Xdoc - Tips - Zexel Calibration Data PDF

1043-806
1401-424
1401-725
101401-7452
on CD 2001/3
has incorrect
test injectors
use
PIE 106 B-5

1401-913
Pump ass’y No.
101401-9167
use
101401-9164
(microfiche PIE-076 C-9,C-10)
1401-9216
use test data
1401-9215
Test Data
for
101401-9702
use
101401-9700
PIE-95 B-4
1402-061
1402-216
1402-234
1402-720
1402-729
1402-750
1402-762
1402-763
1421-007
1421-016
1421-059
1421-073
1421-094
1421-097
1421-415
1421-425
1421-451
1431-901
1431-904
1431-905
1431-909
1431-932
1431-959
1432-902
Test data
1441-9460
1441-946
use
1441-9020
1472-302
1472-306
1472-313
1472-314
1472-315
1482-027
1482-037
1482-073
Test data
14950350...351...352
use
01491-031
1491-053
1491-953
1492-304
1601-052
Test data
1601-5061
1601-605
use
1601-5051
1602-121
1601-292
1602-845
Test data
1603-046
1603-046
use
1603-886
1603-496
Test data
1605-9490
1605-949
use
1605-9081
1606-155
1608-173
1609-331
1641-224
Test data
1671-0110
1671-011
use
1671-0030
1682-716
1691-088
1691-203
1691-265
1691-297
101691-506
S/S to 523
No info available
through Zexel
1691-530
1691-545
2351-001
INJECTION PUMP CALIBRATION DATA 1/4
CONFIDE NTIAL Assy No.: 101401-7110

ENGINE MODEL: 4HF1 Date: 16 Mar 2004 2
Company: ISUZU
No. 897122-6171
Injection pump: PES4A Governor: EP/RLD-F Timing device: EP/SCDM
101041-8260 105932-1350 105676-5120
1. Test conditions
Pump rotation: counter clockwise (viewed from drive side)
Nozzle & nozzle holder assy: 105780-8140 (Bosch type no. EF8511/9A)
Nozzle: 105780-0000 Nozzle holder: 105780-2080

(Bosch type no. DN12SD12T) (Bosch type no. EF8511/9)
Nozzle opening pressure: 17.2 MPa {175 kgf/cm2} Transfer pump pressure: 157 kPa {1.6 kgf/cm2}
Injection pipe: outer dia. 6 mm × inner dia. 2 mm length 600 mm

+5
Test oil: ISO4113 or SAE standard test oil {SAE J967d} Oil temperature: 40 °C
Overflow valve opening pressure: 127 ± 20 kPa {1.3 ± 0.2 kgf/cm2}
2. Injection timing
Pre-stroke: No.1 plunger 4.1 ± 0.05mm Note: Adjust with rack position of R=R1-0.05 mm
Injection order: 1 3,1 4,1 2

90°± 30' 180°± 30' 270°± 30'
Plungers are numbered from the Governor side (interval: ° ± 30').
Tappet clearance: Bolt adjustment type - More than 0.3 mm for all cylinders.
: Shim adjustment type - Manually rotate the camshaft 2 to 3 times and confirm that it rotates smoothly.
4. Injection quantity
Rack Pump Max. variation
Adjusting Injection quantity
position speed between Fixed Remarks
point (cm3/1000 strokes)
(mm) (r/min) cylinders (%)
11.9 1310 64.5 ± 1.6 ±4 Rack Basic Cylinder variation adjustment standard
H Approx 9.8 285 15.5 ± 1.3 ± 10 Rack Cylinder variation adjustment standard
A R1(11.9) 1310 64.5 ± 1 - Lever Basic
B R1 1600 (67.5) ± 2 - Lever
C R1-0.5 500 (44.7) ± 2 - Lever
E R1-0.05 960 (58.5) ± 2 - Lever
I Above 19.5 150 (80) + 16 - Lever
6. Timing advance specification

Pump speed
(Measure) (Measure)
(r/min)
Advance Start Finish

angle (° ) 0 5.0±0.5
BOSCH K.K. 3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572, JAPAN

Sales Automotive Aftermarket Division Tel. 81-48-475-2521 Fax. 81-48-475-2520
101401-7110 2/4
3. Governor adjustment
Full load adjustment

Torque cam no. ‘L31’
Above 19.5
I
Rack position (mm)
R1+0.05 A B
R1(11.9) E
R1-0.05
R1-0.35 C
R1-0.5
10.1±0.12
+1.29
8.1 -1.37
0
Below 225 (400) (630) 960 (1050) (1250) 1845
(360) (1150) (1650) 1925
Pump speed (r/min)
Idling adjustment Confirm that the Vist=2.61±0.28 when R=R1-0.05 with

rack sensor output value at 5±0.01V and N=960.
11.5
+0.20
11.0 -0.22 HJ
Approx 9.8
9.5
Rack position (mm)
8.0±0.09
+0.25
6.0 -0.27
0
275 350 1100
180 285 470
Pump speed (r/min)

101401-7110 3/4
5.FICD adjustment
(1) Adjust the clearance between the actuator lever and the speed lever to approx. 2 mm.
(2) Loosen nut 3 and fully tighten the actuator screw 2.
(3) Supply 53.3 kPa {400 mmHg} negative pressure to the actuator's port 1 and gradually loosen the
screw 2.
(4) Fix the screw 2 using the nut 3 when the rack position is 9.2±0.1 mm and the pump speed is N = 440
r/min.
Specified torque: 1.2 ~ 1.6 N•m {0.12 ~ 0.16 kgf•m}
(5) Supply the above negative pressure several times and confirm that the actuator operates normally
and that the clearance between the actuator lever and the speed lever is as specified.
1
2
Approx. 5 mm
3
101401-7110 4/4
Speed-control lever angle Stop lever angle
Stopper bolt H position Normal Stop
15° ±5°
34°
±3° (Mea
Idling sure)
41° ±5° Np=1600, R=5.5-0.5
±5°
Stopper bolt setting
Full-speed
Timing setting
At No. 1 plunger’s beginning
of injection position
B.T.D.C.: 7°
Timing device aligning mark position Pump perpendicular

(When aligned with bracket aligning mark at B.T.D.C. 13°)
Pump bracket standard Pump bracket aligning
mark position mark position
Engine
perpendicular
(35°)
A/T's outer slit '
20
Position of gear's 3 notch at No.1 8'' ± 20°
6'3 3°
cylinder's beginning of injection °3
26 10°
03 '56
''±3
Center of threaded hole °
3 0')
(1 7°
5°)
A/T's timing device stamping position (9
8'')
4'1
°4
(5
Pump bracket check hole position
Align with bracket check hole projection at No 1 cylinder's beginning of injection

and stamp at A/T's C1 face.

ENGINE MODEL: 4HF1 Date: 29 Jan 2004 3
Company: ISUZU
No. 897146-7880
Injection pump: PES4A Governor: EP/RLD-F Timing device: EP/SCDM
101041-8510 105932-1352 105676-5121
1. Test conditions


+5
2. Injection timing
Pre-stroke: No.1 plunger 4.1 ± 0.05mm Note: Adjust with rack position of R=R1-0.05 mm

90°± 30' 180°± 30' 270°± 30'
11.9 1310 64.5 ± 1.6 ±4 Rack Basic Cylinder variation adjustment standard
H Approx 9.8 285 15.5 ± 1.3 ± 10 Rack Cylinder variation adjustment standard
A R1(11.9) 1310 64.5 ± 1 - Lever Basic
B R1 1600 (67.5) ± 2 - Lever
C R1-0.5 500 (44.7) ± 2 - Lever
E R1-0.05 960 (58.5) ± 2 - Lever
I Above 19.5 150 (80) + 16 - Lever

Pump speed
(Measure) (Measure)
(r/min)

angle (° ) 0 5.0±0.5

101401-7113 2/4

Torque cam no. ‘L31’
Above 19.5
I
Rack position (mm)
R1+0.05 A B
R1(11.9) E
R1-0.05
R1-0.35 C
R1-0.5
10.1±0.12
+1.29
8.1 -1.37
0
Below 225 (400) (630) 960 (1050) (1250) 1845
(360) (1150) (1650) 1925
Pump speed (r/min)
Idling adjustment Confirm that the Vist=2.61±0.28 when R=R1-0.05 with

rack sensor output value at 5±0.01V and N=960.
11.5
+0.20
11.0 -0.22 HJ
Approx 9.8
9.5
Rack position (mm)
8.0±0.09
+0.25
6.0 -0.27
0
275 350 1100
180 285 470
Pump speed (r/min)

101401-7113 3/4
5.FICD adjustment
(1) Adjust the clearance between the actuator lever and the speed lever to approx. 2 mm.
(2) Loosen nut 3 and fully tighten the actuator screw 2.
(3) Supply 53.3 kPa {400 mmHg} negative pressure to the actuator's port 1 and gradually loosen the
screw 2.
(4) Fix the screw 2 using the nut 3 when the rack position is 9.2±0.1 mm and the pump speed is N = 440
r/min.
(5) Supply the above negative pressure several times and confirm that the actuator operates normally
and that the clearance between the actuator lever and the speed lever is as specified.
1
2
Approx. 5 mm
3
101401-7113 4/4
Stopper bolt H position Normal Stop
15° ±5°
34°
±3° (Mea
Idling sure)
41° ±5° Np=1600, R=5.5-0.5
±5°
Full-speed
Timing setting
B.T.D.C.: 7°
Timing device aligning mark position Pump perpendicular

(When aligned with bracket aligning mark at B.T.D.C. 13°)
Pump bracket standard Pump bracket aligning
mark position mark position
Engine
perpendicular
(35°)
A/T's outer slit '
20
Position of gear's φ3 notch at No.1 6'' ± 20°
2'2 ''
cylinder's beginning of injection
26
°0 9'42
2°2 9°2
9 '44
''±3
Center of threaded hole °
0')
°3
(17
5°)
A/T's timing device stamping position (9
8'')
4'1
°4
(5
Pump bracket check hole position
Align with bracket check hole projection at No 1 cylinder's beginning of injection

and stamp at A/T's C1 face.
CONFIDENTIAL Ass'y No.: 101401-9133

ENGINE MODEL: TM Date: 21 Aug 2002 6
Company: MAZDA
No. TM0113800C
Injection pump: PES4A Governor: EP/RLD-E Timing device: EP/SCDM
101040-9871 105921-5852 105671-0241
1. Test conditions
Pump rotation: clockwise ( viewed from drive side )
Nozzle & Nozzle Holder Ass'y: 105780-8140 (Bosch Type No. EF8511/9A)
Nozzle: 105780-0000 Nozzle Holder: 105780-2080

(Bosch Type No. DN12SD12T) (Bosch Type No. EF8511/9)
Nozzle opening pressure: 17.2 MPa { 175 kgf/cm2 } Transfer pump pressure: 157 kPa { 1.6 kgf/cm2 }
Injection pipe: Outer Dia. 6 mm × Inner Dia. 2 mm Length 600 mm

+5
Test Oil: ISO4113 or SAE Standard Test Oil { SAE J967d } Oil Temp. 40 °C
Overflow valve opening pressure: 255 kPa { 2.6 kgf/cm2 }
2. Injection timing
Pre-stroke: No.1 Plunger 3.2 ± 0.05mm Note: Adjust with rack position of mm

90°± 30' 180°± 30' 270°± 30'
Plungers are numbered from the Drive side ( interval: ° ± 30' ).
Tappet clearance: Bolt adjustment type More than 0.3mm for all cylinders.
: Shim adjustment type Manually rotate the camshaft 2 to 3 times and confirm that it rotates smoothly.
Adjusting Injection q'ty
position speed 3 between Fixed Remarks
point (cm / 1000 strokes )
12.3 800 68.5 ± 0.5 ± 2.5 Rack Basic Cylinder variation adjustment standard
H Approx. 9.5 325 9.7 ± 2 ± 14 Rack Cylinder variation adjustment standard
A R1(12.3) 800 68.5 ± 0.5 - Lever Basic
B R1+0.5 1500 (90.9) ± 2 - Lever
C R1+0.25 600 (62.4) ± 2 - Lever
I - 100 (170) - Lever

Pump speed
920 1200 1500
(r/min)
Advance Finish
Bellow. 0.5 1.5 ± 0.5
angle (° ) 5.5 ± 0.5
Bosch Automotive Systems Corporation 3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Service Department Tel. (048)470-1559, Fax. (048)474-9856
101401-9133 2/3
Full load adjustment Torque cam no. ‘G96’
R1+0.55
B
Rack position (mm)
R1+0.5
C
R1+0.25 A
R1(12.3)
R1-0.05
+0.07
12.3 -0.05
+0.72
8.5 -0.76
0
Below 250 600 (650) (880) (1060) (1550) 1840
(450) (850) (1280) 1600
Pump speed (r/min)
Idling adjustment
11.5
+0.49
11.0 -0.73
Approx 9.5
Rack position (mm)
9.5
8.0±0.07
+0.38
5.0 -0.42
0
200 400 610 1420
325
Pump speed (r/min)


ENGINE MODEL: TF Date: 12 May 2003 0
Company: MAZDA
No. TF2013800C
Injection pump: PES4A Governor: EP/RLD-E Timing device: EP/SCDM
101040-9881 105921-5960 105671-0081
1. Test conditions


+5
Overflow valve opening pressure: 255 ± 34 kPa { 2.6 ± 0.35 kgf/cm2 }
2. Injection timing

90°± 30' 180°± 30' 270°± 30'
H Approx 9.5 325 9±2 ± 10 Rack Cylinder variation adjustment standard
A R1(12.8) 1000 70.5 ± 0.5 - Lever Basic
B R1+0.5 1625 (84.1) ± 2 - Lever
C R1-0.5 625 (49.6) ± 2 - Lever
I - 100 Above 160 - Lever

Pump speed
700 1300 1600-25
(r/min)
Advance Finish
Bellow 0.3 2 + 0.5
angle (° ) 5-0.5
101401-9143 2/4
Torque cam no. ‘D71’
R1+0.5 B
Rack position (mm)
R1+0.1
A
R1(12.8)
5
R1-0.15
R1-0.5 C
8.3-0.4
0
Below 250 (480) 900 (1080) (1670) 2000
(300) (770) (960) (1500)
Pump speed (r/min)
Idling adjustment
11.5
11.0±0.08
Approx 9.5 HJ
9.5±0.02
Rack position (mm)
+0.05
8.5 -0.06
+0.38
5.5 -0.42
0
220 400 520 1350
325
Pump speed (r/min)
101401-9143 3/4
Stopper bolt H position
Full-speed Idling
Stop Normal
5°
20° ±
°
14° ±5
41°±3°
(29.5°)±5°
Stop adjuster screw setting
Timing setting
B.T.D.C.: 9°
Engine (bracket)
perpendicular
'
30
°
30 Gear
±
°±
15
20'
9°
21
Bracket's basic hole

( 6) position
Pump
bracket
Standard measuring position

The standard measuring position is the center of the
30
gear tooth marked 'CC' and is 30 mm from the bracket
end face.
101401-9143 4/4
6. Stop lever adjustment

Set the speed lever at Full and pump speed at Np = 1825 r/min, and then set the stop adjuster screw so
that the rack position is R = 4.7±0.3 mm. After setting the screw, confirm non-injection with the speed
lever in the idling position and pump speed at Np = 325 r/min.
Speed lever
Camshaft center line
Speed lever pulled in this direction
Stop lever pulled in this direction
Stop adjuster screw
Stop lever
CONFIDENTIAL Assy No.: 101401-9460

ENGINE MODEL: FD46T Date: 23 Mar 2006 2
Company: NISSAN DIESEL
No. 16700 17D00
Injection pump: PES4AD Governor: EP/RLD-F Timing device: EP/SCDM
101041-9070 105921-7980 105671-0450
1. Test conditions
Pump rotation: clockwise (viewed from drive side)


+5
2. Injection timing
Pre-stroke: No.1 plunger 4.0 ± 0.05mm Note: Adjust with rack position of R=R1 (11.8) mm

90°± 30' 180°± 30' 270°± 30'
Plungers are numbered from the Drive side (interval: ° ± 30').
H Approx 9.5 300 12 ± 1.8 ± 10 Rack Cylinder variation adjustment standard
A R1(11.8) 900 83.5 ± 1 - Lever Basic Boost press. kPa {mmHg}

Above 71.3 {Above 535}
Boost press. kPa {mmHg}
B R1+1.05 1550 (106) ± 2 - Lever Above 71.3 {Above 535}
C R2-0.8 500 (45.2) ± 2 - Lever Boost press. 0
I Above 18.5 100 (100) ± 10 - Lever Boost press. 0

Pump speed
Below 900 850 1500
(r/min)

Below 0.5
angle (° ) 0 5.0±0.3
Bosch Corporation 3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572, JAPAN

Automotive Aftermarket Division Tel. 81-48-475-2521 Fax. 81-48-475-2520
101401-9460 2/4

Torque cam no. ‘K81’
Above 18.5 Boost compensator stroke: 0.8±0.1

I
B
R1+1.05
Rack position (mm)
12.0±0.15
R1+0.15
R1(11.8) A
R2[R1-0.25]
R1-0.3
C
9.3 +1.58
-1.68
0
Below 250 (580) (750) (1030) (1500) 1720
(630) (850) 1100 (1600) 1825
Pump speed (r/min)
Boost compensator adjustment
N = 500
Rack position (mm)
R2[R1-0.25]
Idling adjustment
R2-0.8
11.5 0 Approx 58.0 {Approx 435}

11.0 +0.49
-0.25 18.7±1.3 {140±10}
9.5 J Boost pressure kPa {mmHg}
Rack position (mm)
Approx 9.5 H
7.5±0.07
5.8 +0.36
-0.41
0
225 310 470 1000
300 330
Pump speed (r/min)
101401-9460 3/4
5. Potentiometer adjustment
(1) Supply DC 5.0±0.2V to the potentiometer harness terminals shown in the circuit below to obtain the
specified output voltage.
(2) Fix the speed lever in the full position and loosen bolts A shown below.
Then, move the potentiometer left and right until the output voltage for the full position is as specified.
Tighten bolts A, move the speed lever between full and idle and confirm that the values for full and idle
are as specified.
Potentiometer voltage: Measure actual lever angle at 2.84±0.3 V
Bolts A
Potentiometer
1
Specified output voltage
(5.0)
Voltage (V)
5.0±0.02 V
(3.83)±0.2
Output voltage
0.5±0.3
Potentiometer connections 0 Idle Full

Direction of potentiometer rotation
101401-9460 4/4
Speed-control lever angle
70
°±
5°
(40)° ±3°
ing
Idl
Full
-spe
ed
Stop lever angle
29°±5°
10°±5°
Normal Stop
Timing setting
B.T.D.C.: 8°
Approx. 50°
Center of threaded hole

(Gear mark position)
For 101402-4880 use:

ENGINE MODEL: S4K-T Date: 24 Jul 2002 0
Company: MITSUBISHI
No. 34261-02080
Injection pump: PES4A Governor: EP/RSV Timing device:
101041-8040 105419-1011
1. Test conditions


+5
2. Injection timing

90°± 30' 180°± 30' 270°± 30'
A 9.3 950 84.7 ± 1 ± 2.5 Lever Basic

Adjust max. var. bet. cyl. of R ≒ 5.9.
Approx. 5.9 400 8 ± 1.3 ± 14 Rack Adjust governor as per gov. adj. spec.
D - 100 60 + 5 - Lever Rack limit

Pump speed
(r/min)
Advance
angle (° )
101402-9460 2/3
Recommended speed droop adjustment screw position: 7

(notches from fully tightened position)
Perform torque control spring adjustment

when necessary.
Rack limit
Above 14
Idle sub-spring setting
D
Main spring setting
Rack position (mm)
5
A
9.3
8.8±0.1
8.6
5.6
3.9±0.4
0
325 375 (955) 1040
960
Pump speed (r/min)
101402-9460 3/3
(1°)±5°
±3 °
35°
5°
(22°)±
Idling
Stop Full-speed
Stop lever angle
Normal Stop
26.5°±5° .9°
prox Contacts stop side boss
Ap
53°±5°
Timing setting
Approx. 60°
Camshaft key groove position

ENGINE MODEL: S4K Date: 11 Jun 2002 1
Company: MITSUBISHI
I
No. 34261-04050
101041-8040 105419-3440
1. Test conditions


+5
2. Injection timing

90°± 30' 180°± 30' 270°± 30'
A 8.2 1000 56 ± 1 ± 2.5 Lever Basic

- Approx.6.9 425 12 ± 1.3 ± 1.4 Rack Adjust governor as per gov. adj. spec.

Pump speed
(r/min)
Advance
angle (° )
101402-9810 2/3

Above 14 Rack limit
Difference in control rack

D position between 1000 r/min
Rack position (mm)
8.6 and 250 r/min

A
8.2
1.0±0.1
7.7±0.1
6.0
Idle sub-spring setting:
4.5-0.5 mm
4.5±0.4
0
(300) 425 (1015) 1100
400 (450) 1025
Pump speed (r/min)
101402-9810 3/3
Full-speed
17° ±5°
8° ±5°
Idling
Stop lever angle
Contacts inner boss

53°±5°
x.11°
Contacts outer boss Appro
26.5° ±5°
Stop Normal
Timing setting
Appr
ox.60 Camshaft key groove position
°

ENGINE MODEL:S4K-T Date: 11 Jun 2002 1
Company: MITSUBISHI
No. 34261-04060
101041-8040 105419-3450
1. Test conditions


+5
2. Injection timing

90°± 30' 180°± 30' 270°± 30'
A 8.9 1000 72.5 ± 1 ± 2.5 Rack Basic

- Approx.6.8 425 12 ± 1.3 ± 14 Rack Adjust governor as per gov. adj. spec.

Pump speed
(r/min)
Advance
angle (° )
101402-9880 2/3

Above 14
Rack limit
Difference in control rack
0.4±0.1
position between 1000 r/min
D and 700 r/min
8.9
Rack position (mm)
A
8.5
8.3±0.1 (1100)
6.0
Idle sub-spring setting:
4.1±0.4 4.1-0.5 mm
0
425 (880) 1035 1100
1000 (1030)
Pump speed (r/min)
101402-9880 3/3
Full-speed
18° ±5°
2° ±5°
Idling
Stop lever angle
Contacts inner boss

53°±5°
x.11°
Contacts outer boss Appro
26.5° ±5°
Stop Normal
Timing setting
Appro
x.60° Camshaft key groove position

ENGINE MODEL: 5113 Date: 20 Mar 2006 0
Company: DAIHATSU DIESEL
No. 22100-87302
Injection pump: PES4A Governor: EP/MZ Timing device:
101043-8140 105520-6780
1. Test conditions
Nozzle & nozzle holder assy: (Bosch type no. )

(Bosch type no. DN0SD21) (Bosch type no. )

+5
2. Injection timing
Pre-stroke: No.1 plunger 1.75 ± 0.05mm Note: Adjust with rack position of mm

90°± 30' 180°± 30' 270°± 30'
13.0 1800 50 ± 1.7 ± 3.4 Rack
13.0 1000 47 ± 1.2 ± 2.5 Rack Basic
9.0 1000 (24 ± 1.2) ±5 Rack
Approx 7 300 (8 ± 0.2) ± 15 Rack

Pump speed
(r/min)
Advance
angle (° )

101432-9030 2/2
Pneumatic governor
Operate injection pump at 500 r/min and increase negative pressure gradually from lower pressure.
13
Rack position (mm)
0
3.43±0.1 7.26±0.3
{350±15} {740±30}
4.31±0.2
{440±20}
Negative pressure kPa {mmAq}

ENGINE MODEL: DC24T Date: 7 Feb 2003 0
Company: DAEWOO HEAVY
No.
Injection pump: PES4A Governor: EP/RSV Timing device: EP/SCD
101044-9170 105419-4360 105621-0500
1. Test conditions
Pump rotation: counter clockwise ( viewed from drive side )


+5
2. Injection timing

90°± 30' 180°± 30' 270°± 30'
A 9.9 1300 42.2 ± 1 ± 2.5 Lever Basic
C Approx. 6.0 500 8 ± 1.1 ± 14 Rack
E - 100 65 ± 5 - Lever Rack limit

Pump speed Below
700 1300 (Measure))
(r/min) 750

Below 0.5 1.6 ± 0.5
angle (° ) 0 (6.0)
101441-9990 2/3

20.0+1.0
Rack limit

Main spring setting
E
Rack position (mm)
5
10.3 A
9.9
9.4±0.1
0.65±0.1
9.0
6.0 C D i f fe r e n c e i n c o n t r o l r a ck
5.5 position between 1300 r/min
4.7±0.4 and 500 r/min
0 360 500 (970) (1170) 1330 1440

1050 (1315)
Pump speed (r/min)

101441-9990 3/3
Full-speed Idling
17° ± Stopper bolt setting

5°
21°±5°
Stop lever angle
Norm
al
19° ±5°
°
53° ±5
op
St
Timing setting
B.T.D.C.: 13°
Approx. 60°
Gear mark "z"
INJ.PUMP CALIBRATION DATA 1/3

ENGINE MODEL： S4D95L E-2 Date: 7 Feb 2002 9
Company: KOMATSU
No. 6205-71-1151
Injection pump： PES4A Governor： EP/RSV Timing device：
101049-4040 105400-8942
１．Test condition
Pump rotation： Clockwise (viewed from drive side)
Nozzle ＆ Nozzle Holder Ass'y ：105780-8140 (Bosch Type No.EF8511/9A)
Nozzle：105780-0000 Nozzle Holder：105780-2080

(Bosch Type No.DN12SD12T) (Bosch Type No.EF8511/9)
Nozzle opening pressure： 17.2 MPa｛ 175 kgf/cm2｝ Transfer pump pressure： 157 kPa｛ 1.6 kgf/cm2｝
Injection pipe： Outer Dia.6 mm × Inner Dia.2 mm − Length 600 mm

+5
Test Oil：ISO4113 or SAE Standard Test Oil｛SAE J967d｝ Oil Temp.：40 ℃
Overflow valve opening pressure： kPa｛ kgf/cm2｝
２．Injection timing
Pre-stroke：No.1 Plunger 3.2 ±0.05mm NoteAfter adjustment with rack position of A (11.3) mm
Injection order： 1 − 2 ,1 − 4 ,1 − 3
90°
± 30′ 180°± 30′ 270°± 30′
Plungers are numbered from the Drive side. ( interval: °± ）
Tappet clearance：Bolt adjustment type ；More than 0.3mm for all cylinders.
：Shim adjustment type；Manual rotate the camshaft 2 ∼ 3 times and confirm that it rotates smoothly.
４．Injection quantity
Adjust- Rack Pump Max. var
position Injection q' ty
speed bet. cyl Fixed Remarks
ing point (mm) ( cm3 / 1000 strokes)
(r/ min) (％)
A 11.3 900 91.5±1 ±2.5 Lever Basic

Adjust max. var. bet. cyl. at R≒9.3.±2.5
9.3 ± 0.5 400 24 ± 1 ±15 Rack
Adjust governor as per gov. adj. spec.
５．Timing Advance specification

Pump speed
（r/min）
Advance
angle（°）
101495-3426 2/3
３ . Governor adjustment
Recommended speed droop adjustment screw position : 8

Approx.17.5
Rack position ( mm )
Idle-sub spring setting
Pump speed (r/min)
915 rpm.
0°
760 rpm.
101495-3426 3/3
Test Data
101495 – 3450
use
101495 – 3435
same as
101495 - 3433

ENGINE MODEL: 4D95L Date: 7 Feb 2003 1
Company: KOMATSU
No. 6204-71-1151
101049-4070 105400-9151
1. Test conditions


+5
Overflow valve opening pressure: kPa { kgf/cm2 }
2. Injection timing
Pre-stroke: No.1 Plunger 3.2 ± 0.05mm Note: Adjust with rack position of after injection q'ty adjustment at A

90°± 30' 180°± 30' 270°± 30'
A 10.2 900 70.5 ± 1 ± 2.5 Lever Basic
8.4±0.5 400 12 ± 1 ± 15 Rack Adjust max. var. bet. cyl. of R=8.4±0.5


Pump speed
(r/min)
Advance
angle (° )
101495-3470 2/3

20.0+1.0 Rack cap
Torque control spring set force: 0N {0kg}
12.1±0.1
5
Rack position (mm)
510 A
10.2
9.7±0.1
9.7±0.1
6.9
6.4±0.2 Idle sub-spring setting
4.5±0.1
0 400 (750) (910) 941

(600) 760 915 970
Pump speed (r/min)
Stop lever angle

Without return spring
Approx.55°
R=1.0-0.5, N=0
N=915 23° ±5° (Seal at delivery)
° ±5°
setting position at delivery 27.5
6° ±5°
N=760 set Stop Normal
2° ±5°
Full-speed Idling
101495-3470 3/3
6. Load plunger equipped injection pump adjustment

(1) Confirm the plunger assembly stamping from the part catalogue.
(2) Temporarily insert a pre-stroke adjusting shim t mm into each cylinder and adjust the injection quantity
and the maximum variation between cylinders.
(3) At full load point A adjust the pre-stroke so that it is as specified.
(4) After adjusting the pre-stroke, reconfirm that the injection quantity and the maximum variation between
cylinders are as specified.
t mm 0.8
Timing setting
After injection q'ty adjustment at A point
58
°±
3°
Key groove position

Mark an aligning mark on the pump housing
(Width,depth 0.3 mm)
2° ±30°
C ONF I DENT I A L Assy No.: 101603-2361

