101603-8552 ZEXEL test values diesel fuel-injection equipment 19-05-25 13:45:21 Page 1

ZEXEL Ass'y No. 101603-8552

Bosch Ass'y No. 9 400 610 661
Bosch Typecode
Engine Type 6HH1-S
Manufacturer ISUZU
Edition date 26-11-02 (6)

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 1-5-3-6-2-4
S Pre-stroke mm 3.4 3.35 3.45
P Beginning of injection position NO.1
Governor side
S Difference between angles 1 deg. 60 59.5 60.5
Cal 1-5
S Difference between angles 2 deg. 120 119.5 120.5
Cal 1-3
S Difference between angles 3 deg. 180 179.5 180.5
Cal 1-6
S Difference between angles 4 deg. 240 239.5 240.5
Cyl.1-2
S Difference between angles 5 deg. 300 299.5 300.5
Cal 1-4
2.2 Injection quantity adjustment
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point -
P Rack position 10.7
P Pump speed r/min 850 850 850
S Average injection quantity mm3/st. 59 57.4 60.6
S Max. variation between cylinders % 0 -2.5 2.5
P Basic *
P Fixing the rack *
P Standard for adjustment of the maximum vari *
ation between cylinders
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point -
P Rack position 9.6+-0.5
P Pump speed r/min 275 275 275
S Average injection quantity mm3/st. 9.4 8.1 10.7
S Max. variation between cylinders % 0 -14 14
P Fixing the rack *
P Standard for adjustment of the maximum vari *
ation between cylinders
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 A

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
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P Rack position R1(10.7)

P Pump speed r/min 850 850 850
S Average injection quantity mm3/st. 59 58 60
P Basic *
P Fixing the lever *
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point B
P Rack position R1+0.6
P Pump speed r/min 1425 1425 1425
S Average injection quantity mm3/st. 82 78.8 85.2
P Fixing the lever *
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point C
P Rack position R1+0.2
P Pump speed r/min 600 600 600
S Average injection quantity mm3/st. 49.8 46.6 53
P Fixing the lever *
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point I
P Rack position -
P Pump speed r/min 150 150 150
S Average injection quantity mm3/st. 130 130 138
P Fixing the lever *
P Rack limit *

S = Setting value, C = Check value)

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

Name

T1=K52 N:Pump speed

R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
2.4 Timer adjustment
CAT Designation Unit Set value min. max. Actual values OT
S Pump speed r/min 550--
P Advance angle deg. 0 0 0
Remarks
Start
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 500
S Advance angle deg. 0.5 0.5
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000
S Advance angle deg. 3 2.5 3.5
Remarks
Finish

S = Setting value, C = Check value)

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

Name
a=10deg+-5deg
b=38deg+-3deg

aa=35mm F:Full speed

I:Idle
(1)Use the pin at R = aa
(2)Stopper bolt set position 'H'
2.6 Stop lever angle
Name
a=12.5deg+-5deg
b=40deg+-5deg

aa=45mm N:Pump normal

S:Stop the pump.
(1)Use the pin at R = aa
2.7 Timing setting
Name
a=(160deg)

aa=14deg (1)Pump vertical direction

(2)Position of timer's threaded hole 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)