zexel calibration data

Brett

1043-806

Brett

1401-424

.

1401-725

101401-7452

on CD 2001/3has incorrecttest injectors

use

PIE 106 B-5

Brett

1401-913

Pump ass’y No.101401-9167

use101401-9164

(microfiche PIE-076 C-9,C-10)

1401-9216

use test data

1401-9215

Test Datafor

101401-9702use

101401-9700PIE-95 B-4

Brett

1402-061

Brett

1402-216

Brett

1402-234

.

1402-720

Brett

1402-729

Brett

1402-750

.

1402-762

.

1402-763

Brett

1421-007

Brett

1421-016

Brett

1421-059

Brett

1421-073

Brett

1421-094

Brett

1421-097

Brett

1421-415

Brett

1421-425

Brett

1421-451

Brett

1431-901

Brett

1431-904

Brett

1431-905

Brett

1431-909

Brett

1431-932

Brett

1431-959

Brett

1432-902

Test data1441-9460

use1441-9020

Brett

1441-946

Brett

1472-302

Brett

1472-306

Brett

1472-313

Brett

1472-314

Brett

1472-315

Brett

1482-027

Brett

1482-037

Brett

1482-073

Test data

14950350...351...352

use

01491-031

Brett

1491-053

Brett

1491-953

Brett

1492-304

Brett

1601-052

Test data

1601-5061

use

1601-5051

Brett

1601-605

Brett

1602-121

Brett

1601-292

.

1602-845

Test data

1603-046

use

1603-886

Brett

1603-046

Brett

1603-496

Test data

1605-9490

use

1605-9081

Brett

1605-949

Brett

1606-155

Brett

1608-173

.

1609-331

Brett

1641-224

Test data

1671-0110

use

1671-0030

Brett

1671-011

Brett

1682-716

Brett

1691-088

Brett

1691-203

.

1691-265

Brett

1691-297

101691-506S/S to 523

No info availablethrough Zexel

Brett

1691-530

Brett

1691-545

Brett

2351-001

Oil temperature: 40+5 °C

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

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)

Injection quantity(cm3/1000 strokes)

Max. variationbetween

cylinders (%)Fixed Remarks

11.9 1310 64.5 ± 1.6 ± 4 Rack

H Approx 9.8 285 15.5 ± 1.3 ± 10 Rack

A R1(11.9) 1310 64.5 ± 1 - Lever

B R1 1600 (67.5) ± 2 - Lever

C R1-0.5 500 (44.7) ± 2 - Lever

E R1-0.05 960 (58.5) ± 2 - Lever

I Above 19.5 150 (80) + 16 - Lever

Injection order: 1 3 , 1 4 , 1 290°± 30' 180°± 30' 270°± 30'

Pump speed(r/min)

(Measure) (Measure)

Advanceangle (° )

Start

0

Finish

5.0±0.5

4. Injection quantity

6. Timing advance specification

Company:

Assy No.: 101401-7110ENGINE MODEL: 4HF1

No. Governor: EP/RLD-F Timing device: EP/SCDM

1. Test conditions

Date:

Pump rotation: counter clockwise (viewed from drive side)

Injection pump: PES4A105932-1350 105676-5120

kgf/cm2}

2. Injection timing

Pre-stroke: No.1 plunger 4.1 ± 0.05mm mm

Plungers are numbered from the ° ± 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.

CONFIDENTIAL

INJECTION PUMP CALIBRATION DATA

16 Mar 2004

897122-6171

101041-8260

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

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

Nozzle: 105780-0000 Nozzle holder: 105780-2080(Bosch type no. DN12SD12T) (Bosch type no. EF8511/9)

Nozzle & nozzle holder assy: 105780-8140 (Bosch type no. EF8511/9A)

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

side (interval:

2

Transfer pump pressure: 157 kPa {1.6

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

ISUZU

Governor

1/4

Overflow valve opening pressure: 127 ± 20 kPa {1.3 ± 0.2 kgf/cm2}

Basic Cylinder variation adjustment standard

Basic

Cylinder variation adjustment standard

101401-7110 2/4

3. Governor adjustment

I

0

180

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

0Below 225 (400) (1250)

A B

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

Torque cam no. ‘L31’

R1+0.05R1(11.9)

(630)

(360)

960

(1650)

1845

8.0±0.09

Approx 9.8

Full load adjustment

Idling adjustment

Above 19.5

9.5

H J

11.5

275285

350 1100

C

R1-0.05

(1150)

11.0+0.20-0.22

E

10.1±0.12

R1-0.35R1-0.5

+1.29-1.378.1

(1050)

1925

6.0+0.25-0.27

470

Confirm that the Vist=2.61±0.28 when R=R1-0.05 with rack sensor output value at 5±0.01V and N=960.

101401-7110 3/4

5.FICD adjustment

(1) Adjust the clearance between the actuator lever and the speed lever to approx. 2 mm.

(2) Loosen nut 3 and fully tighten the actuator screw 2.

(3) Supply 53.3 kPa {400 mmHg} negative pressure to the actuator's port 1 and gradually loosen the

screw 2.

(4) Fix the screw 2 using the nut 3 when the rack position is 9.2±0.1 mm and the pump speed is N = 440

r/min.

Specified torque: 1.2 ~ 1.6 N•m {0.12 ~ 0.16 kgf•m}

(5) Supply the above negative pressure several times and confirm that the actuator operates normally

and that the clearance between the actuator lever and the speed lever is as specified.

Approx. 5 mm

1

2

3

101401-7110 4/4

Stopper bolt setting

Stop lever angle

(35°)

Timing setting

At No. 1 plunger’s beginning of injection positionB.T.D.C.: 7°

Position of gear's 3 notch at No.1 cylinder's beginning of injection

Stopper bolt H position

Np=1600, R=5.5-0.5

Stop Normal

34°±3° (Measure)±5°

15°±5°

Speed-control lever angle

Idling 41°±5°

Center of threaded hole

(5°4

4'18''

)

26°36'38'' ± 20'

3°

20°

10°03'56''±3°

(17°30')

(95°)

Timing device aligning mark position(When aligned with bracket aligning mark at B.T.D.C. 13°)

Engine perpendicular

Pump perpendicular

Pump bracket aligning mark position

Pump bracket standard mark position

Align with bracket check hole projection at No 1 cylinder's beginning of injection and stamp at A/T's C1 face.

A/T's timing device stamping position

A/T's outer slit

Pump bracket check hole position

Full-speed




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

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




11.9 1310 64.5 ± 1.6 ± 4 Rack

H Approx 9.8 285 15.5 ± 1.3 ± 10 Rack

A R1(11.9) 1310 64.5 ± 1 - Lever

B R1 1600 (67.5) ± 2 - Lever

C R1-0.5 500 (44.7) ± 2 - Lever

E R1-0.05 960 (58.5) ± 2 - Lever

I Above 19.5 150 (80) + 16 - Lever

Injection order: 1 3 , 1 4 , 1 290°± 30' 180°± 30' 270°± 30'

Pump speed(r/min)

(Measure) (Measure)

Advanceangle (° )

Start

0

Finish

5.0±0.5



Company:

Assy No.: 101401-7113ENGINE MODEL: 4HF1


1. Test conditions

Date:



kgf/cm2}

2. Injection timing




CONFIDENTIAL


29 Jan 2004

897146-7880

101041-8510






side (interval:

3


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

ISUZU

Governor

1/4



Basic Cylinder variation adjustment standard

Basic

101401-7113 2/4


I

0

180

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

0Below 225 (400) (1250)

A B

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

Torque cam no. ‘L31’

R1+0.05R1(11.9)

(630)

(360)

960

(1650)

1845

8.0±0.09

Approx 9.8


Idling adjustment

Above 19.5

9.5

H J

11.5

275285

350 1100

C

R1-0.05

(1150)

11.0+0.20-0.22

E

10.1±0.12

R1-0.35R1-0.5

+1.29-1.378.1

(1050)

1925

6.0+0.25-0.27

470

Confirm that the Vist=2.61±0.28 when R=R1-0.05 with rack sensor output value at 5±0.01V and N=960.

101401-7113 3/4

5.FICD adjustment

(1) Adjust the clearance between the actuator lever and the speed lever to approx. 2 mm.

(2) Loosen nut 3 and fully tighten the actuator screw 2.

(3) Supply 53.3 kPa {400 mmHg} negative pressure to the actuator's port 1 and gradually loosen the

screw 2.

(4) Fix the screw 2 using the nut 3 when the rack position is 9.2±0.1 mm and the pump speed is N = 440

r/min.


(5) Supply the above negative pressure several times and confirm that the actuator operates normally

and that the clearance between the actuator lever and the speed lever is as specified.

Approx. 5 mm

1

2

3

101401-7113 4/4


Stop lever angle

(35°)

Timing setting


Position of gear's φ3 notch at No.1 cylinder's beginning of injection


Np=1600, R=5.5-0.5

Stop Normal

34°±3° (Measure)±5°

15°±5°


Idling 41°±5°


(5°4

4'18''

)

26°02'26'' ± 20'

2°29'42'' 20°

9°29'44''±3°

(17°30')

(95°)

Timing device aligning mark position(When aligned with bracket aligning mark at B.T.D.C. 13°)

Engine perpendicular

Pump perpendicular

Pump bracket aligning mark position

Pump bracket standard mark position

Align with bracket check hole projection at No 1 cylinder's beginning of injection and stamp at A/T's C1 face.

A/T's timing device stamping position

A/T's outer slit

Pump bracket check hole position

Full-speed

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)

Injection q'ty(cm3 / 1000 strokes )



12.3 800 68.5 ± 0.5 ± 2.5 Rack

H Approx. 9.5 325 9.7 ± 2 ± 14 Rack

A R1(12.3) 800 68.5 ± 0.5 - Lever

B R1+0.5 1500 (90.9) ± 2 - Lever

C R1+0.25 600 (62.4) ± 2 - Lever

I - 100 (170) - Lever

Injection order: 1 3 , 1 4 , 1 290°± 30' 180°± 30' 270°± 30'

Pump speed(r/min)

920 1200 1500

Advanceangle (° )

Bellow. 0.5 1.5 ± 0.5 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

Company:

Ass'y No.: 101401-9133ENGINE MODEL: TM

No. Governor: EP/RLD-E Timing device: EP/SCDM

1. Test conditions

Date:

Pump rotation: clockwise ( viewed from drive side )


kgf/cm2 }

2. Injection timing

Pre-stroke: No.1 Plunger 3.2 ± 0.05mm mm

Plungers are numbered from the Drive ° ± 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.

CONFIDENTIAL


21 Aug 2002

TM0113800C

101040-9871

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

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

Nozzle: 105780-0000 Nozzle Holder: 105780-2080(Bosch Type No. DN12SD12T) (Bosch Type No. EF8511/9)

Nozzle & Nozzle Holder Ass'y: 105780-8140 (Bosch Type No. EF8511/9A)

Overflow valve opening pressure: 255 kPa { 2.6 kgf/cm2 }

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

side ( interval:

6

Transfer pump pressure: 157 kPa { 1.6

Note: Adjust with rack position of

MAZDA

1/3



Basic

Basic

101401-9133 2/3


R1+0.55R1+0.5

R1+0.25R1(12.3)

0Below 250

(450)

600 (650) (880)

(1280)

1840(1060)

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

(1550)

1600

AC

I

B

Torque cam no. ‘G96’

R1-0.05

11.5

0200

325400 610 1420

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

Approx 9.5

5.0+0.38-0.42

8.0±0.07


Idling adjustment

+0.07-0.0512.3

+0.72-0.768.5

(850)

11.0+0.49-0.73

9.5

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




12.8 1000 70.5 ± 0.5 ± 2.5 Rack

H Approx 9.5 325 9 ± 2 ± 10 Rack

A R1(12.8) 1000 70.5 ± 0.5 - Lever Basic

B R1+0.5 1625 (84.1) ± 2 - Lever

C R1-0.5 625 (49.6) ± 2 - Lever

I - 100 Above 160 - Lever

Injection order: 1 3 , 1 4 , 1 290°± 30' 180°± 30' 270°± 30'

Pump speed(r/min)

700 1300 1600-25

Advanceangle (° )

Bellow 0.3 2 + 0.5 Finish

5-0.5




Service Department


Tel. (048)470-1559, Fax. (048)474-9856

Company:

Ass'y No.: 101401-9143ENGINE MODEL: TF

No. Governor: EP/RLD-E Timing device: EP/SCDM

1. Test conditions

Date:



kgf/cm2 }

2. Injection timing





CONFIDENTIAL


12 May 2003

TF2013800C

101040-9881





Overflow valve opening pressure: 255 ± 34 kPa { 2.6 ± 0.35 kgf/cm2 }


side ( interval:

0



MAZDA

1/4



Basic

101401-9143 2/4


Adjust the clearance between the pickup and the gear tooth to 1-0.2mm.


0220

325400 1350

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

11.5

8.5+0.05-0.06

R1(12.8)

0Below 250 (480) (1670)

A

B

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

Torque cam no. ‘D71’

R1+0.5

(770)

900

(1500)

520

Approx 9.5


Idling adjustment

R1-0.15R1-0.5

8.3-0.4

2000

(300)

I

H J

C

R1+0.1

(960)

(1080)

11.0±0.08

9.5±0.02

5.5+0.38-0.42

101401-9143 3/4

Bracket's basic hole



IdlingFull-speed

41°±3°

20°±5°

14°±5°

Stop adjuster screw setting

Stop lever angle

Stop Normal

(29.5°)±5°

Engine (bracket)perpendicular

30

Pumpbracket

Gear

Timing setting


Standard measuring positionThe standard measuring position is the center of the gear tooth marked 'CC' and is 30 mm from the bracket end face.

219°

20'

± 30

'

15°±30°

( 6) position

101401-9143 4/4



6. Stop lever adjustment

Set the speed lever at Full and pump speed at Np = 1825 r/min, and then set the stop adjuster screw so

that the rack position is R = 4.7±0.3 mm. After setting the screw, confirm non-injection with the speed

lever in the idling position and pump speed at Np = 325 r/min.

Camshaft center line

Speed lever pulled in this direction

Stop lever pulled in this direction

Speed lever

Stop lever

Stop adjuster screw

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




11.8 900 83.5 ± 1.6 ± 3.5 Rack

H Approx 9.5 300 12 ± 1.8 ± 10 Rack

A R1(11.8) 900 83.5 ± 1 - Lever

B R1+1.05 1550 (106) ± 2 - Lever

C R2-0.8 500 (45.2) ± 2 - Lever

I Above 18.5 100 (100) ± 10 - Lever


Injection order:



Company:

Assy No.: 101401-9460ENGINE MODEL: FD46T


1. Test conditions

Date:

Pump rotation: clockwise (viewed from drive side)

Injection pump: PES4AD105921-7980 105671-0450

kgf/cm2}

2. Injection timing


Plungers are numbered from the Drive ° ± 30').


CONFIDENTIAL


23 Mar 2006

16700 17D00

101041-9070




side (interval:

2


Note: Adjust with rack position of R=R1 (11.8)

1/4

Boost press. kPa {mmHg}Above 71.3 {Above 535}

Boost press. 0

Cylinder variation adjustment standardBasic

1 3 , 1 4 , 1 290°± 30' 180°± 30' 270°± 30'


NISSAN DIESEL



Pump speed(r/min)

Below 900 850 1500

Advanceangle (° )

Start

0 Below 0.5

Finish

5.0±0.3

Bosch CorporationAutomotive Aftermarket Division


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


Basic


Boost press. 0

101401-9460 2/4


I

0

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

0Below 250 (1500)

B

A

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

Torque cam no. ‘K81’

R1+1.05

(580)

(1600)

1720

7.5±0.07 Approx 9.5


Idling adjustment

Above 18.5

HJ

225300

310

12.0±0.15

1100

9.3

R1+0.15

(1030)

330

Boost compensator stroke: 0.8±0.1

R1(11.8)

(850)

11.5

9.5

1000

R2[R1-0.25]

R2-0.8

0

18.7±1.3 {140±10}

Approx 58.0 {Approx 435}

N = 500

Rac

k po

sitio

n (m

m)

Boost pressure kPa {mmHg}

Boost compensator adjustment

470

(630)

C

R2[R1-0.25]R1-0.3

+1.58-1.68

(750)

1825

11.0 +0.49-0.25

5.8 +0.36-0.41

101401-9460 3/4

Bolts A

Potentiometer

5.0±

0.02

V

Potentiometer connections

Output voltage

Direction of potentiometer rotation

Idle Full

(5.0)

(3.83)±0.2

0.5±0.3

0

Specified output voltage

1

2

3

Vol

tage

(V

)

5. Potentiometer adjustment

(1) Supply DC 5.0±0.2V to the potentiometer harness terminals shown in the circuit below to obtain the

specified output voltage.

(2) Fix the speed lever in the full position and loosen bolts A shown below.

Then, move the potentiometer left and right until the output voltage for the full position is as specified.

Tighten bolts A, move the speed lever between full and idle and confirm that the values for full and idle

are as specified.

Potentiometer voltage: Measure actual lever angle at 2.84±0.3 V

101401-9460 4/4



Idling

Full-speed

70°±5°

(40)°±3°

Stop lever angle

Stop Normal


10°±5°

29°±5°

Timing setting


Approx. 50°

(Gear mark position)

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




A 9.3 950 84.7 ± 1 ± 2.5 Lever Basic

Approx. 5.9 400 8 ± 1.3 ± 14 Rack

D - 100 60 + 5 - Lever Rack limit

Injection order: 1 3 , 1 4 , 1 290°± 30' 180°± 30' 270°± 30'

Pump speed(r/min)

Advanceangle (° )




Service Department


Tel. (048)470-1559, Fax. (048)474-9856

Company:

Ass'y No.: 101402-9460ENGINE MODEL: S4K-T

No. Governor: EP/RSV Timing device:

1. Test conditions

Date:


Injection pump: PES4A105419-1011

kgf/cm2 }

2. Injection timing





CONFIDENTIAL


24 Jul 2002

34261-02080

101041-8040







side ( interval:

0



MITSUBISHI

1/3

Adjust max. var. bet. cyl. of R≒ 5.9.Adjust governor as per gov. adj. spec.

101402-9460 2/3




Pump speed (r/min)

0325

8.8±0.1

960

(955) 1040

D

A9.3

8.6

Rac

k po

sitio

n (m

m)

5.6

Above 14

3.9±0.4

Rack limit

Idle sub-spring setting

Main spring setting

Recommended speed droop adjustment screw position: 7(notches from fully tightened position)

375

Perform torque control spring adjustment when necessary.

101402-9460 3/3


Idling

Approx.9°

Stop lever angle

Stop

Full-speed

Normal

Camshaft key groove position

35°±3°

(22°)±5°

(1°)±5°

Contacts stop side boss

53°±5°

26.5°±5°

Stop

Timing setting

At No. 1 plunger’s beginning of injection position

Approx. 60°

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




A 8.2 1000 56 ± 1 ± 2.5 Lever Basic

- Approx.6.9 425 12 ± 1.3 ± 1.4 Rack


Injection order: 1 3 , 1 4 , 1 290°± 30' 180°± 30' 270°± 30'

Pump speed(r/min)

Advanceangle (° )




Service Department


Tel. (048)470-1559, Fax. (048)474-9856

Company:

Ass'y No.: 101402-9810ENGINE MODEL: S4K


1. Test conditions

Date:



kgf/cm2 }

2. Injection timing





CONFIDENTIAL


11 Jun 2002

I

34261-04050

101041-8040







side ( interval:

1



MITSUBISHI

1/3



101402-9810 2/3

Pump speed (r/min)

0(300)

400

425

7.7±0.1

1025

(1015) 1100

D

A

6.0

Rac

k po

sitio

n (m

m)

Above 14

4.5±0.4

Rack limit


(450)

8.6

8.2

1.0±

0.1

Difference in control rack position between 1000 r/min and 250 r/min

Idle sub-spring setting:4.5-0.5 mm

101402-9810 3/3


Idling


Stop lever angle

Stop

Full-speed

Normal

17° ±5°

Camshaft key groove positionApprox.60°

8° ±5°

Approx.11°53°±5°

26.5° ±5°Contacts outer boss

Contacts inner boss

Timing setting


Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




A 8.9 1000 72.5 ± 1 ± 2.5 Rack Basic

- Approx.6.8 425 12 ± 1.3 ± 14 Rack


Injection order: 1 3 , 1 4 , 1 290°± 30' 180°± 30' 270°± 30'

Pump speed(r/min)

Advanceangle (° )




Service Department


Tel. (048)470-1559, Fax. (048)474-9856

Company:

Ass'y No.: 101402-9880ENGINE MODEL:S4K-T


1. Test conditions

Date:



kgf/cm2 }

2. Injection timing





CONFIDENTIAL


11 Jun 2002

34261-04060

101041-8040







side ( interval:

1



MITSUBISHI

1/3



101402-9880 2/3

Pump speed (r/min)

0425

8.3±0.1

1000

(880)

(1100)

D

A

6.0

Rac

k po

sitio

n (m

m)

Above 14

4.1±0.4

Rack limit


8.9

8.5

0.4±

0.1 Difference in control rack

position between 1000 r/min and 700 r/min

Idle sub-spring setting:4.1-0.5 mm

(1030)

1035 1100

101402-9880 3/3

Approx.60°


Idling


Stop lever angle

Stop

Full-speed

Normal

18° ±5°

Camshaft key groove position

2° ±5°

Approx.11°53°±5°

26.5° ±5°Contacts outer boss

Contacts inner boss

Timing setting


Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




13.0 1800 50 ± 1.7 ± 3.4 Rack

13.0 1000 47 ± 1.2 ± 2.5 Rack Basic

9.0 1000 (24 ± 1.2) ± 5 Rack

Approx 7 300 (8 ± 0.2) ± 15 Rack


Injection order:



Company:

Assy No.: 101432-9030ENGINE MODEL: 5113

No. Governor: EP/MZ Timing device:

1. Test conditions

Date:



kgf/cm2}

2. Injection timing




CONFIDENTIAL


20 Mar 2006

22100-87302

101043-8140




side (interval:

0



DAIHATSU DIESEL

1/2

1 3 , 1 4 , 1 290°± 30' 180°± 30' 270°± 30'


Nozzle: 105000-1010 Nozzle holder: 105071-0040(Bosch type no. DN0SD21) (Bosch type no. )

Nozzle & nozzle holder assy: (Bosch type no. )

Pump speed(r/min)

Advanceangle (° )



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

101432-9030 2/2


13

0

9

Rac

k po

sitio

n (m

m)

Negative pressure kPa {mmAq}

Pneumatic governor

Operate injection pump at 500 r/min and increase negative pressure gradually from lower pressure.

7

3.43±0.1{350±15}

4.31±0.2{440±20}

7.26±0.3{740±30}

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




A 9.9 1300 42.2 ± 1 ± 2.5 Lever Basic

C Approx. 6.0 500 8 ± 1.1 ± 14 Rack

E - 100 65 ± 5 - Lever Rack limit

Injection order: 1 3 , 1 4 , 1 290°± 30' 180°± 30' 270°± 30'

Pump speed(r/min)

Below

750700 1300 (Measure))

Advanceangle (° )

Start

0 Below 0.5 1.6 ± 0.5

Finish

(6.0)




Service Department


Tel. (048)470-1559, Fax. (048)474-9856

Company:

Ass'y No.: 101441-9990ENGINE MODEL: DC24T

No. Governor: EP/RSV Timing device: EP/SCD

1. Test conditions

Date:

Pump rotation: counter clockwise ( viewed from drive side )


kgf/cm2 }

2. Injection timing

Pre-stroke: No.1 Plunger 2.25± 0.05mm mm




CONFIDENTIAL


7 Feb 2003

DAEWOO HEAVY

101044-9170







side ( interval:

0



1/3

101441-9990 2/3




Recommended speed droop adjustment screw position: 16 (notches from fully tightened position)

20.0+1.0

9.910.3

0

4.7±0.4

(1170)

A

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

0.65

±0.

