Zexel Calibration Data

1043-806
1401-424
1401-725
101401-7452
on CD 2001/3
has incorrect
test injectors
use
PIE 106 B-5
1401-913
Pump assy 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
Assy No.: 101401-7110
CONFIDE NTIAL
ENGINE MODEL: 4HF1
Date:
16 Mar 2004
Company: ISUZU
No.
897122-6171
Timing device: EP/SCDM
105676-5120
Governor: EP/RLD-F
105932-1350
Injection pump: PES4A

101041-8260
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
(Bosch type no. DN12SD12T)
Nozzle holder: 105780-2080

(Bosch type no. EF8511/9)
Nozzle opening pressure: 17.2 MPa {175 kgf/cm2}
Transfer pump pressure: 157 kPa {1.6
mm inner dia. 2 mm
Injection pipe: outer dia. 6
kgf/cm2}
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
Injection order:
3,1
90 30'
4,1
180 30'
Note: Adjust with rack position of R=R1-0.05
mm
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
position
(mm)
Pump
speed
(r/min)
Injection quantity
(cm3/1000 strokes)
Max. variation
between
cylinders (%)
Fixed
Remarks
11.9
1310
64.5 1.6
Rack
Basic Cylinder variation adjustment standard
Approx 9.8
285
15.5 1.3
10
Rack
Cylinder variation adjustment standard
R1(11.9)
1310
64.5 1
Lever
R1
1600
(67.5) 2
Lever
R1-0.5
500
(44.7) 2
Lever
R1-0.05
960
(58.5) 2
Lever
Above 19.5
150
Lever
Adjusting
point
(80) + 16
Basic
6. Timing advance specification

Pump speed
(r/min)
Advance
angle ( )
(Measure)
(Measure)
Start
Finish
5.00.5
BOSCH K.K.
Sales Automotive Aftermarket Division
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572, JAPAN

Tel. 81-48-475-2521
Fax. 81-48-475-2520
101401-7110 2/4
3. Governor adjustment
Full load adjustment
Torque cam no. L31
Rack position (mm)
Above 19.5
I
A B
R1+0.05
R1(11.9)
R1-0.05
R1-0.35
R1-0.5
10.10.12
+1.29
8.1 -1.37
Below 225
(400)
(630)
960 (1050) (1250)
(360)
(1150) (1650)
1845
1925
Pump speed (r/min)
Idling adjustment
Confirm that the Vist=2.610.28 when R=R1-0.05 with

rack sensor output value at 50.01V and N=960.
11.5
Rack position (mm)
+0.20
11.0 -0.22
Approx 9.8
9.5
8.00.09
HJ
+0.25
6.0 -0.27
275 350
180 285 470
1100
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 9.20.1 mm and the pump speed is N = 440
r/min.
Specified torque: 1.2 ~ 1.6 Nm {0.12 ~ 0.16 kgfm}
(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
34
Idling
41
Stop
Normal
15 5
(Mea
sure)
Np=1600, R=5.5-0.5
Stopper bolt setting
Full-speed
Timing setting
At No. 1 plungers beginning
of injection position
B.T.D.C.: 7
Pump perpendicular
Timing device aligning mark position

(When aligned with bracket aligning mark at B.T.D.C. 13)
Pump bracket standard
mark position
A/T's outer slit
(35)
'
20
''
Position of gear's 3 notch at No.1

cylinder's beginning of injection
Pump bracket aligning

mark position
Engine
perpendicular
8
6'3
3
26
Center of threaded hole
10
03
'56
''3
0')
3
7
(1
20
5
(9
(5
4
4'1
8
'')
A/T's timing device stamping position
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.
1/4
Assy No.: 101401-7113
CONFIDE NTIAL
ENGINE MODEL: 4HF1
Date:
29 Jan 2004
Company: ISUZU
No.
897146-7880
105676-5121
Governor: EP/RLD-F
105932-1352

101041-8510
1. Test conditions

Nozzle: 105780-0000

mm inner dia. 2 mm
kgf/cm2}
length 600 mm
+5
Overflow valve opening pressure: 127 20 kPa {1.3 0.2
kgf/cm2}
2. Injection timing
Injection order:
3,1
90 30'
4,1
180 30'
Note: Adjust with rack position of R=R1-0.05
mm
270 30'
30').
Rack
position
(mm)
Pump
speed
(r/min)
Injection quantity
(cm3/1000 strokes)
Max. variation
between
cylinders (%)
Fixed
Remarks
11.9
1310
64.5 1.6
Rack
Approx 9.8
285
15.5 1.3
10
Rack
R1(11.9)
1310
64.5 1
Lever
R1
1600
(67.5) 2
Lever
R1-0.5
500
(44.7) 2
Lever
R1-0.05
960
(58.5) 2
Lever
Above 19.5
150
Lever
Adjusting
point
(80) + 16
Basic

Pump speed
(r/min)
Advance
angle ( )
(Measure)
(Measure)
Start
Finish
5.00.5
BOSCH K.K.

Tel. 81-48-475-2521
Fax. 81-48-475-2520
101401-7113 2/4
Torque cam no. L31
Rack position (mm)
Above 19.5
I
A B
R1+0.05
R1(11.9)
R1-0.05
R1-0.35
R1-0.5
10.10.12
+1.29
8.1 -1.37
Below 225
(400)
(630)
960 (1050) (1250)
(360)
(1150) (1650)
1845
1925
Pump speed (r/min)
Idling adjustment
Confirm that the Vist=2.610.28 when R=R1-0.05 with

rack sensor output value at 50.01V and N=960.
11.5
Rack position (mm)
+0.20
11.0 -0.22
Approx 9.8
9.5
8.00.09
HJ
+0.25
6.0 -0.27
275 350
180 285 470
1100
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 9.20.1 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
Stop lever angle
34
Idling
41
Stop
Normal
15 5
(Mea
sure)
Np=1600, R=5.5-0.5
Full-speed
Timing setting
B.T.D.C.: 7
Pump perpendicular
Timing device aligning mark position

(When aligned with bracket aligning mark at B.T.D.C. 13)
Pump bracket standard
mark position
A/T's outer slit

''
Position of gear's 3 notch at No.1

cylinder's beginning of injection
Pump bracket aligning

mark position
Engine
perpendicular
(35)
'
20
6
2'2
''
9'42
22
0
26
0')
20
92
9
'44
'
'3
(17
5
(9
(5
4
4'1
8
'')
A/T's timing device stamping position
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.
1/3
Ass'y No.: 101401-9133
CONFIDENTIAL
ENGINE MODEL: TM
Date:
21 Aug 2002
Company: MAZDA
No.
TM0113800C
105671-0241
Governor: EP/RLD-E
105921-5852

101040-9871
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
(Bosch Type No. DN12SD12T)
Nozzle Holder: 105780-2080

(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
Injection order:
3,1
90 30'
4,1
180 30'
Note: Adjust with rack position of
mm
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.
Rack
position
(mm)
Pump
speed
(r/min)
Injection q'ty
(cm / 1000 strokes )
12.3
800
68.5 0.5
2.5
Rack
Approx. 9.5
325
9.7 2
14
Rack
R1(12.3)
800
68.5 0.5
Lever
R1+0.5
1500
(90.9) 2
Lever
R1+0.25
600
(62.4) 2
Lever
100
(170)
Lever
Adjusting
point
Max. variation
between
cylinders (%)
Fixed
Remarks
Basic

Basic

Pump speed
(r/min)
920
1200
Advance
angle ( )
Bellow. 0.5
1.5 0.5
1500
Finish
5.5 0.5
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
101401-9133 2/3
Torque cam no. G96
Rack position (mm)
R1+0.55
R1+0.5
R1+0.25
R1(12.3)
R1-0.05
B
C
+0.07
12.3 -0.05
+0.72
8.5 -0.76
Below 250
600 (650) (880) (1060)
(450)
(850)
(1280)
Pump speed (r/min)
Idling adjustment
11.5
+0.49
Rack position (mm)
11.0 -0.73
Approx 9.5
9.5
8.00.07
+0.38
5.0 -0.42
200
400
325
610
Pump speed (r/min)
1420
(1550)
1840
1600
1/4
Ass'y No.: 101401-9143
CONFIDENTIAL
ENGINE MODEL: TF
Date:
12 May 2003
Company: MAZDA
No.
TF2013800C
105671-0081
Governor: EP/RLD-E
105921-5960

101040-9881
1. Test conditions

Nozzle: 105780-0000

Length 600 mm
+5
Oil Temp. 40 C
Overflow valve opening pressure: 255 34 kPa { 2.6 0.35 kgf/cm2 }
2. Injection timing
Injection order:
3,1
90 30'
4,1
180 30'
mm
270 30'
side ( interval:
30' ).
Rack
position
(mm)
Pump
speed
(r/min)
Injection q'ty
12.8
1000
70.5 0.5
2.5
Rack
Approx 9.5
325
92
10
Rack
R1(12.8)
1000
70.5 0.5
Lever
R1+0.5
1625
(84.1) 2
Lever
R1-0.5
625
(49.6) 2
Lever
100
Lever
Adjusting
point
Max. variation
between
cylinders (%)
Above 160
Fixed
Remarks
Basic

Basic

Pump speed
(r/min)
Advance
angle ( )
700
Bellow 0.3
1300
2 + 0.5
1600-25
Finish
5-0.5

Service Department

Tel. (048)470-1559, Fax. (048)474-9856
101401-9143 2/4
Torque cam no. D71
Rack position (mm)
R1+0.5
R1+0.1
R1(12.8)
R1-0.15
R1-0.5
8.3-0.4
Below 250
(480)
(300)
(770)
900
(1080)
(960)
(1670)
(1500)
Pump speed (r/min)
Rack position (mm)
Idling adjustment
11.5
11.00.08
Approx 9.5
9.50.02
+0.05
8.5 -0.06
HJ
+0.38
5.5 -0.42
220 400 520

325
Pump speed (r/min)
1350
2000
101401-9143 3/4
Stop lever angle
Idling
Full-speed
Stop
Normal
20
14 5
413
(29.5)5
Stop adjuster screw setting
Timing setting
B.T.D.C.: 9
30
15
Gear
21
9
2
0'
30
'
Engine (bracket)
perpendicular
Bracket's basic hole

( 6) position
Pump
bracket
Standard measuring position

The standard measuring position is the center of the
gear tooth marked 'CC' and is 30 mm from the bracket
end face.
30
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 = 4.70.3 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
5
Camshaft center line
Speed lever pulled in this direction

Stop lever pulled in this direction
Stop adjuster screw

Stop lever
1/4
Assy No.: 101401-9460
CONFIDENTIAL
ENGINE MODEL: FD46T
Date:
23 Mar 2006
Company: NISSAN DIESEL
No.
16700 17D00
105671-0450
Governor: EP/RLD-F
105921-7980
Injection pump: PES4AD

101041-9070
1. Test conditions
Pump rotation: clockwise (viewed from drive side)

Nozzle: 105780-0000

mm inner dia. 2 mm
kgf/cm2}
length 600 mm
+5
Overflow valve opening pressure: 255 34 kPa {2.6 0.35 kgf/cm2}
2. Injection timing
Injection order:
3,1
90 30'
Note: Adjust with rack position of R=R1 (11.8) mm
4,1
180 30'
270 30'
side (interval:
30').
Rack
position
(mm)
Pump
speed
(r/min)
Injection quantity
(cm3/1000 strokes)
11.8
900
83.5 1.6
3.5
Rack
Approx 9.5
300
12 1.8
10
Rack
R1(11.8)
900
83.5 1
Lever
R1+1.05
1550
(106) 2
Lever
Boost press. kPa {mmHg}

Above 71.3 {Above 535}
R2-0.8
500
(45.2) 2
Lever
Boost press. 0
Above 18.5
100
(100) 10
Lever
Boost press. 0
Adjusting
point
Max. variation
between
cylinders (%)
Fixed
Remarks
Basic
Basic

Pump speed
(r/min)
Advance
angle ( )
Below 900
Start
0
850
1500
Below 0.5
Finish
5.00.3
Bosch Corporation
Automotive Aftermarket Division

Tel. 81-48-475-2521
Fax. 81-48-475-2520
101401-9460 2/4
Torque cam no. K81
Rack position (mm)
Above 18.5
Boost compensator stroke: 0.80.1
R1+1.05
12.00.15
R1+0.15
R1(11.8)
R2[R1-0.25]
R1-0.3
A
C
9.3 +1.58
-1.68
(750)
(580)
Below 250
(630)
(1030)
(850)
(1500)
1720
(1600) 1825
1100
Pump speed (r/min)
Rack position (mm)
Boost compensator adjustment
Idling adjustment
N = 500
R2[R1-0.25]
R2-0.8
0
11.5
Rack position (mm)
11.0 +0.49
-0.25
9.5
Approx 9.5
7.50.07
18.71.3 {14010}
Boost pressure kPa {mmHg}
J
H
5.8 +0.36
-0.41
Approx 58.0 {Approx 435}
225 310
470
300 330
Pump speed (r/min)
1000
101401-9460 3/4
5. Potentiometer adjustment
(1) Supply DC 5.00.2V 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 2.840.3 V
Bolts A
Potentiometer
1
2
3
Specified output voltage
Output voltage
Potentiometer connections
Voltage (V)
5.00.02 V
(5.0)
(3.83)0.2
0.50.3
0
Idle
Full
Direction of potentiometer rotation
101401-9460 4/4
70
(40) 3
ing
Idl
Full
-spe
ed
Stop lever angle
295
105
Normal
Stop
Timing setting
B.T.D.C.: 8
Approx. 50

(Gear mark position)
For 101402-4880 use:
1/3
Ass'y No.: 101402-9460
CONFIDENTIAL
ENGINE MODEL: S4K-T
Date:
24 Jul 2002
Company: MITSUBISHI
No.
34261-02080
Timing device:
Governor: EP/RSV
105419-1011

101041-8040
1. Test conditions

Nozzle: 105780-0000

Length 600 mm
+5
Oil Temp. 40 C
2. Injection timing
Injection order:
3,1
90 30'
4,1
180 30'
mm
270 30'
side ( interval:
30' ).
Adjusting
point
Rack
position
(mm)
Pump
speed
(r/min)
9.3
950
Approx. 5.9
400
100
Injection q'ty
3
Max. variation
between
cylinders (%)
84.7 1
8 1.3
60 + 5
Fixed
2.5
Lever
14
Rack
Lever
Remarks
Basic
Adjust max. var. bet. cyl. of R 5.9.
Adjust governor as per gov. adj. spec.
Rack limit

Pump speed
(r/min)
Advance
angle ( )
Service Department

Tel. (048)470-1559, Fax. (048)474-9856
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
Rack position (mm)
Main spring setting
9.3
8.80.1
8.6
5.6
3.90.4
325 375
(955) 1040
960
Pump speed (r/min)
101402-9460 3/3
(1)5
3
35
Idling
(22)
Full-speed
Stop
Stop lever angle
Stop
Normal
26.55
.9
rox
p
Ap
Contacts stop side boss
535
Timing setting
Approx. 60
Camshaft key groove position
1/3
Ass'y No.: 101402-9810
CONFIDENTIAL
ENGINE MODEL: S4K
Date:
Company:
No.
Timing device:
Governor: EP/RSV
105419-3440

101041-8040
1. Test conditions
11 Jun 2002
MITSUBISHI
I
34261-04050

Nozzle: 105780-0000

Length 600 mm
+5
Oil Temp. 40 C
2. Injection timing
Injection order:
3,1
90 30'
4,1
180 30'
mm
270 30'
side ( interval:
30' ).
Adjusting
point
Rack
position
(mm)
Pump
speed
(r/min)
Injection q'ty
8.2
1000
56 1
2.5
Lever
Approx.6.9
425
12 1.3
1.4
Rack
100
70 + 10
Lever
Max. variation
between
cylinders (%)
Fixed
Remarks
Basic
Rack limit

Pump speed
(r/min)
Advance
angle ( )
Service Department

Tel. (048)470-1559, Fax. (048)474-9856
101402-9810 2/3

Rack limit
Difference in control rack

position between 1000 r/min
and 250 r/min
D
8.6
8.2
1.00.1
Rack position (mm)
Above 14
7.70.1
6.0
Idle sub-spring setting:
4.5-0.5 mm
4.50.4
(300) 425
(1015) 1100
400 (450)
Pump speed (r/min)
1025
101402-9810 3/3
Full-speed
17 5
8 5
Idling
Stop lever angle

Contacts inner boss
535
x.11
Contacts outer boss Appro
26.5 5
Stop
Normal
Timing setting
Appr
ox.60
1/3
Ass'y No.: 101402-9880
CONFIDENTIAL
ENGINE MODEL:S4K-T
Date:
11 Jun 2002
MITSUBISHI
Company:
No.
34261-04060
Timing device:
Governor: EP/RSV
105419-3450

101041-8040
1. Test conditions

Nozzle: 105780-0000

Length 600 mm
+5
Oil Temp. 40 C
2. Injection timing
Injection order:
3,1
90 30'
4,1
180 30'
mm
270 30'
side ( interval:
30' ).
Adjusting
point
Rack
position
(mm)
Pump
speed
(r/min)
8.9
1000
Approx.6.8
425
100
Injection q'ty
3
Max. variation
between
cylinders (%)
72.5 1
Fixed
2.5
Rack
12 1.3
14
Rack
60 + 10
Lever
Remarks
Basic
Rack limit

Pump speed
(r/min)
Advance
angle ( )
Service Department

Tel. (048)470-1559, Fax. (048)474-9856
101402-9880 2/3
Above 14
0.40.1
Rack limit
Rack position (mm)
D
8.9
8.5
8.30.1
6.0
A
(1100)
Idle sub-spring setting:
4.10.4
Difference in control rack

and 700 r/min
4.1-0.5 mm
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
535
x.11
Contacts outer boss Appro
26.5 5
Stop
Normal
Timing setting
Appro
x.60
1/2
Assy No.: 101432-9030
CONFIDENTIAL
ENGINE MODEL: 5113
Date:
20 Mar 2006
Company: DAIHATSU DIESEL
No.
22100-87302
Timing device:
Governor: EP/MZ
105520-6780

101043-8140
1. Test conditions

Nozzle & nozzle holder assy:
(Bosch type no.
Nozzle: 105000-1010
(Bosch type no. DN0SD21)
Nozzle opening pressure: 9.8

(Bosch type no.
MPa {100 kgf/cm2}
mm inner dia. 2 mm
)
)
kgf/cm2}
length 600 mm
+5
2. Injection timing
Injection order:
3,1
90 30'
4,1
180 30'
mm
270 30'
side (interval:
30').
Adjusting
point
Rack
position
(mm)
Pump
speed
(r/min)
13.0
1800
50 1.7
3.4
Rack
13.0
1000
47 1.2
2.5
Rack
9.0
1000
(24 1.2)
Rack
Approx 7
300
(8 0.2)
15
Rack
Injection quantity
(cm3/1000 strokes)
Max. variation
between
cylinders (%)
Fixed
Remarks
Basic

Pump speed
(r/min)
Advance
angle ( )
Bosch Corporation

Tel. 81-48-475-2521
Fax. 81-48-475-2520
101432-9030 2/2
Pneumatic governor
Operate injection pump at 500 r/min and increase negative pressure gradually from lower pressure.
Rack position (mm)
13
3.430.1
{35015}
7.260.3
{74030}
4.310.2
{44020}
Negative pressure kPa {mmAq}
1/3
Ass'y No.: 101441-9990
CONFIDENTIAL
ENGINE MODEL: DC24T
Date:
7 Feb 2003
Company: DAEWOO HEAVY
No.
Timing device: EP/SCD
105621-0500
Governor: EP/RSV
105419-4360

101044-9170
1. Test conditions
Pump rotation: counter clockwise ( viewed from drive side )

Nozzle: 105780-0000

Length 600 mm
+5
Oil Temp. 40 C
2. Injection timing
Injection order:
3,1
90 30'
4,1
180 30'
mm
270 30'
side ( interval:
30' ).
Adjusting
point
Rack
position
(mm)
Pump
speed
(r/min)
9.9
1300
Approx. 6.0
500
100
Injection q'ty
3
Max. variation
between
cylinders (%)
42.2 1
8 1.1
65 5
Fixed
2.5
Lever
14
Rack
Lever
Remarks
Basic
Rack limit

Pump speed
(r/min)
Below
Advance
angle ( )
Start
750
700
1300
Below 0.5
1.6 0.5

Service Department
(Measure))
Finish
(6.0)
Tel. (048)470-1559, Fax. (048)474-9856
101441-9990 2/3
20.0+1.0
Rack limit
E
10.3
9.9
9.40.1
9.0
6.0
5.5
4.70.4
A
0.650.1
Rack position (mm)
Main spring setting
360 500
(970) (1170)
1330
(1315)
1050
Pump speed (r/min)
D i f fe r e n c e i n c o n t r o l r a ck
and 500 r/min
1440
101441-9990 3/3
Full-speed
Idling
17
215
53 5
19 5
Stop lever angle
Norm
al
St
op
Timing setting
B.T.D.C.: 13
Gear mark "z"
Approx. 60
INJ.PUMP CALIBRATION DATA
1/3
Ass'y No.: 101495-3426
CONFIDENTIAL
7 Feb 2002
Date:
Company: KOMATSU
6205-71-1151
No.
ENGINE MODEL S4D95L E-2
Injection pump PES4A

101049-4040
Test condition
Governor EP/RSV
105400-8942
Timing device
Pump rotation Clockwise (viewed from drive side)

Nozzle Nozzle Holder Ass'y 105780-8140
(Bosch Type No.EF8511/9A)
Nozzle105780-0000
(Bosch Type No.DN12SD12T)
MPa 175 kgf/cm2Transfer pump pressure 157 kPa 1.6
Nozzle opening pressure 17.2

Injection pipe Outer Dia.6
Nozzle Holder105780-2080
(Bosch Type No.EF8511/9)
mm Inner Dia.2
mm Length 600 mm
+5
Oil Temp.40
Test OilISO4113 or SAE Standard Test OilSAE J967d

Overflow valve opening pressure
kPa
kgf/cm2
kgf/cm2
Injection timing
Pre-strokeNo.1 Plunger
Injection order 1
3.2 0.05mm NoteAfter adjustment with rack position of A (11.3) mm
2 ,1 4 ,1 3
90
30
180 30 270 30
side. ( interval:
Tappet clearanceBolt adjustment type More than 0.3mm for all cylinders.
Shim adjustment typeManual rotate the camshaft 2 3 times and confirm that it rotates smoothly.
Injection quantity
Adjusting point
Rack
position
(mm)
11.3
9.3 0.5
Pump
speed
(r/ min)
Injection q' ty
( cm3 / 1000 strokes)
Max. var
bet. cyl
()
Fixed
91.51
2.5
Lever
900
400
24 1
15
Rack
Remarks
Basic
Adjust max. var. bet. cyl. at R9.3.2.5
Timing Advance specification

Pump speed
r/min
Advance
angle
Service Department

Tel. (048)470-1559, Fax. (048)474-9856
101495-3426 2/3
. Governor adjustment
Recommended speed droop adjustment screw position : 8
Rack position ( mm )
Approx.17.5
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
1/3
Ass'y No.: 101495-3470
CONFIDENTIAL
ENGINE MODEL: 4D95L
Date:
7 Feb 2003
Company: KOMATSU
No.
6204-71-1151
Timing device:
Governor: EP/RSV
105400-9151

101049-4070
1. Test conditions

Nozzle: 105780-0000

Length 600 mm
+5
kgf/cm2 }
kPa {
Overflow valve opening pressure:
Oil Temp. 40 C
2. Injection timing
Injection order:
2,1
90 30'
4,1
180 30'
Note: Adjust with rack position of after injection q'ty adjustment at A
270 30'
side ( interval:
30' ).
Adjusting
point
Rack
position
(mm)
Pump
speed
(r/min)
10.2
900
70.5 1
2.5
Lever
8.40.5
400
12 1
15
Rack
Injection q'ty
3
Max. variation
between
cylinders (%)
Fixed
Remarks
Basic
Adjust max. var. bet. cyl. of R=8.40.5

Pump speed
(r/min)
Advance
angle ( )
Service Department

Tel. (048)470-1559, Fax. (048)474-9856
101495-3470 2/3
Rack cap
20.0+1.0
Torque control spring set force: 0N {0kg}
Rack position (mm)
12.10.1
510
10.2
9.70.1
9.70.1
6.9
6.40.2
4.50.1
(750) (910) 941

400
(600)
760 915
970
Pump speed (r/min)
Stop lever angle

Without return spring
N=915
setting position at delivery
R=1.0-0.5, N=0
(Seal at delivery)
23 5
6 5
N=760 set
2 5

Full-speed
Idling
Approx.55
27.5
Stop
Normal
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
1/3
Assy No.: 101603-2361
C ONF I DENT I A L
ENGINE MODEL: J-2
T EMPOR ARI LY
Date:
29 Jun 2007
Company: HINO
No.
22000-9591A
Timing device: EP/SPG
105680-5010
Governor: EP/RLD-F
105932-2171
Injection pump: PE6MD

101060-6170
1. Test conditions

(Bosch type no.
Nozzle: 105025-0360
(Bosch type no.
)
Nozzle opening pressure: 1st 16.7 MPa { 170 kgf/cm2 }
2nd 21.6MPa { 220 kgf/cm2 }

(Bosch type no.
kgf/cm2}
length 600 mm
mm inner dia. 2 mm
+5
2. Injection timing
Injection order: 1
4,1
60 15'
2,1
120 15'
6,1
180 15'
3,1
240 15'
mm
300 15'
30').
Rack
position
(mm)
Pump
speed
(r/min)
Injection quantity
(cm3/1000 strokes)
12.5
850
91 2
Approx 9.5
275
R1(12.5)
850
[R1+0.8] -0.05
Adjusting
point
Max. variation
between
cylinders (%)
Fixed
3.5
Rack
Rack
91 1
Lever
1450
(92) 2
Lever
R1+0.45
1160
(94.5) 2
Lever
100
160 + 10
Lever
(R1-0.85)
580
(77)
Lever
R1-1.05
435
Lever
+0.1
Each cylinder 131
(70.5) 2
Remarks
Basic

Basic
Rack limit

Pump speed
(r/min)
Advance
angle ( )
(Measure)
Start
0
(Measure)
1.25 0.3
1255 - 50
1.25 0.3
1420 - 50
Finish
5.50.3
BOSCH K.K.

Tel. 81-48-475-2521
Fax. 81-48-475-2520
101603-2363 2/3
Torque cam no. M01

RACK LIMIT
Rack position (mm)
I
[R1+0.8] +0.1
-0.05
R1+0.45
R1+0.15
R1(12.5)
12.00.15
R1-0.9
R1-1.05
A
F
8.7 +1.75
-1.87
Below 225 (380)
850 (1000)
(350) (510) (890)
(1100)
Pump speed (r/min)
Rack position (mm)
Idling adjustment
11.5
+0.30
11.0 -0.31
Approx 9.5
9.5
H J
7.80.08
4.0 +0.38
-0.42
195 350 520

275
1160
Pump speed (r/min)
(1250) (1500) 1650

(1400) 1550
101603-2363 3/3
6 5
40
Idling
Full-speed
Stop lever angle

Normal
R=17.80.2
(Speed lever: full, N=100)
Free
0 5
)
(4
33
Stopper screw setting
Stop
(Apply red paint after setting)
Timing setting
Approx
.20 Coupling key groove position
101603-8900
ZEXEL Ass'y No.

Bosch Ass'y No.
Bosch Typecode
Engine Type
Manufacturer
Edition date
P
P
P
P
P
P
Page 1
101603-8900
9 400 610 684
6BG1-T
ISUZU
31/05/06 (1)
1 Adjustment conditions
CAT Designation
Test oil
P
12/11/08 13:19:56
ZEXEL test values diesel fuel-injection equipment
Test Oil Temperature

Nozzle and nozzle holder
Bosch type code
Nozzle
Bosch type code
Nozzle holder
Bosch type code
Opening Pressure
Opening Pressure
Injection pipe
Overflow valve
Tester oil delivery pressure
Direction of rotation (viewed from drive side)
2 Adjustment specification
2.1 Injection timing adjustment
CAT Designation
P
Unit
Set value
min.
ISO4113 or {SAEJ96
7d}
1404 Test oil

degC
max.
40
40
105780-8140
EF8511/9A
105780-0000
DN12SD12T
105780-2080
EF8511/9
MPa
17.2
kgf/cm2
175
mm
6-2-600
Outer diameter - inner diameter - length (mm)
131424-4920
kPa
127
107
kgf/cm2
1.3
1.1
kPa
157
157
kgf/cm2
1.6
1.6
R
Right
45
Unit
min.
max.
1-5-3-6-2-4
3.6
NO.1
3.55
3.65
60
59.5
60.5
120
119.5
120.5
180
179.5
180.5
240
239.5
240.5
300
299.5
300.5
Set value
A
10.9
1100
98.5
0
*
*
66.7
500
Set value
C
6.4+-0.5
415
9
0
*
0
0
Set value
E
100
110
min.
max.
1100
97
-2.5
1100
100
2.5
66.7
500
min.
max.
415
7.7
-14
415
10.3
14
0
0
min.
0
0
max.
100
105
100
115
Set value
R
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
147
1.5
157
1.6
Right
P
S
P
Injection order
Pre-stroke
Beginning of injection position
Difference between angles 1
2.2 Injection quantity adjustment

CAT Designation
P
Adjusting point
P
Rack position
P
Pump speed
S
Average injection quantity
S
Max variation between cylinders
P
Basic
P
Fixing the lever
P
Boost pressure
P
Boost pressure
CAT Designation
P
Adjusting point
P
Rack position
P
Pump speed
S
S
P
Fixing the rack
P
Boost pressure
P
Boost pressure
CAT Designation
P
Adjusting point
P
Rack position
P
Pump speed
S
C = Check value)
OT = Outside Tolerance (X is set)
mm
Drive side
deg.
Cal 1-5
deg.
Cal 1-3
deg.
Cal 1-6
deg.
Cyl.1-2
deg.
Cal 1-4
Unit
r/min
mm3/st.
%
kPa
mmHg
Unit
r/min
mm3/st.
%
kPa
mmHg
Unit
r/min
mm3/st.
101603-8900
12/11/08 13:19:56
P
Fixing the lever
P
Boost pressure
P
Boost pressure
P
Rack limit
2.3 Governor adjustment
Name
K=9
BCL=1.1+-0.1mm
2.4 Boost compensator adjustment

CAT Designation
P
Pump speed
P
Rack position
S
Boost pressure
S
Boost pressure
CAT Designation
P
Pump speed
P
Rack position
S
Boost pressure
S
Boost pressure
2.5 Timer adjustment
CAT Designation
S
Pump speed
P
Advance angle
Remarks
CAT Designation
P
Pump speed
S
Advance angle
kPa
mmHg
*
0
0
*
0
0
0
0
min.
500
max.
500
10.6
80
min.
500
16
120
max.
500
kPa
mmHg
Set value
500
R1-1.1
13.3
100
Set value
500
R1(10.9)
53.3
400
46.6
350
60
450
Unit
r/min
deg.
Set value
1300++
0
min.
max.
N:Pump speed
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
Unit
r/min
kPa
mmHg
Unit
r/min
Do not advance until starting N = 1300.

Unit
Set value
min.
r/min
deg.
5.5
5.5
About
Remarks
C = Check value)
Page 2
Measure the actual speed, stop
max.
5.5
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
101603-8900
12/11/08 13:19:56
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
bb=1-0.5mm
N:Pump normal
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
C = Check value)
(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)-
Page 3
Test Data
101603-8970
use
101603-8900
1/4
Ass'y No.: 101605-0100
CONFIDENTIAL
ENGINE MODEL: 6BG1-T
Date:
17 Jul 2002
Company: ISUZU
No.
115603-3960
Timing device:
Governor: EP/RSV
105411-2300

101062-8410
1. Test conditions

Nozzle: 105780-0000

Length 600 mm
+5
Oil Temp. 40 C
2. Injection timing
Injection order:
5,1
60 30'
3,1
120 30'
6,1
180 30'
2,1
240 30'
mm
300 30'
side ( interval:
30' ).
Adjusting
point
Rack
position
(mm)
Pump
speed
(r/min)
11.0
1075
110.5 1.5
7.70.5
450
12 1.3
Injection q'ty
3
Max. variation
between
cylinders (%)
Fixed
Lever
14
Rack
Remarks
Basic

Above 105 {Above 790}
Boost press. 0
Adjust max. var. bet. cyl. of R = 7.70.5
Above. 11.2
100
105 5
Lever
Rack limit Boost press. 0

Pump speed
(r/min)
Advance
angle ( )
Service Department

Tel. (048)470-1559, Fax. (048)474-9856
101605-0100 2/4
Recommended speed droop adjustment screw position : 16
Rack limit
Main spring setting
Above 14.0
10.50.1
11.2
11.0
A
10.85
10.0
10.20.1
8.2
8.10.3
7.3
245 340 (470)

450
(680) 900 (1140) 1220

(940)
1155
Pump speed (r/min)

Rack position (mm)
Rack position (mm)
N = 500
R2(10.0)
R2-0.3
0
(92.0)6.7 {(690)50}
53.34.0 {40030}
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 Nm {0.25 kgfm}
After adjusting the governor and the boost compensator, tighten the
screws to remove the heads.
Tightening torque T = 2.9 ~ 4.4 Nm {0.30 ~ 0.45 kgfm}
101605-0100 4/4
Idling
Full-speed
(3)
5
(20) 5
Stop lever angle
Stop
Normal
50
N=0, R=1.0-0.5
5
Appro
x.55
Timing setting
B.T.D.C.: 9
Approx. 100
Gear mark CC
Test Data
101606-0180
use
101603-8900
1/3
Assy No.: 101606-1741
C ONF I DENT I A L
ENGINE MODEL: 6D16T
Date:
10 May 2005
Company: MITSUBISHI
No.
ME076211
Timing device: EP/SA-D
105643-0460
Governor: EP/RLD
105931-5401

101061-8050
1. Test conditions

Nozzle: 105780-0000


length 600 mm
mm inner dia. 2 mm
kgf/cm2}
+5
2. Injection timing
Injection order: 1
6,1
5,1
60 30'
3,1
120 30'
180 30'
2,1
240 30'
mm
300 30'
30').
Rack
position
(mm)
Pump
speed
(r/min)
Injection quantity
(cm3/1000 strokes)
13.0
700
Each cylinder 96.82.9
Rack
Approx 9.5
275
Rack
R1(13.0)
700
96.8 1
Lever
R1-0.35
1400
(100.3) 2
Lever

R2-0.6
300
(66.9) 2
Lever
Boost press. 0
R2
(R1+0.25)
500
(96.5) 2
Lever

100
Lever
Adjusting
point
Max. variation
between
cylinders (%)
95 20
Fixed
Remarks
Basic

Basic
Rack limit

Pump speed
(r/min)
1150
1250
Advance
angle ( )
Below 0.5
1.7 0.5
1350
Finish
3.50.5
BOSCH K.K.