T EMPOR ARI LY
ENGINE MODEL: J-2 Date: 29 Jun 2007 0
Company: HINO
No. 22000-9591A
Injection pump: PE6MD Governor: EP/RLD-F Timing device: EP/SPG
101060-6170 105932-2171 105680-5010
1. Test conditions
Nozzle & nozzle holder assy: 105101-8160 (Bosch type no. )

(Bosch type no. ) (Bosch type no. )
Nozzle opening pressure: 1st 16.7 MPa { 170 kgf/cm2 }
2nd 21.6MPa { 220 kgf/cm2 } Transfer pump pressure: 255 kPa {2.6 kgf/cm2}

+5
2. Injection timing
Injection order: 1 4,1 2,1 6,1 3,1 5

60°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'
12.5 850 91 ± 2 ± 3.5 Rack Basic Cylinder variation adjustment standard
H Approx 9.5 275 Each cylinder 13±1 - Rack Cylinder variation adjustment standard
A R1(12.5) 850 91 ± 1 - Lever Basic

+0.1
B [R1+0.8] -0.05 1450 (92) ± 2 - Lever
C R1+0.45 1160 (94.5) ± 2 - Lever
I - 100 160 + 10 - Lever Rack limit
F (R1-0.85) 580 (77) - Lever
G R1-1.05 435 (70.5) ± 2 - Lever

Pump speed
(Measure) (Measure) 1255 - 50 1420 - 50
(r/min)

1.25 ± 0.3 1.25 ± 0.3
angle (° ) 0 5.5±0.3

101603-2363 2/3
Torque cam no. ‘M01’
RACK LIMIT
I
[R1+0.8] +0.1
-0.05 B
Rack position (mm)
R1+0.45
R1+0.15 C
A
R1(12.5)
12.0±0.15
F
R1-0.9 G
R1-1.05
8.7 +1.75
-1.87
0
Below 225 (380) 850 (1000) (1250) (1500) 1650
(350) (510) (890) (1100) (1400) 1550
Pump speed (r/min)
Idling adjustment
11.5
+0.30
11.0 -0.31
H J
Approx 9.5
9.5
Rack position (mm)
7.8±0.08
4.0 +0.38
-0.42
0
195 350 520 1160
275
Pump speed (r/min)
101603-2363 3/3
°
3 ° 6° ±5
°±
40
Idling
Full-speed
Stop lever angle
Normal
R=17.8±0.2
(Speed lever: full, N=100)
Free
0° ±5°
) 5°
0° 7° ±
(4
5 °
°±
33
Stopper screw setting

Stop
(Apply red paint after setting)
Timing setting
Approx
.20° Coupling key groove position
101603-8900 ZEXEL test values diesel fuel-injection equipment 12/11/08 13:19:56 Page 1
ZEXEL Ass'y No. 101603-8900

Bosch Ass'y No. 9 400 610 684
Bosch Typecode
Engine Type 6BG1-T
Manufacturer ISUZU
Edition date 31/05/06 (1)
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) R
Right
2 Adjustment specification
2.1 Injection timing adjustment
P Direction of rotation (viewed from drive side) R
Right
P Injection order 1-5-3-6-2-4
S Pre-stroke mm 3.6 3.55 3.65
P Beginning of injection position NO.1
Drive side
S Difference between angles 1 deg. 60 59.5 60.5
Cal 1-5
Cal 1-3
Cal 1-6
Cyl.1-2
Cal 1-4
2.2 Injection quantity adjustment
P Adjusting point A
P Rack position 10.9
P Pump speed r/min 1100 1100 1100
S Average injection quantity mm3/st. 98.5 97 100
S Max variation between cylinders % 0 -2.5 2.5
P Basic *
P Fixing the lever *
P Boost pressure kPa 66.7 66.7
P Boost pressure mmHg 500 500
P Adjusting point C
P Rack position 6.4+-0.5
S Average injection quantity mm3/st. 9 7.7 10.3
S Max variation between cylinders % 0 -14 14
P Fixing the rack *
P Boost pressure kPa 0 0 0
P Boost pressure mmHg 0 0 0
P Adjusting point E
P Rack position -
S Average injection quantity mm3/st. 110 105 115
C = Check value)
OT = Outside Tolerance (X is set)

P Rack limit *
2.3 Governor adjustment
Name
K=9 N:Pump speed

BCL=1.1+-0.1mm R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
(4)Boost compensator stroke: BCL
(5)Set idle sub-spring
(6)Main spring setting
2.4 Boost compensator adjustment
P Rack position R1-1.1
S Boost pressure kPa 13.3 10.6 16
S Boost pressure mmHg 100 80 120
P Rack position R1(10.9)
S Boost pressure kPa 53.3 46.6 60
2.5 Timer adjustment
S Pump speed r/min 1300++
P Advance angle deg. 0 0 0
Remarks
Do not advance until starting N = 1300.
P Pump speed r/min -
S Advance angle deg. 5.5 5.5 5.5
About
Remarks
Measure the actual speed, stop
C = Check value)
2.6 Speed control lever angle

Name
a=6deg+-5deg
b=23deg+-5deg
F:Full speed
I:Idle
(1)Stopper bolt setting
2.7 Stop lever angle
Name
a=32deg+-5deg
b=(55deg)
aa=0r/min N:Pump normal

bb=1-0.5mm S:Stop the pump.
(1)Pump speed aa and rack position bb (to be sealed at delivery)
2.8 Timing setting
Name
a=(60deg)
aa=12deg (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)-
C = Check value)
Test Data
101603-8970
use
101603-8900

ENGINE MODEL: 6BG1-T Date: 17 Jul 2002 0
Company: ISUZU
No. 115603-3960
Injection pump: PES6AD Governor: EP/RSV Timing device:
101062-8410 105411-2300
1. Test conditions


+5
2. Injection timing
Injection order: 1 5,1 3,1 6,1 2,1 4

60°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'
A 11.0 1075 110.5 ± 1.5 ±2 Lever Basic Above 105 {Above 790}
7.7±0.5 450 12 ± 1.3 ± 14 Rack Boost press. 0
Adjust max. var. bet. cyl. of R = 7.7±0.5
D Above. 11.2 100 105 ± 5 - Lever Rack limit Boost press. 0

Pump speed
(r/min)
Advance
angle (° )
101605-0100 2/4
Recommended speed droop adjustment screw position : 16

Rack limit
Main spring setting

Above 14.0
D Boost compensator stroke: 0.3±0.1

11.2 A
11.0
10.5±0.1 10.85
Rack position (mm)
10.0
10.2±0.1
8.2
8.1±0.3
7.3
0
245 340 (470) (680) 900 (1140) 1220
450 (940) 1155
Pump speed (r/min)
N = 500
Rack position (mm)
R2(10.0)
R2-0.3
0 (92.0)±6.7 {(690)±50}
53.3±4.0 {400±30}
Boost pressure kPa {mmHg}
101605-0100 3/4
■ Tamperproof boost compensator cover installation
269 Temporarily tighten these screws before adjusting the governor and
the boost compensator.
Maximum tightening torque T = 2.5 N•m {0.25 kgf•m}
After adjusting the governor and the boost compensator, tighten the
screws to remove the heads.
Tightening torque T = 2.9 ~ 4.4 N•m {0.30 ~ 0.45 kgf•m}
101605-0100 4/4
Full-speed Idling
(3°)
±5°
(20°) ±5°
Stop lever angle
Stop Normal
50° ±
5°
Appro
x.55°
N=0, R=1.0-0.5
Timing setting
B.T.D.C.: 9°
Approx. 100°
Gear mark “CC”

Test Data
101606-0180
use
101603-8900
C ONF I DENT I A L Assy No.: 101606-1741

ENGINE MODEL: 6D16T Date: 10 May 2005 2
Company: MITSUBISHI
No. ME076211
Injection pump: PES6AD Governor: EP/RLD Timing device: EP/SA-D
101061-8050 105931-5401 105643-0460
1. Test conditions


+5
2. Injection timing
Injection order: 1 5,1 3,1 6,1 2,1 4

60°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'
13.0 700 Each cylinder 96.8±2.9 - Rack Basic Cylinder variation adjustment standard
H Approx 9.5 275 Each cylinder 10.2±1.5 - Rack Cylinder variation adjustment standard
A R1(13.0) 700 96.8 ± 1 - Lever Basic Boost press. kPa {mmHg}

B R1-0.35 1400 (100.3) ± 2 - Lever Above 33.3 {Above 250}
C R2-0.6 300 (66.9) ± 2 - Lever Boost press. 0
R2 Boost press. kPa {mmHg}
D (R1+0.25) 500 (96.5) ± 2 - Lever Above 33.3 {Above 250}
I - 100 95 ± 20 - Lever Rack limit

Pump speed
1150 1250 1350
(r/min)
Advance Finish
Below 0.5 1.7 ± 0.5
angle (° ) 3.5±0.5

101606-1741 2/3
Torque cam no. ‘D24’

Rack limit
Boost compensator stroke:

I 0.6±0.1
R1+0.25 D
Rack position (mm)
R1(13.0) A
R1-0.05
R1-0.15 C B
R1-0.35
R1-0.85
8.7
0
Below 225 (600) (900) (1150) (1480) 1600±50
(750)
700 (1050) (1300) 1500±5
Microswitch adjustment
Adjust the bolt so that the microswitch Pump speed (r/min)
operates at a control lever position of R
= 9.2mm and a pump speed of N=400±5 Boost compensator adjustment
r/min.
Idling adjustment N = 450

Rack position (mm)
R2(R1+0.25)
11.5 R2-0.6
10.8
Approx 9.5 H J 0 (20.0) {(150)}
Rack position (mm)
9.5 6.0±1.3 {45±10}

6.2
4.4
0
200±5 650±15 1000±70
275 350
Pump speed (r/min)
101606-1741 3/3
±5°
18.5°
3°
°±
41
Idling
Full-speed
Stop lever angle
Normal
±5°
11.5°
N=Fixed point, R=6.5-0.5 5°
°±
Stopper bolt setting 27
Confirm that injection does not
occur
After stopper bolt setting : N=275
Confirm that injection does not
occur : R=8.6-0.5 Stop
Non injection rack position
Timing setting
At No. 1 plunger’s beginning of
injection position
B.T.D.C.: 10°
2°
Timing device's tooth position Approx.

ENGINE MODEL: 6D14 Date: 10 July 2006 6
Company: MITSUBISHI
No. ME076986
Injection pump: PES6A Governor: EP/RLD-E Timing device: EP/SA
101061-9500 105931-9422 105643-0750
1. Test conditions


+5
2. Injection timing
Injection order: 1 5,1 3,1 6,1 2,1 4

60°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'
H approx 9.5 275 Each cylinder 13.7±2.1 - Rack Cylinder variation adjustment standard
A R1(11.2) 850 57.7 ± 1 - Lever Basic
B R1+0.1 1450 (72.6) ± 2 - Lever
C R1+0.8 500 (59.7) ± 2 - Lever
D R1+1.25 300 (57.1) ± 2 - Lever

Pump speed
Below 1250 1200 1400
(r/min)

Below 0.5
angle (° ) 0 5±0.5

101607-6153 2/4
Torque cam no. ‘G81’
Rack limit
I D
R1+1.25
Rack position (mm)
C
R1+0.8 B
R1+0.1
A
R1(11.2)
10.7±0.09
+1.08
8.0 -1.02
0
Below 225 500 (750) (1000) (1530) 1690
(370) (1300) 1560
Pump speed (r/min)
Microswitch adjustment (at a control lever full position)

Adjust the bolt so that the microswitch operates at a control lever position of N=1560,R=10.7±0.1
Idling adjustment
11.5
+0.10
10.4 -0.09
HJ
Approx 9.5
9.5
Rack position (mm)
+0.12
5.0 -0.11
+0.32
2.5 -0.29
0
200 325 740 1320
275
Pump speed (r/min)
101607-6153 3/4
5. Load sensor adjustment
[1] Measurement circuit

2 (yellow)
(red)
Supply voltage: 3.57±0.02 V

Trimmer
1k
(yellow)
Output voltage
1 (black) 3 (red)
(black)
[2] Adjustment
(1) With the load lever contacting the FULL side, turn the shaft until the voltage between 1 and 2 is Vf (V).
(2) With the load lever contacting the IDLE side, adjust the trimmer until the voltage between 1 and 2 is Vi
(V).
Vf (V) 3.0+0.05 At full
Vi (V) 1.0+0.1 At idle
(3) Repeat the above adjustments until the specifications are satisfied, and then tighten the nuts.
Shaft
Nuts
Trimmer
Load lever
101607-6153 4/4
6. Measuring the speed lever angle
Measure the speed lever angle when the accelerator lever contacts the base lever at A.
18.5°±5°
Idlin
(39°) ±3°
g
Accelerator lever position at delivery
Full speed
Base lever
Accelerator lever
Stop lever angle

R=(16.8)
°
5°±5
36.
Speed-control lever angle N=1550, R=7.0-0.5
Free
Stopper bolt setting °)
(25 (At delivery)
Confirm that injection
5° Normal
18.5°± does not occur
3° After stopper bolt
°) ± setting N=275 17°±5°
( 39
Confirm that injection does
Idling not occu R=(Measure) Stop
Non injection rack position
Full-speed
Timing setting
B.T.D.C.: 13°
Approx. 0° Timing device's tooth position


ENGINE MODEL: 6D14T Date: 25 May 2004 1
Company: MITSUBISHI
No. ME046025
Injection pump: PES6A Governor: EP/RFD-D Timing device: EP/SA-D
101061-9790 105490-5720 105643-0450
1. Test conditions


+5
2. Injection timing
Injection order: 1 5,1 3,1 6,1 2,1 4

60°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'
A 10.0 1400 88.9 ± 1 ± 2.5 Lever Basic
B 10.0 800 (83.5) - Lever
C Approx 7.8 340 9.2 ± 1.5 ± 15 Rack
F (10.7) 100 (65) - Lever After setting excessive fuel for starting

Pump speed
Below 1050 1000 1400
(r/min)

Below 0.5
angle (° ) 0 2±0.5

101607-6390 2/3
Excessive fuel setting for starting: 10.0+0.2 (N = 500)

(11.0) F
Main spring setting
10.5±0.1
10.5 A
B
(10.1)
10.0
8.5±1.5
Rack position (mm)
Idle sub spring setting
7.8 Damper spring setting
9+0.5
C
5.8±0.5
5.8±0.1
5.6
3.9
0
250 280 480 495 (585) Above 1400 1535
340 (350) 400 1500 1540
Pump speed (r/min)
101607-6390 3/3
Speed-control lever angle Load control lever angle
Full-speed (Fix at full)

18° ±5°
3° ±5°
Idling Full-load
16°±5°
Timing setting
Stop lever angle
B.T.D.C.: 14°
57°
±5°
R=4.5-0.5
Stopper bolt setting 57
° +
Approx. 1° Timing device's tooth position
-5 7°
(Apply red paint after adjustment) °
Stop Normal

Bosch Ass'y No.
Bosch Typecode
Engine Type
Manufacturer
7d}
...
Bosch type code 9 430 610 133
Nozzle 105780-0120
Iinjection Pipe mm 6-2-600
Direction of rotation (viewed from drive side) L
Left
P Direction of rotation (viewed from drive side) L
Left
P Beginning of injection position No.1
Governor side
Cyl 1-5
Cyl 1-3
Cyl 1-6
Cyl.1-2
Cyl 1-4
P Adjusting point -
S = Setting value, C = Check value)


S Each cylinder's injection q'ty mm3/st. 110 106.7 113.3
P Basic *
P Fixing the rack *
P Standard for adjustment of the maximum var *
iation between cylinders
P Adjusting point Z
S Each cylinder's injection q'ty mm3/st. 12.5 10.6 14.4
P Fixing the rack *
P Adjusting point A
P Basic *
P Adjusting point B
P Rack position R1+1.0
S Average injection quantity mm3/st. 114.5 110.5 118.5
P Adjusting point C
P Rack position R2(R1-0.4)
P Adjusting point D
P Adjusting point I
P Rack position (R1+1.7)


P Adjusting point E
Name
N1=2080--r/min N:Pump speed

T1=M20 R:Rack position (mm)
BCL=0.35+-0.05mm (1)Adjust the governor at N=N1.
(2)Torque cam stamping: T1
S Boost pressure kPa 4.0+2.7
S Boost pressure mmHg 30+20


S Boost pressure kPa (10.0)
S Boost pressure mmHg (75)
S Pump speed r/min 1000--
Remarks
Start
P Pump speed r/min 950
S Advance angle deg. 0.5 0.5
S Advance angle deg. 3.5 3 4
Remarks
Finish
Name
a=19deg+-5deg
b=41.5deg+-3deg
aa=40mm F:Full speed

I:Idle
(1)Use the hole at R = aa
(2)-
(3)Stopper bolt set position 'H'
Name

a=11.5deg+-5deg
b=28deg+-5deg

bb=7.0-0.5mm S:Stop the pump.
cc=285r/min (1)After setting the stopper bolt so that the speed lever is in the full position, confirm that there is
dd=(8.4)mm no injection at pump speed aa and rack position bb.
(2)After setting the stopper bolt at the speed lever's idle position, confirm that there is no injectio
n at pump speed cc and rack position dd.
2.8 Timing setting
Name
a=6deg30min+-30min
b=7deg+-2deg

(2)Position of the timer's tooth at the beginning of injection of the No. 1 cylinder
(3)Bracket's center line stamping position.
(4)B.T.D.C.: aa
(5)Tooth stamping

ZEXEL Ass'y No. 101608-1486 101608-1693

Bosch Ass'y No.
Bosch Typecode
Engine Type
Manufacturer
7d}
...
Nozzle 105780-0120
Left
Left
Governor side
Cyl 1-5
Cyl 1-3
Cyl 1-6
Cyl.1-2
Cyl 1-4
P Adjusting point -


S Each cylinder's injection q'ty mm3/st. 110 106.7 113.3
P Basic *
P Fixing the rack *
P Adjusting point Z
S Each cylinder's injection q'ty mm3/st. 12.5 10.6 14.4
P Fixing the rack *
P Adjusting point A
P Basic *
P Adjusting point B
P Adjusting point C
P Adjusting point D
P Adjusting point I


P Adjusting point E
Name
N1=2080--r/min N:Pump speed

T1=M20 R:Rack position (mm)
BCL=0.35+-0.05mm (1)Adjust the governor at N=N1.
S Boost pressure kPa 4.0+2.7
S Boost pressure mmHg 30+20


S Boost pressure kPa (10.0)
S Boost pressure mmHg (75)
S Pump speed r/min 1000--
Remarks
Start
S Advance angle deg. 3.5 3 4
Remarks
Finish
Name
a=19deg+-5deg
b=41.5deg+-3deg

I:Idle
(2)-
Name

a=11.5deg+-5deg
b=28deg+-5deg

bb=7.0-0.5mm S:Stop the pump.
cc=285r/min (1)After setting the stopper bolt so that the speed lever is in the full position, confirm that there is
dd=(8.4)mm no injection at pump speed aa and rack position bb.
(2)After setting the stopper bolt at the speed lever's idle position, confirm that there is no injectio
n at pump speed cc and rack position dd.
2.8 Timing setting
Name
a=6deg30min+-30min
b=7deg+-2deg

(2)Position of the timer's tooth at the beginning of injection of the No. 1 cylinder
(3)Bracket's center line stamping position.
(4)B.T.D.C.: aa
(5)Tooth stamping


Bosch Ass'y No. 9 400 613 229
Bosch Typecode
Engine Type 6D16TL
Manufacturer MITSUBISHI
7d}
...
Nozzle 105780-0000
Left
Left
Governor side
Cal 1-5
Cal 1-3
Cal 1-6
Cyl.1-2
Cal 1-4

P Adjusting point A
S Max variation between cylinders % 0 -2.5 2.5
P Basic *
P Adjusting point -
S Average injection quantity mm3/st. 16.5 15 18
P Fixing the rack *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specificatio
P Adjusting point E
P Rack position 10.6++
P Rack limit *
Name
K=6 N:Pump speed

BCL=0.15+-0.1mm R:Rack position (mm)
N1=1125r/min (1)Target notch: K
N2=550r/min (2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
(5)Set idle sub-spring
(6)Main spring setting
(7)Rack difference between N = N1 and N = N2


S Boost pressure kPa 11.3 11.3 11.3
About
About
S Boost pressure kPa 12 9.3 14.7
About
About
S Advance angle deg. 3 2.5 3.5
Load 0/4
P Pump speed r/min 550+50
S Advance angle deg. 3 2.5 3.5
Load 0/4
Remarks
Start
P Pump speed r/min 650-50
S Advance angle deg. 0 0 0
Load 0/4
Remarks
Finish
Name
a=20deg+-5deg
b=1deg+-5deg

F:Full speed
I:Idle
(1)Stopper bolt setting
Name
a=35deg+-5deg
b=(55deg)

bb=1-0.5mm S:Stop the pump.
(1)Normal
(2)Pump speed aa and rack position bb (to be sealed at delivery)
2.8 Additional device adjustment
2.8.1 Additional device 1
Name TAMPER PROOF
T1=2.5N-m(0.25kgf-m) Tamperproofing-equipped boost compensator cover installation procedure

T2=2.9~4.4N-m(0.3~0.45kgf-m) (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 t
orque.
(Tightening torque T = T1 maximum)
(2)After adjusting the governor and the boost compensator, tighten to the specified torque to bre
ak off the bolt heads.
(Tightening torque T = T2 maximum)
2.9 Timing setting
Name

a=(3deg)

(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-

CO NFI D ENT IA L Assy No.: 101608-9580

TEMPO RARI LY ENGINE MODEL: L7A Date: 14 Jan 2004 2
Company: ASIA MOTOR
No.
Injection pump: PE6AD Governor: EP/RLD-F Timing device: EP/SAG
101060-5570 105921-9690 105672-0660
1. Test conditions

(Bosch type no. ) (Bosch type no. )

+5
2. Injection timing
Injection order: 1 4,1 2,1 6,1 3,1 5

60°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'
11.1 700 78 ± 2 ± 3.5 Rack Basic Cylinder variation adjustment standard
H Approx 9.2 290 16 ± 2 ± 14 Rack Cylinder variation adjustment standard
A R1(11.1) 700 78 ± 1 - Lever Basic
B R1+0.7 1450 (76) ± 2 - Lever

Pump speed
Below 950 900 1150 ± 30
(r/min)

Below 0.5
angle (° ) 0 4.5 - 0.5

101608-9580 2/3

Torque cam no. ‘M76’
Rack limit
I B
R1+0.7
Rack position (mm)
R1+0.55
R1+0.15
R1(11.1) A
R1-0.65
8.35
0
Below 225 (800) (1100) (1400) 1660±50
700 (900) (1300) 1550±10
Pump speed (r/min)
Adjust the bolt so that the microswitch operates at a control lever position of
Idling adjustment R= 8.6 ± 0.1 mm and a pump speed of 415r/min.
11.5
+0.35
11.0 -0.30
HJ
Approx 9.2
9.0
Rack position (mm)
7.8±0.07
5.5±0.3
0
190 400 850
300 290 325
Pump speed (r/min)

101608-9580 3/3
(42°)±3°
°
19° ±5
Idling Full-speed
Stop lever angle
Stop Normal
5°
14.5°±
40° ±5°
Timing setting
B.T.D.C.: 13°
Approx. 50°
Coupling key groove position

ENGINE MODEL: DK20 Date: 14 Sep 2004 0
Company: HINO
No. 6 071 10001 0
Injection pump: PE6A Governor: EP/RQ Timing device: EP/SA
101069-0510 105300-0750 105612-0700
1. Test conditions
Nozzle & nozzle holder assy: (Bosch type no. )

(Bosch type no. DN4SD24) (Bosch type no. KB56SD273)

+5
Overflow valve opening pressure: kPa { kgf/cm2}
2. Injection timing
Injection order: 1 4,1 2,1 6,1 3,1 5

60°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'
14.5 600 112 ± 2.2 ±2 Lever Basic
(14.5) 1050 119.7 ± 7.2 ±3 Lever
8.6 200 23 ± 3 ± 13 Rack
Pump speed
300±50 600 800
(r/min)

1.8 ± 0.5
angle (° ) 0 3.0±0.5

101691-2970 2/2
Rack limit: 17+0.2

0
14.5
Rack position (mm)
Above 9.6
8.6
Below 3
0 Approx 100 320±10 1150

200 Below 1225
Pump speed (r/min)
Turnswitch adjustment
Adjust the bolt so that the turnswitch turns ON at a control lever position of R = 8.7 mm and a pump
speed of 300 r/min.
Speed-control lever angle Timing setting

Ap
54
.5
pr
°±5 Approx. 40°

ox
° Coupling key groove position

.9
0°
26
.5°±
d
ll- loa
Fu
3°
Idling
Stop

TEMPO RARI LY
ENGINE MODEL: 6D95L Date: 30 Aug 2004 0
Company: KOMATSU
No. 6206-71-1341
101069-9180 105400-4630
1. Test conditions

(Bosch type no. DLLA152PN009) (Bosch type no. )
Injection pipe: outer dia. 6 mm × inner dia. 1.6 mm length 600 mm

+5
Overflow valve opening pressure: kPa { kgf/cm2}
2. Injection timing
Pre-stroke: No.1 plunger 3.6 ± 0.05mm Note: Adjust with rack position of R= R1(9.9) mm
Injection order: 1 5,1 3,1 6,1 2,1 4

60°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'
A R1(9.9) 1200 37.2 ± 1 ± 2.5 Lever Basic
C R2(8.6) 350 10.5 ± 1 ± 15 Rack

Pump speed
(r/min)
Advance
angle (° )

101692-3470 2/3

Rack cap: Approx 17.5

20+1
D i f fe r e n c e i n ra ck p o s i t i o n
between N = 1200 and N = 350
2.8±0.1
R2+3
R1(9.9) A
Rack position (mm)
R1-0.3
(1.2)±0.1
C
R2(8.6)
D i f fe r e n c e i n ra ck p o s i t i o n
6.0 between N = 1200 and N = 800
0
350 500±20 (880) 1200 +30
+20 1325±25
350 (1280)
Pump speed (r/min)
101692-3470 3/3
(26°)±5°
°
) ±5
(16°
Full-speed Idling
Stop lever angle
Stop Normal
5°
26.5° ±
53°±5°
Timing setting
59
°3
6'
±3
°
Key groove position

Mark an aligning mark on the pump housing
(Width,depth 0.3 mm)
0°24' ±30'

TEMPORARILY ENGINE MODEL: SA6D170A Date: 27 July 2006 0
Company: KOMATSU
No. 6162-73-2320
Injection pump: PE6ZW Governor: EP/RSUVD Timing device:
103066-8400 105455-0971
1. Test conditions
Nozzle & Nozzle Holder Ass'y: 105111-4090 (Bosch Type No. )

(Bosch Type No. ) (Bosch Type No. )
Injection pipe: Outer Dia. 8 mm × Inner Dia. 2.4mm Length 1400mm

+5
Overflow valve opening pressure: 206± 34 kPa { 2.1 ± 0.35 kgf/cm2 }
2. Injection timing
Injection order: 1 5,1 3,1 6,1 2,1 4

60°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'
A 15.1 1050 (391) ± 5 ±4 Lever Basic Above 61.3 {Above 460}
B Approx 7.3 475 (45) ± 5 ± 14 Rack Boost press. 0

Pump speed
(r/min)
Advance
angle (° )

103662-3180 2/3

Stop lever nomal position setting: 17.5+0.5

Rack limit: 16.5+0.2
Above 26
2±0.1
Difference in rack position between
N = 1050 and N = 750
Rack position (mm)
A
15.1
1.3±0.1
Above 8.8
Idle sub-spring setting: 6.2-0.5

B
7.3
6.2
1.1±0.3
0
475 (670)±30 (925)±30 1175±25
+30 +45
770 -20 1050 +35
Pump speed (r/min)
N = 750
Rack position (mm)
16.4
14.4
0 48.0±6.7 {360±50}
21.3±2.7 {160±20}
103662-3180 3/3
5°
(22°) ±
Full-speed
Load lever angle

5°
Confirm that the clearance is approx

5°
)±
e) ±
Full-load 2mm when contacts inner stopper.

re
asu
sur
Idling Approx 2
(me
mea(
Stop lever angle
32° ±5°
R=17.5+0.5 N=0, R=2-0.2
±5°
(After lever angle setting, 15° (After lever angle setting,
put the seal.) put the seal.)
Normal Stop
Ass'y No.: 103662-3351

TEMPORARY ENGINE MODEL： SA6D170A Date: 2 Apr. 2002 3
Company: KOMATSU
No. 6162-74-1310
Injection pump： PE6ZW Actuator： RED III Timing device：
103066-5011 105955-0110
Pump rotation： Counter clockwise (viewed from drive side)
Nozzle ＆ Nozzle Holder Ass'y ：105111-4820
Nozzle： 105025-1850 Nozzle Holder：105041-7111
Nozzle opening pressure： 29.4 MPa｛ 300 kgf/cm2｝　Transfer pump pressure： 157 kPa｛ 1.6 kgf/cm2｝　
Injection pipe： Outer Dia.8 mm × Inner Dia.2.4 mm － Length 1500 mm

+5
Test Oil：ISO4113 or SAE Standard Test Oil｛SAE J967d｝ Oil Temp.：40　℃
Overflow valve opening pressure：255 kPa｛ 2.6 kgf/cm2｝　
Pre-stroke：No.1 Plunger 3.2 ± 0.05mm　 Note: Perform at voltage V
Injection order：
1 5,1 3,1 6,1 2,1 4
60°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'
Plungers are numbered from the Drive side. ( interval: °± ）
４．Injection quantity RED Ⅲ GOV. C/U : 15 mm

Adjust- Rack Vist Pump Injection q' ty Max. var
position speed bet. cyl Remarks
ing point (V) ( cm3 / 1000 strokes) (％ )
(mm) (r/ min)
(13.2) 1.36 865 513 ± 5 ±4 Basic

(6.1) Approx.2.8 400 30 ± 5 ± 14

Pump speed
Advance
angle（°）
Bosch Automotive Systems Corpo- 3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Ja-
ration pan
103662-3351 2/3
Stop lever angle
Normal Stop
Timing setting
At No.1 plunger’s beginning

Approx.70°

103662-3351 3/3
■ RED Ⅲ governor
Confirmation of the control rack position sensor's output characteristics
(Rack 15mm , Span 6mm)
When the rack sensor output voltages are V1 and V2, confirm that rack positions R1
and R2 are as specified below.