1

500

Rack limit

9.0

6.0

360 (970)1050

1330 1440

C Di f ference in cont ro l rack position between 1300 r/min and 500 r/min

9.4±0.1

(1315)

E

5.5


Main spring setting

101441-9990 3/3


Idling


Full-speed

21°±5°

17°±5°

Stop lever angle

Stop

Normal

53°

±5°

19°

±5°

Timing setting


Approx. 60°Gear mark "z"

Ass'y No.: 101495-3426

1/3

ENGINE MODEL： S4D95L E-2

No.

Governor： EP/RSV Timing device：

１．Test condition

Date:

４．Injection quantity

５．Timing Advance specification

Pump speed（r/min）

Advance

angle（°）

Pump rotation： Clockwise (viewed from drive side)

Injection pump： PES4A 105400-8942

kgf/cm2｝　

２．Injection timing

Pre-stroke：No.1 Plunger 3.2±0.05mm　 NoteAfter adjustment with rack position of A (11.3) mm

Injection order：

Plungers are numbered from the Drive °± ）

Tappet clearance：Bolt adjustment type ；More than 0.3mm for all cylinders.：Shim adjustment type；Manual rotate the camshaft 2～3 times and confirm that it rotates smoothly.

C O N F I D E N T I A L

INJ.PUMP CALIBRATION DATA

Company: 7 Feb 2002

KOMATSU 6205-71-1151

101049-4040

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

Nozzle opening pressure： 17.2 MPa｛ 175 kgf/cm2｝　Transfer pump pressure： 157 kPa｛ 1.6

Nozzle：105780-0000 Nozzle Holder：105780-2080(Bosch Type No.DN12SD12T) (Bosch Type No.EF8511/9)

Nozzle ＆ Nozzle Holder Ass'y ：105780-8140 (Bosch Type No.EF8511/9A)

Overflow valve opening pressure： kPa｛

Test Oil：ISO4113 or SAE Standard Test Oil｛SAE J967d｝ Oil Temp.：40　℃+5

side. ( interval:

Adjust-

ing point

Rackposition(mm)

Pumpspeed(r/ min)

Injection q' ty( cm3 / 1000 strokes)

Max. varbet. cyl Fixed Remarks

9


Service Department


Tel. (048)470-1559, Fax. (048)474-9856

(％)

A 11.3 900 91.5±1 ±2.5 Lever Basic

kgf/cm2｝　

1 － 2 ,1 － 4 ,1 － 390°±30′ 180°±30′ 270°±30′

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

101495-3426 2/3

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)３. Governor adjustment

Recommended speed droop adjustment screw position : 8(notches from fully tightened position)

Idle-sub spring setting

Approx.17.5

915 rpm.

0°

760 rpm.

101495-3426 3/3

Test Data

101495 – 3450

use

101495 – 3435same as

101495 - 3433

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




A 10.2 900 70.5 ± 1 ± 2.5 Lever Basic

8.4±0.5 400 12 ± 1 ± 15 Rack

Injection order: 1 2 , 1 4 , 1 390°± 30' 180°± 30' 270°± 30'

Pump speed(r/min)

Advanceangle (° )




Service Department


Tel. (048)470-1559, Fax. (048)474-9856

Company:

Ass'y No.: 101495-3470ENGINE MODEL: 4D95L


1. Test conditions

Date:



kgf/cm2 }

2. Injection timing

Pre-stroke: No.1 Plunger 3.2 ± 0.05mm




CONFIDENTIAL


7 Feb 2003

6204-71-1151

101049-4070





Overflow valve opening pressure: kPa { kgf/cm2 }


side ( interval:

1



KOMATSU

1/3

Adjust max. var. bet. cyl. of R=8.4±0.5Adjust governor as per gov. adj. spec.

after injection q'ty adjustment at A

101495-3470 2/3




10.2

0 400

A

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

Recommended speed droop adjustment screw position: 12 (notches from fully tightened position)

20.0+1.0

12.1±0.1

9.7±0.1

6.4±0.2

(600)941


Rack cap

9.7±0.1

6.9

4.5±0.1

(750)760

(910)915 970

510

Torque control spring set force: 0N {0kg}

N=760 set

23°±5°


Idling


N=915

setting position at delivery

Full-speed

6°±5°

2°±5°

Stop lever angle

Approx.55°

Stop Normal

27.5°±5°

R=1.0-0.5, N=0

(Seal at delivery)

Without return spring

101495-3470 3/3

58° ±3°

Timing setting


Key groove position

After injection q'ty adjustment at A point

2°±30°

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

Mark an aligning mark on the pump housing(Width,depth 0.3 mm)

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




12.5 850 91 ± 2 ± 3.5 Rack

H Approx 9.5 275 - Rack

A R1(12.5) 850 91 ± 1 - Lever

B 1450 (92) ± 2 - Lever

C R1+0.45 1160 (94.5) ± 2 - Lever

I - 100 160 + 10 - Lever Rack limit

F (R1-0.85) 580 (77) - Lever

G R1-1.05 435 (70.5) ± 2 - Lever




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

Injection order:



Company:

Assy No.: 101603-2361ENGINE MODEL: J-2

No. Governor: EP/RLD-F Timing device: EP/SPG

1. Test conditions

Date:


Injection pump: PE6MD105932-2171 105680-5010

kgf/cm2}

2. Injection timing




CONFIDENTIAL


29 Jun 2007

22000-9591A

101060-6170



side (interval:

0



Governor

1/3


TEMPORARILY

1 4 , 1 2 , 1 6 , 1 3 , 1 560°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'


HINO

Nozzle opening pressure: 1st 16.7 MPa { 170 kgf/cm2 } 2nd 21.6 kgf/cm2 }MPa { 220

Each cylinder 13±1

+0.1-0.05[R1+0.8]

Nozzle: 105025-0360 Nozzle holder: 105030-3700(Bosch type no. ) (Bosch type no. )

Nozzle & nozzle holder assy: 105101-8160 (Bosch type no. )

Pump speed(r/min)

(Measure) (Measure) 1255 - 50 1420 - 50

Advanceangle (° )

Start

0 1.25 ± 0.3 1.25 ± 0.3

Finish

5.5±0.3


Basic

101603-2363 2/3


0195

275350 1160

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

11.0+0.30-0.31

R1(12.5)R1+0.15

0Below 225 (380)

A

B

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

Torque cam no. ‘M01’

R1+0.45

(1000)

520

Approx 9.5


Idling adjustment

RACK LIMIT

R1-0.9

7.8±0.08

I

H J

F

C

8.7 +1.75-1.87

[R1+0.8] +0.1-0.05

R1-1.05

12.0±0.15

(350) (510)

850

(890) (1100)

(1250)

(1400)

(1500)

1550

1650

4.0 +0.38-0.42

9.5

11.5

G

101603-2363 3/3

R=17.8±0.2

Free

Timing setting


(40°)


(Apply red paint after setting)

Stopper screw setting

Coupling key groove positionApprox.20°

40° ±3°


Idling

Full-speed

6° ±5°

Stop lever angle

33°±

5°

0°±5°

Stop

7°±5°

Normal

(Speed lever: full, N=100)

101603-8900 ZEXEL test values diesel fuel-injection equipment 12/11/08 13:19:56 Page 1

ZEXEL Ass'y No. 101603-8900Bosch Ass'y No. 9 400 610 684Bosch TypecodeEngine Type 6BG1-TManufacturer ISUZUEdition date 31/05/06 (1)

1 Adjustment conditionsCAT Designation Unit Set value min. max. Actual values OT

Test oil ISO4113 or {SAEJ967d}

1404 Test oilP Test Oil Temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140Bosch type code EF8511/9ANozzle 105780-0000Bosch type code DN12SD12TNozzle holder 105780-2080Bosch type code EF8511/9

P Opening Pressure MPa 17.2P Opening Pressure kgf/cm2 175

Injection pipe mm 6-2-600Outer diameter - inner diameter - length (mm)

Overflow valve 131424-4920P Overflow valve opening pressure kPa 127 107 147P Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5P Tester oil delivery pressure kPa 157 157 157P Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side) RRight

2 Adjustment specification2.1 Injection timing adjustmentCAT Designation Unit Set value min. max. Actual values OT

P Direction of rotation (viewed from drive side) RRight

P Injection order 1-5-3-6-2-4S Pre-stroke mm 3.6 3.55 3.65P Beginning of injection position NO.1

Drive sideS Difference between angles 1 deg. 60 59.5 60.5

Cal 1-5S Difference between angles 2 deg. 120 119.5 120.5



Cyl.1-2S Difference between angles 5 deg. 300 299.5 300.5

Cal 1-42.2 Injection quantity adjustmentCAT Designation Unit Set value min. max. Actual values OT

P Adjusting point AP Rack position 10.9P Pump speed r/min 1100 1100 1100S Average injection quantity mm3/st. 98.5 97 100S Max variation between cylinders % 0 -2.5 2.5P Basic *P Fixing the lever *P Boost pressure kPa 66.7 66.7P Boost pressure mmHg 500 500

CAT Designation Unit Set value min. max. Actual values OTP Adjusting point CP Rack position 6.4+-0.5P Pump speed r/min 415 415 415S Average injection quantity mm3/st. 9 7.7 10.3S Max variation between cylinders % 0 -14 14P Fixing the rack *P Boost pressure kPa 0 0 0P Boost pressure mmHg 0 0 0

CAT Designation Unit Set value min. max. Actual values OTP Adjusting point EP Rack position -P Pump speed r/min 100 100 100S Average injection quantity mm3/st. 110 105 115

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


P Fixing the lever *P Boost pressure kPa 0 0 0P Boost pressure mmHg 0 0 0P Rack limit *

2.3 Governor adjustmentName

K=9BCL=1.1+-0.1mm

N:Pump speedR:Rack position (mm)(1)Target notch: K(2)Tolerance for racks not indicated: +-0.05mm.(3)RACK LIMIT(4)Boost compensator stroke: BCL(5)Set idle sub-spring(6)Main spring setting

2.4 Boost compensator adjustmentCAT Designation Unit Set value min. max. Actual values OT

P Pump speed r/min 500 500 500P Rack position R1-1.1S Boost pressure kPa 13.3 10.6 16S Boost pressure mmHg 100 80 120

CAT Designation Unit Set value min. max. Actual values OTP Pump speed r/min 500 500 500P Rack position R1(10.9)S Boost pressure kPa 53.3 46.6 60S Boost pressure mmHg 400 350 450

2.5 Timer adjustmentCAT Designation Unit Set value min. max. Actual values OT

S Pump speed r/min 1300++P Advance angle deg. 0 0 0

RemarksDo not advance until starting N = 1300.

CAT Designation Unit Set value min. max. Actual values OTP Pump speed r/min -S Advance angle deg. 5.5 5.5 5.5

AboutRemarks

Measure the actual speed, stop



2.6 Speed control lever angleName

a=6deg+-5degb=23deg+-5deg

F:Full speedI:Idle(1)Stopper bolt setting

2.7 Stop lever angleName

a=32deg+-5degb=(55deg)

aa=0r/minbb=1-0.5mm

N:Pump normalS:Stop the pump.(1)Pump speed aa and rack position bb (to be sealed at delivery)

2.8 Timing settingName

a=(60deg)

aa=12deg (1)Pump vertical direction(2)Position of timer's threaded hole at No 1 cylinder's beginning of injection(3)B.T.D.C.: aa(4)-


Test Data

101603-8970

use

101603-8900

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




A 11.0 1075 110.5 ± 1.5 ± 2 Lever Basic

7.7±0.5 450 12 ± 1.3 ± 14 Rack

D Above. 11.2 100 105 ± 5 - Lever Rack limit

Injection order:

Pump speed(r/min)

Advanceangle (° )




Service Department


Tel. (048)470-1559, Fax. (048)474-9856

Company:

Ass'y No.: 101605-0100ENGINE MODEL: 6BG1-T


1. Test conditions

Date:


Injection pump: PES6AD105411-2300

kgf/cm2 }

2. Injection timing





CONFIDENTIAL


17 Jul 2002

ISUZU

115603-3960

101062-8410







side ( interval:

0



1 5 , 1 3 , 1 6 , 1 2 , 1 460°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'

1/4

Boost press. 0

Adjust max. var. bet. cyl. of R = 7.7±0.5Adjust governor as per gov. adj. spec.

Boost press. kPa {mmHg}Above 105 {Above 790}

Boost press. 0

101605-0100 2/4


Recommended speed droop adjustment screw position : 16(notches from fully tightened position)

A

D

Pump speed (r/min)

12200

245450

340 900

Above 14.0

10.5±0.1

Rac

k po

sitio

n (m

m)

7.3

Rack limit


Main spring setting


1155(1140)

(940)(680)

11.2

8.1±0.3

10.85

R2(10.0)

R2-0.3

0

53.3±4.0 {400±30}

(92.0)±6.7 {(690)±50}

N = 500

Rac

k po

sitio

n (m

m)



11.0

10.0

8.2

(470)

10.2±0.1

101605-0100 3/4

■ Tamperproof boost compensator cover installation

Temporarily tighten these screws before adjusting the governor and

the boost compensator.

Maximum tightening torque T = 2.5 N•m {0.25 kgf•m}

After adjusting the governor and the boost compensator, tighten the

screws to remove the heads.

Tightening torque T = 2.9 ~ 4.4 N•m {0.30 ~ 0.45 kgf•m}

269

101605-0100 4/4


Idling


Approx.55°

Stop lever angle

N=0, R=1.0-0.5

Stop

Full-speed

Normal

(20°) ±5°

(3°)±5°

50°±5°

Timing setting


Approx. 100°

Gear mark “CC”

Test Data

101606-0180

use

101603-8900

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




13.0 700 - Rack

H Approx 9.5 275 - Rack

A R1(13.0) 700 96.8 ± 1 - Lever

B R1-0.35 1400 (100.3) ± 2 - Lever

C R2-0.6 300 (66.9) ± 2 - Lever

D R2(R1+0.25) 500 (96.5) ± 2 - Lever

I - 100 95 ± 20 - Lever Rack limit




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

Injection order:



Company:

Assy No.: 101606-1741ENGINE MODEL: 6D16T

No. Governor: EP/RLD Timing device: EP/SA-D

1. Test conditions

Date:


Injection pump: PES6AD105931-5401 105643-0460

kgf/cm2}

2. Injection timing




CONFIDENTIAL


10 May 2005

ME076211

101061-8050




side (interval:

2



1 5 , 1 3 , 1 6 , 1 2 , 1 460°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'

Governor

1/3


Boost press. 0


Basic


MITSUBISHI

Each cylinder 10.2±1.5



Pump speed(r/min)

1150 1250 1350

Advanceangle (° )

Below 0.5 1.7 ± 0.5 Finish

3.5±0.5

Each cylinder 96.8±2.9 Basic




101606-1741 2/3


0200±5

275 350

1000±70

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

11.5

R1(13.0)

0Below 225 (600)

(1300)

A

B

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

Torque cam no. ‘D24’

R1+0.25

700

(900) (1150)

650±15


Idling adjustment

R1-0.05

R1-0.35

8.7

(750)

I

H J

C

(1050)


Rack limit

1600±50

1500±5

10.8

4.4

6.2

Approx 9.59.5

R2(R1+0.25)

R2-0.6

0

6.0±1.3 {45±10}

(20.0) {(150)}

N = 450

Rac

k po

sitio

n (m

m)



R1-0.15

R1-0.85

D

(1480)

Microswitch adjustmentAdjust the bolt so that the microswitch operates at a control lever position of R = 9.2mm and a pump speed of N=400±5 r/min.

101606-1741 3/3


Timing device's tooth position Approx. 2°

Timing setting


N=Fixed point, R=6.5-0.5

Stopper bolt H position 41° ±3°


IdlingFull-speed

18.5° ±5°

Stop lever angle

Stop

Normal

11.5° ±5°

27°±5°

After stopper bolt setting : N=275

Confirm that injection does not occur

Confirm that injection does not occur : R=8.6-0.5Non injection rack position

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




11.2 850 - Rack

H approx 9.5 275 - Rack

A R1(11.2) 850 57.7 ± 1 - Lever

B R1+0.1 1450 (72.6) ± 2 - Lever

C R1+0.8 500 (59.7) ± 2 - Lever

D R1+1.25 300 (57.1) ± 2 - Lever



Injection order:



Company:

Assy No.: 101607-6153ENGINE MODEL: 6D14

No. Governor: EP/RLD-E Timing device: EP/SA

1. Test conditions

Date:



kgf/cm2}

2. Injection timing




CONFIDENTIAL


10 July 2006

ME076986

101061-9500




side (interval:

6



1 5 , 1 3 , 1 6 , 1 2 , 1 460°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'

Governor

1/4


Basic


MITSUBISHI




Pump speed(r/min)

Below 1250 1200 1400

Advanceangle (° )

Start

0 Below 0.5

Finish

5±0.5



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

Each cylinder 13.7±2.1 Cylinder variation adjustment standard

Basic

101607-6153 2/4


0200

275325 1320

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

11.5

10.4+0.10-0.09

R1(11.2)

R1+0.8

0Below 225 500

(1300)

AB

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

Torque cam no. ‘G81’

R1+1.25

R1+0.1

(370)

(750)

740

9.5Approx 9.5


Idling adjustment

Rack limit

I

(1000)

HJ

DC

8.0+1.08-1.02

10.7±0.09

(1530)

1560

1690

5.0+0.12-0.11

2.5+0.32-0.29

Microswitch adjustment (at a control lever full position)Adjust the bolt so that the microswitch operates at a control lever position of N=1560,R=10.7±0.1

101607-6153 3/4

5. Load sensor adjustment

[1] Measurement circuit

1 (black)

2 (yellow)

3 (red) (black)

(yellow)

(red)

Output voltage

Trimmer1k

Supply voltage: 3.57±0.02 V

[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).

Load lever

Trimmer

Nuts

Shaft

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.


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.

Full speed

Base lever

Accelerator lever

A

(39°) ±3°

18.5°±5°

Accelerator lever position at delivery

Idling

Timing device's tooth positionApprox. 0°

Timing setting



Idling

Full-speed

18.5°±5°

(39°

)±3°


Free(25°)

36.5°±5°

Stop lever angle

(At delivery)

Normal

Stop

17°±5°

R=(16.8)

N=1550, R=7.0-0.5Stopper bolt setting

Confirm that injection does not occurAfter stopper bolt setting N=275Confirm that injection does not occu R=(Measure)Non injection rack position




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

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




A 10.0 1400 88.9 ± 1 ± 2.5 Lever Basic

B 10.0 800 (83.5) - Lever

C Approx 7.8 340 9.2 ± 1.5 ± 15 Rack

F (10.7) 100 (65) - Lever

Injection order:

Pump speed(r/min)

Below 1050 1000 1400

Advanceangle (° )

Start

0 Below 0.5

Finish

2±0.5



Company:

Assy No.: 101607-6390ENGINE MODEL: 6D14T

No. Governor: EP/RFD-D Timing device: EP/SA-D

1. Test conditions

Date:



kgf/cm2}

2. Injection timing




CONFIDENTIAL


25 May 2004

ME046025

101061-9790






side (interval:

1



1 5 , 1 3 , 1 6 , 1 2 , 1 460°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'

MITSUBISHI

Governor

1/3


After setting excessive fuel for starting

101607-6390 2/3


A

C

B

F

7.8

0250

9+0.

5

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

Excessive fuel setting for starting: 10.0+0.2 (N = 500)

Damper spring setting

Main spring setting

Idle sub spring setting

(11.0)

10.5±0.110.5

(10.1)10.0

8.5±1.5

5.8±0.55.8±0.1

5.63.9

280340 (350)

(585)495480400

Above 14001500

15351540

101607-6390 3/3

16°±5°


Stop lever angle

R=4.5-0.5

Stop

(Fix at full)

Normal

Timing setting


Full-load

Timing device's tooth position


Idling


Full-speed 18°±5°

3° ±5°

Approx. 1°

Load control lever angle

57°±5°57°

-5°+7°(Apply red paint after adjustment)


ZEXEL Ass'y No. 101608-1486

Bosch Ass'y No.

Bosch Typecode

Engine Type

Manufacturer

Edition date 27/09/00 (10)

1 Adjustment conditions

CAT Designation Unit Set value min. max. Actual values OT


...

P Test Oil Temperature degC 40 40 45

Nozzle and nozzle holder 1005780-8260

Bosch type code 9 430 610 133

Nozzle 105780-0120


Nozzle holder 105780-2190

P Opening Pressure MPa 18.0

P Opening Pressure kgf/cm2 184

Iinjection Pipe mm 6-2-600

Outer diameter - inner diameter - length (mm)

Overflow valve 131424-8420

P Overflow valve opening pressure kPa 255 255 255

P Overflow valve opening pressure kgf/cm2 2.6 2.6 2.6

P Tester oil delivery pressure kPa 255 255 255

P Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

Direction of rotation (viewed from drive side) L

Left

2 Adjustment specification

2.1 Injection timing adjustment


P Direction of rotation (viewed from drive side) L

Left

P Injection order 1-5-3-6-2-4

S Pre-stroke mm 3.2 3.15 3.25

P Beginning of injection position No.1

Governor side

S Difference between angles 1 deg. 60 59.5 60.5

Cyl 1-5


Cyl 1-3


Cyl 1-6


Cyl.1-2


Cyl 1-4

2.2 Injection quantity adjustment


P Adjusting point -

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


P Rack position 12.1

P Pump speed r/min 700 700 700

S Each cylinder's injection q'ty mm3/st. 110 106.7 113.3

P Basic *

P Fixing the rack *

P Standard for adjustment of the maximum variation between cylinders

*


P Adjusting point Z

P Rack position 9.5+-0.5


S Each cylinder's injection q'ty mm3/st. 12.5 10.6 14.4

P Fixing the rack *


*


P Adjusting point A

P Rack position R1(12.1)


S Average injection quantity mm3/st. 110 109 111

P Basic *

P Fixing the lever *

P Boost pressure kPa 23.3 23.3

P Boost pressure mmHg 175 175


P Adjusting point B

P Rack position R1+1.0


S Average injection quantity mm3/st. 114.5 110.5 118.5





P Adjusting point C

P Rack position R2(R1-0.4)







P Adjusting point D

P Rack position R2-0.35




P Boost pressure kPa 0 0 0

P Boost pressure mmHg 0 0 0


P Adjusting point I

P Rack position (R1+1.7)









P Adjusting point E







2.3 Governor adjustment

Name

N1=2080--r/minT1=M20BCL=0.35+-0.05mm

N:Pump speedR:Rack position (mm)(1)Adjust the governor at N=N1.(2)Torque cam stamping: T1(3)Tolerance for racks not indicated: +-0.05mm.(4)Boost compensator stroke: BCL

2.4 Boost compensator adjustment




S Boost pressure kPa 4.0+2.7

S Boost pressure mmHg 30+20






S Boost pressure kPa (10.0)

S Boost pressure mmHg (75)

2.5 Timer adjustment


S Pump speed r/min 1000--

P Advance angle deg. 0 0 0

Remarks

Start


P Pump speed r/min 950

S Advance angle deg. 0.5 0.5



S Advance angle deg. 3.5 3 4

Remarks

Finish

2.6 Speed control lever angle

Name

a=19deg+-5degb=41.5deg+-3deg

aa=40mm F:Full speedI:Idle(1)Use the hole at R = aa(2)-(3)Stopper bolt set position 'H'

2.7 Stop lever angle

Name



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

aa=1400r/minbb=7.0-0.5mmcc=285r/mindd=(8.4)mm

N:Pump normalS:Stop the pump.(1)After setting the stopper bolt so that the speed lever is in the full position, confirm that there isno 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 injection at pump speed cc and rack position dd.