Tel. 81-48-475-2521
Fax. 81-48-475-2520
101606-1741 2/3
Torque cam no. D24
Rack limit
Rack position (mm)
Boost compensator stroke:

0.60.1
R1+0.25
R1(13.0)
R1-0.05
R1-0.15
R1-0.35
A
C
R1-0.85
8.7
Below 225 (600)
(750)
700
Microswitch adjustment
Adjust the bolt so that the microswitch
operates at a control lever position of R
= 9.2mm and a pump speed of N=4005
r/min.
(1050)
160050
(1480)
15005
(1300)
Rack position (mm)
11.5
10.8
Rack position (mm)
(1150)
Pump speed (r/min)
Idling adjustment
H J
Approx 9.5
9.5
6.2
(900)
N = 450
R2(R1+0.25)
R2-0.6
0
6.01.3 {4510}
4.4
(20.0) {(150)}
2005
65015
100070
275 350
Pump speed (r/min)
101606-1741 3/3
18.5
41
Full-speed

Idling
Stop lever angle
Normal
N=Fixed point, R=6.5-0.5
27
11.5
Confirm that injection does not

occur
After stopper bolt setting : N=275
Confirm that injection does not
occur : R=8.6-0.5
Non injection rack position
Stop
Timing setting
At No. 1 plungers beginning of
injection position
B.T.D.C.: 10
Timing device's tooth position
Approx.
1/4
Assy No.: 101607-6153
CONFIDENTIAL
ENGINE MODEL: 6D14
Date:
10 July 2006
Company: MITSUBISHI
No.
ME076986
Timing device: EP/SA
105643-0750
Governor: EP/RLD-E
105931-9422

101061-9500
1. Test conditions

Nozzle: 105780-0000


length 600 mm
mm inner dia. 2 mm
kgf/cm2}
+5
2. Injection timing
Injection order:
5,1
60 30'
3,1
120 30'
6,1
180 30'
2,1
240 30'
mm
300 30'
30').
Rack
position
(mm)
Pump
speed
(r/min)
Injection quantity
(cm3/1000 strokes)
11.2
850
Rack
approx 9.5
275
Rack
R1(11.2)
850
57.7 1
Lever
R1+0.1
1450
(72.6) 2
Lever
R1+0.8
500
(59.7) 2
Lever
R1+1.25
300
(57.1) 2
Lever
100
Lever
Adjusting
point
140 10
Max. variation
between
cylinders (%)
Fixed
Remarks
Basic
Basic
Rack limit

Pump speed
(r/min)
Advance
angle ( )
Below 1250
Start
0
1200
1400
Below 0.5
Finish
50.5
Bosch Corporation

Tel. 81-48-475-2521
Fax. 81-48-475-2520
101607-6153 2/4
Torque cam no. G81
Rack position (mm)
Rack limit
R1+1.25
R1+0.8
R1+0.1
R1(11.2)
B
A
10.70.09
+1.08
8.0 -1.02
Below 225
500
(750) (1000)
(1530) 1690
(1300)
(370)
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=10.70.1
Idling adjustment
11.5
+0.10
Rack position (mm)
10.4 -0.09
Approx 9.5
9.5
HJ
+0.12
5.0 -0.11
+0.32
2.5 -0.29
200 325
275
740
Pump speed (r/min)
1320
101607-6153 3/4
5. Load sensor adjustment
[1] Measurement circuit
2 (yellow)
(red)
Supply voltage: 3.570.02 V
Trimmer
1k
(yellow)
1 (black)
Output voltage
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.
18.55
Idlin
(39) 3
g
Accelerator lever position at delivery
Full speed
Base lever
Accelerator lever
A
Stop lever angle

R=(16.8)
5
36.
5
18.5
)
39
Idling
Full-speed
N=1550, R=7.0-0.5
)
(25
Confirm that injection
does not occur
After stopper bolt
175
setting N=275
Confirm that injection does
Stop
not occu R=(Measure)
Non injection rack position
Free
(At delivery)
Normal
Timing setting
B.T.D.C.: 13
Approx. 0 Timing device's tooth position
1/3
Assy No.: 101607-6390
CONFIDE NTIAL
ENGINE MODEL: 6D14T
Date:
25 May 2004
Company: MITSUBISHI
No.
ME046025
Timing device: EP/SA-D
105643-0450
Governor: EP/RFD-D
105490-5720

101061-9790
1. Test conditions

Nozzle: 105780-0000


length 600 mm
mm inner dia. 2 mm
kgf/cm2}
+5
2. Injection timing
Injection order:
5,1
60 30'
3,1
120 30'
6,1
180 30'
2,1
240 30'
mm
300 30'
30').
Adjusting
point
Rack
position
(mm)
Pump
speed
(r/min)
10.0
1400
10.0
800
Approx 7.8
340
(10.7)
100
Injection quantity
(cm3/1000 strokes)
Max. variation
between
cylinders (%)
88.9 1
(83.5)
9.2 1.5
(65)
Fixed
2.5
Lever
Lever
15
Rack
Lever
Remarks
Basic
After setting excessive fuel for starting

Pump speed
(r/min)
Advance
angle ( )
Below 1050
Start
0
1000
Below 0.5
1400
Finish
20.5
BOSCH K.K.

Tel. 81-48-475-2521
Fax. 81-48-475-2520
101607-6390 2/3
Excessive fuel setting for starting: 10.0+0.2 (N = 500)
Main spring setting
8.51.5
Idle sub spring setting
7.8
Damper spring setting
5.80.5
5.80.1
5.6
3.9
9+0.5
Rack position (mm)
(11.0)
10.50.1
10.5
(10.1)
10.0
250 280
480 495 (585) Above 1400 1535
340 (350) 400
1500 1540
Pump speed (r/min)
101607-6390 3/3
Load control lever angle

(Fix at full)
Full-speed
18 5
3 5
Idling
Full-load

165
Stop lever angle
57
R=4.5-0.5
(Apply red paint after adjustment)

B.T.D.C.: 14
57
Stop
Timing setting
+
-5 7
Normal
Approx. 1 Timing device's tooth position
101608-1486
ZEXEL Ass'y No.
07/05/03 11:17:29
Page 1
101608-1486
Bosch Ass'y No.

Bosch Typecode
Engine Type
Manufacturer
Edition date
27/09/00 (10)
CAT Designation
Unit
Test oil
Set value
min.
max.
40
45
Actual values
OT
Actual values
OT
Actual values
OT
ISO4113 or {SAEJ96
7d}
...
degC
40
1005780-8260
Bosch type code
9 430 610 133
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2190
Opening Pressure
MPa
18.0
Opening Pressure
kgf/cm2
184
Iinjection Pipe
mm
6-2-600

Overflow valve
131424-8420
kPa
255
255
255
kgf/cm2
2.6
2.6
2.6
kPa
255
255
255
kgf/cm2
2.6
2.6
2.6
min.
max.
3.15
3.25
60
59.5
60.5
120
119.5
120.5
180
179.5
180.5
240
239.5
240.5
300
299.5
300.5
Set value
min.
max.
L
Left
CAT Designation
P
Unit
Set value
L
Left
P
Injection order
Pre-stroke
1-5-3-6-2-4
mm
3.2
No.1
Governor side
S
deg.
Cyl 1-5
deg.
Cyl 1-3
deg.
Cyl 1-6
deg.
Cyl.1-2
deg.
Cyl 1-4

CAT Designation
P
Adjusting point
S = Setting value, C = Check value)

Unit
101608-1486
07/05/03 11:17:29
Rack position
Pump speed
r/min
700
700
700
Each cylinder's injection q'ty
mm3/st.
110
106.7
113.3
Basic
Fixing the rack
Standard for adjustment of the maximum var

iation between cylinders
*
min.
max.
CAT Designation
12.1
Unit
Set value
Adjusting point
Rack position
Pump speed
r/min
275
275
275
mm3/st.
12.5
10.6
14.4
Fixing the rack

*
min.
max.
CAT Designation
Unit
Set value
Adjusting point
Rack position
R1(12.1)
Pump speed
r/min
700
700
700
mm3/st.
110
109
111
Basic
Fixing the lever
Boost pressure
kPa
23.3
23.3
Boost pressure
mmHg
175
175
Unit
Set value
min.
max.
Adjusting point
Rack position
Pump speed
r/min
1400
1400
1400
mm3/st.
114.5
110.5
118.5
Fixing the lever
Boost pressure
kPa
23.3
23.3
Boost pressure
mmHg
175
175
Unit
Set value
min.
max.
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Rack position
Pump speed
r/min
500
500
500
mm3/st.
108.5
104.5
112.5
Fixing the lever
Boost pressure
kPa
23.3
23.3
Boost pressure
mmHg
175
175
Unit
Set value
min.
max.
R2(R1-0.4)
Adjusting point
Rack position
R2-0.35
Pump speed
r/min
400
400
400
mm3/st.
95
91
99
Fixing the lever
Boost pressure
kPa
Boost pressure
mmHg
Unit
Set value
min.
max.
100
100
Adjusting point
Rack position
(R1+1.7)
Pump speed

OT
R1+1.0
Adjusting point
CAT Designation
Actual values
CAT Designation
OT
9.5+-0.5
CAT Designation
Actual values
CAT Designation
Page 2
r/min
100
101608-1486
Fixing the lever
Boost pressure
kPa
Boost pressure
CAT Designation
mm3/st.
07/05/03 11:17:29
160
160
160
mmHg
Unit
Set value
min.
max.
Page 3
Adjusting point
Rack position
(R1+0.4)
Pump speed
r/min
1100
1100
1100
mm3/st.
108.5
104.5
112.5
Fixing the lever
Boost pressure
kPa
23.3
23.3
Boost pressure
mmHg
175
175
Actual values
OT
Actual values
OT
Actual values
OT

Name
N1=2080--r/min
T1=M20
BCL=0.35+-0.05mm
N:Pump speed
(1)Adjust the governor at N=N1.
(2)Torque cam stamping: T1

CAT Designation
Unit
Set value
min.
max.
r/min
400
400
400
Pump speed
Rack position
Boost pressure
kPa
4.0+2.7
Boost pressure
mmHg
30+20
Unit
Set value
min.
max.
r/min
400
400
400
CAT Designation
P
Pump speed

R2-0.35
101608-1486
07/05/03 11:17:29
Rack position
Boost pressure
kPa
(10.0)
Boost pressure
mmHg
(75)
Page 4
R2(R1-0.4)

CAT Designation
Unit
Set value
Pump speed
r/min
1000--
min.
max.
Advance angle
deg.
Unit
Set value
min.
max.
Actual values
OT
Actual values
OT
Actual values
OT
Remarks
Start
CAT Designation
P
Pump speed
r/min
950
Advance angle
deg.
0.5
Unit
Set value
CAT Designation
P
Pump speed
r/min
1400
Advance angle
deg.
3.5
Remarks
Finish
Name
a=19deg+-5deg
b=41.5deg+-3deg
aa=40mm

Name

F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)(3)Stopper bolt set position 'H'
0.5
min.
max.
101608-1486
07/05/03 11:17:29
Page 5
a=11.5deg+-5deg
b=28deg+-5deg
aa=1400r/min
bb=7.0-0.5mm
cc=285r/min
dd=(8.4)mm
N:Pump normal
S:Stop the pump.
(1)After setting the stopper bolt so that the speed lever is in the full position, confirm that there is
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
aa=13deg


(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
101608-1486
ZEXEL Ass'y No.
101608-1486
07/05/03 11:17:29
Page 1
101608-1693
Bosch Ass'y No.

Bosch Typecode
Engine Type
Manufacturer
Edition date
27/09/00 (10)
CAT Designation
Unit
Test oil
Set value
min.
max.
40
45
Actual values
OT
Actual values
OT
Actual values
OT
ISO4113 or {SAEJ96
7d}
...
degC
40
1005780-8260
Bosch type code
9 430 610 133
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2190
Opening Pressure
MPa
18.0
Opening Pressure
kgf/cm2
184
Iinjection Pipe
mm
6-2-600

Overflow valve
131424-8420
kPa
255
255
255
kgf/cm2
2.6
2.6
2.6
kPa
255
255
255
kgf/cm2
2.6
2.6
2.6
min.
max.
3.15
3.25
60
59.5
60.5
120
119.5
120.5
180
179.5
180.5
240
239.5
240.5
300
299.5
300.5
Set value
min.
max.
L
Left
CAT Designation
P
Unit
Set value
L
Left
P
Injection order
Pre-stroke
1-5-3-6-2-4
mm
3.2
No.1
Governor side
S
deg.
Cyl 1-5
deg.
Cyl 1-3
deg.
Cyl 1-6
deg.
Cyl.1-2
deg.
Cyl 1-4

CAT Designation
P
Adjusting point

Unit
101608-1486
07/05/03 11:17:29
Rack position
Pump speed
r/min
700
700
700
mm3/st.
110
106.7
113.3
Basic
Fixing the rack

*
min.
max.
CAT Designation
12.1
Unit
Set value
Adjusting point
Rack position
Pump speed
r/min
275
275
275
mm3/st.
12.5
10.6
14.4
Fixing the rack

*
min.
max.
CAT Designation
Unit
Set value
Adjusting point
Rack position
R1(12.1)
Pump speed
r/min
700
700
700
mm3/st.
110
109
111
Basic
Fixing the lever
Boost pressure
kPa
23.3
23.3
Boost pressure
mmHg
175
175
Unit
Set value
min.
max.
Adjusting point
Rack position
Pump speed
r/min
1400
1400
1400
mm3/st.
114.5
110.5
118.5
Fixing the lever
Boost pressure
kPa
23.3
23.3
Boost pressure
mmHg
175
175
Unit
Set value
min.
max.
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Rack position
Pump speed
r/min
500
500
500
mm3/st.
108.5
104.5
112.5
Fixing the lever
Boost pressure
kPa
23.3
23.3
Boost pressure
mmHg
175
175
Unit
Set value
min.
max.
R2(R1-0.4)
Adjusting point
Rack position
R2-0.35
Pump speed
r/min
400
400
400
mm3/st.
95
91
99
Fixing the lever
Boost pressure
kPa
Boost pressure
mmHg
Unit
Set value
min.
max.
100
100
Adjusting point
Rack position
(R1+1.7)
Pump speed

OT
R1+1.0
Adjusting point
CAT Designation
Actual values
CAT Designation
OT
9.5+-0.5
CAT Designation
Actual values
CAT Designation
Page 2
r/min
100
101608-1486
Fixing the lever
Boost pressure
kPa
Boost pressure
CAT Designation
mm3/st.
07/05/03 11:17:29
160
160
160
mmHg
Unit
Set value
min.
max.
Page 3
Adjusting point
Rack position
(R1+0.4)
Pump speed
r/min
1100
1100
1100
mm3/st.
108.5
104.5
112.5
Fixing the lever
Boost pressure
kPa
23.3
23.3
Boost pressure
mmHg
175
175
Actual values
OT
Actual values
OT
Actual values
OT

Name
N1=2080--r/min
T1=M20
BCL=0.35+-0.05mm
N:Pump speed
(1)Adjust the governor at N=N1.

CAT Designation
Unit
Set value
min.
max.
r/min
400
400
400
Pump speed
Rack position
Boost pressure
kPa
4.0+2.7
Boost pressure
mmHg
30+20
Unit
Set value
min.
max.
r/min
400
400
400
CAT Designation
P
Pump speed

R2-0.35
101608-1486
07/05/03 11:17:29
Rack position
Boost pressure
kPa
(10.0)
Boost pressure
mmHg
(75)
Page 4
R2(R1-0.4)

CAT Designation
Unit
Set value
Pump speed
r/min
1000--
min.
max.
Advance angle
deg.
Unit
Set value
min.
max.
Actual values
OT
Actual values
OT
Actual values
OT
Remarks
Start
CAT Designation
P
Pump speed
r/min
950
Advance angle
deg.
0.5
Unit
Set value
CAT Designation
P
Pump speed
r/min
1400
Advance angle
deg.
3.5
Remarks
Finish
Name
a=19deg+-5deg
b=41.5deg+-3deg
aa=40mm

Name

F:Full speed
I:Idle
(2)(3)Stopper bolt set position 'H'
0.5
min.
max.
101608-1486
07/05/03 11:17:29
Page 5
a=11.5deg+-5deg
b=28deg+-5deg
aa=1400r/min
bb=7.0-0.5mm
cc=285r/min
dd=(8.4)mm
N:Pump normal
S:Stop the pump.
(1)After setting the stopper bolt so that the speed lever is in the full position, confirm that there is
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
aa=13deg


(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
101608-6511
ZEXEL Ass'y No.
101608-6511
Bosch Ass'y No.
9 400 613 229
25/10/04 13:08:15
Page 1
Bosch Typecode
Engine Type
6D16TL
Manufacturer
MITSUBISHI
Edition date
29/10/02 (1)
CAT Designation
Unit
Test oil
Set value
min.
max.
40
45
Actual values
OT
Actual values
OT
Actual values
OT
ISO4113 or {SAEJ96
7d}
...
degC
40
105780-8140
Bosch type code
EF8511/9A
Nozzle
105780-0000
Bosch type code
DN12SD12T
Nozzle holder
105780-2080
Bosch type code
EF8511/9
Opening Pressure
MPa
17.2
Opening Pressure
kgf/cm2
175
Iinjection Pipe
mm
6-2-600

Overflow valve
131424-5520
kPa
255
221
289
kgf/cm2
2.6
2.25
2.95
kPa
255
255
255
kgf/cm2
2.6
2.6
2.6
min.
max.
4.45
4.55
60
59.5
60.5
120
119.5
120.5
180
179.5
180.5
240
239.5
240.5
300
299.5
300.5
Set value
min.
max.
L
Left
CAT Designation
P
Injection order
Pre-stroke
Unit
Set value
L
Left
1-5-3-6-2-4
mm
4.5
NO.1
Governor side
deg.
Cal 1-5
S
deg.
Cal 1-3
deg.
Cal 1-6
deg.
Cyl.1-2
deg.
Cal 1-4

CAT Designation
Unit
101608-6511
25/10/04 13:08:15
Adjusting point
Rack position
Pump speed
r/min
1125
1125
1125
mm3/st.
90.5
89.5
91.5
-2.5
2.5
Basic
Fixing the lever
Boost pressure
kPa
26.7
26.7
Boost pressure
mmHg
200
200
Unit
Set value
min.
max.
Page 2
A
10.4
CAT Designation
P
Adjusting point
Rack position
Pump speed
r/min
375
375
375
mm3/st.
16.5
15
18
-15
15
Fixing the rack
Boost pressure
kPa
Boost pressure
mmHg
Actual values
OT
8.1+-0.5
Remarks
Adjust only variation between cylinders; adjust governor according to governor specificatio
CAT Designation
Unit
Set value
min.
max.
Adjusting point
Rack position
Pump speed
r/min
100
100
100
mm3/st.
100
100
110
Fixing the lever
Boost pressure
kPa
Boost pressure
mmHg
Rack limit
10.6++

Name
K=6
BCL=0.15+-0.1mm
N1=1125r/min
N2=550r/min

N:Pump speed
(1)Target notch: K
(3)RACK LIMIT
(5)Set idle sub-spring
(6)Main spring setting
(7)Rack difference between N = N1 and N = N2
Actual values
OT
101608-6511
CAT Designation
P
Pump speed
Rack position
Boost pressure
25/10/04 13:08:15
Unit
Set value
min.
max.
r/min
500
500
500
11.3
11.3
11.3
85
85
85
Unit
Set value
min.
max.
r/min
500
500
500
Page 3
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
R1-0.15
kPa
About
Boost pressure
mmHg
About
CAT Designation
P
Pump speed
Rack position
Boost pressure
kPa
12
9.3
14.7
Boost pressure
mmHg
90
70
110
Unit
Set value
min.
max.
r/min
500
500
500
13.3
13.3
13.3
100
100
100
Unit
Set value
min.
max.
2.5
3.5
min.
max.
2.5
3.5
min.
max.
CAT Designation
P
Pump speed
Rack position
Boost pressure
R1-0.1
R1(9.75)
kPa
About
Boost pressure
mmHg
About

CAT Designation
P
Pump speed
r/min
Advance angle
deg.
Load
CAT Designation
0/4
Unit
Set value
Pump speed
r/min
550+50
Advance angle
deg.
Load
0/4
Remarks
Start
CAT Designation
Unit
Set value
Pump speed
r/min
650-50
Advance angle
deg.
Load
0/4
Remarks
Finish
Name
a=20deg+-5deg
b=1deg+-5deg
101608-6511
25/10/04 13:08:15
Page 4
F:Full speed
I:Idle
(1)Stopper bolt setting
Name
a=35deg+-5deg
b=(55deg)
aa=0r/min
bb=1-0.5mm
N:Pump normal
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)
T2=2.9~4.4N-m(0.3~0.45kgf-m)
2.9 Timing setting

Name
Tamperproofing-equipped boost compensator cover installation procedure

(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)
101608-6511
25/10/04 13:08:15
a=(3deg)
aa=8deg

(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
Page 5
1/3
Assy No.: 101608-9580
CO NFI D ENT IA L
ENGINE MODEL: L7A
TEMPO RARI LY
Date:
14 Jan 2004
Company: ASIA MOTOR
No.
Timing device: EP/SAG
105672-0660
Governor: EP/RLD-F
105921-9690
Injection pump: PE6AD

101060-5570
1. Test conditions

Nozzle: 105025-0780
(Bosch type no.
(Bosch type no.

(Bosch type no.
kgf/cm2}
length 600 mm
mm inner dia. 2 mm
+5
2. Injection timing
Injection order: 1
6,1
4,1
60 15'
2,1
120 15'
180 15'
3,1
240 15'
mm
300 15'
side (interval:
30').
Rack
position
(mm)
Pump
speed
(r/min)
Injection quantity
(cm3/1000 strokes)
11.1
700
78 2
3.5
Rack
Approx 9.2
290
16 2
14
Rack
R1(11.1)
700
78 1
Lever
R1+0.7
1450
(76) 2
Lever
100
140 10
Lever
Adjusting
point
Max. variation
between
cylinders (%)
Fixed
Remarks
Basic

Basic
Rack limit

Pump speed
(r/min)
Advance
angle ( )
Below 950
Start
0
900
Below 0.5
1150 30
Finish
4.5 - 0.5
BOSCH K.K.

Tel. 81-48-475-2521
Fax. 81-48-475-2520
101608-9580 2/3
Torque cam no. M76
Rack limit
Rack position (mm)
R1+0.7
R1+0.55
R1+0.15
R1(11.1)
R1-0.65
8.35
(800) (1100) (1400)
Below 225
700 (900)
166050
(1300) 155010
Pump speed (r/min)
Adjust the bolt so that the microswitch operates at a control lever position of
R= 8.6 0.1 mm and a pump speed of 415r/min.
Idling adjustment
Rack position (mm)
11.5
+0.35
11.0 -0.30
Approx 9.2
9.0
7.80.07
HJ
5.50.3
400
190
325
300 290
Pump speed (r/min)
850
101608-9580 3/3
(42)3
19 5

Idling
Full-speed
Stop lever angle
Stop
Normal
14.5
40 5
Timing setting
B.T.D.C.: 13
Coupling key groove position
Approx. 50
1/2
Assy No.: 101691-2970
CO NFI D ENT IA L
ENGINE MODEL: DK20
Date:
14 Sep 2004
Company: HINO
No.
6 071 10001 0
105612-0700
Governor: EP/RQ
105300-0750
Injection pump: PE6A

101069-0510
1. Test conditions

Nozzle & nozzle holder assy:
(Bosch type no.
Nozzle: 105000-1130
(Bosch type no. DN4SD24)

(Bosch type no. KB56SD273)

length 600 mm
mm inner dia. 2 mm
+5
kgf/cm2}
kPa {
kgf/cm2}
2. Injection timing
Injection order: 1
6,1
4,1
60 30'
2,1
120 30'
180 30'
3,1
240 30'
mm
300 30'
side (interval:
30').
Adjusting
point
Rack
position
(mm)
Pump
speed
(r/min)
Injection quantity
(cm3/1000 strokes)
Max. variation
between
cylinders (%)
Fixed
14.5
600
112 2.2
Lever
(14.5)
1050
119.7 7.2
Lever
8.6
200
23 3
13
Rack
Remarks
Basic

Pump speed
(r/min)
Advance
angle ( )
30050
Start
0
600
1.8 0.5
800
Finish
3.00.5
BOSCH K.K.

Tel. 81-48-475-2521
Fax. 81-48-475-2520
101691-2970 2/2
Rack limit: 17+0.2
0
Rack position (mm)
14.5
Above 9.6
8.6
Below 3
0 Approx 100 32010

200
1150
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.
Timing setting
Ap
pr
54
.5
.9
ox
3
.5
26
d
loa
llFu
Idling
Stop
Approx. 40
1/3
Assy No.: 101692-3470
CO NFI D ENT IA L
ENGINE MODEL: 6D95L
TEMPO RARI LY
Date:
30 Aug 2004
Company: KOMATSU
No.
6206-71-1341
Timing device:
Governor: EP/RSV
105400-4630

101069-9180
1. Test conditions

(Bosch type no.
Nozzle: 105017-0090
(Bosch type no. DLLA152PN009)

(Bosch type no.
+5
kgf/cm2}
kPa {
kgf/cm2}
length 600 mm
mm inner dia. 1.6 mm
2. Injection timing
Note: Adjust with rack position of R= R1(9.9) mm
Injection order: 1
6,1
5,1
60 30'
3,1
120 30'
180 30'
2,1
240 30'
300 30'
side (interval:
30').
Adjusting
point
Rack
position
(mm)
Pump
speed
(r/min)
R1(9.9)
1200
37.2 1
2.5
Lever
R2(8.6)
350
10.5 1
15
Rack
Injection quantity
(cm3/1000 strokes)
Max. variation
between
cylinders (%)
Fixed
Remarks
Basic

Pump speed
(r/min)
Advance
angle ( )
BOSCH K.K.

Tel. 81-48-475-2521
Fax. 81-48-475-2520
101692-3470 2/3
Rack cap: Approx 17.5
20+1
A
C
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 = 800
6.0
2.80.1
R2+3
R1(9.9)
R1-0.3
R2(8.6)
(1.2)0.1
Rack position (mm)
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
350 50020
(880)
350
Pump speed (r/min)
1200 +30
+20 132525
(1280)
101692-3470 3/3
(26)5
) 5
(16

Idling
Full-speed
Stop lever angle
Stop
Normal
26.5
535
Timing setting
59
6'
Key groove position

Mark an aligning mark on the pump housing
(Width,depth 0.3 mm)
024' 30'
1/3
Ass'y No.: 103662-3180
CONFIDENTIAL
ENGINE MODEL: SA6D170A
TEMPORARILY
Date:
27 July 2006
Company: KOMATSU
No.
6162-73-2320
Timing device:
Governor: EP/RSUVD
105455-0971
Injection pump: PE6ZW

103066-8400
1. Test conditions

Nozzle: 105015-6140
(Bosch Type No.
(Bosch Type No.

(Bosch Type No.

Injection pipe: Outer Dia. 8 mm Inner Dia. 2.4mm
Length 1400mm
+5
Oil Temp. 40 C
2. Injection timing
Injection order:
5,1
60 30'
3,1
120 30'
6,1
180 30'
2,1
240 30'
mm
300 30'
side ( interval:
30' ).
Adjusting
point
Rack
position
(mm)
Pump
speed
(r/min)
15.1
1050
Approx 7.3
475
Max. variation
between
cylinders (%)
Fixed
(391) 5
Lever
(45) 5
14
Rack
Injection q'ty
3
Remarks
Basic

Boost press. 0

Pump speed
(r/min)
Advance
angle ( )
Bosch Corporation

Tel. 81-48-475-2521
Fax. 81-48-475-2520
103662-3180 2/3
Stop lever nomal position setting: 17.5+0.5
Rack limit: 16.5+0.2
Above 26
20.1
A
1.30.1
15.1
Above 8.8
7.3
Idle sub-spring setting: 6.2-0.5
6.2
1.10.3
0
475 (670)30
(925)30
117525
+30
+45
770 -20
1050 +35
Pump speed (r/min)
Rack position (mm)
Rack position (mm)
Difference in rack position between

N = 1050 and N = 750
N = 750
16.4
14.4
0
48.06.7 {36050}
21.32.7 {16020}
103662-3180 3/3
(22)
Full-speed
5
)
Confirm that the clearance is approx

2mm when contacts inner stopper.
Approx 2
Idling
(me
re
asu
Full-load
sur
mea
5
e)
Load lever angle
Stop lever angle
32 5
R=17.5+0.5
(After lever angle setting,
put the seal.)
N=0, R=2-0.2
5
15
Normal
(After lever angle setting,

put the seal.)
Stop
1/3
Ass'y No.: 103662-3351
ENGINE MODEL SA6D170A
TEMPORARY
Injection pump PE6ZW

103066-5011
Actuator RED III

105955-0110
Test condition
Date: 2 Apr. 2002

KOMATSU
Company:
No.
6162-74-1310
Timing device
Pump rotation Counter clockwise (viewed from drive side)

Nozzle Nozzle Holder Ass'y 105111-4820
Nozzle 105025-1850

kgf/cm2
mm Inner Dia.2.4 mm Length 1500 mm

+5
Oil Temp.40

Overflow valve opening pressure255
kgf/cm2
kPa 2.6
Injection timing
Pre-strokeNo.1 Plunger 3.2
Injection order
5,1
60 30'
Rack
position
(mm)
(13.2)
(6.1)
3,1
120 30'
Injection quantity
Adjusting point
0.05mm Note: Perform at voltage
Vist
(V)
1.36
Approx.2.8
6,1
180 30'
2,1
240 30'
300 30'
side. ( interval:
RED GOV. C/U : 15 mm

Pump
speed
(r/ min)
Injection q' ty
Max. var
bet. cyl
( )
865
513 5
400
30 5
14
Remarks
Basic

Pump speed
Advance
angle
103662-3351 2/3
Stop lever angle
Stop
Normal
Timing setting
At No.1 plungers beginning
Approx.70
103662-3351 3/3
RED 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.
1/3
Ass'y No.: 103672-0350
CONFIDENTIAL
ENGINE MODEL: 6NSD
Date:
11 Sep 2002
3
Company: NIIGATA ENGINEERING
No.
74V47000A
Timing device:
Governor: EP/RSUV
105455-0730
Injection pump: PE6ZW

103067-8171
1. Test conditions

(Bosch Type No. EFEP215A)
Nozzle: 105780-0050
(Bosch Type No. DN6TD119NP1T)

(Bosch Type No. EFEP215)
Injection pipe: Outer Dia. 8 mm Inner Dia.4 mm
Length 1500mm
+5
Oil Temp. 40 C
2. Injection timing
Pre-stroke: No.1 Plunger 3
Injection order:
0.05mm
3,6
60 30'
5,6
120 30'
1,6
180 30'
4,6
240 30'
mm
300 30'
side ( interval:
30' ).
Adjusting
point
Rack
position
(mm)
Pump
speed
(r/min)
Injection q'ty
Max. variation
between
cylinders (%)
Fixed
14.3
750
523 15
Rack
Approx. 6.7
250
41.5 3.5
10
Rack
Remarks
Basic

Pump speed
(r/min)
Advance
angle ( )
Service Department

Tel. (048)470-1559, Fax. (048)474-9856
103672-0350 2/3
Above 26
Rack limit: 21+1
Rack position (mm)
Do not adjust idling spring
14.3
9.0
6.7
5.7
235 250
7505 Below 815

Pump speed (r/min)
103672-0350 3/3
18 5
(30) 5
Full-speed
Idling
Stop lever angle
Normal
Stop
35 5
10
Timing setting
Approx. 50
Center of pump side coupling's elongated hole
CONFIDENTIAL

TEST OIL
I S O 4113 or
S A E J967d
ENGINE MODEL: N844L-T
INJ. Pump Ass'y No. 104135-4030 (NP - PFR4KX60/2NP10)
ZEXEL No.:
Date:
Company:
No.:
104135-4030
24 Aug. 2001 3
ISHIKAWAJIMA
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 28)
2. Injection Timing:
Pre-stroke P :
L 1 (Port Closing Dimension):
L 2 (Mounting Dimension):
L 3 (Pump Ass'y Dimension):
2.450.05 mm (*)
73.550.05 mm (*)
760.05 mm (*)
Above 77 mm
(*) The control rack is pushed fully in the fuel

increase direction.
Rc=0; this position is half of full rack stroke

a: a=-1.50.02
(full rack stroke=16mm).
Rack Position Pump Speed Injection Q'ty Max. var. bet. cyl.
Fixed
Remarks
(%)
(mm)
(r/min) (cm3/1,000strokes)
3. Injection Quantity:
a=-1.50.02
1,100
24.30.3
a+1
1,400
*(33.8)
R=7.5mm
a+2.4
a-2.2
850
1,500
*(40.2)
*(12)
R=8.9mm
R=4.3mm
a-0.4
400
*(12)
R=6.1mm
-7
1,500
+8
150
Basic R=6.5mm
Below 1
Non-injection
*(51)
Starting
*: Enter after measuring
4. Control Rack Sliding Resistance:

Pump Speed
(r/min)
Sliding Resistance
(g)
1,000
Below 25

Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken 352-8572, JAPAN
Tel: (048) 470-1559 Fax: (048) 474-9856
) =Reference value

TEST OIL:
ISO 4113 or
SAE J967d
CONFIDENTIAL
ENGINE MODEL: V2203-DI
Assy no.:
Date:
Company:
No.
Injection pump assy no. 104139-4090 (NP-PFR4KX80/2NP12)
104139-4090
27 Aug 2003
KUBOTA
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.:
Oil temperature.:
40-5 C
Cam profile: PFK - T - 00 (tangential cam; cam lift 7 mm; base circle 28)
2. Injection timing:
Pre-stroke P :
L 1 (port closing dimension):
L2 (mounting dimension):
L3 (pump assy dimension):
1.90.05 mm *
74.10.05 mm *
760.05 mm *
Above 77 mm
* The control rack is set at +2.50.5 mm

(R = approx 10.50.5 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
Rc (mm)
Pump speed
(r/min)
Injection qty
Max. var. between
(cm3 / 1000 strokes ) cylinders (mm3/st)
a = +1.00.02
1100
50.90.3
a-1
1100
(35.8)*
R = approx 8.0
700
(42.3)*
Torque point R = approx 9.0
a-1.7
450
(14.2)*
Low idle
-7
1100
Below 1
Non injection R = approx 1.0
+8
150
(64.0)*
Start
Fixed
Remarks
Basic
* Enter after measuring; (
R = approx 9.0
R = approx 7.3
R = approx 16
) = reference value; R = Rc+8
4. Control rack sliding resistance:

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

Tel. 81-48-475-2521
Fax. 81-48-475-2520

TEST OIL:
ISO 4113 or
SAE J967d
CONFIDENTIAL
ENGINE MODEL: 03-DI
Assy no.:
Date:
Company:
No.
Injection pump assy no. 104139-4150 (NP-PFR4KX80/2NP23)
1/2
104139-4150
1 Oct 2004
KUBOTA
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:
Oil temperature:
40-5 C
Cam profile: PFK - T - 00 (tangential cam; cam lift 7 mm; base circle 28)
2. Injection timing:
Pre-stroke P:
L 1 (port closing dimension):
L2 (mounting dimension):
L3 (pump assy dimension):
2.50.05 mm *
74.50.05 mm *
770.05 mm *
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)
Rack position
Rc (mm)
Pump speed
(r/min)
Injection qty
(cm3/1000 strokes )
Max. var. between

cylinders (mm3/st)
a = +2.80.02
1100
54.00.3
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
+8
150
(73.3)*
Start
Fixed
Remarks
Basic
BOSCH K.K.
R = approx 10.8
R = approx 16.0

Tel. 81-48-475-2521
Fax. 81-48-475-2520
104139-4150
2/2
4. Non injection quantity: (at the mounting dimension 76 mm; i.e., without the shims)
Rack position
Rc (mm)
Pump speed
(r/min)
Injection qty
(cm3/1000 strokes )
Max. var. between

cylinders (mm3/st)
-5
1500
(0)*
-6
1500
(0)*
-7
1500
(0)*
Fixed
5. Control rack sliding resistance:

Pump speed (r/min)
Sliding resistance (g)
1000
Below 25
Remarks
Test Data 104142-3450 ,

Rack Position
24 mm
18 mm
12 mm
12 mm
Pump(rpm) CC/100st
300
300
300
100
*
*(114 to 120) basic ( Temporary fuel Q'ty)
*
*
104740-0756
ZEXEL Ass'y No.