ENGINE MODEL: 6NSD Date: 11 Sep 2002 3
Company: NIIGATA ENGINEERING
No. 74V47000A
Injection pump: PE6ZW Governor: EP/RSUV Timing device:
103067-8171 105455-0730
1. Test conditions
Nozzle & Nozzle Holder Ass'y: 105780-8130 (Bosch Type No. EFEP215A)

(Bosch Type No. DN6TD119NP1T) (Bosch Type No. EFEP215)
Injection pipe: Outer Dia. 8 mm × Inner Dia.4 mm Length 1500mm

+5
2. Injection timing
Pre-stroke: No.1 Plunger 3 ± 0.05mm Note: Adjust with rack position of mm
Injection order: 6 3,6 5,6 1,6 4,6 2

60°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'
A 14.3 750 523 ± 15 ±2 Rack Basic
B Approx. 6.7 250 41.5 ± 3.5 ± 10 Rack

Pump speed
(r/min)
Advance
angle (° )
103672-0350 2/3
Rack limit: 21+1

Above 26
Do not adjust idling spring
A
Rack position (mm)
14.3
5
9.0
6.7 B
5.7
0 235 250 750±5 Below 815
Pump speed (r/min)

103672-0350 3/3
18° ±5° (30°) ±5

°
Idling Full-speed
Stop lever angle
Normal Stop
35° ±5 5°
° 10° ±
Timing setting
Approx. 50°
Center of pump side coupling's elongated hole

CONFIDENTIAL
INJECTION PUMP CALIBRATION DATA

TEST OIL
I S O 4113 or ZEXEL No.: 104135-4030
S A E J967d Date: 24 Aug. 2001 3
ENGINE MODEL: N844L-T
Company: ISHIKAWAJIMA
INJ. Pump Ass'y No. 104135-4030 (NP - PFR4KX60/2NP10) No.: 13101-7800
1. Test Conditions:
Drive Shaft Rotation: Clockwise ( viewed from drive side )
Nozzle & Nozzle Holder Ass'y No.: 105780 - 8190
Nozzle No.: 105780 - 0060 (Bosch Type No. DN0SD1510)
Nozzle Holder No.: 105780 - 2150
Nozzle Opening Press.: 13.0+0.3 MPa {133+3 kgf/cm2}
Injection Pipe No.: Inner Dia. 2 mm x Outer Dia. 6 mm - Length 450 mm
Transfer Pump Press.: 49 kPa {0.5 kgf/cm2}
Oil Temp.: 40-5℃
Cam Profile: PFK - T - 00 (Tangential Cam; Cam Lift 7mm; Base Circle φ 28)
2. Injection Timing:
Pre-stroke P : 2.45±0.05 mm (*)
L 1 (Port Closing Dimension): 73.55±0.05 mm (*)
L 2 (Mounting Dimension): 76±0.05 mm (*)
L 3 (Pump Ass'y Dimension): Above 77 mm
(*) The control rack is pushed fully in the fuel
increase direction.
3. Injection Quantity: Rc=0; this position is half of full rack stroke

a: a=-1.5±0.02
(full rack stroke=16mm).
Rack Position Pump Speed Injection Q'ty Max. var. bet. cyl.
Fixed Remarks
(mm) (r/min) (cm3/1,000strokes) (%)
a=-1.5±0.02 1,100 24.3±0.3 Basic R=6.5mm
a+1 1,400 *(33.8) R=7.5mm
a+2.4 850 *(40.2) R=8.9mm
a-2.2 1,500 *(12) R=4.3mm
a-0.4 400 *(12) R=6.1mm
-7 1,500 Below 1 Non-injection
+8 150 *(51) Starting
*: Enter after measuring ( ) =Reference value

4. Control Rack Sliding Resistance:
Pump Speed Sliding Resistance
(r/min) (g)
1,000 Below 25
Bosch Automotive Systems Corporation

Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken 352-8572, JAPAN
Tel: (048) 470-1559 Fax: (048) 474-9856
TEST OIL:
ISO 4113 or CONFIDENTIAL ENGINE MODEL: V2203-DI Assy no.: 104139-4090
SAE J967d Date: 27 Aug 2003 2
Company: KUBOTA
Injection pump assy no. 104139-4090 (NP-PFR4KX80/2NP12) No. 1G911-51012
1. Test conditions:
Drive shaft rotation: Clockwise (viewed from drive side)
Nozzle & nozzle holder assy no.: 105780 - 8190
Nozzle no.: 105780 - 0060 (Bosch type no. DN0SD1510)
Nozzle holder no.: 105780 - 2150
Nozzle opening pressure.: 13.0+0.3 MPa {133+3 kgf/cm2}
Injection pipe no.: Inner dia. 2 mm x outer dia. 6 mm - length 450 mm
Transfer pump pressure.: 49 kPa {0.5 kgf/cm2}
Oil temperature.: 40-5 °C
Cam profile: PFK - T - 00 (tangential cam; cam lift 7 mm; base circle ø28)
2. Injection timing:
Pre-stroke P : 1.9±0.05 mm *
L 1 (port closing dimension): 74.1±0.05 mm *
L2 (mounting dimension): 76±0.05 mm *
L3 (pump assy dimension): Above 77 mm
* The control rack is set at +2.5±0.5 mm

(R = approx 10.5±0.5 mm).
3. Injection quantity:
(1) Set the rack's standard "0" position using the gauge. (Refer to service information S.I. 441 for "0"
point setting procedure.)
(2) Standard "0" (8 mm) is half of the full rack stroke (16 mm).
(3) Rc is the rack position relative to standard "0".
Rack position Pump speed Injection qty Max. var. between
Fixed Remarks
Rc (mm) (r/min) (cm3 / 1000 strokes ) cylinders (mm3/st)
a = +1.0±0.02 1100 50.9±0.3 Basic R = approx 9.0
a-1 1100 (35.8)* R = approx 8.0
a 700 (42.3)* Torque point R = approx 9.0
a-1.7 450 (14.2)* Low idle R = approx 7.3
-7 1100 Below 1 Non injection R = approx 1.0
+8 150 (64.0)* Start R = approx 16
* Enter after measuring; ( ) = reference value; R = Rc+8
4. Control rack sliding resistance:

Pump speed (r/min) Sliding resistance (g)
1000 Below 25

1/2
TEST OIL:
ISO 4113 or CONFIDENTIAL ENGINE MODEL: 03-DI Assy no.: 104139-4150
SAE J967d Date: 1 Oct 2004 3
Company: KUBOTA
Injection pump assy no. 104139-4150 (NP-PFR4KX80/2NP23) No. 1G796-51011
1. Test conditions:
Drive shaft rotation: Clockwise (viewed from drive side)
Nozzle & nozzle holder assy no.: 105780 - 8190
Nozzle no.: 105780 - 0060 (Bosch type no. DN0SD1510)
Nozzle holder no.: 105780 - 2150
Nozzle opening pressure: 13.0+0.3 MPa {133+3 kgf/cm2}
Injection pipe no.: Inner dia. 2 mm x outer dia. 6 mm - length 450 mm
Transfer pump pressure: 49 kPa {0.5 kgf/cm2}
Oil temperature: 40-5 °C
Cam profile: PFK - T - 00 (tangential cam; cam lift 7 mm; base circle ø28)
2. Injection timing:
Pre-stroke P: 2.5±0.05 mm *
L 1 (port closing dimension): 74.5±0.05 mm *
L2 (mounting dimension): 77±0.05 mm *
L3 (pump assy dimension): Above 78 mm
* Set the control rack at R = 9.0 ~ 11.0 mm.

Install the shims (139400-2900: 6 pc) between the pump flange
and driving stand (to adjust the mounting dimension to 77 mm).
3. Injection quantity: (at the mounting dimension 77 mm)
Fixed Remarks
Rc (mm) (r/min) (cm3/1000 strokes ) cylinders (mm3/st)
a = +2.8±0.02 1100 54.0±0.3 Basic R = approx 10.8
a-0.2 1400 (55.1)* Rated output R = approx 10.6
a+0.4 1300 (62.8)* Rated output R = approx 11.2
a+1.0 800 (62.1)* Torque point R = approx 11.8
a-2.1 500 (15.0)* Low idle R = approx 8.7
a-2.8 1500 (18.0)* High idle R = approx 8.0
-4 1500 Below 1 Non injection R = approx 4.0
+8 150 (73.3)* Start R = approx 16.0

104139-4150 2/2
4. Non injection quantity: (at the mounting dimension 76 mm; i.e., without the shims)
Fixed Remarks
Rc (mm) (r/min) (cm3/1000 strokes ) cylinders (mm3/st)
-5 1500 (0)* Non injection R = approx 3.0
5. Control rack sliding resistance:

Pump speed (r/min) Sliding resistance (g)
1000 Below 25
Test Data 104142-3450 ,
Rack Position Pump(rpm) CC/100st
24 mm 300 *
18 mm 300 *(114 to 120) basic ( Temporary fuel Q'ty)
12 mm 300 *
12 mm 100 *

Bosch Ass'y No. 9 460 612 455
Bosch Typecode
Engine Type WL-NA
Manufactures MAZDA
Test oil ISO4113orSAEJ967
d
...
Nozzle 105780-0060
Bosch type code NP-DN0SD1510
P Opening Pressure MPa 13 13 13.3
P Opening Pressure kgf/cm2 133 133 136
Iinjection Pipe 157805-7320
P Iinjection Pipe mm 2-6-450
Inside diameter - outside diameter - length (mm)
Joint Assembly 157641-4720
Tube Assembly 157641-4020
P Transfer pump pressure kPa 20 20 20
P Transfer pump pressure kgf/cm2 0.2 0.2 0.2
Left
2.1 Full load delivery
S Differnce in delivery mm3/st. 4 4
P Basic *
P Oil temperature degC 50 48 52
C Average injection quantity mm3/st. 46 43 49
About
C Average injection quantity mm3/st. 47.7 46.7 48.7
C Differnce in delivery mm3/st. 4.5 4.5
P Basic *
About
2.2 Governing
P Basic *
C Average injection quantity mm3/st. 5 5
P Basic *
2.3 Idle


S Differnce in delivery mm3/st. 1.7 1.7
P Basic *
C Average injection quantity mm3/st. 9 7.5 10.5
P Basic *
2.4 Start
Remarks
Full
About
Remarks
Full
2.5 Stop
Remarks
Magnet OFF
2.6 Overflow
C Overflow quantity cm3/min 400 270 530
2.7 Pump chamber Pressure
S Pressure kPa 510 481 539
S Pressure kgf/cm2 5.2 4.9 5.5
P Basic *
C Pressure kPa 510 471 549
C Pressure kgf/cm2 5.2 4.8 5.6
P Basic *
2.8 Timer
S Timer Stroke mm 4.4 4.2 4.6
P Basic *
C Timer Stroke mm 1.8 1 2.6
C Timer Stroke mm 4.4 4 4.8
P Basic *
C Timer Stroke mm 9 8.2 9.8
2.9 Magnet
C MAX applied voltage V 8 8 8
P Test voltage V 13 12 14
2.10 Compensator
2.10.1 Load-Timer adjustment
S Timer stroke TA mm 3.7 3.5 3.9
S Timer stroke variation dT mm 0.7 0.7 0.7
About
P Basic *
C Timer stroke TA mm 3.7 3.3 4.1
C Timer stroke variation dT mm 0.7 0.7 0.7
About
P Basic *
C Timer stroke variation dT mm 1.5 1.5 1.5
About
Name CONTROL STANDARD AT IDLING

Standards for idle difference in delivery control

After idle adjustment, measure the idle injection quantities of (A) to (D).
Install the colored rings to the delivery valve holders (A) to (D) in accordance with the table.
(A): A cylinder
(B): B cylinder (C) C cylinder
(D): D Cylinder (E) Color ring
(F): (A) >= (C)
(G): (C) > (A)
(H): (A) - (C) or (C) - (A)
(I): 0.2, 0.1cm3/1,000st
(J): (B) - (D) or (D) - (B)
(K): Ring color
(L): At least 0.6cm3/1,000st
(M): 0.3, 0.4, 0.5 cm3/1,000st
(N): 0.2, 0.1, 0.0 cm3/1,000st
(O): (B) >= (D)
(P): (D) > (B)
(T): Yellow
(U): White
(V): Red
Name WIRE
a=7.6deg
b=12.5+-4deg
L2=4.6+-0.5mm
L1=34.1+3.5mm (1)Wire length confirmation

L2=4.6+-0.5mm Accelerator wire: Idle-full stroke: L1 mm
P1=-66.0kPa (2)Idle switch confirmation
P2=-500mmHg Confirm that the switch is ON in the idle lever position.
a=7.6deg (3)2 stage lever adjustment
b=12.5deg+-4deg 1. Apply negative pressure of P1kPa {P2 mmHg} to the actuator from the negative pressure inlet
T=6~9Nm(0.6~0.9Kgfm) port(A).
2. Under the conditions in 1, adjust with the screw (C) so that the position of the control lever (B)
becomes angle a [gap L2 from the idle screw (E)] and fix the nut (D).
T:Tightening torque
3 Assembly dimension
S K dimension mm 3.3 3.2 3.4
S KF dimension mm 6.01 5.91 6.11
S MS dimension mm 0.9 0.8 0.9
S Control lever angle alpha deg. 12.5 8.5 16.5
S Control lever angle beta deg. 40 37 43
About


Bosch Ass'y No.
Bosch Typecode
Engine Type 4D56
d
...
Nozzle 105780-0000
Bosch type code NP-DN12SD12T
P Opening Pressure MPa 14.7 14.7 15.19
Right
P Basic *
2.2 Governing
P Basic *


2.3 Idle
P Basic *
2.4 Start
P Basic *
2.5 Stop
Remarks
Magnet OFF
2.6 Overflow
S Pressure kPa 470.5 441 500
P Basic *
C Pressure kPa 313.5 284 343
2.8 Timer
P Basic *


C Timer Stroke mm 1.2 0.6 1.8
2.9 Magnet
2.10 Compensator
P Basic *
About
C Timer stroke variation dT mm 0.6 0.2 1
About
S Control lever angle alpha deg. 59 55 63


Bosch Ass'y No. 9 460 610 297
Bosch Typecode
Engine Type 4D56
d
...
Nozzle 105780-0000
Bosch type code NP-DN12SD12T
P Opening Pressure MPa 14.7 14.7 15.19
Right
P Basic *
2.2 Governing
P Basic *
C = Check value)

2.3 Idle
P Basic *
2.4 Start
P Basic *
2.5 Stop
Remarks
Magnet OFF
2.6 Overflow
S Pressure kPa 470.5 441 500
P Basic *
2.8 Timer
P Basic *
C = Check value)

2.9 Magnet
2.10 Compensator
P Basic *
About
About
C = Check value)
TEST OIL: INJECTION PUMP CALIBRATION DATA 1/2
ISO 4113 or
SAE J967d CONFIDENTIAL ENGINE MODEL: 4JB1A Assy no.: 104741-1030
Date: 23 Nov 2004 0
Injection pump no.: 104641-1011 [ NP-VE 4/11F1800RNP251 ] Company: ISUZU
Pump rotation: clockwise - viewed from drive side No. 8 94153 194 0
Refer to the service manual (VE pump B.I.S.: Publication No. EE14E-11042) for all procedures and details other
than the following.
1. Test conditions
1-1 Nozzle: 105780-0000 (NP-DN12SD12T) 1-4 Injection pipe: ø2×ø6×840mm
1-2 Nozzle holder: 105780-2080 (EF8511/9) 1-5 Fuel oil temperature: 45+5°C
1-3 Nozzle opening pressure: 14.7+0.5 MPa {150+5 kgf/cm2} 1-6 Supply pump pressure: 20kPa {0.2kgf/cm2}
Pump speed Charge air pressure Difference in

2. Setting (r/min)
Settings
kPa {mmHg} delivery (cm3)
2-1 Full load delivery 1,000 44.6±0.5 (cm3/1,000st) 3.5
Full load delivery (cm3/1,000st)
2-2 Supply pump pressure 1,550 520±20 {5.3±0.2} kPa {kgf/cm2}
2-3 Timing device travel 1,550 1.9±0.2 (mm)
2-4 Idle speed regulation 390 9.0±2.0 (cm3/1,000st) 2.0
2-5 Start (Full lever) 100 95.0±20.0 (cm3/1,000st)
2-6 Full-load speed regulation 2,100 12.7±3.1 (cm3/1,000st) 3.5
2-7
3. Test
Solenoid
ON OFF
specifications Timer
N = r/min 730±100 1,440±50 1,550 1,850
3-1 Timing device
mm 0.5 0.5 1.9±0.3 5.7±0.4
N = r/min 1,000 1,550 1,850
3-2 Supply pump kPa {kgf/cm2}
314±29 520±20 618±29
{3.2±0.3} {5.3±0.2} {6.3±0.3}
N = r/min 1,550
3-3 Overflow delivery
cm3/min 530±130
3-4 Fuel injection quantities

Speed control Pump speed Fuel delivery Charge air pressure
4. Dimensions
lever position (r/min) (cm3/1,000st) kPa { mmHg }
Maximum speed 1,000 44.6±1.0 K 2.8±0.1 mm
700 36.6±2.0 KF 5.0±0.1 mm
1,350 47.5±2.0 MS 1.0±0.1 mm
1,700 47.3±2.5
BCS - mm
2,100 12.8±3.5
2,300 Below 7.0 Pre-stroke 0.45±0.02 mm
Control lever angle
α 18.0±4.0 (°)
Magnet valve 390 0 (Idle) β 35.0±5.0 (°)
switch OFF
γ - (°)
Idling 390 9.0±2.0
550 Below 3.0
3-5 Solenoid Maximum cut-in voltage: 8 V, Test voltage: 12 - 14 V

104741-1513
use
104741-1514
TEST OIL:
ISO 4113 or INJ.PUMP CALIBRATION DATA 1/2
SAE J967d
CONFIDENTIAL ENGINE MODEL : Ass’y No. 104741-4760
QD32
Date: 6 Fev 2002 0
Injection pump No : 104641-4760 [NP-VE4/11F1800RNP2395 ] Company: NISSAN DIESEL
Pump rotation : Clockwise-viewed from drive side No. 16700 2S608
Refer to the service manual (VE pump B.I.S.;Publication No. EE14E-11042) for all procedures and details other
than the following.
1. Test Conditions
1-1 Nozzle : 105780-0060(NP-DN0SD1510) 1-5 Fuel oil temperature : 45＋５°C
1-2 Nozzle holder : 105780-2150 1-6 Supply pump pressure : 20kPa {0.2kgf/cm2}
1-3 Nozzle opening pressure : 13.0+0.3MPa {133+3kgf/cm2} 1-7 Joint ass’y : 157641-4720
1-4 Injection pipe : φ2×φ6×450mm 1-8 Tube ass’y : 157641-4020
Pump speed Charge air press Difference in
2. Setting Settings
( r / min ) kPa { mmHg } delivery(cm3)
Full load delivery (cm3/1,000st)
2-2 Supply pump pressure 1,000 539 ± 20 {5.5 ± 0.2} kPa {kgf/cm2}
2-4 Idle speed regulation 375 12.9±2.0 (cm3/1,000st) 2.0
2-5 Start (Full) 100 (90 ＋ 20.0
− 15.0) (cm3/1,000st)
2-6 Full-load speed regulation 2,350 17.8±2.0 (cm3/1,000st)
2-7 Load-timerAdjustment 1,000 2.3±0.2 (mm)
3. Test Specifi-
cations
3-1 Timing device N=r/min 600 1,000 1,800 2,050
mm (1.4 ± 0.5) 3.5 ± 0.3 (7.4 ± 0.5) 8.2 ＋ 0.4
− 0.5
1,000 1,800
3-2 Supply pump N=r/min 539 ± 39 736 ± 59
kPa{kgf/cm2} {5.5 ± 0.4} {7.5 ± 0.6}
3-3 Overflow delivery N=r/min 1,000

cm3/min 390 ± 130
Speed control Pump speed Fuel delivery Charge air press
lever position ( r / min ) (cm3/1,000st) kPa { mmHg } 4. Dimensions
Max. speed 1,000 58.3±1 K 3.3±0.1 mm
500 (52.0±3.5) KF 5.62±0.1 mm
800 (57.1±3.5)
MS 0.9±0.1 mm
1,500 (58.3±3)
1,800 (60.5±3) BCS − mm
2,350 17.8±2.5 Pre-stroke 0.1 ± 0.02 mm
2,600 Below 5.0
Control lever angle
α 55.5±2.0 （°）
Switch OFF 375 0 (Idle) β 32.5±5.0 （°）
Magnet valve
γ − （°）
Idling 375 12.9±2.5
3-5 Solenoid Max. cut-in voltage : 8 V, Test voltage : 12∼14 V
Bosch Automotive Systems Corporation 3-4-1 Kitano,Niiza-shi, Saitama-ken, 352-8572, JAPAN

Service Department Tel. (048) 470-1559 Fax. (048) 474-9856
104741-4760 2/2
■Load timer adjustment
1.Adjust the governor shaft so that the clearance between the end of the flange and the
end of the governor shaft is approxiamely 3 mm and then lock the nut.
2.Load timer adjustment

(1) Fix the control lever in the position satisfying the following conditions:
Boost Pressure ： - kPa ｛ - mmHg｝

Pump Speed ： 1,000 r/min
Fuel injection ： 29.0±0.5 cm3/1，000st
Quantity
(2) With the control lever positioned as described in (1) above, adjust the governor sleeve
so that timer reduction value (ΔT)conforms to the specified values (Item2-7).
T=17∼22N・m｛1.7∼2.2 kgf・m｝
3.Confirmation of Timer Characteristics

Fix the control lever in the position satisfying the following condition, and confirm the
timer stroke.
Control lever position Specified Values

Pump speed Fuel Injection q'ty Boost pressure Timer stroke Timer reduction value
（r/min）（cm3/1,000st）（kPa ｛mmHg｝）（mm）（mm）
-
1,000 29.0 ± 1 2.3 ± 0.3 (1.2)
{-}
-
1,000 20.0 ± 2.5 (1.2 ± 0.5) (2.3)
{-}
104741-6670

Bosch Ass'y No. 9 460 614 810
Bosch Typecode
Engine Type WLT
Manufacturer MAZDA
d
1404 Test oil
Nozzle 105780-0060
Injection pipe 157805-7320
P Injection pipe mm 2-6-450
Joint assembly 157641-4720
Tube assembly 157641-4020
Left
(Sorenoid Timer Adjustment Condition) ON
With S/T O-ring; S/T ON.
P Basic *
Remarks
NA
P Boost pressure kPa 43.3 42 44.6
P Basic *
Remarks
CBS


P Boost pressure kPa 80 78.7 81.3
P Basic *
Remarks
Full
P Basic *
Remarks
NA
P Boost pressure kPa 43.3 42 44.6
C Differnce in delivery mm3/st. 6 6
P Basic *
Remarks
CBS
P Basic *
Remarks
Full
About
2.2 Governing


P Basic *
P Basic *
2.3 Idle
P Basic *
C Average injection quantity mm3/st. 10.5 9 12
P Basic *
2.4 Partial injection quantity
About
2.5 Start
P Basic *

Remarks
Full
About
Remarks
Full
2.6 Stop
Remarks
Magnet OFF at idling position
2.7 Overflow
C Overflow quantity with S/T ON cm3/min 430 300 560
C Overflow quantity with S/T OFF cm3/min 450 320 580
About
S Pressure WITH S/T ON kPa 510 481 539
S Pressure WITH S/T ON kgf/cm2 5.2 4.9 5.5
S Pressure with S/T OFF kPa 422 383 461
S Pressure with S/T OFF kgf/cm2 4.3 3.9 4.7
P Basic *
Remarks
ON
C Pressure WITH S/T ON kPa 510 471 549
C Pressure WITH S/T ON kgf/cm2 5.2 4.8 5.6
P Basic *
Remarks
ON

2.9 Timer
S Timer stroke with S/T ON mm 4.8 4.6 5
S Timer stroke with S/T OFF mm 3.2 2.8 3.6
P Basic *
Remarks
ON
C Timer stroke with S/T ON mm 2.2 1.4 3
C Timer stroke with S/T ON mm 4.8 4.4 5.2
C Timer stroke with S/T OFF mm 3.2 2.6 3.8
P Basic *
Remarks
ON
About
2.10 Magnet


Name CONTROL STANDARD AT IDLING
Standards for idle difference in delivery control

After idle adjustment, measure the idle injection quantities of (A) to (D).
Install the colored rings to the delivery valve holders (A) to (D) in accordance with the table.
(A): A cylinder (B) :B cylinder (C) : C cylinder (D): D cylinder
(E): Collar ring
(F): (A) >= (C)
(G): (C) > (A)
(H): (A) - (C) or (C) - (A)
(I): 0.2, 0.1(mm3/st)
(J): (B) - (D) or (D) - (B)
(K): Ring color
(L): At least 0.6 mm3/st
(M): 0.3, 0.4, 0.5 (mm3/st)
(N): 0.2, 0.1, 0.0 (mm3/st)
(O): (B) >= (D)
(P): (D) > (B)
(T): Yellow
(U): White
(V): Red


Name POTENTIOMETER ADJUSTMENT
N1=1000(r/min)
Q1=24.6+1.5+0.1(mm3/st)
V1=4.81+0.01-0.05(V)
V2=2.0+-0.43(V)
V3=8.5+-0.48(V)
Vi=10(V)
P1=80.0(kPa)
P2=600(mmHg)
N1=1000(r/min) Adjustment of the potentiometer

Q1=24.6+1.5+0.1(mm3/st) Dummy bolt method
V1=4.81+0.01-0.05(V) 1. Hold the dummy bolt against the control lever at position Np = N1 (r/min) and Q = Q1 (mm3/st
Vi=10(V) ) and fix using the lock nut.
2. When adjusting the potentiometer, position the control lever against the dummy bolt and adju
st so that the output voltage is V1 (V).
3. After adjustment, remove the dummy bolt and confirm that the potentiometer output voltage at
the control lever's idling and full speed positions is as specified above.
Vi:Applied voltage
N:Pump speed (r/min)
V:Output voltage (V)
Q:Injection quantity (mm3/st)
A:Adjusting point
B:Checking point
C:Position of the control lever
C1:Idling
C2:Full speed
P1:Boost pressure (kPa)
P2:Boost pressure (mmHg)
Name WIRE
L2=(3.8(mm))
a=9(deg)
b=12.5+-4(deg)
L1=34.1+3.5-5.5(mm) (1)Wire length confirmation

L2=3.8(mm) Accelerator wire (idle~full stroke: L1 mm)
P1=-66.6(kPa) (2)Idle switch confirmation
P2=-500(mmHg) Confirm that the switch is ON in the control lever's idle position.
T=6~9(Nm)(0.6~0.9(kgfm)) (3)Adjustment of the two stage actuator
a=9(deg) 1. Apply negative pressure P1 kPa {P2 mmHg} to the actuator through the negative pressure suc
b=12.5+-4(deg) tion inlet.
2. In the above condition, adjust using screw (C) so that the control lever (B) position is a [cleara
nce L2+-0.5 (mm) from the idle screw (E)] , and fix using the nut (D). (Tightening torque T)
b:Angle alpha


Name DASHPOT ADJUSTMENT
L=8.1+-0.05(mm)
a=14.1(deg)
b=12.5+-4(deg)
L=8.1+-0.05(mm) Adjustment of the dash pot

T=6~9(N-m)(0.6~0.9(kgf-m)) 1. Hold the control lever (A) at position a (clearance L).
a=14.1(deg) 2. In the above condition, adjust the position of the dash pot so that the end of the dash pot (B) c
b=12.5+-4(deg) ontacts the control lever (A) and fix using the nut (C).
(Tightening torque T)
D:Dash pot contact position
b:Angle alpha
S MS dimension mm 0.9 0.8 1
S BCS stroke mm 6.8 6.6 7
S Control lever angle alpha deg. 12.5 8.5 16.5


Bosch Ass'y No. 9 460 613 020
Bosch Typecode
Engine Type TD27-T
Manufacturer NISSAN DIESEL
Edition date 01/11/02
d
...
Nozzle 105780-0060
Right
P Basic *
Remarks
BCS
P Boost pressure kPa 66.7 65.4 68
P Basic *
Remarks
Full


About
About
P Basic *
Remarks
BCS
P Basic *
Remarks
Full
About
About
2.2 Governing
P Basic *


About
P Basic *
2.3 Idle
P Basic *
P Basic *
2.4 Start
About
P Basic *
Remarks
Full