2.8 Timing setting

Name

a=6deg30min+-30minb=7deg+-2deg

aa=13deg (1)Pump vertical direction(2)Position of the timer's tooth at the beginning of injection of the No. 1 cylinder(3)Bracket's center line stamping position.(4)B.T.D.C.: aa(5)Tooth stamping




Bosch Ass'y No.

Bosch Typecode

Engine Type

Manufacturer





...




Nozzle 105780-0120













Left





Left




Governor side


Cyl 1-5


Cyl 1-3


Cyl 1-6


Cyl.1-2


Cyl 1-4



P Adjusting point -





S Each cylinder's injection q'ty mm3/st. 110 106.7 113.3

P Basic *

P Fixing the rack *


*


P Adjusting point Z



S Each cylinder's injection q'ty mm3/st. 12.5 10.6 14.4

P Fixing the rack *


*


P Adjusting point A




P Basic *





P Adjusting point B

P Rack position R1+1.0







P Adjusting point C








P Adjusting point D








P Adjusting point I










P Adjusting point E








Name

N1=2080--r/minT1=M20BCL=0.35+-0.05mm

N:Pump speedR:Rack position (mm)(1)Adjust the governor at N=N1.(2)Torque cam stamping: T1(3)Tolerance for racks not indicated: +-0.05mm.(4)Boost compensator stroke: BCL





S Boost pressure kPa 4.0+2.7

S Boost pressure mmHg 30+20






S Boost pressure kPa (10.0)

S Boost pressure mmHg (75)



S Pump speed r/min 1000--


Remarks

Start






S Advance angle deg. 3.5 3 4

Remarks

Finish


Name


aa=40mm F:Full speedI:Idle(1)Use the hole at R = aa(2)-(3)Stopper bolt set position 'H'


Name



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

aa=1400r/minbb=7.0-0.5mmcc=285r/mindd=(8.4)mm

N:Pump normalS:Stop the pump.(1)After setting the stopper bolt so that the speed lever is in the full position, confirm that there isno 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 injection at pump speed cc and rack position dd.

2.8 Timing setting

Name

a=6deg30min+-30minb=7deg+-2deg

aa=13deg (1)Pump vertical direction(2)Position of the timer's tooth at the beginning of injection of the No. 1 cylinder(3)Bracket's center line stamping position.(4)B.T.D.C.: aa(5)Tooth stamping




Bosch Ass'y No. 9 400 613 229

Bosch Typecode

Engine Type 6D16TL

Manufacturer MITSUBISHI





...



Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T


Bosch type code EF8511/9











Left





Left



P Beginning of injection position NO.1

Governor side


Cal 1-5


Cal 1-3


Cal 1-6


Cyl.1-2


Cal 1-4



OT = Outside Tolerance (X is set)


P Adjusting point A




S Max variation between cylinders % 0 -2.5 2.5

P Basic *





P Adjusting point -



S Average injection quantity mm3/st. 16.5 15 18

S Max variation between cylinders % 0 -15 15

P Fixing the rack *



Remarks

Adjust only variation between cylinders; adjust governor according to governor specifications.


P Adjusting point E

P Rack position 10.6++






P Rack limit *


Name

K=6BCL=0.15+-0.1mmN1=1125r/minN2=550r/min

N:Pump speedR: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(7)Rack difference between N = N1 and N = N2







S Boost pressure kPa 11.3 11.3 11.3

About

S Boost pressure mmHg 85 85 85

About




S Boost pressure kPa 12 9.3 14.7





S Boost pressure kPa 13.3 13.3 13.3

About


About




S Advance angle deg. 3 2.5 3.5

Load 0/4


P Pump speed r/min 550+50

S Advance angle deg. 3 2.5 3.5

Load 0/4

Remarks

Start


P Pump speed r/min 650-50

S Advance angle deg. 0 0 0

Load 0/4

Remarks

Finish


Name




F:Full speedI:Idle(1)Stopper bolt setting


Name

a=35deg+-5degb=(55deg)

aa=0r/minbb=1-0.5mm

N:Pump normalS: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)

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 torque.(Tightening torque T = T1 maximum)(2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads.(Tightening torque T = T2 maximum)

2.9 Timing setting

Name



a=(3deg)

aa=8deg (1)Pump vertical direction(2)Coupling's key groove position at No 1 cylinder's beginning of injection(3)B.T.D.C.: aa(4)-





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

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




11.1 700 78 ± 2 ± 3.5 Rack

H Approx 9.2 290 16 ± 2 ± 14 Rack

A R1(11.1) 700 78 ± 1 - Lever

B R1+0.7 1450 (76) ± 2 - Lever


Injection order:

Pump speed(r/min)

Below 950 900 1150 ± 30

Advanceangle (° )

Start

0 Below 0.5

Finish

4.5 - 0.5



Company:

Assy No.: 101608-9580ENGINE MODEL: L7A

No. Governor: EP/RLD-F Timing device: EP/SAG

1. Test conditions

Date:


Injection pump: PE6AD105921-9690 105672-0660

kgf/cm2}

2. Injection timing




CONFIDENTIAL


14 Jan 2004

ASIA MOTOR

101060-5570



Nozzle: 105025-0780 Nozzle holder: 105030-4730(Bosch type no. ) (Bosch type no. )



side (interval:

2



1 4 , 1 2 , 1 6 , 1 3 , 1 560°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'

1/3



TEMPORARILY


Basic

101608-9580 2/3


0190300 325

850

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

11.5

11.0+0.35-0.30

R1+0.55

0Below 225 (1400)

A

B

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

Torque cam no. ‘M76’

R1+0.7

R1(11.1)

(900)

(1100)

1550±10

400

5.5±0.3

9.0Approx 9.2


Idling adjustment

I

7.8±0.07

290

Microswitch adjustment Adjust the bolt so that the microswitch operates at a control lever position ofR= 8.6 ± 0.1 mm and a pump speed of 415r/min.

Rack limit

R1+0.15

R1-0.65

8.35

700

(800)

(1300)

1660±50

HJ

101608-9580 3/3


Idling Full-speed

Coupling key groove position


Timing setting


Approx. 50°

14.5°±5°

Stop lever angle

40°±5°

19°±5°

(42°)±3°

Stop Normal




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

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




14.5 600 112 ± 2.2 ± 2 Lever Basic

(14.5) 1050 119.7 ± 7.2 ± 3 Lever

8.6 200 23 ± 3 ± 13 Rack

Injection order:



Company:

Assy No.: 101691-2970ENGINE MODEL: DK20

No. Governor: EP/RQ Timing device: EP/SA

1. Test conditions

Date:


Injection pump: PE6A105300-0750 105612-0700

kgf/cm2}

2. Injection timing




CONFIDENTIAL


14 Sep 2004

6 071 10001 0

101069-0510




side (interval:

0



1/2

1 4 , 1 2 , 1 6 , 1 3 , 1 560°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'

Overflow valve opening pressure: kPa { kgf/cm2}

HINO

Nozzle: 105000-1130 Nozzle holder: 105031-2010(Bosch type no. DN4SD24) (Bosch type no. KB56SD273)

Nozzle & nozzle holder assy: (Bosch type no. )

Pump speed(r/min)

300±50 600 800

Advanceangle (° )

Start

0 1.8 ± 0.5

Finish

3.0±0.5

101691-2970 2/2


0 Approx 100

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

Above 9.6

1150

Rack limit: 17+0.2 0

8.6

14.5

Below 3

200320±10

Below 1225


26.5°±3°

Full-load

Stop

Idling

54.5°±5° Coupling key groove position

Timing setting


Approx. 40°

Turnswitch adjustmentAdjust 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.

Approx. 90°




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

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




A R1(9.9) 1200 37.2 ± 1 ± 2.5 Lever Basic

C R2(8.6) 350 10.5 ± 1 ± 15 Rack

Injection order:

Pump speed(r/min)

Advanceangle (° )



Company:

Assy No.: 101692-3470ENGINE MODEL: 6D95L


1. Test conditions

Date:



kgf/cm2}

2. Injection timing




CONFIDENTIAL


30 Aug 2004

6206-71-1341

101069-9180

Injection pipe: outer dia. 6 mm × inner dia. 1.6mm length 600 mm


Nozzle: 105017-0090 Nozzle holder: 105048-3060(Bosch type no. DLLA152PN009) (Bosch type no. )



side (interval:

0


Note: Adjust with rack position of R= R1(9.9)

1 5 , 1 3 , 1 6 , 1 2 , 1 460°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'

KOMATSU

1/3

Overflow valve opening pressure: kPa { kgf/cm2}

TEMPORARILY

101692-3470 2/3



Pump speed (r/min)

0500±20 (880)

A

R2(8.6)

Rac

k po

sitio

n (m

m)

6.0

Rack cap: Approx 17.5

R2+3

(1280)

1200 1325±25350

C

20+1

R1(9.9)

350

+30+20

R1-0.3

Di f ference in rack posi t ion between N = 1200 and N = 800

Di f ference in rack posi t ion between N = 1200 and N = 350

(1.2

)±0.

1

2.8±

0.1

101692-3470 3/3



Idling

Stop lever angle

Stop

Full-speed

Normal

(16°) ±5°

(26°)±5°

53°±5° 26.5° ±5°

59°36' ±3°

Timing setting


Key groove position

0°24' ±30'

Mark an aligning mark on the pump housing(Width,depth 0.3 mm)

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




A 15.1 1050 (391) ± 5 ± 4 Lever Basic

B Approx 7.3 475 (45) ± 5 ± 14 Rack

Injection order:

Pump speed(r/min)

Advanceangle (° )



Company:

Ass'y No.: 103662-3180ENGINE MODEL: SA6D170A

No. Governor: EP/RSUVD Timing device:

1. Test conditions

Date:


Injection pump: PE6ZW105455-0971

kgf/cm2 }

2. Injection timing





CONFIDENTIAL


27 July 2006

6162-73-2320

103066-8400

Injection pipe: Outer Dia. 8 mm × Inner Dia. 2.4mm Length 1400mm


Nozzle: 105015-6140 Nozzle Holder: 105041-7020(Bosch Type No. ) (Bosch Type No. )

Nozzle & Nozzle Holder Ass'y: 105111-4090 (Bosch Type No. )

Overflow valve opening pressure: 206± 34 kPa { 2.1 ± 0.35 kgf/cm2 }


side ( interval:

0



1 5 , 1 3 , 1 6 , 1 2 , 1 460°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'

KOMATSU

1/3


Boost press. 0

TEMPORARILY



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

103662-3180 2/3


Pump speed (r/min)

0475

770 1050

A15.1

Rac

k po

sitio

n (m

m)

6.2

Above 26

1.1±0.3


(670)±30

Boost compensator stroke:2±0.1

16.4

14.4

0

N = 750

Rac

k po

sitio

n (m

m)



B1.

3±0.

1

Difference in rack position between N = 1050 and N = 750

Rack limit: 16.5+0.2

7.3

Above 8.8

+30-20

(925)±30+45+35

1175±25

Stop lever nomal position setting: 17.5+0.5

Idle sub-spring setting: 6.2-0.5

48.0±6.7 {360±50}

21.3±2.7 {160±20}

103662-3180 3/3

Idling


R=17.5+0.5

Full-load


Load lever angle

Full-speed

(22°) ±5°

Stop lever angle

Stop Normal

N=0, R=2-0.2

(After lever angle setting,put the seal.)

(After lever angle setting,put the seal.)

(m

easu

re)

±5°

Approx 2

Confirm that the clearance is approx

2mm when contacts inner stopper.

(mea

sure

)±5

°

32° ±5°

15° ±5°

1/3

Ass'y No.: 103662-3351ENGINE MODEL： SA6D170A

No.

Actuator： RED III Timing device：


Date:



Pump speed

Advance

angle（°）

Pump rotation： Counter clockwise (viewed from drive side)

Injection pump： PE6ZW

kgf/cm2｝　


Pre-stroke：No.1 Plunger 3.2 ± 0.05mm　 Note: Perform at voltage

V

Injection order：

Plungers are numbered from the Drive °± ）

(13.2) 1.36 865 513 ± 5 ± 4 Basic


Company:

2 Apr. 2002

KOMATSU

6162-74-1310

103066-5011

Injection pipe： Outer Dia.8 mm × Inner Dia.2.4mm － Length 1500 mm


Nozzle： 105025-1850 Nozzle Holder：105041-7111

Nozzle ＆ Nozzle Holder Ass'y ：105111-4820

Overflow valve opening pressure：255 kPa｛ 2.6 kgf/cm2｝　


side. ( interval:

Adjust-

ing point

Rackposition (mm)

Pumpspeed(r/ min)

Max. varbet. cyl

(％ ) Remarks

3

Bosch Automotive Systems Corpo-

ration

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

pan

105955-0110

RED Ⅲ GOV. C/U : 15 mm

Injection q' ty

( cm3 / 1000 strokes)Vist

(V)

1 5 , 1 3 , 1 6 , 1 2 , 1 460°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'

TEMPORARY

(6.1) Approx.2.8 400 30 ± 5 ± 14

103662-3351 2/3

At No.1 plunger’s beginning

of injection position

Timing setting

Approx.70°


Stop lever angle

StopNormal

103662-3351 3/3

■ RED Ⅲ governor

Confirmation of the control rack position sensor's output characteristics

(Rack 15mm , Span 6mm)

When the rack sensor output voltages are V1 and V2, confirm that rack positions R1

and R2 are as specified below.

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




A 14.3 750 523 ± 15 ± 2 Rack Basic

B Approx. 6.7 250 41.5 ± 3.5 ± 10 Rack

Injection order:

Pump speed(r/min)

Advanceangle (° )




Service Department


Tel. (048)470-1559, Fax. (048)474-9856

Company:

Ass'y No.: 103672-0350ENGINE MODEL: 6NSD

No. Governor: EP/RSUV Timing device:

1. Test conditions

Date:


Injection pump: PE6ZW105455-0730

kgf/cm2 }

2. Injection timing

Pre-stroke: No.1 Plunger 3 ± 0.05mm mm




CONFIDENTIAL


11 Sep 2002

NIIGATA ENGINEERING74V47000A

103067-8171

Injection pipe: Outer Dia. 8 mm × Inner Dia.4 mm Length 1500mm


Nozzle: 105780-0050 Nozzle Holder: 105780-2090(Bosch Type No. DN6TD119NP1T) (Bosch Type No. EFEP215)

Nozzle & Nozzle Holder Ass'y: 105780-8130 (Bosch Type No. EFEP215A)



side ( interval:

3



1/3

6 3 , 6 5 , 6 1 , 6 4 , 6 260°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'

103672-0350 2/3




Above 26

6.7

0 235Below 815

A

BRac

k po

sitio

n (m

m)

Pump speed (r/min)

Rack limit: 21+1


14.39.0

5.7

250 750±5

Do not adjust idling spring

103672-0350 3/3

35°±5°


Idling


Stop lever angle

Stop

Full-speed

Normal

(30°) ±5°18°±5°

10°±5°

Timing setting


Approx. 50°

Center of pump side coupling's elongated hole

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Assy no.:Date:Company:No.

CONFIDENTIALTEST OIL:ISO 4113 orSAE J967d

ENGINE MODEL:



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

Injection pump assy no.

INJECTION PUMP CALIBRATION DATA104139-409027 Aug 2003KUBOTA1G911-51012

V2203-DI

104139-4090 (NP-PFR4KX80/2NP12)

2

1. Test conditions: Drive shaft rotation: Clockwise (viewed from drive side) Nozzle & nozzle holder assy no.: 105780 - 8190 Nozzle no.: 105780 - 0060 (Bosch type no. DN0SD1510) Nozzle holder no.: 105780 - 2150 Nozzle opening pressure.: 13.0+0.3 MPa {133+3 kgf/cm2} Injection pipe no.: Inner dia. 2 mm x outer dia. 6 mm - length 450 mm Transfer pump pressure.: 49 kPa {0.5 kgf/cm2} Oil temperature.: 40-5 °C Cam profile: PFK - T - 00 (tangential cam; cam lift 7 mm; base circle ø28)

2. Injection timing: Pre-stroke P : 1.9±0.05 mm * L1 (port closing dimension): 74.1±0.05 mm * L2 (mounting dimension): 76±0.05 mm * L3 (pump assy dimension): Above 77 mm

* The control rack is set at +2.5±0.5 mm (R = approx 10.5±0.5 mm).

3. Injection quantity:(1) Set the rack's standard "0" position using the gauge. (Refer to service information S.I. 441 for "0"

point setting procedure.) (2) Standard "0" (8 mm) is half of the full rack stroke (16 mm). (3) Rc is the rack position relative to standard "0".

Rack positionRc (mm)

Pump speed(r/min)

Injection qty(cm3 / 1000 strokes )

Max. var. betweencylinders (mm3/st)

Fixed Remarks

a = +1.0±0.02 1100 50.9±0.3 Basic R = approx 9.0

a-1 1100 (35.8)* R = approx 8.0

a 700 (42.3)* Torque point R = approx 9.0

a-1.7 450 (14.2)* Low idle R = approx 7.3

-7 1100 Below 1 Non injection R = approx 1.0

+8 150 (64.0)* Start R = approx 16

* Enter after measuring; ( ) = reference value; R = Rc+8

4. Control rack sliding resistance:

Pump speed (r/min) Sliding resistance (g)

1000 Below 25


CONFIDENTIALTEST OIL:ISO 4113 orSAE J967d

ENGINE MODEL:



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

Injection pump assy no.

INJECTION PUMP CALIBRATION DATA104139-41501 Oct 2004KUBOTA1G796-51011

03-DI

104139-4150 (NP-PFR4KX80/2NP23)

3

1. Test conditions: Drive shaft rotation: Clockwise (viewed from drive side) Nozzle & nozzle holder assy no.: 105780 - 8190 Nozzle no.: 105780 - 0060 (Bosch type no. DN0SD1510) Nozzle holder no.: 105780 - 2150 Nozzle opening pressure: 13.0+0.3 MPa {133+3 kgf/cm2} Injection pipe no.: Inner dia. 2 mm x outer dia. 6 mm - length 450 mm Transfer pump pressure: 49 kPa {0.5 kgf/cm2} Oil temperature: 40-5 °C Cam profile: PFK - T - 00 (tangential cam; cam lift 7 mm; base circle ø28)

2. Injection timing: Pre-stroke P: 2.5±0.05 mm * L1 (port closing dimension): 74.5±0.05 mm * L2 (mounting dimension): 77±0.05 mm * L3 (pump assy dimension): Above 78 mm

* Set the control rack at R = 9.0 ~ 11.0 mm.

3. Injection quantity: (at the mounting dimension 77 mm)(1) Set the rack's standard "0" position using the gauge. (Refer to service information S.I. 441 for "0"



Pump speed(r/min)

Injection qty(cm3/1000 strokes )


Fixed Remarks

a = +2.8±0.02 1100 54.0±0.3 Basic R = approx 10.8

a-0.2 1400 (55.1)* Rated output R = approx 10.6

a+0.4 1300 (62.8)* Rated output R = approx 11.2

a+1.0 800 (62.1)* Torque point R = approx 11.8

a-2.1 500 (15.0)* Low idle R = approx 8.7

a-2.8 1500 (18.0)* High idle R = approx 8.0

-4 1500 Below 1 Non injection R = approx 4.0

+8 150 (73.3)* Start R = approx 16.0


1/2

Install the shims (139400-2900: 6 pc) between the pump flangeand driving stand (to adjust the mounting dimension to 77 mm).

2/2104139-4150

5. Control rack sliding resistance:

Pump speed (r/min) Sliding resistance (g)

1000 Below 25


Pump speed(r/min)

Injection qty(cm3/1000 strokes )


Fixed Remarks

-5 1500 (0)* Non injection R = approx 3.0




4. Non injection quantity: (at the mounting dimension 76 mm; i.e., without the shims)(1) Set the rack's standard "0" position using the gauge. (Refer to service information S.I. 441 for "0"


Test Data 104142-3450 ,Rack Position Pump(rpm) CC/100st

24 mm 300 *18 mm 300 *(114 to 120) basic ( Temporary fuel Q'ty)12 mm 300 *12 mm 100 *


ZEXEL Ass'y No. 104740-0756Bosch Ass'y No. 9 460 612 455Bosch TypecodeEngine Type WL-NAManufactures MAZDAEdition date 20/09/00 (5)


Test oil ISO4113orSAEJ967d

...P Test Oil Temperature degC 45 45 50

Nozzle 105780-0060Bosch type code NP-DN0SD1510Nozzle holder 105780-2150

P Opening Pressure MPa 13 13 13.3P Opening Pressure kgf/cm2 133 133 136

Iinjection Pipe 157805-7320P Iinjection Pipe mm 2-6-450

Inside diameter - outside diameter - length (mm)Joint Assembly 157641-4720Tube Assembly 157641-4020

P Transfer pump pressure kPa 20 20 20P Transfer pump pressure kgf/cm2 0.2 0.2 0.2

Direction of rotation (viewed from drive side) LLeft

2 Adjustment specification2.1 Full load deliveryCAT Designation Unit Set value min. max. Actual values OT

P Pump speed r/min 1000 1000 1000S Average injection quantity mm3/st. 47.7 47.2 48.2S Differnce in delivery mm3/st. 4 4P Basic *P Oil temperature degC 50 48 52

CAT Designation Unit Set value min. max. Actual values OTP Pump speed r/min 500 500 500C Average injection quantity mm3/st. 46 43 49

AboutP Oil temperature degC 48 46 50

CAT Designation Unit Set value min. max. Actual values OTP Pump speed r/min 1000 1000 1000C Average injection quantity mm3/st. 47.7 46.7 48.7C Differnce in delivery mm3/st. 4.5 4.5P Basic *P Oil temperature degC 50 48 52

CAT Designation Unit Set value min. max. Actual values OTP Pump speed r/min 2000 2000 2000C Average injection quantity mm3/st. 44.4 41.9 46.9


2.2 GoverningCAT Designation Unit Set value min. max. Actual values OT

P Pump speed r/min 2450 2450 2450S Average injection quantity mm3/st. 15.7 12.7 18.7S Differnce in delivery mm3/st. 5 5P Basic *P Oil temperature degC 55 52 58

CAT Designation Unit Set value min. max. Actual values OTP Pump speed r/min 2700 2700 2700C Average injection quantity mm3/st. 5 5P Oil temperature degC 55 52 58

CAT Designation Unit Set value min. max. Actual values OTP Pump speed r/min 2450 2450 2450C Average injection quantity mm3/st. 15.7 5.7 25.7C Differnce in delivery mm3/st. 5.5 5.5P Basic *P Oil temperature degC 55 52 58

2.3 IdleCAT Designation Unit Set value min. max. Actual values OT




S Average injection quantity mm3/st. 9 8 10S Differnce in delivery mm3/st. 1.7 1.7P Basic *P Oil temperature degC 48 46 50

CAT Designation Unit Set value min. max. Actual values OTP Pump speed r/min 360 360 360C Average injection quantity mm3/st. 9 7.5 10.5C Differnce in delivery mm3/st. 2.2 2.2P Basic *P Oil temperature degC 48 46 50

2.4 StartCAT Designation Unit Set value min. max. Actual values OT

P Pump speed r/min 150 150 150S Average injection quantity mm3/st. 70 55 90P Oil temperature degC 48 46 50

RemarksFull

CAT Designation Unit Set value min. max. Actual values OTP Pump speed r/min 150 150 150C Average injection quantity mm3/st. 70 50 90


RemarksFull

2.5 StopCAT Designation Unit Set value min. max. Actual values OT

P Pump speed r/min 360 360 360C Average injection quantity mm3/st. 0 0 0P Oil temperature degC 48 46 50