Bosch Ass'y No.
Bosch Typecode
Engine Type
Manufactures
Edition date
P
P
P
P
P
Page 1
104740-0756
9 460 612 455
WL-NA
MAZDA
20/09/00 (5)
CAT Designation
Test oil
14/02/02 18:32:57

Nozzle
Bosch type code
Nozzle holder
Opening Pressure
Opening Pressure
Iinjection Pipe
Iinjection Pipe
Joint Assembly
Tube Assembly
Transfer pump pressure
Unit
Set value
ISO4113orSAEJ967
d
min.
...
degC
max.
45
45
105780-0060
NP-DN0SD1510
105780-2150
MPa
13
13
kgf/cm2
133
133
157805-7320
mm
2-6-450
Inside diameter - outside diameter - length (mm)
157641-4720
157641-4020
kPa
20
20
kgf/cm2
0.2
0.2
L
Left
50
Unit
r/min
mm3/st.
mm3/st.
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
13.3
136
20
0.2
2.1 Full load delivery
CAT Designation
P
Pump speed
S
S
Differnce in delivery
P
Basic
P
Oil temperature
Set value
1000
47.7
4
*
50
min.
1000
47.2
max.
1000
48.2
4
48
52
Unit
r/min
mm3/st.
About
degC
Set value
500
46
min.
500
43
max.
500
49
48
46
50
Designation
Pump speed
Basic
Oil temperature
Unit
r/min
mm3/st.
mm3/st.
Set value
1000
47.7
4.5
*
50
min.
1000
46.7
max.
1000
48.7
4.5
48
52
CAT Designation
P
Pump speed
C Average injection quantity
Unit
r/min
mm3/st.
About
degC
Set value
2000
44.4
min.
2000
41.9
max.
2000
46.9
50
48
52
Unit
r/min
mm3/st.
mm3/st.
min.
2450
12.7
max.
2450
18.7
5
CAT Designation
P
Pump speed
P
CAT
P
C
C
P
P
Oil temperature
P
Oil temperature
2.2 Governing
CAT Designation
P
Pump speed
S
S
P
Basic
P
Oil temperature
degC
degC
degC
Set value
2450
15.7
5
*
55
52
58
Designation
Pump speed
Oil temperature
Unit
r/min
mm3/st.
degC
Set value
2700
5
55
min.
2700
max.
2700
5
58
Actual values
OT
CAT Designation
P
Pump speed
C Differnce in delivery
P
Basic
P
Oil temperature
2.3 Idle
CAT Designation
P
Pump speed
Unit
r/min
mm3/st.
mm3/st.
min.
2450
5.7
max.
2450
25.7
5.5
Actual values
OT
degC
Set value
2450
15.7
5.5
*
55
52
58
Unit
r/min
Set value
360
min.
360
max.
360
Actual values
OT
CAT
P
C
P

52
104740-0756
S
S
P
P
14/02/02 18:32:57

Basic
Oil temperature
mm3/st.
mm3/st.
9
1.7
*
48
10
1.7
CAT Designation
P
Pump speed
C Differnce in delivery
P
Basic
P
Oil temperature
2.4 Start
CAT Designation
P
Pump speed
S
P
Oil temperature
Remarks
Unit
r/min
mm3/st.
mm3/st.
46
50
min.
360
7.5
max.
360
10.5
2.2
degC
Set value
360
9
2.2
*
48
46
50
Unit
r/min
mm3/st.
degC
Set value
150
70
48
min.
150
55
46
Set value
150
70
degC
Page 2
Actual values
OT
max.
150
90
50
Actual values
OT
min.
150
50
max.
150
90
Actual values
OT
48
46
50
Set value
360
0
48
min.
360
0
46
max.
360
0
50
Actual values
OT
Unit
r/min
cm3/min
degC
Set value
1000
400
50
min.
1000
270
48
max.
1000
530
52
Actual values
OT
Unit
r/min
kPa
kgf/cm2
Set value
1000
510
5.2
*
50
min.
1000
481
4.9
max.
1000
539
5.5
Actual values
OT
48
52
Set value
1000
510
5.2
*
50
min.
1000
471
4.8
max.
1000
549
5.6
Actual values
OT
48
52
min.
1000
4.2
max.
1000
4.6
Actual values
OT
degC
Set value
1000
4.4
*
50
48
52
Full
CAT Designation
P
Pump speed
P
Oil temperature
Remarks
Unit
r/min
mm3/st.
About
degC
Full
2.5 Stop
CAT Designation
P
Pump speed
P
Oil temperature
Remarks
Unit
r/min
mm3/st.
degC
Magnet OFF
2.6 Overflow
CAT Designation
P
Pump speed
C Overflow quantity
P
Oil temperature
2.7 Pump chamber Pressure
CAT Designation
P
Pump speed
S
Pressure
S
Pressure
P
Basic
P
Oil temperature
CAT Designation
P
Pump speed
C Pressure
C Pressure
P
Basic
P
Oil temperature
2.8 Timer
CAT Designation
P
Pump speed
S
Timer Stroke
P
Basic
P
Oil temperature
degC
Unit
r/min
kPa
kgf/cm2
degC
Unit
r/min
mm
CAT
P
C
P
Designation
Pump speed
Timer Stroke
Oil temperature
Unit
r/min
mm
degC
Set value
500
1.8
48
min.
500
1
46
max.
500
2.6
50
Actual values
OT
CAT
P
C
P
P
Designation
Pump speed
Timer Stroke
Basic
Oil temperature
Unit
r/min
mm
min.
1000
4
max.
1000
4.8
Actual values
OT
degC
Set value
1000
4.4
*
50
48
52
Unit
r/min
mm
degC
Set value
2000
9
50
min.
2000
8.2
48
max.
2000
9.8
52
Actual values
OT
Unit
V
V
Set value
8
13
min.
8
12
max.
8
14
Actual values
OT
CAT Designation
P
Pump speed
C Timer Stroke
P
Oil temperature
2.9 Magnet
CAT Designation
C MAX applied voltage
P
Test voltage
104740-0756
14/02/02 18:32:57
Page 3
2.10 Compensator
2.10.1 Load-Timer adjustment
CAT Designation
P
Pump speed
S
S
Timer stroke TA
S
Timer stroke variation dT
P
P
CAT
P
C
C
C
P
P
CAT
P
C
C
C
Basic
Oil temperature
Designation
Pump speed
Timer stroke TA
Basic
Oil temperature
Designation
Pump speed
Timer stroke TA
P
Oil temperature
Unit
r/min
mm3/st.
mm
mm
About
degC
Unit
r/min
mm3/st.
mm
mm
About
degC
Unit
r/min
mm3/st.
mm
mm
About
degC

Name
CONTROL STANDARD AT IDLING

Set value
1000
30
3.7
0.7
min.
1000
29.5
3.5
0.7
max.
1000
30.5
3.9
0.7
*
50
48
52
Set value
1000
30
3.7
0.7
min.
1000
29
3.3
0.7
max.
1000
31
4.1
0.7
*
50
48
52
Set value
1000
20
2.9
1.5
min.
1000
18.5
2.3
1.5
max.
1000
21.5
3.5
1.5
50
48
52
Actual values
OT
Actual values
OT
Actual values
OT
104740-0756
14/02/02 18:32:57
Page 4
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
L2=4.6+-0.5mm
P1=-66.0kPa
P2=-500mmHg
a=7.6deg
b=12.5deg+-4deg
T=6~9Nm(0.6~0.9Kgfm)
3 Assembly dimension
CAT Designation
S
K dimension
S
KF dimension
S
MS dimension
S
Pre-stroke
S
Control lever angle alpha
S
Control lever angle beta

(1)Wire length confirmation

Accelerator wire: Idle-full stroke: L1 mm
(2)Idle switch confirmation
Confirm that the switch is ON in the idle lever position.
(3)2 stage lever adjustment
1. Apply negative pressure of P1kPa {P2 mmHg} to the actuator from the negative pressure inlet
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
Unit
mm
mm
mm
mm
deg.
deg.
About
Set value
3.3
6.01
0.9
0.03
12.5
40
min.
3.2
5.91
0.8
0.01
8.5
37
max.
3.4
6.11
0.9
0.05
16.5
43
Actual values
OT
104740-3622
ZEXEL Ass'y No.
02/07/03 14:10:21
Page 1
104740-3622
Bosch Ass'y No.

Bosch Typecode
Engine Type
4D56
Manufacturer
MITSUBISHI
Edition date
13/03/02 (1)
CAT Designation
Unit
Test oil
Set value
min.
max.
45
50
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
ISO4113orSAEJ967
d
...
degC
45
Nozzle
105780-0000
Bosch type code
NP-DN12SD12T
Nozzle holder
105780-2080
Opening Pressure
MPa
14.7
14.7
15.19
Opening Pressure
kgf/cm2
150
150
155
Iinjection Pipe
mm
2-6-840
kPa
20
20
20
kgf/cm2
0.2
0.2
0.2
R
Right
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
1250
1250
1250
mm3/st.
45.8
45.3
46.3
mm3/st.
Basic
CAT Designation
*
Unit
Set value
min.
max.
Pump speed
r/min
2550
2550
2550
mm3/st.
18.1
13.1
23.1
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
2100
2100
2100
mm3/st.
39.2
37.2
41.2
Unit
Set value
min.
max.
CAT Designation
P
Pump speed
r/min
1250
1250
1250
mm3/st.
45.8
44.8
46.8
Unit
Set value
min.
max.
CAT Designation
P
Pump speed
r/min
600
600
600
mm3/st.
44.3
42.3
46.3
Unit
Set value
min.
max.
2.2 Governing
CAT Designation
P
Pump speed
r/min
2550
2550
2550
mm3/st.
18.1
15.1
21.1
mm3/st.
Basic
CAT Designation
P
Pump speed

*
Unit
Set value
min.
max.
r/min
2900
2900
2900
104740-3622
C
02/07/03 14:10:21
mm3/st.
Page 2
2.3 Idle
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
375
375
375
mm3/st.
6.5
9.5
mm3/st.
Basic
CAT Designation
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
*
Unit
Set value
min.
max.
600
600
Pump speed
r/min
600
mm3/st.
Unit
Set value
min.
max.
CAT Designation
Actual values
Pump speed
r/min
375
375
375
mm3/st.
10
Unit
Set value
min.
max.
2.4 Start
CAT Designation
P
Pump speed
r/min
100
100
100
mm3/st.
73
63
83
Basic
2.5 Stop
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
375
375
375
mm3/st.
Unit
Set value
min.
max.
Remarks
Magnet OFF
2.6 Overflow
CAT Designation
P
Pump speed
r/min
1250
1250
1250
Overflow quantity
cm3/min
420
288
552
Unit
Set value
min.
max.

CAT Designation
P
Pump speed
r/min
1250
1250
1250
Pressure
kPa
470.5
441
500
Pressure
kgf/cm2
4.8
4.5
5.1
Basic
CAT Designation
*
Unit
Set value
min.
max.
Pump speed
r/min
600
600
600
Pressure
kPa
313.5
284
343
Pressure
kgf/cm2
3.2
2.9
3.5
Unit
Set value
min.
max.
CAT Designation
P
Pump speed
r/min
1250
1250
1250
Pressure
kPa
470.5
441
500
Pressure
kgf/cm2
4.8
4.5
5.1
Unit
Set value
min.
max.
CAT Designation
P
Pump speed
r/min
2100
2100
2100
Pressure
kPa
666.5
637
696
Pressure
kgf/cm2
6.8
6.5
7.1
2.8 Timer
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
1250
1250
1250
Timer Stroke
mm
3.7
3.5
3.9
Basic

104740-3622
CAT Designation
02/07/03 14:10:21
Unit
Set value
min.
max.
Pump speed
r/min
500
500
500
Timer Stroke
mm
1.2
0.6
1.8
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
750
750
750
Timer Stroke
mm
1.4
2.6
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
1250
1250
1250
Timer Stroke
mm
3.7
3.3
4.1
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
2100
2100
2100
Timer Stroke
mm
7.2
6.6
7.8
Page 3
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
2.9 Magnet
CAT Designation
Unit
Set value
min.
max.
MAX applied voltage
Test voltage
13
12
14
2.10 Compensator
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
1250
1250
1250
mm3/st.
35.7
35.2
36.2
mm
0.6
0.4
0.8
Basic
CAT Designation
*
Unit
Set value
min.
max.
Pump speed
r/min
1250
1250
1250
mm3/st.
35.7
34.7
36.7
Timer stroke TA
mm
3.1
3.1
3.1
mm
0.6
0.2
About
C
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
1250
1250
1250
mm3/st.
28.2
26.7
29.7
Timer stroke TA
mm
2.3
2.3
2.3
mm
1.4
0.8
About
C
CAT Designation
Unit
Set value
min.
max.
K dimension
mm
3.3
3.2
3.4
KF dimension
mm
5.8
5.7
5.9
MS dimension
mm
1.2
1.1
1.3
deg.
59
55
63
deg.
46
41
51

104740-3632
ZEXEL Ass'y No.
104740-3632
Bosch Ass'y No.
9 460 610 297
02/07/03 14:10:54
Page 1
Bosch Typecode
Engine Type
4D56
Manufacturer
MITSUBISHI
Edition date
13/03/02 (1)
CAT Designation
Unit
Test oil
Set value
min.
max.
45
50
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
ISO4113orSAEJ967
d
...
degC
45
Nozzle
105780-0000
Bosch type code
NP-DN12SD12T
Nozzle holder
105780-2080
Opening Pressure
MPa
14.7
14.7
15.19
Opening Pressure
kgf/cm2
150
150
155
Iinjection Pipe
mm
2-6-840
kPa
20
20
20
kgf/cm2
0.2
0.2
0.2
R
Right
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
1250
1250
1250
mm3/st.
45.8
45.3
46.3
mm3/st.
Basic
CAT Designation
*
Unit
Set value
min.
max.
Pump speed
r/min
2550
2550
2550
mm3/st.
18.1
13.1
23.1
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
2100
2100
2100
mm3/st.
39.2
37.2
41.2
Unit
Set value
min.
max.
CAT Designation
P
Pump speed
r/min
1250
1250
1250
mm3/st.
45.8
44.8
46.8
Unit
Set value
min.
max.
CAT Designation
P
Pump speed
r/min
600
600
600
mm3/st.
44.3
42.3
46.3
Unit
Set value
min.
max.
2.2 Governing
CAT Designation
P
Pump speed
r/min
2550
2550
2550
mm3/st.
18.1
15.1
21.1
mm3/st.
Basic
CAT Designation
P
Pump speed
C = Check value)
*
Unit
Set value
min.
max.
r/min
2900
2900
2900
104740-3632
C
02/07/03 14:10:54
mm3/st.
Page 2
2.3 Idle
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
375
375
375
mm3/st.
6.5
9.5
mm3/st.
Basic
CAT Designation
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
*
Unit
Set value
min.
max.
600
600
Pump speed
r/min
600
mm3/st.
Unit
Set value
min.
max.
CAT Designation
Actual values
Pump speed
r/min
375
375
375
mm3/st.
10
Unit
Set value
min.
max.
2.4 Start
CAT Designation
P
Pump speed
r/min
100
100
100
mm3/st.
73
63
83
Basic
2.5 Stop
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
375
375
375
mm3/st.
Unit
Set value
min.
max.
Remarks
Magnet OFF
2.6 Overflow
CAT Designation
P
Pump speed
r/min
1250
1250
1250
Overflow quantity
cm3/min
420
288
552
Unit
Set value
min.
max.

CAT Designation
P
Pump speed
r/min
1250
1250
1250
Pressure
kPa
470.5
441
500
Pressure
kgf/cm2
4.8
4.5
5.1
Basic
CAT Designation
*
Unit
Set value
min.
max.
Pump speed
r/min
600
600
600
Pressure
kPa
313.5
284
343
Pressure
kgf/cm2
3.2
2.9
3.5
Unit
Set value
min.
max.
CAT Designation
P
Pump speed
r/min
1250
1250
1250
Pressure
kPa
470.5
441
500
Pressure
kgf/cm2
4.8
4.5
5.1
Unit
Set value
min.
max.
CAT Designation
P
Pump speed
r/min
2100
2100
2100
Pressure
kPa
666.5
637
696
Pressure
kgf/cm2
6.8
6.5
7.1
2.8 Timer
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
1250
1250
1250
Timer Stroke
mm
3.7
3.5
3.9
Basic
C = Check value)
104740-3632
CAT Designation
02/07/03 14:10:54
Unit
Set value
min.
max.
Pump speed
r/min
500
500
500
Timer Stroke
mm
1.2
0.6
1.8
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
750
750
750
Timer Stroke
mm
1.4
2.6
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
1250
1250
1250
Timer Stroke
mm
3.7
3.3
4.1
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
2100
2100
2100
Timer Stroke
mm
7.2
6.6
7.8
Page 3
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
2.9 Magnet
CAT Designation
Unit
Set value
min.
max.
MAX applied voltage
Test voltage
13
12
14
2.10 Compensator
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
1250
1250
1250
mm3/st.
35.7
35.2
36.2
mm
0.6
0.4
0.8
Basic
CAT Designation
*
Unit
Set value
min.
max.
Pump speed
r/min
1250
1250
1250
mm3/st.
35.7
34.7
36.7
Timer stroke TA
mm
3.1
3.1
3.1
mm
0.6
0.2
About
C
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
1250
1250
1250
mm3/st.
28.2
26.7
29.7
Timer stroke TA
mm
2.3
2.3
2.3
mm
1.4
0.8
About
C
CAT Designation
Unit
Set value
min.
max.
K dimension
mm
3.3
3.2
3.4
KF dimension
mm
5.8
5.7
5.9
MS dimension
mm
1.2
1.1
1.3
deg.
59
55
63
deg.
46
41
51
C = Check value)
TEST OIL:
ISO 4113 or
SAE J967d

CONFIDENTIAL
Injection pump no.:
4JB1A
ENGINE MODEL:
Assy no.:
Date:
Company:
No.
104641-1011 [ NP-VE 4/11F1800RNP251 ]
Pump rotation: clockwise - viewed from drive side
1/2
104741-1030
23 Nov 2004
ISUZU
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)
1-2 Nozzle holder: 105780-2080 (EF8511/9)
1-3 Nozzle opening pressure: 14.7+0.5 MPa {150+5 kgf/cm2}
Pump speed
(r/min)
2. Setting
2-1
2-2
2-3
2-4
2-5
2-6
2-7
Full load delivery

Full load delivery
Supply pump pressure
Timing device travel
Idle speed regulation
(Full lever)
Start
Full-load speed regulation
1-4 Injection pipe: 26840mm

1-5 Fuel oil temperature: 45+5C
1-6 Supply pump pressure: 20kPa {0.2kgf/cm2}
Charge air pressure
kPa {mmHg}
Settings
Difference in
delivery (cm3)
(cm3/1,000st)
(cm3/1,000st)
52020 {5.30.2} kPa {kgf/cm2}
1.90.2
(mm)
9.02.0
(cm3/1,000st)
95.020.0 (cm3/1,000st)
12.73.1
(cm3/1,000st)
1,000
44.60.5
1,550
1,550
390
100
2,100
3. Test
specifications
Solenoid
Timer
ON
3-1 Timing device
N = r/min
mm
730100
0.5
3-2 Supply pump
N = r/min
kPa {kgf/cm2}
3-3 Overflow delivery
N = r/min
cm3/min
3.5
2.0
3.5
OFF
1,44050
0.5
1,000
31429
{3.20.3}
1,550
1.90.3
1,550
52020
{5.30.2}
1,850
5.70.4
1,850
61829
{6.30.3}
1,550
530130
3-4 Fuel injection quantities

Speed control
lever position
Maximum speed
Pump speed
(r/min)
1,000
700
1,350
1,700
2,100
2,300
Fuel delivery
(cm3/1,000st)
Charge air pressure

kPa { mmHg }
44.61.0
36.62.0
47.52.0
47.32.5
12.83.5
Below 7.0
4. Dimensions
K
KF
MS
BCS
Pre-stroke
2.80.1
5.00.1
1.00.1
0.450.02
mm
mm
mm
mm
mm
Control lever angle
Magnet valve
switch OFF
390
Idling
390
550
3-5 Solenoid
0 (Idle)
9.02.0
Below 3.0
18.04.0
()
35.05.0
()
()
Maximum cut-in voltage: 8 V, Test voltage: 12 - 14 V

BOSCH K.K.

Tel. 81-48-475-2521
Fax. 81-48-475-2520
104741-1513
use
104741-1514
TEST OIL:
ISO 4113 or
SAE J967d
1/2
Assy No. 104741-4760

6 Fev 2002
0
Date:
Injection pump No : 104641-4760 [NP-VE4/11F1800RNP2395
]
Pump rotation :
Clockwise-viewed from drive side
16700 2S608
No.
Refer to the service manual (VE pump B.I.S.;Publication No. EE14E-11042) for all procedures and details other
than the following.
CONFIDENTIAL
ENGINE MODEL :
QD32
1. Test Conditions
1-5Fuel oil temperature : 45C
1-6Supply pump pressure : 20kPa {0.2kgf/cm2}
1-7Joint assy : 157641-4720
1-8Tube assy : 157641-4020
1-1Nozzle : 105780-0060(NP-DN0SD1510)
1-2Nozzle holder : 105780-2150
1-3Nozzle opening pressure : 13.0+0.3MPa {133+3kgf/cm2}
1-4Injection pipe : 26450mm
Pump speed
( r / min )
2. Setting
2-1
2-2
2-3
2-4
2-5
2-6
2-7
Full load delivery

Full load delivery
Start
(Full)
Load-timerAdjustment
1,000
1,000
1,000
375
100
2,350
1,000
Charge air press

kPa { mmHg }
Settings
Difference in
delivery(cm3)
(cm3/1,000st)
(cm3/1,000st)
539 20 {5.5 0.2} kPa {kgf/cm2}
3.50.2
(mm)
12.92.0
(cm3/1,000st)
)
(90 20.0
(cm3/1,000st)
15.0
17.82.0
(cm3/1,000st)
2.30.2
(mm)
58.30.5
4.5
2.0
3. Test Specifications
3-1 Timing device
N=r/min
mm
3-2 Supply pump
N=r/min
kPa{kgf/cm2}
1,000
3.5 0.3
1,000
539 39
{5.5 0.4}
N=r/min
cm3/min
1,000
390 130
600
(1.4 0.5)
1,800
(7.4 0.5)
1,800
736 59
{7.5 0.6}
2,050
0.4
8.2
0.5

Speed control
lever position
Max. speed
Pump speed
( r / min )
1,000
500
800
1,500
1,800
2,350
2,600
Fuel delivery
(cm3/1,000st)
Charge air press

kPa { mmHg }
58.31
(52.03.5)
(57.13.5)
(58.33)
(60.53)
17.82.5
Below 5.0
4. Dimensions
K
KF
MS
BCS
Pre-stroke
3.30.1
5.620.1
0.90.1
0.1 0.02
mm
mm
mm
mm
mm
Control lever angle
(Idle)
Switch OFF
Magnet valve
375
Idling
375
12.92.5
3-5 Solenoid
55.52.0
32.55.0
Max. cut-in voltage : 8 V, Test voltage : 1214 V

Service Department
3-4-1 Kitano,Niiza-shi, Saitama-ken, 352-8572, JAPAN

Tel. (048) 470-1559
Fax. (048) 474-9856
104741-4760
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
Pump Speed
Fuel injection
Quantity
1,000
29.00.5
kPa - mmHg
r/min
cm3/1000st
(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=1722Nm1.72.2 kgfm
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)
{-}
2/2
104741-6670
104745-0074
ZEXEL Ass'y No.
104745-0074
Bosch Ass'y No.
9 460 614 810
28/05/07 13:16:08
Page 1
Bosch Typecode
Engine Type
WLT
Manufacturer
MAZDA
Edition date
23/10/06 (5)
CAT Designation
Unit
Test oil
Set value
min.
max.
45
50
Actual values
OT
Actual values
OT
Actual values
OT
ISO4113orSAEJ967
d
1404 Test oil
degC
45
Nozzle
105780-0060
Bosch type code
NP-DN0SD1510
Nozzle holder
105780-2150
Opening Pressure
MPa
13
13
13.3
Opening Pressure
kgf/cm2
133
133
136
Injection pipe
P
Injection pipe
157805-7320
mm
2-6-450

Joint assembly
157641-4720
Tube assembly
157641-4020
kPa
20
20
20
kgf/cm2
0.2
0.2
0.2
L
Left
(Sorenoid Timer Adjustment Condition)
ON
With S/T O-ring; S/T ON.
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
750
750
750
Boost pressure
kPa
Boost pressure
mmHg
mm3/st.
47.9
47.4
48.4
mm3/st.
Basic
Oil temperature
*
degC
50
48
52
Unit
Set value
min.
max.
Remarks
NA
CAT Designation
P
Pump speed
r/min
750
750
750
Boost pressure
kPa
43.3
42
44.6
Boost pressure
mmHg
325
315
335
mm3/st.
64.1
63.6
64.6
mm3/st.
5.5
Basic
Oil temperature
*
degC
Remarks
CBS

5.5
50
48
52
104745-0074
CAT Designation
28/05/07 13:16:08
Unit
Set value
min.
max.
Pump speed
r/min
1000
1000
1000
Boost pressure
kPa
80
78.7
81.3
Boost pressure
mmHg
600
590
610
mm3/st.
76.3
75.8
76.8
mm3/st.
6.5
Basic
Oil temperature
Page 2
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
6.5
*
degC
50
48
52
Unit
Set value
min.
max.
Remarks
Full
CAT Designation
P
Pump speed
r/min
750
750
750
Boost pressure
kPa
Boost pressure
mmHg
mm3/st.
47.9
46.9
48.9
mm3/st.
4.5
Basic
Oil temperature
4.5
*
degC
50
48
52
Unit
Set value
min.
max.
Remarks
NA
CAT Designation
P
Pump speed
r/min
750
750
750
Boost pressure
kPa
43.3
42
44.6
Boost pressure
mmHg
325
315
335
mm3/st.
64.1
63.1
65.1
mm3/st.
Basic
Oil temperature
*
degC
50
48
52
Remarks
CBS
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
1000
1000
1000
Boost pressure
kPa
80
78.7
81.3
Boost pressure
mmHg
600
590
610
mm3/st.
76.3
75.3
77.3
mm3/st.
Basic
Oil temperature
*
degC
50
48
52
Remarks
Full
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
2000
2000
2000
Boost pressure
kPa
80
78.7
81.3
Boost pressure
mmHg
600
590
610
mm3/st.
67.8
64.3
71.3
Oil temperature
degC
50
48
52
About
2.2 Governing
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
2450
2450
2450
Boost pressure
kPa
80
78.7
81.3
Boost pressure
mmHg
600
590
610

104745-0074
28/05/07 13:16:08
mm3/st.
23.5
mm3/st.
Basic
Oil temperature
CAT Designation
19.5
23.5
7
*
degC
55
52
58
Unit
Set value
min.
max.
Pump speed
r/min
2800
2800
2800
Boost pressure
kPa
80
78.7
81.3
Boost pressure
mmHg
600
590
610
mm3/st.
Oil temperature
degC
55
52
58
CAT Designation
Page 3
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Unit
Set value
min.
max.
Pump speed
r/min
2450
2450
2450
Boost pressure
kPa
80
78.7
81.3
Boost pressure
mmHg
600
590
610
mm3/st.
23.5
13.5
33.5
mm3/st.
7.5
Basic
Oil temperature
7.5
*
degC
55
52
58
Unit
Set value
min.
max.
2.3 Idle
CAT Designation
P
Pump speed
r/min
370
370
370
Boost pressure
kPa
Boost pressure
mmHg
mm3/st.
10.5
9.5
11.5
mm3/st.
1.7
Basic
Oil temperature
CAT Designation
1.7
*
degC
48
46
50
Unit
Set value
min.
max.
Pump speed
r/min
370
370
370
Boost pressure
kPa
Boost pressure
mmHg
mm3/st.
10.5
12
mm3/st.
2.2
Basic
Oil temperature
2.2
*
degC
48
46
50
Unit
Set value
min.
max.
2.4 Partial injection quantity

CAT Designation
P
Pump speed
r/min
400
400
400
Boost pressure
kPa
Boost pressure
mmHg
mm3/st.
17
15
19
mm3/st.
About
P
Oil temperature
degC
48
46
50
2.5 Start
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
150
150
150
Boost pressure
kPa
Boost pressure
mmHg
mm3/st.
70
55
90
Basic
Oil temperature
46
50

