed from drive side) R Right P Injection order S Pre-stroke mm S Rack position R=A Q=80.3(mm3/st)/N=700(r/min) P Beginning of injection position NO.1 Drive side S Difference between angles 1 deg Rack position at N = 900 is the same as in the reference point A for row L S Difference between angles 2 deg Rack position at N = 900 is the same as in the reference point A for row L S Difference between angles 3 deg Rack position at N = 900 is the same as in the reference point A for row L Injection quantity adjustment P Adjusting point - P Rack position 12.1 P Pump speed r/min S Average injection quantity mm3/st S Max. variation between cylinders % P Basic * P Fixing the rack * P Standard for adjustment of the maximum vari * ation between cylinders P Adjusting point H P Rack position P Pump speed r/min S Average injection quantity mm3/st S Max. variation between cylinders % P Fixing the rack *

2 ZEXEL test values diesel fuel-injection equipment 2009/12/04 23:17:48 Page 2 P Standard for adjustment of the maximum vari * ation between cylinders P Adjusting point A P Rack position R1(12.1) P Pump speed r/min S Average injection quantity mm3/st P Basic * P Boost pressure kpa P Boost pressure mmhg P Adjusting point B P Rack position R1-0.5 P Pump speed r/min S Average injection quantity mm3/st P Boost pressure kpa P Boost pressure mmhg P Adjusting point C P Rack position R2(R1-0.15) S Average injection quantity mm3/st P Boost pressure kpa P Boost pressure mmhg P Adjusting point D P Rack position R2-0.3 S Average injection quantity mm3/st P Boost pressure kpa P Boost pressure mmhg P Adjusting point I P Rack position - P Pump speed r/min S Average injection quantity mm3/st P Boost pressure kpa P Boost pressure mmhg Governor adjustment

3 ZEXEL test values diesel fuel-injection equipment 2009/12/04 23:17:48 Page 3 T1=F86 BCL= mm N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: mm. (3)Boost compensator stroke: BCL 2.4 Boost compensator adjustment P Rack position R2-0.3 S Boost pressure kpa S Boost pressure mmhg P Rack position R2(R1-0.15) S Boost pressure kpa About S Boost pressure mmhg About 2.5 Timer adjustment S Pump speed r/min P Advance angle deg Remarks Start P Pump speed r/min 500 S Advance angle deg P Pump speed r/min 1500 S Advance angle deg Remarks Finish 2.6 Speed control lever angle

4 ZEXEL test values diesel fuel-injection equipment 2009/12/04 23:17:48 Page 4 a=6.5deg+-5deg b=32deg+-3deg aa=0.1mm bb=0.25mm 2.7 Stop lever angle a=45deg+-5deg b=29deg+-5deg F:Full speed 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. 2.8 Additional device adjustment Additional device 1 ACS N:Pump normal S:Stop the pump.

5 ZEXEL test values diesel fuel-injection equipment 2009/12/04 23:17:48 Page 5 L1= mm L2= mm Additional device 2 ACS Ra=R1(12.1)mm Rb=R1-0.25mm P1= kPa( mmHg) P2= kPa(462+-5mmHg) Q1= cm3/1000st Q2=(70.7)+-2cm3/1000st (A) Aneroid compensator (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. N1=950r/min L1= mm L2= mm h1=0.15mm Additional device 3 FICD (A) Set screw (B) Push rod 1 (C) Push rod 2 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.

6 ZEXEL test values diesel fuel-injection equipment 2009/12/04 23:17:48 Page 6 L1=(3)mm P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) N1=450r/min R1= mm 2.9 Timing setting a=(100deg) (a) actuator (B) Screw (c) Nut 1. FICD adjustment (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. 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)-