RemarksMagnet OFF

2.6 OverflowCAT Designation Unit Set value min. max. Actual values OT

P Pump speed r/min 1000 1000 1000C Overflow quantity cm3/min 400 270 530P Oil temperature degC 50 48 52

2.7 Pump chamber PressureCAT Designation Unit Set value min. max. Actual values OT

P Pump speed r/min 1000 1000 1000S Pressure kPa 510 481 539S Pressure kgf/cm2 5.2 4.9 5.5P Basic *P Oil temperature degC 50 48 52

CAT Designation Unit Set value min. max. Actual values OTP Pump speed r/min 1000 1000 1000C Pressure kPa 510 471 549C Pressure kgf/cm2 5.2 4.8 5.6P Basic *P Oil temperature degC 50 48 52

2.8 TimerCAT Designation Unit Set value min. max. Actual values OT

P Pump speed r/min 1000 1000 1000S Timer Stroke mm 4.4 4.2 4.6P Basic *P Oil temperature degC 50 48 52

CAT Designation Unit Set value min. max. Actual values OTP Pump speed r/min 500 500 500C Timer Stroke mm 1.8 1 2.6P Oil temperature degC 48 46 50

CAT Designation Unit Set value min. max. Actual values OTP Pump speed r/min 1000 1000 1000C Timer Stroke mm 4.4 4 4.8P Basic *P Oil temperature degC 50 48 52

CAT Designation Unit Set value min. max. Actual values OTP Pump speed r/min 2000 2000 2000C Timer Stroke mm 9 8.2 9.8P Oil temperature degC 50 48 52

2.9 MagnetCAT Designation Unit Set value min. max. Actual values OT

C MAX applied voltage V 8 8 8P Test voltage V 13 12 14



2.10 Compensator2.10.1 Load-Timer adjustmentCAT Designation Unit Set value min. max. Actual values OT

P Pump speed r/min 1000 1000 1000S Average injection quantity mm3/st. 30 29.5 30.5S Timer stroke TA mm 3.7 3.5 3.9S Timer stroke variation dT mm 0.7 0.7 0.7

AboutP Basic *P Oil temperature degC 50 48 52

CAT Designation Unit Set value min. max. Actual values OTP Pump speed r/min 1000 1000 1000C Average injection quantity mm3/st. 30 29 31C Timer stroke TA mm 3.7 3.3 4.1C Timer stroke variation dT mm 0.7 0.7 0.7

AboutP Basic *P Oil temperature degC 50 48 52

CAT Designation Unit Set value min. max. Actual values OTP Pump speed r/min 1000 1000 1000C Average injection quantity mm3/st. 20 18.5 21.5C Timer stroke TA mm 2.9 2.3 3.5C Timer stroke variation dT mm 1.5 1.5 1.5


2.11 Additional device adjustment2.11.1 Additional device 1Name CONTROL STANDARD AT IDLING



Standards for idle difference in delivery controlAfter 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

2.11.2 Additional device 2Name WIRE

a=7.6degb=12.5+-4degL2=4.6+-0.5mm

L1=34.1+3.5mmL2=4.6+-0.5mmP1=-66.0kPaP2=-500mmHga=7.6degb=12.5deg+-4degT=6~9Nm(0.6~0.9Kgfm)

(1)Wire length confirmationAccelerator wire: Idle-full stroke: L1 mm(2)Idle switch confirmationConfirm that the switch is ON in the idle lever position.(3)2 stage lever adjustment1. Apply negative pressure of P1kPa {P2 mmHg} to the actuator from the negative pressure inletport(A).2. Under the conditions in 1, adjust with the screw (C) so that the position of the control lever (B)becomes angle a [gap L2 from the idle screw (E)] and fix the nut (D).T:Tightening torque

3 Assembly dimensionCAT Designation Unit Set value min. max. Actual values OT

S K dimension mm 3.3 3.2 3.4S KF dimension mm 6.01 5.91 6.11S MS dimension mm 0.9 0.8 0.9S Pre-stroke mm 0.03 0.01 0.05S Control lever angle alpha deg. 12.5 8.5 16.5S Control lever angle beta deg. 40 37 43

About




Bosch Ass'y No.

Bosch Typecode

Engine Type 4D56






...


Nozzle 105780-0000

Bosch type code NP-DN12SD12T


P Opening Pressure MPa 14.7 14.7 15.19

P Opening Pressure kgf/cm2 150 150 155

P Iinjection Pipe mm 2-6-840

Inside diameter - outside diameter - length (mm)

P Transfer pump pressure kPa 20 20 20

P Transfer pump pressure kgf/cm2 0.2 0.2 0.2

Direction of rotation (viewed from drive side) R

Right


2.1 Full load delivery




S Differnce in delivery mm3/st. 3 3

P Basic *



C Average injection quantity mm3/st. 18.1 13.1 23.1










2.2 Governing





P Basic *





C Average injection quantity mm3/st. 5 5

2.3 Idle



S Average injection quantity mm3/st. 8 6.5 9.5


P Basic *






C Average injection quantity mm3/st. 8 6 10

2.4 Start




P Basic *

2.5 Stop




Remarks

Magnet OFF

2.6 Overflow



C Overflow quantity cm3/min 420 288 552

2.7 Pump chamber Pressure



S Pressure kPa 470.5 441 500

S Pressure kgf/cm2 4.8 4.5 5.1

P Basic *



C Pressure kPa 313.5 284 343

C Pressure kgf/cm2 3.2 2.9 3.5









2.8 Timer



S Timer Stroke mm 3.7 3.5 3.9

P Basic *





C Timer Stroke mm 1.2 0.6 1.8



C Timer Stroke mm 2 1.4 2.6







2.9 Magnet


C MAX applied voltage V 8 8 8

P Test voltage V 13 12 14

2.10 Compensator

2.10.1 Load-Timer adjustment




S Timer stroke variation dT mm 0.6 0.4 0.8

P Basic *




C Timer stroke TA mm 3.1 3.1 3.1

About

C Timer stroke variation dT mm 0.6 0.2 1





About


3 Assembly dimension


S K dimension mm 3.3 3.2 3.4

S KF dimension mm 5.8 5.7 5.9

S MS dimension mm 1.2 1.1 1.3

S Control lever angle alpha deg. 59 55 63

S Control lever angle beta deg. 46 41 51




Bosch Ass'y No. 9 460 610 297

Bosch Typecode

Engine Type 4D56






...


Nozzle 105780-0000

Bosch type code NP-DN12SD12T


P Opening Pressure MPa 14.7 14.7 15.19







Right







P Basic *













2.2 Governing





P Basic *






2.3 Idle





P Basic *







2.4 Start




P Basic *

2.5 Stop




Remarks

Magnet OFF

2.6 Overflow







S Pressure kPa 470.5 441 500

S Pressure kgf/cm2 4.8 4.5 5.1

P Basic *













2.8 Timer




P Basic *








C Timer Stroke mm 2 1.4 2.6







2.9 Magnet




2.10 Compensator






P Basic *





About






About










Magnet valveswitch OFF


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

2. Setting

4. Dimensions

CONFIDENTIAL

TEST OIL:ISO 4113 orSAE J967d ENGINE MODEL:

Injection pump no.:

Pump speed(r/min)

Settings Charge air pressurekPa {mmHg}

Difference indelivery (cm3)

Full load delivery

Supply pump pressureTiming device travelIdle speed regulationStart Full-load speed regulation

2-1

2-22-32-42-52-62-7

(cm3/1,000st)

kPa {kgf/cm2}(mm)(cm3/1,000st)(cm3/1,000st)(cm3/1,000st)

Pump speed(r/min)

Charge air pressurekPa { mmHg }

3.

3-1 Timing device

3-2 Supply pump

3-3 Overflow delivery

N = r/min mm

N = r/minkPa {kgf/cm2}

N = r/mincm3/min

3-4 Fuel injection quantities

Speed controllever position

Fuel delivery(cm3/1,000st)

Maximum speed

Idling

3-5 Solenoid

KKFMSBCSPre-stroke

mmmmmmmmmm

(°)

(°)

(°)

Control lever angle



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

Pump rotation:

[ NP-VE ]clockwise - viewed from drive side

Testspecifications

α

β

γ


1,000

1,5501,550 390 1002,100

44.6±0.5

520±20 {5.3±0.2}1.9±0.29.0±2.0

95.0±20.012.7±3.1

3.5

2.0

3.5

730±100 1,440±50 1,550 1,850 0.5 0.5 1.9±0.3 5.7±0.4

1,000 1,550 1,850 314±29 520±20 618±29 {3.2±0.3} {5.3±0.2} {6.3±0.3}

1,550 530±130

2.8±0.15.0±0.11.0±0.1

-0.45±0.02

18.0±4.0

35.0±5.0

-

44.6±1.036.6±2.047.5±2.047.3±2.512.8±3.5Below 7.0

0

9.0±2.0 Below 3.0

390 550

390

1,000 7001,3501,7002,1002,300

104741-103023 Nov 2004ISUZU8 94153 194 0

1/2

4JB1A

4/11F1800RNP251104641-10110

Maximum cut-in voltage: 8 V, Test voltage: 12 - 14 V

Full load delivery

Solenoid Timer

(Full lever)

1-4 Injection pipe: ø2×ø6×840mm1-5 Fuel oil temperature: 45+5°C

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+0.5 MPa {150+5 kgf/cm2}

Full load delivery

(without O-ring)

(with O-ring)

Charge air pressureSolenoid timer

(cm3/1,000st)

(Idle)

ON OFF

104741-1513

use

104741-1514

Ass’y No.Date:Company:No.

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

2. Setting

4. Dimensions

CONFIDENTIAL

INJ.PUMP CALIBRATION DATATEST OIL:TEST OIL:TEST OIL:TEST OIL:TEST OIL:ISO 4113ISO 4113ISO 4113ISO 4113ISO 4113 or or or or orSAE J967dSAE J967dSAE J967dSAE J967dSAE J967d

ENGINE MODEL :

Injection pump No : [NP-VE ]Pump rotation : Clockwise-viewed from drive side

Pump speed( r / min )

Settings Charge air presskPa { mmHg }

Difference indelivery(cm3)

Full load delivery

Supply pump pressureTiming device travelIdle speed regulationStartFull-load speed regulation

2-1

2-22-32-42-52-62-7

(cm3/1,000st)



Charge air presskPa { mmHg }

3. Test Specifi- cations

3-1 Timing device

3-2 Supply pump


N=r/min mm

N=r/minkPa{kgf/cm2}

N=r/mincm3/min




Max. speed

Switch OFFMagnet valve

Idling

3-5 Solenoid

KKFMSBCSPre-stroke

mmmmmmmmmm

α

β

γ

（°）

（°）

（°）－

Control lever angle

Bosch Automotive Systems CorporationService Department

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

Tel. (048) 470-1559 Fax. (048) 474-9856

1,000

1,0001,000 375 1002,3501,000

600 1,000 1,800 2,050(1.4±0.5) 3.5±0.3 (7.4±0.5) 8.2＋ 0.4 － 0.5

1,000 1,800539±39 736±59

{5.5±0.4} {7.5±0.6}

1,000390±130

6 Fev 2002

104741-47600

NISSAN DIESEL16700 2S608

4/11F1800RNP2395104641-4760

QD32

58.3±0.5

539± 20 {5.5± 0.2} 3.5±0.212.9±2.0

(90＋ 20.0 － 15.0)17.8±2.0 2.3±0.2

4.5

2.0

1,000 500 8001,5001,8002,3502,600

1/2

58.3±1(52.0±3.5)(57.1±3.5)(58.3±3)(60.5±3)17.8±2.5Below 5.0

375 0

375 12.9±2.5

3.3±0.15.62±0.10.9±0.1－

0.1±0.02

55.5±2.0

32.5±5.0

Max. cut-in voltage : 8 V, Test voltage : 12～14 V

Load-timer Adjustment (mm)

Full load delivery (cm3/1,000st)

1-1　Nozzle : 105780-0060(NP-DN0SD1510)1-2　Nozzle holder : 105780-21501-3　Nozzle opening pressure : 13.0+0.3MPa {133+3kgf/cm2}1-4　Injection pipe : φ2×φ6×450mm

1-5　Fuel oil temperature : 45＋５°C1-6　Supply pump pressure : 20kPa {0.2kgf/cm2}1-7　Joint ass’y : 157641-47201-8　Tube ass’y : 157641-4020

(Idle)

(Full)

104741-4760 2/2

■Load timer adjustment

1.Adjust the governor shaft so that the clearance between the end of the flange and the

end of the governor shaft is approxiamely 3 mm and then lock the nut.

2.Load timer adjustment

(1) Fix the control lever in the position satisfying the following conditions:

　Boost Pressure ： - kPa ｛ - mmHg｝　Pump Speed ： 1,000 r/min

　Fuel injection ： 29.0±0.5 cm3/1，000st

Quantity

(2) With the control lever positioned as described in (1) above, adjust the governor sleeve

so that timer reduction value (ΔT)conforms to the specified values (Item2-7).

T=17～22N・m ｛1.7～2.2 kgf・m｝

3.Confirmation of Timer Characteristics

Fix the control lever in the position satisfying the following condition, and confirm the

timer stroke.

Control lever position Specified ValuesPump speed（r/min）

Fuel Injection q'ty（cm3/1,000st）

Boost pressure（kPa ｛mmHg｝）

Timer stroke（mm）

Timer reduction value（mm）

1,000 29.0 1 -{ - } 2.3 0.3 (1.2)

1,000 20.0 2.5 -{ - } (1.2 0.5) (2.3)±

±

±

±



Bosch Ass'y No. 9 460 614 810

Bosch Typecode

Engine Type WLT

Manufacturer MAZDA





1404 Test oil


Nozzle 105780-0060

Bosch type code NP-DN0SD1510


P Opening Pressure MPa 13 13 13.3


Injection pipe 157805-7320

P Injection pipe mm 2-6-450


Joint assembly 157641-4720

Tube assembly 157641-4020




Left

(Sorenoid Timer Adjustment Condition) ON

With S/T O-ring; S/T ON.









P Basic *

P Oil temperature degC 50 48 52

Remarks

NA



P Boost pressure kPa 43.3 42 44.6



S Differnce in delivery mm3/st. 5.5 5.5

P Basic *


Remarks

CBS





P Boost pressure kPa 80 78.7 81.3




P Basic *


Remarks

Full






C Differnce in delivery mm3/st. 4.5 4.5

P Basic *


Remarks

NA



P Boost pressure kPa 43.3 42 44.6



C Differnce in delivery mm3/st. 6 6

P Basic *


Remarks

CBS







P Basic *


Remarks

Full






About


2.2 Governing









P Basic *














P Basic *


2.3 Idle







P Basic *






C Average injection quantity mm3/st. 10.5 9 12


P Basic *


2.4 Partial injection quantity







About


2.5 Start






P Basic *




Remarks

Full






About


Remarks

Full

2.6 Stop







Remarks

Magnet OFF at idling position

2.7 Overflow





C Overflow quantity with S/T ON cm3/min 430 300 560

C Overflow quantity with S/T OFF cm3/min 450 320 580

About







S Pressure WITH S/T ON kPa 510 481 539

S Pressure WITH S/T ON kgf/cm2 5.2 4.9 5.5

S Pressure with S/T OFF kPa 422 383 461

S Pressure with S/T OFF kgf/cm2 4.3 3.9 4.7

P Basic *


Remarks

ON





C Pressure WITH S/T ON kPa 510 471 549

C Pressure WITH S/T ON kgf/cm2 5.2 4.8 5.6

P Basic *


Remarks

ON



2.9 Timer





S Timer stroke with S/T ON mm 4.8 4.6 5

S Timer stroke with S/T OFF mm 3.2 2.8 3.6

P Basic *


Remarks

ON





C Timer stroke with S/T ON mm 2.2 1.4 3






C Timer stroke with S/T ON mm 4.8 4.4 5.2

C Timer stroke with S/T OFF mm 3.2 2.6 3.8

P Basic *


Remarks

ON







About


2.10 Magnet








Name CONTROL STANDARD AT IDLING

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




Name POTENTIOMETER ADJUSTMENT

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

N1=1000(r/min)Q1=24.6+1.5+0.1(mm3/st)V1=4.81+0.01-0.05(V)Vi=10(V)

Adjustment of the potentiometerDummy bolt method1. 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 adjust so that the output voltage is V1 (V).3. After adjustment, remove the dummy bolt and confirm that the potentiometer output voltage atthe control lever's idling and full speed positions is as specified above.Vi:Applied voltageN:Pump speed (r/min)V:Output voltage (V)Q:Injection quantity (mm3/st)A:Adjusting pointB:Checking pointC:Position of the control leverC1:IdlingC2:Full speedP1: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 confirmationAccelerator wire (idle~full stroke: L1 mm)(2)Idle switch confirmationConfirm that the switch is ON in the control lever's idle position.(3)Adjustment of the two stage actuator1. Apply negative pressure P1 kPa {P2 mmHg} to the actuator through the negative pressure suction inlet.2. In the above condition, adjust using screw (C) so that the control lever (B) position is a [clearance L2+-0.5 (mm) from the idle screw (E)] , and fix using the nut (D). (Tightening torque T)b:Angle alpha




Name DASHPOT ADJUSTMENT

L=8.1+-0.05(mm)a=14.1(deg)b=12.5+-4(deg)

L=8.1+-0.05(mm)T=6~9(N-m)(0.6~0.9(kgf-m))a=14.1(deg)b=12.5+-4(deg)

Adjustment of the dash pot1. 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) contacts the control lever (A) and fix using the nut (C).(Tightening torque T)D:Dash pot contact positionb:Angle alpha





S MS dimension mm 0.9 0.8 1

S BCS stroke mm 6.8 6.6 7


S Control lever angle alpha deg. 12.5 8.5 16.5





Bosch Ass'y No. 9 460 613 020

Bosch Typecode

Engine Type TD27-T

Manufacturer NISSAN DIESEL

Edition date 01/11/02




...


Nozzle 105780-0060





Iinjection Pipe 157805-7320



Joint Assembly 157641-4720

Tube Assembly 157641-4020




Right








P Basic *


Remarks

BCS



P Boost pressure kPa 66.7 65.4 68




P Basic *


Remarks

Full








About







About







P Basic *


Remarks

BCS







P Basic *


Remarks

Full






About






C Average injection quantity mm3/st. 60 57.5 62.5

About


2.2 Governing






P Basic *















About







P Basic *


2.3 Idle







P Basic *








P Basic *


2.4 Start






About

P Basic *


Remarks

Full








About


Remarks

Full

2.5 Stop







Remarks


2.6 Overflow






About


Remarks

Without an O-ring






About


Remarks

With an O-ring







About

S Pressure WITH S/T ON kgf/cm2 6.6 6.2 7

About



P Basic *


Remarks

OFF







C Pressure with S/T OFF kPa 481 442 520

C Pressure with S/T OFF kgf/cm2 4.9 4.5 5.3

P Basic *






C Pressure with S/T OFF kPa 588 549 627

About

C Pressure with S/T OFF kgf/cm2 6 5.6 6.4

About


2.8 Timer






About


P Basic *


Remarks

OFF






About


P Basic *







About


About







About


2.9 Magnet






2.10 Compensator







S Timer stroke TA mm 3.8 3.6 4


About

P Basic *








P Basic *







C Timer stroke TA mm 3 2.5 3.5

About




Name POTENTIOMETER ADJUSTMENT

N1=850r/minQ1=22.9+-1.0cm3/1,000stV1=3.72+-0.03VV2=(2.0+-0.43)VV3=(7.86+-0.58)VC3=(2.5)degC4=(17.0)deg



V1=3.72+-0.03VP1=0kPaP2=0mmHgVi=10V

Potentiometer adjustment1. Applied voltage: Vi2. 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 speedQ:Injection quantityV:Output voltageA:Performance standardsB:ON, OFF switch standardC:Angle of the control leverD:OFF-->ONE:OFF-->ONF:Adjusting pointG:Checking pointC1:IdleC2:Full-speed





S MS dimension mm 1 0.9 1.1

S Varid Stroke mm 0.964 0.944 0.984



About




than the following.

1. Test Conditions

2. Setting

4. Dimensions

CONFIDENTIAL

INJ.PUMP CALIBRATION DATATEST OIL:TEST OIL:TEST OIL:TEST OIL:TEST OIL:ISO 4113ISO 4113ISO 4113ISO 4113ISO 4113 or or or or orSAE J967dSAE J967dSAE J967dSAE J967dSAE J967d

ENGINE MODEL :





Full load delivery


2-1

2-22-32-42-52-62-7

(cm3/1,000st)





3-1 Timing device

3-2 Supply pump

3-3 Overflow deliverey

N=r/min mm

N=r/minkPa{kgf/cm2}

N=r/mincm3/min




Max. speed


Idling

3-5 Solenoid

KKFMSBCSPre-stroke

mmmmmmmmmm

α

β

γ

（°）

（°）

（°）－

Control lever angle



Tel. (048) 470-1559 Fax. (048) 474-9856

1,100 850 5001,1001,100 400 1002,5001,100

1,100 1,100 1,500 2,000(6.4± 0.5) 4.2± 0.3 (6.4± 0.5) 7.0＋ 0.4 － 0.5

1,100 1,500451± 39 (549± 39)

{4.6± 0.4} {(5.6± 0.4)}

1,100 1,100550± 130 430± 130

66.7± 1.3 kPa {500± 10 mmHg}

25 Jun. 2001

104745-91733

NISSAN DIESEL16700 86P03

4/10F2000RNP1442104645-9173

TD27- T

65.2± 0.555.4± 0.548.4± 0.5

451± 20 {4.6± 0.2} 4.2± 0.210.2± 2.0(75.0＋ 20.0 － 15.0)23.5± 2.0 3.6± 0.2

66.7± 1.3{500± 10}32.0± 1.3{240± 10}

066.7± 1.3{500± 10}66.7± 1.3{500± 10}

00

66.7± 1.3{500± 10}66.7± 1.3{500± 10}

5.0

2.0

1,100 850 500 8501,5002,0002,2502,5002,700

1/4

65.2± 1.055.4± 1.048.4± 1.0

(47.4± 2.5)(64.0± 2.5)(58.3± 3.0)(44.9± 4.5)23.5± 3.0Below 10.0

66.7± 1.3{500± 10}32.0± 1.3{240± 10}

00

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}

350 0 0

400 10.2± 2.5 0

3.3± 0.15.9± 0.11.0± 0.1－－

10.0± 4.0

36.0± 5.0

Max. cut-in voltage : 8 V, Test voltage : 12～14 V

OFF

OFF


ON OFFCharge air pressSolenoid Timer

Full load delivery

(Full)(BCS)(NA)

(Full)(BCS)(NA)

(cm3/1,000st)Full load delivery (cm3/1,000st)

1-1　Nozzle : 105780-0060(NP-DN0SD1510)1-2　Nozzle holder : 105780-21501-3　Nozzle opening pressure : 13.0+0.3MPa {133+3kgf/cm2}1-4　Injection pipe : φ 2×φ 6× 450mm

1-5　Fuel oil tempetature : 45＋５°C1-6　Supply pump pressure : 20kPa {0.2kgf/cm2}1-7　Joint ass’y : 157641-47201-8　Tube ass’y : 157641-4020

(Idle)

(Full)

(O-Ring)

※ When no instruction, adjust and confirm with S/T OFF.

(O-Ring less)

104745-9173 2/4

■Load timer adjustment





　Boost Pressure ： 66.7±1.3 kPa｛ 500±10 mmHg｝　Pump Speed ： 1,100 r/min

　Fuel injection ： 44.0±0.5 cm3/1，000st

Quantity

(2) With the control lever positioned as described in (1) above, adjust the governor sleeve

so that timer reduction value (ΔT)conforms to the specified values (Item2-7).

T=17～22N・m ｛1.7～2.2 kgf・m｝



timer stroke.