About
Remarks
Full
2.5 Stop
Remarks
2.6 Overflow
About
Remarks
Without an O-ring
About
Remarks
With an O-ring
About
S Pressure WITH S/T ON kgf/cm2 6.6 6.2 7
About
P Basic *
Remarks
OFF

C Pressure with S/T OFF kPa 481 442 520

C Pressure with S/T OFF kgf/cm2 4.9 4.5 5.3
P Basic *
C Pressure with S/T OFF kPa 588 549 627
About
C Pressure with S/T OFF kgf/cm2 6 5.6 6.4
About
2.8 Timer
About
P Basic *
Remarks
OFF
About
P Basic *
About
About
About
2.9 Magnet


2.10 Compensator
S Timer stroke TA mm 3.8 3.6 4
About
P Basic *
P Basic *
C Timer stroke TA mm 3 2.5 3.5
About
Name POTENTIOMETER ADJUSTMENT
N1=850r/min
Q1=22.9+-1.0cm3/1,000st
V1=3.72+-0.03V
V2=(2.0+-0.43)V
V3=(7.86+-0.58)V
C3=(2.5)deg
C4=(17.0)deg

V1=3.72+-0.03V Potentiometer adjustment

P1=0kPa 1. Applied voltage: Vi
P2=0mmHg 2. Boost pressure = P1kPa {P2 mmHg}
Vi=10V 3. Set the control lever at the adjusting point. Position the dummy bolt against the lever and fix.
4. Assemble the potentiometer to obtain output voltage V1 (V) at the fixed position.
5. After mounting the potentiometer, remove the dummy bolt.
N:Pump speed
Q:Injection quantity
V:Output voltage
A:Performance standards
B:ON, OFF switch standard
C:Angle of the control lever
D:OFF-->ON
E:OFF-->ON
F:Adjusting point
G:Checking point
C1:Idle
C2:Full-speed
S MS dimension mm 1 0.9 1.1
S Varid Stroke mm 0.964 0.944 0.984
About

TEST OIL:
SAE J967d
CONFIDENTIAL ENGINE MODEL : TD27- T Ass’y No. 104745-9173
Date: 25 Jun. 2001 3
Injection pump No : 104645-9173 [NP-VE 4/10F2000RNP1442 ] Company: NISSAN DIESEL
Pump rotation : Clockwise-viewed from drive side No. 16700 86P03
than the following.
1. Test Conditions ※ When no instruction, adjust and confirm with S/T OFF.
1-1 Nozzle : 105780-0060(NP-DN0SD1510) 1-5 Fuel oil tempetature : 45＋５°C

1-4 Injection pipe : φ 2 ×φ 6 × 450mm 1-8 Tube ass’y : 157641-4020
2. Setting Settings
2-1 Full load delivery 1,100 (Full) 65.2 ± 0.5 (cm3/1,000st) 66.7 ± 1.3{500 ± 10} 5.0
Full load delivery 850 (BCS) 55.4 ± 0.5 (cm3/1,000st) 32.0 ± 1.3{240 ± 10}
Full load delivery 500 (NA) 48.4 ± 0.5 (cm3/1,000st) 0
2-2 Supply pump pressure 1,100 OFF 451 ± 20 {4.6 ± 0.2} kPa {kgf/cm2} 66.7 ± 1.3{500 ± 10}
2-3 Timing device travel 1,100 OFF 4.2 ± 0.2 (mm) 66.7 ± 1.3{500 ± 10}
2-4 Idle speed regulation 400 10.2 ± 2.0 (cm3/1,000st) 0 2.0
2-5 Start (Full) 100 (75.0 ＋ 20.0
− 15.0) (cm3/1,000st) 0
2-6 Full-load speed regulation 2,500 23.5 ± 2.0 (cm3/1,000st) 66.7 ± 1.3{500 ± 10}
2-7 Load-timer Adjustment 1,100 3.6 ± 0.2 (mm) 66.7 ± 1.3{500 ± 10}
66.7 ± 1.3 kPa {500 ± 10 mmHg}
3. Test Specifi-
Charge air press
cations Solenoid Timer ON OFF
3-1 Timing device N=r/min 1,100 1,100 1,500 2,000
mm (6.4 ± 0.5) 4.2 ± 0.3 (6.4 ± 0.5) 7.0 ＋ 0.4
− 0.5
1,100 1,500
3-2 Supply pump N=r/min 451 ± 39 (549 ± 39)
kPa{kgf/cm2} {4.6 ± 0.4} {(5.6 ± 0.4)}
N=r/min 1,100 (O-Ring less) 1,100 (O-Ring)
3-3 Overflow deliverey
cm3/min 550 ± 130 430 ± 130
Max. speed 1,100 (Full) 65.2 ± 1.0 66.7 ± 1.3{500 ± 10} K 3.3 ± 0.1 mm
850 (BCS) 55.4 ± 1.0 32.0 ± 1.3{240 ± 10} KF 5.9 ± 0.1 mm
500 (NA) 48.4 ± 1.0 0
MS 1.0 ± 0.1 mm
850 (47.4 ± 2.5) 0
1,500 (64.0 ± 2.5) 66.7 ± 1.3{500 ± 10} BCS − mm
2,000 (58.3 ± 3.0) 66.7 ± 1.3{500 ± 10} Pre-stroke − mm
2,250 (44.9 ± 4.5) 66.7 ± 1.3{500 ± 10}
2,500 23.5 ± 3.0 66.7 ± 1.3{500 ± 10} Control lever angle
2,700 Below 10.0 66.7 ± 1.3{500 ± 10}
α 10.0 ± 4.0 （°）
Switch OFF 350 0 (Idle) 0 β 36.0 ± 5.0 （°）
Magnet valve
γ − （°）
Idling 400 10.2 ± 2.5 0
3-5 Solenoid Max. cut-in voltage : 8 V, Test voltage : 12∼14 V

104745-9173 2/4
■Load timer adjustment

Boost Pressure ： 66.7±1.3 kPa｛ 500±10 mmHg｝

Pump Speed ： 1,100 r/min
Fuel injection ： 44.0±0.5 cm3/1，000st
Quantity
(2) With the control lever positioned as described in (1) above, adjust the governor sleeve
so that timer reduction value (ΔT)conforms to the specified values (Item2-7).
T=17∼22N・m｛1.7∼2.2 kgf・m｝

timer stroke.

Pump speed Fuel Injection q'ty Boost pressure Timer stroke Timer reduction value
（r/min）（cm3/1,000st）（kPa ｛mmHg｝）（mm）（mm）
66.7 ± 1.3
1,100 44.0 ±1.0 3.6 ± 0.3 (0.6)
｛500 ±10｝
66.7 ± 1.3
1,100 33.0 ± 2.5 (2.9 ±0.5) (1.3)
｛500 ±10｝
104745-9173 3/4
■Boost compensator adjustment BCS①

①
1. Adjust full load injection quantities to value as described in item 2-1.

2. Adjust BCS's injection quantities to value as described in item 2-1 .
3. Confirm the NA's injection quantities to value as described in item 2-1.
4. If the NA above is not specified, loosen nut 53 and adjust screw 50 so that NA is as
specified and thed fix nut 53 .
<Caution>
Do not tighten or loosen screw 50 more than 1 turn.
104745-9173 4/4
■Potentiometer adjustment
Pump speed Out-put Fuel injection q'ty Control lever

(r/min) (V) (cm3/1,000st) position Remarks
850 3.72 ± 0.03 20.9 ± 1.0 − Adjustment point

Function − (2.18 ± 0.43) − Idle −
Specs
− (8.10 ± 0.58) − Full −
− − − (1.4°
) ON → OFF
ON, OFF
Switch Specs − − (15.9°
) OFF → ON
−
Input voltage: 10V
1. At pump speed of 850 r/min, hold the control lever in a position where a fuel injection
quantity of 20.9 ± 1.0 cm3/1,000st can be obtained.
2. Screw in the dummy bolt until contacts the control lever and lock it using the nut.
3. Adjust the potentiometer so that the out-put voltage is 3.72± 0.03 V and then remove
the dummy bolt.
104745-9570
Doowon
Refer to Kia

Bosch Ass'y No. 9 460 612 303
Bosch Typecode
Engine Type 4JG2
Manufacturer ISUZU
d
...
Nozzle 105780-0060
Right
P Basic *
About
P Basic *
About


About
2.2 Governing
P Basic *
2.3 Idle
P Basic *
2.4 Start
P Basic *
Remarks
Full
About
2.5 Stop
Remarks

Magnet OFF
2.6 Overflow
About
S Pressure kPa 422 393 451
S Pressure kgf/cm2 4.3 4 4.6
P Basic *
C Pressure kgf/cm2 4.3 4 4.6
P Basic *
2.8 Timer
P Basic *
P Basic *
P Basic *
P Basic *


2.9 Magnet
2.10 Compensator
About
P Basic *
C Timer stroke variation dT mm 0.3 -0.1 0.7
P Basic *
C Timer stroke variation dT mm 1 0.4 1.6
Name W-CSD ADJUSTMENT
TA:TA=-0.0345t+2.59
Adjustment of the W-CSD

1. Adjustment of the advance angle of the timer
(1)Determine the timer advance angle using the graph.
(2)(1) Adjust with the screw (A) so that the timer advance angle determined in the item (1) is obt
ained.
Y:Timer stroke TA
X:Temperature t
(C): timer stroke TA(mm)

Name V-FICD ADJUSTMENT

T=3.4~4.9N-m(0.35~0.50kgf-m)
L1=1.40+-0.1mm
L1=1.40+-0.1mm Adjustment of the V-FICD

L2=0.5mm 1. Insert the shim of L1 between the control lever (A) and the idle adjusting screw (B).
L3=5mm Adjust using the FICD adjusting screw (C) so that the actuator moves through its full stroke, then
P1=-53.3kPa fix using the nut (D).
P2=-400mmHg If adjustment with the FICD adjusting screw (C) is not possible, adjust by moving the actuator str
oke with (E) and (F).
2. Apply P1{P2} to the actuator. Confirm that it moves through its full stroke.
After releasing, confirm that the clearance between the control lever (A) and the adjusting screw
(C) is L2 or more.
(G): exceeds L2 after releasing actuator
(H): stroke L3

Test Data
104746 – 6890
use
104746 - 6152
TEST OIL:
SAE J967d
CONFIDENTIAL ENGINE MODEL : 4EE1TC Ass’y No. 104749-5372
Date: 4 July 2002 5
Injection pump No : 104649-5372 [NP-VE 4/9F2250RNP1386 ] Company: ISUZU
Pump rotation : Clockwise-viewed from drive side No. 8 97088 463 0
than the following.
1. Test Conditions
1-1 Nozzle : 105780-0060(NP-DN0SD1510) 1-5 Fuel oil temperature : 45+5°C
1-4 Injection pipe :ø2×ø6×450mm 1-8 Tube ass’y : 157641-4020
2. Setting Settings
2-1 Full load delivery 1,500 (Full) 49.2 ± 0.5 (cm3/1,000st) 72.0 ± 1.3{540 ± 10} 3.5
Full load delivery 750 (BCS) 43.8 ± 0.5 (cm3/1,000st) 26.7 ± 1.3{200 ± 10} 3.5
2-2 Supply pump pressure 1,250 412 ± 20 {4.2 ± 0.2} kPa {kgf/cm2} 72.0 ± 1.3{540 ± 10}
2-3 Timing device travel 1,250 4.7 ± 0.2 (mm) 72.0 ± 1.3{540 ± 10}
2-4 Idle speed regulation 425 10.2 ± 2.0 (cm3/1,000st) 0
2-5 Start (Idle) 150 40.0 ± 10 (cm3/1,000st) 0 2.0
2-6 Full-load speed regulation 2,650 24.4 ± 3.0 (cm3/1,000st) 72.0 ± 1.3{540 ± 10} 5.5
2-7
3. Test Specifi- Charge air 72.0 ± 1.3kPa {540 ± 10mmHg}

cations press
N=r/min 600 1,250 1,500 2,000
3-1 Timing device
mm 0.5 ＋ −
1.0
0.4 4.7±0.2 6.3±0.4 9.0 ＋ 0.4
− 0.3
1,250
3-2 Supply pump N=r/min 412 ± 20
kPa{kgf/cm2} {4.2 ± 0.2}
N=r/min 1,250
3-3 Overflow delivery
cm3/min 630 ± 130

Max. speed 1,500 (Full) 49.2 ± 1 72.0 ± 1.3{540 ± 10} K 3.3 ± 0.1 mm
750 (BCS) 43.8 ± 1.0 26.7 ± 1.3{200 ± 10} KF 5.8 ± 0.1 mm
550 (38.3 ± 3) 0
MS 0.9 ± 0.1 mm
750 (46.0 ± 2.5) 33.3 ± 1.3{250 ± 10}
1,500 35.6 ± 2.5 0 BCS - mm
2,250 (50.8 ± 3) 72.0 ± 1.3{540 ± 10} Pre-stroke - mm
2,650 24.4 ± 3 72.0 ± 1.3{540 ± 10}
2,950 Below 4 72.0 ± 1.3{540 ± 10} Control lever angle
20 ± 4 (°)
Switch OFF 425 0 (Idle) 0 40 ± 3 (°)
Magnet valve
- (°)
Idling 425 10.2 ± 2 0
3-5 Solenoid Max. cut-in voltage : 8 V, Test voltage : 12~14 V

104749-5372 2/6
■Potentiometer adjustment
Pump speed Out-put voltage Fuel injection q'ty

Remarks
(r/min) (V) (cm3/1,000st)
13.8±1.0
750 2.76±0.03 BCS pre.:72kPa{540mmHg} Adjusting point
1.18±0.45 Check point
7.85±0.65 Check point
1. At a pump speed of 750 r/min, hold the control lever in a position where a fuel injection
quantity of 13.8 ± 1.0cm3/1,000st can be obtained.
2. Screw in the dummy bolt until it contacts the control lever and lock it using the nut.
3. Adjust the potentiometer so that the out-put voltage is 2.76 ± 0.03 V.
4. Following adjustment, remove the dummy bolt, hold the control lever in the idling position,
and confirm that the potentiometer voltage is as described above.
Dummy bolt
104749-5372 3/6
■V-FICD Adjustment (Adjust with W-FICD disengaged)
1. Adjust so that S=1+1mm. (Figure 1)
Pin
Control lever Actuator shaft
Fig.1
2. At a negative pressure of 53.3kPa {400mmHg} adjust the actuator stroke using the
adjusting screw so that L=0.84±0.1 (Figure 2)
Actuator
Locknut (T=1.2~1.5 N·m {0.12~0.15 kgf·m})
Stroke adjusting screw
Fig.2
104749-5372 4/6
■W-CSD adjustment
1. Timer stroke adjustment

Adjust the screw ① so that the timer stroke is as determined from the graph in Figure
3 (see next page.{Figures 1 and 3})
2. Intermediate lever position adjustment
Insert a shim (L=1.2±0.05) between the control lever ⑨ and the idle set screw ⑦, align
the intermediate lever ⑥ with the aligning mark and adjust the intermediate lever adjusting
screw so that it contacts the control lever. Then, fix the screw. (Figures 1 and 2)
3. FICD adjustment
Insert a shim (L±0.05) between the control lever and the idle set screw and adjust the
screw ② so that the CSD lever ③ operates the intermedate lever through the rod ④.
Then, fix the screw. (Figures 1,2 and 3)
LINE ON BRACKET 8
⑨
L
⑧
⑤
⑦
⑥
②
④ EDGE OF LEVER 6
③
① ⑤
Figure 1 Figure 2
104749-5372 5/6
±0.2 (mm) ±1 (¡)

9
①
L (mm)
8
1.5
7
Timer stroke TA (mm)
Control lever positionθ(deg),

6
1 5
4
②
3
0.5
③ 2
0
15 20 25 30
Temperature t (¡C)
Figure 3
① Timer stroke (mm) ; TA =-0.041t+2.42

② Lever position (deg) ; θ1 =-0.108t+4.79 (-20℃≦t≦20℃)
; θ2 =-0.133t+5.29 (20℃≦t≦50℃)
③ Lever position (mm) ; L1 =-0.035t+1.57 (-20℃≦t≦20℃)
; L2 =-0.044t+1.75 (20℃≦t≦50℃)
Note: ③ indicates the distance between the control lever and the idle set screw.
Cooling water Timer piston Lever pos Lever pos

Cold advancer
temp (℃) stroke (mm) (deg) (mm)
Conditions
Cooling water temp : 20 1.9±0.4 3.6±1.0 1.2±0.3

increasing
Pump speed : 500r/min -20 3.4±0.6 7.9±3.0 2.6±1
104749-5372 6/6
■A/T plate adjustment
Adjust the A/T plate so that OB - OA = 35 ± 2 mm when the control lever is turned from the
idling position (OA) to the full speed position (OB) and then fix the A/T plate.
54.6
3.4 4.9N･m{0.35 0.5kgf･m}

77.1
Control
lever
Idle
A B
A/T plate 94.3

A/T Brkt
188.5
104749-7150
Not Bosch/Zexel
Product of DPICO
No information available
Refer to Kia
TEST OIL:
SAE J967d
CONFIDENTIAL ENGINE MODEL : TD42 Ass’y No. 104760-4441
Date: 19 July 2002 1
Injection pump No : 104660-4441 [NP-VE 6/10F2000RNP126 ] Company: NISSAN DIESEL
Pump rotation : Clockwise-viewed from drive side No. 16700 51N62
than the following.
1. Test Conditions
1-1 Nozzle : 105780-0000(NP-DN12SD12T) 1-4 Injection pipe : ø2×ø6×840mm
1-2 Nozzle holder : 105780-2080(EF8511/9) 1-5 Fuel oil temperature : 45+5°C
1-3 Nozzle opening pressure : 14.7+0.49MPa {150+5kgf/cm2} 1-6 Supply pump pressure : 20kPa {0.2kgf/cm2}

2. Setting Settings
2-2 Supply pump pressure 1,000 324±29 {3.3±0.2} kPa {kgf/cm2}

2-4 Idle speed regulation 350 8.8±2 (cm3/1,000st) 2.0
2-5 Start (Full) 100 60 ＋ 20.0
− 15.0 (cm3/1,000st)
2-6 Full-load speed regulation 2,300 16.6±2 (cm3/1,000st) 5.0
2-7 Load-timer Adjustment 1,200 2.5±0.2 (mm)
3. Test Specifi- Charge air

cations press
N=r/min 800 1,000 1,800 2,200
3-1 Timing device 0.5±0.5 1.6±0.3 5.8±0.5 +0.4
7.4-0.5
mm
1,000 1,800
3-2 Supply pump N=r/min 324±29 608±29
kPa{kgf/cm2} {3.3±0.3} {6.2±0.4}
N=r/min 1,000
3-3 Overflow delivery 400±130
cm3/min
Max. speed 600 52.6±2.0 K 3.3±0.1 mm
1,000 50.9±1.0 KF 6.64±0.1 mm
2,000 44.7±2.1
MS 1.0±0.1 mm
2,100 43.8±4.5
2,300 16.6±2.5 BCS - mm
2,500 Below 5 Pre-stroke - mm
Control lever angle
25±2 (° )
Switch OFF 350 0 (Idle) 40±5 (° )
Magnet valve 250 Below 5 (Full)
350 - (° )
Idling 8.8±2.5
3-5 Solenoid Max. cut-in voltage : 8 V, Test voltage : 12~14 V

104760-4441 2/3
Load timer adjustment

Boost Pressure : - kPa { - mmHg}

Pump Speed : 1,200 r/min
Fuel injection : 22.0±0.5 cm3/1,000st
Quantity
(2) With the control lever positioned as described in (1) above, adjust the governor
sleeve so that timer reduction value ( T)conforms to the specified values (Item2-7).
T=17~22Nm 1.7~2.2 kgfm

timer stroke.

Pump
Fuel Injection q'ty Boost pressure Timer Timer reduction value
speed
(cm3/1,000st) (kPa {mmHg}) stroke(mm) (mm)
(r/min)
-
1,200 22.0 ± 1.0 2.5 ± 0.3 -
{-}
-
1,200 15.0 ± 2.5 2.1 ± 0.7 -
{-}
104760-4441 3/3
Potentiometer adjustment standards

From the graph below calculate the voltage value from the injection quantity obtained at a
pump speed of 700 r/min and a control lever position 7.5 (clearance 4.9 mm) from the idle
position. Then, adjust the potentiometer.
Formula: V±0.03=0.044Q+20.7(V) (Input-voltage: 10V)
Control lever Out-put voltage

Potentiometer position (V)
performance
standard Idle 1.6 ± 0.4
Full-speed 8.0 ± 0.55
5.0
4.0
Voltage（V）
3.0
2.8
Change Lever angle

over point （From idling）
ON → OFF 6.0°±3.5°
2.0
OFF → ON 19.5°±3.5°
10.0 12.0 14.0 16.0 18.0 20.0 22.0
16.5
Inj/q'ty（cm3/1000st）
Potentiometer solid line ① ④
④ ①
Solid line ②③ output
→
Output
⑤ ②
②
ON Solid line ④⑥ Switch turned OFF → ON
OFF Solid line ④⑤ Switch turned ON → OFF ⑥ ③
③ ⑥ ⑤

Bosch Ass'y No. 9 460 611 678
Bosch Typecode
Engine Type TD42
Manufacturer NISSAN DIESEL
d
...
Nozzle 105780-0060
Right
P Basic *
About
P Basic *
About

2.2 Governing
P Basic *
About
P Basic *
2.3 Idle
P Basic *
P Basic *
2.4 Start
P Basic *
Remarks
Full
Remarks
Full
2.5 Stop


Remarks
Remarks
Magnet OFF at full-load position
2.6 Overflow
Remarks
Without an O-ring
About
S Pressure WITH S/T ON kgf/cm2 5.5 5.1 5.9
About
P Basic *
Remarks
OFF
C Pressure kgf/cm2 4.3 4 4.6
P Basic *
About
C Pressure kgf/cm2 7 6.6 7.4
About
2.8 Timer
About

P Basic *
Remarks
OFF
About
About
P Basic *
About
2.9 Magnet
2.10 Compensator
About
P Basic *
P Basic *


Name ACCELERATOR SWITCH ADJ
a=5deg+2deg
d=25+-2deg
SW=SW10
T=6~9Nm(0.6~0.9kgfm)
L1=3.3mm
a=5deg+2deg Accelerator switch adjustment

b=5deg ON - OFF changeover point: from idle to a (shim thickness A = L)
c=5deg Idle~c: ON
L1=3.3+-0.13mm c~full: OFF
A = shim thickness
B = idle lever position
S MS dimension mm 1 0.9 1.1

Test Data
104761-4290
use
104761-4260
2003/02/25 09:53:05 Page 1
Assy name ZexelAssy 104761-4371 Make data 2003/02/25

Manufacturer No. Engine Type Manufacturer No. ZexelAssy 104761-4370 Renew data2003/02/25
1006 TD42T 16700VC700 Manuf. NISSAN DIESEL
P Parts No. Parts name B.T.C. Modify Edition data Kinds VE

Cylinder 6
[1] Adjustment conditions

Designation Unit PSC Set value Remark
Test oil ISO4113orSAEJ967d
Test Oil Temperature degC P 45+5
Nozzle 105780-0060
BOSCH type code NP-DN0SD1510
Opening Pressure MPa P 13.0+0.3
Opening Pressure kgf/cm2 P 133+3
Injection Pipe No. 157805-7320
Injection Pipe mm P 2-6-450 Inside Die.-Outside Die.-Length（mm)
Joint Ass'y 157641-4720
Tube Ass'y 157641-4020
Transfer pump pressure kPa P 20
Transfer pump pressure kgf/cm2 P 0.2
Dir.of rot.viewed fromdriveside R Right
Checker NO. 407980-228*
ECU NO. 407913-1342
ECU Voltage D.C. V
TCV Drive Voltage D.C. V
TCV Drive Voltage Hz
Wire Harness 407980-2300
Inter. Harness 157992-8900
[1] Adjustment specification

[2] Full load delivery
Pump speed Boost pressure Boost pressure Boost pressure TCV DUTY (%) F TCV Ave.inj.qty Diff in dely Basic Test oil Remark
60Hz
r/min kPa kgf/cm2 mmHg % mm3/st. mm3/st. degC
P 500 P 0 P 0 P 100 S 49.7 50.7 P * P 48+-2 NA
P 700 P 25.4 28.0 P 190 210 P 100 S 55.9 56.9 P * P 50+-2 BCS
P 1000 P 52.0 62.5 P 390 410 P 100 S 51.5 62.5 S 5.0-- P * P 50+-2 FULL
P 500 P 0 P 0 P 100 C 49.2 51.2 P * P 48+-2 NA
P 700 P 25.4 28.0 P 190 210 P 100 C 55.4 57.4 P * P 50+-2 BCS
P 1000 P 52.0 54.6 P 390 410 P 100 C 61.0 63.0 P * P 50+-2 FULL
P 1250 P 52.0 54.6 P 390 410 P 100 C 57.7 59.7 P 50+-2
P 1800 P 52.7 60.7 P 390 410 P 100 C 52.7 60.7 P 50+-2
[2] Governing
60Hz
P 2300 P 52.0 54.6 P 390 410 P 100 S 20.8 24.8 P * P 52+-2
P 2500 P 52.0 54.6 P 390 410 P 100 C 5.0-- P 55+-3
P 2300 P 52.0 54.6 P 390 410 P 100 C 20.3 25.3 P 52+-2
[2] Idle
60Hz
P 385 P 0 P 0 P 100 S 4.6 8.6 S 2.0-- P * P 48+-2
P 385 P 0 P 0 P 100 C 4.1 9.1 P 48+-2
P 650 P 0 P 0 P 100 C 3.0-- P 50+-2
Ass'y NO. 104761-4371 2003/02/25 09:53:05 Page 2
[2] Partial quantity

Pump speed Boost pressure Boost pressure Boost pressure Ave.inj.qty Diff in dely Basic Test oil Thickness guage Remark
r/min kPa kgf/cm2 mmHg mm3/st. mm3/st. degC mm
[2] Start
60Hz
P 100 P 0 P 0 P 0 S 51.5 81.5 P * P 48+-2 FULL
[2] Stop
60Hz
P 385 P 0 P 0 P 100 C 0 P 48+-2 Magnet OFF
P 150 P 0 P 0 P 0 C 5-- P 48+-2 Magnet OFF
[2] Overflow
Pump speed Boost pressure Boost pressure Boost pressure TCV DUTY (%) F TCV Overflow quantity S/T ON Overflow qtyS/T OFFOverflow qtyBasic Test oil
60Hz
r/min kPa kgf/cm2 mmHg % cm3/min cm3/min cm3/min degC
P 1100 P 52.0 54.6 P 390 410 P 100 C 468 732 P 50+-2
Remark
[2] Pump chamber Pressure

Pump speed Boost pressure Boost pressure Boost pressure TCV DUTY (%) F TCV Pressure Pressure S/T ON Pressure S/T ON Pressure S/T OFF Pressure
60Hz
r/min kPa kgf/cm2 mmHg % kPa kgf/cm2 kPa kgf/cm2 kPa
P 1100 P 52.0 54.6 P 390 410 P 100 S 550 608 S 5.6 6.2
P 100 P 52.0 54.6 P 390 410 P 100 C 294++ C 3.0++
P 1100 P 52.0 54.6 P 390 410 P 100 C 540 618 C 5.5 6.3
P 1800 P 52.0 54.6 P 390 410 P 100 C 618 716 C 6.3 7.3
S/T OFF Pressure Basic Test oil Remark
kgf/cm2 degC
P * P 50+-2
P 48+-2
P 50+-2
P 50+-2
[2] Timer
Pump speed Boost pressure Boost pressure Boost pressure TCV DUTY (%) F TCV Timer stroke S/T ON Timer S/T OFF Timer Basic Test oil
60Hz stroke stroke
r/min kPa kgf/cm2 mmHg % mm mm mm degC
P 1100 P 52.0 54.6 P 390 410 P 70 S 3.2 3.8 P * P 50+-2
P 500 P 52.0 54.6 P 390 410 P 100 C 3.6 7.6 P 48+-2
P 1100 P 52.0 54.6 P 390 410 P 100 C 5.0 9.0 P 50+-2
P 1100 P 52.0 54.6 P 390 410 P 70 C 3.1 3.9 P 50+-2
P 1100 P 52.0 54.6 P 390 410 P 0 C 0 P 50+-2
P 1800 P 52.0 54.6 P 390 410 P 100 C 6.5 7.4 P 50+-2
Remark
[2] TPS Output

Pump speed Boost pressure Boost pressure Boost pressure TCV DUTY (%) F TCV TA-ist Basic Test oil Remark
60Hz
r/min kPa kgf/cm2 mmHg % V degC
[2] Magnet
Ass'y NO. 104761-4371 2003/02/25 09:53:05 Page 3
MAX applied voltage V C 8
Test voltage V P 12 14
[2]
[3] Load-Timer adjustment
Designation Image Explanation 2 Explanation 3 Explanation 4
Pump speed Boost pressure Boost pressure Boost pressure Ave.inj.qty Timer stroke TA Timer stroke Basic Test oil Remark
Change volume ΔT
r/min kPa kgf/cm2 mmHg mm3/st. mm mm degC
[3] ACS adjustment
Pump speed Height Pressure differencePressure differenceAve.inj.qty Decrease quantity Decrease rate Basic Test oil Remark
r/min m kPa mmHg mm3/st. mm3/st. % degC
[3] BCS adjustment
[2] Additional device adjustment