*
degC
48
104745-0074
28/05/07 13:16:08
Page 4
Remarks
Full
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
150
150
150
Boost pressure
kPa
Boost pressure
mmHg
mm3/st.
70
50
90
Oil temperature
48
46
50
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
About
degC
Remarks
Full
2.6 Stop
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
370
370
370
Boost pressure
kPa
Boost pressure
mmHg
mm3/st.
Oil temperature
degC
48
46
50
Remarks
Magnet OFF at idling position
2.7 Overflow
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
1000
1000
1000
Boost pressure
kPa
80
78.7
81.3
Boost pressure
mmHg
600
590
610
Overflow quantity with S/T ON
cm3/min
430
300
560
Overflow quantity with S/T OFF
cm3/min
450
320
580
Oil temperature
degC
50
48
52
Unit
Set value
min.
max.
About
CAT Designation
P
Pump speed
r/min
1000
1000
1000
Boost pressure
kPa
80
78.7
81.3
Boost pressure
mmHg
600
590
610
Pressure WITH S/T ON
kPa
510
481
539
kgf/cm2
5.2
4.9
5.5
Pressure with S/T OFF
kPa
422
383
461
kgf/cm2
4.3
3.9
4.7
Basic
Oil temperature
50
48
52
Unit
Set value
min.
max.
*
degC
Remarks
ON
CAT Designation
P
Pump speed
r/min
1000
1000
1000
Boost pressure
kPa
80
78.7
81.3
Boost pressure
mmHg
600
590
610
kPa
510
471
549
kgf/cm2
5.2
4.8
5.6
Basic
Oil temperature
48
52
*
degC
Remarks
ON
50
104745-0074
28/05/07 13:16:08
Page 5
2.9 Timer
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
1000
1000
1000
Boost pressure
kPa
80
78.7
81.3
Boost pressure
mmHg
600
590
610
Timer stroke with S/T ON
mm
4.8
4.6
Timer stroke with S/T OFF
mm
3.2
2.8
3.6
Basic
Oil temperature
50
48
52
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
*
degC
Remarks
ON
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
500
500
500
Boost pressure
kPa
80
78.7
81.3
Boost pressure
mmHg
600
590
610
mm
2.2
1.4
Oil temperature
degC
48
46
50
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
1000
1000
1000
Boost pressure
kPa
80
78.7
81.3
Boost pressure
mmHg
600
590
610
mm
4.8
4.4
5.2
mm
3.2
2.6
3.8
Basic
Oil temperature
50
48
52
*
degC
Remarks
ON
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
2000
2000
2000
Boost pressure
kPa
80
78.7
81.3
Boost pressure
mmHg
600
590
610
mm
9.4
8.6
10.2
mm
7.8
6.8
8.8
degC
50
48
52
About
P
Oil temperature
2.10 Magnet
CAT Designation
Unit
Set value
min.
max.
MAX applied voltage
Test voltage
13
12
14

104745-0074
28/05/07 13:16:08
Page 6

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

104745-0074
28/05/07 13:16:08
Page 7

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)
Q1=24.6+1.5+0.1(mm3/st)
V1=4.81+0.01-0.05(V)
Vi=10(V)
Adjustment of the potentiometer

Dummy bolt method
1. Hold the dummy bolt against the control lever at position Np = N1 (r/min) and Q = Q1 (mm3/st
) 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)
L2=3.8(mm)
P1=-66.6(kPa)
P2=-500(mmHg)
T=6~9(Nm)(0.6~0.9(kgfm))
a=9(deg)
b=12.5+-4(deg)

(1)Wire length confirmation

Accelerator wire (idle~full stroke: L1 mm)
(2)Idle switch confirmation
Confirm that the switch is ON in the control lever's idle position.
(3)Adjustment of the two stage actuator
1. Apply negative pressure P1 kPa {P2 mmHg} to the actuator through the negative pressure suc
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
104745-0074
28/05/07 13:16:08
Page 8

Name
DASHPOT ADJUSTMENT
L=8.1+-0.05(mm)
a=14.1(deg)
b=12.5+-4(deg)
L=8.1+-0.05(mm)
T=6~9(N-m)(0.6~0.9(kgf-m))
a=14.1(deg)
b=12.5+-4(deg)
Adjustment of the dash pot

1. Hold the control lever (A) at position a (clearance L).
2. In the above condition, adjust the position of the dash pot so that the end of the dash pot (B) c
ontacts the control lever (A) and fix using the nut (C).
(Tightening torque T)
D:Dash pot contact position
b:Angle alpha
CAT Designation
Unit
Set value
min.
max.
K dimension
mm
3.3
3.2
3.4
KF dimension
mm
6.01
5.91
6.11
MS dimension
mm
0.9
0.8
BCS stroke
mm
6.8
6.6
Pre-stroke
mm
0.03
0.01
0.05
deg.
12.5
8.5
16.5
deg.
40
37
43

Actual values
OT
104745-9160
ZEXEL Ass'y No.
104745-9160
Bosch Ass'y No.
9 460 613 020
26/06/03 09:56:56
Page 1
Bosch Typecode
Engine Type
TD27-T
Manufacturer
NISSAN DIESEL
Edition date
01/11/02
CAT Designation
Unit
Test oil
Set value
min.
max.
45
50
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
ISO4113orSAEJ967
d
...
degC
45
Nozzle
105780-0060
Bosch type code
NP-DN0SD1510
Nozzle holder
105780-2150
Opening Pressure
MPa
13
13
13.3
Opening Pressure
kgf/cm2
133
133
136
Iinjection Pipe
P
Iinjection Pipe
157805-7320
mm
2-6-450

Joint Assembly
157641-4720
Tube Assembly
157641-4020
kPa
20
20
20
kgf/cm2
0.2
0.2
0.2
R
Right
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
850
850
850
Boost pressure
kPa
32
30.7
33.3
Boost pressure
mmHg
240
230
250
mm3/st.
56
55.5
56.5
Basic
Oil temperature
50
48
52
Unit
Set value
min.
max.
*
degC
Remarks
BCS
CAT Designation
P
Pump speed
r/min
1100
1100
1100
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
mm3/st.
66.2
65.7
66.7
mm3/st.
Basic
Oil temperature
*
degC
50
48
52
Remarks
Full
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
500
500
500
Boost pressure
kPa

104745-9160
26/06/03 09:56:56
Boost pressure
mmHg
mm3/st.
47.5
44.5
50.5
degC
48
46
50
Page 2
About
P
Oil temperature
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
850
850
850
Boost pressure
kPa
Boost pressure
mmHg
mm3/st.
47.6
44.6
50.6
Oil temperature
degC
50
48
52
Unit
Set value
min.
max.
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
About
CAT Designation
P
Pump speed
r/min
850
850
850
Boost pressure
kPa
32
30.7
33.3
Boost pressure
mmHg
240
230
250
mm3/st.
56
55
57
Basic
Oil temperature
50
48
52
Unit
Set value
min.
max.
*
degC
Remarks
BCS
CAT Designation
P
Pump speed
r/min
1100
1100
1100
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
mm3/st.
66.2
65.2
67.2
mm3/st.
5.5
Basic
Oil temperature
5.5
*
degC
50
48
52
Unit
Set value
min.
max.
Remarks
Full
CAT Designation
P
Pump speed
r/min
1500
1500
1500
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
mm3/st.
66.9
64.4
69.4
degC
50
48
52
About
P
Oil temperature
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
2000
2000
2000
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
mm3/st.
60
57.5
62.5
degC
50
48
52
About
P
Oil temperature
2.2 Governing
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
2500
2500
2500
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
mm3/st.
23.4
21.4
25.4
Basic
Oil temperature
52
58

*
degC
55
104745-9160
CAT Designation
26/06/03 09:56:56
Unit
Set value
min.
max.
Pump speed
r/min
2700
2700
2700
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
mm3/st.
10
Oil temperature
degC
55
52
58
Unit
Set value
min.
max.
CAT Designation
Page 3
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
10
Pump speed
r/min
2250
2250
2250
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
mm3/st.
47.9
43.4
52.4
Oil temperature
degC
52
50
54
Unit
Set value
min.
max.
About
CAT Designation
P
Pump speed
r/min
2500
2500
2500
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
mm3/st.
23.4
20.4
26.4
Basic
Oil temperature
*
degC
55
52
58
2.3 Idle
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
400
400
400
Boost pressure
kPa
Boost pressure
mmHg
mm3/st.
7.9
5.9
9.9
mm3/st.
Basic
Oil temperature
CAT Designation
*
degC
48
46
50
Unit
Set value
min.
max.
Pump speed
r/min
400
400
400
Boost pressure
kPa
Boost pressure
mmHg
mm3/st.
7.9
5.4
10.4
mm3/st.
2.5
Basic
Oil temperature
2.5
*
degC
48
46
50
Unit
Set value
min.
max.
2.4 Start
CAT Designation
P
Pump speed
r/min
100
100
100
Boost pressure
kPa
Boost pressure
mmHg
mm3/st.
75
65
95
48
46
50
Unit
Set value
min.
max.
About
P
Basic
Oil temperature
*
degC
Remarks
Full
CAT Designation
P
Pump speed
r/min
100
100
100
Boost pressure
kPa
Boost pressure
mmHg

104745-9160
Oil temperature
mm3/st.
26/06/03 09:56:56
75
60
95
48
46
50
Unit
Set value
min.
max.
Page 4
About
degC
Remarks
Full
2.5 Stop
CAT Designation
P
Pump speed
r/min
400
400
400
Boost pressure
kPa
Boost pressure
mmHg
mm3/st.
Oil temperature
degC
48
46
50
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Remarks
2.6 Overflow
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
1100
1100
1100
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
cm3/min
553
423
683
50
48
52
About
P
Oil temperature
degC
Remarks
Without an O-ring
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
1100
1100
1100
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
cm3/min
440
310
570
50
48
52
Unit
Set value
min.
max.
About
P
Oil temperature
degC
Remarks
With an O-ring
CAT Designation
P
Pump speed
r/min
1100
1100
1100
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
kPa
647
608
686
6.6
6.2
About
S
kgf/cm2
About
kPa
481
461
501
kgf/cm2
4.9
4.7
5.1
Basic
Oil temperature
50
48
52
*
degC
Remarks
OFF
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
1100
1100
1100
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510

104745-9160
26/06/03 09:56:56
kPa
481
442
520
kgf/cm2
4.9
4.5
5.3
Basic
Oil temperature
CAT Designation
Page 5
*
degC
50
48
52
Unit
Set value
min.
max.
Pump speed
r/min
1500
1500
1500
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
kPa
588
549
627
5.6
6.4
Oil temperature
degC
50
48
52
Unit
Set value
min.
max.
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
About
kgf/cm2
About
2.8 Timer
CAT Designation
P
Pump speed
r/min
1100
1100
1100
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
mm
6.6
6.2
4.4
4.2
4.6
Basic
Oil temperature
50
48
52
About
mm
*
degC
Remarks
OFF
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
1100
1100
1100
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
mm
6.6
6.1
7.1
4.4
4.1
4.7
Basic
Oil temperature
About
CAT Designation
mm
*
degC
50
48
52
Unit
Set value
min.
max.
Pump speed
r/min
1500
1500
1500
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
mm
8.1
7.6
8.6
6.2
5.7
6.7
degC
50
48
52
Unit
Set value
min.
max.
About
C
mm
About
Oil temperature
CAT Designation
P
Pump speed
r/min
2000
2000
2000
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
mm
7.9
7.3
8.5
Oil temperature
degC
50
48
52
Unit
Set value
min.
max.
About
2.9 Magnet
CAT Designation
104745-9160
26/06/03 09:56:56
MAX applied voltage
Test voltage
13
12
14
Unit
Set value
min.
max.
Page 6
2.10 Compensator
CAT Designation
P
Pump speed
r/min
1100
1100
1100
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
mm3/st.
45
44.5
45.5
Timer stroke TA
mm
3.8
3.6
mm
0.6
0.6
0.6
Actual values
OT
Actual values
OT
Actual values
OT
About
P
Basic
Oil temperature
CAT Designation
degC
50
48
52
Unit
Set value
min.
max.
Pump speed
r/min
1100
1100
1100
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
mm3/st.
45
44
46
Timer stroke TA
mm
3.8
3.5
4.1
Basic
Oil temperature
CAT Designation
degC
50
48
52
Unit
Set value
min.
max.
Pump speed
r/min
1100
1100
1100
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
mm3/st.
34
31.5
36.5
Timer stroke TA
mm
2.5
3.5
50
48
52
About
P
Oil temperature
degC

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

104745-9160
V1=3.72+-0.03V
P1=0kPa
P2=0mmHg
Vi=10V
26/06/03 09:56:56
Page 7
Potentiometer adjustment
1. Applied voltage: Vi
2. Boost pressure = P1kPa {P2 mmHg}
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
CAT Designation
Unit
Set value
min.
max.
K dimension
mm
3.3
3.2
3.4
KF dimension
mm
5.4
5.3
5.5
MS dimension
mm
0.9
1.1
Varid Stroke
mm
0.964
0.944
0.984
deg.
10
14
deg.
36
31
41
About

Actual values
OT
TEST OIL:
ISO 4113 or
SAE J967d
1/4
Assy No. 104745-9173

3
25 Jun. 2001
Date:
Injection pump No : 104645-9173 [NP-VE 4/10F2000RNP1442 ]
Pump rotation :
16700 86P03
No.
than the following.
CONFIDENTIAL
ENGINE MODEL : TD27- T
When no instruction, adjust and confirm with S/T OFF.
1. Test Conditions
1-5Fuel oil tempetature : 45C

1-6Supply pump pressure : 20kPa {0.2kgf/cm2}
1-7Joint assy : 157641-4720
1-8Tube assy : 157641-4020
1-1Nozzle : 105780-0060(NP-DN0SD1510)
1-2Nozzle holder : 105780-2150
1-3Nozzle opening pressure : 13.0+0.3MPa {133+3kgf/cm2}
1-4Injection pipe : 2 6 450mm
Pump speed
( r / min )
2. Setting
2-1
2-2
2-3
2-4
2-5
2-6
2-7
Full load delivery

Full load delivery
Full load delivery
Start
(Full)
Load-timer Adjustment
1,100 (Full)
850 (BCS)
500 (NA)
OFF
1,100
OFF
1,100
400
100
2,500
1,100
Charge air press

3. Test SpecifiSolenoid Timer
cations
3-1 Timing device
N=r/min
mm
3-2 Supply pump
N=r/min
kPa{kgf/cm2}
3-3 Overflow deliverey
Charge air press

kPa { mmHg }
Difference in
delivery(cm3)
66.7 1.3{500 10}

32.0 1.3{240 10}
0
66.7 1.3{500 10}
66.7 1.3{500 10}
0
0
66.7 1.3{500 10}
66.7 1.3{500 10}
5.0
Settings
65.2 0.5
55.4 0.5
48.4 0.5
451 20 {4.6 0.2}
4.2 0.2
10.2 2.0
20.0
(75.0
15.0)
23.5 2.0
3.6 0.2
(cm3/1,000st)
(cm3/1,000st)
(cm3/1,000st)
kPa {kgf/cm2}
(mm)
(cm3/1,000st)
(cm3/1,000st)
(cm3/1,000st)
(mm)
2.0
66.7 1.3 kPa {500 10 mmHg}

OFF
ON
1,100
(6.4 0.5)
1,100
4.2 0.3
1,100
451 39
{4.6 0.4}
1,500
(6.4 0.5)
1,500
(549 39)
{(5.6 0.4)}
2,000
0.4
7.0
0.5
1,100 (O-Ring less) 1,100 (O-Ring)

550 130
430 130
N=r/min
cm3/min

Speed control
lever position
Max. speed
Pump speed
( r / min )
1,100 (Full)
850 (BCS)
500 (NA)
850
1,500
2,000
2,250
2,500
2,700
Fuel delivery
(cm3/1,000st)
65.2 1.0
55.4 1.0
48.4 1.0
(47.4 2.5)
(64.0 2.5)
(58.3 3.0)
(44.9 4.5)
23.5 3.0
Below 10.0
66.7 1.3{500 10}

32.0 1.3{240 10}
0
0
66.7 1.3{500 10}
66.7 1.3{500 10}
66.7 1.3{500 10}
66.7 1.3{500 10}
66.7 1.3{500 10}
(Idle)
Switch OFF
Magnet valve
350
Idling
400
10.2 2.5
3-5 Solenoid
Charge air press

kPa { mmHg }
4. Dimensions
K
KF
MS
BCS
Pre-stroke
mm
mm
mm
mm
mm
Control lever angle
10.0 4.0
36.0 5.0
3.3 0.1
5.9 0.1
1.0 0.1
Max. cut-in voltage : 8 V, Test voltage : 1214 V

Service Department

Tel. (048) 470-1559
Fax. (048) 474-9856
104745-9173
Boost Pressure
Pump Speed
Fuel injection
Quantity
66.71.3
1,100
44.00.5
kPa
50010 mmHg
r/min
cm3/1000st
(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=1722Nm1.72.2 kgfm
timer stroke.

Specified Values
Pump speed Fuel Injection q'ty Boost pressure Timer stroke Timer reduction value
mm
mm
r/min
cm3/1,000st kPa mmHg
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
2/4
104745-9173
Boost compensator adjustment BCS
1.
2.
3.
4.
Adjust full load injection quantities to value as described in item 2-1.

Adjust BCS's injection quantities to value as described in item 2-1 .
Confirm the NA's injection quantities to value as described in item 2-1.
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.
3/4
104745-9173
Function
Specs
ON, OFF
Switch Specs
Pump speed
(r/min)
Out-put
(V)
Fuel injection q'ty Control lever

(cm3/1,000st)
position
850
3.72 0.03
20.9 1.0
Adjustment point
(2.18 0.43)
Idle
(8.10 0.58)
Full
(1.4
)
ON OFF
(15.9
)
OFF ON
Remarks
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.
4/4
104745-9570
Doowon
Refer to Kia
104746-1012
ZEXEL Ass'y No.
104746-1012
Bosch Ass'y No.
9 460 612 303
13/05/03 08:58:43
Page 1
Bosch Typecode
Engine Type
4JG2
Manufacturer
ISUZU
Edition date
24/12/02 (5)
CAT Designation
Unit
Test oil
Set value
min.
max.
45
50
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
ISO4113orSAEJ967
d
...
degC
45
Nozzle
105780-0060
Bosch type code
NP-DN0SD1510
Nozzle holder
105780-2150
Opening Pressure
MPa
13
13
13.3
Opening Pressure
kgf/cm2
133
133
136
Iinjection Pipe
P
Iinjection Pipe
157805-7320
mm
2-6-450

Joint Assembly
157641-4720
Tube Assembly
157641-4020
kPa
20
20
20
kgf/cm2
0.2
0.2
0.2
R
Right
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
1000
1000
1000
mm3/st.
60.9
60.4
61.4
mm3/st.
3.5
Basic
Oil temperature
CAT Designation
3.5
*
degC
50
48
52
Unit
Set value
min.
max.
Pump speed
r/min
500
500
500
mm3/st.
60
60
60
degC
48
46
50
Unit
Set value
min.
max.
About
P
Oil temperature
CAT Designation
P
Pump speed
r/min
1000
1000
1000
mm3/st.
60.9
59.9
61.9
mm3/st.
3.5
Basic
Oil temperature
CAT Designation
3.5
*
degC
50
48
52
Unit
Set value
min.
max.
Pump speed
r/min
1440
1440
1440
mm3/st.
58.9
58.9
58.9
Oil temperature
50
48
52
About

degC
104746-1012
CAT Designation
13/05/03 08:58:43
Unit
Set value
min.
max.
Pump speed
r/min
1800
1800
1800
mm3/st.
59.2
59.2
59.2
Oil temperature
degC
50
48
52
Unit
Set value
min.
max.
Page 2
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
About
2.2 Governing
CAT Designation
P
Pump speed
r/min
2100
2100
2100
mm3/st.
19.6
16.6
22.6
mm3/st.
5.5
Basic
Oil temperature
CAT Designation
5.5
*
degC
52
50
54
Unit
Set value
min.
max.
Pump speed
r/min
2300
2300
2300
mm3/st.
Oil temperature
degC
52
50
54
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
2100
2100
2100
mm3/st.
19.6
16.6
22.6
mm3/st.
5.5
Oil temperature
degC
52
50
54
5.5
2.3 Idle
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
360
360
360
mm3/st.
13.2
11.2
15.2
mm3/st.
Basic
Oil temperature
CAT Designation
*
degC
48
46
50
Unit
Set value
min.
max.
Pump speed
r/min
360
360
360
mm3/st.
13.2
11.2
15.2
mm3/st.
Oil temperature
degC
48
46
50
2.4 Start
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
100
100
100
mm3/st.
80
80
120
Basic
Oil temperature
48
46
50
Unit
Set value
min.
max.
*
degC
Remarks
Full
CAT Designation
P
Pump speed
r/min
100
100
100
mm3/st.
80
80
120
Oil temperature
degC
48
46
50
Unit
Set value
min.
max.
About
2.5 Stop
CAT Designation
P
Pump speed
r/min
360
360
360
mm3/st.
Oil temperature
degC
48
46
50
Remarks
104746-1012
13/05/03 08:58:43
Page 3
Magnet OFF
2.6 Overflow
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
1000
1000
1000
Overflow quantity
cm3/min
680
550
810
degC
50
48
52
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
About
P
Oil temperature

CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
1000
1000
1000
Pressure
kPa
422
393
451
Pressure
kgf/cm2
4.3
4.6
Basic
Oil temperature
CAT Designation
*
degC
50
48
52
Unit
Set value
min.
max.
Pump speed
r/min
1000
1000
1000
Pressure
kPa
422
393
451
Pressure
kgf/cm2
4.3
4.6
Basic
Oil temperature
*
degC
50
48
52
Unit
Set value
min.
max.
2.8 Timer
CAT Designation
P
Pump speed
r/min
1000
1000
1000
Timer Stroke
mm
2.5
2.3
2.7
Basic
Oil temperature
CAT Designation
*
degC
50
48
52
Unit
Set value
min.
max.
Pump speed
r/min
1700
1700
1700
Timer Stroke
mm
5.8
5.5
6.1
Basic
Oil temperature
CAT Designation
*
degC
50
48
52
Unit
Set value
min.
max.
Pump speed
r/min
520
520
520
Timer Stroke
mm
0.5
0.1
1.3
Oil temperature
degC
50
48
52
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
1000
1000
1000
Timer Stroke
mm
2.5
2.3
2.7
Basic
Oil temperature
CAT Designation
*
degC
50
48
52
Unit
Set value
min.
max.
Pump speed
r/min
1440
1440
1440
Timer Stroke
mm
3.9
3.6
4.2
Oil temperature
degC
50
48
52
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
1700
1700
1700
Timer Stroke
mm
5.8
5.4
6.2
Basic
Oil temperature
CAT Designation
P
Pump speed

*
degC
50
48
52
Unit
Set value
min.
max.
r/min
1950
1950
1950
104746-1012
13/05/03 08:58:43
Timer Stroke
mm
7.8
7.5
8.2
Oil temperature
degC
50
48
52
Unit
Set value
min.
max.
Page 4
2.9 Magnet
CAT Designation
C
MAX applied voltage
Test voltage
13
12
14
Unit
Set value
min.
max.
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
2.10 Compensator
CAT Designation
P
Pump speed
r/min
1000
1000
1000
mm3/st.
31.8
31.3
32.3
Timer stroke TA
mm
2.2
2.2
2.2
0.3
0.1
0.5
About
S
Basic
Oil temperature
mm
CAT Designation
degC
50
48
52
Unit
Set value
min.
max.
Pump speed
r/min
1000
1000
1000
mm3/st.
31.8
30.8
32.8
mm
0.3
-0.1
0.7
Basic
Oil temperature
CAT Designation
degC
50
48
52
Unit
Set value
min.
max.
Pump speed
r/min
1000
1000
1000
mm3/st.
16.7
15.7
17.7
mm
0.4
1.6
Oil temperature
degC
50
48
52

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)

104746-1012
Name
13/05/03 08:58:43
Page 5
V-FICD ADJUSTMENT
T=3.4~4.9N-m(0.35~0.50kgf-m)
L1=1.40+-0.1mm
L1=1.40+-0.1mm
L2=0.5mm
L3=5mm
P1=-53.3kPa
P2=-400mmHg
Adjustment of the V-FICD

1. Insert the shim of L1 between the control lever (A) and the idle adjusting screw (B).
Adjust using the FICD adjusting screw (C) so that the actuator moves through its full stroke, then
fix using the nut (D).
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
CAT Designation
Unit
Set value
min.
max.
K dimension
mm
3.3
3.2
3.4
KF dimension
mm
5.8
5.7
5.9
MS dimension
mm
0.7
0.6
0.8
Pre-stroke
mm
0.1
0.08
0.12
deg.
18
14
22
deg.
31
26
36

Actual values
OT
Test Data
104746 6890
use
104746 -
6152
TEST OIL:
ISO 4113 or
SAE J967d
1/6
Assy No. 104749-5372

5
4 July 2002
Date:
Injection pump No : 104649-5372 [NP-VE 4/9F2250RNP1386
]
ISUZU
Company:
Pump rotation :
8 97088 463 0
No.
than the following.
CONFIDENTIAL
ENGINE MODEL : 4EE1TC
1. Test Conditions
1-5 Fuel oil temperature : 45+5C
1-6 Supply pump pressure : 20kPa {0.2kgf/cm2}
1-7 Joint assy : 157641-4720
1-8 Tube assy : 157641-4020
1-1 Nozzle : 105780-0060(NP-DN0SD1510)

1-2 Nozzle holder : 105780-2150
1-3 Nozzle opening pressure : 13.0+0.3MPa {133+3kgf/cm2}
1-4 Injection pipe :26450mm
Pump speed
( r / min )
2. Setting
2-1
2-2
2-3
2-4
2-5
2-6
2-7
Full load delivery

Full load delivery
(Idle)
Start
1,500 (Full)
750 (BCS)
1,250
1,250
425
150
2,650
3. Test Specifi- Charge air

press
cations
Settings
49.2 0.5
43.8 0.5
412 20 {4.2 0.2}
4.7 0.2
10.2 2.0
40.0 10
24.4 3.0
Difference in
delivery(cm3)
72.0 1.3{540 10}

26.7 1.3{200 10}
72.0 1.3{540 10}
72.0 1.3{540 10}
0
0
72.0 1.3{540 10}
3.5
3.5
2.0
5.5
72.0 1.3kPa {540 10mmHg}
3-1 Timing device
N=r/min
mm
3-2 Supply pump
N=r/min
kPa{kgf/cm2}
1,250
4.70.2
1,250
412 20
{4.2 0.2}
N=r/min
cm3/min
1,250
630 130
(cm3/1,000st)
(cm3/1,000st)
kPa {kgf/cm2}
(mm)
(cm3/1,000st)
(cm3/1,000st)
(cm3/1,000st)
Charge air press

kPa { mmHg }
600
1.0
0.5
0.4
1,500
6.30.4
2,000
0.4
9.0
0.3

Speed control
lever position
Max. speed
Pump speed
( r / min )
1,500 (Full)
750 (BCS)
550
750
1,500
2,250
2,650
2,950
Switch OFF
Magnet valve
425
Idling
425
3-5 Solenoid
Fuel delivery
(cm3/1,000st)
49.2 1
43.8 1.0
(38.3 3)
(46.0 2.5)
35.6 2.5
(50.8 3)
24.4 3
Below 4
Charge air press

kPa { mmHg }
72.0 1.3{540 10}
26.7 1.3{200 10}
0
33.3 1.3{250 10}
0
72.0 1.3{540 10}
72.0 1.3{540 10}
72.0 1.3{540 10}
0 (Idle)
10.2 2
4. Dimensions
K
KF
MS
BCS
Pre-stroke
0
0
3.3 0.1
5.8 0.1
0.9 0.1
-
mm
mm
mm
mm
mm
Control lever angle

20 4
()
40 3
()
()
Max. cut-in voltage : 8 V, Test voltage : 12~14 V

Service Department

Tel. (048) 470-1559
Fax. (048) 474-9856
104749-5372
Pump speed
(r/min)
Out-put voltage
(V)
750
2.760.03
Fuel injection q'ty

Remarks
(cm3/1,000st)
13.81.0
BCS pre.:72kPa{540mmHg} Adjusting point
1.180.45
Check point
7.850.65
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
2/6
104749-5372
V-FICD Adjustment (Adjust with W-FICD disengaged)
1. Adjust so that S=1+1mm. (Figure 1)
Pin
S
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=0.840.1 (Figure 2)
Actuator
Locknut (T=1.2~1.5 Nm {0.12~0.15 kgfm})

Stroke adjusting screw
Fig.2
3/6
104749-5372
W-CSD adjustment
1. Timer stroke adjustment
Adjust the screw 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=1.20.05) between the control lever and the idle set screw , align
the intermediate lever 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 (L0.05) between the control lever and the idle set screw and adjust the
screw so that the CSD lever operates the intermedate lever through the rod .
Then, fix the screw. (Figures 1,2 and 3)
LINE ON BRACKET 8
EDGE OF LEVER 6
Figure 1
Figure 2
4/6
104749-5372
0.2 (mm)
1 ()
Timer stroke TA (mm)
7
6
5
3
0.5
2
1
0
15
20
25
Control lever position(deg),
8
1.5
L (mm)
30
Temperature t (C)
Figure 3
Timer stroke (mm) ; TA =-0.041t+2.42
Lever position (deg) ; 1 =-0.108t+4.79 (-20t20)
; 2 =-0.133t+5.29 (20t50)
Lever position (mm) ; L1 =-0.035t+1.57 (-20t20)
; L2 =-0.044t+1.75 (20t50)
Note: indicates the distance between the control lever and the idle set screw.
Conditions
Cold advancer
Cooling water temp :
increasing
Pump speed : 500r/min
Cooling water
temp ()
Timer piston
stroke (mm)
Lever pos
(deg)
Lever pos
(mm)
20
1.90.4
3.61.0
1.20.3
-20
3.40.6
7.93.0
2.61
5/6
104749-5372
A/T plate adjustment
54.6
77.1
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.
3.4 4.9Nm{0.35 0.5kgfm}

Control
lever
Idle
A
B
94.3
A/T plate
A/T Brkt
188.5
6/6
104749-7150
Not Bosch/Zexel
Product of DPICO
No information available
Refer to Kia
TEST OIL:
ISO 4113 or
SAE J967d
1/3
Assy No. 104760-4441

1
Date:
19 July 2002
Injection pump No : 104660-4441 [NP-VE 6/10F2000RNP126 ]
Pump rotation :
16700 51N62
No.
than the following.
CONFIDENTIAL
ENGINE MODEL :
TD42
1. Test Conditions
1-4 Injection pipe : 26840mm
1-5 Fuel oil temperature : 45+5C
1-6 Supply pump pressure : 20kPa {0.2kgf/cm2}
1-1 Nozzle : 105780-0000(NP-DN12SD12T)

1-2 Nozzle holder : 105780-2080(EF8511/9)
1-3 Nozzle opening pressure : 14.7+0.49MPa {150+5kgf/cm2}
Pump speed
( r / min )
2. Setting
Charge air press

kPa { mmHg }
Settings
2-1
Full load delivery
1,000
50.90.5
(cm3/1,000st)
2-2
2-3
2-4
2-5
2-6
2-7

Start
(Full)
Load-timer Adjustment
1,000
1,000
350
100
2,300
1,200
32429 {3.30.2}
1.60.2
8.82
20.0
60
15.0
16.62
2.50.2
kPa {kgf/cm2}
(mm)
(cm3/1,000st)
(cm3/1,000st)
(cm3/1,000st)
(mm)
Difference in
delivery(cm3)
3.5
2.0
5.0
3. Test Specifi- Charge air

press
cations
1,000
1.60.3
1,800
5.80.5
N=r/min
kPa{kgf/cm2}
1,000
32429
{3.30.3}
1,800
60829
{6.20.4}
N=r/min
cm3/min
1,000
400130
3-1 Timing device
N=r/min
mm
3-2 Supply pump

800
0.50.5
2,200
+0.4
7.4-0.5

Speed control
lever position
Max. speed
Pump speed
( r / min )
600
1,000
2,000
2,100
2,300
2,500
Fuel delivery
(cm3/1,000st)
Charge air press

kPa { mmHg }
52.62.0
50.91.0
44.72.1
43.84.5
16.62.5
Below 5
4. Dimensions
K
KF
MS
BCS
Pre-stroke
3.30.1
6.640.1
1.00.1
-
mm
mm
mm
mm
mm
Control lever angle
Switch OFF
Magnet valve
Idling
3-5 Solenoid
350
250
350
0
(Idle)
Below 5 (Full)
8.82.5
252
( )
405
( )
( )
Max. cut-in voltage : 8 V, Test voltage : 12~14 V

Service Department

Tel. (048) 470-1559
Fax. (048) 474-9856
104760-4441
Boost Pressure :
Pump Speed
:
Fuel injection
:
Quantity
kPa { - mmHg}
r/min
cm3/1,000st
1,200
22.00.5
(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.
Specified Values
Pump
speed
(r/min)
Fuel Injection q'ty

(cm3/1,000st)
Boost pressure
(kPa {mmHg})
Timer
stroke(mm)
Timer reduction value

(mm)
1,200
22.0 1.0
{-}
2.5 0.3
1,200
15.0 2.5
{-}
2.1 0.7
2/3
3/3
104760-4441
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:
V0.03=0.044Q+20.7(V) (Input-voltage: 10V)
Potentiometer
performance
standard
Control lever
position
Out-put voltage
(V)
Idle
1.6 0.4
Full-speed
8.0 0.55
5.0
VoltageV
4.0
3.0
2.8
Change Lever angle

over point From idling
ON OFF
2.0
6.03.5
OFF ON 19.53.5
10.0
12.0
14.0
16.0
18.0
20.0
22.0
16.5
Inj/q'tycm3/1000st
Output
Potentiometer solid line
Solid line output
ON
Solid line Switch turned OFF ON
OFF
Solid line Switch turned ON OFF
104760-4650
ZEXEL Ass'y No.
104760-4650
Bosch Ass'y No.
9 460 611 678
11/03/03 16:06:42
Page 1
Bosch Typecode
Engine Type
TD42
Manufacturer
NISSAN DIESEL
Edition date
08/04/02 (3)
CAT Designation
Unit
Test oil
Set value
min.
max.
45
50
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
ISO4113orSAEJ967
d
...
degC
45
Nozzle
105780-0060
Bosch type code
NP-DN0SD1510
Nozzle holder
105780-2150
Opening Pressure
MPa
13
13
13.3
Opening Pressure
kgf/cm2
133
133
136
Iinjection Pipe
P
Iinjection Pipe
157805-7320
mm
2-6-450

Joint Assembly
157641-4720
Tube Assembly
157641-4020
kPa
20
20
20
kgf/cm2
0.2
0.2
0.2
R
Right
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
1000
1000
1000
mm3/st.
50.3
49.8
50.8
mm3/st.
3.5
Basic
Oil temperature
CAT Designation
3.5
*
degC
50
48
52
Unit
Set value
min.
max.
Pump speed
r/min
600
600
600
mm3/st.
48.8
46.3
51.3
degC
50
48
52
Unit
Set value
min.
max.
About
P
Oil temperature
CAT Designation
P
Pump speed
r/min
1000
1000
1000
mm3/st.
50.3
49.3
51.3
mm3/st.
Basic
Oil temperature
CAT Designation
*
degC
50
48
52
Unit
Set value
min.
max.
Pump speed
r/min
2000
2000
2000
mm3/st.
48.3
45.8
50.8
Oil temperature
50
48
52
About

degC
104760-4650
11/03/03 16:06:42
Page 2
2.2 Governing
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
2300
2300
2300
mm3/st.
17.8
15.8
19.8
mm3/st.
Basic
Oil temperature
CAT Designation
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
*
degC
52
50
54
Unit
Set value
min.
max.
Pump speed
r/min
2500
2500
2500
mm3/st.
Oil temperature
degC
55
52
58
Unit
Set value
min.
max.
CAT Designation
Actual values
Pump speed
r/min
2100
2100
2100
mm3/st.
48.1
43.6
52.6
degC
52
50
54
About
P
Oil temperature
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
2300
2300
2300
mm3/st.
17.8
15.3
20.3
Basic
Oil temperature
*
degC
52
50
54
2.3 Idle
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
350
350
350
mm3/st.
10.1
8.1
12.1
mm3/st.
Basic
Oil temperature
CAT Designation
*
degC
48
46
50
Unit
Set value
min.
max.
Pump speed
r/min
350
350
350
mm3/st.
10.1
7.6
12.6
mm3/st.
2.5
Basic
Oil temperature
2.5
*
degC
48
46
50
Unit
Set value
min.
max.
2.4 Start
CAT Designation
P
Pump speed
r/min
100
100
100
mm3/st.
60
50
80
Basic
Oil temperature
48
46
50
*
degC
Remarks
Full
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
100
100
100
mm3/st.
60
50
80
Oil temperature
degC
48
46
50
Unit
Set value
min.
max.
Remarks
Full
2.5 Stop
CAT Designation
P
Pump speed
r/min
350
350
350
mm3/st.