Control lever position Specified ValuesPump speed（r/min）

Fuel Injection q'ty（cm3/1,000st）

Boost pressure（kPa ｛mmHg｝）

Timer stroke（mm）

Timer reduction value（mm）

1,100 44.0 1.0 66.7 1.3｛500 10｝ 3.6 0.3 (0.6)

1,100 33.0 2.5 66.7 1.3｛500 10｝ (2.9 0.5) (1.3)±

±

±

±±±

±±

104745-9173 3/4

■Boost compensator adjustment BCS ①①①①①

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

2. Adjust BCS's injection quantities to value as described in item 2-1 .3. Confirm the NA's injection quantities to value as described in item 2-1.

4. If the NA above is not specified, loosen nut 53 and adjust screw 50 so that NA is as

specified and thed fix nut 53 .

<Caution>

Do not tighten or loosen screw 50 more than 1 turn.

104745-9173 4/4

■Potentiometer adjustment

Pump speed Out-put Fuel injection q'ty Control leverRemarks(r/min) (V) (cm3/1,000st) position

850 3.72 ± 0.03 20.9 ± 1.0 Adjustment point

Function (2.18 ± 0.43) IdleSpecs

(8.10 ± 0.58) Full

ON, OFF (1.4°) ON → OFF

Switch Specs (15.9°) OFF → ON

Input voltage: 10V

1. At pump speed of 850 r/min, hold the control lever in a position where a fuel injection

quantity of 20.9± 1.0 cm3/1,000st can be obtained.

2. Screw in the dummy bolt until contacts the control lever and lock it using the nut.

3. Adjust the potentiometer so that the out-put voltage is 3.72± 0.03 V and then remove

the dummy bolt.

－－

－

－

－

－

－

－

－

－

－

－

－

104745-9570

Doowon

Refer to Kia



Bosch Ass'y No. 9 460 612 303

Bosch Typecode

Engine Type 4JG2

Manufacturer ISUZU





...


Nozzle 105780-0060













Right







P Basic *





About






P Basic *





About







About


2.2 Governing





P Basic *











2.3 Idle





P Basic *







2.4 Start




P Basic *


Remarks

Full




About


2.5 Stop





Remarks



Magnet OFF

2.6 Overflow




About





S Pressure kPa 422 393 451

S Pressure kgf/cm2 4.3 4 4.6

P Basic *




C Pressure kPa 422 393 451

C Pressure kgf/cm2 4.3 4 4.6

P Basic *


2.8 Timer




P Basic *





P Basic *









P Basic *









P Basic *








2.9 Magnet




2.10 Compensator





S Timer stroke TA mm 2.2 2.2 2.2

About


P Basic *





C Timer stroke variation dT mm 0.3 -0.1 0.7

P Basic *





C Timer stroke variation dT mm 1 0.4 1.6




Name W-CSD ADJUSTMENT

TA:TA=-0.0345t+2.59

Adjustment of the W-CSD1. 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 obtained.Y:Timer stroke TAX:Temperature t(C): timer stroke TA(mm)




Name V-FICD ADJUSTMENT

T=3.4~4.9N-m(0.35~0.50kgf-m)L1=1.40+-0.1mm

L1=1.40+-0.1mmL2=0.5mmL3=5mmP1=-53.3kPaP2=-400mmHg

Adjustment of the V-FICD1. 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, thenfix using the nut (D).If adjustment with the FICD adjusting screw (C) is not possible, adjust by moving the actuator stroke with (E) and (F).2. Apply P1{P2} to the actuator. Confirm that it moves through its full stroke.After releasing, confirm that the clearance between the control lever (A) and the adjusting screw(C) is L2 or more.(G): exceeds L2 after releasing actuator(H): stroke L3










Test Data

104746 � 6890

use

104746 - 6152



than the following.

1. Test Conditions

2. Setting

4. Dimensions

CONFIDENTIAL

INJ.PUMP CALIBRATION DATATEST OIL:ISO 4113 orSAE J967d

ENGINE MODEL :





Full load delivery


2-1

2-22-32-42-52-62-7

(cm3/1,000st)





3-1 Timing device

3-2 Supply pump


N=r/min mm

N=r/minkPa{kgf/cm2}

N=r/mincm3/min




Max. speed


Idling

3-5 Solenoid

KKFMSBCSPre-stroke

mmmmmmmmmm

(°)

(°)

(°)-

Control lever angle



Tel. (048) 470-1559 Fax. (048) 474-9856

1,500 750 1,250 1,250 425 1502,650

49.2 ± 0.543.8 ± 0.5

412 ± 20 {4.2 ± 0.2}4.7 ± 0.210.2 ± 2.040.0 ± 1024.4 ± 3.0

72.0 ± 1.3{540 ± 10}26.7 ± 1.3{200 ± 10}72.0 ± 1.3{540 ± 10}72.0 ± 1.3{540 ± 10}

00

72.0 ± 1.3{540 ± 10}

3.5 3.5

2.05.5

72.0 ± 1.3kPa {540 ± 10mmHg}

600 1,250 1,500 2,000 0.5＋ 1.0 － 0.4 4.7±0.2 6.3±0.4 9.0＋ 0.4 － 0.3

1,250412 ± 20

{4.2 ± 0.2}

1,250630 ± 130

3.3 ± 0.15.8 ± 0.10.9 ± 0.1

--

20 ± 4

40 ± 3

0

0

72.0 ± 1.3{540 ± 10}26.7 ± 1.3{200 ± 10}

033.3 ± 1.3{250 ± 10}

072.0 ± 1.3{540 ± 10}72.0 ± 1.3{540 ± 10}72.0 ± 1.3{540 ± 10}

49.2 ± 143.8 ± 1.0(38.3 ± 3)

(46.0 ± 2.5)35.6 ± 2.5(50.8 ± 3)24.4 ± 3Below 4

0

10.2 ± 2 425

425

1,500 750 550 7501,5002,2502,6502,950

104749-53724 July 2002

ISUZU 8 97088 463 0

5

1/6

4EE1TC

4/9F2250RNP1386104649-5372

Max. cut-in voltage : 8 V, Test voltage : 12~14 V

(Full)(BCS)

(Full)(BCS)

Full load delivery (cm3/1,000st)

(Idle)

Charge air press

(Idle)

1-5 Fuel oil temperature : 45+5°C1-6 Supply pump pressure : 20kPa {0.2kgf/cm2}1-7 Joint ass’y : 157641-47201-8 Tube ass’y : 157641-4020

1-1 Nozzle : 105780-0060(NP-DN0SD1510)1-2 Nozzle holder : 105780-21501-3 Nozzle opening pressure : 13.0+0.3MPa {133+3kgf/cm2}1-4 Injection pipe :ø2×ø6×450mm

104749-5372 2/6

■Potentiometer adjustment

Pump speed Out-put voltage Fuel injection q'tyRemarks(r/min) (V) (cm3/1,000st)

750 2.76±0.0313.8±1.0

Adjusting pointBCS pre.:72kPa{540mmHg}

1.18±0.45 Check point

7.85±0.65 Check point

1. At a pump speed of 750 r/min, hold the control lever in a position where a fuel injection

quantity of 13.8± 1.0cm3/1,000st can be obtained.

2. Screw in the dummy bolt until it contacts the control lever and lock it using the nut.

3. Adjust the potentiometer so that the out-put voltage is 2.76±0.03 V.

4. Following adjustment, remove the dummy bolt, hold the control lever in the idling position,

and confirm that the potentiometer voltage is as described above.

Dummy bolt

104749-5372 3/6

■V-FICD Adjustment (Adjust with W-FICD disengaged)

1. Adjust so that S=1+1mm. (Figure 1)

Fig.1

2. At a negative pressure of 53.3kPa {400mmHg} adjust the actuator stroke using the

adjusting screw so that L=0.84±0.1 (Figure 2)

Fig.2

Pin

Actuator shaftControl lever

S

Actuator

Locknut (T=1.2~1.5 N·m {0.12~0.15 kgf·m})

L

Stroke adjusting screw

104749-5372 4/6

■W-CSD adjustment

1. Timer stroke adjustment

Adjust the screw ① so that the timer stroke is as determined from the graph in Figure

3 (see next page.{Figures 1 and 3})

2. Intermediate lever position adjustment

Insert a shim (L=1.2±0.05) between the control lever ⑨ and the idle set screw ⑦, align

the intermediate lever ⑥ with the aligning mark and adjust the intermediate lever adjusting

screw so that it contacts the control lever. Then, fix the screw. (Figures 1 and 2)

3. FICD adjustment

Insert a shim (L±0.05) between the control lever and the idle set screw and adjust the

screw ② so that the CSD lever ③ operates the intermedate lever through the rod ④.

Then, fix the screw. (Figures 1,2 and 3)

Figure 1 Figure 2

LINE ON BRACKET 8

EDGE OF LEVER 6

①�

②�

③� ④�

⑤�

⑥�

⑨�

L

⑨�

⑤�

⑧�

⑦�

L

104749-5372

① Timer stroke (mm) ; TA =-0.041t+2.42

② Lever position (deg) ; θ1 =-0.108t+4.79 (-20℃≦t≦20℃)

; θ2 =-0.133t+5.29 (20℃≦t≦50℃)

③ Lever position (mm) ; L1 =-0.035t+1.57 (-20℃≦t≦20℃)

; L2 =-0.044t+1.75 (20℃≦t≦50℃)

Note: ③ indicates the distance between the control lever and the idle set screw.

Figure 3

Cold advancerCooling water Timer piston Lever pos Lever pos

temp (℃) stroke (mm) (deg) (mm)

20 1.9±0.4 3.6±1.0 1.2±0.3

-20 3.4±0.6 7.9±3.0 2.6±1

Cooling water temp :

increasing

Pump speed : 500r/minCon

ditio

ns

1

0.5

015 20 25

Temperature t (¡C)

30

1.57

6

9

±0.2 (mm) ±1 (¡)

8

5

4

3

2

1

Tim

er s

trok

e T

A (

mm

)

Con

trol

leve

r po

sitio

nθ(d

eg),

L (m

m)

①�

②�

③�

5/6

104749-5372

■■■■■A/T plate adjustment

Adjust the A/T plate so that OB - OA = 35 ± 2 mm when the control lever is turned from the

idling position (OA) to the full speed position (OB) and then fix the A/T plate.54.6

3.4~4.9N･m{0.35~0.5kgf･m}

A/T plate

Idle

Controllever

188.5A/T Brkt

A B

94.3

77.1

6/6

104749-7150

Not Bosch/Zexel

Product of DPICO

No information available

Refer to Kia



than the following.

1. Test Conditions

2. Setting

4. Dimensions

CONFIDENTIAL

INJ.PUMP CALIBRATION DATATEST OIL:ISO 4113 orSAE J967d

ENGINE MODEL :





Full load delivery


2-1

2-22-32-42-52-62-7

(cm3/1,000st)





3-1 Timing device

3-2 Supply pump


N=r/min mm

N=r/minkPa{kgf/cm2}

N=r/mincm3/min




Max. speed


Idling

3-5 Solenoid

KKFMSBCSPre-stroke

mmmmmmmmmm

(° )

(° )

(° )-

Control lever angle



Tel. (048) 470-1559 Fax. (048) 474-9856

TD42

6/10F2000RNP126104660-4441

1,000

1,0001,000 350 1002,3001,200

50.9±0.5

324±29 {3.3±0.2} 1.6±0.2

8.8±2 60＋ 20.0 － 15.0

16.6±2 2.5±0.2

3.5

2.0

5.0

800 1,000 1,800 2,2000.5±0.5 1.6±0.3 5.8±0.5 7.4 +0.4 -0.5

1,000 1,800324±29 608±29

{3.3±0.3} {6.2±0.4}

1,000400±130

6001,0002,0002,1002,3002,500

52.6±2.050.9±1.044.7±2.143.8±4.516.6±2.5Below 5

3.3±0.16.64±0.11.0±0.1

--

25±2

40±5

8.8±2.5

0 Below 5

350

350 250

1/3

104760-444119 July 2002NISSAN DIESEL16700 51N62

1

Max. cut-in voltage : 8 V, Test voltage : 12~14 V


(Idle)

Charge air press

(Full)

1-4 Injection pipe : ø2×ø6×840mm1-5 Fuel oil temperature : 45+5°C1-6 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}

(Full)

104760-4441 2/3

Load timer adjustment





Boost Pressure : - kPa { - mmHg}

Pump Speed : 1,200 r/min

Fuel injection : 22.0±0.5 cm3/1,000st

Quantity

(2) With the control lever positioned as described in (1) above, adjust the governor

sleeve so that timer reduction value ( T)conforms to the specified values (Item2-7).

T=17~22Nm 1.7~2.2 kgfm



timer stroke.

Control lever position Specified Values

Pumpspeed(r/min)

Fuel Injection q'ty(cm3/1,000st)

Boost pressure(kPa {mmHg})

Timerstroke(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 -±

±

±

±

104760-4441 3/3

Formula: V±0.03=0.044Q+20.7(V) (Input-voltage: 10V)

①�Potentiometer solid line

→�

Solid line ②③ output

5.0

4.0

3.0

2.0

Vol

tage（

V）�

10.0 12.0 14.0 16.0 18.0 20.0 22.0

Inj/q'ty（cm3/1000st）�

④�

⑤� ②�

⑥�

①�

③�

④�

③� ⑥�⑤�

②�ON

OFF

Changeover point

ON → OFF 6.0°±3.5°OFF → ON 19.5°±3.5°�

Lever angle�（From idling）�

Out

put

Solid line ④⑤ Switch turned ON → OFF

Solid line ④⑥ Switch turned OFF → ON��

2.8

16.5

Potentiometerperformancestandard

Control leverposition

Out-put voltage(V)

Idle 1.6 0.4

Full-speed 8.0 0.55±

±

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.



Bosch Ass'y No. 9 460 611 678

Bosch Typecode

Engine Type TD42

Manufacturer NISSAN DIESEL





...


Nozzle 105780-0060













Right







P Basic *





About






P Basic *





About




2.2 Governing





P Basic *









About





P Basic *


2.3 Idle





P Basic *






P Basic *


2.4 Start




P Basic *


Remarks

Full





Remarks

Full

2.5 Stop







Remarks






Remarks

Magnet OFF at full-load position

2.6 Overflow









Remarks

Without an O-ring





About

S Pressure WITH S/T ON kgf/cm2 5.5 5.1 5.9

About



P Basic *


Remarks

OFF




C Pressure kgf/cm2 4.3 4 4.6

P Basic *





About

C Pressure kgf/cm2 7 6.6 7.4

About


2.8 Timer




About




P Basic *


Remarks

OFF




About





About


P Basic *





About






2.9 Magnet




2.10 Compensator





S Timer stroke TA mm 3.4 3.2 3.6


About

P Basic *






P Basic *











Name ACCELERATOR SWITCH ADJ

a=5deg+2degd=25+-2degSW=SW10T=6~9Nm(0.6~0.9kgfm)L1=3.3mm

a=5deg+2degb=5degc=5degL1=3.3+-0.13mm

Accelerator switch adjustmentON - OFF changeover point: from idle to a (shim thickness A = L)Idle~c: ONc~full: OFFA = shim thicknessB = idle lever position





S MS dimension mm 1 0.9 1.1




Test Data

104761-4290

use

104761-4260

2003/02/25 09:53:05 Page 1

ZexelAssyZexelAssyManuf.

Assy nameManufacturer No. Engine Type Manufacturer No.

Make dataRenew data

2003/02/252003/02/25

104761-4371104761-4370NISSAN DIESEL 1006 TD42T 16700VC700

P Parts No. Parts name B.T.C. Modify Edition data Kinds VECylinder 6

[1] Adjustment conditionsDesignation Unit PSC Set value RemarkTest oil ISO4113orSAEJ967dTest Oil Temperature degC P 45+5Nozzle 105780-0060BOSCH type code NP-DN0SD1510Nozzle holder 105780-2150Opening Pressure MPa P 13.0+0.3Opening Pressure kgf/cm2 P 133+3Injection Pipe No. 157805-7320Injection Pipe mm P 2-6-450 Inside Die.-Outside Die.-Length（mm)Joint Ass'y 157641-4720Tube Ass'y 157641-4020Transfer pump pressure kPa P 20Transfer pump pressure kgf/cm2 P 0.2Dir.of rot.viewed fromdriveside R RightChecker NO. 407980-228*ECU NO. 407913-1342ECU Voltage D.C. V TCV Drive Voltage D.C. V TCV Drive Voltage Hz Wire Harness 407980-2300Inter. Harness 157992-8900

[1] Adjustment specification[2] Full load delivery

Pump speed Boost pressure Boost pressure Boost pressure TCV DUTY (%) F TCV 60Hz

Ave.inj.qty Diff in dely Basic Test oil Remark

r/min kPa kgf/cm2 mmHg % mm3/st. mm3/st. degC500P 0P 0P 100P 49.7~50.7S *P 48+-2P NA700P 25.4~28.0P 190~210P 100P 55.9~56.9S *P 50+-2P BCS1000P 52.0~62.5P 390~410P 100P 51.5~62.5S 5.0--S *P 50+-2P FULL500P 0P 0P 100P 49.2~51.2C *P 48+-2P NA700P 25.4~28.0P 190~210P 100P 55.4~57.4C *P 50+-2P BCS1000P 52.0~54.6P 390~410P 100P 61.0~63.0C *P 50+-2P FULL1250P 52.0~54.6P 390~410P 100P 57.7~59.7C 50+-2P1800P 52.7~60.7P 390~410P 100P 52.7~60.7C 50+-2P

[2] GoverningPump speed Boost pressure Boost pressure Boost pressure TCV DUTY (%) F TCV

60HzAve.inj.qty Diff in dely Basic Test oil Remark

r/min kPa kgf/cm2 mmHg % mm3/st. mm3/st. degC2300P 52.0~54.6P 390~410P 100P 20.8~24.8S *P 52+-2P2500P 52.0~54.6P 390~410P 100P 5.0--C 55+-3P2300P 52.0~54.6P 390~410P 100P 20.3~25.3C 52+-2P

[2] IdlePump speed Boost pressure Boost pressure Boost pressure TCV DUTY (%) F TCV


r/min kPa kgf/cm2 mmHg % mm3/st. mm3/st. degC385P 0P 0P 100P 4.6~8.6S 2.0--S *P 48+-2P385P 0P 0P 100P 4.1~9.1C 48+-2P650P 0P 0P 100P 3.0--C 50+-2P

Ass'y NO. 104761-4371 2003/02/25 09:53:05 Page 2

[2] Partial quantityPump speed Boost pressure Boost pressure Boost pressure Ave.inj.qty Diff in dely Basic Test oil Thickness guage Remarkr/min kPa kgf/cm2 mmHg mm3/st. mm3/st. degC mm

[2] StartPump speed Boost pressure Boost pressure Boost pressure TCV DUTY (%) F TCV


r/min kPa kgf/cm2 mmHg % mm3/st. mm3/st. degC100P 0P 0P 0P 51.5~81.5S *P 48+-2P FULL

[2] StopPump speed Boost pressure Boost pressure Boost pressure TCV DUTY (%) F TCV


r/min kPa kgf/cm2 mmHg % mm3/st. mm3/st. degC385P 0P 0P 100P 0C 48+-2P Magnet OFF150P 0P 0P 0P 5--C 48+-2P Magnet OFF

[2] OverflowPump speed Boost pressure Boost pressure Boost pressure TCV DUTY (%) F TCV

60HzOverflow quantity S/T ON Overflow qtyS/T OFFOverflow qtyBasic Test oil

r/min kPa kgf/cm2 mmHg % cm3/min cm3/min cm3/min degC1100P 52.0~54.6P 390~410P 100P 468~732C 50+-2P

Remark

[2] Pump chamber PressurePump speed Boost pressure Boost pressure Boost pressure TCV DUTY (%) F TCV

60HzPressure Pressure S/T ON Pressure S/T ON Pressure S/T OFF Pressure

r/min kPa kgf/cm2 mmHg % kPa kgf/cm2 kPa kgf/cm2 kPa1100P 52.0~54.6P 390~410P 100P 550~608S 5.6~6.2S100P 52.0~54.6P 390~410P 100P 294++C 3.0++C1100P 52.0~54.6P 390~410P 100P 540~618C 5.5~6.3C1800P 52.0~54.6P 390~410P 100P 618~716C 6.3~7.3C

S/T OFF Pressure Basic Test oil Remark

kgf/cm2 degC*P 50+-2P

48+-2P50+-2P50+-2P

[2] TimerPump speed Boost pressure Boost pressure Boost pressure TCV DUTY (%) F TCV

60HzTimer stroke S/T ON Timer

strokeS/T OFF Timer stroke

Basic Test oil

r/min kPa kgf/cm2 mmHg % mm mm mm degC1100P 52.0~54.6P 390~410P 70P 3.2~3.8S *P 50+-2P500P 52.0~54.6P 390~410P 100P 3.6~7.6C 48+-2P1100P 52.0~54.6P 390~410P 100P 5.0~9.0C 50+-2P1100P 52.0~54.6P 390~410P 70P 3.1~3.9C 50+-2P1100P 52.0~54.6P 390~410P 0P 0C 50+-2P1800P 52.0~54.6P 390~410P 100P 6.5~7.4C 50+-2P

Remark

[2] TPS OutputPump speed Boost pressure Boost pressure Boost pressure TCV DUTY (%) F TCV

60HzTA-ist Basic Test oil Remark

r/min kPa kgf/cm2 mmHg % V degC[2] Magnet

Ass'y NO. 104761-4371 2003/02/25 09:53:05 Page 3

Designation Unit PSC Set value RemarkMAX applied voltage V C 8Test voltage V P 12~14

[2] [3] Load-Timer adjustment

Designation Image Explanation 2 Explanation 3 Explanation 4

Pump speed Boost pressure Boost pressure Boost pressure Ave.inj.qty Timer stroke TA Timer strokeChange volume ΔT

Basic Test oil Remark

r/min kPa kgf/cm2 mmHg mm3/st. mm mm degC[3] ACS adjustment


Pump speed Height Pressure differencePressure differenceAve.inj.qty Decrease quantity Decrease rate Basic Test oil Remarkr/min m kPa mmHg mm3/st. mm3/st. % degC[3] BCS adjustment


[2] Additional device adjustment[3] Additional device１

Designation Image Explanation 2 Explanation 3 Explanation 4POTENTIOMETER ADJUSTMENT 4-PM5-1 4-PM5-2F 4-PM5-3 104761-4370 4-PM5-4 104761-4370N1=1240r/minQ1=40.6+-1.0cm3/1,000stV1=6.00+-0.03VV2=1.04+-0.69VV3=8.18+-0.61Va=-degV1=6.00+-0.03VP1=0kPaP2=0mmHgVi=10V

Potentiometer adjustment standards (Bosch mini mass piping)1.Applied voltage=Vi2.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 itcontacts the lever. 4.In the above position, adjust the installation position of the potentiometer so that the output voltage is 6.00±0.03 V. 5.Fix the potentiometer and remove the dummy bolt.At TCV duty ratio 100%A=Adjusting pointB=Check pointC=Control lever positionN=Pump speed(r/min)V=Potentiometer output voltage(V)Q=Injection quantity(cm3/1000st)C1=IdleC2=Full speed

[3] Additional device 2Designation Image Explanation 2 Explanation 3 Explanation 4






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


[1] Assembly dimensionDesignation Unit PSC Set value RemarkK dimension mm S 3.2~3.4KF dimension mm S 6.66~6.86MS dimension mm S 1.2~1.4Effectiveness storoke mm BCS storoke mm S 2.7~3.1Pre-storoke mm S 0.08~0.12Control lever angle α deg. S 51.5~59.5Control lever angle β deg. S 38~48Control lever angle γ deg.

2003/02/25 09:51:55 Page 1

ZexelAssyZexelAssyManuf.