[3] Additional device１
POTENTIOMETER ADJUSTMENT 4-PM5-1 4-PM5-2F 4-PM5-3 104761-4370 4-PM5-4 104761-4370
N1=1240r/min
Q1=40.6+-1.0cm3/1,000st
V1=6.00+-0.03V
V2=1.04+-0.69V
V3=8.18+-0.61V
a=-deg
V1=6.00+-0.03V Potentiometer adjustment standards (Bosch mini mass piping)
P1=0kPa 1.Applied voltage=Vi
P2=0mmHg 2.Boost pressure =P1kPa{P2mmHg}
Vi=10V 3.Adjust the dummy bolt to determine the control lever position for the above adjusting point and then fix the dummy bolt so that it
contacts the lever. 4.In the above position, adjust the installation position of the potentiometer so that the output voltage is
6.00±0.03 V. 5.Fix the potentiometer and remove the dummy bolt.
At TCV duty ratio 100%
A=Adjusting point
B=Check point
C=Control lever position
N=Pump speed(r/min)
V=Potentiometer output voltage(V)
Q=Injection quantity(cm3/1000st)
C1=Idle
C2=Full speed
[3] Additional device 2





Ass'y NO. 104761-4371 2003/02/25 09:53:05 Page 4

[1] Assembly dimension

K dimension mm S 3.2 3.4
KF dimension mm S 6.66 6.86
MS dimension mm S 1.2 1.4
Effectiveness storoke mm
BCS storoke mm S 2.7 3.1
Pre-storoke mm S 0.08 0.12
Control lever angle α deg. S 51.5 59.5
Control lever angle β deg. S 38 48
Control lever angle γ deg.
2003/02/25 09:51:55 Page 1
Assy name ZexelAssy 104761-4381 Make data 2003/02/25

Manufacturer No. Engine Type Manufacturer No. ZexelAssy 104761-4380 Renew data2003/02/25
1006 TD42T 167001Y700 Manuf. NISSAN DIESEL
P Parts No. Parts name B.T.C. Modify Edition data Kinds VE

Cylinder 6
[1] Adjustment conditions

Test oil ISO4113orSAEJ967d
Test Oil Temperature degC P 45+5
Nozzle 105780-0060
BOSCH type code NP-DN0SD1510
Opening Pressure MPa P 13.0+0.3
Opening Pressure kgf/cm2 P 133+3
Injection Pipe No. 157805-7320
Injection Pipe mm P 2-6-450 Inside Die.-Outside Die.-Length（mm)
Joint Ass'y 157641-4720
Tube Ass'y 157641-4020
Transfer pump pressure kPa P 20
Transfer pump pressure kgf/cm2 P 0.2
Dir.of rot.viewed fromdriveside R Right
Checker NO. 407980-228*
ECU NO. 407913-1342
ECU Voltage D.C. V
TCV Drive Voltage D.C. V
TCV Drive Voltage Hz
Wire Harness 407980-2300
Inter. Harness 157992-8300
[1] Adjustment specification

[2] Full load delivery
60Hz
P 500 P 0 P 0 P 100 S 49.7 50.7 P * P 48+-2 NA
P 700 P 25.4 28.0 P 190 210 P 100 S 55.9 56.9 P * P 50+-2 BCS
P 1000 P 52.0 54.6 P 390 410 P 100 S 51.5 62.5 S 5.0-- P * P 50+-2 FULL
P 500 P 0 P 0 P 100 C 49.2 51.2 P * P 48+-2 NA
P 700 P 25.4 28.0 P 190 210 P 100 C 55.4 57.4 P * P 50+-2 BCS
P 1000 P 52.0 54.6 P 390 410 P 100 C 61.0 63.0 P * P 50+-2 FULL
P 1250 P 52.0 54.6 P 390 410 P 100 C 57.7 59.7 P 50+-2
P 1800 P 52.0 54.6 P 390 410 P 100 C 52.7 60.7 P 50+-2
[2] Governing
60Hz
P 2300 P 52.0 54.6 P 390 410 P 100 S 20.8 24.8 P * P 52+-2
P 2500 P 52.0 54.6 P 390 410 P 100 C 5.0-- P 55+-3
P 2300 P 52.0 54.6 P 390 410 P 100 C 20.3 25.3 P 52+-2
[2] Idle
60Hz
P 385 P 0 P 0 P 100 S 4.6 8.6 S 2.0-- P * P 48+-2
P 385 P 0 P 0 P 100 C 4.1 9.1 P 48+-2
P 650 P 0 P 0 P 100 C 3.0-- P 50+-2
Ass'y NO. 104761-4381 2003/02/25 09:51:55 Page 2
[2] Partial quantity

Pump speed Boost pressure Boost pressure Boost pressure 平均噴射量 Diff in dely Basic Test oil Thickness guage Remark
r/min kPa kgf/cm2 mmHg mm3/st. mm3/st. degC mm
[2] Start
60Hz
P 100 P 0 P 0 P 0 S 51.5 81.5 P * P 48+-2 FULL
[2] Stop
60Hz
P 385 P 0 P 0 P 100 C 0 P 48+-2 Magnet OFF
P 150 P 0 P 0 P 0 C 5-- P 48+-2 Magnet OFF
[2] Overflow
Pump speed Boost pressure Boost pressure Boost pressure TCV DUTY (%) F TCV Overflow quantity S/T ON Overflow qtyS/T OFFOverflow qtyBasic Test oil
60Hz
r/min kPa kgf/cm2 mmHg % cm3/min cm3/min cm3/min degC
P 1100 P 52.0 54.6 P 390 410 P 100 C 468 732 P 50+-2
Remark
[2] Pump chamber Pressure

Pump speed Boost pressure Boost pressure Boost pressure TCV DUTY (%) F TCV Pressure Pressure S/T ON Pressure S/T ON Pressure S/T OFF Pressure
60Hz
r/min kPa kgf/cm2 mmHg % kPa kgf/cm2 kPa kgf/cm2 kPa
P 1100 P 52.0 54.6 P 390 410 P 100 S 550 608 S 5.6 6.2
P 100 P 52.0 54.6 P 390 410 P 100 C 294++ C 3.0++
P 1100 P 52.0 54.6 P 390 410 P 100 C 540 618 C 5.5 6.3
P 1800 P 52.0 54.6 P 390 410 P 100 C 618 716 C 6.3 7.3
S/T OFF Pressure Basic Test oil Remark
kgf/cm2 degC
P * P 50+-2
P 48+-2
P 50+-2
P 50+-2
[2] Timer
Pump speed Boost pressure Boost pressure Boost pressure TCV DUTY (%) F TCV Timer stroke S/T ON Timer S/T OFF Timer Basic Test oil
60Hz stroke stroke
r/min kPa kgf/cm2 mmHg % mm mm mm degC
P 1100 P 52.0 54.6 P 390 410 P 70 S 3.2 3.8 P * P 50+-2
P 500 P 52.0 54.6 P 390 410 P 100 C 3.6 7.6 P 48+-2
P 1100 P 52.0 54.6 P 390 410 P 100 C 5.0 9.0 P 50+-2
P 1100 P 52.0 54.6 P 390 410 P 70 C 3.1 3.9 P 50+-2
P 1100 P 52.0 54.6 P 390 410 P 0 C 0 P 50+-2
P 1800 P 52.0 54.6 P 390 410 P 100 C 6.5 7.4 P 50+-2
Remark
[2] TPS Output

Pump speed Boost pressure Boost pressure Boost pressure TCV DUTY (%) F TCV TA-ist Basic Test oil Remark
60Hz
r/min kPa kgf/cm2 mmHg % V degC
[2] Magnet
Ass'y NO. 104761-4381 2003/02/25 09:51:55 Page 3
MAX applied voltage V C 8
Test voltage V P 12 14
[2]
[3] Load-Timer adjustment
Pump speed Boost pressure Boost pressure Boost pressure Ave.inj.qty Timer stroke TA Timer stroke Basic Test oil Remark
Change volume ΔT
r/min kPa kgf/cm2 mmHg mm3/st. mm mm degC
[3] ACS adjustment
Pump speed Height Pressure differencePressure differenceAve.inj.qty Decrease quantity Decrease rate Basic Test oil Remark
r/min m kPa mmHg mm3/st. mm3/st. % degC
[3] BCS adjustment
[2] Additional device adjustment

POTENTIOMETER ADJUSTMENT 4-PM5-1 4-PM5-2F 4-PM5-3 104761-4380 4-PM5-4 104761-4380
N1=1240r/min
Q1=40.6+-1.0cm3/1,000st
V1=6.00+-0.03V
V2=1.04+-0.69V
V3=8.18+-0.61V
a=-deg
V1=6.00+-0.03V Potentiometer adjustment standards (Bosch mini mass piping)
P1=0kPa 1.Applied voltage=Vi
P2=0mmHg 2.Boost pressure=P1kPa{P2mmHg}
Vi=10V 3.Adjust the dummy bolt to determine the control lever position for the above adjusting point and then fix the dummy bolt so that it
contacts the lever. 4.In the above position, adjust the installation position of the potentiometer so that the output voltage is
6.00±0.03 V. 5.Fix the potentiometer and remove the dummy bolt.
At TCV duty ratio 100%
A=Adjusting point
B=Check point
C=Control lever position
N=Pump speed(r/min)
V=Potentiometer output voltage(V)
Q=Injection quantity(cm3/1000st)
C1=Idle
C2=Full speed





Ass'y NO. 104761-4381 2003/02/25 09:51:55 Page 4

名称 Image Explanation 2 Explanation 3 Explanation 4
[1] Assembly dimension

Designation Unit PSC 値 Remark
K dimension mm S 3.2 3.4
KF dimension mm S 6.66 6.86
MS dimension mm S 1.2 1.4
Effectiveness storoke mm
BCS storoke mm S 2.7 3.1
Pre-storokee mm S 0.08 0.12
Control lever angle α deg. S 51.5 59.5
Control lever angle β deg. S 38 48
Control lever angle γ deg.
Opening Pressure for NHA Stamped 31-3862 L
Nozzle Holder Part Number : 105031-3862

Stamping Identification : 31-3862 L
Nozzle Number : 105025-4000
Nozzle Holder Assembly : 105160-5330
Opening Pressure : 19.0 Mpa
Dated 10th July 2007

Injector Number 31-3862 N
Nozzle & holder assembly no.: 105160-5420

Nozzle holder number: 105031-3862
Nozzle no.: 105025-4200
Opening pressure: 20.0 MPa

Injector 105041-3220 is the nozzle holder number. Injector 105041-3220 is referred to the
nozzle and nozzle holder assembly number for 105110-8300 and 105110-8290.
Test data repair information as follows;
Engine model Nozzle & nozzle holder assembly no. Nozzle holder part no. Nozzle part no.
Nozzle service kid no. Pre-lift
(Stamping mark and discrimination mark) (Stamping mark) (+-0.02mm)
6WF1TC 105110-8300 105041-3220 105025-3950 105019-2312 0.06
(41-3220,B) (NP-DLLA156SM395)
6WG1TC 105110-8290 105041-3220 105025-3940 105019-2302 0.06
(41-3220,A) (NP-DLLA156SM394)
First nozzle opening pressure Second nozzle opening pressure Valve lift Nozzle holder type
MPa{kgf/cm2} MPa{kgf/cm2} (mm)
17.7{180} 23.1~24.1{236~246} 0.03 KBL2.4/DLLA-S
17.7{180} 23.1~24.1{236~246} 0.32 KBL2.4/DLLA-S

105041-7140 C
NHA
This Nozzle holder is out of

production.
This is now replaced by :
105041-7141 C Assembly number

105111-4831
Nozzle 105025-1950 = NP-
DLLA160SM195
Opening pressure 26.0 MPa ( 265

kgf/cm2 )
Engine SA6D170 for Komatsu
Injector Opening Pressure
Body Number 105041-7150 J

Assembly Number 105111-4920
Nozzle DLLA143SM262
Opening Pressure 24.5 Mpa (250 Kgf/m)
Application Komatsu
Dated 20th October 2004

Nozzle holder: 48-2081Q
Assy No: 105118-7190
Nozzle holder: 105048-2081
Nozzle: 105017-1570
First opening pressure: 17.7 MPa ( 180 kgf/cm2 )

Second opening Press: 20.6 MPa ( 210 kgf/cm2 )
Nozzle lift: 0.20 mm

Pre lift: 0.055 mm
NHA 105048-2270 G (Isuzu)
Opening Pressure for Test purposes only. This NHA is not

serviceable in the field.
Assy No. 105118-8211

Nozzle No. 105017-3090
First nozzle opening pressure : 19.5 MPa

Second nozzle opening pressure : 33.8 MPa
Dated Dec 2005

NHA 105048-2270 B
Opening pressure for Nozzle Holder 105048-2270 B
Stamping Mark 48-2270 B

Nozzle 105017-3090 = NP-DLLA144PN309
Assy No 105118-8210
First Opening pressure: 19.5 MPa ( 199 kgf/cm2 )
Second opening pressure 33.8 MPa ( 345 kgf/cm2 )
Pre-lift = 0.04 mm
Valve lift = 0.25 mm
THIS PARTICULAR INJECTOR FITTED TO

ISUZU / HOLDEN RODEO IS NOT
SERVICABLE AND ONLY TO BE REPLACED
AS A COMPLETE UNIT.
(Refer to Zexel SI 443 of Sept.2003)

(Refer to Zexel SI 443 -Sept 2003)
NHA 105048-2270 B
Opening pressure for Nozzle Holder 105048-2270 B
Stamping Mark 48-2270 B

Nozzle 105017-3090 = NP-DLLA144PN309
Assy No 105118-8210
First Opening pressure: 19.5 MPa ( 199 kgf/cm2 )
Second opening pressure 33.8 MPa ( 345 kgf/cm2 )
Pre-lift = 0.04 mm
Valve lift = 0.25 mm
THIS PARTICULAR INJECTOR FITTED TO

ISUZU / HOLDEN RODEO IS NOT
SERVICABLE AND ONLY TO BE REPLACED
AS A COMPLETE UNIT.
(Refer to Zexel SI 443 of Sept.2003)

(Refer to Zexel SI 443 -Sept 2003)
Injector 105048-3770 A
Holder Assembly Number 105118-5191

Nozzle Number 105017-0870
Spacer Ring 150630-3200
Opening Pressure 16.7Mpa (170Kgf/cm2)

Nozzle Holder Stamping 105048-3790 Z
Nozzle and Holder Assembly 105118-7151
1st opening pressure: 18.1 MPa (185 kgf/cm2)

2nd opening pressure: 23.1 to 24.6 MPa (236 to 251 kgf/cm2)
Pre-lift : 0.07 mm
Valve lift : 0.3 mm.
Dated 09/01/2007
ISUZU 2 – SPRING INJECTOR OPENING PRESSURES
NOZZLE HOLDER 105048-3832

ASSEMBLY No. 105118-7542
NOZZLE KIT 105019-1470 (Includes 105017-3250 –
DLLA143PN325 NOZZLE)
First Opening Press 18.1 MPa ( 185 kgf/cm2 )

Second Opening Press 21.1 MPa ( 215 kgf/cm2 )
105048-4120 (KBL 2.5P) NHA
The Opening Pressures for the following Nozzle Holder
Assemblies are listed for information purposes only. The NHA is
only to be replaced as complete unit and please confirm
application part number with OE (Nissan) before replacing NHA.
These NHAs are not to be serviced in the field for the following
reasons:-
1) Nozzle retaining nuts are fastened using special tightening
machines. If tightened by hand using standard tools, damage
will result.
2) The pre-lift is close to 0.03 mm. This cannot be measured
using a dial gauge. It is measured using special device that
measures oil flow.
3) Injection holes are extremely small (around 0.18 mm).
Damage will result if work is not performed in a special clean
room.
Holder Stamping Assembly 1 st Opening Pressure 2 nd Opening Pressure

Number [Factory Setting] [Factory Setting]
48-4120 E 105118-7621 21.0 MPa (214 kgf/cm²) 39.5 MPa (403 kgf/cm²)
[21.5-22.5 MPa (219-229 [40.0-41.5 MPa (408-423

kgf/cm²)] Kgf/cm²)]
48-4120 S 105118-7331 19.0 MPa (194 kgf/cm²) 37.5 MPa (382 kgf/cm²)
48-4120 S or L 105118-7770 [19.5-20.5 MPa (199-209 [38.0-39.5 MPa (387-402

kgf/cm²)] kgf/cm²)]
48-4120 T or U 105118-7911 19.0 MPa (194 kgf/cm²) 37.5 MPa (382 kgf/cm²)
[19.5-20.5 MPa (199-209 [37.8-39.8 MPa (385-405
48-4120 V or Z 105118-8310 19.0 MPa (194 kgf/cm²) 37.5 MPa (382 kgf/cm²)
48-4120 W or X 105118-8420 [19.5-20.5 MPa (199-209 [37.8-39.8 MPa (385-405

48-4120 H 105118-7981 19.0 MPa (194 kgf/cm²) 37.5 MPa (382 kgf/cm²)
[19.5-20.5 MPa (199-209 [37.8-39.8 MPa (385-405
48-4120 G 105118-7981 No test pressures available No test pressures available
Dated 26th May 2006

105048-4120 (KBL 2.5P) NHA
The Opening Pressures for the following Nozzle Holder
Assemblies are listed for information purposes only. The NHA is
only to be replaced as complete unit and please confirm
application part number with OE (Nissan) before replacing NHA.
These NHAs are not to be serviced in the field for the following
reasons:-
1) Nozzle retaining nuts are fastened using special tightening
machines. If tightened by hand using standard tools, damage
will result.
2) The pre-lift is close to 0.03 mm. This cannot be measured
using a dial gauge. It is measured using special device that
measures oil flow.
3) Injection holes are extremely small (around 0.18 mm).
Damage will result if work is not performed in a special clean
room.
Holder Stamping Assembly 1 st Opening Pressure 2 nd Opening Pressure

Number [Factory Setting] [Factory Setting]
48-4120 E 105118-7621 21.0 MPa (214 kgf/cm²) 39.5 MPa (403 kgf/cm²)
[21.5-22.5 MPa (219-229 [40.0-41.5 MPa (408-423

kgf/cm²)] Kgf/cm²)]
48-4120 S 105118-7331 19.0 MPa (194 kgf/cm²) 37.5 MPa (382 kgf/cm²)
48-4120 S or L 105118-7770 [19.5-20.5 MPa (199-209 [38.0-39.5 MPa (387-402

48-4120 T or U 105118-7911 19.0 MPa (194 kgf/cm²) 37.5 MPa (382 kgf/cm²)
[19.5-20.5 MPa (199-209 [37.8-39.8 MPa (385-405
48-4120 V or Z 105118-8310 19.0 MPa (194 kgf/cm²) 37.5 MPa (382 kgf/cm²)
48-4120 W or X 105118-8420 [19.5-20.5 MPa (199-209 [37.8-39.8 MPa (385-405

48-4120 H 105118-7981 19.0 MPa (194 kgf/cm²) 37.5 MPa (382 kgf/cm²)
[19.5-20.5 MPa (199-209 [37.8-39.8 MPa (385-405
48-4120 G 105118-7981 No test pressures available No test pressures available
Dated 26th May 2006

105078-0140
DN0PDN121 (105007-1210)
Nozzle and holder assembly - 105148-1240
Opening pressure: 13.2 MPa (135 kgf/cm2)

Injector 105041-3220 is the nozzle holder number. Injector 105041-3220 is refered to the nozzle and nozzle holder assembly number for 105110-8300 and 105110-8290.
Test data repair information
Engine model Nozzle & nozzle holder assembly no. Nozzle holder part no. Nozzle part no. Nozzle service kit no. Pre-lift
(Stamping mark and discrimination mark)
6WF1TC 105110-8300 105041-3220 105025-3950 105019-2312 0.06
(41-3220,B) (NP-DLLA156SM395) (+-0.02mm)
6WG1TC 105110-8290 105041-3220 105025-3940 105019-2302 0.06

(41-3220,A) (NP-DLLA156SM394) (+-0.02mm)
First nozzle opening pressure Second nozzle opening pressure Valve lift Nozzle holder type
MPa{kgf/cm2} MPa{kgf/cm2} (mm)
17.7{180} 23.1~24.1{236~246} 0.3 KBL2.4/DLLA-S
17.7{180} 23.1~24.1{236~246} 0.32 KBL2.4/DLLA-S


TEMPORARILY ENGINE MODEL: PE6T Date: 6 Sep 2002 2
No. 16713 96672
Injection pump: PE6P Governor: EP/RFD Timing device: EP/SP
106066-5440 105487-3270 105636-1220
1. Test conditions


+5
(
2. Injection timing
Injection order: 1 4,1 2,1 6,1 3,1 5

60°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'
Tappet clearance: Manually rotate the camshaft 2 to 3 times and confirm that it rotates smoothly.
A 12.4 650 171 ± 2 ±4 Lever Basic
B Approx. 4.8 255 13 ± 1 ± 10 Rack

Pump speed
Below 750 700 900 +40
-10 1150 +30
(r/min) -20

Below 0.5 0.9 ± 0.5
angle (° ) 0 3± 0.5
106661-5310 2/3
Perform idle sub-spring adjustment when

necessary.
Rack limit using stop lever

Rack position (mm)
12.6+0.2
12.4
A
Above 6.3
Damper spring setting:
11.5
4.8-0.2
4.8 B
0.9±0.5
0 255 465±15 1150+20 Below 1250
Pump speed (r/min)
Variable speed specification at idle setting
Main spring setting
4.8
Rack position (mm)
0
280
Pump speed (r/min)
106661-5310 3/3
22° ±5°
10° ±5°
Idling Full-load
Full-speed Idling 32.5°±

5°
43.5°±3°
Stop lever angle Timing setting

Approx. 25°
Stop Normal
5°
30° ±
32°±3°
R=1+0.5 R=12.4

ENGINE MODEL: PE6T Date: 9 Feb 2004 4
T E MP ORA RILY
No. 16713 96902
Injection pump: PE6P Governor: EP/RFD-B Timing device: EP/SA
106066-1191 105487-5771 105614-4220
1. Test conditions

(Bosch type no. DLLA137S374N417) (Bosch type no. )
Injection pipe: outer dia.6 mm × inner dia. 2 mm length 500 mm

+5
2. Injection timing
Injection order: 1 4,1 2,1 6,1 3,1 5

60°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'
A 11.7 750 146 ± 2 ±4 Lever Basic Above 66.7 {Above 500}
B 9.7 300 88 ± 3 ±4 Lever Boost press. 0
C Approx 6.4 240 10 ± 1 ± 10 Rack Boost press. 0

Pump speed +40 +30
700+50 900 -10 1150 -20
(r/min)
Advance Finish
Below 0.5 0.9 ± 0.5
angle (° ) 3.0±0.5

106661-5541 2/3

2.0±0.1 mm

Rack position (mm)
12.7
11.7
11.2±0.1 A
9.7
B
Above 8.7 Damper spring setting
10.5+0.5
6.4±2.0 C
6.4
4.1
2.2±0.3
1.7
0 240 (500) (1150) 1205
Below (150) 430 485 1175
Pump speed (r/min)
Main spring setting
6.4
Rack position (mm)
N = 300
Rack position (mm)
11.7
0
260
Pump speed (r/min)
9.7
0 53.3-13.3 {400-100}
4.0+2.0 {30+15}
106661-5541 3/3
Speed-control lever angle Load-control lever angle
(24°) ±5° N=260
13° ±5°
Idling Full-load
Full-speed Idling
28.5°
±5°
40.5°
±3°

Drive side of injection position
Stop Normal Approx. 30°

28° ±5°
30° ±5°
R=11.7
R=1.5±0.1

ENGINE MODEL: PE6T Date: 9 Feb 2004 4
T E MP ORA RILY
No. 16713 96902
Injection pump: PE6P Governor: EP/RFD-B Timing device: EP/SA
106066-1191 105487-5771 105614-4220
1. Test conditions

(Bosch type no. DLLA137S374N417) (Bosch type no. )
Injection pipe: outer dia.6 mm × inner dia. 2 mm length 500 mm

+5
2. Injection timing
Injection order: 1 4,1 2,1 6,1 3,1 5

60°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'
B 9.7 300 88 ± 3 ±4 Lever Boost press. 0

Pump speed +40 +30
700+50 900 -10 1150 -20
(r/min)
Advance Finish
Below 0.5 0.9 ± 0.5
angle (° ) 3.0±0.5

106661-5541 2/3

2.0±0.1 mm

Rack position (mm)
12.7
11.7
11.2±0.1 A
9.7
B
Above 8.7 Damper spring setting
10.5+0.5
6.4±2.0 C
6.4
4.1
2.2±0.3
1.7
0 240 (500) (1150) 1205
Below (150) 430 485 1175
Pump speed (r/min)
Main spring setting
6.4
Rack position (mm)
N = 300
Rack position (mm)
11.7
0
260
Pump speed (r/min)
9.7
0 53.3-13.3 {400-100}
4.0+2.0 {30+15}
106661-5541 3/3
(24°) ±5° N=260
13° ±5°
Idling Full-load
Full-speed Idling
28.5°
±5°
40.5°
±3°

Drive side of injection position
Stop Normal Approx. 30°

28° ±5°
30° ±5°
R=11.7
R=1.5±0.1

TEMPORARILY
ENGINE MODEL: PF6TB Date: 17 Jun 2002 1
No. 16800-96577
Injection pump: PE6P Governor: EP/RFD Timing device: EP/SPGH
106060-7790 105487-3680 105691-3270
1. Test conditions

Injection pipe: Outer Dia. 6 mm × Inner Dia. 2.2mm Length 500 mm

+5
2. Injection timing
Injection order: 1 4,1 2,1 6,1 3,1 5

60°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'
D 9.7 300 130 ± 2 - Lever Boost press. 0

Pump speed
(r/min)
Advance
angle (° )
106671-0620 2/4
Rack limit by using stop lever
12.1+0.1 A
Rack position (mm)
2.4+0.1
11.9
9.7
D
Above 8.7 Boost compensator stroke:
11.0
(N=300)
7.2 C
6.1
Damper spring setting:
6.2-0.2
E
3.4±0.5
0 225 450±10 Below 1300

500 -10 1150 +40
-25 +20
Pump speed (r/min)
Note : The injection quantity and the governor must be adjusted at an ambient temperare of at least 15
(as the boost compensator start spring is a shape-memory alloy) .
N = 300
Rack position (mm)
12.1+0.1
11.5
9.7
0
20.0±1.3 {150±10} (62.7) {(470)}
(50.7) {(380)}

106671-0620 3/4
°
24° ±5
Idling Full-load
Full-speed Stopper bolt setting
22° ±
5°
31.5°
±3°

36°±5°
R=12.1+0.1
Approx. 30°
11.5°±5°
Stop Normal
Timing advance specification
Adjust the clearance between the pickup and the gear tooth to 1-0.2mm.
4/4 load P = 392 kPa {4kgf/cm2}

7.0±0.3
Advance angle (° )
4/4 load P =196 kPa {2kgf/cm2}

Bellow4
Above3
0/4 load P = 0
0 300 Above 900 1100
Pump speed (r/min)

106671-0620 4/4
Rack sensor adjustment
1.Do not operate the aneroid compensator if installed.

Secure the speed control lever in the full position and set the pump speed at 600r/min.
(If equipped with a boost compensator, first apply boost pressure.)
2.Adjust the bobbin ① so that the rack sensor's output voltage is VR±0.01.
3.After adjustment, mark the area where the joint ② and the nut ③ contact and the area where
the joint ② and the pump housing contact with red paint.
Output voltage VR±0.01(V) VR Control unit parts no.

407912-1742
Pump speed N 600 r/min
2V 105782-6320
Rack position R1 11.9 mm
407910-303*
3V 407910-6010
407980-224*

TEMPO RARI LY ENGINE MODEL: PE6TC Date: 27 Sep 2004 1
No. 16713 96818
Injection pump: PE6P Governor: EP/RFD-D Timing device: EP/SP
106061-5300 105487-4580 105636-1810
1. Test conditions

(Bosch type no. DLLA140SN634) (Bosch type no. EF8511/9)

+5
2. Injection timing
Injection order: 1 4,1 2,1 6,1 3,1 5

60°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'
B 12.1 1100 (164.6) ± 3 ±5 Lever Above 29.3 {Above 220}
C 10.4 300 114 ± 2 - Lever Boost press. 0

D 12.4±0.1 300 (173) ± 5 - Lever Above 29.3 {Above 220}
E Approx 8.0 250 16 ± 1 ± 10 Rack Boost press. 0

Pump speed
Below 875 825 925
(r/min)

Below 0.5
angle (° ) 0 1±0.5

106671-0830 2/4
Boost compensator stroke: (2.0)
Rack limit using stop lever: 12.4±0.1
D
12.4
A B
Rack position (mm)
12.1
10.5±1.5
10.4 C
Above 9.5
11.5+0.5
Damper spring setting
8.0 E
7.1±0.1
6.0
3.9±0.3
0 250 460 1205 1260

395
Pump speed (r/min)
Note: The injection quantity and the governor must be adjusted at an ambient temperature of at least 15°C
(as the boost compensator start spring is a shape-memory alloy) .