104760-4650
P
Oil temperature
degC
11/03/03 16:06:42
48
46
50
Page 3
Remarks
CAT Designation
Unit
Set value
min.
max.
250
250
Pump speed
r/min
250
mm3/st.
Oil temperature
degC
48
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
5
46
50
Remarks
Magnet OFF at full-load position
2.6 Overflow
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
1000
1000
1000
cm3/min
400
270
530
Oil temperature
degC
50
48
52
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
1000
1000
1000
cm3/min
450
320
580
Oil temperature
degC
50
48
52
Remarks
Without an O-ring
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
1000
1000
1000
kPa
539
500
578
5.5
5.1
5.9
kPa
422
402
442
kgf/cm2
4.3
4.1
4.5
Basic
Oil temperature
50
48
52
Unit
Set value
min.
max.
About
kgf/cm2
About
*
degC
Remarks
OFF
CAT Designation
P
Pump speed
r/min
1000
1000
1000
Pressure
kPa
422
393
451
Pressure
kgf/cm2
4.3
4.6
Basic
Oil temperature
CAT Designation
*
degC
50
48
52
Unit
Set value
min.
max.
Pump speed
r/min
1800
1800
1800
Pressure
kPa
686
647
725
6.6
7.4
degC
50
48
52
Unit
Set value
min.
max.
About
C
Pressure
kgf/cm2
About
Oil temperature
2.8 Timer
CAT Designation
P
Pump speed
r/min
1000
1000
1000
mm
4.6
4.2
2.9
2.7
3.1
About
S

mm
104760-4650
Basic
Oil temperature
11/03/03 16:06:42
Page 4
*
degC
50
48
52
Remarks
OFF
CAT Designation
Unit
Set value
min.
max.
Pump speed
r/min
650
650
650
mm
1.2
0.7
1.7
Oil temperature
degC
50
48
52
Unit
Set value
min.
max.
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
About
CAT Designation
P
Pump speed
r/min
1000
1000
1000
mm
4.6
4.1
5.1
2.9
2.6
3.2
Basic
Oil temperature
About
CAT Designation
mm
*
degC
50
48
52
Unit
Set value
min.
max.
Pump speed
r/min
1800
1800
1800
mm
6.6
6.1
7.1
degC
50
48
52
Unit
Set value
min.
max.
About
P
Oil temperature
CAT Designation
P
Pump speed
r/min
2200
2200
2200
mm
8.2
7.7
8.6
Oil temperature
degC
52
50
54
Unit
Set value
min.
max.
2.9 Magnet
CAT Designation
C
MAX applied voltage
16
16
16
Test voltage
25
24
26
Unit
Set value
min.
max.
2.10 Compensator
CAT Designation
P
Pump speed
r/min
1200
1200
1200
mm3/st.
32
31.5
32.5
Timer stroke TA
mm
3.4
3.2
3.6
mm
0.5
0.5
0.5
About
P
Basic
Oil temperature
CAT Designation
*
degC
50
48
52
Unit
Set value
min.
max.
Pump speed
r/min
1200
1200
1200
mm3/st.
32
31
33
Timer stroke TA
mm
3.4
3.1
3.7
Basic
Oil temperature
CAT Designation
*
degC
50
48
52
Unit
Set value
min.
max.
Pump speed
r/min
1200
1200
1200
mm3/st.
23
20.5
25.5
Timer stroke TA
mm
2.9
2.3
3.5
Oil temperature
degC
50
48
52

104760-4650
11/03/03 16:06:42
Page 5

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
b=5deg
c=5deg
L1=3.3+-0.13mm
Accelerator switch adjustment

ON - OFF changeover point: from idle to a (shim thickness A = L)
Idle~c: ON
c~full: OFF
A = shim thickness
B = idle lever position
CAT Designation
Unit
Set value
min.
max.
K dimension
mm
3.3
3.2
3.4
KF dimension
mm
5.8
5.7
5.9
MS dimension
mm
0.9
1.1
deg.
25
23
27
deg.
40
35
45

Actual values
OT
Test Data
104761-4290
use
104761-4260
2003/02/25 09:53:05
Assy name
Manufacturer No. Engine Type
1006
TD42T
P
Parts No.
Manufacturer No.
16700VC700
Make data 2003/02/25

Renew data2003/02/25
ZexelAssy 104761-4371
Manuf.
NISSAN DIESEL
B.T.C.
Parts name
Page
Modify
Edition data
Kinds
Cylinder
VE
[1] Adjustment conditions

Designation
Test oil
Nozzle
BOSCH type code
Nozzle holder
Opening Pressure
Opening Pressure
Injection Pipe No.
Injection Pipe
Joint Ass'y
Tube Ass'y
Dir.of rot.viewed fromdriveside
Checker NO.
ECU NO.
ECU Voltage D.C.
TCV Drive Voltage D.C.
TCV Drive Voltage
Wire Harness
Inter. Harness
Unit
degC
MPa
kgf/cm2
mm
kPa
kgf/cm2
PSC Set value

ISO4113orSAEJ967d
P 45+5
105780-0060
NP-DN0SD1510
105780-2150
P 13.0+0.3
P 133+3
157805-7320
P 2-6-450
157641-4720
157641-4020
P 20
P 0.2
R
407980-228*
407913-1342
Remark
Inside Die.-Outside Die.-Lengthmm)
Right
V
V
Hz
407980-2300
157992-8900
[1] Adjustment specification

[2] Full load delivery
Pump speed
Boost pressure
Boost pressure
Boost pressure
r/min
P 500
P 700
P 1000
P 500
P 700
P 1000
P 1250
P 1800
kPa
P 0
P 25.4
P 52.0
P 0
P 25.4
P 52.0
P 52.0
P 52.7
kgf/cm2
mmHg
P 0
P 190
P 390
P 0
P 190
P 390
P 390
P 390
28.0
62.5
28.0
54.6
54.6
60.7
210
410
210
410
410
410
TCV DUTY (%) F TCV Ave.inj.qty

60Hz
%
mm3/st.
P 100
S 49.7 50.7
P 100
S 55.9 56.9
P 100
S 51.5 62.5
P 100
C 49.2 51.2
P 100
C 55.4 57.4
P 100
C 61.0 63.0
P 100
C 57.7 59.7
P 100
C 52.7 60.7
Diff in dely

60Hz
%
mm3/st.
P 100
S 20.8 24.8
P 100
C 5.0-P 100
C 20.3 25.3
Diff in dely

60Hz
%
mm3/st.
P 100
S 4.6 8.6
P 100
C 4.1 9.1
P 100
C 3.0--
Diff in dely
Basic
mm3/st.
S 2.0--
P *
Basic
mm3/st.
S 5.0--
P
P
P
P
P
P
*
*
*
*
*
*
Test oil
degC
P 48+-2
P 50+-2
P 50+-2
P 48+-2
P 50+-2
P 50+-2
P 50+-2
P 50+-2
Remark
NA
BCS
FULL
NA
BCS
FULL
[2] Governing
Pump speed
Boost pressure
Boost pressure
Boost pressure
r/min
P 2300
P 2500
P 2300
kPa
P 52.0 54.6
P 52.0 54.6
P 52.0 54.6
kgf/cm2
mmHg
P 390 410
P 390 410
P 390 410
Pump speed
Boost pressure
Boost pressure
Boost pressure
r/min
P 385
P 385
P 650
kPa
P 0
P 0
P 0
kgf/cm2
mmHg
P 0
P 0
P 0
Basic
mm3/st.
P *
Test oil
Remark
degC
P 52+-2
P 55+-3
P 52+-2
[2] Idle
Test oil
degC
P 48+-2
P 48+-2
P 50+-2
Remark
Ass'y NO.
104761-4371
2003/02/25 09:53:05
Page
[2] Partial quantity

Pump speed
r/min
Boost pressure
kPa
Boost pressure
kgf/cm2
Boost pressure
mmHg
Ave.inj.qty
mm3/st.
Pump speed
Boost pressure
Boost pressure
Boost pressure
r/min
P 100
kPa
P 0
kgf/cm2
mmHg
P 0
Pump speed
Boost pressure
Boost pressure
Boost pressure
r/min
P 385
P 150
kPa
P 0
P 0
kgf/cm2
mmHg
P 0
P 0
Pump speed
Boost pressure
Boost pressure
Boost pressure
r/min
P 1100
Remark
kPa
P 52.0 54.6
kgf/cm2
mmHg
P 390 410
Diff in dely
mm3/st.
Basic
Test oil
degC
Thickness guage
mm
Remark

60Hz
%
mm3/st.
P 0
S 51.5 81.5
Diff in dely
Basic
Test oil
Remark
P *
degC
P 48+-2

60Hz
%
mm3/st.
P 100
C 0
P 0
C 5--
Diff in dely
Basic
Test oil
TCV DUTY (%) F TCV Overflow quantity

60Hz
%
cm3/min
P 100
C 468 732
S/T ON Overflow qtyS/T OFFOverflow qtyBasic
Test oil
cm3/min
cm3/min
degC
P 50+-2
TCV DUTY (%) F TCV Pressure

60Hz
%
kPa
P 100
S 550 608
P 100
C 294++
P 100
C 540 618
P 100
C 618 716
Pressure
S/T ON Pressure
S/T ON Pressure
S/T OFF Pressure
kgf/cm2
S 5.6 6.2
C 3.0++
C 5.5 6.3
C 6.3 7.3
kPa
kgf/cm2
kPa
TCV DUTY (%) F TCV Timer stroke

60Hz
%
mm
P 70
S 3.2 3.8
P 100
C 3.6 7.6
P 100
C 5.0 9.0
P 70
C 3.1 3.9
P 0
C 0
P 100
C 6.5 7.4
S/T ON Timer
stroke
mm
S/T OFF Timer

stroke
mm
Basic
Test oil
TCV DUTY (%) F TCV TA-ist

60Hz
%
V
Basic
[2] Start
mm3/st.
FULL
[2] Stop
mm3/st.
degC
P 48+-2
P 48+-2
Remark
Magnet OFF
Magnet OFF
[2] Overflow
[2] Pump chamber Pressure

Pump speed
Boost pressure
Boost pressure
Boost pressure
r/min
P 1100
P 100
P 1100
P 1800
S/T OFF Pressure
kPa
P 52.0
P 52.0
P 52.0
P 52.0
Basic
kgf/cm2
mmHg
P 390 410
P 390 410
P 390 410
P 390 410
Remark
54.6
54.6
54.6
54.6
Test oil
kgf/cm2
degC
P 50+-2
P 48+-2
P 50+-2
P 50+-2
P *
[2] Timer
Pump speed
Boost pressure
Boost pressure
Boost pressure
r/min
P 1100
P 500
P 1100
P 1100
P 1100
P 1800
Remark
kPa
P 52.0
P 52.0
P 52.0
P 52.0
P 52.0
P 52.0
kgf/cm2
mmHg
P 390
P 390
P 390
P 390
P 390
P 390
54.6
54.6
54.6
54.6
54.6
54.6
410
410
410
410
410
410
P *
[2] TPS Output

Pump speed
Boost pressure
Boost pressure
Boost pressure
r/min
kPa
kgf/cm2
mmHg
[2] Magnet
Test oil
degC
Remark
degC
P 50+-2
P 48+-2
P 50+-2
P 50+-2
P 50+-2
P 50+-2
Ass'y NO.
104761-4371
2003/02/25 09:53:05
Designation
MAX applied voltage
Test voltage
PSC Set value

C 8
P 12 14
Unit
V
V
Page
Remark
[2]
[3] Load-Timer adjustment
Designation
Explanation 2
Image
Explanation 3
Explanation 4
Pump speed
Boost pressure
Boost pressure
Boost pressure
Ave.inj.qty
Timer stroke TA
r/min
kPa
kgf/cm2
mmHg
mm3/st.
mm
Timer stroke
Basic
Change volume T
mm
Test oil
Decrease rate
%
Test oil
degC
Remark
degC
[3] ACS adjustment

Designation
Pump speed
r/min
Image
Height
m
Explanation 2
Explanation 3
Explanation 4
Pressure differencePressure differenceAve.inj.qty

kPa
mmHg
mm3/st.
Decrease quantity
mm3/st.
Basic
Remark
[3] BCS adjustment

Designation
Image
Explanation 2
Explanation 3
Explanation 4
Explanation 2
4-PM5-2F
Explanation 3
4-PM5-3 104761-4370
Explanation 4
4-PM5-4 104761-4370
[2] Additional device adjustment

[3] Additional device
Designation
Image
POTENTIOMETER ADJUSTMENT 4-PM5-1
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
P1=0kPa
P2=0mmHg
Vi=10V
Potentiometer adjustment standards (Bosch mini mass piping)

1.Applied voltage=Vi
2.Boost pressure =P1kPa{P2mmHg}
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
6.000.03 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

Designation
Image
Explanation 2
Explanation 3
Explanation 4
Explanation 2
Explanation 3
Explanation 4
Explanation 2
Explanation 3
Explanation 4
Explanation 2
Explanation 3
Explanation 4
Explanation 2
Explanation 3
Explanation 4
Explanation 2
Explanation 3
Explanation 4

Designation
Image

Designation
Image

Designation
Image

Designation
Image

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

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

Designation
K dimension
KF dimension
MS dimension
Effectiveness
BCS storoke
Pre-storoke
Control lever
Control lever
Control lever
storoke
angle
angle
angle
Unit
mm
mm
mm
mm
mm
mm
deg.
deg.
deg.
PSC Set value

S 3.2 3.4
S 6.66 6.86
S 1.2 1.4
S
S
S
S
2.7 3.1
0.08 0.12
51.5 59.5
38 48
Remark
Page
2003/02/25 09:51:55
Assy name
Manufacturer No. Engine Type
1006
TD42T
P
Parts No.
Manufacturer No.
167001Y700
Parts name
Make data 2003/02/25

Renew data2003/02/25
Manuf.
NISSAN DIESEL
B.T.C.
Page
Modify
Edition data
Kinds
Cylinder
VE
[1] Adjustment conditions

Designation
Test oil
Nozzle
BOSCH type code
Nozzle holder
Opening Pressure
Opening Pressure
Injection Pipe No.
Injection Pipe
Joint Ass'y
Tube Ass'y
Dir.of rot.viewed fromdriveside
Checker NO.
ECU NO.
ECU Voltage D.C.
TCV Drive Voltage D.C.
TCV Drive Voltage
Wire Harness
Inter. Harness
Unit
degC
MPa
kgf/cm2
mm
kPa
kgf/cm2
PSC Set value

ISO4113orSAEJ967d
P 45+5
105780-0060
NP-DN0SD1510
105780-2150
P 13.0+0.3
P 133+3
157805-7320
P 2-6-450
157641-4720
157641-4020
P 20
P 0.2
R
407980-228*
407913-1342
Remark
Inside Die.-Outside Die.-Lengthmm)
Right
V
V
Hz
407980-2300
157992-8300
[1] Adjustment specification

[2] Full load delivery
Pump speed
Boost pressure
Boost pressure
Boost pressure
r/min
P 500
P 700
P 1000
P 500
P 700
P 1000
P 1250
P 1800
kPa
P 0
P 25.4
P 52.0
P 0
P 25.4
P 52.0
P 52.0
P 52.0
kgf/cm2
mmHg
P 0
P 190
P 390
P 0
P 190
P 390
P 390
P 390
28.0
54.6
28.0
54.6
54.6
54.6
210
410
210
410
410
410

60Hz
%
mm3/st.
P 100
S 49.7 50.7
P 100
S 55.9 56.9
P 100
S 51.5 62.5
P 100
C 49.2 51.2
P 100
C 55.4 57.4
P 100
C 61.0 63.0
P 100
C 57.7 59.7
P 100
C 52.7 60.7
Diff in dely
Basic

60Hz
%
mm3/st.
P 100
S 20.8 24.8
P 100
C 5.0-P 100
C 20.3 25.3
Diff in dely

60Hz
%
mm3/st.
P 100
S 4.6 8.6
P 100
C 4.1 9.1
P 100
C 3.0--
Diff in dely
Basic
mm3/st.
S 2.0--
P *
mm3/st.
S 5.0--
P
P
P
P
P
P
*
*
*
*
*
*
Test oil
degC
P 48+-2
P 50+-2
P 50+-2
P 48+-2
P 50+-2
P 50+-2
P 50+-2
P 50+-2
Remark
NA
BCS
FULL
NA
BCS
FULL
[2] Governing
Pump speed
Boost pressure
Boost pressure
Boost pressure
r/min
P 2300
P 2500
P 2300
kPa
P 52.0 54.6
P 52.0 54.6
P 52.0 54.6
kgf/cm2
mmHg
P 390 410
P 390 410
P 390 410
Pump speed
Boost pressure
Boost pressure
Boost pressure
r/min
P 385
P 385
P 650
kPa
P 0
P 0
P 0
kgf/cm2
mmHg
P 0
P 0
P 0
Basic
mm3/st.
P *
Test oil
Remark
degC
P 52+-2
P 55+-3
P 52+-2
[2] Idle
Test oil
degC
P 48+-2
P 48+-2
P 50+-2
Remark
Ass'y NO.
104761-4381
2003/02/25 09:51:55
Page
[2] Partial quantity

Pump speed
r/min
Boost pressure
kPa
Boost pressure
kgf/cm2
Boost pressure
mmHg
mm3/st.
Pump speed
Boost pressure
Boost pressure
Boost pressure
r/min
P 100
kPa
P 0
kgf/cm2
mmHg
P 0
Pump speed
Boost pressure
Boost pressure
Boost pressure
r/min
P 385
P 150
kPa
P 0
P 0
kgf/cm2
mmHg
P 0
P 0
Pump speed
Boost pressure
Boost pressure
Boost pressure
r/min
P 1100
Remark
kPa
P 52.0 54.6
kgf/cm2
mmHg
P 390 410
Diff in dely
mm3/st.
Basic
Test oil
degC
Thickness guage
mm
Remark

60Hz
%
mm3/st.
P 0
S 51.5 81.5
Diff in dely
Basic
Test oil
Remark
P *
degC
P 48+-2

60Hz
%
mm3/st.
P 100
C 0
P 0
C 5--
Diff in dely
Basic
Test oil
TCV DUTY (%) F TCV Overflow quantity

60Hz
%
cm3/min
P 100
C 468 732
S/T ON Overflow qtyS/T OFFOverflow qtyBasic
Test oil
cm3/min
degC
TCV DUTY (%) F TCV Pressure

60Hz
%
kPa
P 100
S 550 608
P 100
C 294++
P 100
C 540 618
P 100
C 618 716
Pressure
S/T ON Pressure
S/T ON Pressure
S/T OFF Pressure
kgf/cm2
S 5.6 6.2
C 3.0++
C 5.5 6.3
C 6.3 7.3
kPa
kgf/cm2
kPa
TCV DUTY (%) F TCV Timer stroke

60Hz
%
mm
P 70
S 3.2 3.8
P 100
C 3.6 7.6
P 100
C 5.0 9.0
P 70
C 3.1 3.9
P 0
C 0
P 100
C 6.5 7.4
S/T ON Timer
stroke
mm
S/T OFF Timer

stroke
mm
Basic
Test oil
TCV DUTY (%) F TCV TA-ist

60Hz
%
V
Basic
[2] Start
mm3/st.
FULL
[2] Stop
mm3/st.
degC
P 48+-2
P 48+-2
Remark
Magnet OFF
Magnet OFF
[2] Overflow
cm3/min
P 50+-2
[2] Pump chamber Pressure

Pump speed
Boost pressure
Boost pressure
Boost pressure
r/min
P 1100
P 100
P 1100
P 1800
S/T OFF Pressure
kPa
P 52.0
P 52.0
P 52.0
P 52.0
Basic
kgf/cm2
mmHg
P 390 410
P 390 410
P 390 410
P 390 410
Remark
54.6
54.6
54.6
54.6
Test oil
kgf/cm2
degC
P 50+-2
P 48+-2
P 50+-2
P 50+-2
P *
[2] Timer
Pump speed
Boost pressure
Boost pressure
Boost pressure
r/min
P 1100
P 500
P 1100
P 1100
P 1100
P 1800
Remark
kPa
P 52.0
P 52.0
P 52.0
P 52.0
P 52.0
P 52.0
kgf/cm2
mmHg
P 390
P 390
P 390
P 390
P 390
P 390
54.6
54.6
54.6
54.6
54.6
54.6
410
410
410
410
410
410
P *
[2] TPS Output

Pump speed
Boost pressure
Boost pressure
Boost pressure
r/min
kPa
kgf/cm2
mmHg
[2] Magnet
Test oil
degC
Remark
degC
P 50+-2
P 48+-2
P 50+-2
P 50+-2
P 50+-2
P 50+-2
Ass'y NO.
104761-4381
2003/02/25 09:51:55
Designation
MAX applied voltage
Test voltage
Unit
V
V
PSC Set value

C 8
P 12 14
Page
Remark
[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
r/min
kPa
kgf/cm2
mmHg
mm3/st.
mm
Timer stroke
Basic
Change volume T
mm
Test oil
Decrease rate
%
Test oil
degC
Remark
degC
[3] ACS adjustment

Designation
Pump speed
r/min
Image
Height
m
Explanation 2
Explanation 3
Explanation 4
Pressure differencePressure differenceAve.inj.qty

kPa
mmHg
mm3/st.
Decrease quantity
mm3/st.
Basic
Remark
[3] BCS adjustment

Designation
Image
Explanation 2
Explanation 3
Explanation 4
Explanation 2
4-PM5-2F
Explanation 3
4-PM5-3 104761-4380
Explanation 4
4-PM5-4 104761-4380
[2] Additional device adjustment

Designation
Image
POTENTIOMETER ADJUSTMENT 4-PM5-1
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
P1=0kPa
P2=0mmHg
Vi=10V
Potentiometer adjustment standards (Bosch mini mass piping)

1.Applied voltage=Vi
2.Boost pressure=P1kPa{P2mmHg}
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
6.000.03 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

Designation
Image
Explanation 2
Explanation 3
Explanation 4
Explanation 2
Explanation 3
Explanation 4
Explanation 2
Explanation 3
Explanation 4
Explanation 2
Explanation 3
Explanation 4
Explanation 2
Explanation 3
Explanation 4
Explanation 2
Explanation 3
Explanation 4

Designation
Image

Designation
Image

Designation
Image

Designation
Image

Designation
Image
Ass'y NO.
104761-4381
2003/02/25 09:51:55
Image
Explanation 2
Explanation 3
Explanation 4
[1] Assembly dimension

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

Stamping Identification
Nozzle Number
Nozzle Holder Assembly
:
:
:
:
105031-3862
31-3862 L
105025-4000
105160-5330
Opening Pressure
19.0 Mpa
Dated 10th July 2007
Injector Number 31-3862 N

Nozzle & holder assembly no.:
Nozzle holder number:
Nozzle no.:
Opening pressure:
105160-5420
105031-3862
105025-4200
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 = NPDLLA160SM195
Opening pressure 26.0 MPa ( 265
kgf/cm2 )
Engine SA6D170 for Komatsu
Injector Opening Pressure
Body Number
Assembly Number
Nozzle
Opening Pressure
Application
Dated 20th October 2004
105041-7150 J
105111-4920
DLLA143SM262
24.5 Mpa (250 Kgf/m)
Komatsu
Nozzle holder:
Assy No:
Nozzle holder:
Nozzle:
48-2081Q
105118-7190
105048-2081
105017-1570
First opening pressure:

Second opening Press:
17.7 MPa ( 180 kgf/cm2 )

20.6 MPa ( 210 kgf/cm2 )
Nozzle lift:
Pre lift:
0.20 mm
0.055 mm
NHA 105048-2270 G (Isuzu)

Opening Pressure for Test purposes only. This NHA is not
serviceable in the field.
Assy No.
Nozzle No.
105118-8211
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
Stamping Mark 48-2270 B
Nozzle holder 105048-2270
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
Stamping Mark 48-2270 B
Nozzle holder 105048-2270
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

Nozzle Number
Spacer Ring
105118-5191
105017-0870
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
ASSEMBLY No.
NOZZLE KIT
105048-3832
105118-7542
105019-1470 (Includes 105017-3250
DLLA143PN325 NOZZLE)
First Opening Press

Second Opening Press
18.1 MPa ( 185 kgf/cm2 )

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
Number
1 st Opening Pressure
[Factory Setting]
2 nd Opening Pressure
[Factory Setting]
48-4120 E
105118-7621
21.0 MPa (214 kgf/cm)
39.5 MPa (403 kgf/cm)
[21.5-22.5 MPa (219-229

kgf/cm)]
[40.0-41.5 MPa (408-423

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

kgf/cm)]
[38.0-39.5 MPa (387-402

kgf/cm)]
48-4120 T or U
105118-7911
19.0 MPa (194 kgf/cm)

[19.5-20.5 MPa (199-209
kgf/cm)]
37.5 MPa (382 kgf/cm)

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

kgf/cm)]
[37.8-39.8 MPa (385-405

kgf/cm)]
48-4120 H
105118-7981
48-4120 G
105118-7981
19.0 MPa (194 kgf/cm)

[19.5-20.5 MPa (199-209
kgf/cm)]
No test pressures available
37.5 MPa (382 kgf/cm)

[37.8-39.8 MPa (385-405
kgf/cm)]
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
Number
1 st Opening Pressure
[Factory Setting]
2 nd Opening Pressure
[Factory Setting]
48-4120 E
105118-7621
21.0 MPa (214 kgf/cm)
39.5 MPa (403 kgf/cm)
[21.5-22.5 MPa (219-229

kgf/cm)]
[40.0-41.5 MPa (408-423

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

kgf/cm)]
[38.0-39.5 MPa (387-402

kgf/cm)]
48-4120 T or U
105118-7911
19.0 MPa (194 kgf/cm)

[19.5-20.5 MPa (199-209
kgf/cm)]
37.5 MPa (382 kgf/cm)

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

kgf/cm)]
[37.8-39.8 MPa (385-405

kgf/cm)]
48-4120 H
105118-7981
48-4120 G
105118-7981
19.0 MPa (194 kgf/cm)

[19.5-20.5 MPa (199-209
kgf/cm)]
37.5 MPa (382 kgf/cm)

[37.8-39.8 MPa (385-405
kgf/cm)]
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.

(Stamping mark and discrimination mark)
105041-3220
(41-3220,B)
Nozzle part no.
Nozzle service kit no.
Pre-lift
6WF1TC
105110-8300
105025-3950
105019-2312
(NP-DLLA156SM395)
0.06
(+-0.02mm)
6WG1TC
105110-8290
105041-3220
(41-3220,A)
105025-3940
105019-2302
(NP-DLLA156SM394)
0.06
(+-0.02mm)
First nozzle opening pressure

MPa{kgf/cm2}
17.7{180}
Second nozzle opening pressure

MPa{kgf/cm2}
23.1~24.1{236~246}
Valve lift
(mm)
0.3
Nozzle holder type
17.7{180}
23.1~24.1{236~246}
0.32
KBL2.4/DLLA-S
KBL2.4/DLLA-S
1/3
Ass'y No.: 106661-5310
CONFIDENTIAL
TEMPORARILY
ENGINE MODEL: PE6T
Date:
6 Sep 2002
No.
16713 96672
Timing device: EP/SP
105636-1220
Governor: EP/RFD
105487-3270
Injection pump: PE6P

106066-5440
1. Test conditions

Nozzle: 105015-5040
(Bosch Type No.
(Bosch Type No.

(Bosch Type No.

Length 500 mm
+5
Oil Temp. 40 C
2. Injection timing
Injection order:
4,1
60 30'
2,1
120 30'
6,1
180 30'
3,1
240 30'
mm
300 30'
side ( interval:
30' ).
Tappet clearance: Manually rotate the camshaft 2 to 3 times and confirm that it rotates smoothly.
Adjusting
point
Rack
position
(mm)
Pump
speed
(r/min)
12.4
650
Approx. 4.8
255
Max. variation
between
cylinders (%)
Fixed
171 2
Lever
13 1
10
Rack
Injection q'ty
3
Remarks
Basic

Pump speed
(r/min)
Below 750
700
900 +40
-10
1150 +30
-20
Advance
angle ( )
Start
0
Below 0.5
0.9 0.5
Finish
3 0.5

Service Department

Tel. (048)470-1559, Fax. (048)474-9856
106661-5310 2/3
Perform idle sub-spring adjustment when
necessary.
12.6+0.2
12.4
Above 6.3
Damper spring setting:
4.8-0.2
4.8
11.5
0.90.5
0
255 46515
1150+20 Below 1250
Pump speed (r/min)
Variable speed specification at idle setting
Main spring setting
Rack position (mm)
Rack position (mm)
Rack limit using stop lever
4.8
280
Pump speed (r/min)
106661-5310 3/3
22 5
10 5
Idling
Full-speed
Idling
Full-load
32.5
43.53
Stop lever angle
Timing setting
Normal
Stop
5
30
R=1+0.5
323
R=12.4
Approx. 25
1/3
Assy No.: 106661-5541
CONFIDE NTIAL
ENGINE MODEL: PE6T
T E MP ORA RILY
Date:
9 Feb 2004
No.
16713 96902
105614-4220
Governor: EP/RFD-B
105487-5771

106066-1191
1. Test conditions

(Bosch type no.
Nozzle: 105015-4170
(Bosch type no. DLLA137S374N417)

(Bosch type no.
kgf/cm2}
length 500 mm
mm inner dia. 2 mm
Injection pipe: outer dia.6
+5
2. Injection timing
Injection order:
4,1
60 30'
2,1
120 30'
6,1
180 30'
3,1
240 30'
mm
300 30'
side (interval:
30').
Adjusting
point
Rack
position
(mm)
Pump
speed
(r/min)
Max. variation
between
cylinders (%)
Fixed
11.7
750
146 2
Lever
9.7
300
88 3
Lever
Boost press. 0
Approx 6.4
240
10 1
10
Rack
Boost press. 0
Injection quantity
(cm3/1000 strokes)
Remarks
Basic


Pump speed
(r/min)
700+50
900 -10
Advance
angle ( )
Below 0.5
0.9 0.5
+40
+30
1150 -20
Finish
3.00.5
BOSCH K.K.

Tel. 81-48-475-2521
Fax. 81-48-475-2520
106661-5541 2/3
2.00.1 mm
12.7
11.7
11.20.1
9.7
Above 8.7
6.42.0
6.4
4.1
B
10.5+0.5
Rack position (mm)
2.20.3
1.7
0
240
(500)
1205
(1150)
Below (150) 430 485
1175
Pump speed (r/min)
6.4
260
Pump speed (r/min)
Rack position (mm)
Rack position (mm)
Main spring setting
N = 300
11.7
9.7
0
53.3-13.3 {400-100}
4.0+2.0 {30+15}
106661-5541 3/3
Load-control lever angle
(24) 5
N=260
13 5
Full-load
Idling
Idling
Full-speed
Stop lever angle
40.5

Normal
28 5
30 5
R=1.50.1
Timing setting
Drive side
Stop
28.5
R=11.7
Approx. 30
1/3
Assy No.: 106661-5541
CONFIDE NTIAL
ENGINE MODEL: PE6T
T E MP ORA RILY
Date:
9 Feb 2004
No.
16713 96902
105614-4220
Governor: EP/RFD-B
105487-5771

106066-1191
1. Test conditions

(Bosch type no.
Nozzle: 105015-4170
(Bosch type no. DLLA137S374N417)

(Bosch type no.
kgf/cm2}
length 500 mm
mm inner dia. 2 mm
Injection pipe: outer dia.6
+5
2. Injection timing
Injection order:
4,1
60 30'
2,1
120 30'
6,1
180 30'
3,1
240 30'
mm
300 30'
side (interval:
30').
Adjusting
point
Rack
position
(mm)
Pump
speed
(r/min)
Max. variation
between
cylinders (%)
Fixed
11.7
750
146 2
Lever
9.7
300
88 3
Lever
Boost press. 0
Approx 6.4
240
10 1
10
Rack
Boost press. 0
Injection quantity
(cm3/1000 strokes)
Remarks
Basic


Pump speed
(r/min)
700+50
900 -10
Advance
angle ( )
Below 0.5
0.9 0.5
+40
+30
1150 -20
Finish
3.00.5
BOSCH K.K.