Assy nameManufacturer No. Engine Type Manufacturer No.

Make dataRenew data

2003/02/252003/02/25

104761-4381104761-4380NISSAN DIESEL 1006 TD42T 167001Y700

P Parts No. Parts name B.T.C. Modify Edition data Kinds VECylinder 6

[1] Adjustment conditionsDesignation Unit PSC Set value RemarkTest oil ISO4113orSAEJ967dTest Oil Temperature degC P 45+5Nozzle 105780-0060BOSCH type code NP-DN0SD1510Nozzle holder 105780-2150Opening Pressure MPa P 13.0+0.3Opening Pressure kgf/cm2 P 133+3Injection Pipe No. 157805-7320Injection Pipe mm P 2-6-450 Inside Die.-Outside Die.-Length（mm)Joint Ass'y 157641-4720Tube Ass'y 157641-4020Transfer pump pressure kPa P 20Transfer pump pressure kgf/cm2 P 0.2Dir.of rot.viewed fromdriveside R RightChecker NO. 407980-228*ECU NO. 407913-1342ECU Voltage D.C. V TCV Drive Voltage D.C. V TCV Drive Voltage Hz Wire Harness 407980-2300Inter. Harness 157992-8300

[1] Adjustment specification[2] Full load delivery

Pump speed Boost pressure Boost pressure Boost pressure TCV DUTY (%) F TCV 60Hz

Ave.inj.qty Diff in dely Basic Test oil Remark

r/min kPa kgf/cm2 mmHg % mm3/st. mm3/st. degC500P 0P 0P 100P 49.7~50.7S *P 48+-2P NA700P 25.4~28.0P 190~210P 100P 55.9~56.9S *P 50+-2P BCS1000P 52.0~54.6P 390~410P 100P 51.5~62.5S 5.0--S *P 50+-2P FULL500P 0P 0P 100P 49.2~51.2C *P 48+-2P NA700P 25.4~28.0P 190~210P 100P 55.4~57.4C *P 50+-2P BCS1000P 52.0~54.6P 390~410P 100P 61.0~63.0C *P 50+-2P FULL1250P 52.0~54.6P 390~410P 100P 57.7~59.7C 50+-2P1800P 52.0~54.6P 390~410P 100P 52.7~60.7C 50+-2P

[2] GoverningPump speed Boost pressure Boost pressure Boost pressure TCV DUTY (%) F TCV


r/min kPa kgf/cm2 mmHg % mm3/st. mm3/st. degC2300P 52.0~54.6P 390~410P 100P 20.8~24.8S *P 52+-2P2500P 52.0~54.6P 390~410P 100P 5.0--C 55+-3P2300P 52.0~54.6P 390~410P 100P 20.3~25.3C 52+-2P

[2] IdlePump speed Boost pressure Boost pressure Boost pressure TCV DUTY (%) F TCV


r/min kPa kgf/cm2 mmHg % mm3/st. mm3/st. degC385P 0P 0P 100P 4.6~8.6S 2.0--S *P 48+-2P385P 0P 0P 100P 4.1~9.1C 48+-2P650P 0P 0P 100P 3.0--C 50+-2P

Ass'y NO. 104761-4381 2003/02/25 09:51:55 Page 2

[2] Partial quantityPump speed Boost pressure Boost pressure Boost pressure 平均噴射量 Diff in dely Basic Test oil Thickness guage Remarkr/min kPa kgf/cm2 mmHg mm3/st. mm3/st. degC mm

[2] StartPump speed Boost pressure Boost pressure Boost pressure TCV DUTY (%) F TCV


r/min kPa kgf/cm2 mmHg % mm3/st. mm3/st. degC100P 0P 0P 0P 51.5~81.5S *P 48+-2P FULL

[2] StopPump speed Boost pressure Boost pressure Boost pressure TCV DUTY (%) F TCV


r/min kPa kgf/cm2 mmHg % mm3/st. mm3/st. degC385P 0P 0P 100P 0C 48+-2P Magnet OFF150P 0P 0P 0P 5--C 48+-2P Magnet OFF

[2] OverflowPump speed Boost pressure Boost pressure Boost pressure TCV DUTY (%) F TCV

60HzOverflow quantity S/T ON Overflow qtyS/T OFFOverflow qtyBasic Test oil

r/min kPa kgf/cm2 mmHg % cm3/min cm3/min cm3/min degC1100P 52.0~54.6P 390~410P 100P 468~732C 50+-2P

Remark

[2] Pump chamber PressurePump speed Boost pressure Boost pressure Boost pressure TCV DUTY (%) F TCV

60HzPressure Pressure S/T ON Pressure S/T ON Pressure S/T OFF Pressure

r/min kPa kgf/cm2 mmHg % kPa kgf/cm2 kPa kgf/cm2 kPa1100P 52.0~54.6P 390~410P 100P 550~608S 5.6~6.2S100P 52.0~54.6P 390~410P 100P 294++C 3.0++C1100P 52.0~54.6P 390~410P 100P 540~618C 5.5~6.3C1800P 52.0~54.6P 390~410P 100P 618~716C 6.3~7.3C

S/T OFF Pressure Basic Test oil Remark

kgf/cm2 degC*P 50+-2P

48+-2P50+-2P50+-2P

[2] TimerPump speed Boost pressure Boost pressure Boost pressure TCV DUTY (%) F TCV

60HzTimer stroke S/T ON Timer

strokeS/T OFF Timer stroke

Basic Test oil

r/min kPa kgf/cm2 mmHg % mm mm mm degC1100P 52.0~54.6P 390~410P 70P 3.2~3.8S *P 50+-2P500P 52.0~54.6P 390~410P 100P 3.6~7.6C 48+-2P1100P 52.0~54.6P 390~410P 100P 5.0~9.0C 50+-2P1100P 52.0~54.6P 390~410P 70P 3.1~3.9C 50+-2P1100P 52.0~54.6P 390~410P 0P 0C 50+-2P1800P 52.0~54.6P 390~410P 100P 6.5~7.4C 50+-2P

Remark

[2] TPS OutputPump speed Boost pressure Boost pressure Boost pressure TCV DUTY (%) F TCV

60HzTA-ist Basic Test oil Remark

r/min kPa kgf/cm2 mmHg % V degC[2] Magnet

Ass'y NO. 104761-4381 2003/02/25 09:51:55 Page 3

Designation Unit PSC Set value RemarkMAX applied voltage V C 8Test voltage V P 12~14

[2] [3] Load-Timer adjustment


Pump speed Boost pressure Boost pressure Boost pressure Ave.inj.qty Timer stroke TA Timer strokeChange volume ΔT

Basic Test oil Remark

r/min kPa kgf/cm2 mmHg mm3/st. mm mm degC[3] ACS adjustment


Pump speed Height Pressure differencePressure differenceAve.inj.qty Decrease quantity Decrease rate Basic Test oil Remarkr/min m kPa mmHg mm3/st. mm3/st. % degC

[3] BCS adjustmentDesignation Image Explanation 2 Explanation 3 Explanation 4

[2] Additional device adjustment[3] Additional device 1

Designation Image Explanation 2 Explanation 3 Explanation 4POTENTIOMETER ADJUSTMENT 4-PM5-1 4-PM5-2F 4-PM5-3 104761-4380 4-PM5-4 104761-4380N1=1240r/minQ1=40.6+-1.0cm3/1,000stV1=6.00+-0.03VV2=1.04+-0.69VV3=8.18+-0.61Va=-degV1=6.00+-0.03VP1=0kPaP2=0mmHgVi=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 6.00±0.03 V. 5.Fix the potentiometer and remove the dummy bolt.At TCV duty ratio 100%A=Adjusting pointB=Check pointC=Control lever positionN=Pump speed(r/min)V=Potentiometer output voltage(V)Q=Injection quantity(cm3/1000st)C1=IdleC2=Full speed







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

[3] Additional device 8名称 Image Explanation 2 Explanation 3 Explanation 4

[1] Assembly dimensionDesignation Unit PSC 値 RemarkK dimension mm S 3.2~3.4KF dimension mm S 6.66~6.86MS dimension mm S 1.2~1.4Effectiveness storoke mm BCS storoke mm S 2.7~3.1Pre-storokee mm S 0.08~0.12Control lever angle α deg. S 51.5~59.5Control lever angle β deg. S 38~48Control lever angle γ deg.

Opening Pressure for NHA Stamped 31-3862 L Nozzle Holder Part Number : 105031-3862 Stamping Identification : 31-3862 L Nozzle Number : 105025-4000 Nozzle Holder Assembly : 105160-5330 Opening Pressure : 19.0 Mpa

Dated 10th July 2007

Injector Number 31-3862 N

Nozzle & holder assembly no.: 105160-5420 Nozzle holder number: 105031-3862 Nozzle no.: 105025-4200 Opening pressure: 20.0 MPa

Injector 105041-3220 is the nozzle holder number. Injector 105041-3220 is referred to thenozzle 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 CNHA

This Nozzle holder is out ofproduction.

This is now replaced by :

105041-7141 C Assembly number105111-4831Nozzle 105025-1950 = NP-DLLA160SM195

Opening pressure 26.0 MPa ( 265kgf/cm2 )

Engine SA6D170 for Komatsu

Injector Opening Pressure

Body Number 105041-7150 JAssembly Number 105111-4920Nozzle DLLA143SM262Opening Pressure 24.5 Mpa (250 Kgf/m)Application Komatsu

Dated 20th October 2004

Nozzle holder: 48-2081QAssy No: 105118-7190Nozzle holder: 105048-2081Nozzle: 105017-1570

First opening pressure: 17.7 MPa ( 180 kgf/cm2 )Second opening Press: 20.6 MPa ( 210 kgf/cm2 )

Nozzle lift: 0.20 mmPre lift: 0.055 mm

NHA 105048-2270 G (Isuzu)

Opening Pressure for Test purposes only. This NHA is not serviceable in the field.

Assy No. 105118-8211 Nozzle No. 105017-3090 First nozzle opening pressure : 19.5 MPa Second nozzle opening pressure : 33.8 MPa Dated Dec 2005

NHA 105048-2270 B

Opening pressure for Nozzle Holder 105048-2270 B

Stamping Mark 48-2270 BNozzle holder 105048-2270Nozzle 105017-3090 = NP-DLLA144PN309Assy 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

QI PeaCy

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)

QI PeaCy

QI PeaCy

(Refer to Zexel SI 443 -Sept 2003)

Injector 105048-3770 A

Holder Assembly Number 105118-5191Nozzle Number 105017-0870Spacer Ring 150630-3200

Opening Pressure 16.7Mpa (170Kgf/cm2)

Nozzle Holder Stamping 105048-3790 Z

Nozzle and Holder Assembly 105118-7151

1st opening pressure: 18.1 MPa (185 kgf/cm2) 2nd opening pressure: 23.1 to 24.6 MPa (236 to 251 kgf/cm2)

Pre-lift : 0.07 mm Valve lift : 0.3 mm. Dated 09/01/2007

ISUZU 2 � SPRING INJECTOR OPENING PRESSURES

NOZZLE HOLDER 105048-3832ASSEMBLY No. 105118-7542NOZZLE KIT 105019-1470 (Includes 105017-3250 �

DLLA143PN325 NOZZLE)

First Opening Press 18.1 MPa ( 185 kgf/cm2 )Second Opening Press 21.1 MPa ( 215 kgf/cm2 )

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

Holder Stamping Assembly Number

1 st Opening Pressure [Factory Setting]

2 nd Opening Pressure [Factory Setting]

48-4120 E 105118-7621 21.0 MPa (214 kgf/cm²)

[21.5-22.5 MPa (219-229 kgf/cm²)]

39.5 MPa (403 kgf/cm²) [40.0-41.5 MPa (408-423 Kgf/cm²)]

48-4120 S 48-4120 S or L

105118-7331 105118-7770

19.0 MPa (194 kgf/cm²) [19.5-20.5 MPa (199-209 kgf/cm²)]


48-4120 T or U 105118-7911



48-4120 V or Z 48-4120 W or X

105118-8310 105118-8420



48-4120 H 48-4120 G

105118-7981 105118-7981

19.0 MPa (194 kgf/cm²) [19.5-20.5 MPa (199-209 kgf/cm²)] No test pressures available

37.5 MPa (382 kgf/cm²) [37.8-39.8 MPa (385-405 kgf/cm²)] No test pressures available

Dated 26th May 2006

105078-0140

DN0PDN121 (105007-1210)

Nozzle and holder assembly - 105148-1240

Opening pressure: 13.2 MPa (135 kgf/cm2)

Injector 105041-3220 is the nozzle holder number. Injector 105041-3220 is refered to the nozzle and nozzle holder assembly number for 105110-8300 and 105110-8290.

Test data repair information

Engine model Nozzle & nozzle holder assembly no. Nozzle holder part no. Nozzle part no. Nozzle service kit no. Pre-lift(Stamping mark and discrimination mark)

6WF1TC 105110-8300 105041-3220 105025-3950 105019-2312 0.06(41-3220,B) (NP-DLLA156SM395) (+-0.02mm)

6WG1TC 105110-8290 105041-3220 105025-3940 105019-2302 0.06(41-3220,A) (NP-DLLA156SM394) (+-0.02mm)

First nozzle opening pressure Second nozzle opening pressure Valve lift Nozzle holder typeMPa{kgf/cm2} MPa{kgf/cm2} (mm)17.7{180} 23.1~24.1{236~246} 0.3 KBL2.4/DLLA-S

17.7{180} 23.1~24.1{236~246} 0.32 KBL2.4/DLLA-S

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




A 12.4 650 171 ± 2 ± 4 Lever Basic

B Approx. 4.8 255 13 ± 1 ± 10 Rack

Injection order:

Pump speed(r/min)

Below 750 700 900 1150

Advanceangle (° )

Start0 Below 0.5 0.9 ± 0.5 Finish

3± 0.5




Service Department


Tel. (048)470-1559, Fax. (048)474-9856

Company:

Ass'y No.: 106661-5310ENGINE MODEL: PE6T

No. Governor: EP/RFD Timing device: EP/SP

1. Test conditions

Date:


Injection pump: PE6P105487-3270 105636-1220

kgf/cm2 }

2. Injection timing



CONFIDENTIAL


6 Sep 2002

NISSAN DIESEL

16713 96672

106066-5440







side ( interval:

2



1 4 , 1 2 , 1 6 , 1 3 , 1 560°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'

1/3

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

TEMPORARILY

(qA-27 qB qA-19)

+30-20-10

+40

106661-5310 2/3


Above 6.3

0 255 Below 1250

A

B

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

Rack limit using stop lever

12.6+0.2

0.9±0.5

4.8

465±15

11.5

Damper spring setting: 4.8-0.2

12.4

1150+20

4.8

2800

Variable speed specification at idle setting

Main spring setting

Pump speed (r/min)

Rac

k po

sitio

n (m

m)

Perform idle sub-spring adjustment when necessary.

106661-5310 3/3

32.5°±5°


Idling


Stop lever angle

R=1+0.5

Stop

Full-speed

Normal

22°±5°

10° ±5°



Full-load


Idling

43.5°±3°

32°±3°

30°±5°

Timing setting


Approx. 25°

R=12.4




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

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




A 11.7 750 146 ± 2 ± 4 Lever Basic

B 9.7 300 88 ± 3 ± 4 Lever

C Approx 6.4 240 10 ± 1 ± 10 Rack

Injection order:

Pump speed(r/min)

700+50 900 1150

Advanceangle (° )


3.0±0.5



Company:

Assy No.: 106661-5541ENGINE MODEL: PE6T

No. Governor: EP/RFD-B Timing device: EP/SA

1. Test conditions

Date:



kgf/cm2}

2. Injection timing



CONFIDENTIAL


9 Feb 2004

NISSAN DIESEL

16713 96902

106066-1191

Injection pipe: outer dia.6 mm × inner dia. 2 mm length 500 mm


Nozzle: 105015-4170 Nozzle holder: 105031-4370(Bosch type no. DLLA137S374N417) (Bosch type no. )



side (interval:

4



1 4 , 1 2 , 1 6 , 1 3 , 1 560°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'

1/3




Boost press. 0

TEMPORARILY

Boost press. 0

+40-10

+30-20

106661-5541 2/3


Above 8.7

0

Below (150)

1205

A

C

Rac

k po

sitio

n (m

m)

Pump speed (r/min)


1.7

9.7

(500)

10.5

+0.

5Damper spring setting

12.7

(1150)

6.4

2600


Main spring setting

Pump speed (r/min)

Rac

k po

sitio

n (m

m)

B

Boost compensator stroke:2.0±0.1 mm

11.711.2±0.1

6.4±2.06.44.1

2.2±0.3

240

430 485 1175

11.7

9.7

0

4.0+2.0 {30+15}

53.3-13.3 {400-100}

N = 300

Rac

k po

sitio

n (m

m)



106661-5541 3/3


Stop lever angle

Stop Normal

Drive side

Idling


Full-speed

(24°) ±5°

13° ±5°

Idling

40.5° ±3°

28.5°±5°

Full-load

Load-control lever angle


28°±5°

30°±5° R=11.7


Timing setting


Approx. 30°

R=1.5±0.1

N=260




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

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




A 11.7 750 146 ± 2 ± 4 Lever Basic

B 9.7 300 88 ± 3 ± 4 Lever

C Approx 6.4 240 10 ± 1 ± 10 Rack

Injection order:

Pump speed(r/min)

700+50 900 1150

Advanceangle (° )


3.0±0.5



Company:

Assy No.: 106661-5541ENGINE MODEL: PE6T

No. Governor: EP/RFD-B Timing device: EP/SA

1. Test conditions

Date:



kgf/cm2}

2. Injection timing



CONFIDENTIAL


9 Feb 2004

NISSAN DIESEL

16713 96902

106066-1191

Injection pipe: outer dia.6 mm × inner dia. 2 mm length 500 mm


Nozzle: 105015-4170 Nozzle holder: 105031-4370(Bosch type no. DLLA137S374N417) (Bosch type no. )



side (interval:

4



1 4 , 1 2 , 1 6 , 1 3 , 1 560°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'

1/3




Boost press. 0

TEMPORARILY

Boost press. 0

+40-10

+30-20

106661-5541 2/3


Above 8.7

0

Below (150)

1205

A

C

Rac

k po

sitio

n (m

m)

Pump speed (r/min)


1.7

9.7

(500)

10.5

+0.

5Damper spring setting

12.7

(1150)

6.4

2600


Main spring setting

Pump speed (r/min)

Rac

k po

sitio

n (m

m)

B


11.711.2±0.1

6.4±2.06.44.1

2.2±0.3

240

430 485 1175

11.7

9.7

0

4.0+2.0 {30+15}

53.3-13.3 {400-100}

N = 300

Rac

k po

sitio

n (m

m)



106661-5541 3/3


Stop lever angle

Stop Normal

Drive side

Idling


Full-speed

(24°) ±5°

13° ±5°

Idling

40.5° ±3°

28.5°±5°

Full-load



28°±5°

30°±5° R=11.7


Timing setting


Approx. 30°

R=1.5±0.1

N=260

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




A 11.9 600 203 ± 2 ± 4 Lever Basic

C Approx 7.2 225 15 ± 1 ± 10 Rack

D 9.7 300 130 ± 2 - Lever

Injection order:

Pump speed(r/min)

Advanceangle (° )




Service Department


Tel. (048)470-1559, Fax. (048)474-9856

Company:

Ass'y No.: 106671-0620ENGINE MODEL: PF6TB

No. Governor: EP/RFD Timing device: EP/SPGH

1. Test conditions

Date:



kgf/cm2 }

2. Injection timing



CONFIDENTIAL


17 Jun 2002

NISSAN DIESEL

16800-96577

106060-7790

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






side ( interval:

1



1 4 , 1 2 , 1 6 , 1 3 , 1 560°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'

1/4



Boost press. 0

Rack limit

TEMPORARILY

Boost press. 0


106671-0620 2/4

Above 8.7

0 225 Below 1300

A

C

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

Rack limit by using stop lever

Boost compensator stroke:(N=300)

12.1+0.1

11.9

3.4±0.5

9.7

7.2

6.1

450±10

11.0

500-10-25

1150+40+20

D

E

Damper spring setting: 6.2-0.2

2.4+

0.1

12.1+0.1

0

20.0±1.3 {150±10} (62.7) {(470)}

N = 300

11.5

9.7

(50.7) {(380)}

Rac

k po

sitio

n (m

m)



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) .

106671-0620 3/4


Idling

Stop lever angle

Stop

Full-speed

Normal


Timing setting


Approx. 30°

31.5° ±3°

22°±5°

R=12.1+0.1

Full-load

24°±5°



36°±5°

11.5°±5°

300

Timing advance specification

Pump speed (r/min)

7.0±0.3

0 Above 900

0/4 load P = 0

4/4 load P = 392 kPa {4kgf/cm2}

Adv

ance

ang

le (

° )


1100

4/4 load P =196 kPa {2kgf/cm2}

Above3

Bellow4

106671-0620 4/4

Rack sensor adjustment

1.Do not operate the aneroid compensator if installed.

Secure the speed control lever in the full position and set the pump speed at 600r/min.

(If equipped with a boost compensator, first apply boost pressure.)

2.Adjust the bobbin ① so that the rack sensor's output voltage is VR±0.01.

3.After adjustment, mark the area where the joint ② and the nut ③ contact and the area where

the joint ② and the pump housing contact with red paint.

VR Control unit parts no.

407912-1742

2V 105782-6320

407910-303*

3V 407910-6010

407980-224*

Output voltage VR±0.01(V)

Pump speed N 600 r/min

Rack position R1 11.9 mm




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

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




A 12.1 600 170 ± 2 ± 4 Lever Basic

B 12.1 1100 (164.6) ± 3 ± 5 Lever

C 10.4 300 114 ± 2 - Lever

D 12.4±0.1 300 (173) ± 5 - Lever

E Approx 8.0 250 16 ± 1 ± 10 Rack

Injection order:

Pump speed(r/min)

Below 875 825 925

Advanceangle (° )

Start

0 Below 0.5

Finish

1±0.5



Company:

Assy No.: 106671-0830ENGINE MODEL: PE6TC

No. Governor: EP/RFD-D Timing device: EP/SP

1. Test conditions

Date:



kgf/cm2}

2. Injection timing



CONFIDENTIAL


27 Sep 2004

NISSAN DIESEL

16713 96818

106061-5300



Nozzle: 105015-6340 Nozzle holder: 105031-4370(Bosch type no. DLLA140SN634) (Bosch type no. EF8511/9)



side (interval:

1



1 4 , 1 2 , 1 6 , 1 3 , 1 560°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'

1/4


Boost pressure kPa {mmHg}Above 29.3 {Above 220}


Boost press. 0

TEMPORARILY



Boost press. 0

106671-0830 2/4


Above 9.5

0 250 1260

A

E

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

Rack limit using stop lever: 12.4±0.1

Boost compensator stroke: (2.0)

12.4

12.1

3.9±0.3

10.4

8.0

6.0

395

11.5

+0.

5

C


12.4±0.1

0

Below 5.3{Below 40} (16.0) {(120)}

N = 300

11.2

10.4

9.3±1.3 {70±10}

Rac

k po

sitio

n (m

m)



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

D

B

10.5±1.5

7.1±0.1

460 1205

7.9

2650

Variable speed specification at idle setting(Fix at Full at delivery.)

Main spring setting

Pump speed (r/min)

Rac

k po

sitio

n (m

m)


275

106671-0830 3/4

5. Aneroid compensator kit adjustment

[1] Aneroid compensator adjustment

[2] Adjustment at governor installationWith 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.