(Fix at Full at delivery.)
N = 300
Rack position (mm)
Main spring setting 12.4±0.1

Rack position (mm)
Idle sub-spring setting 11.2

10.4
7.9
0
Below 5.3{Below 40} (16.0) {(120)}
0 9.3±1.3 {70±10}
265 275
Pump speed (r/min) Boost pressure kPa {mmHg}
106671-0830 3/4
5. Aneroid compensator kit adjustment
[1] Aneroid compensator adjustment

Setscrew
Adjust clearance to 0.1 ~ 0.5 mm

(using setscrew)
[2] Adjustment at governor installation

With the load control lever in the Full position (pump speed N = 1100 r/min), screw in the aneroid
compensator assembly so that the following performance can be obtained.
Q = (164.6)±3 cm3/1000 st
12.1
Q = 139±2 cm3/1000 st
Rack position (mm)
(11.1)
79.4±2.7 {596±20} 57.6±0.7 {432±5}
Absolute pressure kPa {mmHg}

106671-0830 4/4

(Secure at Full at delivery)
± 5 °
24°
Idling Full-load
5° ±5° N=275
16.
Idling Stopper bolt setting
22° ±
5°
Full-speed
30.5°
±3°
Stop lever angle

Timing setting
Drive side
Stop Normal
Approx. 30°
30° ±5°
32° ±5°
R=12.4±0.1

ENGINE MODEL： 6SD1-TC2 Date: 25 Oct 2001 8
Company: ISUZU
No. 1-15602-142-7
Injection pump： PE6P Actuator： EP/RED- Ⅲ Timing device： EP/SPGH
106060-5771 105952-0223 105691-3140
Pump rotation： Counter clockwise (viewed from drive side)
Nozzle ＆ Nozzle Holder Ass'y ：105780-8140 (Bosch Type No.EF8511/9A)
Nozzle：105780-0000 Nozzle Holder：105780-2080

(Bosch Type No.DN12SD12T) (Bosch Type No.EF8511/9)
Nozzle opening pressure： 17.2 MPa｛ 175 kgf/cm2｝ Transfer pump pressure： 157 kPa｛ 1.6 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 ℃
Overflow valve opening pressure： 127 kPa｛ 1.3 kgf/cm2｝
Pre-stroke：No.1 Plunger 4.2 ± 0.03mm Note: Perform at voltage V
Injection order： 1 − 5 ,1 − 3 ,1 − 6 ,1 − 2 ,1 − 4
± 15′ 120°± 15′ 180°±15′ 240°±15′ 300°
60° ± 15′
Plungers are numbered from the Governor side. ( interval: °± ）
４．Injection quantity RED Ⅲ GOV. C/U : 15mm

Rack Pump Max. var
Adjust- Vist Injection q' ty
position speed bet. cyl
ing point (V) ( cm3 / 1000 strokes) Remarks
(mm) (r/ min) (％)
(12.0) 1.59 800 151.7±2 ±3 Basic
(6.9) Approx.2.6 225 8.9±3.2 ± 13

Pump speed
（r/min）
Advance
angle（°）
106671-1447 2/3
■RED Ⅲ governor
When the rack sensor output voltages are V1 and V2, confirm that rack positions R1 and R2
are as specified below.
106671-1447 3/3
■Timing device adjustment
Adjust the clearance between the pickup and the gear tooth to 1-0.2 mm.
4/4 load P=392 kPa {4 kg/cm2)

5.5 ± 0.3
Advance angle (°)
0/4 load P=0

0 Above 800
Pump speed (r/min)
Timing setting
At No.1 plunger’s beginning
B.T.D.C. : 10°
Approx.40°
Center of timing device’s threaded hole


ENGINE MODEL: EK100 Date: 22 Aug 2002 1
Company: HINO
No. 22020-1791A
Injection pump: PE6P Governor: EP/RSV Timing device: EP/SP
106061-5472 105407-1670 105635-0041
1. Test conditions


+5
(
Overflow valve opening pressure: 147~177 kPa { 1.5~1.8 kgf/cm2 }
2. Injection timing
Pre-stroke: No.1 Plunger 3.3 - 0.1mm Note: Adjust with rack position of mm
Injection order: 1 4,1 2,1 6,1 3,1 5

60°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'
A 9.3 700 129.5 ± 2 ±4 Lever Basic
B 9.3 1100 127 ± 3 ±4 Lever
C (5) 360 16 ± 3 ± 15 Rack

Pump speed
700 ± 50 900 1150
(r/min)

1.4 ± 0.5
angle (° ) 0 4 ± 0.5
106671-3521 2/2

Perform torque control spring adjustment

when necessary.
Above 14
Rack position (mm)
A B
9.3
8
C
(5)
4
0
360 1100+10 1210-40
Pump speed (r/min)
(28°) ±5° 53°±5°
(9°)±5° 27° ±5°
Full-speed Idling
Normal Stop


TEMPORARILY
ENGINE MODEL: S6BF Date: 10 Apr 2003 2
Company: MITSUBISHI
No. 36265-23180
Injection pump: PE6P Governor: EP/RSV Timing device: EP/SPG
106060-7560 105407-3452 105681-0231
1. Test conditions

Injection pipe: Outer Dia. 6 mm × Inner Dia. 2.4mm Length 1019mm

+5
(
2. Injection timing
Injection order: 1 5,1 3,1 6,1 2,1 4

60°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'
Plungers are numbered from the Governor side ( interval: ° ± 30' ).
A 16.9 900 280 ± 7 ±3 Lever Basic
B Approx 7.3 250 30 ± 3 ± 10 Rack
C 18.9+0.2 100 (324) - Lever Rack limit

Pump speed
Below 450 400 650
(r/min)

Below 0.5
angle (° ) 0 4 ± 0.5
106671-4451 2/3

(notches from fully tightened position; fix in this position)
20+1
Rack limit;18.9+0.2
C
A
Rack position (mm)
16.9
Idle sub-spring setting;

9.2-0.5
9.2
B
7.3
0
250 400±25 1100+10 (1190)±25
Pump speed (r/min)

106671-4451 3/3
(41°) ±5°
°
20° ±5
Full-speed Idling
Stop lever angle
l
rma
19°
No
53° ±5°
±5°
Sto
p
Timing setting
Approx. 90°


ENGINE MODEL: PF6T Date: 26 Sep 2003 3
No. 16800 96664
Injection pump: PE6P Governor: EP/RFD-C Timing device: EP/SPGH
106061-7531 105487-5810 105691-3622
1. Test conditions


+5
2. Injection timing
Injection order: 1 4,1 2,1 6,1 3,1 5

60°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'
A 10.8 600 174.4 ± 2 ±4 Lever Basic Solenoid OFF
C Approx 5.3 225 9±1 ± 10 Rack Solenoid OFF
D 8.4 300 107.4 ± 2 - Lever Solenoid ON

Pump speed
(r/min)
Advance
angle (° )

106671-5171 2/5
Rack limit using stop lever: 11.1±0.1

11.7±0.3
11.3
11.1
A
10.8
Rack position (mm)
10.2
8.4
D
Above 6.8
10.0+0.5
5.3 C Damper spring setting
4.3±2.0
3.6
1.5±0.5
0
225 350 420 460 1150 1240
Below 160 410
Pump speed (r/min)

(Fix at Full at delivery.)
Main spring setting
R1(5.2)
Rack position (mm)
0
290
Pump speed (r/min)
106671-5171 3/5
5.Timing advance specification

6.5±0.3
Advance angle (° )
4/4 load P =196 kPa {2kgf/cm2}

Bellow4
Above3
0/4 load P = 0
0 300 Above 900 1100
Pump speed (r/min)
6.Rack sensor adjustment (-0620)

Note: Do not operate the aneroid compensator if installed.
(1)Fix the speed control lever in the FULL position.
(2) Set the speed at N r/min and the rack position at R. (If equipped with a boost compensator, apply boost
pressure.)
(3)Adjust the bobbin 1 so that the rack sensor output voltage is VR±0.01.
(4)Apply red paint to the joint 2 and nut 3 join and to the joint 2 and pump end face join.
Constant voltage Control unit part no.

5±0.01V VR
power supply
407912-1742
Output voltage VR±0.01V 2V
105782-6320
Speed N 600 r/min
407910-3032
Rack position R 10.8 mm
3V 407910-6010
407910-7210
2 3
1
Apply red paint Pump end face
106671-5171 4/5
7.Solenoid type boost compensator adjustment

(1) Supply DC24V to the solenoid terminals and confirm that the solenoid operates.
(2) Preadjustment
With the solenoid ON, calculate dimension L (refer to figure below) for adjustment standard R2 using
the formula below.
L = 28 – (10.5 – R2) ± 0.2 = 25.9 ± 0.2
Then, adjust the solenoid using 1 so that L is as calculated.
(3) Install the solenoid on the governor.
If the rack position is not R2±0.5 with the solenoid ON, repeat step 2 above. (Correction)
(4) With the solenoid OFF, adjust everything except the rack limit to standard.
Note:
When the solenoid is OFF, positioning the boost compensator link 3 so that rack R2 + 4 does not
hinder adjustment.
(5) Operate the pump at N = 300, turn the solenoid ON, and fine adjust 2 within the range of ±0.5 so that
the rack position is R2.
(6) Solenoid stroke confirmation
At Np = 0 and with the load lever in the FULL position, turn the solenoid ON and OFF and confirm that
the rack movement (ie, solenoid boost compensator stroke) is 3.5 ~ 5.0 mm. Then set the rack limit.
(7) Seal the solenoid as shown at the top of the figure below.
2: For fine adjustment

(within the range of ±0.5)
Thread sealing wire through

sealing holes at 3 locations
DC24V
Rack limit Boost compensator stroke
+1
4 mm -0.5
Boost compensator OFF
R2
Rack position
8.4 Boost compensator ON
1: For preadjustment
3 Pump speed
ON
OFF
Boost compensator stroke

Control rack +1
4 mm -0.5
Rack decrease direction
106671-5171 5/5
Speed-control lever angle Load lever angle
Stopper bolt setting 45°

±5°
(Secure at full at delivery) Full-load 34.
5 ° ±3
(13°) ±5° N=290 °
5°
5.5°±
Idling
Full-speed Idling
Timing setting
Stop lever angle of injection position
Approx. 30°
33° ±
5°
Stop
33° R=11.1±0.1
±5°
Normal
NISSAN DIESEL

ENGINE MODEL: 6SD1-TCE Date: 9 JUL 2002 0
Company: ISUZU
No. 115603-1510
Injection pump: PE6P Governor: EP/RLD-J Timing device: EP/SPG
106067-1221 105923-2100 105681-5380
1. Test conditions


+5
2. Injection timing
Injection order: 1 5,1 3,1 6,1 2,1 4

60°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'
11.5 800 149 ± 2 ±3 Rack Basic Cylinder variation adjustment standard
H Approx. 6.4 290 10.5 ± 3.2 ± 13 Rack Cylinder variation adjustment standard
Basic Boost press. kPa {mmHg}

A R1(11.5) 800 149 ± 2 - Lever Above 28.7 {Above 215}
B R1+0.3 1100 (153.5) ± 3 - Lever Above 28.7 {Above 215}
C R2[R1-1.3] 500 (119.5) - Lever Above 28.7 {Above 215}
D (R1-1.6) 300 (98) - Lever Boost press. 0
I Approx. R1+1.35 150 (165) - Lever Boost press. 0

Pump speed
Beiow 850 800 875
(r/min)

Beiow 0.5
angle (° ) 0 1.5±0.5
106671-6220 2/3
Full load adjustment Torque cam no. ‘AD53’
I
Approx. R1+1.35 Boost compensator stroke:
1.15±0.1 mm
B
R1+0.3
A
R1(11.5)
Rack position (mm)
R1-0.35
R1-0.45
10.8±0.1
R2[R1-1.3]
C
D
6.8±1.0
0
Below 200 (470) (560) 700 (750) (1180) 1310
(280) (900) (1050) 1200
Pump speed (r/min)
N = 500
Rack position (mm)
Idling adjustment
R2[R1-1.3]
8.5
8.0±0.5
6.5 R2-1.15
Rack position (mm)
Approx 6.4
0 Approx 15.3 {Approx 115}
4.0±0.1
10.0±1.3 {75±10}
+0.5
0.5 -0.45
0
185 315 430 820
240 290
Pump speed (r/min)

106671-6220 3/3
27° ±5°
29
.5
ng
°±
Idli
3°
Stopper bolt setting Full-speed
Stop lever angle
Normal 22°±5° Stop
41°±5°
Timing setting
B.T.D.C.: 10°
x. 50°
Center of timing device's threaded hole Appro
ZEXEL Ass'y No. 106671-3841 use for - 106671-8030

Bosch Ass'y No.
Bosch Typecode
Engine Type EK200
Manufacturer HINO
7d}
...
Nozzle 105780-0000
Left
Left
Drive side
Cyl 1-4
Cyl.1-2
Cyl 1-6
Cyl 1-3
Cyl 1-5

P Adjusting point A
P Rack position 7.9
P Adjusting point B
P Rack position 7.9
P Basic *
P Adjusting point C
P Rack position 8.3
P Adjusting point D
P Fixing the rack *
P Adjusting point E
P Rack limit *
P Adjusting point F
P Rack position 7.2
Name

RT=0.8 N:Pump speed

TH=2.4mm R:Rack position (mm)
R1=8.6mm (1)Lever ratio: RT
DL=3.3-0.2mm (2)Target shim dimension: TH
N1=300+25r/min (3)RACK LIMIT: R1
R2=4mm (4)Damper spring setting: DL
(5)Adjust the bolt so that the switch goes on at pump speed N = N1 and rack position R = R2.
S Pump speed r/min 865+50
P Load 4/4
Remarks
Start
P Load 3/4
S Advance angle deg. 4.5 4.2 4.8
P Load 4/4
Remarks
Finish
Name
a=17deg+-5deg
F:Full speed

2.6 Load control lever angle

Name
a=17deg+-5deg
b=39deg+-3deg
F:Full load
I:Idle
(1)-
(2)-
Name
a=40deg+-5deg
b=64deg+-5deg
N:Pump normal
S:Stop the pump.
(1)-
(2)-
2.8 Timing setting
Name
a=0deg+-3deg
(1)Pump vertical direction

(2)Coupling key groove position for the No. 1 cylinder's beginning of injection


ENGINE MODEL: M10C-TB Date: 22 Sep 2004 1
Company: HINO
No. 22020-4990A
Injection pump: PE6P Governor: EP/RSV Timing device:
106067-1070 105407-6550
1. Test conditions


+5
Overflow valve opening pressure: 147~177 kPa {1.5~1.8 kgf/cm2}
2. Injection timing
Injection order: 1 4,1 2,1 6,1 3,1 5

60°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'
A 9.8 750 89.3 ± 1 ±2 Rack Basic Above 74.6 {Above 560}
B Approx 8.2 360 14 ± 3 ± 15 Rack Boost press. 0
D - 100 187 ± 10 - Lever Rack limit Boost press. 0

Pump speed
(r/min)
Advance
angle (° )

106672-3740 2/3

(notches from fully tightened position; fix in this position)
Rack limit
Above 14.0
Boost compensator stroke: 1.4±0.1

D
11.5±0.1 Main spring setting

10.9
Rack position (mm)
9.8±0.1 A
9.0±0.2
8.4±0.1 B Idle sub spring setting
8.2
6.2±1.5
4.8±0.1
0 300 (430) 750 850 900

360 798
Pump speed (r/min)
N = 600
Rack position (mm)
10.9
9.5

3.3+2.0 {25+15}
106672-3740 3/3
Full-speed (18°) ±5°

N=900 set
°
Stopper bolt setting (8°) ±5
N=750 set
(5°) ±5°
Idling
Stop lever angle
Normal Stop
25° ±5°
70°±5° N=0, R=1.0-0.5

(Seal at delivery)
Timing setting
Approx. 50°

Pump Assembly # 106672-3810
Governor Assembly # 105407-7100
This Pump and Governor combination is only released to OEM and Test Data is
available thru OE as well..
6673-299

ENGINE MODEL: 6D24T2 Date: 26 SEP 2002 3
Company: MITSUBISHI
No. ME152038
Injection pump: PE6P Governor: EP/RLD-J Timing device: EP/SPGH
106067-1050 105923-2333 105691-3802
1. Test conditions
Nozzle & Nozzle Holder Ass'y: 105780-8250 (Bosch Type No. 1 688 901 101)

(Bosch Type No. 1 688 901 990) (Bosch Type No. )

+5
(
2. Injection timing
Injection order: 1 5,1 3,1 6,1 2,1 4

60°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'
Z Approx 8.0 390 Each cylinder 26±3.9 - Rack Cylinder variation adjustment standard
B
Boost press. kPa {mmHg} A
A R1(13.7) 700 172.5 ± 2 - Lever Basic Above 29.3 {Above 220}
B R1+0.9 1100 (157) ± 2 - Lever Above 29.3 {Above 220}
C (R1-0.85) 500 (171.5) ± 3 - Lever Above 29.3 {Above 220}
I Approx 100 (185) - Lever
R1-0.8 Boost press. 0

Pump speed
(r/min)
Advance
angle (° )
106673-7463 2/4

Torque cam no. ‘AE17’
B
R1+0.9
Rack position (mm)
R1+0.75
I A
R1(13.7)
Approx R1-0.8 C
13.5±0.1
R2[R1-1.7]
8.4±1.0
Below 5.0
0
Below 210 (340) 700 (1000) (1050) 1210 1290 1500
(890) (1190)
Pump speed (r/min)
Adjust the bolt so that the microswitch operates at a control lever position of
Idling adjustment R= 7.6 ± 0.1 mm and a pump speed of 325r/min.
10.0
+0.8
9.0 -0.6 Damper spring setting
Approx 8.0
8.0
Rack position (mm)
6.2-0.1
4.3±0.1
2.7±0.5
0
185 350 400 700
225 255 285
Pump speed (r/min)

106673-7463 3/4
N = 250
Rack position (mm)

R2[R1-1.7]
R2-1.65

6.7±1.3 {50±10}

10.0±0.3
Advance angle (° )
0/4 load P = 0
0 Above 750
Pump speed (r/min)
106673-7463 4/4
6. Rack sensor adjustment (-0620)

(1) Fix the speed control lever in the FULL position.
(2) Set the speed at N r/min and the rack position at R. (If equipped with a boost compensator, apply
boost pressure.)
(3) Adjust the bobbin 1 so that the rack sensor output voltage is VR±0.01.
(4) Apply red paint to the joint 2 and nut 3 join and to the joint 2 and pump end face join.

5±0.01V VR
power supply
407912-1742
105782-6320
Speed N 1100 r/min
407910-3032
Rack position R R1(13.7)+0.9 mm
3V 407910-6010
3 407910-7210
2

(Supply pump side)
1
37
Full-speed ° ±3
°
2°±5°
Idling

At No. 1 plunger’s beginning of
injection position
B.T.D.C.: 5°
Stop Normal
Coupling key groove position Approx. 2°
°
5° ±5
29.
5°
N=1100, R=3.5±0.3 40° ±
(Confirm that injection does not occur.)
6675-450

ENGINE MODEL: S6A3 Date: 31 Oct 2007 1
TEMPORARILY
Company: MITSUBISHI. HEAVY
No. 35A65-11070
Injection pump: PE6P Governor: Timing device:
106068-4030
1. Test conditions

(Bosch type no. DLLA158SM268) (Bosch type no. )

+5
2. Injection timing
Pre-stroke: No.1 plunger 3.5 ± 0.05mm Note: Adjust with rack position of R=A(13.6) mm
Injection order: 1 5,1 3,1 6,1 2,1 4

60°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'
Plungers are numbered from the Opposite Drive side (interval: ° ± 30').
A 13.6 1025 313 ± 9 ±3 Rack Basic Rack limit
B Approx 6.5 400 30 ± 3 ± 10 Rack

Pump speed
(r/min)
Advance
angle (° )

106684-4460 2/2
Timing setting
0°
11
x.
pro
Ap

ENGINE MODEL: S6A3 Date: 20 Sep 2007 1
TEMPORARILY
Company: MITSUBISHI. HEAVY
No. 35A65-11070
Injection pump: PE6P Governor: Timing device:
106068-3462
1. Test conditions

(Bosch type no. DLLA158SM268) (Bosch type no. )

+5
2. Injection timing
Pre-stroke: No.1 plunger 3.5 ± 0.05mm Note: Adjust with rack position of R=A(13.6) mm
Injection order: 1 5,1 3,1 6,1 2,1 4

60°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'
Plungers are numbered from opposite the Drive side (interval: ° ± 30').
A 13.6 1025 313 ± 9 ±3 Rack Basic Rack limit
B Approx 6.5 400 30 ± 3 ± 10 Rack

Pump speed
(r/min)
Advance
angle (° )

106684-4461 2/2
Timing setting
Approx. 110°


ENGINE MODEL: 12PC1 Date: 28 Jul 2004 7
Company: ISUZU
No. 115601-7317
Injection pump: PES12P Governor: EP/RFD-D Timing device: EP/SPM
106096-9241 105488-0430 105687-0200
1. Test conditions


+5
2
Overflow valve opening pressure: 255 ± 34 kPa {2.6 ± 0.35 kgf/cm } Drive side
Overflow valve opening pressure: 255 ± 34 kPa {2.6 ± 0.35 kgf/cm2} Governor side
2. Injection timing
Pre-stroke: No.1 plunger 4 ± 0.03mm Note: Adjust with rack position of mm
Injection order:
1 4,1 9,1 8,1 5,1 2,1 11 , 1 10 , 1 3,1 6,1 7,1 12
15°± 15' 60°± 15' 75°± 15' 120°± 15' 135°± 15' 180°± 15' 195°± 15' 240°± 15' 255°± 15' 300°± 15' 315°± 15'

B 8.1 700 85.6 ± 1.5 ±2 Lever Basic
C (7.9) 1250 (95.9) ± 2 ±3 Lever
D Approx 5.4 225 8 ± 1.4 ± 13 Rack
E (10.3) 150 (102) - Lever Excessive fuel lever ; Normal position

Excessive fuel lever ; Excessive fuel
F - 150 Above 137 - Lever position

Pump speed
(Measure) (Measure) (1075) 1150 1250
(r/min)

1 - 0.5 1 - 0.5 2.5 ± 0.3
angle (° ) 0 5+1

106961-1564 2/3
Set so that the damper spring is not operating at delivery.
Not exceeding 2 at excessive fuel setting for starting
F
Excessive fuel setting for starting: 9.2±0.1
E
Rack position (mm)
8.1 B C
7.8
Above 6.9
D
7.8+0.2
5.4
4.8
2.0±0.5
0
225 450+25 (1235) (1360) 1485-10
270±20 1300
Pump speed (r/min)
With the power on and the solenoid in the maximum stroke position, adjust the solenoid body
and set it so that the excessive fuel lever is in the excessive fuel position.
106961-1564 3/3
9° ±5°
Idling Full-load
Full-speed
10° ±5
°
33°±3°
Stop lever angle

Excessive fuel lever angle
Normal Stop
Normal At excessive fuel

60° for starting
±5
°
73°
±5°
Timing setting
Appro
At No. 1 plunger’s beginning x.5° (24°)
B.T.D.C.: 12°
Approx. 170°
governor side
Gear mark "Z"
C ON F I D EN T I AL Ass'y No.: 107491-3190

T E MPOR AR ILY ENGINE MODEL: J05C-TJ Date: 16 Mar 2007 2
Company: HINO
No. 22040-2421A
Injection pump: TC4MD Governor: EP/RLD-J Pre-stroke actuator:
107049-0060 105933-1730 159645-4120
1. Test conditions
Pump rotation: Counter clockwise ( viewed from drive side )

2
Nozzle opening pressure: 1st 17.7 MPa { 180 kgf/cm }
Transfer pump pressure: 255 kPa { 2.6 kgf/cm2 }
2nd 21.6MPa { 220 kgf/cm2 }
+5
Overflow valve opening pressure: 255 ± 34 kPa { 2.6 ± 0.35 kgf/cm2 } DIGI switch No.: 17 (For C/U 407980-224*)
2. Injection timing
Pre-stroke: No. 1 Plunger 5.1 ± 0.03 mm
Connector 1
Note: Stopper 2
1. Adjust using the shim 3. (Timing retard side)
2. Adjust with the rack in the full-load position.

3. Adjust with the connector 1 contacting the stopper 2. Shim 3

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. Pre-stroke actuator adjustment

Pre-stroke actuator type: Retard
Power supply voltage: 24±0.5 V Ambient temperature: 23±5°C
Pre-stroke Pre-stroke sensor

Remarks
(mm) output voltage (V)
2.0 ± 0.05 2.83 ± 0.01 Pre-stroke actuator adjustment
5.1 ± 0.03 V1 = 1.2 ± 0.2 Confirmation

Confirmation
- Above 3.05
(Pre-stroke actuator operating range)

107491-3190 2/6
Note:
1. Move the pre-stroke actuator fully clockwise (viewed from the drive side), and temporarily secure it to the actuator
housing using the bolts.
Tightening torque: 1.0 ~ 1.5 N•m {0.1 ~ 0.15 kgf•m}
2. Move the pre-stroke actuator counter clockwise (viewed from the drive side) to adjust it.
3. After pre-stroke actuator adjustment, stamp both the pre-stroke actuator and the housing with an aligning mark.
Stamping position
Pre-stroke actuator
Injection pump
4. Injection quantity variation rate adjustment
P = pre-stroke sensor output at injection quantity adjustment
P1 V = 2.25 ± 0.01 (V) 3.1 ± 0.05 (mm)
P2 V =V1 + 0.05±0.01 (V) 5.0 ± 0.03 (mm)

P position speed 3 between Fixed Remarks
- P1 (12.8) 750 110 ± 3 ± 3.5 Rack Basic

Approx Each cylinder 11.5±1.15
H P2 325 - Rack
8.0
107491-3190 3/6
Torque cam no. ‘AH27’
R1+2.15 B
I
Rack position (mm)
Approx R1+0.4
A
R1(12.8)
R1-0.25
12.3±0.1
R1-0.95(R2)
11.4±1.0
0
Below 275 (500) (700) (1200) 1500 1530
650 (800) (1300)
Pump speed (r/min)
N = 400
Idling adjustment
Rack position (mm)
R1-0.95(R2)
10.0
+0.2
9.7 -0.3 R2-1.15
H J
Approx 8.0 0 Approx 37.3 {Approx 280}
Rack position (mm)
8.0
23.3±1.3 {175±10}
6.8±0.1
4.5±0.6
0
230 375 450 800
325
Pump speed (r/min)
107491-3190 4/6
6. Injection quantity adjustment (after governor adjustment)
P1 V = 2.25 ± 0.01 (V) 3.1 ± 0.05 (mm)
P2 - -

A P1 R1(12.8) 750 110 ± 2 - Lever Basic
B P1 R1+2.15 1250 (120.5) ± 3 - Lever
C P1 R2-1.15 400 (83) ± 3 - Lever Boost press: 0
Approx
I P1 100 (175) - Lever Boost press: 0
R1+0.4
7. Control lever angle
5°
5° ±
°
° ±3
3 4.5
Idling
Full-speed
op
St
al
rm
No
40
°±
Stopper bolt H position 5°
10.5°±5
°
Fully loosen the stopper screw to position the lever in the

normal position. then,tighten the stopper screw so that it
contacts the stop lever, and set the stopper screw.

Pump speed
Below 1170 1120 1250-50
(r/min)

0-0.3
angle (° ) 0 -1.5±0.3
107491-3190 5/6
9. Injection timing setting

Pointer At No. 1 plunger’s beginning
Injection timing aligning mark
(Pre-stroke: 5.1±0.03 mm)
Approx
Flywheel
(Actual shapes and positions may differ

from the illustration.)
1. Turn the pre-stroke actuator OFF.

2. Position the camshaft in the No.1 plunger's beginning of injection position.
3. Confirm that the injection pump pointer's aligning mark and the flywheel's aligning mark are aligned.
4. If not aligned, remove the incorrect flywheel aligning mark and remark it.
5. Confirm that the center of the flywheel's threaded hole is as specified.
107491-3190 6/6
10. Rack sensor adjustment

Amp-equipped rack sensor adjustment (154610-5*20)
• Threaded type rack sensor (without rack limit; for P type, TICS)
Rack sensor power supply 5±0.01V

Speed No 1250 r/min
Rack position Ro R1(12.8) + 2.15 mm
Output voltage VR 3.00±0.01V
(1) Screw in bobbin 1 until it contacts the joint 2.

(2) Fix the pump lever at full and screw in the bobbin 1 to adjust the depth so that the amp’s output
voltage V = VR at Np = No and R = Ro. Then, fix the rack sensor using the nut 6.
(3) Move the pump lever 2 or 3 times, reset at full and confirm that the amp’s output voltage V = VR.
(4) Attach the caution plate to the top of the joint 2 and apply red paint to the joint 2 - nut 6 join, and the
pump end face - joint 2 join.
Note:
(1) When adjusting the bobbin 1 and joint 2, the fully tightened position of the bobbin is 9 threads (ie, 9
turns) from where it first engages the joint.
(2) With the welded rack block type, refer to the table below for the R = Ro range (the range varies with
the joint).
Joint part no. Ro

Rack sensor adjusting position
Adjustment Np = No 154614-2500 10.2 ~ 13.7
154614-4800 5.2 ~ 8.7
Output voltage
Rack position
Ro 154614-8300 15.2 ~ 18.7

VR 154614-8400 20.2 ~ 23.7
154614-8700 7.7 ~ 11.2
154614-8800 12.7 ~ 16.2
No Np Ro 154614-8900 17.7 ~ 21.2
4 3 3
5 4
Pump end face Pump end face
6 1 2 Apply red paint 6 1 2 Apply red paint
Threaded rack block type Welded rack block type


ENGINE MODEL: J05C-TJ Date: 29 Nov 2002 4
Company: HINO
No. 22040-2421A
107049-0061 105933-1730 159645-4120
1. Test conditions


+5
2. Injection timing
Connector 1
Note: Stopper 2


90°± 15' 180°± 15' 270°± 15'


Remarks
5.1 ± 0.03 V1 = 1.2 ± 0.2 Confirmation

Confirmation
- Above 3.05
107491-3191 2/6
Note:
Stamping position
Pre-stroke actuator
Injection pump
P1 V = 2.25 ± 0.01 (V) 3.1 ± 0.05 (mm)
P2 V =V1 + 0.05±0.01 (V) 5.0 ± 0.03 (mm)

- P1 13.1 750 123.5 ± 3 ± 3.5 Rack Basic
Each cylinder 11.5±1.15 Adjust injection q'ty at N = 505.

