101401-7140 ZEXEL test values diesel fuel-injection equipment 21.05.

15 21:19:44 Page 1

ZEXEL Ass'y No. 101401-7140

Bosch Ass'y No. 9 400 610 411
Bosch Typecode
Engine Type 4HF1
Manufacturer ISUZU
Edition date 20.02.06 (2)

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) L
Left

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) L
Left
P Injection order 1-3-4-2
S Pre-stroke mm 4.1 4.05 4.15
S Rack position R=E
Point E
P Beginning of injection position NO.1
Governor 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 11.9
P Pump speed r/min 1310 1310 1310
S Average injection quantity mm3/st. 64.5 62.9 66.1
S Max. variation between cylinders % 0 -4 4
P Basic *
P Fixing the rack *
P Standard for adjustment of the maximum var *
iation between cylinders
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point H
P Rack position 9.8+-0.5
P Pump speed r/min 285 285 285
S Average injection quantity mm3/st. 15.5 14.2 16.8
S Max. variation between cylinders % 0 -10 10
P Fixing the rack *
C = Check value)
OT = Outside Tolerance (X is set)
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P Standard for adjustment of the maximum var *

iation between cylinders
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point A
P Rack position R1(11.9)
P Pump speed r/min 1310 1310 1310
S Average injection quantity mm3/st. 64.5 63.5 65.5
P Basic *
P Fixing the lever *
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point B
P Rack position R1
P Pump speed r/min 1600 1600 1600
S Average injection quantity mm3/st. 67.5 63.5 71.5
P Fixing the lever *
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point C
P Rack position R1-0.5
P Pump speed r/min 500 500 500
S Average injection quantity mm3/st. 44.7 40.7 48.7
P Fixing the lever *
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point E
P Rack position R1-0.05
P Pump speed r/min 960 960 960
S Average injection quantity mm3/st. 58.5 54.5 62.5
P Fixing the lever *

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

Name

T1=L31 N:Pump speed

R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
2.4 Timer adjustment
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min -
S Advance angle deg. 0 0 0
Remarks
Measure speed (beginning of operation).
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min -
S Advance angle deg. 5 4.5 5.5
Remarks
Measure the actual speed, stop

C = Check value)
OT = Outside Tolerance (X is set)
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2.5 Speed control lever angle

Name
a=41deg+-5deg
b=34deg+-3deg

F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
2.6 Stop lever angle
Name
a=20deg+-5deg
b=29deg+-5deg

aa=64mm N:Pump normal

S:Stop the pump.
(1)Use the hole at R = aa
2.7 Additional device adjustment

C = Check value)
OT = Outside Tolerance (X is set)
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2.7.1 Additional device 1

Name RACK SENSOR

V1=5+-0.01V Rack sensor adjustment

N1=960r/min 1. Flange type rack sensor (rack sensor adjustment -5*20)
Ra=R1(11.9)-0.05mm (1)These types of rack sensors do not need adjustment. Confirm the performance with the follo
Vist=2.61+-0.28V wing procedures.
(2)Mount the rack sensor main body to the pump main body.
(3)Fix the pump lever at full.
(4)At supply voltage V1, pump speed N1 and rack position Ra, confirm that the amp's output volt
age is Vist.
(5)Move the pump lever two or three times.
(6)Set again to full.
(7)Confirm that the amplifier output voltage is Vist.
(8)Fix the caution plate to the upper part of the rack sensor.
(For those without the caution plate instructions, make sure the nameplate of the rack sensor car
ries the "Don't hold here" caution.)
(9)Apply red paint to the rack sensor mounting bolts (2 places).

C = Check value)
OT = Outside Tolerance (X is set)
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2.7.2 Additional device 2

Name FICD
L=(5)mm

P1=53.3kPa(400mmHg) (A) applied negative pressure

P2=53.3kPa(400mmHg) (B) Screw
Na=440r/min (c) Nut
Ra=9.2+-0.1mm 1. Set the actuator as described below.
T1=1.2~1.6N-m(0.12~0.16kgf-m) (1)Confirm that there is clearance between the actuator lever and the speed lever.
(2)Loosen the nut (C).
(3)Push in the screw (B).
(4)Apply P1 from the actuator (A) part.
(5)Pull out the screw (B) slowly.
(6)Tighten and fix the nut (C) when pump speed is Na and the rack position is Ra.
(7)Torque the nut (C) to T1.
(8)Apply P2 several times.
(9)Confirm that the actuator functions normally.
(10)Confirm that there is a clearance between the actuator lever and the speed lever at that time.

C = Check value)
OT = Outside Tolerance (X is set)
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2.8 Timing setting

Name
a=(60deg)
b=(85deg)

aa=7deg (1)Pump vertical direction

(2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection
(3)Stamping position on the A/T outer rim
(4)Pump bracket check hole position.
(5)At the No 1 cylinder's beginning of injection, align with the projection seen through the bracket'
s check hole and mark the A/T's bevel C1.
(6)B.T.D.C.: aa

C = Check value)
OT = Outside Tolerance (X is set)
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