Absolute pressure kPa {mmHg}

Rac

k po

sitio

n (m

m)

Q = (164.6)±3 cm3/1000 st

Q = 139±2 cm3/1000 st

79.4±2.7 {596±20} 57.6±0.7 {432±5}

12.1

(11.1)

Setscrew

Adjust clearance to 0.1 ~ 0.5 mm(using setscrew)

106671-0830 4/4

Stop lever angle

R=12.4±0.1

Stop

(Secure at Full at delivery)

Normal

16.5°±5°

Drive side


Full-speed


Idling

24°±5°

N=275

30°±5°

32°±5°

Idling

30.5° ±3°

22°±5°

Full-load



Timing setting


Approx. 30°Coupling key groove position

1/3

Ass'y No.: 106671-1447ENGINE MODEL： 6SD1-TC2

No.

Actuator： EP/RED-Ⅲ Timing device： EP/SPGH


Date:



Pump speed（r/min）

Advance

angle（°）

Pump rotation： Counter clockwise (viewed from drive side)

Injection pump： PE6P

105691-3140

kgf/cm2｝　


Pre-stroke：No.1 Plunger 4.2 ± 0.03mm　 Note: Perform at voltage V

Injection order：

Plungers are numbered from the Governor °± ）

(12.0) 1.59 800 151.7±2 ±3 Basic



Company:

25 Oct 2001

ISUZU 1-15602-142-7

106060-5771

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


Nozzle：105780-0000 Nozzle Holder：105780-2080(Bosch Type No.DN12SD12T) (Bosch Type No.EF8511/9)

Nozzle ＆ Nozzle Holder Ass'y ：105780-8140 (Bosch Type No.EF8511/9A)

Overflow valve opening pressure： 127 kPa｛ 1.3 kgf/cm2｝　


side. ( interval:

Adjust-

ing point

Rackposition (mm)

Pumpspeed(r/ min)

Max. varbet. cyl

(％) Remarks

8


Service Department


Tel. (048)470-1559, Fax. (048)474-9856

105952-0223

REDⅢ GOV. C/U : 15mm

Injection q' ty

( cm3 / 1000 strokes)Vist

(V)

(6.9) Approx.2.6 225 8.9±3.2 ±13

1 － 5 ,1 － 3 ,1 － 6 ,1 － 2 ,1 － 460°±15′ 120°±15′ 180°±15′ 240°±15′ 300°±15′

106671-1447 2/3

■■■■■RED RED RED RED RED ⅢⅢⅢⅢⅢ governor governor governor governor governor Confirmation of the control rack position sensor's output characteristics


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.

Pump speed (r/min)

Adv

ance

ang

le (°

)4/4 load

Above 8000

5.5± 0.3

0/4 load P=0

P=392 kPa {4 kg/cm2)

At No.1 plunger’s beginning


B.T.D.C. : 10°

Timing setting

Approx.40°

Center of timing device’s threaded hole

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




A 9.3 700 129.5 ± 2 ± 4 Lever Basic

B 9.3 1100 127 ± 3 ± 4 Lever

C (5) 360 16 ± 3 ± 15 Rack

Injection order:

Pump speed(r/min)

700 ± 50 900 1150

Advanceangle (° )

Start

0 1.4 ± 0.5

Finish

4 ± 0.5




Service Department


Tel. (048)470-1559, Fax. (048)474-9856

Company:

Ass'y No.: 106671-3521ENGINE MODEL: EK100

No. Governor: EP/RSV Timing device: EP/SP

1. Test conditions

Date:



kgf/cm2 }

2. Injection timing

Pre-stroke: No.1 Plunger 3.3 - 0.1mm mm


CONFIDENTIAL


22 Aug 2002

22020-1791A

106061-5472





Overflow valve opening pressure: 147~177 kPa { 1.5~1.8 kgf/cm2 }


side ( interval:

1



HINO

1 4 , 1 2 , 1 6 , 1 3 , 1 560°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'

1/2


(qA-27 qB qA-19)

106671-3521 2/2


Pump speed (r/min)

0360 1100+10 1210-40

A9.3

8

Rac

k po

sitio

n (m

m)

(5)

Above 14

4


Perform torque control spring adjustment when necessary.

B

C


Idling


Full-speed

(28°) ±5°

(9°)±5°

53°±5°

27°±5°

Stop lever angle

Normal Stop

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




A 16.9 900 280 ± 7 ± 3 Lever Basic

B Approx 7.3 250 30 ± 3 ± 10 Rack

C 18.9+0.2 100 (324) - Lever Rack limit

Injection order:

Pump speed(r/min)

Below 450 400 650

Advanceangle (° )

Start

0 Below 0.5

Finish

4 ± 0.5




Service Department


Tel. (048)470-1559, Fax. (048)474-9856

Company:

Ass'y No.: 106671-4451ENGINE MODEL: S6BF

No. Governor: EP/RSV Timing device: EP/SPG

1. Test conditions

Date:



kgf/cm2 }

2. Injection timing


Plungers are numbered from the ° ± 30' ).

CONFIDENTIAL


10 Apr 2003

36265-23180

106060-7560

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





side ( interval:

2



1 5 , 1 3 , 1 6 , 1 2 , 1 460°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'

MITSUBISHI

Governor

1/3


TEMPORARILY

(qA-27 qB qA-19)


106671-4451 2/3


20+1

16.9

9.2

0

250 1100+10 (1190)±25

A

B

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

400±25

7.3

Rack limit;18.9+0.2

Idle sub-spring setting;

9.2-0.5

C

Recommended speed droop adjustment screw position: 10 (notches from fully tightened position; fix in this position)

106671-4451 3/3

(41°) ±5°

20° ±5°


Stop adjuster screw setting



Full-speed

Stop lever angle

Idling

53°±5°

19°±5°

Stop

Normal

Timing setting


Approx. 90°




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

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




A 10.8 600 174.4 ± 2 ± 4 Lever Basic

C Approx 5.3 225 9 ± 1 ± 10 Rack

D 8.4 300 107.4 ± 2 - Lever

Injection order:

Pump speed(r/min)

Advanceangle (° )



Company:

Assy No.: 106671-5171ENGINE MODEL: PF6T

No. Governor: EP/RFD-C Timing device: EP/SPGH

1. Test conditions

Date:



kgf/cm2}

2. Injection timing



CONFIDENTIAL


26 Sep 2003

NISSAN DIESEL

16800 96664

106061-7531






side (interval:

3



1 4 , 1 2 , 1 6 , 1 3 , 1 560°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'

1/5



Solenoid ON

Solenoid OFF

Solenoid OFF

106671-5171 2/5


Below 160

11.7±0.311.311.1

10.8

8.4

0

10.0

+0.

5

A

D

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

Rack limit using stop lever: 11.1±0.1

10.2

5.3

3.6

C

225


Above 6.8

1.5±0.5

410350 460 1150 1240

R1(5.2)

2900

Variable speed specification at idle setting(Fix at Full at delivery.)

Main spring setting

Pump speed (r/min)

Rac

k po

sitio

n (m

m)

4.3±2.0

420

106671-5171 3/5

6.Rack sensor adjustment (-0620)Note: Do not operate the aneroid compensator if installed.

(1)Fix the speed control lever in the FULL position.

(2) Set the speed at N r/min and the rack position at R. (If equipped with a boost compensator, apply boost

pressure.)

(3)Adjust the bobbin 1 so that the rack sensor output voltage is VR±0.01.

(4)Apply red paint to the joint 2 and nut 3 join and to the joint 2 and pump end face join.

1

2 3

Constant voltage

power supply5±0.01V

Output voltage VR±0.01V

Speed N 600 r/min

Rack position R 10.8 mm

VR Control unit part no.

2V407912-1742

105782-6320

3V

407910-3032

407910-6010

407910-7210

Apply red paint Pump end face

300

5.Timing advance specification

Pump speed (r/min)

6.5±0.3

0 Above 900

0/4 load P = 0


Adv

ance

ang

le (

° )


1100

4/4 load P =196 kPa {2kgf/cm2}

Above3

Bellow4

106671-5171 4/5

7.Solenoid type boost compensator adjustment(1) Supply DC24V to the solenoid terminals and confirm that the solenoid operates.

(2) Preadjustment

With the solenoid ON, calculate dimension L (refer to figure below) for adjustment standard R2 using

the formula below.

L = 28 – (10.5 – R2) ± 0.2 = 25.9 ± 0.2

Then, adjust the solenoid using 1 so that L is as calculated.

(3) Install the solenoid on the governor.

If the rack position is not R2±0.5 with the solenoid ON, repeat step 2 above. (Correction)

(4) With the solenoid OFF, adjust everything except the rack limit to standard.

Note:

When the solenoid is OFF, positioning the boost compensator link 3 so that rack R2 + 4 does not

hinder adjustment.

(5) Operate the pump at N = 300, turn the solenoid ON, and fine adjust 2 within the range of ±0.5 so that

the rack position is R2.

(6) Solenoid stroke confirmation

At Np = 0 and with the load lever in the FULL position, turn the solenoid ON and OFF and confirm that

the rack movement (ie, solenoid boost compensator stroke) is 3.5 ~ 5.0 mm. Then set the rack limit.

(7) Seal the solenoid as shown at the top of the figure below.

2: For fine adjustment

(within the range of ±0.5)

DC24V

1: For preadjustment

ON

OFF

Control rack

Rack decrease direction

Boost compensator OFF

Rack limit

L

3

8.4

Thread sealing wire through sealing holes at 3 locations

Rac

k po

sitio

n

Pump speed

Boost compensator stroke

4 mm +1-0.5

Boost compensator ON

Boost compensator stroke

4 mm +1-0.5

R2

106671-5171 5/5


Idling


Stop lever angle

Full-speed

(Secure at full at delivery)


N=290(13°) ±5°

5.5°±5°

45° ±5°34.5°±3°

Normal

33°±5° 33°±5°

R=11.1±0.1Stop

Load lever angle

Full-load

Idling


Timing setting


Approx. 30°

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




11.5 800 149 ± 2 ± 3 Rack

H Approx. 6.4 290 10.5 ± 3.2 ± 13 Rack

A R1(11.5) 800 149 ± 2 - Lever

B R1+0.3 1100 (153.5) ± 3 - Lever

C R2[R1-1.3] 500 (119.5) - Lever

D (R1-1.6) 300 (98) - Lever

I Approx. R1+1.35 150 (165) - Lever

Injection order:

Pump speed(r/min)

Beiow 850 800 875

Advanceangle (° )

Start

0Beiow 0.5

Finish

1.5±0.5




Service Department


Tel. (048)470-1559, Fax. (048)474-9856

Company:

Ass'y No.: 106671-6220ENGINE MODEL: 6SD1-TCE

No. Governor: EP/RLD-J Timing device: EP/SPG

1. Test conditions

Date:



kgf/cm2 }

2. Injection timing



CONFIDENTIAL


9 JUL 2002

NISSAN DIESEL

115603-1510

106067-1221







side ( interval:

0



1 5 , 1 3 , 1 6 , 1 2 , 1 460°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'

ISUZU

Governor

1/3


Boost press. 0



Basic Boost press. kPa {mmHg}Above 28.7 {Above 215}Boost press. kPa {mmHg}Above 28.7 {Above 215}


Boost press. 0

106671-6220 2/3


R1+0.3R1(11.5)R1-0.35R1-0.45

0Below 200

(280)

(470) (560) 700

(900)

1310

(1050)

(750)

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

Approx. R1+1.35

(1180)

1200

A

C

I

B

Torque cam no. ‘AD53’


R2[R1-1.3]10.8±0.1

6.8±1.0D

8.5

6.5

0185

240 290315 430 820

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

Approx 6.4

0.5+0.5-0.45

8.0±0.5

4.0±0.1

R2[R1-1.3]

R2-1.15

0

10.0±1.3 {75±10}


N = 500

Rac

k po

sitio

n (m

m)




Idling adjustment

106671-6220 3/3

22°±5°


Idlin

g


Stop lever angle

Stop

Full-speed

Normal

29.5°±3°

Center of timing device's threaded hole

27°±5°

41°±5°

Timing setting


Approx. 50°



Bosch Ass'y No.

Bosch Typecode

Engine Type EK200

Manufacturer HINO





...



Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T


Bosch type code EF8511/9











Left





Left




Drive side


Cyl 1-4


Cyl.1-2


Cyl 1-6


Cyl 1-3


Cyl 1-5





P Adjusting point A

P Rack position 7.9






P Adjusting point B

P Rack position 7.9




P Basic *



P Adjusting point C

P Rack position 8.3






P Adjusting point D





P Fixing the rack *


P Adjusting point E





P Rack limit *


P Adjusting point F

P Rack position 7.2





Name



RT=0.8TH=2.4mmR1=8.6mmDL=3.3-0.2mmN1=300+25r/minR2=4mm

N:Pump speedR:Rack position (mm)(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.



S Pump speed r/min 865+50


P Load 4/4

Remarks

Start




P Load 3/4



S Advance angle deg. 4.5 4.2 4.8

P Load 4/4

Remarks

Finish


Name

a=17deg+-5deg

F:Full speed



2.6 Load control lever angle

Name


F:Full loadI:Idle(1)-(2)-


Name


N:Pump normalS:Stop the pump.(1)-(2)-

2.8 Timing setting

Name

a=0deg+-3deg

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





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

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




A 9.8 750 89.3 ± 1 ± 2 Rack Basic

B Approx 8.2 360 14 ± 3 ± 15 Rack

D - 100 187 ± 10 - Lever Rack limit

Injection order:

Pump speed(r/min)

Advanceangle (° )



Company:

Assy No.: 106672-3740ENGINE MODEL: M10C-TB


1. Test conditions

Date:


Injection pump: PE6P105407-6550

kgf/cm2}

2. Injection timing



CONFIDENTIAL


22 Sep 2004

22020-4990A

106067-1070






side (interval:

1



HINO

1 4 , 1 2 , 1 6 , 1 3 , 1 560°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'

1/3



Overflow valve opening pressure: 147~177 kPa {1.5~1.8 kgf/cm2}

Boost press. 0

Boost press. 0

106672-3740 2/3

Rack limit


10.9

0 300

A

Rac

k po

sitio

n (m

m)

Pump speed (r/min)


Recommended speed droop adjustment screw position: 18 (notches from fully tightened position; fix in this position)

Above 14.0

11.5±0.1

9.8±0.1

6.2±1.5

10.9

9.5

0

3.3+2.0 {25+15}

N = 600

Rac

k po

sitio

n (m

m)



D

798900


8.2B Idle sub spring setting

Main spring setting

4.8±0.1

750 850

9.0±0.28.4±0.1

360(430)

106672-3740 3/3

70°±5°


25°±5°

Stop lever angle

Stop Normal

N=0, R=1.0-0.5(Seal at delivery)

Timing setting



Approx. 50°


Idling

(8°) ±5°

Full-speedN=900 set

(18°) ±5°

(5°) ±5°

N=750 set


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

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




13.7 700 - Rack

Z Approx 8.0 390 - Rack

A R1(13.7) 700 172.5 ± 2 - Lever

B R1+0.9 1100 (157) ± 2 - Lever

C (R1-0.85) 500 (171.5) ± 3 - Lever

I ApproxR1-0.8 100 (185) - Lever

Injection order:

Pump speed(r/min)

Advanceangle (° )




Service Department


Tel. (048)470-1559, Fax. (048)474-9856

Company:

Ass'y No.: 106673-7463ENGINE MODEL: 6D24T2

No. Governor: EP/RLD-J Timing device: EP/SPGH

1. Test conditions

Date:



kgf/cm2 }

2. Injection timing



CONFIDENTIAL


26 SEP 2002

ME152038

106067-1050



Nozzle: 105780-0120 Nozzle Holder: 105780-2190(Bosch Type No. 1 688 901 990) (Bosch Type No. )

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



side ( interval:

3



1 5 , 1 3 , 1 6 , 1 2 , 1 460°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'

MITSUBISHI

Governor

1/4



Boost press. 0

Cylinder variation adjustment standardEach cylinder 172.5±4.3

(qA-27 qB qA-19)

Each cylinder 26±3.9

Basic


Basic


Boost press. kPa {mmHg}Above 29.3 {Above 220}Boost press. kPa {mmHg}Above 29.3 {Above 220}

Approx. R1-0.8

106673-7463 2/4


0185225 285

700

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

10.0

9.0+0.8-0.6

Approx R1-0.8

R1+0.75

0Below 210 (340) (1050)

A

B

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

Torque cam no. ‘AE17’

R1+0.9

R1(13.7)

700

(890)

(1000)

(1190)

1210

400

2.7±0.5

8.0Approx 8.0


Idling adjustment


R2[R1-1.7]

8.4±1.0

1290

6.2-0.1

CI

13.5±0.1

Below 5.0

1500

4.3±0.1

255350


Microswitch adjustment Adjust the bolt so that the microswitch operates at a control lever position ofR= 7.6 ± 0.1 mm and a pump speed of 325r/min.

106673-7463 3/4


Pump speed (r/min)

10.0±0.3

0 Above 750

0/4 load P = 0


Adv

ance

ang

le (

° )


R2[R1-1.7]

R2-1.65

0

6.7±1.3 {50±10}


N = 250

Rac

k po

sitio

n (m

m)



106673-7463 4/4

6. Rack sensor adjustment (-0620)

Note: Do not operate the aneroid compensator if installed.

(1) Fix the speed control lever in the FULL position.

(2) Set the speed at N r/min and the rack position at R. (If equipped with a boost compensator, apply

boost pressure.)

(3) Adjust the bobbin 1 so that the rack sensor output voltage is VR±0.01.

(4) Apply red paint to the joint 2 and nut 3 join and to the joint 2 and pump end face join.

1

2 3

Constant voltage



Speed N 1100 r/min

Rack position R R1(13.7)+0.9 mm


2V407912-1742

105782-6320

3V

407910-3032

407910-6010

407910-7210



Idling

Full-speed


(Supply pump side)

2°±5°

37°±3°

Stop lever angle

Stop Normal

(Confirm that injection does not occur.)

40°±5°29.5°±5°

Stopper bolt settingN=1100, R=3.5±0.3

Coupling key groove position Approx. 2°

Timing setting


.

6675-450


Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




A 13.6 1025 313 ± 9 ± 3 Rack Basic Rack limit

B Approx 6.5 400 30 ± 3 ± 10 Rack

Injection order:

Pump speed(r/min)

Advanceangle (° )



Company:

Assy No.: 106684-4460ENGINE MODEL: S6A3

No. Governor: Timing device:

1. Test conditions

Date:


Injection pump: PE6P

kgf/cm2}

2. Injection timing


Plungers are numbered from the Opposite Drive ° ± 30').

CONFIDENTIAL


31 Oct 2007

35A65-11070

106068-4030



Nozzle: 105025-2680 Nozzle holder: 105040-5020(Bosch type no. DLLA158SM268) (Bosch type no. )



side (interval:

1


Note: Adjust with rack position of R=A(13.6)

1 5 , 1 3 , 1 6 , 1 2 , 1 460°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'

1/2



MITSUBISHI. HEAVYTEMPORARILY



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

106684-4460 2/2


Timing setting


Appr

ox. 1

10°


Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




A 13.6 1025 313 ± 9 ± 3 Rack Basic Rack limit

B Approx 6.5 400 30 ± 3 ± 10 Rack

Injection order:

Pump speed(r/min)

Advanceangle (° )



Company:

Assy No.: 106684-4461ENGINE MODEL: S6A3

No. Governor: Timing device:

1. Test conditions

Date:


Injection pump: PE6P

kgf/cm2}

2. Injection timing


Plungers are numbered from opposite the Drive ° ± 30').

CONFIDENTIAL


20 Sep 2007

35A65-11070

106068-3462



Nozzle: 105025-2680 Nozzle holder: 105040-5020(Bosch type no. DLLA158SM268) (Bosch type no. )



side (interval:

1


Note: Adjust with rack position of R=A(13.6)

1 5 , 1 3 , 1 6 , 1 2 , 1 460°± 30' 120°± 30' 180°± 30' 240°± 30' 300°± 30'

1/2



MITSUBISHI. HEAVYTEMPORARILY



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

106684-4461 2/2


Timing setting


Approx. 110°




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

Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)




B 8.1 700 85.6 ± 1.5 ± 2 Lever Basic

C (7.9) 1250 (95.9) ± 2 ± 3 Lever

D Approx 5.4 225 8 ± 1.4 ± 13 Rack

E (10.3) 150 (102) - Lever

F - 150 Above 137 - Lever

Injection order:

Pump speed(r/min)

(Measure) (Measure) (1075) 1150 1250

Advanceangle (° )

Start

0 1 - 0.5 1 - 0.5 2.5 ± 0.3

Finish

5+1



Company:

Assy No.: 106961-1564ENGINE MODEL: 12PC1

No. Governor: EP/RFD-D Timing device: EP/SPM

1. Test conditions

Date:


Injection pump: PES12P105488-0430 105687-0200

kgf/cm2}

2. Injection timing

Pre-stroke: No.1 plunger 4 ± 0.03mm mm


CONFIDENTIAL


28 Jul 2004

115601-7317

106096-9241






side (interval:

7



1 3 , 1 6 , 1 7 , 1 12 255°± 15' 300°± 15' 315°± 15'240°± 15'

1 4 , 1 9 , 1 8 , 1 5 , 1 2 , 1 11 , 1 10 ,15°± 15' 60°± 15' 75°± 15' 120°± 15' 135°± 15' 180°± 15' 195°± 15'

ISUZU

Governor side

1/3


Overflow valve opening pressure: 255 ± 34 kPa {2.6 ± 0.35 kgf/cm2} Drive sideOverflow valve opening pressure: 255 ± 34 kPa {2.6 ± 0.35 kgf/cm2}

Governor

Excessive fuel lever ; Normal position

Excessive fuel lever ; Excessive fuel position

106961-1564 2/3


D

8.1

Above 6.9

5.4

2.0±0.5

0225

7.8+

0.2

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

Excessive fuel setting for starting: 9.2±0.1

4.8

7.8

450+25 (1360)

C

F

E

270±20(1235)

13001485-10

Not exceeding 2 at excessive fuel setting for starting

Set so that the damper spring is not operating at delivery.

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.

B

106961-1564 3/3

Approx.5°

Stop lever angleExcessive fuel lever angle

(24°)


Full-load

At excessive fuel for starting


Full-speed

9° ±5°

Idling


33°±3°

10°±5°

60°±5° 73° ±5°

Normal Stop

Normal

Timing setting


Approx. 170°

Gear mark "Z"governor side

Pre-stroke(mm)

Pre-stroke sensoroutput voltage (V) Remarks

2.0 ± 0.05 2.83 ± 0.01 Pre-stroke actuator adjustment

5.1 ± 0.03 V1 = 1.2 ± 0.2 Confirmation

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

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:

2. Injection timing

Pre-stroke: No. 1 Plunger 5.1 ± 0.03 mm

Plungers are numbered from the Governor side.