Z P2 8.0±0.5 505 - Rack
107491-3191 3/6
R1+2.15 B
I
Rack position (mm)
Approx R1+0.4
A
R1(13.1)
R1-0.25
12.5±0.1
R1-0.95(R2)
11.1±1.0
0
Below 275 (500) (700) (1200) 1500 1530
650 (800) (1300)
Pump speed (r/min)
N = 400
Idling adjustment
Rack position (mm)
R1-0.95(R2)
10.0
+0.2
9.7 -0.3 R2-1.15

Rack position (mm)
8.0
23.3±1.3 {175±10}
6.8±0.1
4.5±0.6
0
230 375 450 800
325
Pump speed (r/min)
107491-3191 4/6
P1 V = 2.25 ± 0.01 (V) 3.1 ± 0.05 (mm)
P2 - -

A P1 R1(13.1) 750 123.5 ± 2 - Lever Basic
B P1 R1+2.15 1250 136 ± 6 - Lever
5°
5° ±
°
° ±3
34.5
Idling
Full-speed
op
St
al
rm
No
40
°±
Stopper bolt setting 5°
10.5°±5
°
Fully loosen the stopper screw to position the lever in the

normal position. then,tighten the stopper screw so that it
contacts the stop lever, and set the stopper screw.

Pump speed
Below 1170 1120 1250-50
(r/min)

0-0.3
angle (° ) 0 -1.5±0.3
107491-3191 5/6

Approx
Flywheel


107491-3191 6/6


Speed No 1250 r/min

Note:
the joint).
Joint part no. Ro

Adjustment Np = No 154614-2500 10.2 ~ 13.7
154614-4800 5.2 ~ 8.7
Output voltage
Rack position
Ro 154614-8300 15.2 ~ 18.7

VR 154614-8400 20.2 ~ 23.7
154614-8700 7.7 ~ 11.2
154614-8800 12.7 ~ 16.2
No Np Ro 154614-8900 17.7 ~ 21.2
4 3 3
5 4

INJ. PUMP CALIBRATION DATA 1/11

ENGINE MODEL: 4HE1-X Date: 27 Nov.2001 5
Company: ISUZU
No. 8-97212-185-0
Injection pump: 107049-2061 Governor: 105934-0090
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 )

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

107492-1101 2/11
3. Injection timing adjustment

(Refer to the MITICS Repair and Maintenance Service Manual for adjustment details.)
3-1 Adjustment Preparation

(1) Install setscrew ③ (P/N 157927-2820), screw ④ (P/N 157927-3321) and solenoid switch
⑤ into housing ① .
(2) -1. Screw in setscrew ③ until the counterweight contacts the housing's pressfitted
stopper pin.
-2. Tighten screw ④ until clearance between screw ④ and counterweight ② is 1∼2
mm.
-3. Tighten solenoid switch ⑤ until clearance between solenoid switch and
counterweight ② 's pin is 1 ∼ 2 mm, then tighten locknut ⑥ .
(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 ① .
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 ① .
3 6 5
1. Setscrew installation 2. Pre-stroke adjustment

3. Individual cylinder's injection
order adjustment
107492-1101 3/11
3-4 Measuring pre-stroke output voltage

(1) Install measuring device (P/N 105782-6420).
(2) Remove setscrew ③ (P/N 157927-2820) and install air bleeder bolt.
(3) Screw in screw ④ (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
3.36 a1 + tolerance
a
3.10 a2 -tolerance
2.96 b1 + tolerance
b
2.76 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 ④ (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 ⑤ .
(2) Loosen solenoid switch ⑤ 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.
107492-1101 4/11
4-1. Governor adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
Boost compensator stroke: 1.25 ±0.1

Torque cam No. “ AF60”
B
R1+0.9
I D
Approx.R1+0.3 A
R1(15.0)
13.9 ± 0.1
R2 [R1-2.15]
10.7 ± 1.0
0
250-40 (650) 1000 (1150) 1690
(1600) 1810
Pump speed (r/min)
Idling adjustment
10.5 Confirm rack sensor Vist = 2.55 ± 0.28

10.0 ± 0.1
at supply voltage 5±0.01V , N =1000 r/min , R = R1 (15.0).
H J
Approx.8.9
7.8
6.6 ± 0.1
3.9 ± 0.3
0
240 400 500 880
400 475
Pump speed (r/min)

107492-1101 5/11
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
R2 [R1-2.15]
R2-1.25
0
Approx. 28.7 {Approx. 215}
12.0 ± 1.3 {90 ± 10}
Boost press. kPa｛mmHg｝

107492-1101 6/11
4-3 Timing cam adjustment (Timing cam No:A07)

(1) Hold speed control lever against full speed stopper bolt.
(2) Supply boost pressure of at least 42.0 kPa {at least 315 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
3.36 a1 + tolerance
a
3.10 a2 -tolerance
(5) Operate the pump at the timing cam confirmation point

(point b in table below: Np = 1,200 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
2.96 b1 + tolerance
b
2.76 b2 -tolerance
Pre-stroke (Pre-stroke output voltage)
＋ 0.03 Solenoid starting advance angle

2.0
− 0.10
2.76 (b2)
2.96 (b1) b (confirmation point)
3.10 (a2)
a (adjusting point)
3.36 (a1)
Minimum advance angle adjustment

3.7 ± 0.03 (c)
stopper
Pre-stroke at stopper contact

4.0 ± 0.03
0 (500) 900 1,200
Pump speed (r/min)

107492-1101 7/11
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
- 15.0 1,000 109.5 ± 1.6 ±4 Rack a1∼a2(v) Basic
adjustment standard
Cylinder variation
Z 8.9±0.5 510 22 ± 1.5 ± 14 Rack c(v) adjustment standard

A R1(15.0) 1,000 109.5 ± 1 - Lever a1∼a2(v) Basic Above 42.0｛Above 315｝

B R1＋0.9 1,200 (112.5) ± 2 - Lever b1∼b2(v)
Above 42.0｛Above 315｝
Approx.
I 150 (180) - Lever c(v) Boost press. 0
R1＋0.3
Above 42.0 ｛Above 315 ｝
D* 15.3±0.1 1,200 (106) - Lever b1∼b2(v) Negative press. kPa｛mmHg｝
53.3 kPa｛ 400 mmHg｝
D*: Aneroid compensator actuator adjustment point

107492-1101 8/11
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 ③ and fully tighten FICD set bolt ② .
(5) Apply 53.3 kPa { 400 mmHg} negative pressure to the actuator ① and set the pump
speed at 450 r/min.
(6) Gradually loosen set bolt ② then fix bolt using nut when the rack position is 8.7±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

③
Tightening torque
① 5 ∼ 7 N.m {0.5 ∼ 0.7 kgf.m}
107492-1101 9/11
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 1,200 r/min.
(4) Apply at least 42.0 kPa { 315 mmHg} boost pressure to the boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt so control rack
position is 15.3±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

107492-1101 10/11
8. Speed control lever angle 9. Stop lever angle

45°± 5°
Hole(R42) Set the position
±5° R=1.5 ± 0.2
22.5°
Idling
Normal Stop
29.
5°
±3
30° °
±5 Full-speed
° Hole(R41.3)
10. Rack Sensor Adjustment
(1) Before removing rack position measuring device, apply at least 42.0 kPa
{at least 315 mmHg} boost pressure and confirm rack position is R1 = 15.0 mm and
fuel injection quantity is 109.5 ± 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.
(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 42.0 kPa {at least 315 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 = 2.55 ± 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)
107492-1101 11/11
11. Drive Coupling Timing
Timing setting (At pre-stroke 3.7 ± 0.05mm)
At No. 1 plunger’s beginning Bracket mark Pump

Engine
B.T.D.C. : 8°
Gear hole (Dia. 3mm) ) (35°)

6 ° ′
(9 20
±
″ 13°2
14 8′48
′ ″±3
35 °
Gear’s threaded hole 8 °
2
Gear side )
32″
Pump side
12′
(3°
Check hole
Stamp on coupling and bracket

°)
(B.T.D.C. 8°
°
Mark position of coupling at B.T.D.C. 13°
INJ. PUMP CALIBRATION DATA 1/11

ENGINE MODEL: 4HE1-X Date: 18 Mar.2003 3
Company: ISUZU
No. 8-97212-188-1
Injection pump: 107049-2073 Governor: 105934-0081
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 )

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

107492-1132 2/11
3. Injection timing adjustment

(Refer to the MITICS Repair and Maintenance Service Manual for adjustment details.)
3-1 Adjustment Preparation

(1) Install setscrew ③ (P/N 157927-2820), screw ④ (P/N 157927-3321) and solenoid switch
⑤ into housing ① .
(2) -1. Screw in setscrew ③ until the counterweight contacts the housing's pressfitted
stopper pin.
-2. Tighten screw ④ until clearance between screw ④ and counterweight ② is 1∼2
mm.
-3. Tighten solenoid switch ⑤ until clearance between solenoid switch and
counterweight ② 's pin is 1 ∼ 2 mm, then tighten locknut ⑥ .
(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 ① .
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 ① .
3 6 5
1. Setscrew installation 2. Pre-stroke adjustment

3. Individual cylinder's injection
order adjustment
107492-1132 3/11
3-4 Measuring pre-stroke output voltage

(1) Install measuring device (P/N 105782-6420).
(2) Remove setscrew ③ (P/N 157927-2820) and install air bleeder bolt.
(3) Screw in screw ④ (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 ④ (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 ⑤ .
(2) Loosen solenoid switch ⑤ 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.
107492-1132 4/11
4-1. Governor adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
Boost compensator stroke: 1.1 ±0.1

Torque cam No. “ AG00”
B
R1+2.9
I D
Approx.R1+2.0
R1(12.9) A
+0.5
R3 [R1-0.6] -0.1 14.0 ± 0.1
E
R2 [R1-0.6]
C (1050)
10.2 ± 1.0
(1300)
0
250-40 (700) 900 (1400) 1620
700 (1550) 1775
Pump speed (r/min)
Idling adjustment
10.5 Confirm rack sensor Vist = 2.13 ± 0.28

10.0 ± 0.1
at supply voltage 5±0.01V , N =900 r/min , R = R1 (12.9).
H J
Approx.8.5
7.8
6.6 ± 0.1
3.9 ± 0.3
0
240 400 500 880
400 475
Pump speed (r/min)

107492-1132 5/11
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
R2 [R1-0.6]
R2-1.1
0
Approx. 26.7 {Approx. 200}
10.7 ± 1.3 {80 ± 10}

107492-1132 6/11
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 40.0 kPa {at least 300 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 ± 0.03
0 (500) 900 1,450
Pump speed (r/min)

107492-1132 7/11
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
- 12.9 900 81 ± 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

A R1(12.9) 900 81 ± 1 - Lever a1∼a2(v) Basic Above 40.0｛Above 300｝

B R1＋2.9 1,450 (102.5) ± 2 - Lever b1∼b2(v)
Above 40.0｛Above 300｝
Approx.
I 150 (175) - Lever c(v) Boost press. 0
R1＋2.0
Above 40.0 ｛Above 300 ｝
D* 15.2±0.1 1,450 (96.5) - Lever b1∼b2(v) Negative press. kPa｛mmHg｝
53.3 kPa｛ 400 mmHg｝
D*: Aneroid compensator actuator adjustment point

107492-1132 8/11
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 ③ and fully tighten FICD set bolt ② .
(5) Apply 53.3 kPa { 400 mmHg} negative pressure to the actuator ① and set the pump
speed at 450 r/min.
(6) Gradually loosen set bolt ② 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

③
Tightening torque
① 5 ∼ 7 N.m {0.5 ∼ 0.7 kgf.m}
107492-1132 9/11
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 40.0 kPa { 300 mmHg} boost pressure to the boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt so control rack
position is 15.2±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

107492-1132 10/11
8. Speed control lever angle 9. Stop lever angle

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 40.0 kPa
{at least 300 mmHg} boost pressure and confirm rack position is R1 = 12.9 mm and
fuel injection quantity is 81 ± 1 mm3/st at N = 900 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).
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
(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 40.0 kPa {at least 300 mmHg} boost pressure, set pump speed at
N= 900 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 = 2.13 ± 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)
107492-1132 11/11
11. Drive Coupling Timing
Timing setting (At pre-stroke 3.7 ± 0.05mm)
At No. 1 plunger’s beginning Bracket mark Pump

Engine
B.T.D.C. : 8°
Gear hole (Dia. 3mm) ) (35°)

° ′
( 96 20
±
″ 13°2
14 1 ′18″
′ ±
35 3°
Gear’s threaded hole °
28
Gear side
2″)
2′3
Pump side
1
(3°
Check hole
Stamp on coupling and bracket

°)
(B.T.D.C. 8°
°
Mark position of coupling at B.T.D.C. 13°

ENGINE MODEL: FE6TA Date: 18 Sep 2002 8
No. 16801 Z5607
Injection pump: TC6MD Governor: EP/RED-IV Pre-stroke actuator:
107069-1460 105961-0071 159645-2020
1. Test conditions


+5
Overflow valve opening pressure: 255 kPa { 2.6 kgf/cm2 } DIGI switch No.: 14 (For C/U 407980-224*)
R=1.0
Stop
37°±5°
20° ±5°
Normal
R=20.0
3. Confirmation of RED-IV governor's output characteristics

[1] Rack sensor output characteristics
(1) Measure the rack position R2 at PWM 72.5% and confirm that R2 = 15±1 mm.
(2) Measure the rack position R1 at PWM16.25% and confirm that R2 - R1 = 10±0.1 mm.
Switch box part no. 407980-4340 72.5%
Control unit part no. 407915-0590 PWM (%)

PWM72.5% rack position R2 = 15±1 (mm)
PWM16.25% rack characteristics R2 - R1 = 10±0.1 (mm) 16.25%
R1 R2
Rack position (mm)
107691-0144 2/4
[2] Limp home operation confirmation

(1) Position the switch box's LIMP HOME switch at LIMP HOME.
(2) Confirm that the rack positions for the PWM are as specified in the table below.
PWM Rack position
5% 1 mm or less
95% 19 mm or above
[3] Pull down operation confirmation

(1) Confirm that the rack position R at PWM95% is approx. 19 mm.
(2) In the above condition, position the switch box's PULL DOWN switch at PULL DOWN and confirm that
the rack position immediately returns to 1 mm or less.
4. Injection timing
Pre-stroke: No. 1 Plunger 5.1 ± 0.03 mm Connector 1
Note: Stopper pin 2

4 Injection order: 1 4,1 2,1 6,1 3,1 5

30' 60°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'
Plungers are numbered from the Drive side.


Remarks
5.1 ± 0.03 V1 = 1.2 ± 0.2 Confirmation

Confirmation
- Above 3.05
107691-0144 3/4
Note:
1. Move the pre-stroke actuator fully counter clockwise (viewed from the drive side), and temporarily secure it to the
actuator housing using the bolts.
2. Move the pre-stroke actuator clockwise (viewed from the drive side) to adjust it.
Stamping position
Pre-stroke actuator
Injection pump

P1 V = 2.25 ± 0.01 (V) 3.1 ± 0.05 (mm)
P2 V = V1 + 0.05 ± 0.01 (V) 5.0 ± 0.03 (mm)

PWM Injection q'ty
P position speed 3 between Remarks
(%) (cm / 1000 strokes )
P1 (11.3) 51.5 700 108 ± 1 ±4 Basic
P2 (6.7) Approx 25.6 445 11 ± 1.8 ± 10

Pump speed
Below 1150 1100 1300
(r/min)

Below 0.3
angle (° ) 0 4.0 ± 0.3
107691-0144 4/4

pprox. 25°
Flywheel Coupling key groove position A



ENGINE MODEL: 6D16T3 Date: 29 Oct 2002 0
Company: MITSUBISHI
No. ME301247
Injection pump: TC6MD Actuator: EP/RED-III Pre-stroke actuator:
107069-0590 105956-0112 159601-5420
1. Test conditions


+5
39
°±
5° R=20.0
R=1.0
37°
±5°
Stop Normal
3. RED-III governor
(Rack 19mm, Span 6mm)
When the rack sensor output voltages are V1 and V2, confirm that rack positions R1 and R2 are as
specified below.
Rack type 19 mm
Output voltage (V)
Control unit no. 407910-3960 V1

V1 = (V2+0.9±0.0075)
Output voltage
V2 = 2.2±0.01 V2
R2 = 11±1
Rack position (mm)
R2 - R1 = 6±0.05 R1 R2
Rack position (mm)
107691-2930 2/4
4. Injection timing
Connector 1
Note: Stopper 2
(Timing retard side)
1. Adjust using the shim 3.
Injection order: 1 5,1 3,1 6,1 2,1 4

60°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'


Remarks
5.1 ± 0.03 V1 = 1.2 ± 0.2 Confirmation

Confirmation
- Above 3.05
Note:
1. Move the pre-stroke actuator fully counter clockwise (viewed from the drive side), and temporarily secure it to the
actuator housing using the bolts.
2. Move the pre-stroke actuator clockwise (viewed from the drive side) to adjust it.
Stamping position
Pre-stroke actuator
Injection pump
107691-2930 3/4

P1 V = 2.25 ± 0.01 (V) 3.1 ± 0.05 (mm)
P2 V = V1 + 0.05 ± 0.01 (V) 5.0 ± 0.03 (mm)

Vist Injection q'ty
(V) (cm / 1000 strokes )
P1 (12.5) 1.98 800 140 ± 1 ±3 Basic
P2 (6.6) 2.9 ± 0.1 395 16.5 ± 1.8 ± 15

Pump speed
Below1050 1000 1075
(r/min)

0 - 0.5
angle (° ) 0 -1.5±0.5

B.T.D.C.: 2°
Approx
Flywheel


107691-2930 4/4
7. Drive side rack sensor adjustment (-0620)

• Threaded type rack sensor (For REDIII governor)
(2) When the governor side rack sensor output is VG, adjust the depth that the bobbin 1 is screwed in so
that the drive side rack sensor output voltage is VR±0.01V. Then, fix using the nut 5.
Rack sensor power supply 5±0.01V VR Control unit part no.

Governor side rack sensor output VG 1.60V 407912-1742
2V
Drive side rack sensor output voltage VR±0.01V 105782-6320
4 3 407910-3032
3V 407910-6010
407910-7210
Pump end face
1 5 2 Apply red paint
(3) Reset the governor side rack sensor output at VG and confirm that the drive side rack sensor output
voltage is VR±0.01V.
(4) Attach the caution plate to the top of the joint 2 and apply red paint to the joint 2 and nut 5 join and to
the pump end face and joint 2 join.
Note:
When adjusting the depth that the bobbin 1 is screwed into the joint 2, the fully tightened position of the
bobbin is 9 threads (ie, 9 turns) from where it first engages the threads.

ENGINE MODEL: J08C-UJ Date: 29 Nov 2002 1
Company: HINO
No. 22040-2341B
107069-0740 105933-1700 159645-4120
1. Test conditions


+5
2. Injection timing
Connector 1
Note: Stopper 2

Injection order: 1 4,1 2,1 6,1 3,1 5

60°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'


Remarks
5.1 ± 0.03 V1 = 1.2 ± 0.2 Confirmation

Confirmation
- Above 3.05
107691-3570 2/6
Note:
Stamping position
Pre-stroke actuator
Injection pump
P1 V = 2.25 ± 0.01 (V) 3.1 ± 0.05 (mm)
P2 V =V1 + 0.05±0.01 (V) 5.0 ± 0.03 (mm)

- P1 12.7 750 114.5 ± 3 ± 3.5 Rack Basic

Adjust injection q'ty at N = 440.
Z P2 8.2±0.5 440 Each cylinder 13.5±1.35 - Rack
107691-3570 3/6
Stop lever normal position setting: (18.0)

R1+2.05 B
Rack position (mm)
R1+1.1 I
Approx R1+0.25 A
R1(12.7)
12.3±0.1
R1-0.25
R2[R1-1.0]
9.3±1.0
0
Below 225 650 (700) (950) (1050) (1300) 1510 1575
(500) (800) (1200) (1470)
Pump speed (r/min)
N = 300
Idling adjustment
Rack position (mm)
R2[R1-1.0]
10.0
+0.2
9.7 -0.3 R2-1.15

Rack position (mm)
8.0
36.0±1.3 {270±10}
6.7±0.1
5.1±0.6
0
190 350 400 700
275
Pump speed (r/min)
107691-3570 4/6
P1 V = 2.25 ± 0.01 (V) 3.1 ± 0.05 (mm)
P2 - -

A P1 R1(12.7) 750 114.5 ± 2 - Lever Basic
B P1 R1+2.05 1250 124 ± 6 - Lever
°±5°
8.5
°
°) ±3
(38
Stop Normal
Idling
Full-speed

15° ±5°
N=0, R=1.5±0.1 35° ±5°

R=(18.0)
Note;
After adjusting the governor, confirm that the rack position is
at R1(12.7)+2.05 (B) with full set when setting the stop lever.

Pump speed
Below 1200 1150 1290
(r/min)

0-0.3
angle (° ) 0 -1.5±0.3
107691-3570 5/6

Approx
Flywheel


107691-3570 6/6


Speed No 1250 r/min

Note:
the joint).
Joint part no. Ro

Adjustment Np = No 154614-2500 10.2 ~ 13.7
154614-4800 5.2 ~ 8.7
Output voltage
Rack position
Ro 154614-8300 15.2 ~ 18.7

VR 154614-8400 20.2 ~ 23.7
154614-8700 7.7 ~ 11.2
154614-8800 12.7 ~ 16.2
No Np Ro 154614-8900 17.7 ~ 21.2
4 3 3
5 4


ENGINE MODEL: JC8C-UK Date: 7 May 2003 2
Company: HINO
No. 22040-2451B
Injection pump: TC6MD Governor: EP/RED-IV Pre-stroke actuator:
107069-0750 105962-0220 159645-4220
1. Test conditions


+5
37° ±5°
R=1.0 R=20.0
18.5° ±5°
Stop Normal
3. Confirmation of RED-IV governor's output characteristics

[1] Rack sensor output characteristics
(1) Measure the rack position R2 at PWM 72.5% and confirm that R2 = 15±1 mm.
(2) Measure the rack position R1 at PWM16.25% and confirm that R2 - R1 = 10±0.1 mm.
Switch box part no. 407980-4340 72.5%
Control unit part no. 407915-0590 PWM (%)

PWM72.5% rack position R2 = 15±1 (mm)
PWM16.25% rack characteristics R2 - R1 = 10±0.1 (mm) 16.25%
R1 R2
Rack position (mm)
107691-3580 2/4
[2] Limp home operation confirmation

(1) Position the switch box's LIMP HOME switch at LIMP HOME.
(2) Confirm that the rack positions for the PWM are as specified in the table below.
PWM Rack position
5% 1 mm or less
95% 19 mm or above
[3] Pull down operation confirmation

(1) Confirm that the rack position R at PWM95% is approx. 19 mm.
(2) In the above condition, position the switch box's PULL DOWN switch at PULL DOWN and confirm that
the rack position immediately returns to 1 mm or less.
4. Injection timing
Pre-stroke: No. 1 Plunger 5.1 ± 0.03 mm Connector 1
Stopper 2
Note: (Timing retard side)
Injection order: 1 4,1 2,1 6,1 3,1 5

60°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'


Remarks
5.1 ± 0.03 V1 = 1.2 ± 0.2 Confirmation

Confirmation
- Above 3.05
107691-3580 3/4
Note:
Stamping position
Pre-stroke actuator
Injection pump

P1 V = 2.25 ± 0.01 (V) 3.1 ± 0.05 (mm)
P2 V = V1 + 0.05 ± 0.01 (V) 5.0 ± 0.03 (mm)

PWM Injection q'ty
(%) (cm / 1000 strokes )
P1 (11.8) 54.5 750 123.5 ± 2 ± 3.5 Basic

Each cylinder
P2 (6.8) 26.3±2.8 440 -
11 ± 1.1

Pump speed POINTER stamping position
Below 1220 1170 1320-50 Advance angle: 0°; Pump speed:
(r/min)
1170r/min
0-0.3
angle (° ) 0 -1.5±0.3
107691-3580 4/4

B.T.D.C.: 3°
(Pre-stroke: 5.1±0.03 mm) Co
Approx
Flywheel

Adjust the clearance between the pickup
and the timer housing projection to 1-0.2mm.


ENGINE MODEL: J08C-UK Date: 29 Nov 2002 2
Company: HINO
No. 22040-2351B
107069-0760 105933-1710 159645-4120
1. Test conditions


+5
2. Injection timing
Connector 1
Note: Stopper 2

Injection order: 1 4,1 2,1 6,1 3,1 5

60°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'


Remarks
5.1 ± 0.03 V1 = 1.2 ± 0.2 Confirmation

Confirmation
- Above 3.05
107691-3590 2/6
Note:
Stamping position
Pre-stroke actuator
Injection pump
P1 V = 2.25 ± 0.01 (V) 3.1 ± 0.05 (mm)
P2 V =V1 + 0.05±0.01 (V) 5.0 ± 0.03 (mm)

- P1 12.9 750 125 ± 3 ± 3.5 Rack Basic

107691-3590 3/6

R1+2.45 B
Rack position (mm)
R1+0.4 I
Approx R1+0.4 A
R1(12.9)
12.3±0.1
R2[R1-1.15]
9.3±1.0
0
Below 225 (500) (820) (910) (1320) 1520 1585
750 (1200) (1475)
Pump speed (r/min)
N = 300
Idling adjustment
Rack position (mm)
R2[R1-1.15]
10.0
+0.2
9.7 -0.3 R2-0.95

Rack position (mm)
8.0
38.0±1.3 {285±10}
6.7±0.1
5.1±0.6
0
190 350 400 700
275
Pump speed (r/min)
107691-3590 4/6
P1 V = 2.25 ± 0.01 (V) 3.1 ± 0.05 (mm)
P2 - -

A P1 R1(12.9) 750 125 ± 2 - Lever Basic
B P1 R1+2.45 1250 141.5 ± 6 - Lever
°
° ±5
8.5
3°
°±
39
Stop Normal
Idling
Full-speed

15° ±5°
N=0, R=1.5±0.1 35° ±5°

R=(18.0)
Note;

Pump speed POINTER stamping position
Below 1180 1130 1260 Advance angle: 0°; Pump speed:
(r/min)
1130r/min
0-0.3
angle (° ) 0 -1.5±0.3
107691-3590 5/6

Approx
Flywheel


107691-3590 6/6


Speed No 1250 r/min

Note:
the joint).
Joint part no. Ro

Adjustment Np = No 154614-2500 10.2 ~ 13.7
154614-4800 5.2 ~ 8.7
Output voltage
Rack position
Ro 154614-8300 15.2 ~ 18.7

VR 154614-8400 20.2 ~ 23.7
154614-8700 7.7 ~ 11.2
154614-8800 12.7 ~ 16.2
No Np Ro 154614-8900 17.7 ~ 21.2
4 3 3
5 4


ENGINE MODEL: J08C-UK Date: 29 Nov 2002 2
Company: HINO
No. 22040-2371A
107069-0760 105933-1770 159645-4120
1. Test conditions


+5
2. Injection timing
Connector 1
Note: Stopper 2

Injection order: 1 4,1 2,1 6,1 3,1 5

60°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'


Remarks
5.1 ± 0.03 V1 = 1.2 ± 0.2 Confirmation

Confirmation
- Above 3.05
107691-3630 2/6
Note:
Stamping position
Pre-stroke actuator
Injection pump
P1 V = 2.25 ± 0.01 (V) 3.1 ± 0.05 (mm)
P2 V =V1 + 0.05±0.01 (V) 5.0 ± 0.03 (mm)

- P1 12.9 750 125 ± 3 ± 3.5 Rack Basic

107691-3630 3/6

R1+2.45 B
Rack position (mm)
R1+0.4 I
Approx R1+0.4 A
R1(12.9)
12.3±0.1
R2[R1-1.15]
9.3±1.0
0
Below 225 (500) (820) (910) (1320) 1520 1585
750 (1200) (1475)
Pump speed (r/min)
N = 300
Idling adjustment
Rack position (mm)
R2[R1-1.15]
10.0
+0.2
9.7 -0.3 R2-0.95

Rack position (mm)
8.0
38.0±1.3 {285±10}
6.7±0.1
5.1±0.6
0
190 350 400 700
275
Pump speed (r/min)
107691-3630 4/6
P1 V = 2.25 ± 0.01 (V) 3.1 ± 0.05 (mm)
P2 - -

A P1 R1(12.9) 750 125 ± 2 - Lever Basic
B P1 R1+2.45 1250 141.5 ± 6 - Lever
°
° ±5
8.5
3°
°±
39
Stop Normal
Idling
Full-speed

15° ±5°
N=0, R=1.5±0.1 35° ±5°

R=(18.0)
Note;

POINTER stamping position
Pump speed
Below 1180 1130 1260 Advance angle: 0°; Pump speed:
(r/min) 1130r/min
0-0.3
angle (° ) 0 -1.5±0.3
107691-3630 5/6

Approx
Flywheel


107691-3630 6/6


Speed No 1250 r/min

Note:
the joint).
Joint part no. Ro

Adjustment Np = No 154614-2500 10.2 ~ 13.7
154614-4800 5.2 ~ 8.7
Output voltage
Rack position
Ro 154614-8300 15.2 ~ 18.7

VR 154614-8400 20.2 ~ 23.7
154614-8700 7.7 ~ 11.2
154614-8800 12.7 ~ 16.2
No Np Ro 154614-8900 17.7 ~ 21.2
4 3 3
5 4

C ON F I D E N T I A L Ass'y No.: 107691-3690

ENGINE MODEL: J08C-UL Date: 10 Feb 2003 1
Company: HINO
No. 22040-2320B
107069-0740 105933-1830 159645-4120
1. Test conditions


+5
2. Injection timing
Connector 1
Note: Stopper 2

Injection order: 1 4,1 2,1 6,1 3,1 5

60°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'


Remarks
5.1 ± 0.03 V1 = 1.2 ± 0.2 Confirmation

Confirmation
- Above 3.05
107691-3690 2/6
Note:
Stamping position
Pre-stroke actuator
Injection pump
P1 V = 2.25 ± 0.01 (V) 3.1 ± 0.05 (mm)
P2 V =V1 + 0.05±0.01 (V) 5.0 ± 0.03 (mm)

- P1 11.9 750 102 ± 3 ± 3.5 Rack Basic

Each cylinder Adjust injection q'ty at N = 440.
Z P2 8.2±0.5 440 13.5±1.35 - Rack
107691-3690 3/6
If not indicated, the rack position allowance is ± 0.05 mm.