Tel. 81-48-475-2521
Fax. 81-48-475-2520
106661-5541 2/3
2.00.1 mm
12.7
11.7
11.20.1
9.7
Above 8.7
6.42.0
6.4
4.1
B
10.5+0.5
Rack position (mm)
2.20.3
1.7
0
240
(500)
1205
(1150)
Below (150) 430 485
1175
Pump speed (r/min)
6.4
260
Pump speed (r/min)
Rack position (mm)
Rack position (mm)
Main spring setting
N = 300
11.7
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
Full-load
Idling
Idling
Full-speed
Stop lever angle
40.5

Normal
28 5
30 5
R=1.50.1
Timing setting
Drive side
Stop
28.5
R=11.7
Approx. 30
1/4
Ass'y No.: 106671-0620
CONFIDENTIAL
ENGINE MODEL: PF6TB
TEMPORARILY
Date:
17 Jun 2002
No.
16800-96577
Timing device: EP/SPGH
105691-3270
Governor: EP/RFD
105487-3680

106060-7790
1. Test conditions

Nozzle: 105015-7350
(Bosch Type No.
(Bosch Type No.

(Bosch Type No.

Length 500 mm
+5
Oil Temp. 40 C
2. Injection timing
Injection order:
4,1
60 30'
2,1
120 30'
6,1
180 30'
3,1
240 30'
mm
300 30'
side ( interval:
30' ).
Adjusting
point
Rack
position
(mm)
Pump
speed
(r/min)
Max. variation
between
cylinders (%)
Fixed
11.9
600
203 2
Lever

Basic Above 76.0 {Above 570}
Approx 7.2
225
15 1
10
Rack
Boost press. 0
9.7
300
130 2
Lever
Boost press. 0
Injection q'ty
3
Remarks

Pump speed
(r/min)
Advance
angle ( )
Service Department

Tel. (048)470-1559, Fax. (048)474-9856
106671-0620 2/4
11.9
9.7
Above 8.7

(N=300)
7.2
6.1
11.0
2.4+0.1
12.1+0.1
Damper spring setting:
6.2-0.2
3.40.5
0
225 45010
500 -10
1150 +40
+20
-25
Below 1300
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) .

Rack position (mm)
Rack position (mm)
Rack limit by using stop lever
N = 300
12.1+0.1
11.5
9.7
0
20.01.3 {15010}
(62.7) {(470)}
(50.7) {(380)}
106671-0620 3/4
24 5
Idling
Full-speed
Full-load
22
31.5
Stop lever angle
Timing setting
365
R=12.1+0.1
11.55
Stop
Normal
Timing advance specification
Advance angle ( )
Adjust the clearance between the pickup and the gear tooth to 1-0.2mm.
7.00.3
4/4 load
P = 392 kPa {4kgf/cm2}

4/4 load P =196 kPa {2kgf/cm2}
Bellow4
Above3
0/4 load P = 0
300
Above 900 1100

Pump speed (r/min)
Approx. 30
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 so that the rack sensor's output voltage is VR0.01.
3.After adjustment, mark the area where the joint and the nut contact and the area where
the joint and the pump housing contact with red paint.
Output voltage
VR0.01(V)
Pump speed N
600 r/min
Rack position R1
11.9 mm
VR
Control unit parts no.

407912-1742
2V
105782-6320
407910-303*
3V
407910-6010
407980-224*
1/4
Assy No.: 106671-0830
CO NFI D ENT IA L
ENGINE MODEL: PE6TC
TEMPO RARI LY
Date:
27 Sep 2004
No.
16713 96818
105636-1810
Governor: EP/RFD-D
105487-4580

106061-5300
1. Test conditions

(Bosch type no.
Nozzle: 105015-6340
(Bosch type no. DLLA140SN634)


length 500 mm
mm inner dia. 2 mm
kgf/cm2}
+5
2. Injection timing
Injection order: 1
6,1
4,1
60 30'
2,1
120 30'
180 30'
3,1
240 30'
mm
300 30'
side (interval:
30').
Adjusting
point
Rack
position
(mm)
Pump
speed
(r/min)
Max. variation
between
cylinders (%)
Fixed
12.1
600
170 2
Lever
12.1
1100
(164.6) 3
Lever
10.4
300
114 2
Lever
Boost press. 0
12.40.1
300
(173) 5
Lever

Approx 8.0
250
16 1
10
Rack
Boost press. 0
Injection quantity
(cm3/1000 strokes)
Remarks


Pump speed
(r/min)
Advance
angle ( )
Below 875
Start
0
825
Below 0.5
925
Finish
10.5
BOSCH K.K.

Tel. 81-48-475-2521
Fax. 81-48-475-2520
106671-0830 2/4
Boost compensator stroke: (2.0)
Rack limit using stop lever: 12.40.1
12.1
10.51.5
10.4
Above 9.5
8.0
7.10.1
6.0
11.5+0.5
Rack position (mm)
12.4
3.90.3
0
250
460
395
1205 1260
Pump speed (r/min)
Note: The injection quantity and the governor must be adjusted at an ambient temperature of at least 15C
(as the boost compensator start spring is a shape-memory alloy) .

(Fix at Full at delivery.)
Main spring setting

7.9
Rack position (mm)
Rack position (mm)
N = 300
12.40.1
11.2
10.4
0
Below 5.3{Below 40}
265 275
Pump speed (r/min)
(16.0) {(120)}
9.31.3 {7010}
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
Rack position (mm)
12.1
Q = 1392 cm3/1000 st
(11.1)
79.42.7 {59620} 57.60.7 {4325}

Absolute pressure kPa {mmHg}
106671-0830 4/4

(Secure at Full at delivery)
24
5
16.
Full-load
Idling
N=275
Idling
22
Full-speed
30.5
Timing setting
Stop lever angle

Drive side
Stop
Normal
Approx. 30
30 5
32 5
R=12.40.1
1/3
Ass'y No.: 106671-1447
CONFIDENTIAL
25 Oct 2001
Date:
Company: ISUZU
1-15602-142-7
No.
ENGINE MODEL 6SD1-TC2
Injection pump PE6P

106060-5771
Test condition
Actuator EP/RED-
105952-0223
Timing device EP/SPGH

105691-3140
Pump rotation Counter clockwise (viewed from drive side)

Nozzle Nozzle Holder Ass'y 105780-8140 (Bosch Type No.EF8511/9A)
Nozzle105780-0000
(Bosch Type No.DN12SD12T)
(Bosch Type No.EF8511/9)

mm Inner Dia.3
mm Length 600 mm
+5
Oil Temp.40

Overflow valve opening pressure 127
kgf/cm2
kPa 1.3
kgf/cm2
Injection timing
Pre-strokeNo.1 Plunger 4.2
Injection order 1
0.03mm Note: Perform at voltage
5 ,1 3 ,1 6 ,1 2 ,1 4
15
60
15 120 15 18015 24015 300
Plungers are numbered from the Governor side. ( interval:
Injection quantity
Adjusting point
Rack
position
(mm)
Vist
(V)
RED GOV. C/U : 15mm

Pump
speed
(r/ min)
(12.0)
1.59
800
(6.9)
Approx.2.6
225
Injection q' ty
151.72
8.93.2
Max. var
bet. cyl
()
Remarks
Basic
13

Pump speed
r/min
Advance
angle
Service Department

Tel. (048)470-1559, Fax. (048)474-9856
106671-1447 2/3
RED 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.
Advance angle ()
4/4 load
P=392 kPa {4 kg/cm2)
5.5 0.3
0/4 load P=0

0
Above 800
Pump speed (r/min)
Timing setting
At No.1 plungers beginning
B.T.D.C. : 10
Approx.40
Center of timing devices threaded hole
1/2
Ass'y No.: 106671-3521
CONFIDENTIAL
ENGINE MODEL: EK100
Date:
22 Aug 2002
Company: HINO
No.
22020-1791A
105635-0041
Governor: EP/RSV
105407-1670

106061-5472
1. Test conditions

Nozzle: 105780-0000


Length 600 mm
+5
Oil Temp. 40 C
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
Injection order:
4,1
60 30'
2,1
120 30'
6,1
180 30'
3,1
240 30'
mm
300 30'
side ( interval:
30' ).
Adjusting
point
Rack
position
(mm)
Pump
speed
(r/min)
Max. variation
between
cylinders (%)
Fixed
9.3
700
129.5 2
Lever
9.3
1100
127 3
Lever
(5)
360
16 3
15
Rack
Injection q'ty
3
Remarks
Basic

Pump speed
(r/min)
Advance
angle ( )
700 50
Start
0
900
1.4 0.5
1150
Finish
4 0.5

Service Department

Tel. (048)470-1559, Fax. (048)474-9856
106671-3521 2/2
Perform torque control spring adjustment
when necessary.
Rack position (mm)
Above 14
9.3
(5)
4
360
1100+10 1210-40
Pump speed (r/min)
Stop lever angle

535
(28) 5
27 5
(9)5
Full-speed
Idling
Normal
Stop
1/3
Ass'y No.: 106671-4451
CONFIDENTIAL
ENGINE MODEL: S6BF
TEMPORARILY
Date:
10 Apr 2003
Company: MITSUBISHI
No.
36265-23180
105681-0231
Governor: EP/RSV
105407-3452

106060-7560
1. Test conditions

Nozzle: 105015-4350
(Bosch Type No.
(Bosch Type No.

(Bosch Type No.
Length 1019mm
+5
Oil Temp. 40 C
2. Injection timing
Injection order:
5,1
60 30'
3,1
120 30'
6,1
180 30'
2,1
240 30'
mm
300 30'
Plungers are numbered from the Governor side ( interval:
30' ).
Adjusting
point
Rack
position
(mm)
Pump
speed
(r/min)
16.9
900
Approx 7.3
250
18.9+0.2
100
Max. variation
between
cylinders (%)
Fixed
280 7
Lever
30 3
10
Rack
Lever
Injection q'ty
3
(324)
Remarks
Basic
Rack limit

Pump speed
(r/min)
Advance
angle ( )
Below 450
Start
0
400
Below 0.5
650
Finish
4 0.5

Service Department

Tel. (048)470-1559, Fax. (048)474-9856
106671-4451 2/3
(notches from fully tightened position; fix in this position)
20+1
Rack limit;18.9+0.2
Rack position (mm)
C
A
16.9
Idle sub-spring setting;

9.2-0.5
9.2
7.3
0
250
40025
1100+10
Pump speed (r/min)
(1190)25
106671-4451 3/3
(41) 5
20 5
Idling
Full-speed
Stop lever angle
53 5
19
rma
No
Sto
Timing setting
Approx. 90
1/5
Assy No.: 106671-5171
CONFIDE NTIAL
ENGINE MODEL: PF6T
Date:
26 Sep 2003
No.
16800 96664
105691-3622
Governor: EP/RFD-C
105487-5810

106061-7531
1. Test conditions

Nozzle: 105780-0000


length 600 mm
mm inner dia. 3 mm
kgf/cm2}
+5
2. Injection timing
Injection order:
4,1
60 30'
2,1
120 30'
6,1
180 30'
3,1
240 30'
mm
300 30'
side (interval:
30').
Adjusting
point
Rack
position
(mm)
Pump
speed
(r/min)
10.8
600
174.4 2
Approx 5.3
225
91
8.4
300
107.4 2
Injection quantity
(cm3/1000 strokes)
Max. variation
between
cylinders (%)
Fixed
Lever
10
Rack
Solenoid OFF
Lever
Solenoid ON
Remarks
Basic
Solenoid OFF

Pump speed
(r/min)
Advance
angle ( )
BOSCH K.K.

Tel. 81-48-475-2521
Fax. 81-48-475-2520
106671-5171 2/5
Rack limit using stop lever: 11.10.1
10.8
10.2
8.4
5.3
4.32.0
3.6
1.50.5
0
225
Below 160
350
420 460
410
1150 1240
Pump speed (r/min)

(Fix at Full at delivery.)
Main spring setting
R1(5.2)
290
Pump speed (r/min)
10.0+0.5
Above 6.8
Rack position (mm)
Rack position (mm)
11.70.3
11.3
11.1
106671-5171 3/5
5.Timing advance specification
Advance angle ( )
6.50.3
4/4 load
4/4 load P =196 kPa {2kgf/cm2}

Bellow4
Above3
0/4 load P = 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 VR0.01.
(4)Apply red paint to the joint 2 and nut 3 join and to the joint 2 and pump end face join.
Constant voltage
power supply
50.01V
Output voltage
VR0.01V
Speed N
600 r/min
Rack position R
10.8 mm
VR
2V
Control unit part no.

407912-1742
105782-6320
407910-3032
3V
407910-6010
407910-7210
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 R20.5 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
1: For preadjustment
Rack position
Boost compensator OFF

R2
8.4
Boost compensator ON
Pump speed
3
L
ON
OFF
Control rack
Rack decrease direction
Boost compensator stroke

+1
4 mm -0.5
106671-5171 5/5
Load lever angle

(Secure at full at delivery)
(13) 5
45
Full-load
34.
5
N=290
5
5.5
Idling
Idling
Full-speed
Timing setting
Stop lever angle
Stop
33
33
Normal
R=11.10.1
Approx. 30
NISSAN DIESEL
1/3
Ass'y No.: 106671-6220
CONFIDENTIAL
ENGINE MODEL: 6SD1-TCE
Date:
9 JUL 2002
Company: ISUZU
No.
115603-1510
105681-5380
Governor: EP/RLD-J
105923-2100

106067-1221
1. Test conditions

Nozzle: 105780-0000


Length 600 mm
+5
Oil Temp. 40 C
2. Injection timing
Injection order:
5,1
60 15'
3,1
120 15'
6,1
180 15'
2,1
240 15'
mm
300 15'
30' ).
Rack
position
(mm)
Pump
speed
(r/min)
Max. variation
between
cylinders (%)
Fixed
11.5
800
149 2
Rack
Approx. 6.4
290
10.5 3.2
13
Rack
R1(11.5)
800
149 2
Lever
R1+0.3
1100
(153.5) 3
Lever
R2[R1-1.3]
500
(119.5)
Lever

(R1-1.6)
300
(98)
Lever
Boost press. 0
Approx. R1+1.35
150
(165)
Lever
Boost press. 0
Adjusting
point
Injection q'ty
3
Remarks
Basic

Basic

Pump speed
(r/min)
Advance
angle ( )
Beiow 850
Start
0
800
Beiow 0.5
875
Finish
1.50.5

Service Department

Tel. (048)470-1559, Fax. (048)474-9856
106671-6220 2/3
Rack position (mm)
Approx. R1+1.35
Torque cam no. AD53
1.150.1 mm
R1+0.3
R1(11.5)
R1-0.35
R1-0.45
10.80.1
R2[R1-1.3]
C
D
6.81.0
Below 200
(470)
(560)
700 (750)
(1180) 1310
(900) (1050)
(280)
1200
Pump speed (r/min)
Rack position (mm)
Idling adjustment
8.5
Rack position (mm)
8.00.5
6.5
Approx 6.4
N = 500
R2[R1-1.3]
R2-1.15
0
4.00.1
10.01.3 {7510}
+0.5
0.5 -0.45
185
315 430
240 290
Pump speed (r/min)
820
106671-6220 3/3
27 5
29
Idli
ng
.5
Full-speed
Stop lever angle
Normal
Stop
225
415
Timing setting
B.T.D.C.: 10
Center of timing device's threaded hole
x. 50
Appro
106671-3841
ZEXEL Ass'y No.
106671-3841
02/09/03 09:20:09
Page 1
use for - 106671-8030
Bosch Ass'y No.

Bosch Typecode
Engine Type
EK200
Manufacturer
HINO
Edition date
28/09/00 (2)
CAT Designation
Unit
Test oil
Set value
min.
max.
40
45
Actual values
OT
Actual values
OT
Actual values
OT
ISO4113 or {SAEJ96
7d}
...
degC
40
105780-8140
Bosch type code
EF8511/9A
Nozzle
105780-0000
Bosch type code
DN12SD12T
Nozzle holder
105780-2080
Bosch type code
EF8511/9
Opening Pressure
MPa
17.2
Opening Pressure
kgf/cm2
175
Iinjection Pipe
mm
8-3-600

Overflow valve
134424-0920
kPa
162
147
177
kgf/cm2
1.65
1.5
1.8
kPa
157
157
157
kgf/cm2
1.6
1.6
1.6
min.
max.
4.74
4.8
60
59.75
60.25
120
119.75
120.25
180
179.75
180.25
240
239.75
240.25
300
299.75
300.25
Set value
min.
max.
L
Left
CAT Designation
P
Injection order
Pre-stroke
Unit
Set value
L
Left
1-4-2-6-3-5
mm
4.8
No.1
Drive side
deg.
Cyl 1-4
S
deg.
Cyl.1-2
deg.
Cyl 1-6
deg.
Cyl 1-3
deg.
Cyl 1-5

CAT Designation

Unit
106671-3841
02/09/03 09:20:09
Adjusting point
Rack position
Pump speed
r/min
500
500
500
mm3/st.
153
150
156
-4
Fixing the lever
min.
max.
CAT Designation
A
7.9
*
Unit
Set value
Adjusting point
Rack position
7.9
Pump speed
r/min
700
700
700
mm3/st.
151
149
153
-2
Basic
Fixing the lever
*
min.
max.
CAT Designation
Unit
Set value
Adjusting point
Rack position
8.3
Pump speed
r/min
1075
1075
1075
mm3/st.
159
156
162
-4
Fixing the lever
min.
max.
CAT Designation
Unit
Set value
Adjusting point
Rack position
Pump speed
r/min
225
225
225
mm3/st.
13
10
16
-15
15
Fixing the rack
min.
max.
Unit
Set value
E
Rack position
8.6+-0.5
Pump speed
r/min
100
100
100
mm3/st.
140
140
150
Fixing the lever
Rack limit
*
min.
max.
Unit
Set value
Adjusting point
Rack position
Pump speed
r/min
1150
1150
1150
mm3/st.
134.7
129.7
139.7
Fixing the lever

OT
Actual values
OT
Actual values
OT
Actual values
OT
Adjusting point
Name
Actual values
4.0+-0.5
OT
CAT Designation
Actual values
CAT Designation
Page 2
F
7.2
106671-3841
RT=0.8
TH=2.4mm
R1=8.6mm
DL=3.3-0.2mm
N1=300+25r/min
R2=4mm
02/09/03 09:20:09
Page 3
N:Pump speed
(1)Lever ratio: RT
(2)Target shim dimension: TH
(3)RACK LIMIT: R1
(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.

CAT Designation
Unit
Set value
Pump speed
r/min
865+50
Advance angle
deg.
Load
min.
max.
min.
max.
Actual values
OT
Actual values
OT
Actual values
OT
4/4
Remarks
Start
CAT Designation
Unit
Set value
Pump speed
r/min
850
Advance angle
deg.
0.3
Load
3/4
CAT Designation
Unit
Set value
Pump speed
r/min
1075
Advance angle
deg.
4.5
Load
4/4
Remarks
Finish
Name
a=17deg+-5deg
F:Full speed
0.3
min.
max.
4.2
4.8
106671-3841
02/09/03 09:20:09
2.6 Load control lever angle

Name
a=17deg+-5deg
b=39deg+-3deg
F:Full load
I:Idle
(1)(2)2.7 Stop lever angle
Name
a=40deg+-5deg
b=64deg+-5deg
N:Pump normal
S:Stop the pump.
(1)(2)2.8 Timing setting
Name
a=0deg+-3deg

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

Page 4
1/3
Assy No.: 106672-3740
CO NFI D ENT IA L
ENGINE MODEL: M10C-TB
Date:
22 Sep 2004
Company: HINO
No.
22020-4990A
Timing device:
Governor: EP/RSV
105407-6550

106067-1070
1. Test conditions

Nozzle: 105780-0000


length 600 mm
mm inner dia. 3 mm
kgf/cm2}
+5
kgf/cm2}
Overflow valve opening pressure: 147~177 kPa {1.5~1.8
2. Injection timing
Injection order: 1
6,1
4,1
60 30'
2,1
120 30'
180 30'
3,1
240 30'
mm
300 30'
side (interval:
30').
Adjusting
point
Rack
position
(mm)
Pump
speed
(r/min)
9.8
750
89.3 1
Approx 8.2
360
14 3
100
187 10
Injection quantity
(cm3/1000 strokes)
Max. variation
between
cylinders (%)
Fixed
Remarks
Rack

15
Rack
Boost press. 0
Lever
Rack limit Boost press. 0

Pump speed
(r/min)
Advance
angle ( )
BOSCH K.K.

Tel. 81-48-475-2521
Fax. 81-48-475-2520
106672-3740 2/3
(notches from fully tightened position; fix in this position)
Rack limit
Above 14.0
D
Main spring setting
9.80.1
9.00.2
8.40.1
8.2
Idle sub spring setting
6.21.5
4.80.1
300 (430)
360
750
850 900
798
Pump speed (r/min)

Rack position (mm)
Rack position (mm)
11.50.1
10.9
N = 600
10.9
9.5
0
3.3+2.0 {25+15}
106672-3740 3/3
(18) 5
Full-speed
N=900 set
(8) 5
N=750 set
(5) 5
Idling
Stop lever angle
Stop
Normal
25 5
705
Timing setting
Approx. 50
N=0, R=1.0-0.5
(Seal at delivery)
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
1/4
Ass'y No.: 106673-7463
CONFIDENTIAL
ENGINE MODEL: 6D24T2
Date:
26 SEP 2002
Company: MITSUBISHI
No.
ME152038
105691-3802
Governor: EP/RLD-J
105923-2333

106067-1050
1. Test conditions

(Bosch Type No. 1 688 901 101)
Nozzle: 105780-0120
(Bosch Type No. 1 688 901 990)

(Bosch Type No.
Length 600 mm
+5
Oil Temp. 40 C
2. Injection timing
Injection order:
5,1
60 30'
3,1
120 30'
6,1
180 30'
2,1
240 30'
mm
300 30'
30' ).
Adjusting
point
Rack
position
(mm)
Pump
speed
(r/min)
Injection q'ty
13.7
700
Rack
Approx 8.0
390
Each cylinder
Rack
Max. variation
between
cylinders (%)
263.9
Fixed
R1(13.7)
700
172.5 2
Lever
R1+0.9
1100
(157) 2
Lever
(R1-0.85)
500
(171.5) 3
Lever
Approx
R1-0.8
100
Lever
(185)
Remarks
Basic


Boost press. 0

Pump speed
(r/min)
Advance
angle ( )
Service Department

Tel. (048)470-1559, Fax. (048)474-9856
B
A
106673-7463 2/4
Torque cam no. AE17
Rack position (mm)
R1+0.9
R1+0.75
R1(13.7)
Approx R1-0.8
13.50.1
R2[R1-1.7]
B
A
8.41.0
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
R= 7.6 0.1 mm and a pump speed of 325r/min.
Idling adjustment
10.0
Rack position (mm)
+0.8
9.0 -0.6
Approx 8.0
8.0
6.2-0.1
4.30.1
2.70.5
185
350 400
285
225 255
Pump speed (r/min)
700
106673-7463 3/4
Rack position (mm)

N = 250
R2[R1-1.7]
R2-1.65
0

6.71.3 {5010}
Advance angle ( )
10.00.3
4/4 load
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 VR0.01.
(4) Apply red paint to the joint 2 and nut 3 join and to the joint 2 and pump end face join.
Constant voltage
power supply
50.01V
Output voltage
VR0.01V
Speed N
1100 r/min
Rack position R
R1(13.7)+0.9 mm
VR
2V
105782-6320
407910-3032
3V
407910-6010
407910-7210
407912-1742

(Supply pump side)
1
Pump end face
Apply red paint
Full-speed
37
25
Idling
Timing setting
Stop lever angle

injection position
B.T.D.C.: 5
Stop
Normal
5
29.
40
N=1100, R=3.50.3
(Confirm that injection does not occur.)
Approx. 2
6675-450
1/2
Assy No.: 106684-4460
CONFIDENTIAL
ENGINE MODEL: S6A3
TEMPORARILY
Date:
31 Oct 2007
1
Company: MITSUBISHI. HEAVY
No.
35A65-11070
Timing device:
Governor:

106068-4030
1. Test conditions

(Bosch type no.
Nozzle: 105025-2680
(Bosch type no. DLLA158SM268)

(Bosch type no.
kgf/cm2}
length 1215 mm
+5
2. Injection timing
Note: Adjust with rack position of R=A(13.6) mm

Injection order:
5,1
60 30'
3,1
120 30'
6,1
180 30'
2,1
240 30'
300 30'
Plungers are numbered from the Opposite Drive side (interval:
30').
Adjusting
point
Rack
position
(mm)
Pump
speed
(r/min)
13.6
1025
Approx 6.5
400
Max. variation
between
cylinders (%)
Fixed
313 9
Rack
30 3
10
Rack
Injection quantity
(cm3/1000 strokes)
Remarks
Basic Rack limit

Pump speed
(r/min)
Advance
angle ( )
Bosch Corporation

Tel. 81-48-475-2521
Fax. 81-48-475-2520
106684-4460 2/2
Timing setting
Ap
pro
x.
11
0

1/2
Assy No.: 106684-4461
CONFIDENTIAL
ENGINE MODEL: S6A3
TEMPORARILY
Date:
20 Sep 2007
1
Company: MITSUBISHI. HEAVY
No.
35A65-11070
Timing device:
Governor:

106068-3462
1. Test conditions

(Bosch type no.
Nozzle: 105025-2680
(Bosch type no. DLLA158SM268)

(Bosch type no.
kgf/cm2}
length 1215 mm
+5
2. Injection timing
Note: Adjust with rack position of R=A(13.6) mm

Injection order:
5,1
60 30'
3,1
120 30'
6,1
180 30'
2,1
240 30'
300 30'
Plungers are numbered from opposite the Drive side (interval:
30').
Adjusting
point
Rack
position
(mm)
Pump
speed
(r/min)
13.6
1025
Approx 6.5
400
Max. variation
between
cylinders (%)
Fixed
313 9
Rack
30 3
10
Rack
Injection quantity
(cm3/1000 strokes)
Remarks
Basic Rack limit

Pump speed
(r/min)
Advance
angle ( )
Bosch Corporation

Tel. 81-48-475-2521
Fax. 81-48-475-2520
106684-4461 2/2
Timing setting
Approx. 110
1/3
Assy No.: 106961-1564
CO NFI D ENT IA L
ENGINE MODEL: 12PC1
Governor: EP/RFD-D
105488-0430
Injection pump: PES12P

106096-9241
1. Test conditions
Date:
28 Jul 2004
Company: ISUZU
No.
115601-7317
Timing device: EP/SPM
105687-0200

Nozzle: 105780-0000


length 600 mm
mm inner dia. 3 mm
kgf/cm2}
+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
mm
Injection order:
4,1
15 15'
9,1
60 15'
8,1
75 15'
5,1
120 15'
2,1
135 15'
11 , 1
10 , 1
195 15'
180 15'
3,1
240 15'
6,1
255 15'
7,1
300 15'
12
315 15'
30').
Adjusting
point
Rack
position
(mm)
Pump
speed
(r/min)
Injection quantity
(cm3/1000 strokes)
Max. variation
between
cylinders (%)
Fixed
8.1
700
85.6 1.5
Lever
(7.9)
1250
Lever
Approx 5.4
225
13
Rack
(10.3)
150
(102)
Lever
Excessive fuel lever ; Normal position
150
Above 137
Lever
Excessive fuel lever ; Excessive fuel

position
(95.9) 2
8 1.4
Remarks
Basic

Pump speed
(r/min)
Advance
angle ( )
(Measure)
Start
0
(Measure)
(1075)
1150
1 - 0.5
1 - 0.5
2.5 0.3
BOSCH K.K.
1250
Finish
5+1
Tel. 81-48-475-2521
Fax. 81-48-475-2520
106961-1564 2/3
Set so that the damper spring is not operating at delivery.
Not exceeding 2 at excessive fuel setting for starting
Excessive fuel setting for starting: 9.20.1
8.1
7.8
Above 6.9
5.4
7.8+0.2
Rack position (mm)
4.8
2.00.5
0
450+25
225
27020
(1235) (1360) 1485-10

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-speed
Full-load
10 5
333
Stop lever angle
Excessive fuel lever angle
Stop
Normal
60
73
Normal
At excessive fuel
for starting
Timing setting
Appro
x.5

B.T.D.C.: 12
Approx. 170
governor side
Gear mark "Z"
(24)
1/6
Ass'y No.: 107491-3190
C ON F I D EN T I AL
T E MPOR AR ILY
ENGINE MODEL: J05C-TJ
Date:
16 Mar 2007
Company: HINO
No.
22040-2421A
Pre-stroke actuator:
159645-4120
Governor: EP/RLD-J
105933-1730
Injection pump: TC4MD

107049-0060
1. Test conditions
Pump rotation: Counter clockwise ( viewed from drive side )

Nozzle: 105025-1940
(Bosch Type No.
(Bosch Type No.

(Bosch Type No.
Nozzle opening pressure: 1st 17.7 MPa { 180 kgf/cm }

2nd 21.6MPa { 220 kgf/cm2 }
Length 600 mm
+5
Oil Temp. 40 C
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:
1. Adjust using the shim 3.
2. Adjust with the rack in the full-load position.
3. Adjust with the connector 1 contacting the stopper 2.
Injection order: 1
3,1
90 15'
4,1
180 15'
Stopper 2
(Timing retard side)
Shim 3
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:
240.5 V
Pre-stroke
(mm)
Pre-stroke sensor
output voltage (V)
2.0 0.05
2.83 0.01
5.1 0.03
V1 = 1.2 0.2
Above 3.05
Ambient temperature: 235C

Remarks
Pre-stroke actuator adjustment
Confirmation
Confirmation
(Pre-stroke actuator operating range)
Bosch Corporation

Tel. 81-48-475-2521
Fax. 81-48-475-2520
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 Nm {0.1 ~ 0.15 kgfm}
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 + 0.050.01 (V)
5.0 0.03 (mm)
Adjusting
P
point
Rack
position
(mm)
Pump
speed
(r/min)
P1
(12.8)
750
P2
Approx
8.0
325
Injection q'ty
3
110 3
Max. variation
between
cylinders (%)
Fixed
3.5
Rack
Rack
Remarks
Basic
107491-3190 3/6
Torque cam no. AH27
Rack position (mm)
R1+2.15
Approx R1+0.4
R1(12.8)
R1-0.25
12.30.1
R1-0.95(R2)
I
A
11.41.0
Below 275
(700)
(500)
650
(1200)
(800)
1500
1530
(1300)
Pump speed (r/min)

Rack position (mm)
Idling adjustment
10.0
+0.2
Rack position (mm)
9.7 -0.3
H J
Approx 8.0
8.0
N = 400
R1-0.95(R2)
R2-1.15
0
23.31.3 {17510}
6.80.1
4.50.6
230
375 450
325
Pump speed (r/min)
800
107491-3190 4/6
6. Injection quantity adjustment (after governor adjustment)
P1
V = 2.25 0.01 (V)
3.1 0.05 (mm)
P2
Rack
position
(mm)
Adjusting
P
point
Pump
speed
(r/min)
Injection q'ty
3
Max. variation
between
cylinders (%)
Fixed
Remarks

Basic
P1 R1(12.8)
750
110 2
Lever
P1 R1+2.15
1250
(120.5) 3
Lever
P1 R2-1.15
400
(83) 3
Lever
Boost press: 0
P1
Approx
R1+0.4
100
Lever
Boost press: 0
(175)
7. Control lever angle

4.5
Stop lever angle
5
5
Idling
op
40
al
St
No
rm
Full-speed
10.55
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
(r/min)
Below 1170
1120
1250-50
Advance
angle ( )
Start
0
0-0.3
Finish
-1.50.3
107491-3190 5/6
9. Injection timing setting
Pointer
Injection timing aligning mark

(Pre-stroke: 5.10.03 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
50.01V
Speed No
1250 r/min
Rack position Ro
R1(12.8) + 2.15 mm
Output voltage VR
3.000.01V
(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 amps 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 amps 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).
Rack sensor adjusting position
Rack position
Adjustment Np = No
Output voltage
Ro
VR
No
Ro
Np
Joint part no.
Ro
154614-2500
10.2 ~ 13.7
154614-4800
5.2 ~ 8.7
154614-8300
15.2 ~ 18.7
154614-8400
20.2 ~ 23.7
154614-8700
7.7 ~ 11.2
154614-8800
12.7 ~ 16.2
154614-8900
17.7 ~ 21.2
Pump end face
Pump end face
1 2
Apply red paint
Threaded rack block type
1 2
Welded rack block type
Apply red paint
1/6
Ass'y No.: 107491-3191
ENGINE MODEL: J05C-TJ
Date:
29 Nov 2002
Company: HINO
No.
22040-2421A
159645-4120
Governor: EP/RLD-J
105933-1730

107049-0061
1. Test conditions

(Bosch Type No. 1 688 901 101)
Nozzle: 105780-0120
(Bosch Type No. 1 688 901 990)

(Bosch Type No.
Length 600 mm
+5
Oil Temp. 40 C
2. Injection timing
Connector 1
Note:
Injection order: 1
3,1
90 15'
4,1
180 15'
Stopper 2
Shim 3
270 15'


240.5 V
Pre-stroke
(mm)
Pre-stroke sensor
output voltage (V)
2.0 0.05
2.83 0.01
5.1 0.03
V1 = 1.2 0.2
Above 3.05

Remarks
Confirmation
Confirmation

Service Department

Tel. (048)470-1559, Fax. (048)474-9856
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 + 0.050.01 (V)
5.0 0.03 (mm)
Adjusting
P
point
Rack
position
(mm)
Pump
speed
(r/min)
13.1
750
P1
P2 8.00.5
505
Injection q'ty
3
123.5 3
Max. variation
between
cylinders (%)
Fixed
Remarks
3.5
Rack
Basic
Rack
Adjust injection q'ty at N = 505.

