INJ.

PUMP CALIBRATION DATA 1/11

CONFIDENTIAL Ass'y No.: 107492-1112

ENGINE MODEL: 4HE1-X Date: 14 Mar.2003 4
Company: ISUZU
No. 8-97212-189-1
Injection pump: 107049-2073 Governor: 105934-0101
TCS4MD EP/RLD-M
1. Test condition
Pump rotation: Counter clockwise (viewed from drive side)

Nozzle & Nozzle Holder Ass'y: 105780-8250 (Bosch Type No. 1 688 901 101 )

Nozzle: 105780-0120 Nozzle Holder: 105780-2190

(Bosch Type No. 1 688 901 990) (Bosch Type No. 9 430 610 144)

Nozzle opening pressure: 20.7 MPa { 211 kgf/cm2 } Transfer pump pressure: 255 kPa { 2.6 kgf/cm2 }

Injection pipe: Outer Dia. 8 mm Inner Dia. 3 mm - Length 600 mm

+5
Test Oil: ISO4113 or SAE Standard Test Oil { SAE J967d } Oil Temp.: 40 C Ambient temperature: 23 5 C

Overflow valve opening pressure: 255 34 kPa { 2.6 0.35 kgf/cm2 } Selector switch No. 00 (For C/U 407910-303*)
Digi switch No. 11 (For C/U 407980-224*)
2. Injection timing
Pre-stroke: No.1 Plunger 4.0 0.03mm

Injection order: 1 3, 1 4, 1 2
90 15' 180 15' 270 15'

Plungers are numbered from the Governor side.

Tappet clearance Manually rotate the camshaft 2 3 times and confirm that it rotates smoothly.

3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan

Service Department Tel. (048)470-1559, Fax. (048)474-9856
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3. Injection timing adjustment

(Refer to the MITICS Repair and Maintenance Service Manual for adjustment details.)

3-1 Adjustment Preparation

(1) Install setscrew • •(P/N 157927-2820), screw • • (P/N
• • 157927-3321) and solenoid switch
• •into housing • •.
(2) -1. Screw in setscrew • •until the counterweight contacts the housing's pressfitted
stopper pin.
-2. Tighten screw • •until clearance between screw • •and counterweight • • is 1• •2
mm.
-3. Tighten solenoid switch • • until clearance between solenoid switch and
counterweight • •'s• •pin is 1 • •2 mm, then tighten locknut • •.
(3) Install starting advance mechanism's cover.
(4) Position control rack in full position.
(5) Set power supply voltage to manual controller at 12V.

3-2 Pre-stroke adjustment

Adjust No 1 cylinder's start of static injection using the shim• • •. •

3-3 Individual cylinder's injection order adjustment

Adjust difference between each cylinder's injection angle based on that of the No. 1
cylinder using the shim • •.

3 6 5

1. Setscrew installation 2. Pre-stroke adjustment

3. Individual cylinder's injection
order adjustment
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3-4 Measuring pre-stroke output voltage

(1) Install measuring device (P/N 105782-6420).
(2) Remove setscrew • •(P/N 157927-2820) and install air bleeder bolt.
(3) Screw in screw • •(P/N 157927-3321) and measure the No 1 cylinder's output voltage
for pre-stroke lift values in the table below.
Adjusting point
Pre-stroke (mm) Output voltage (actual) Remarks
Confirmation point

3.43 a1 + tolerance
a
3.17 a2 -tolerance

2.85 b1 + tolerance
b
2.65 b2 -tolerance

(calculate from each specification)

Advice
If measuring device (P/N 105782-6420) is removed, the output voltage (a1, a2) should be
remeasured.

3-5 Minimum advance angle adjustment stopper adjustment

(1) Remove screw • •(P/N 157927-3321) and install minimum advance angle adjustment
stopper.
(2) Screw in minimum advance angle adjustment stopper until No 1 cylinder's pre-stroke
is 3.67 • •3.73. Then, tighten locknut to specified torque.
(3) Measure the output voltage (c) at this time.