R1+2.05 B
Rack position (mm)
11.9±0.1 I
Approx R1+1.75
R1(11.9) A
R1-0.1
R2[R1-0.35]
9.1±1.0
0
Below 225 650 (800) (1300) 1485 1550
(530) (700) (1200) (1460)
Pump speed (r/min)
N = 300
Idling adjustment
Rack position (mm)
R2[R1-0.35]
10.0
+0.2
9.7 -0.3 R2-1.0
H J 0 Approx 50.0 {Approx 375}
Approx 8.2
Rack position (mm)
8.0
37.3±1.3 {280±10}
6.7±0.1
5.1±0.6
0
190 350 400 700
275
Pump speed (r/min)
107691-3690 4/6
P1 V = 2.25 ± 0.01 (V) 3.1 ± 0.05 (mm)
P2 - -

A P1 R1(11.9) 750 102 ± 2 - Lever Basic
B P1 R1+2.05 1250 114 ± 6 - Lever
3° °±5°
°± 8.5
.5
35
Stop Normal
Idling
Full-speed

15° ±5°
N=0, R=1.5±0.1 35° ±5°

R=(18.0)
Note;

Pump speed
Below 1150 1100 1250-50
(r/min)

0-0.3
angle (° ) 0 -1.5±0.3
107691-3690 5/6

Approx
Flywheel


107691-3690 6/6


Speed No 1250 r/min

Note:
the joint).
Joint part no. Ro

Adjustment Np = No 154614-2500 10.2 ~ 13.7
154614-4800 5.2 ~ 8.7
Output voltage
Rack position
Ro 154614-8300 15.2 ~ 18.7

VR 154614-8400 20.2 ~ 23.7
154614-8700 7.7 ~ 11.2
154614-8800 12.7 ~ 16.2
No Np Ro 154614-8900 17.7 ~ 21.2
4 3 3
5 4


ENGINE MODEL: 6D16T3 Date: 17 Aug 2004 0
Company: MITSUBISHI
No. ME302925
107069-0590 105956-0250 159601-5420
1. Test conditions


+5
R=1.0 37° ±5°

R=20.0
33.5° ±
5°
Stop Normal
3. RED-III governor
specified below.
Rack type 19 mm
Output voltage (V)

V1 = (V2+0.9±0.0075)
Output voltage
V2 = 2.2±0.01 V2
R2 = 11±1
Rack position (mm)
R2 - R1 = 6±0.05 R1 R2
Rack position (mm)

107691-7020 2/4
4. Injection timing
Connector 1
Note: Stopper 2
Injection order: 1 5,1 3,1 6,1 2,1 4

60°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'


Remarks
5.1 ± 0.03 V1 = 1.2 ± 0.2 Confirmation

Confirmation
- Above 3.05
Note:
2. Move the pre-stroke actuator Counter clockwise (viewed from the drive side) to adjust it.
Stamping position
Pre-stroke actuator
Injection pump
107691-7020 3/4

P1 V = 2.25 ± 0.01 (V) 3.1 ± 0.05 (mm)
P2 V = V1 + 0.05 ± 0.01 (V) 5.0 ± 0.03 (mm)

Vist Injection q'ty
P1 (12.5) 1.98 800 140 ± 1 ±3 Basic
P2 (6.6) 2.9 ± 0.1 395 16.5 ± 1.8 ± 15

Pump speed
Below1050 1000 1075
(r/min)

0 - 0.5
angle (° ) 0 -1.5±0.5

B.T.D.C.: 2°
Approx
Flywheel


107691-7020 4/4


2V
4 3 407910-3032
3V 407910-6010
407910-7210
Pump end face
Note:

ENGINE MODEL: 6D16T3 Date: 19 May 2006 0
Company: MITSUBISHI
No. ME304583
107069-0590 105956-0250 159601-8820
1. Test conditions


+5
R=1.0 37° ±5°

R=20.0
33.5° ±
5°
Stop Normal
3. RED-III governor
specified below.
Rack type 19 mm
Output voltage (V)

V1 = (V2+0.9±0.0075)
Output voltage
V2 = 2.2±0.01 V2
R2 = 11±1
Rack position (mm)
R2 - R1 = 6±0.05 R1 R2
Rack position (mm)

107691-7040 2/4
4. Injection timing
Connector 1
Note: Stopper 2
Injection order: 1 5,1 3,1 6,1 2,1 4

60°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'


Remarks
5.1 ± 0.03 V1 = 1.2 ± 0.2 Confirmation

Confirmation
- Above 3.05
Note:
2. Move the pre-stroke actuator Counter clockwise (viewed from the drive side) to adjust it.
Stamping position
Pre-stroke actuator
Injection pump
107691-7040 3/4

P1 V = 2.25 ± 0.01 (V) 3.1 ± 0.05 (mm)
P2 V = V1 + 0.05 ± 0.01 (V) 5.0 ± 0.03 (mm)

Vist Injection q'ty
P1 (12.5) 1.98 800 140 ± 1 ±3 Basic
P2 (6.6) 2.9 ± 0.1 395 16.5 ± 1.8 ± 15

Pump speed
Below1050 1000 1075
(r/min)

0 - 0.5
angle (° ) 0 -1.5±0.5

B.T.D.C.: 2°
Approx
Flywheel


107691-7040 4/4


2V
4 3 407910-3032
3V 407910-6010
407910-7210
Pump end face
Note:
CONF I DE NT I A L Assy No.: 107692-2086

ENGINE MODEL: 6D16T5 Date: 10 Apr 2006 8
Company: MITSUBISHI
No. ME075629
107069-0120 105933-0252 159600-2620
1. Test conditions
Pump rotation: Countor clockwise (viewed from drive side)
Nozzle & nozzle holder assy: 105780-8250 (Bosch type no. 1 688 901 101)

(Bosch type no. 1 688 901 990) (Bosch type no. )

+5
Overflow valve opening pressure: 255 ± 34 kPa {2.6 ± 0.35 kgf/cm2} DIGI switch no.: 17 (for C/U 407980-224*)
2. Injection timing
Pre-stroke: No. 1 plunger 5.6 ± 0.03 mm Stopper 2
Note: Connector 1
Injection order: 1 5,1 3,1 6,1 2,1 4

60°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'


Remarks
5.6 ± 0.03 V1 = 1.2 ± 0.2 Confirmation

Confirmation
- Above 3.05

107692-2086 2/6
Note:
2. Move the pre-stroke actuator counterclockwise (viewed from the drive side) to adjust it.
Stamping position
Pre-stroke actuator
Injection pump
P1 V = 2.25 ± 0.01 (V) 3.6 ± 0.05 (mm)
P2 V = V1 + 0.05 ± 0.01 (V) 5.5 ± 0.03 (mm)

P position speed between Fixed Remarks
- P1 13.4 700 122 ± 2 ±3 Rack Basic Cylinder variation adjustment standard

Approx
Z P2 510 10.5 ± 1.8 ± 15 Rack Cylinder variation adjustment standard
7.7
107692-2086 3/6
Torque cam no. ‘AC34’
Full load adjustment If not indicated, the rack position allowance is ± 0.05 mm.
Boost compensator stroke: (1.4)±0.1

B
R1+1.55
R1+1.3
Rack position (mm)
A
R1(13.4)
Approx R1-0.8 D 12.0±1.0
I
R2[R1-1.3]
9.2±0.1
0 (380) 700 (1030) (1310)

Below 225 (1270) (1450) 1590
1530
Pump speed (r/min)
Idling adjustment N = 250

Rack position (mm)
R2[R1-1.3]
9.5
+0.2
9.2 -0.3
H J
Approx 7.7 (R2-1.4)
7.5 0 Approx 22.7 {Approx 170}
6.1±0.1
Rack position (mm)
8.0±1.3 {60±10}
2.4±0.5
0 400 900
185 290 325
275 (320)
Pump speed (r/min)
107692-2086 4/6
P1 V = 2.25 ± 0.01 (V) 3.6 ± 0.03 (mm)
P2 - -

P position speed between Fixed Remarks
A P1 R1(13.4) 700 122 ± 1 - Lever Basic
B P1 R1+1.55 1350 (113) ± 2 - Lever
Boost pressure
C P1 (R2-1.4) 250 69 ± 2 - Lever
0
D P1 (R1-0.55) 550 (118.5) ± 2 - Lever
°
30° ±5
±3°
.5°
39 Stop Normal
Idli
ng
4° ±5°
Full-speed 41° ±5°
Set the stopper bolt at R=3.5±0.3,N=0
Confirm that injection does not occur.
107692-2086 5/6

(1)Fix the speed control lever in the FULL position.
(2) Set the speed at N r/min and the rack position at R. (If equipped with a boost compensator, apply boost
pressure.)
(3)Adjust the bobbin 1 so that the rack sensor output voltage is VR±0.01.
(4)Apply red paint to the joint 2 and nut 3 join and to the joint 2 and pump end face join.

5±0.01V VR
power supply
407912-1742
105782-6320
Speed N 1350 r/min
407910-3032
Rack position R R1+1.55 mm
3V 407910-6010
407910-7210
2 3
1
107692-2086 6/6

Pointer At No. 1 plunger’s beginning of
injection position
(Pre-stroke: 5.6±0.03mm)
B.T.D.C.: 2°
Appro
Flywheel x.1° Coupling key groove position


2. Position the camshaft in the No. 1 plunger's beginning of injection position.

Bosch Ass'y No.
Bosch Typecode
Engine Type 6D16T5
7d}
...
Nozzle 105780-0120
Injection pipe mm 8-3-600
P PS/ACT control unit part no. 407980-224*
P Digi switch no. 17
Left
Left
Governor side
Cal 1-5
Cal 1-3
Cal 1-6
Cyl.1-2
Cal 1-4
P Adjusting point -
P Basic *
P Fixing the rack *
P PS407980-224* V 2.25+-0.01
P PS407980-224* mm 3.6+-0.05


P Adjusting point Z
P Fixing the rack *
P PS407980-224* V V1+0.05+-0.01
P PS407980-224* mm 5.5+-0.03
Remarks
Refer to items regarding the pre-stroke actuator
P Adjusting point A
P Basic *
P Boost pressure kPa 36 36
P PS407980-224* V 2.25+-0.01
P PS407980-224* mm 3.6+-0.05
P Adjusting point B
P PS407980-224* V 2.25+-0.01
P PS407980-224* mm 3.6+-0.05
P Adjusting point C
P Rack position (R2-1.4)
P PS407980-224* V 2.25+-0.01
P PS407980-224* mm 3.6+-0.05
P Adjusting point D
P PS407980-224* V 2.25+-0.01
P PS407980-224* mm 3.6+-0.05


Name
T1=AC34 N:Pump speed

BCL=(1.4)+-0.1mm R:Rack position (mm)
S Boost pressure kPa 8 6.7 9.3
About
About


Name
a=30deg+-5deg
b=39.5deg+-3deg

I:Idle
Name
a=4deg+-5deg
b=(31deg)
c=41deg+-5deg
aa=47mm N:Pump normal

bb=17.4mm S:Stop the pump.
cc=3.5+-0.3mm (1)Use the hole at R = aa
dd=0r/min (2)Normal engine position (equivalent to R = bb).
(3)Set the stopper bolt at rack position = cc and speed = dd and confirm non-injection

2.7 Timing setting

Name
a=(0deg)
b=(40deg)

bb=5.6+-0.03mm (2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)At the No 1 cylinder's beginning of injection position, stamp an aligning mark on the damper t
o align with the pointer's groove.
(4)Damper
(5)Pointer
(6)B.T.D.C.: aa
(7)Pre-stroke: bb
2.8 Timing marking line (MD-TICS)
Name
(1)Pointer
(2)Injection timing aligning mark
(3)Fly weight
(4)The actual shape and direction may be different from this illustration.
Operation sequence
1. Turn the prestroke actuator OFF.
2. Turn the camshaft as far as the No.1 cylinder's beginning of injection position.
3. Check that the pointer alignment mark of the injection pump and the alignment mark of the fly
wheel are matching.
4. If they are not matching, erase the alignment mark on the flywheel side, and stamp an alignm
ent mark on the flywheel position that matches with the pointer side alignment mark.
5. Check again that the coupling's key groove position is in the No.1 cylinder's beginning of inject
ion position.
2.9 Pre-stroke actuator adjustment
2.9.1 Adjustment value
P CU407980-224* *
P Actuator retarding type *
P Supply voltage V 24 23.5 24.5
P Ambient temperature degC 23 18 28

P Pre-stroke mm 2.5 2.45 2.55

S Output voltage V 2.83 2.82 2.84
P Adjustment *
P CU407980-224* *
P Pre-stroke mm 5.6 5.57 5.63
S Output voltage V 1.2 1 1.4
P Confirmation *
Remarks
Output voltage V1
P CU407980-224* *
S Output voltage V 3.05 3.05
P Confirmation of operating range *
2.9.2 Actuator type (MD-TICS)
Name
A : Stopper pin
B: Connector
2.9.3 Shim position indication (MD-TICS)
Name
C:Shim

2.9.4 Adjusting method and stamping position

Name
A:Sealing position
B:Pre-stroke actuator
1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely,
then move the actuator fully clockwise (viewed from the drive side).
Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m)
2. Move the actuator in the counterclockwise direction when viewed from the drive side, and adju
st so that it becomes the adjustment point of the adjustment value. Then tighten it.
Tightening torque: 7^9 N.m (0.7^0.9 kgf.m)
3. After prestroke actuator installation adjustment, simultaneously stamp both the actuator side a
nd housing side.


Name RACK SENSOR
N1=1350r/min (VR) measurement voltage

Ra=R1(13.4)+1.55mm (I) Part number of the control unit
(G) Apply red paint.
(H): End surface of the pump
(1)Fix the speed control lever at the full position
(2)Set the speed to N1 r/min.
(If the boost compensator is provided, apply boost pressure.)
(3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01.
(4)At that time, rack position must be Ra.
(5)Apply G at two places.
Connecting part between the joint (B) and the nut (F)
Connecting part between the joint (B) and the end surface of the pump (H)


Name SPEED SENSOR
L=0.8~1mm (A) Flyweight projection

(B) Pickup sensor
(c) Lock nut
Speed sensor installation
(1)Install the speed sensor so that the clearance between the sensor and the flyweight projection
is L.
(This gap is the gap when the pickup sensor is returned 1 turn from where it contacts the flyweig
ht tooth.)


ENGINE MODEL: PF6TC Date: 3 Jul 2002 5
No. 16801 96618
Injection pump: TC6HD Governor: EP/RED-III pre-stroke actuator:
108062-3182 105952-1140 159600-0420
1. Test conditions


+5
DIGI Switch No. 31(For C/U 407980-224*)
Stop Normal
20°±5°
R=20.0
R=1.0 37°±5°
3. RED-III governor
specified below.
Rack type 19 mm
Output voltage (V)

V1 = (V2+0.9±0.0075)
Output voltage
V2 = 2.2±0.01 V2
R2 = 11±1
Rack position (mm)
R2 - R1 = 6±0.05 R1 R2
Rack position (mm)
108622-0106 2/3
4. Injection timing
Pre-stroke: No.1 Plunger 6.4 ± 0.03mm Note: Perform at voltage V
Injection order: 1 4,1 2,1 6,1 3,1 5

60°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'
• Pre-stroke: h1 = 6.4±0.03 mm (when the timing sleeve is pushed up using the jig)
• Connector angle when tightening the eccentric pin: 8°30'±30'
• Power supply voltage: 24±0.5 V
• Ambient temperature: 23±5° C
• Adjustment and confirmation
Adjustment Confirmation Confirmation Confirmation

Pre-stroke (mm) 4.0±0.05 h1 = 6.4±0.03 Below 3.4 Operation
Sensor output (V) 2.45±0.01 V1 = 1.2±0.2 3 - 0.02 Above 3.05
Stamp aligning mark on housing
Pre-stroke actuator
108622-0106 3/3
Vist Injection q'ty
position speed 3 between Remarks
(mm) (cm / 1000 strokes )
At adjustment pre-stroke
(16.1) 1.43 600 192 ± 2 ±4 Basic 4.0±0.05(mm) (V=2.45±0.01(V))
(8.6) Approx.2.6 300 13.3 ± 1 ± 10 6.3±0.03(mm) (V=[V1+0.05]±0.01(V))
7. Timing setting
At No. 1 plunger’s beginning of injection position
°
ox.30
Appr

ENGINE MODEL: 6D40T1 Date: 3 Jul 2002 1
Company: MITSUBISHI
No. ME121502
108062-3192 105952-1480 159600-3420
1. Test conditions


+5
29°±5° R=1.0
R=16.0
19°±5°
Normal Stop
3. RED-III governor
specified below.
Rack type 15 mm
Output voltage (V)

V1 = (V2+1.2±0.01)
Output voltage
V2 = 1.8±0.01 V2
R2 = 11±1
Rack position (mm)
R2 - R1 = 6±0.05 R1 R2
Rack position (mm)
108622-2080 2/3
4. Injection timing
Injection order: 1 5,1 3,1 6,1 2,1 4

60°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'

Pre-stroke actuator
108622-2080 3/3
Vist Injection q'ty
position speed between Remarks
(mm) (cm3 / 1000 strokes )
(12.3) 1.53 650 155.5 ± 1 ±2 Basic 3.2±0.05(mm) (V=2.45±0.01(V))
(7.1) Approx.2.6 370 20 ± 2 ± 15 5.5±0.03(mm) (V=[V1+0.05]±0.01(V))
7. Drive side rack sensor adjustment (RED-III governor)
(1) With the injection pump stopped, set the REDIII governor’s Vist to the value shown in the table below.
(2) Adjust the bobbin 1 so that the drive side rack sensor's output voltage is VR±0.01, then fix using the
nut 3.
(3) Apply red paint to the joint 2 - nut 3 join and to the joint 2 - pump end face join.
Rack sensor supply voltage 5±0.01V VR Control unit part no.

Speed N 0r/min 407912-1742
2V
REDIII governor Vist 1.00V 105782-6320
3V 407910-6010
407910-7210
1 3 2
Pump end face
Apply red paint
8. Timing setting

Ap
pro
3° ±3° x. 4
4° Stamp an aligning mark on
the damper to align with the
Damper pointer groove.
Pointer

ENGINE MODEL: 6D40T1 Date: 3 Jul 2002 1
Company: MITSUBISHI
No. ME121502
108062-3192 105952-1480 159600-3421
1. Test conditions


+5
29°±5° R=1.0
R=16.0
19°±5°
Normal Stop
3. RED-III governor
specified below.
Rack type 15 mm
Output voltage (V)

V1 = (V2+1.2±0.01)
Output voltage
V2 = 1.8±0.01 V2
R2 = 11±1
Rack position (mm)
R2 - R1 = 6±0.05 R1 R2
Rack position (mm)
108622-2081 2/3
4. Injection timing
Injection order: 1 5,1 3,1 6,1 2,1 4

60°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'

Pre-stroke actuator
108622-2081 3/3
Vist Injection q'ty
position speed between Remarks
(mm) (cm3 / 1000 strokes )
(12.3) 1.53 650 155.5 ± 1 ±2 Basic 3.2±0.05(mm) (V=2.45±0.01(V))
(7.1) Approx.2.6 370 20 ± 2 ± 15 5.5±0.03(mm) (V=[V1+0.05]±0.01(V))
7. Drive side rack sensor adjustment (RED-III governor)
(1) With the injection pump stopped, set the REDIII governor’s Vist to the value shown in the table below.
(2) Adjust the bobbin 1 so that the drive side rack sensor's output voltage is VR±0.01, then fix using the
nut 3.
(3) Apply red paint to the joint 2 - nut 3 join and to the joint 2 - pump end face join.
Rack sensor supply voltage 5±0.01V VR Control unit part no.

Speed N 0r/min 407912-1742
2V
REDIII governor Vist 1.00V 105782-6320
3V 407910-6010
407910-7210
1 3 2
Pump end face
Apply red paint
8. Timing setting

Ap
pro
3° ±3° x. 4
4° Stamp an aligning mark on
the damper to align with the
Damper pointer groove.
Pointer
PV-No..............: 1 469 426 357
Test Specification Change.............: 4 22.07.2004
Robert Bosch
mecanically-governed Status
................: vorläufig
GmbH
Distributor pumps
Stuttgart Page ..............: 1 / 2
Kundendienstvorschrift Date of print......: 01.03.2005 08:44
pump..............................: 0 460 426 357 VE 6 / 12 F 1100 L 936

............................:
Customer Drawing A460907012 Engine ...............: NEF
Power..............: 85 kW
..............................:
Customer Iveco-Fiat ..............:
pist. swept vol. 5,9 l
.............................:
Customer Order no. 504047351 Application : Traktoren
test conditions
calibr. nozzle-and-holder assembly ...................: 1 688 901 027
test fuel-injection tubing
...........................................: a 6,00 x i 2,00 x 450 mm
...............................................:
calibrating oil ISONORM
calibration-oil inlet pressure
........................................: 35,00 ± 5,00 kPa
calibration oil.......................................:
Overflow temperature 55 ± 0,50 °C
opening pressure .........................: 25,0 ± 0,3 MPa
overflow restriction....................................: 0,75 mm
Test Index n Sollwert/ distribution DA-Sollwert/ LDA- ELAB TV KSB
point Tolerance Tolerance Pressure
1/min hPa V % V
overflow quantity at pump (l/h)

USMU 400 22,0 ± 8,0 12 0
USMO 1100 47,0 ± 10,0 12 0
supply pump pressure (MPa)
PKU 100 0,40 ± 0,09 12 12
PSU 400 0,55 ± 0,07 12 0
PSEP 900 0,70 ± 0,07 12 0
timing device travel (mm) N
SVKU 100 3,8 0,8 12 12
SVEP 900 1,2 ± 0,6 12 0
SVO 1100 2,6 ± 0,6 12 0
full-load start-quantity (mm³/H)
STAM 100 95,0 ± 15,0 12 0
STO 250 118,0 ± 10,0 12 0
full-load (mm³/H)
VU 400 115,5 ± 4,0 12 0
VEP 800 108,5 ± 3,0 3,5 12 0
VO 1100 92,0 ± 3,0 12 0
speed regulation breakaway (mm³/H)
AB1 1280 1,5 ± 1,5 12 0
idle (mm³/H)
LEP 430 10,0 ± 6,0 6,0 12 0
LK 500 1,5 ± 1,5 12 0
electric shut-off (mm³/H)
SPE1 430 1,5 ± 1,5 5,0 0 0
SPE2 430 1,5 ± 1,5 0 0
LFB-quantity (mm³/H)
DQ2 1100 -14,0 ± 6,0 12 0
Q4 1100 27,5 ± 0,5 12 0
Q3 1100 47,5 ± 0,5 12 0
LFB timing device travel (mm) N
DS2 1100 -0,6 ± 0,1 12 0
DS3 1100 -0,7 ± 0,5 12 0
S4 1100 3,4 ± 0,6 12 0
control lever spacing, -angle
Ya 38,9 ± 2,0 mm
Yb 43,0 ± 3,0 mm
Remarks:
Alle Rechte bei ROBERT BOSCH GmbH, auch für den Fall von Schutzrechtsanmeldungen.
Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
PV-No..............: 1 469 426 357
Test Specification Change.............: 4 22.07.2004
Robert Bosch
mecanically-governed Status
................: vorläufig
GmbH
Distributor pumps
Stuttgart Page ..............: 2 / 2
Kundendienstvorschrift Date of print......: 01.03.2005 08:44
Pumpe mit Kolben-KSB und Badewanne LFB, Pumpe mit EDC Ueberstroemventil.
SVKU Messreihenfolge : von obere Drehzahl auf "null" fahren, 15 secunden warten, KKSB ELAB spannen
und SVKU Weg messen. DS bei Teillastmenge Q3 messen.
Changes:
Nr. Change Date Dept. Name
4 Kundenwuensch-Leerlauf und Abregeldrehzahl 22.07.04 FeW/FAV2/P FeW/FAV2/P-Bk
Aenderung
3 Neue Serienreferenzpumpe Nr. 424 890 23.10.03 MICO/DVE MICO/DVE-Ak
2 Anpassung nach der FeW Statistik vom 07.11.02 11.11.02 MICO/DVE MICO/DVE-Ak
1 Einstellversuch - PSEP auf 7,0 bar 16.10.02 MICO/DVE MICO/DVE-Ak
0 Erstausgabe nach Ref.pp. LV 15330 - Nr. 191 509 21.08.02 MICO/DVE MICO/DVE-Ak
K = 3,7 +- 0,06 mm MS1 = 0,81 +- 0,1 mm Ausl. A = 1,10 +- 0,02 mm
Alle Rechte bei ROBERT BOSCH GmbH, auch für den Fall von Schutzrechtsanmeldungen.
Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

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1043-806

PIE 106 B-5

use test data

CONFIDE NTIAL Assy No.: 101401-7110

Nozzle: 105780-0000 Nozzle holder: 105780-2080

Injection pipe: outer dia. 6 mm × inner dia. 2 mm length 600 mm

Injection order: 1 3,1 4,1 2

Plungers are numbered from the Governor side (interval: ° ± 30').

A R1(11.9) 1310 64.5 ± 1 - Lever Basic

B R1 1600 (67.5) ± 2 - Lever

C R1-0.5 500 (44.7) ± 2 - Lever

E R1-0.05 960 (58.5) ± 2 - Lever

I Above 19.5 150 (80) + 16 - Lever

6. Timing advance specification

Advance Start Finish

BOSCH K.K. 3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572, JAPAN

Full load adjustment

Idling adjustment Confirm that the Vist=2.61±0.28 when R=R1-0.05 with

Pump speed (r/min)

Speed-control lever angle Stop lever angle

Stopper bolt H position Normal Stop

Timing device aligning mark position Pump perpendicular

Pump bracket check hole position

Align with bracket check hole projection at No 1 cylinder's beginning of injection

CONFIDE NTIAL Assy No.: 101401-7113

Nozzle: 105780-0000 Nozzle holder: 105780-2080

Injection pipe: outer dia. 6 mm × inner dia. 2 mm length 600 mm

Injection order: 1 3,1 4,1 2

Plungers are numbered from the Governor side (interval: ° ± 30').

A R1(11.9) 1310 64.5 ± 1 - Lever Basic

B R1 1600 (67.5) ± 2 - Lever

C R1-0.5 500 (44.7) ± 2 - Lever

E R1-0.05 960 (58.5) ± 2 - Lever

I Above 19.5 150 (80) + 16 - Lever

6. Timing advance specification

Advance Start Finish

BOSCH K.K. 3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572, JAPAN

Full load adjustment

Idling adjustment Confirm that the Vist=2.61±0.28 when R=R1-0.05 with

Pump speed (r/min)

Speed-control lever angle Stop lever angle

Stopper bolt H position Normal Stop

Timing device aligning mark position Pump perpendicular

Pump bracket check hole position

Align with bracket check hole projection at No 1 cylinder's beginning of injection

CONFIDENTIAL Ass'y No.: 101401-9133

Nozzle: 105780-0000 Nozzle Holder: 105780-2080

Injection pipe: Outer Dia. 6 mm × Inner Dia. 2 mm Length 600 mm

Injection order: 1 3,1 4,1 2

Plungers are numbered from the Drive side ( interval: ° ± 30' ).

H Approx. 9.5 325 9.7 ± 2 ± 14 Rack Cylinder variation adjustment standard

A R1(12.3) 800 68.5 ± 0.5 - Lever Basic

B R1+0.5 1500 (90.9) ± 2 - Lever

C R1+0.25 600 (62.4) ± 2 - Lever

I - 100 (170) - Lever

5. Timing advance specification

Pump speed (r/min)

Pump speed (r/min)

CONFIDENTIAL Ass'y No.: 101401-9143

Nozzle: 105780-0000 Nozzle Holder: 105780-2080

Injection pipe: Outer Dia. 6 mm × Inner Dia. 2 mm Length 600 mm

Injection order: 1 3,1 4,1 2

Plungers are numbered from the Drive side ( interval: ° ± 30' ).