107491-3191 3/6
Torque cam no. AH27
Rack position (mm)
R1+2.15
Approx R1+0.4
R1(13.1)
R1-0.25
12.50.1
R1-0.95(R2)
I
A
11.11.0
Below 275
(700)
(500)
650
(1200)
(800)
1500
1530
(1300)
Pump speed (r/min)

Rack position (mm)
Idling adjustment
10.0
+0.2
Rack position (mm)
9.7 -0.3
N = 400
R1-0.95(R2)
R2-1.15
0
Approx 8.0
8.0
23.31.3 {17510}
6.80.1
4.50.6
230
375 450
325
Pump speed (r/min)
800
107491-3191 4/6
P1
V = 2.25 0.01 (V)
3.1 0.05 (mm)
P2
Rack
position
(mm)
Adjusting
P
point
Pump
speed
(r/min)
Injection q'ty
3
Max. variation
between
cylinders (%)
Fixed
P1 R1(13.1)
750
123.5 2
Lever
P1 R1+2.15
1250
136 6
Lever
Remarks

Basic

4.5
Stop lever angle
5
5
Idling
op
40
al
St
No
rm
Full-speed
10.55
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
(r/min)
Below 1170
1120
1250-50
Advance
angle ( )
Start
0
0-0.3
Finish
-1.50.3
107491-3191 5/6
Pointer

Approx
Flywheel


107491-3191 6/6
50.01V
Speed No
1250 r/min
Rack position Ro
R1(13.1) + 2.15 mm
Output voltage VR
3.000.01V

Note:
the joint).
Rack position
Adjustment Np = No
Output voltage
Ro
VR
No
Ro
Np
Joint part no.
Ro
154614-2500
10.2 ~ 13.7
154614-4800
5.2 ~ 8.7
154614-8300
15.2 ~ 18.7
154614-8400
20.2 ~ 23.7
154614-8700
7.7 ~ 11.2
154614-8800
12.7 ~ 16.2
154614-8900
17.7 ~ 21.2
Pump end face
Pump end face
1 2
Apply red paint
1 2
Apply red paint
INJ. PUMP CALIBRATION DATA
Ass'y No.: 107492-1101
CONFIDENTIAL
ENGINE MODEL: 4HE1-X
Date:
27 Nov.2001
Company: ISUZU
No.
8-97212-185-0
Governor: 105934-0090
EP/RLD-M
Injection pump: 107049-2061

TCS4MD
1. Test condition
Pump rotation:
1/11
Counter clockwise (viewed from drive side)
(Bosch Type No. 1 688 901 101 )
Nozzle: 105780-0120
(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
Oil Temp.: 40
Ambient temperature: 23
Pre-stroke: No.1 Plunger 4.0
3, 1
90
Selector switch No. 00 (For C/U 407910-303*)
15'
180
0.03mm
4, 1
15'
270
15'
Plungers are numbered from the Governor

Tappet clearance
5 C
Digi switch No. 11 (For C/U 407980-224*)
2. Injection timing
Injection order:
+5
Manually rotate the camshaft 2
Service Department
side.
3 times and confirm that it rotates smoothly.

Tel. (048)470-1559, Fax. (048)474-9856
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 (P/N 157927-2820), screw (P/N 157927-3321) and solenoid switch
into housing .
(2) -1. Screw in setscrew until the counterweight contacts the housing's pressfitted
stopper pin.
-2. Tighten screw until clearance between screw and counterweight is 12
mm.
-3. Tighten solenoid switch until clearance between solenoid switch and
counterweight 's pin is 1 2 mm, then tighten locknut .
(3) Install starting advance mechanism's cover.
(4) Position control rack in full position.
(5) Set power supply voltage to manual controller at 12V.
3-2 Pre-stroke adjustment
Adjust No 1 cylinder's start of static injection using the shim .
3-3 Individual cylinder's injection order adjustment
Adjust difference between each cylinder's injection angle based on that of the No. 1
cylinder using the shim .
1.
Setscrew installation
2.
3.
Pre-stroke adjustment
Individual cylinder's injection
order adjustment
107492-1101 3/11
3-4
(1)
(2)
(3)
Measuring pre-stroke output voltage

Install measuring device (P/N 105782-6420).
Remove setscrew (P/N 157927-2820) and install air bleeder bolt.
Screw in screw (P/N 157927-3321) and measure the No 1 cylinder's output voltage
for pre-stroke lift values in the table below.
Adjusting point
Confirmation point
Pre-stroke (mm)
Output voltage (actual)
Remarks
3.36
a1
+ tolerance
3.10
a2
-tolerance
2.96
b1
+ tolerance
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 (P/N 157927-3321) and install minimum advance angle adjustment
stopper.
(2) Screw in minimum advance angle adjustment stopper until No 1 cylinder's pre-stroke
is 3.67 3.73. Then, tighten locknut to specified torque.
(3) Measure the output voltage (c) at this time.
3-6 Solenoid switch adjustment
(1) Apply 24 V voltage to solenoid switch .
(2) Loosen solenoid switch until No 1 cylinder's pre-stroke is 1.90 2.03 mm, then
tighten locknut to specified torque.
(3) Confirm solenoid switch operates at 14.5 -0.1 V.
107492-1101 4/11
4.
Governor adjustment
4-1. Governor adjustment

Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
Boost compensator stroke: 1.25 0.1
R1+0.9
Approx.R1+0.3
R1(15.0)
Torque cam No. AF60
B
I
13.9 0.1
R2 [R1-2.15]
C
10.7 1.0
(650)
250-40
1000
1690
(1150)
(1600)
1810
Pump speed (r/min)
Idling adjustment
10.5
10.0 0.1
Confirm rack sensor Vist = 2.55 0.28

at supply voltage 50.01V , N =1000 r/min , R = R1 (15.0).
H J
Approx.8.9
7.8
6.6 0.1
3.9 0.3
240
400 500
400 475
Pump speed (r/min)
880
107492-1101 5/11
4-2 Boost compensator adjustment
(2)
Select a push rod so C = 37.50.5 at full boost pressure. (C is the distance from the
end face of the housing to top of the lever.)
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.
Top of lever
Pushrod
Boost pressure inlet
Boost compensator
stroke adjusting screw
Notch adjusting nut
Boost compensator spring
(1)
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. kPammHg
107492-1101 6/11
4-3
(1)
(2)
(3)
(4)
Timing cam adjustment (Timing cam No:A07)

Hold speed control lever against full speed stopper bolt.
Supply boost pressure of at least 42.0 kPa {at least 315 mmHg}.
Operate pump at the timing cam adjusting point
(point a in table below: Np = 900 r/min).
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)
Remarks
3.36
a1
+ tolerance
3.10
a2
-tolerance
(5)
(6)
Operate the pump at the timing cam confirmation point

(point b in table below: Np = 1,200 r/min).
Confirm that the pre-stroke output voltage is within the range b1 b2.
Confirmation point
Pre-stroke (mm)
Remarks
2.96
b1
+ tolerance
2.76
b2
-tolerance
Pre-stroke (Pre-stroke output voltage)
2.0
Solenoid starting advance angle
0.03
0.10
2.76 (b2)
b (confirmation point)
2.96 (b1)
3.10 (a2)
a (adjusting point)
3.36 (a1)
Minimum advance angle adjustment

stopper
3.7 0.03 (c)
Pre-stroke at stopper contact
4.0 0.03
0
(500)
900
Pump speed (r/min)
1,200
107492-1101 7/11
5.
Injection quantity
Adjusting
point
Rack
position
( mm )
Pump
speed
( r/min )
Injection q'ty
( cm3/100 strokes )
Max.
variation
between
cylinders
Fixed
Pre-stroke
at adjustment
15.0
1,000
109.5 1.6
Rack
a1a2(v)
8.90.5
510
22 1.5
14
Rack
c(v)
R1(15.0)
1,000
109.5 1
Lever
a1a2(v)
R10.9
1,200
(112.5) 2
Lever
b1b2(v)
Approx.
R10.3
150
(180)
Lever
c(v)
D*
15.30.1
1,200
(106)
Lever
D*: Aneroid compensator actuator adjustment point
b1b2(v)
Remarks
Basic
Cylinder variation
adjustment standard
Cylinder variation
adjustment standard
Basic

Above 42.0Above 315
Above 42.0Above 315
Boost press. 0

Above 42.0 Above 315
Negative press. kPammHg
53.3 kPa 400 mmHg
107492-1101 8/11
6.
FICD Adjustment
(1)
(2)
(3)
(4)
(5)
Stop the injection pump.

Hold speed control lever against idling stopper bolt.
Adjust clearance between FICD actuator lever and speed control lever to approx. 1+1mm.
Loosen nut and fully tighten FICD set bolt .
Apply 53.3 kPa { 400 mmHg} negative pressure to the actuator and set the pump
speed at 450 r/min.
Gradually loosen set bolt then fix bolt using nut when the rack position is 8.70.1 mm.
Apply above negative pressure several times and confirm FICD actuator is operating
properly and clearance between FICD actuator lever and speed control lever.
(6)
(7)
1+1 mm
Speed control lever
FICD actuator lever
Tightening torque
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 15.30.1 mm and fuel injection quantity is as specified. Then, fix the set bolt.
Rack position (mm)
Stroke
D
Injection quantity decrease

adjustment point
Pump speed (r/min)
A
B
Full load set lever
Full load set bolt
107492-1101 10/11
8.
Speed control lever angle
9.
Stop lever angle

Hole(R42)
45 5
5
22.5
Set the position

R=1.5 0.2
Idling
Normal
29.
5
30
Stop
Full-speed
Hole(R41.3)
10. Rack Sensor Adjustment

(1)
(2)
(3)
(4)
(5)
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.
Remove rack position measuring device.
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}
While pulling stop lever, install rack sensor to rack sensor core.
Tighten two flange fixing screws.
R1
N
Pump speed (r/min)
Sensor output voltage (V)
Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
Turn constant voltage power supply power switch ON and set it to DC 5 0.01V.
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.
Rack position (mm)
(6)
(7)
(8)
Vist
R1
Rack position (mm)
107492-1101 11/11
11.
Drive Coupling Timing
Timing setting (At pre-stroke 3.7 0.05mm)

Bracket mark

B.T.D.C. : 8
Engine
Gear hole (Dia. 3mm)
6
(9
14
35
8
2
Pump side
20
(3
12
32
)
Gears threaded hole
Gear side
Pump
Check hole
Stamp on coupling and bracket
)
(B.T.D.C. 8
Mark position of coupling at B.T.D.C. 13
(35)
132
848
3
INJ. PUMP CALIBRATION DATA
Ass'y No.: 107492-1132
CONFIDENTIAL
ENGINE MODEL: 4HE1-X
Date:
18 Mar.2003
Company: ISUZU
No.
8-97212-188-1
Governor: 105934-0081
EP/RLD-M
Injection pump: 107049-2073

TCS4MD
1. Test condition
Pump rotation:
1/11
Counter clockwise (viewed from drive side)
(Bosch Type No. 1 688 901 101 )
Nozzle: 105780-0120
(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
Oil Temp.: 40
Ambient temperature: 23
Pre-stroke: No.1 Plunger 4.0
3, 1
90
Selector switch No. 00 (For C/U 407910-303*)
15'
180
0.03mm
4, 1
15'
270
15'
Plungers are numbered from the Governor

Tappet clearance
5 C
Digi switch No. 11 (For C/U 407980-224*)
2. Injection timing
Injection order:
+5
Manually rotate the camshaft 2
Service Department
side.
3 times and confirm that it rotates smoothly.

Tel. (048)470-1559, Fax. (048)474-9856
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 (P/N 157927-2820), screw (P/N 157927-3321) and solenoid switch
into housing .
(2) -1. Screw in setscrew until the counterweight contacts the housing's pressfitted
stopper pin.
-2. Tighten screw until clearance between screw and counterweight is 12
mm.
-3. Tighten solenoid switch until clearance between solenoid switch and
counterweight 's pin is 1 2 mm, then tighten locknut .
(3) Install starting advance mechanism's cover.
(4) Position control rack in full position.
(5) Set power supply voltage to manual controller at 12V.
3-2 Pre-stroke adjustment
Adjust No 1 cylinder's start of static injection using the shim .
3-3 Individual cylinder's injection order adjustment
Adjust difference between each cylinder's injection angle based on that of the No. 1
cylinder using the shim .
1.
Setscrew installation
2.
3.
Pre-stroke adjustment
Individual cylinder's injection
order adjustment
107492-1132 3/11
3-4
(1)
(2)
(3)
Measuring pre-stroke output voltage

Install measuring device (P/N 105782-6420).
Remove setscrew (P/N 157927-2820) and install air bleeder bolt.
Screw in screw (P/N 157927-3321) and measure the No 1 cylinder's output voltage
for pre-stroke lift values in the table below.
Adjusting point
Confirmation point
Pre-stroke (mm)
Remarks
3.43
a1
+ tolerance
3.17
a2
-tolerance
2.85
b1
+ tolerance
2.65
b2
-tolerance
(calculate from each specification)

Advice
If measuring device (P/N 105782-6420) is removed, the output voltage (a1, a2) should be
remeasured.
3-5 Minimum advance angle adjustment stopper adjustment
(1) Remove screw (P/N 157927-3321) and install minimum advance angle adjustment
stopper.
(2) Screw in minimum advance angle adjustment stopper until No 1 cylinder's pre-stroke
is 3.67 3.73. Then, tighten locknut to specified torque.
(3) Measure the output voltage (c) at this time.
3-6 Solenoid switch adjustment
(1) Apply 24 V voltage to solenoid switch .
(2) Loosen solenoid switch until No 1 cylinder's pre-stroke is 1.90 2.03 mm, then
tighten locknut to specified torque.
(3) Confirm solenoid switch operates at 14.5 -0.1 V.
107492-1132 4/11
4.
Governor adjustment
4-1. Governor adjustment

Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
Boost compensator stroke: 1.1 0.1
R1+2.9
Torque cam No. AG00
B
D
I
Approx.R1+2.0
R1(12.9)
+0.5
R3 [R1-0.6] -0.1
14.0 0.1
R2 [R1-0.6]
(1050)
10.2 1.0
(1300)
0
(700)
250-40
900
1620
(1400)
700
(1550)
1775
Pump speed (r/min)
Idling adjustment
10.5
10.0 0.1
Confirm rack sensor Vist = 2.13 0.28

at supply voltage 50.01V , N =900 r/min , R = R1 (12.9).
H J
Approx.8.5
7.8
6.6 0.1
3.9 0.3
240
400 500
400 475
Pump speed (r/min)
880
107492-1132 5/11
4-2 Boost compensator adjustment
(2)
Select a push rod so C = 37.50.5 at full boost pressure. (C is the distance from the
end face of the housing to top of the lever.)
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.
Top of lever
Pushrod
Boost pressure inlet
Boost compensator
stroke adjusting screw
Notch adjusting nut
Boost compensator spring
(1)
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
(1)
(2)
(3)
(4)
Timing cam adjustment (Timing cam No:A08)

Hold speed control lever against full speed stopper bolt.
Supply boost pressure of at least 40.0 kPa {at least 300 mmHg}.
Operate pump at the timing cam adjusting point
(point a in table below: Np = 900 r/min).
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)
Remarks
3.43
a1
+ tolerance
3.17
a2
-tolerance
(5)
(6)
Operate the pump at the timing cam confirmation point

(point b in table below: Np = 1,450 r/min).
Confirm that the pre-stroke output voltage is within the range b1 b2.
Confirmation point
Pre-stroke (mm)
Remarks
2.85
b1
+ tolerance
2.65
b2
-tolerance
Pre-stroke (Pre-stroke output voltage)
2.0
Solenoid starting advance angle
0.03
0.10
2.65 (b2)
b (confirmation point)
2.85 (b1)
3.17 (a2)
a (adjusting point)
3.43 (a1)
Minimum advance angle adjustment

stopper
3.7 0.03 (c)
Pre-stroke at stopper contact
4.0 0.03
0
(500)
900
Pump speed (r/min)
1,450
107492-1132 7/11
5.
Injection quantity
Adjusting
point
Rack
position
( mm )
Pump
speed
( r/min )
Injection q'ty
( cm3/100 strokes )
Max.
variation
between
cylinders
Fixed
Pre-stroke
at adjustment
12.9
900
81 1.6
Rack
a1a2(v)
8.50.5
500
19 1.5
14
Rack
c(v)
R1(12.9)
900
81 1
Lever
a1a2(v)
R12.9
1,450
(102.5) 2
Lever
b1b2(v)
Approx.
R12.0
150
(175)
Lever
c(v)
D*
15.20.1
1,450
(96.5)
Lever
D*: Aneroid compensator actuator adjustment point
b1b2(v)
Remarks
Basic
Cylinder variation
adjustment standard
Cylinder variation
adjustment standard
Basic

Above 40.0Above 300
Above 40.0Above 300
Boost press. 0

Above 40.0 Above 300
Negative press. kPammHg
53.3 kPa 400 mmHg
107492-1132 8/11
6.
FICD Adjustment
(1)
(2)
(3)
(4)
(5)
Stop the injection pump.

Hold speed control lever against idling stopper bolt.
Adjust clearance between FICD actuator lever and speed control lever to approx. 1+1mm.
Loosen nut and fully tighten FICD set bolt .
Apply 53.3 kPa { 400 mmHg} negative pressure to the actuator and set the pump
speed at 450 r/min.
Gradually loosen set bolt then fix bolt using nut when the rack position is 8.30.1 mm.
Apply above negative pressure several times and confirm FICD actuator is operating
properly and clearance between FICD actuator lever and speed control lever.
(6)
(7)
1+1 mm
Speed control lever
FICD actuator lever
Tightening torque
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 15.20.1 mm and fuel injection quantity is as specified. Then, fix the set bolt.
Rack position (mm)
Stroke
D
Injection quantity decrease

adjustment point
Pump speed (r/min)
A
B
Full load set lever
Full load set bolt
107492-1132 10/11
8.
Speed control lever angle
9.
Stop lever angle

Hole(R42)
45 5
5
22.5
Set the position

R=1.5 0.2
Idling
Normal
29
30
Stop
3
5
Full-speed
Hole(R41.3)
10. Rack Sensor Adjustment

(1)
(2)
(3)
(4)
(5)
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.
Remove rack position measuring device.
Attach rack sensor core to control rack.
At this time, hold control rack using a spanner (to prevent the rack from bending).
While pulling stop lever, install rack sensor to rack sensor core.
Tighten two flange fixing screws.
R1
N
Pump speed (r/min)
Sensor output voltage (V)
Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
Turn constant voltage power supply power switch ON and set it to DC 5 0.01V.
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.
Rack position (mm)
(6)
(7)
(8)
Vist
R1
Rack position (mm)
107492-1132 11/11
11.
Drive Coupling Timing
Timing setting (At pre-stroke 3.7 0.05mm)

Bracket mark

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

(
96
Gears threaded hole
2)
23
Pump side
28
35
14
20
(3
1
Gear side
Pump
Check hole
Stamp on coupling and bracket
)
(B.T.D.C. 8
Mark position of coupling at B.T.D.C. 13
(35)
132
1
18
1/4
Ass'y No.: 107691-0144
CONFIDENTIAL
ENGINE MODEL: FE6TA
Date:
18 Sep 2002
No.
16801 Z5607
159645-2020
Governor: EP/RED-IV
105961-0071

107069-1460
1. Test conditions

(Bosch Type No. 1 688 901 101)
Nozzle: 105780-0120
(Bosch Type No. 1 688 901 990)

(Bosch Type No.
Length 600 mm
+5
Oil Temp. 40 C

R=1.0
20 5
375
Stop
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 = 151 mm.
(2) Measure the rack position R1 at PWM16.25% and confirm that R2 - R1 = 100.1 mm.
Switch box part no.
407980-4340
407915-0590
PWM72.5% rack position

PWM16.25% rack characteristics
72.5%
PWM (%)
R2 = 151 (mm)
R2 - R1 = 100.1 (mm)
16.25%
R1
R2
Rack position (mm)

Service Department

Tel. (048)470-1559, Fax. (048)474-9856
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
Connector 1
Note:
Injection order: 1
4,1
60 15'
30'
2,1
120 15'
6,1
180 15'
Stopper pin 2
Shim 3
3,1
240 15'
300 15'
side.

240.5 V
Pre-stroke
(mm)
Pre-stroke sensor
output voltage (V)
2.0 0.05
2.83 0.01
5.1 0.03
V1 = 1.2 0.2
Above 3.05

Remarks
Confirmation
Confirmation
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)
Rack
position
(mm)
PWM
(%)
Pump
speed
(r/min)
P1
(11.3)
51.5
700
P2
(6.7)
Approx 25.6
445
Injection q'ty
3
108 1
11 1.8

Pump speed
(r/min)
Below 1150
1100
1300
Advance
angle ( )
Start
0
Below 0.3
Finish
4.0 0.3
Max. variation
between
cylinders (%)
4
10
Remarks
Basic
107691-0144 4/4
Pointer
Flywheel

pprox. 25
Coupling key groove position A


1/4
Ass'y No.: 107691-2930
CONFIDENTIAL
Date:
29 Oct 2002
Company: MITSUBISHI
No.
ME301247
159601-5420
Actuator: EP/RED-III
105956-0112

107069-0590
1. Test conditions

(Bosch Type No. 1 688 901 101)
Nozzle: 105780-0120
(Bosch Type No. 1 688 901 990)

(Bosch Type No.
Length 600 mm
+5
Oil Temp. 40 C

39
R=1.0
37
Stop
R=20.0
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
Rack type
19 mm
Control unit no.
407910-3960
Output voltage
V1 = (V2+0.90.0075)
V2 = 2.20.01
Rack position (mm)
R2 = 111
R2 - R1 = 60.05

Service Department
Output voltage (V)
specified below.
V1
V2
R1
R2
Rack position (mm)
Tel. (048)470-1559, Fax. (048)474-9856
107691-2930 2/4
4. Injection timing
Connector 1
Note:
Injection order: 1
5,1
60 15'
3,1
120 15'
6,1
180 15'
Stopper 2
Shim 3
2,1
240 15'
300 15'


240.5 V
Pre-stroke
(mm)
Pre-stroke sensor
output voltage (V)
2.0 0.05
2.83 0.01
5.1 0.03
V1 = 1.2 0.2
Above 3.05

Remarks
Confirmation
Confirmation
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
Injection pump
Pre-stroke actuator
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)
Rack
position
(mm)
Vist
(V)
Pump
speed
(r/min)
P1
(12.5)
1.98
800
140 1
P2
(6.6)
2.9 0.1
395
16.5 1.8
15
Injection q'ty
3
Max. variation
between
cylinders (%)
Remarks
Basic

Pump speed
(r/min)
Below1050
1000
1075
Advance
angle ( )
Start
0
0 - 0.5
Finish
-1.50.5

Pointer
Flywheel

B.T.D.C.: 2
Approx


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 VR0.01V. Then, fix using the nut 5.
50.01V
Governor side rack sensor output VG
1.60V
Drive side rack sensor output voltage
VR0.01V
VR
2V

407912-1742
105782-6320
407910-3032
3
3V
407910-6010
407910-7210
Pump end face
Apply red paint
(3) Reset the governor side rack sensor output at VG and confirm that the drive side rack sensor output
voltage is VR0.01V.
(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.
1/6
Ass'y No.: 107691-3570
ENGINE MODEL: J08C-UJ
Date:
29 Nov 2002
Company: HINO
No.
22040-2341B
159645-4120
Governor: EP/RLD-J
105933-1700

107069-0740
1. Test conditions

(Bosch Type No. 1 688 901 101)
Nozzle: 105780-0120
(Bosch Type No. 1 688 901 990)

(Bosch Type No.
Length 600 mm
+5
Oil Temp. 40 C
2. Injection timing
Connector 1
Note:
Injection order: 1
4,1
60 15'
2,1
120 15'
6,1
180 15'
Stopper 2
Shim 3
3,1
240 15'
300 15'


240.5 V
Pre-stroke
(mm)
Pre-stroke sensor
output voltage (V)
2.0 0.05
2.83 0.01
5.1 0.03
V1 = 1.2 0.2
Above 3.05

Remarks
Confirmation
Confirmation

Service Department

Tel. (048)470-1559, Fax. (048)474-9856
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 + 0.050.01 (V)
5.0 0.03 (mm)
Adjusting
P
point
Rack
position
(mm)
Pump
speed
(r/min)
12.7
750
P1
P2 8.20.5
440
Injection q'ty
3
114.5 3
Max. variation
between
cylinders (%)
Fixed
Remarks
3.5
Rack
Basic
Rack

107691-3570 3/6
Torque cam no. AH02
Stop lever normal position setting: (18.0)
Rack position (mm)
R1+2.05
R1+1.1
Approx R1+0.25
R1(12.7)
12.30.1
R1-0.25
R2[R1-1.0]
B
I
9.31.0
Below 225 650 (700) (950) (1050)
(500)
(800)
(1300) 1510 1575
(1200)
(1470)
Pump speed (r/min)

Rack position (mm)
Idling adjustment
10.0
+0.2
Rack position (mm)
9.7 -0.3
N = 300
R2[R1-1.0]
R2-1.15
0
Approx 8.2
8.0
36.01.3 {27010}
6.70.1
5.10.6
190
350 400
275
Pump speed (r/min)
700
107691-3570 4/6
P1
V = 2.25 0.01 (V)
3.1 0.05 (mm)
P2
Rack
position
(mm)
Adjusting
P
point
Pump
speed
(r/min)
Injection q'ty
3
Max. variation
between
cylinders (%)
Fixed
P1 R1(12.7)
750
114.5 2
Lever
P1 R1+2.05
1250
124 6
Lever
Remarks
Basic


Stop lever angle
)
(38
Full-speed
8.5
Stop
Normal
Idling
15 5
N=0, R=1.50.1
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
(r/min)
Below 1200
1150
1290
Advance
angle ( )
Start
0
0-0.3
Finish
-1.50.3
107691-3570 5/6
Pointer

Approx
Flywheel


107691-3570 6/6
50.01V
Speed No
1250 r/min
Rack position Ro
R1(12.7) + 2.05 mm
Output voltage VR
3.000.01V

Note:
the joint).
Rack position
Adjustment Np = No
Output voltage
Ro
VR
No
Ro
Np
Joint part no.
Ro
154614-2500
10.2 ~ 13.7
154614-4800
5.2 ~ 8.7
154614-8300
15.2 ~ 18.7
154614-8400
20.2 ~ 23.7
154614-8700
7.7 ~ 11.2
154614-8800
12.7 ~ 16.2
154614-8900
17.7 ~ 21.2
Pump end face
Pump end face
1 2
Apply red paint
1 2
Apply red paint
1/4
Ass'y No.: 107691-3580
CONFIDENTIAL
ENGINE MODEL: JC8C-UK
Date:
7 May 2003
Company: HINO
No.
22040-2451B
159645-4220
Governor: EP/RED-IV
105962-0220

107069-0750
1. Test conditions

(Bosch Type No. 1 688 901 101)
Nozzle: 105780-0120
(Bosch Type No. 1 688 901 990)

(Bosch Type No.
Length 600 mm
+5
Oil Temp. 40 C
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 = 151 mm.
(2) Measure the rack position R1 at PWM16.25% and confirm that R2 - R1 = 100.1 mm.
Switch box part no.
407980-4340
407915-0590
PWM72.5% rack position

PWM16.25% rack characteristics
72.5%
PWM (%)
R2 = 151 (mm)
R2 - R1 = 100.1 (mm)
16.25%
R1
R2
Rack position (mm)

Service Department

Tel. (048)470-1559, Fax. (048)474-9856
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
Connector 1
Stopper 2
Note:
Injection order: 1
4,1
60 15'
2,1
120 15'
6,1
180 15'
Shim 3
3,1
240 15'
300 15'


240.5 V
Pre-stroke
(mm)
Pre-stroke sensor
output voltage (V)
2.0 0.05
2.83 0.01
5.1 0.03
V1 = 1.2 0.2
Above 3.05

Remarks
Confirmation
Confirmation
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)
Rack
position
(mm)
PWM
(%)
Pump
speed
(r/min)
P1
(11.8)
54.5
750
123.5 2
3.5
P2
(6.8)
26.32.8
440
Each cylinder
11 1.1
Injection q'ty
3
Max. variation
between
cylinders (%)
Remarks
Basic

Pump speed
(r/min)
Below 1220
1170
1320-50
Advance
angle ( )
Start
0
0-0.3
Finish
-1.50.3
POINTER stamping position

Advance angle: 0; Pump speed:
1170r/min
107691-3580 4/4
Pointer

B.T.D.C.: 3
Approx
Flywheel

.30
Adjust the clearance between the pickup

and the timer housing projection to 1-0.2mm.