3-6 Solenoid switch adjustment

(1) Apply 24 V voltage to solenoid switch • •.
(2) Loosen solenoid switch • •until No 1 cylinder's pre-stroke is 1.90 • •2.03 mm, then
tighten locknut to specified torque.
(3) Confirm solenoid switch operates at 14.5 -0.1 V.
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4. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.

Boost compensator stroke: 0.8 • •0.1

Torque cam No. “ AG41”

B
R1+1.85
I D
Approx.R1+1.5 A
Rack position ( mm )

R1(13.5)

14.0 • •0.1
R2 [R1-1.4]

10.3 • •1.0

0
250-40 (700) 1000 (1400) 1630
(1560) 1775

Pump speed (r/min)

Idling adjustment

10.5 Confirm rack sensor Vist = 2.25 • • • • • • • • • •

10.0 • •0.1
at supply voltage 5• • • • • •V• •••,•• N =1000 r/min , R = R1 (13.5).
H J
Approx.8.5
Rack position ( mm )

7.8

6.6 • •0.1

3.9 • •0.3

0
240 400 500 880
400 475

Pump speed (r/min)

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4-2 Boost compensator adjustment

(1) Select a push rod so C = 37.5• •0.5 at full boost pressure. (C is the distance from the
end face of the housing to top of the lever.)
(2) Adjust the boost compensator stroke using screw A.
(0 boost pressure position adjustment)
Adjust the beginning of boost compensator operation by adjusting the notch adjusting
nut B.

C Top of lever
Pushrod

Boost pressure inlet

A Boost compensator
stroke adjusting screw
B Notch adjusting nut
Boost compensator spring

N = 500 r/min
Rack position ( mm )

R2 [R1-1.4]

R2-0.8

0
Approx. 24.7 {Approx. 185}
13.3 • •1.3 {100 • •10}

Boost press. kPa• •mmHg• •

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4-3 Timing cam adjustment (Timing cam No:A08)

(1) Hold speed control lever against full speed stopper bolt.
(2) Supply boost pressure of at least 38.0 kPa {at least 285 mmHg}.
(3) Operate pump at the timing cam adjusting point
(point a in table below: Np = 900 r/min).
(4) Perform timing cam adjustment so output voltage is within range of a1 • • •a2
• actually
measured for pre-stroke output voltage during injection timing adjustment in 3-4.
Adjusting point Pre-stroke (mm) Output voltage (actual) Remarks

3.43 a1 + tolerance
a
3.17 a2 -tolerance

(5) Operate the pump at the timing cam confirmation point

(point b in table below: Np = 1,450 r/min).
(6) Confirm that the pre-stroke output voltage is within the range b1 • •b2.

Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks

2.85 b1 + tolerance
b
2.65 b2 -tolerance

Pre-stroke (Pre-stroke output voltage)

• •0.03 Solenoid starting advance angle

2.0
• •0.10

2.65 (b2)
2.85 (b1) b (confirmation point)

3.17 (a2)
a (adjusting point)
3.43 (a1)

Minimum advance angle adjustment

3.7 • •0.03 (c)
stopper

Pre-stroke at stopper contact

4.0 • • • • • • • • • •
0 (500) 900 1,450

Pump speed (r/min)

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5. Injection quantity

Max.
Rack Pump
Adjusting Injection q'ty variation Pre-stroke
position speed Fixed Remarks
point ( cm3 /100 strokes ) between at adjustment
( mm ) ( r/min )
cylinders

Cylinder variation
- 13.5 1,000 87 ± 1.6 ±4 Rack a1• •a2(v) Basic
adjustment standard

Cylinder variation
Z 8.5±0.5 500 19 ± 1.5 ± 14 Rack c(v) adjustment standard

Boost press. kPa• •mmHg• •

A R1(13.5) 1,000 87 ± 1 - Lever a1• •a2(v) Basic Above 38.0• •Above 285• •

R1 Boost press. kPa• •mmHg• •

B 1,450 (98) ± 2 - Lever b1• •b2(v) Above 38.0• •Above 285• •
• •1.85
Approx. Boost press. 0
I 150 (175) - Lever c(v)
R1• 1
• .5
Boost press. kPa• m
• mHg• •
Above 38.0 • •Above 285 • •
D* 15.0±0.1 1,450 (94.5) - Lever b1• •b2(v) Negative press. kPa• •mmHg• •
53.3 kPa• •400 mmHg• •

D*: Aneroid compensator actuator adjustment point

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6. FICD Adjustment

(1) Stop the injection pump.