Co
1/6
Ass'y No.: 107691-3590
ENGINE MODEL: J08C-UK
Date:
29 Nov 2002
Company: HINO
No.
22040-2351B
159645-4120
Governor: EP/RLD-J
105933-1710

107069-0760
1. Test conditions

(Bosch Type No. 1 688 901 101)
Nozzle: 105780-0120
(Bosch Type No. 1 688 901 990)

(Bosch Type No.
Length 600 mm
+5
Oil Temp. 40 C
2. Injection timing
Connector 1
Note:
Injection order: 1
4,1
60 15'
2,1
120 15'
6,1
180 15'
Stopper 2
Shim 3
3,1
240 15'
300 15'


240.5 V
Pre-stroke
(mm)
Pre-stroke sensor
output voltage (V)
2.0 0.05
2.83 0.01
5.1 0.03
V1 = 1.2 0.2
Above 3.05

Remarks
Confirmation
Confirmation

Service Department

Tel. (048)470-1559, Fax. (048)474-9856
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 + 0.050.01 (V)
5.0 0.03 (mm)
Adjusting
P
point
Rack
position
(mm)
Pump
speed
(r/min)
12.9
750
P1
P2 8.20.5
440
Injection q'ty
3
125 3
Max. variation
between
cylinders (%)
Fixed
Remarks
3.5
Rack
Basic
Rack

107691-3590 3/6
Torque cam no. AH29
Rack position (mm)
R1+2.45
R1+0.4
Approx R1+0.4
R1(12.9)
12.30.1
R2[R1-1.15]
B
I
9.31.0
(820) (910)
Below 225 (500)
750
(1320) 1520 1585
(1200)
(1475)
Pump speed (r/min)

Rack position (mm)
Idling adjustment
10.0
+0.2
Rack position (mm)
9.7 -0.3
N = 300
R2[R1-1.15]
R2-0.95
0
Approx 8.2
8.0
38.01.3 {28510}
6.70.1
5.10.6
190
350 400
275
Pump speed (r/min)
700
107691-3590 4/6
P1
V = 2.25 0.01 (V)
3.1 0.05 (mm)
P2
Rack
position
(mm)
Adjusting
P
point
Pump
speed
(r/min)
Injection q'ty
3
Max. variation
between
cylinders (%)
Fixed
P1 R1(12.9)
750
125 2
Lever
P1 R1+2.45
1250
141.5 6
Lever
Remarks
Basic


Stop lever angle
8.5
39
Stop
Full-speed
Normal
Idling
15 5
N=0, R=1.50.1
35 5
R=(18.0)
Note;

Pump speed
(r/min)
Below 1180
1130
1260
Advance
angle ( )
Start
0
0-0.3
Finish
-1.50.3

1130r/min
107691-3590 5/6
Pointer

Approx
Flywheel


107691-3590 6/6
50.01V
Speed No
1250 r/min
Rack position Ro
R1(12.9) + 2.45 mm
Output voltage VR
3.000.01V

Note:
the joint).
Rack position
Adjustment Np = No
Output voltage
Ro
VR
No
Ro
Np
Joint part no.
Ro
154614-2500
10.2 ~ 13.7
154614-4800
5.2 ~ 8.7
154614-8300
15.2 ~ 18.7
154614-8400
20.2 ~ 23.7
154614-8700
7.7 ~ 11.2
154614-8800
12.7 ~ 16.2
154614-8900
17.7 ~ 21.2
Pump end face
Pump end face
1 2
Apply red paint
1 2
Apply red paint
1/6
Ass'y No.: 107691-3630
ENGINE MODEL: J08C-UK
Date:
29 Nov 2002
Company: HINO
No.
22040-2371A
159645-4120
Governor: EP/RLD-J
105933-1770

107069-0760
1. Test conditions

(Bosch Type No. 1 688 901 101)
Nozzle: 105780-0120
(Bosch Type No. 1 688 901 990)

(Bosch Type No.
Length 600 mm
+5
Oil Temp. 40 C
2. Injection timing
Connector 1
Note:
Injection order: 1
4,1
60 15'
2,1
120 15'
6,1
180 15'
Stopper 2
Shim 3
3,1
240 15'
300 15'


240.5 V
Pre-stroke
(mm)
Pre-stroke sensor
output voltage (V)
2.0 0.05
2.83 0.01
5.1 0.03
V1 = 1.2 0.2
Above 3.05

Remarks
Confirmation
Confirmation

Service Department

Tel. (048)470-1559, Fax. (048)474-9856
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 + 0.050.01 (V)
5.0 0.03 (mm)
Adjusting
P
point
Rack
position
(mm)
Pump
speed
(r/min)
12.9
750
P1
P2 8.20.5
440
Injection q'ty
3
125 3
Max. variation
between
cylinders (%)
Fixed
Remarks
3.5
Rack
Basic
Rack

107691-3630 3/6
Torque cam no. AH29
Rack position (mm)
R1+2.45
R1+0.4
Approx R1+0.4
R1(12.9)
12.30.1
R2[R1-1.15]
B
I
9.31.0
(820) (910)
Below 225 (500)
750
(1320) 1520 1585
(1200)
(1475)
Pump speed (r/min)

Rack position (mm)
Idling adjustment
10.0
+0.2
Rack position (mm)
9.7 -0.3
N = 300
R2[R1-1.15]
R2-0.95
0
Approx 8.2
8.0
38.01.3 {28510}
6.70.1
5.10.6
190
350 400
275
Pump speed (r/min)
700
107691-3630 4/6
P1
V = 2.25 0.01 (V)
3.1 0.05 (mm)
P2
Rack
position
(mm)
Adjusting
P
point
Pump
speed
(r/min)
Injection q'ty
3
Max. variation
between
cylinders (%)
Fixed
P1 R1(12.9)
750
125 2
Lever
P1 R1+2.45
1250
141.5 6
Lever
Remarks
Basic


Stop lever angle
8.5
39
Stop
Full-speed
Normal
Idling
15 5
N=0, R=1.50.1
35 5
R=(18.0)
Note;

Pump speed
(r/min)
Below 1180
1130
1260
Advance
angle ( )
Start
0
0-0.3
Finish
-1.50.3

1130r/min
107691-3630 5/6
Pointer

Approx
Flywheel


107691-3630 6/6
50.01V
Speed No
1250 r/min
Rack position Ro
R1(12.9) + 2.45 mm
Output voltage VR
3.000.01V

Note:
the joint).
Rack position
Adjustment Np = No
Output voltage
Ro
VR
No
Ro
Np
Joint part no.
Ro
154614-2500
10.2 ~ 13.7
154614-4800
5.2 ~ 8.7
154614-8300
15.2 ~ 18.7
154614-8400
20.2 ~ 23.7
154614-8700
7.7 ~ 11.2
154614-8800
12.7 ~ 16.2
154614-8900
17.7 ~ 21.2
Pump end face
Pump end face
1 2
Apply red paint
1 2
Apply red paint
1/6
Ass'y No.: 107691-3690
C ON F I D E N T I A L
ENGINE MODEL: J08C-UL
Date:
10 Feb 2003
Company: HINO
No.
22040-2320B
159645-4120
Governor: EP/RLD-J
105933-1830

107069-0740
1. Test conditions

(Bosch Type No. 1 688 901 101)
Nozzle: 105780-0120
(Bosch Type No. 1 688 901 990)

(Bosch Type No.
Length 600 mm
+5
Oil Temp. 40 C
2. Injection timing
Connector 1
Note:
Injection order: 1
4,1
60 15'
2,1
120 15'
6,1
180 15'
Stopper 2
Shim 3
3,1
240 15'
300 15'


240.5 V
Pre-stroke
(mm)
Pre-stroke sensor
output voltage (V)
2.0 0.05
2.83 0.01
5.1 0.03
V1 = 1.2 0.2
Above 3.05

Remarks
Confirmation
Confirmation

Service Department

Tel. (048)470-1559, Fax. (048)474-9856
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 + 0.050.01 (V)
5.0 0.03 (mm)
Adjusting
P
point
Rack
position
(mm)
Pump
speed
(r/min)
11.9
750
P1
P2 8.20.5
440
Injection q'ty
3
102 3
Each cylinder
13.51.35
Max. variation
between
cylinders (%)
Fixed
Remarks
3.5
Rack
Basic
Rack

107691-3690 3/6
If not indicated, the rack position allowance is 0.05 mm.
Torque cam no. AH33

Rack position (mm)
R1+2.05
11.90.1
Approx R1+1.75
R1(11.9)
R1-0.1
R2[R1-0.35]
9.11.0
Below 225
650
(800)
(1300) 1485 1550
(700)
(530)
(1200)
(1460)
Pump speed (r/min)

Rack position (mm)
Idling adjustment
10.0
+0.2
Rack position (mm)
9.7 -0.3
H J
Approx 8.2
8.0
N = 300
R2[R1-0.35]
R2-1.0
0
37.31.3 {28010}
6.70.1
5.10.6
190
350 400
275
Pump speed (r/min)
700
107691-3690 4/6
P1
V = 2.25 0.01 (V)
3.1 0.05 (mm)
P2
Rack
position
(mm)
Adjusting
P
point
Pump
speed
(r/min)
Injection q'ty
3
Max. variation
between
cylinders (%)
Fixed
P1 R1(11.9)
750
102 2
Lever
P1 R1+2.05
1250
114 6
Lever
Remarks
Basic


.5
35
Stop lever angle
8.5
Stop
Full-speed
Normal
Idling
15 5
N=0, R=1.50.1
35 5
R=(18.0)
Note;

Pump speed
(r/min)
Below 1150
1100
1250-50
Advance
angle ( )
Start
0
0-0.3
Finish
-1.50.3
107691-3690 5/6
Pointer

Approx
Flywheel


107691-3690 6/6
50.01V
Speed No
1250 r/min
Rack position Ro
R1(11.9) + 2.05 mm
Output voltage VR
3.000.01V

Note:
the joint).
Rack position
Adjustment Np = No
Output voltage
Ro
VR
No
Ro
Np
Joint part no.
Ro
154614-2500
10.2 ~ 13.7
154614-4800
5.2 ~ 8.7
154614-8300
15.2 ~ 18.7
154614-8400
20.2 ~ 23.7
154614-8700
7.7 ~ 11.2
154614-8800
12.7 ~ 16.2
154614-8900
17.7 ~ 21.2
Pump end face

6
1 2
Apply red paint
Pump end face

6
1 2
Apply red paint

CONFIDENTIAL
1/4
Ass'y No.: 107691-7020

Date:
17 Aug 2004
Company: MITSUBISHI
No.
ME302925
159601-5420
105956-0250

107069-0590
1. Test conditions

(Bosch Type No. 1 688 901 101)
Nozzle: 105780-0120
(Bosch Type No. 1 688 901 990)

(Bosch Type No.
Length 600 mm
+5
Oil Temp. 40 C

37 5
R=1.0
R=20.0
33.5
Stop
Normal
3. RED-III governor
Rack type
19 mm
Control unit no.
407910-3960
Output voltage
V1 = (V2+0.90.0075)
V2 = 2.20.01
Rack position (mm)
R2 = 111
R2 - R1 = 60.05
BOSCH K.K.
Output voltage (V)
specified below.
V1
V2
R1
R2
Rack position (mm)
Tel. 81-48-475-2521
Fax. 81-48-475-2520
107691-7020 2/4
4. Injection timing
Connector 1
Note:
Injection order: 1
5,1
60 15'
3,1
120 15'
6,1
180 15'
Stopper 2
Shim 3
2,1
240 15'
300 15'


240.5 V
Pre-stroke
(mm)
Pre-stroke sensor
output voltage (V)
2.0 0.05
2.83 0.01
5.1 0.03
V1 = 1.2 0.2
Above 3.05

Remarks
Confirmation
Confirmation
Note:
2. Move the pre-stroke actuator Counter clockwise (viewed from the drive side) to adjust it.
Stamping position
Injection pump
Pre-stroke actuator
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)
Rack
position
(mm)
Vist
(V)
Pump
speed
(r/min)
P1
(12.5)
1.98
800
140 1
P2
(6.6)
2.9 0.1
395
16.5 1.8
15
Injection q'ty
3
Max. variation
between
cylinders (%)
Remarks
Basic

Pump speed
(r/min)
Below1050
1000
1075
Advance
angle ( )
Start
0
0 - 0.5
Finish
-1.50.5

Pointer
Flywheel

B.T.D.C.: 2
Approx


107691-7020 4/4
50.01V
1.60V
VR0.01V
VR
2V

407912-1742
105782-6320
407910-3032
3
3V
407910-6010
407910-7210
Pump end face
Apply red paint
voltage is VR0.01V.
Note:

CONFIDENTIAL
1/4
Ass'y No.: 107691-7040

Date:
19 May 2006
Company: MITSUBISHI
No.
ME304583
159601-8820
105956-0250

107069-0590
1. Test conditions

(Bosch Type No. 1 688 901 101)
Nozzle: 105780-0120
(Bosch Type No. 1 688 901 990)

(Bosch Type No.
Length 600 mm
+5
Oil Temp. 40 C

37 5
R=1.0
R=20.0
33.5
Stop
Normal
3. RED-III governor
Rack type
19 mm
Control unit no.
407910-3960
Output voltage
V1 = (V2+0.90.0075)
V2 = 2.20.01
Rack position (mm)
R2 = 111
R2 - R1 = 60.05
Bosch Corporation
Output voltage (V)
specified below.
V1
V2
R1
R2
Rack position (mm)
Tel. 81-48-475-2521
Fax. 81-48-475-2520
107691-7040 2/4
4. Injection timing
Connector 1
Note:
Injection order: 1
5,1
60 15'
3,1
120 15'
6,1
180 15'
Stopper 2
Shim 3
2,1
240 15'
300 15'


240.5 V
Pre-stroke
(mm)
Pre-stroke sensor
output voltage (V)
2.0 0.05
2.83 0.01
5.1 0.03
V1 = 1.2 0.2
Above 3.05

Remarks
Confirmation
Confirmation
Note:
2. Move the pre-stroke actuator Counter clockwise (viewed from the drive side) to adjust it.
Stamping position
Injection pump
Pre-stroke actuator
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)
Rack
position
(mm)
Vist
(V)
Pump
speed
(r/min)
P1
(12.5)
1.98
800
140 1
P2
(6.6)
2.9 0.1
395
16.5 1.8
15
Injection q'ty
3
Max. variation
between
cylinders (%)
Remarks
Basic

Pump speed
(r/min)
Below1050
1000
1075
Advance
angle ( )
Start
0
0 - 0.5
Finish
-1.50.5

Pointer
Flywheel

B.T.D.C.: 2
Approx


107691-7040 4/4
50.01V
1.60V
VR0.01V
VR
2V

407912-1742
105782-6320
407910-3032
3
3V
407910-6010
407910-7210
Pump end face
Apply red paint
voltage is VR0.01V.
Note:
1/6
Assy No.: 107692-2086
CONF I DE NT I A L
Date:
10 Apr 2006
Company: MITSUBISHI
No.
ME075629
159600-2620
Governor: EP/RLD-J
105933-0252

107069-0120
1. Test conditions
Pump rotation: Countor clockwise (viewed from drive side)

(Bosch type no. 1 688 901 101)
Nozzle: 105780-0120
(Bosch type no. 1 688 901 990)

(Bosch type no.
)
kgf/cm2}
length 600 mm
mm inner dia. 3 mm
+5
DIGI switch no.: 17 (for C/U 407980-224*)
2. Injection timing
Stopper 2
Pre-stroke: No. 1 plunger 5.6 0.03 mm

Note:
Injection order: 1
5,1
60 15'
3,1
120 15'
6,1
180 15'
Connector 1
Shim 3
2,1
240 15'
300 15'


240.5 V
Pre-stroke
(mm)
Pre-stroke sensor
output voltage (V)
2.5 0.05
2.83 0.01
5.6 0.03
V1 = 1.2 0.2
Above 3.05

Remarks
Confirmation
Confirmation
BOSCH K.K.

Tel. 81-48-475-2521
Fax. 81-48-475-2520
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)
Adjusting
P
point
Rack
position
(mm)
Pump
speed
(r/min)
Injection quantity
(cm3/1000 strokes)
Max. variation
between
cylinders (%)
Fixed
Remarks
P1
13.4
700
122 2
Rack
P2
Approx
7.7
510
10.5 1.8
15
Rack
107692-2086 3/6
Torque cam no. AC34
If not indicated, the rack position allowance is 0.05 mm.
Boost compensator stroke: (1.4)0.1
Rack position (mm)
R1+1.55
R1+1.3
R1(13.4)
Approx R1-0.8
12.01.0
R2[R1-1.3]
C
9.20.1
(380)
700
(1030)
(1310)
(1270)
(1450)
Below 225
1530
1590
Pump speed (r/min)

Rack position (mm)
Idling adjustment
9.5
+0.2
9.2 -0.3
Approx 7.7
H J
Rack position (mm)
7.5
N = 250
R2[R1-1.3]
(R2-1.4)
0
6.10.1
8.01.3 {6010}
2.40.5
0
400
185
290
325
275
(320)
Pump speed (r/min)
900
107692-2086 4/6
P1
V = 2.25 0.01 (V)
3.6 0.03 (mm)
P2
Adjusting
P
point
Rack
position
(mm)
Pump
speed
(r/min)
Injection quantity
(cm3/1000 strokes)
Max. variation
between
cylinders (%)
Fixed
P1 R1(13.4)
700
122 1
Lever
P1 R1+1.55
1350
(113) 2
Lever
P1 (R2-1.4)
250
69 2
Lever
P1 (R1-0.55)
550
(118.5) 2
Remarks
Basic
Lever

Boost pressure
0
Stop lever angle
.
39
30 5
Stop
Normal
ng
Idli
4 5
Full-speed
Set the stopper bolt at R=3.50.3,N=0

Confirm that injection does not occur.
41 5
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 VR0.01.
(4)Apply red paint to the joint 2 and nut 3 join and to the joint 2 and pump end face join.
Constant voltage
power supply
50.01V
Output voltage
VR0.01V
Speed N
1350 r/min
Rack position R
VR
2V

407912-1742
105782-6320
407910-3032
R1+1.55 mm
3V
407910-6010
407910-7210
Apply red paint
Pump end face
107692-2086 6/6
Pointer

injection position
(Pre-stroke: 5.60.03mm)
B.T.D.C.: 2
Flywheel
Appro
x.1 Coupling key groove position


2. Position the camshaft in the No. 1 plunger's beginning of injection position.
107692-2170
ZEXEL Ass'y No.

Bosch Ass'y No.
Bosch Typecode
Engine Type
Manufacturer
Edition date
P
P
P
P
P
P
P
P
Page 1
107692-2170
6D16T5
MITSUBISHI
10/04/06 (8)
CAT Designation
Test oil
03/10/06 11:42:27

Bosch type code
Nozzle
Bosch type code
Nozzle holder
Opening Pressure
Opening Pressure
Injection pipe
Unit
Set value
min.
ISO4113 or {SAEJ96
7d}
...
degC
40
40
105780-8250
1 688 901 101
105780-0120
1 688 901 990
105780-2190
MPa
20.7
kgf/cm2
211
mm
8-3-600
Overflow valve
131424-8420
kPa
255
221
kgf/cm2
2.6
2.25
kPa
255
255
kgf/cm2
2.6
2.6
PS/ACT control unit part no.
407980-224*
Digi switch no.
17
L
Left
max.
Actual values
OT
Actual values
OT
Actual values
OT
45
289
2.95
255
2.6
CAT Designation
Unit
P
Left
P
Injection order
S
Pre-stroke
mm
P
Governor side
S
deg.
Cal 1-5
S
deg.
Cal 1-3
S
deg.
Cal 1-6
S
deg.
Cyl.1-2
S
deg.
Cal 1-4
CAT Designation
P
Adjusting point
P
Rack position
P
Pump speed
S
S
P
Basic
P
Fixing the rack
P
PS407980-224*
P
PS407980-224*
P
Unit
r/min
mm3/st.
%
V
mm
Set value
L
min.
max.
1-5-3-6-2-4
5.6
NO.1
5.57
5.63
60
59.75
60.25
120
119.75
120.25
180
179.75
180.25
240
239.75
240.25
300
299.75
300.25
Set value
13.4
700
122
0
*
*
2.25+-0.01
3.6+-0.05
*
min.
max.
700
120
-3
700
124
3
107692-2170
03/10/06 11:42:27
CAT
P
P
P
S
S
P
P
P
P
Designation
Adjusting point
Rack position
Pump speed
Fixing the rack
PS407980-224*
PS407980-224*
Remarks
Unit
CAT
P
P
P
S
P
P
P
P
P
P
Designation
Adjusting point
Rack position
Pump speed
Basic
Fixing the lever
Boost pressure
Boost pressure
PS407980-224*
PS407980-224*
Unit
CAT
P
P
P
S
P
P
P
P
P
Designation
Adjusting point
Rack position
Pump speed
Fixing the lever
Boost pressure
Boost pressure
PS407980-224*
PS407980-224*
Unit
CAT
P
P
P
S
P
P
P
P
P
Designation
Adjusting point
Rack position
Pump speed
Fixing the lever
Boost pressure
Boost pressure
PS407980-224*
PS407980-224*
Unit
CAT
P
P
P
S
P
P
P
P
P
Designation
Adjusting point
Rack position
Pump speed
Fixing the lever
Boost pressure
Boost pressure
PS407980-224*
PS407980-224*
Unit
r/min
mm3/st.
%
V
mm
Set value
Z
7.7+-0.5
510
10.5
0
*
V1+0.05+-0.01
5.5+-0.03
*
min.
max.
510
8.7
-15
510
12.3
15
Page 2
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Actual values
OT
Refer to items regarding the pre-stroke actuator

r/min
mm3/st.
kPa
mmHg
V
mm
r/min
mm3/st.
kPa
mmHg
V
mm
r/min
mm3/st.
kPa
mmHg
V
mm
r/min
mm3/st.
kPa
mmHg
V
mm
Set value
A
R1(13.4)
700
122
*
*
36
270
2.25+-0.01
3.6+-0.05
min.
max.
700
121
700
123
Set value
B
R1+1.55
1350
113
*
36
270
2.25+-0.01
3.6+-0.05
min.
max.
1350
109
1350
117
Set value
C
(R2-1.4)
250
69
*
0
0
2.25+-0.01
3.6+-0.05
min.
max.
250
67
250
71
0
0
0
0
Set value
D
(R1-0.55)
550
118.5
*
36
270
2.25+-0.01
3.6+-0.05
min.
max.
550
114.5
550
122.5
36
270
36
270
36
270
107692-2170
03/10/06 11:42:27
Page 3

Name
T1=AC34
BCL=(1.4)+-0.1mm

CAT Designation
P
Pump speed
P
Rack position
S
Boost pressure
S
Boost pressure
CAT
P
P
S
Designation
Pump speed
Rack position
Boost pressure
Boost pressure

N:Pump speed
Unit
r/min
kPa
mmHg
Unit
r/min
kPa
About
mmHg
About
Set value
250
(R2-1.4)
8
60
min.
250
max.
250
6.7
50
9.3
70
Set value
250
R2(R1-1.3)
22.7
min.
250
max.
250
22.7
22.7
170
170
170
Actual values
OT
Actual values
OT
107692-2170
03/10/06 11:42:27
Page 4

Name
a=30deg+-5deg
b=39.5deg+-3deg
aa=38mm
F:Full speed
I:Idle
(2)Stopper bolt set position 'H'

Name
a=4deg+-5deg
b=(31deg)
c=41deg+-5deg
aa=47mm
bb=17.4mm
cc=3.5+-0.3mm
dd=0r/min

N:Pump normal
S:Stop the pump.
(2)Normal engine position (equivalent to R = bb).
(3)Set the stopper bolt at rack position = cc and speed = dd and confirm non-injection
107692-2170
03/10/06 11:42:27
Page 5
2.7 Timing setting

Name
a=(0deg)
b=(40deg)
aa=2deg
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
CAT Designation
P
CU407980-224*
P
Actuator retarding type
P
Supply voltage
P
Ambient temperature
Unit
V
degC
Set value
*
*
24
23
min.
max.
23.5
18
24.5
28
Actual values
OT
107692-2170
P
S
P
03/10/06 11:42:27
Pre-stroke
Output voltage
Adjustment
mm
V
2.5
2.83
*
2.45
2.82
2.55
2.84
CAT
P
P
P
P
S
P
Designation
CU407980-224*
Supply voltage
Ambient temperature
Pre-stroke
Output voltage
Confirmation
Remarks
Unit
Set value
*
24
23
5.6
1.2
*
min.
max.
23.5
18
5.57
1
24.5
28
5.63
1.4
CAT
P
P
P
S
P
Designation
CU407980-224*
Supply voltage
Ambient temperature
Output voltage
Confirmation of operating range
min.
max.
23.5
18
3.05
24.5
28
V
degC
mm
V
Page 6
Actual values
OT
Actual values
OT
Output voltage V1
Unit
V
degC
V
2.9.2 Actuator type (MD-TICS)

Name
A : Stopper pin
B: Connector
2.9.3 Shim position indication (MD-TICS)
Name

C:Shim
Set value
*
24
23
3.05
*
107692-2170
03/10/06 11:42:27
Page 7
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.

107692-2170
03/10/06 11:42:27

Name
RACK SENSOR
N1=1350r/min
Ra=R1(13.4)+1.55mm

(VR) measurement voltage

(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)
Page 8
107692-2170
03/10/06 11:42:27
Page 9

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.)
1/3
Ass'y No.: 108622-0106
CONFIDENTIAL
ENGINE MODEL: PF6TC
Date:
3 Jul 2002
No.
16801 96618
pre-stroke actuator:
159600-0420
Governor: EP/RED-III
105952-1140
Injection pump: TC6HD

108062-3182
1. Test conditions

(Bosch Type No. 1 688 901 101)
Nozzle: 105780-0120
(Bosch Type No. 1 688 901 990)

(Bosch Type No.
Length 600 mm
+5
Oil Temp. 40 C

DIGI Switch No. 31(For C/U 407980-224*)
Stop
Normal
205
R=1.0
R=20.0
375
3. RED-III governor
Rack type
19 mm
Control unit no.
407910-3960
Output voltage
V1 = (V2+0.90.0075)
V2 = 2.20.01
Rack position (mm)
R2 = 111
R2 - R1 = 60.05

Service Department
Output voltage (V)
specified below.
V1
V2
R2
R1
Rack position (mm)
Tel. (048)470-1559, Fax. (048)474-9856
108622-0106 2/3
4. Injection timing
Injection order:
4,1
60 15'
2,1
120 15'
Note: Perform at voltage
6,1
180 15'
3,1
240 15'
300 15'
side ( interval:
30' ).

Pre-stroke: h1 = 6.40.03 mm (when the timing sleeve is pushed up using the jig)
Connector angle when tightening the eccentric pin: 830'30'
Power supply voltage: 240.5 V
Ambient temperature: 235 C
Adjustment and confirmation
Adjustment
Confirmation
Confirmation
Confirmation
Pre-stroke (mm)
4.00.05
h1 = 6.40.03
Below 3.4
Operation
Sensor output (V)
2.450.01
V1 = 1.20.2
3 - 0.02
Above 3.05
Stamp aligning mark on housing

Pre-stroke actuator
108622-0106 3/3
Rack
position
(mm)
Vist
(mm)
Pump
speed
(r/min)
(16.1)
1.43
600
192 2
(8.6)
Approx.2.6
300
13.3 1
10
Injection q'ty
3
Max. variation
between
cylinders (%)
Remarks
Basic
7. Timing setting
At No. 1 plungers beginning of injection position
Appr
ox.30
At adjustment pre-stroke
4.00.05(mm) (V=2.450.01(V))
6.30.03(mm) (V=[V1+0.05]0.01(V))
1/3
Ass'y No.: 108622-2080
CONFIDENTIAL

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

(Bosch Type No. 1 688 901 101)
Nozzle: 105780-0120
(Bosch Type No. 1 688 901 990)

(Bosch Type No.
Length 600 mm
+5
Oil Temp. 40 C


R=1.0
295
R=16.0
195
Normal
Stop
3. RED-III governor
Rack type
15 mm
Control unit no.
407910-2470
Output voltage
V1 = (V2+1.20.01)
V2 = 1.80.01
Rack position (mm)
R2 = 111
R2 - R1 = 60.05

Service Department
Output voltage (V)
specified below.
V1
V2
R1
R2
Rack position (mm)
Tel. (048)470-1559, Fax. (048)474-9856
108622-2080 2/3
4. Injection timing
Injection order:
5,1
60 15'
3,1
120 15'
6,1
180 15'
2,1
240 15'
300 15'
30' ).

Adjustment
Confirmation
Confirmation
Confirmation
Pre-stroke (mm)
3.20.05
h1 = 5.60.03
Below 2.6
Operation
Sensor output (V)
2.450.01
V1 = 1.20.2
3 - 0.02
Above 3.05

Pre-stroke actuator
108622-2080 3/3
Rack
position
(mm)
Vist
(mm)
Pump
speed
(r/min)
(12.3)
1.53
650
155.5 1
(7.1)
Approx.2.6
370
20 2
Max. variation
between
cylinders (%)
Injection q'ty
(cm3 / 1000 strokes )
Remarks
3.20.05(mm) (V=2.450.01(V))
Basic
5.50.03(mm) (V=[V1+0.05]0.01(V))
15
7. Drive side rack sensor adjustment (RED-III governor)

(1) With the injection pump stopped, set the REDIII governors 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 VR0.01, 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.
50.01V
Rack sensor supply voltage

Speed N
0r/min
REDIII governor Vist
1.00V
VR
2V
VR0.01V
407912-1742
105782-6320
407910-3032
3V
407910-6010
407910-7210
Pump end face

Apply red paint
8. Timing setting
Ap
3 3
pro
x. 4
Damper
Pointer
Stamp an aligning mark on

the damper to align with the
pointer groove.
1/3
Ass'y No.: 108622-2081
CONFIDENTIAL

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

(Bosch Type No. 1 688 901 101)
Nozzle: 105780-0120
(Bosch Type No. 1 688 901 990)

(Bosch Type No.
Length 600 mm
+5
Oil Temp. 40 C


R=1.0
295
R=16.0
195
Normal
Stop
3. RED-III governor
Rack type
15 mm
Control unit no.
407910-2470
Output voltage
V1 = (V2+1.20.01)
V2 = 1.80.01
Rack position (mm)
R2 = 111
R2 - R1 = 60.05

Service Department
Output voltage (V)
specified below.
V1
V2
R1
R2
Rack position (mm)
Tel. (048)470-1559, Fax. (048)474-9856
108622-2081 2/3
4. Injection timing
Injection order:
5,1
60 15'
3,1
120 15'
6,1
180 15'
2,1
240 15'
300 15'
30' ).

Adjustment
Confirmation
Confirmation
Confirmation
Pre-stroke (mm)
3.20.05
h1 = 5.60.03
Below 2.6
Operation
Sensor output (V)
2.450.01
V1 = 1.20.2
3 - 0.02
Above 3.05

Pre-stroke actuator
108622-2081 3/3
Rack
position
(mm)
Vist
(mm)
Pump
speed
(r/min)
(12.3)
1.53
650
155.5 1
(7.1)
Approx.2.6
370
20 2
Max. variation
between
cylinders (%)
Injection q'ty
(cm3 / 1000 strokes )
Remarks
3.20.05(mm) (V=2.450.01(V))
Basic
5.50.03(mm) (V=[V1+0.05]0.01(V))
15
7. Drive side rack sensor adjustment (RED-III governor)

(1) With the injection pump stopped, set the REDIII governors 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 VR0.01, 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.
50.01V
Rack sensor supply voltage

Speed N
0r/min
REDIII governor Vist
1.00V
VR
2V
VR0.01V
407912-1742
105782-6320
407910-3032
3V
407910-6010
407910-7210
Pump end face

Apply red paint
8. Timing setting
Ap
3 3
pro
x. 4
Damper
Pointer
Stamp an aligning mark on

the damper to align with the
pointer groove.
PV-No..............: 1 469 426 357

Change.............: 4
22.07.2004
Status
................: vorlufig
Test Specification
mecanically-governed
Distributor pumps
Robert Bosch
GmbH
Stuttgart
Page ..............: 1 / 2
Date of print......: 01.03.2005 08:44
Kundendienstvorschrift
VE 6 / 12 F 1100 L 936
...............: NEF
Engine
Power..............:
85 kW
..............:
pist. swept
vol.
5,9 l
: Traktoren
Application
pump..............................: 0 460 426 357

............................:
Customer
Drawing
A460907012
..............................:
Customer
.............................:
Customer
Order no.
Iveco-Fiat
504047351
test conditions
calibr. nozzle-and-holder assembly
...................: 1 688 901 027
test fuel-injection
tubing
...........................................:
a 6,00 x i 2,00 x
...............................................:
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
point
Index
Sollwert/
Tolerance
distribution
1/min
overflow quantity at pump (l/h)
22,0
400
USMU
47,0
1100
USMO
supply pump pressure (MPa)
0,40
100
PKU
0,55
400
PSU
0,70
900
PSEP
timing device travel (mm) N
3,8
100
SVKU
1,2
900
SVEP
2,6
1100
SVO
full-load start-quantity (mm/H)
95,0
100
STAM
118,0
250
STO
full-load (mm/H)
115,5
400
VU
108,5
800
VEP
92,0
1100
VO
speed regulation breakaway (mm/H)
1,5
1280
AB1
idle (mm/H)
10,0
430
LEP
1,5
500
LK
electric shut-off (mm/H)
1,5
430
SPE1
1,5
430
SPE2
LFB-quantity (mm/H)
-14,0
1100
DQ2
27,5
1100
Q4
47,5
1100
Q3
LFB timing device travel (mm) N
-0,6
1100
DS2
-0,7
1100
DS3
3,4
1100
S4
control lever spacing, -angle
38,9
Ya
43,0
Yb
450 mm
DA-Sollwert/
Tolerance
LDA- ELAB
Pressure
V
hPa
TV
KSB
8,0
10,0
12
12
0
0
0,09
0,07
0,07
12
12
12
12
0
0
0,8
0,6
0,6
12
12
12
12
0
0
15,0
10,0
12
12
0
0
12
12
12
0
0
0
12
4,0
3,0
3,0
3,5
1,5
6,0
1,5
6,0
12
12
0
0
1,5
1,5
5,0
0
0
0
0
6,0
0,5
0,5
12
12
12
0
0
0
0,1
0,5
0,6
12
12
12
0
0
0
2,0 mm
3,0 mm
Remarks:
Alle Rechte bei ROBERT BOSCH GmbH, auch fr den Fall von Schutzrechtsanmeldungen.
Jede Verfgungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.
Robert Bosch
GmbH
Stuttgart
Test Specification
mecanically-governed
Distributor pumps
Kundendienstvorschrift
PV-No..............: 1 469 426 357

Change.............: 4
22.07.2004
Status
................: vorlufig
Page ..............: 2 / 2
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
4 Kundenwuensch-Leerlauf und Abregeldrehzahl
Aenderung
3 Neue Serienreferenzpumpe Nr. 424 890
2 Anpassung nach der FeW Statistik vom 07.11.02
1 Einstellversuch - PSEP auf 7,0 bar
0 Erstausgabe nach Ref.pp. LV 15330 - Nr. 191 509
Date
22.07.04
Dept.
Name
FeW/FAV2/P FeW/FAV2/P-Bk
23.10.03
11.11.02
16.10.02
21.08.02
MICO/DVE
MICO/DVE
MICO/DVE
MICO/DVE
MICO/DVE-Ak
MICO/DVE-Ak
MICO/DVE-Ak
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 fr den Fall von Schutzrechtsanmeldungen.
Jede Verfgungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

Zexel Calibration Data

Diunggah oleh

Informasi Dokumen

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

Zexel Calibration Data

Diunggah oleh

Hak Cipta:

Format Tersedia

1043-806

Pump assy No.

INJECTION PUMP CALIBRATION DATA

Assy No.: 101401-7110

ENGINE MODEL: 4HF1

Injection pump: PES4A

Pump rotation: counter clockwise (viewed from drive side)

(Bosch type no. EF8511/9A)

Nozzle holder: 105780-2080

Nozzle opening pressure: 17.2 MPa {175 kgf/cm2}

Transfer pump pressure: 157 kPa {1.6

Injection pipe: outer dia. 6

Test oil: ISO4113 or SAE standard test oil {SAE J967d}

Overflow valve opening pressure: 127 20 kPa {1.3 0.2

Note: Adjust with rack position of R=R1-0.05

Plungers are numbered from the Governor side (interval:

Basic Cylinder variation adjustment standard

Cylinder variation adjustment standard

6. Timing advance specification

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

Torque cam no. L31

Rack position (mm)

960 (1050) (1250)

Pump speed (r/min)

Confirm that the Vist=2.610.28 when R=R1-0.05 with

Rack position (mm)

Pump speed (r/min)

Stop lever angle

Stopper bolt H position

Timing device aligning mark position

A/T's outer slit

Position of gear's 3 notch at No.1

Pump bracket aligning

Center of threaded hole

A/T's timing device stamping position

Pump bracket check hole position

INJECTION PUMP CALIBRATION DATA

Assy No.: 101401-7113

ENGINE MODEL: 4HF1

Injection pump: PES4A

Pump rotation: counter clockwise (viewed from drive side)

(Bosch type no. EF8511/9A)

Nozzle holder: 105780-2080

Nozzle opening pressure: 17.2 MPa {175 kgf/cm2}

Transfer pump pressure: 157 kPa {1.6

Injection pipe: outer dia. 6

Test oil: ISO4113 or SAE standard test oil {SAE J967d}

Overflow valve opening pressure: 127 20 kPa {1.3 0.2

Note: Adjust with rack position of R=R1-0.05

Plungers are numbered from the Governor side (interval:

Basic Cylinder variation adjustment standard

Cylinder variation adjustment standard

6. Timing advance specification

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

Torque cam no. L31

Rack position (mm)

960 (1050) (1250)

Pump speed (r/min)

Confirm that the Vist=2.610.28 when R=R1-0.05 with

Rack position (mm)

Pump speed (r/min)

Stop lever angle

Stopper bolt H position

Timing device aligning mark position