(2) Hold speed control lever against idling stopper bolt.
(3) Adjust clearance between FICD actuator lever and speed control lever to approx. 1+1mm.
(4) Loosen nut • •and fully tighten FICD set bolt • •.
(5) Apply 53.3 kPa { 400 mmHg} negative pressure to the actuator • •and set the pump
speed at 450 r/min.
(6) Gradually loosen set bolt • •then fix bolt using nut when the rack position is 8.3• •0.1 mm.
(7) Apply above negative pressure several times and confirm FICD actuator is operating
properly and clearance between FICD actuator lever and speed control lever.

1+1 mm

• •

Speed control lever

FICD actuator lever

• •

Tightening torque
• • 5 • •7 N.m {0.5 • •0.7 kgf.m}
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7. Aneroid compensator actuator adjustment ( injection quantity decrease )

Note:
Set this actuator after adjusting the full rack position.
(1) Stop injection pump.
(2) Adjust wire nut so full load set lever contacts full load set bolt and aneroid compensator
actuator wire is not loose. Then, fix the nut.
(3) Apply 53.3 kPa { 400 mmHg} negative pressure to aneroid compensator, set pump
speed at 1,450 r/min.
(4) Apply at least 38.0 kPa { 285 mmHg} boost pressure to the boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt so control rack
position is 15.0• •0.1 mm and fuel injection quantity is as specified. Then, fix the set bolt.

Stroke
D
Rack position (mm)

Injection quantity decrease

adjustment point

Pump speed (r/min)

Full load set lever

Full load set bolt

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8. Speed control lever angle 9. Stop lever angle

Stopper bolt H position

45• • •5•• •
Hole(R42) Set the position
• •• •
• 5 R=1.5 • •0.2
22.5•

Idling

Normal Stop

29•
• •
3••
30• •
• •5 Full-speed
•• • Hole(R41.3)

10. Rack Sensor Adjustment

(1) Before removing rack position measuring device, apply at least 38.0 kPa
{at least 285 mmHg} boost pressure and confirm rack position is R1 = 13.5 mm and
fuel injection quantity is 87 • •1 mm3/st at N = 1,000 r/min.
(2) Remove rack position measuring device.
(3) Attach rack sensor core to control rack.
At this time, hold control rack using a spanner (to prevent the rack from bending).
Specified torque : 3.4 • ••4.9 N.m {0.35 • ••0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9 • ••8.8 N.m {0.7 • ••0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5 • •0.01V.
(8) Apply at least 38.0 kPa {at least 285 mmHg} boost pressure, set pump speed at
N= 1,000 r/min, and hold speed control lever against the full speed stopper bolt.
(9) Confirm the rack sensor output voltage from the digital voltmeter. (Vist = 2.25 • •0.28)
(10) Confirm that the voltage changes when the speed control lever is moved to the idle and
full sides.
Sensor output voltage (V)
Rack position (mm)

A
R1
Vist

R1
N
Pump speed (r/min) Rack position (mm)
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11. Drive Coupling Timing

Timing setting (At pre-stroke 3.7 • •0.05mm)

At No. 1 plunger’s beginning Bracket mark Pump

of injection position
• Engine
B.T.D.C. : 8• • •
•
• •
Gear hole (Dia. 3mm) •• • (35• • • •
••
6• 0••
(9 •2
•
• 13• •
•• •• ••
• •• • • •
3•• ••
Gear’s threaded hole • • • •

•
28 • •

••••
••••
Gear side

Pump side •••

•••
( 3•

Check hole

Stamp on coupling and bracket

(B.T.D.C. 8•• •)

Mark position of coupling at B.T.D.C. 13•• •