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

Shim 3

DIGI switch No.: 17 (For C/U 407980-224*)

Oil Temp. 40+5 °C

Company:

Ass'y No.: 107491-3190ENGINE MODEL: J05C-TJ

No. Governor: EP/RLD-J

1. Test conditions

Date:

Pump rotation: Counter clockwise ( viewed from drive side )

Injection pump: TC4MD105933-1730

kgf/cm2 }

CONFIDENTIAL


16 Mar 2007

22040-2421A

107049-0060




Test Oil: ISO4113 or SAE Standard Test Oil { SAE J967d }

2


1/6

Pre-stroke actuator:159645-4120

3. Pre-stroke actuator adjustment

Pre-stroke actuator type: Retard

Power supply voltage: 24±0.5 V Ambient temperature: 23±5°C

(Timing retard side)

Connector 1

Stopper 2

1 3 , 1 4 , 1 290°± 15' 180°± 15' 270°± 15'

HINO


TEMPORARILY

Nozzle opening pressure: 1st 17.7 MPa { 180 kgf/cm2 } 2nd 21.6 kgf/cm2 }MPa { 220



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 N•m {0.1 ~ 0.15 kgf•m}

2. Move the pre-stroke actuator counter clockwise (viewed from the drive side) to adjust it.

3. After pre-stroke actuator adjustment, stamp both the pre-stroke actuator and the housing with an aligning mark.

Injection pump

Stamping position

Pre-stroke actuator

Adjustingpoint

PRack

position(mm)

Pumpspeed(r/min)




- P1 (12.8) 750 110 ± 3 ± 3.5 Rack Basic

H P2 Approx8.0 325 - Rack

4. Injection quantity variation rate adjustment

P = pre-stroke sensor output at injection quantity adjustment

P1 V = 2.25 ± 0.01 (V) 3.1 ± 0.05 (mm)

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


107491-3190 3/6


0230

325375 800

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

10.0

9.7+0.2-0.3

R1-0.25

Approx R1+0.4

0Below 275 (500) (1200)

A

B

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

Torque cam no. ‘AH27’

R1+2.15

R1(12.8)

650

(700)

(800) (1300)

1500

450

4.5±0.6

8.0Approx 8.0


Idling adjustment


12.3±0.1R1-0.95(R2)

11.4±1.0

1530

6.8±0.1

R1-0.95(R2)

R2-1.15

0

23.3±1.3 {175±10}


N = 400

Rac

k po

sitio

n (m

m)



I

H J

7. Control lever angle

Pump speed(r/min)

Below 1170 1120 1250-50

Advanceangle (° )

Start0 0 -0.3 Finish

-1.5±0.3


107491-3190 4/6

Adjustingpoint

PRack

position(mm)

Pumpspeed(r/min)




A P1 R1(12.8) 750 110 ± 2 - Lever Boost press. kPa {mmHg} Above 50.7 {Above 380}

B P1 R1+2.15 1250 (120.5) ± 3 - Lever Boost press. kPa {mmHg} Above 50.7 {Above 380}

C P1 R2-1.15 400 (83) ± 3 - Lever Boost press: 0

I P1 A p p r o x R1+0.4 100 (175) - Lever Boost press: 0

6. Injection quantity adjustment (after governor adjustment)


P1 V = 2.25 ± 0.01 (V) 3.1 ± 0.05 (mm)

P2 - -

34.5° ±3°


Idling

Stop lever angle

Full-speed

5° ±5°

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

10.5°±5°

40°±5°

Nor

malStop

Basic


107491-3190 5/6

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.

9. Injection timing setting

At No. 1 plunger’s beginning of injection position(Pre-stroke: 5.1±0.03 mm)

Injection timing aligning mark

Pointer

Flywheel

(Actual shapes and positions may differfrom the illustration.)


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)

(1) Screw in bobbin 1 until it contacts the joint 2.

(2) Fix the pump lever at full and screw in the bobbin 1 to adjust the depth so that the amp’s output

voltage V = VR at Np = No and R = Ro. Then, fix the rack sensor using the nut 6.

(3) Move the pump lever 2 or 3 times, reset at full and confirm that the amp’s output voltage V = VR.

(4) Attach the caution plate to the top of the joint 2 and apply red paint to the joint 2 - nut 6 join, and the

pump end face - joint 2 join.

Note:

(1) When adjusting the bobbin 1 and joint 2, the fully tightened position of the bobbin is 9 threads (ie, 9

turns) from where it first engages the joint.

(2) With the welded rack block type, refer to the table below for the R = Ro range (the range varies with

the joint).

Rack sensor power supply 5±0.01V

Speed No 1250 r/min

Rack position Ro R1(12.8) + 2.15 mm

Output voltage VR 3.00±0.01V

Threaded rack block type Welded rack block type

6 1 2

5 4 3

Apply red paint

Pump end face

6 1 2 Apply red paint

Pump end face

4 3

Rack sensor adjusting position

Ro

No Np

Rac

k po

sitio

n Output voltage

VR

Ro

Adjustment Np = No

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

Pre-stroke(mm)



5.1 ± 0.03 V1 = 1.2 ± 0.2 Confirmation


Note:




Injection order:

2. Injection timing




Shim 3


Oil Temp. 40+5 °C


Service Department


Tel. (048)470-1559, Fax. (048)474-9856

Company:

Ass'y No.: 107491-3191ENGINE MODEL: J05C-TJ


1. Test conditions

Date:



kgf/cm2 }

CONFIDENTIAL


29 Nov 2002

22040-2421A

107049-0061






4


1/6






Connector 1

Stopper 2

1 3 , 1 4 , 1 290°± 15' 180°± 15' 270°± 15'

HINO


107491-3191 2/6

Note:






Injection pump

Stamping position

Pre-stroke actuator

Adjustingpoint

PRack

position(mm)

Pumpspeed(r/min)




- P1 13.1 750 123.5 ± 3 ± 3.5 Rack Basic

Z P2 8.0±0.5 505 - Rack Adjust injection q'ty at N = 505.Adjust governor as per gov. adj. spec.



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)


107491-3191 3/6

If not indicated, the rack position allowance is ± 0.05 mm.


0230

325375 800

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

10.0

9.7+0.2-0.3

R1-0.25

Approx R1+0.4

0Below 275 (500) (1200)

A

B

Rac

k po

sitio

n (m

m)

Pump speed (r/min)


R1+2.15

R1(13.1)

650

(700)

(800) (1300)

1500

450

4.5±0.6

8.0Approx 8.0


Idling adjustment


12.5±0.1R1-0.95(R2)

11.1±1.0

1530

6.8±0.1

R1-0.95(R2)

R2-1.15

0

23.3±1.3 {175±10}


N = 400

Rac

k po

sitio

n (m

m)



I


Pump speed(r/min)

Below 1170 1120 1250-50

Advanceangle (° )


-1.5±0.3


107491-3191 4/6

Adjustingpoint

PRack

position(mm)

Pumpspeed(r/min)




A P1 R1(13.1) 750 123.5 ± 2 - Lever Boost press. kPa {mmHg} Above 50.0 {Above 375}

B P1 R1+2.15 1250 136 ± 6 - Lever Boost press. kPa {mmHg} Above 50.0 {Above 375}



P1 V = 2.25 ± 0.01 (V) 3.1 ± 0.05 (mm)

P2 - -

34.5° ±3°


Idling


Stop lever angle

Full-speed

5° ±5°

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

10.5°±5°

40°±5°

Nor

malStop

Basic

107491-3191 5/6









Pointer

Flywheel



107491-3191 6/6









Note:




the joint).


Speed No 1250 r/min




6 1 2

5 4 3

Apply red paint

Pump end face


Pump end face

4 3


Ro

No Np

Rac

k po

sitio

n Output voltage

VR

Ro

Adjustment Np = No

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

Service Department


Tel. (048)470-1559, Fax. (048)474-9856

1/11

Ass'y No.: 107492-1101ENGINE MODEL: 4HE1-X

No.

Governor: 105934-0090

1. Test condition

Date:

Pump rotation:

Injection pump: 107049-2061 EP/RLD-M

kgf/cm2 }

2. Injection timing

Pre-stroke: No.1 Plunger 4.0 0.03mm

Injection order:

Plungers are numbered from the Governor

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


INJ. PUMP CALIBRATION DATA

Company:27 Nov.2001

ISUZU8-97212-185-0

TCS4MD

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

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

Nozzle: 105780-0120 Nozzle Holder: 105780-2190(Bosch Type No. 1 688 901 990) (Bosch Type No. 9 430 610 144)

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

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

side.

Counter clockwise (viewed from drive side)

Ambient temperature: 23 5 C

1 3 , 1 4 , 1 290 15' 180 15' 270 15'

5

Overflow valve opening pressure: 255 34 kPa { 2.6 0.35 kgf/cm2 } Selector switch No. 00 (For C/U 407910-303*)

Digi switch No. 11 (For C/U 407980-224*)

107492-1101 2/11

3. Injection timing adjustment

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

3-1 Adjustment Preparation

(1) Install setscrew ③ (P/N 157927-2820), screw ④ (P/N 157927-3321) and solenoid switch

⑤ into housing ① .

(2) -1. Screw in setscrew ③ until the counterweight contacts the housing's pressfitted

stopper pin.

-2. Tighten screw ④ until clearance between screw ④ and counterweight ② is 1～2

mm.

-3. Tighten solenoid switch ⑤ until clearance between solenoid switch and

counterweight ② 's pin is 1～ 2 mm, then tighten locknut ⑥ .

(3) Install starting advance mechanism's cover.

(4) Position control rack in full position.

(5) Set power supply voltage to manual controller at 12V.

3-2 Pre-stroke adjustment

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

3-3 Individual cylinder's injection order adjustment

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

cylinder using the shim ① .

1. Setscrew installation 2. Pre-stroke adjustment

3. Individual cylinder's injection

order adjustment

1

2

4

563

107492-1101 3/11

3-4 Measuring pre-stroke output voltage

(1) Install measuring device (P/N 105782-6420).

(2) Remove setscrew ③ (P/N 157927-2820) and install air bleeder bolt.

(3) Screw in screw ④ (P/N 157927-3321) and measure the No 1 cylinder's output voltage

for pre-stroke lift values in the table below.

Advice

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

remeasured.

3-5 Minimum advance angle adjustment stopper adjustment

(1) Remove screw ④ (P/N 157927-3321) and install minimum advance angle adjustment

stopper.

(2) Screw in minimum advance angle adjustment stopper until No 1 cylinder's pre-stroke

is 3.67 ～ 3.73. Then, tighten locknut to specified torque.

(3) Measure the output voltage (c) at this time.

3-6 Solenoid switch adjustment

(1) Apply 24 V voltage to solenoid switch ⑤ .

(2) Loosen solenoid switch ⑤ until No 1 cylinder's pre-stroke is 1.90 ～ 2.03 mm, then

tighten locknut to specified torque.

(3) Confirm solenoid switch operates at 14.5 -0.1 V.

Adjusting pointConfirmation point

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

a3.36 a1 + tolerance

3.10 a2 -tolerance

b2.96 b1 + tolerance

2.76 b2 -tolerance

(calculate from each specification)

107492-1101 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)

Boost compensator stroke: 1.25 ±0.1

Torque cam No. “ AF60”

Pump speed (r/min)

Confirm rack sensor Vist = 2.55±0.28

at supply voltage 5±0.01V , N =1000 r/min , R = R1 (15.0).


4-1. Governor adjustment


Advice

Loosen timing cam and lock screw.

Fully tighten the adjusting nut.

R1+0.9

Approx.R1+0.3R1(15.0)

R2 [R1-2.15]

10.7± 1.0

0250-40 (650) 1000 (1150)

(1600)

1690

1810

13.9± 0.1

A

B

D

C

I

10.510.0± 0.1

Approx.8.9

7.8

6.6± 0.1

3.9± 0.3

0 880500

475

400

400

240

H J

107492-1101 5/11

4-2 Boost compensator adjustment

(1) Select a push rod so C = 37.5±0.5 at full boost pressure. (C is the distance from the

end face of the housing to top of the lever.)

(2) Adjust the boost compensator stroke using screw A.

(0 boost pressure position adjustment)

Adjust the beginning of boost compensator operation by adjusting the notch adjusting

nut B.

Boost pressure inlet

A Boost compensator

stroke adjusting screw

Boost compensator spring

B Notch adjusting nut

Top of lever

Boost press. kPa｛mmHg｝

Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.25

Approx. 28.7 {Approx. 215}

12.0± 1.3 {90± 10}

PushrodC

0

107492-1101 6/11

4-3 Timing cam adjustment (Timing cam No:A07)

(1) Hold speed control lever against full speed stopper bolt.

(2) Supply boost pressure of at least 42.0 kPa {at least 315 mmHg}.

(3) Operate pump at the timing cam adjusting point

(point a in table below: Np = 900 r/min).

(4) Perform timing cam adjustment so output voltage is within range of a1 ～ a2 actually

measured for pre-stroke output voltage during injection timing adjustment in 3-4.

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

(point b in table below: Np = 1,200 r/min).

(6) Confirm that the pre-stroke output voltage is within the range b1～ b2.

Solenoid starting advance angle

b (confirmation point)

a (adjusting point)

Minimum advance angle adjustment

stopper

Pre-stroke(Pre-stroke output voltage)

Pump speed (r/min)

Pre-stroke at stopper contact

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


3.10 a2 -tolerance

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


2.76 b2 -tolerance

2.76 (b2)

2.96 (b1)

3.10 (a2)

3.36 (a1)

3.7± 0.03 (c)

4.0±0.03(500) 900 1,200

2.0 ＋ 0.03－ 0.10

0

Adjustingpoint

Rackposition( mm )

Pumpspeed

( r/min )

Injection q'ty( cm3/100 strokes )

Max.variationbetweencylinders

FixedPre-stroke

at adjustmentRemarks

- 15.0 1,000 109.5 ± 1.6 ±4 Rack a1～a2(v)

Z 8.9±0.5 510 22 ± 1.5 ± 14 Rack c(v)

A R1(15.0) 1,000 109.5 ± 1 - Lever a1～a2(v)

B R1＋0.9 1,200 (112.5) ± 2 - Lever b1～b2(v)

IApprox.

R1＋0.3150 (180) - Lever c(v)

D* 15.3±0.1 1,200 (106) - Lever b1～b2(v)

107492-1101 7/11


Cylinder variation

adjustment standardBasic

BasicBoost press. kPa｛mmHg｝Above 42.0｛Above 315｝

Cylinder variation

adjustment standard

Boost press. 0

Boost press. kPa｛mmHg｝Above 42.0 ｛Above 315 ｝Negative press. kPa｛mmHg｝ 53.3 kPa｛ 400 mmHg｝

D*: Aneroid compensator actuator adjustment point

Boost press. kPa｛mmHg｝Above 42.0｛Above 315｝

107492-1101 8/11

6. FICD Adjustment

(1) Stop the injection pump.

(2) Hold speed control lever against idling stopper bolt.

(3) Adjust clearance between FICD actuator lever and speed control lever to approx. 1+1mm.

(4) Loosen nut ③ and fully tighten FICD set bolt ② .

(5) Apply 53.3 kPa { 400 mmHg} negative pressure to the actuator ① and set the pump

speed at 450 r/min.

(6) Gradually loosen set bolt ② then fix bolt using nut when the rack position is 8.7±0.1 mm.

(7) Apply above negative pressure several times and confirm FICD actuator is operating

properly and clearance between FICD actuator lever and speed control lever.

Tightening torque

5 ～ 7 N.m {0.5 ～ 0.7 kgf.m}

FICD actuator lever

Speed control lever

②

1+1 mm

①

③

107492-1101 9/11

7. Aneroid compensator actuator adjustment ( injection quantity decrease )

Note:

Set this actuator after adjusting the full rack position.

(1) Stop injection pump.

(2) Adjust wire nut so full load set lever contacts full load set bolt and aneroid compensator

actuator wire is not loose. Then, fix the nut.

(3) Apply 53.3 kPa { 400 mmHg} negative pressure to aneroid compensator, set pump

speed at 1,200 r/min.

(4) Apply at least 42.0 kPa { 315 mmHg} boost pressure to the boost compensator.

(5) After operating full load set lever, adjust aneroid compensator set bolt so control rack

position is 15.3±0.1 mm and fuel injection quantity is as specified. Then, fix the set bolt.

Stroke

Injection quantity decrease

adjustment point

Full load set lever

Full load set bolt

D

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

B

A

107492-1101 10/11

8. Speed control lever angle 9. Stop lever angle

Hole(R42)Stopper bolt H position

Idling

Full-speedHole(R41.3)

Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°

10. Rack Sensor Adjustment

(1) Before removing rack position measuring device, apply at least 42.0 kPa

{at least 315 mmHg} boost pressure and confirm rack position is R1 = 15.0 mm and

fuel injection quantity is 109.5± 1 mm3/st at N = 1,000 r/min.

(2) Remove rack position measuring device.

(3) Attach rack sensor core to control rack.

At this time, hold control rack using a spanner (to prevent the rack from bending).

Specified torque : 3.4～～～～～ 4.9 N.m {0.35～～～～～ 0.5 kgf.m}

(4) While pulling stop lever, install rack sensor to rack sensor core.

(5) Tighten two flange fixing screws.


(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.

(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.

(8) Apply at least 42.0 kPa {at least 315 mmHg} boost pressure, set pump speed at

N= 1,000 r/min, and hold speed control lever against the full speed stopper bolt.

(9) Confirm the rack sensor output voltage from the digital voltmeter. (Vist = 2.55±0.28)

(10) Confirm that the voltage changes when the speed control lever is moved to the idle and

full sides.

Rac

k po

sitio

n (m

m)

R1

N

Pump speed (r/min)

Sen

sor

outp

ut v

olta

ge (

V)

Vist

R1

Rack position (mm)

A

107492-1101 11/11

Timing setting

At No. 1 plunger’s beginning


B.T.D.C. : 8°

(At pre-stroke 3.7± 0.05mm)

Pump

Engine

Bracket mark

Gear hole (Dia. 3mm)

Gear’s threaded hole

Gear side

Pump side

Stamp on coupling and bracket

(B.T.D.C. 8°°°°°)

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

Check hole

28°35′14″±

20′

13°28′48″±3°

(35°)

(96°)

(3°12′32″)

11. Drive Coupling Timing

Service Department


Tel. (048)470-1559, Fax. (048)474-9856

1/11

Ass'y No.: 107492-1132ENGINE MODEL: 4HE1-X

No.

Governor: 105934-0081

1. Test condition

Date:

Pump rotation:

Injection pump: 107049-2073 EP/RLD-M

kgf/cm2 }

2. Injection timing

Pre-stroke: No.1 Plunger 4.0 0.03mm

Injection order:

Plungers are numbered from the Governor

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


INJ. PUMP CALIBRATION DATA

Company:18 Mar.2003

ISUZU8-97212-188-1

TCS4MD

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

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

Nozzle: 105780-0120 Nozzle Holder: 105780-2190(Bosch Type No. 1 688 901 990) (Bosch Type No. 9 430 610 144)

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

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

side.

Counter clockwise (viewed from drive side)

Ambient temperature: 23 5 C

1 3 , 1 4 , 1 290 15' 180 15' 270 15'

3

Overflow valve opening pressure: 255 34 kPa { 2.6 0.35 kgf/cm2 } Selector switch No. 00 (For C/U 407910-303*)

Digi switch No. 11 (For C/U 407980-224*)

107492-1132 2/11

3. Injection timing adjustment

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

3-1 Adjustment Preparation

(1) Install setscrew ③ (P/N 157927-2820), screw ④ (P/N 157927-3321) and solenoid switch

⑤ into housing ① .

(2) -1. Screw in setscrew ③ until the counterweight contacts the housing's pressfitted

stopper pin.

-2. Tighten screw ④ until clearance between screw ④ and counterweight ② is 1～2

mm.

-3. Tighten solenoid switch ⑤ until clearance between solenoid switch and

counterweight ② 's pin is 1～ 2 mm, then tighten locknut ⑥ .

(3) Install starting advance mechanism's cover.

(4) Position control rack in full position.

(5) Set power supply voltage to manual controller at 12V.

3-2 Pre-stroke adjustment

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

3-3 Individual cylinder's injection order adjustment

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

cylinder using the shim ① .

1. Setscrew installation 2. Pre-stroke adjustment

3. Individual cylinder's injection

order adjustment

1

2

4

563

107492-1132 3/11

3-4 Measuring pre-stroke output voltage

(1) Install measuring device (P/N 105782-6420).

(2) Remove setscrew ③ (P/N 157927-2820) and install air bleeder bolt.

(3) Screw in screw ④ (P/N 157927-3321) and measure the No 1 cylinder's output voltage

for pre-stroke lift values in the table below.

Advice

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

remeasured.

3-5 Minimum advance angle adjustment stopper adjustment

(1) Remove screw ④ (P/N 157927-3321) and install minimum advance angle adjustment

stopper.

(2) Screw in minimum advance angle adjustment stopper until No 1 cylinder's pre-stroke

is 3.67 ～ 3.73. Then, tighten locknut to specified torque.

(3) Measure the output voltage (c) at this time.

3-6 Solenoid switch adjustment

(1) Apply 24 V voltage to solenoid switch ⑤ .

(2) Loosen solenoid switch ⑤ until No 1 cylinder's pre-stroke is 1.90 ～ 2.03 mm, then

tighten locknut to specified torque.

(3) Confirm solenoid switch operates at 14.5 -0.1 V.

Adjusting pointConfirmation point

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


3.17 a2 -tolerance


2.65 b2 -tolerance

(calculate from each specification)

107492-1132 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)

Boost compensator stroke: 1.1 ±0.1

Torque cam No. “ AG00”

Pump speed (r/min)

Confirm rack sensor Vist = 2.13±0.28

at supply voltage 5±0.01V , N =900 r/min , R = R1 (12.9).


4-1. Governor adjustment


Advice

Loosen timing cam and lock screw.

Fully tighten the adjusting nut.

R1+2.9

Approx.R1+2.0

R1(12.9)

R2 [R1-0.6]

10.2± 1.0

0250-40 (700) 900 (1400)

(1550)

1620

1775

14.0± 0.1

A

B

D

C

I

10.510.0± 0.1

Approx.8.5

7.8

6.6± 0.1

3.9± 0.3

0 880500

475

400

400

240

H J

R3 [R1-0.6]+0.5-0.1

(1300)

700

E

(1050)

107492-1132 5/11

4-2 Boost compensator adjustment

(1) Select a push rod so C = 37.5±0.5 at full boost pressure. (C is the distance from the

end face of the housing to top of the lever.)

(2) Adjust the boost compensator stroke using screw A.

(0 boost pressure position adjustment)

Adjust the beginning of boost compensator operation by adjusting the notch adjusting

nut B.

Boost pressure inlet

A Boost compensator

stroke adjusting screw

Boost compensator spring

B Notch adjusting nut

Top of lever

Boost press. kPa｛mmHg｝

Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-0.6]

R2-1.1

Approx. 26.7 {Approx. 200}

10.7± 1.3 {80± 10}

PushrodC

0

107492-1132 6/11

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

(1) Hold speed control lever against full speed stopper bolt.

(2) Supply boost pressure of at least 40.0 kPa {at least 300 mmHg}.

(3) Operate pump at the timing cam adjusting point

(point a in table below: Np = 900 r/min).

(4) Perform timing cam adjustment so output voltage is within range of a1 ～ a2 actually

measured for pre-stroke output voltage during injection timing adjustment in 3-4.

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

(point b in table below: Np = 1,450 r/min).

(6) Confirm that the pre-stroke output voltage is within the range b1～ b2.

Solenoid starting advance angle

b (confirmation point)

a (adjusting point)

Minimum advance angle adjustment

stopper

Pre-stroke(Pre-stroke output voltage)

Pump speed (r/min)

Pre-stroke at stopper contact

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


3.17 a2 -tolerance

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


2.65 b2 -tolerance

2.65 (b2)

2.85 (b1)

3.17 (a2)

3.43 (a1)

3.7± 0.03 (c)

4.0±0.03(500) 900 1,450

2.0 ＋ 0.03－ 0.10

0

Adjustingpoint

Rackposition( mm )

Pumpspeed

( r/min )

Injection q'ty( cm3/100 strokes )

Max.variationbetweencylinders

FixedPre-stroke

at adjustmentRemarks

- 12.9 900 81 ± 1.6 ±4 Rack a1～a2(v)

Z 8.5±0.5 500 19 ± 1.5 ± 14 Rack c(v)

A R1(12.9) 900 81 ± 1 - Lever a1～a2(v)

B R1＋2.9 1,450 (102.5) ± 2 - Lever b1～b2(v)

IApprox.

R1＋2.0150 (175) - Lever c(v)

D* 15.2±0.1 1,450 (96.5) - Lever b1～b2(v)

107492-1132 7/11


Cylinder variation

adjustment standardBasic

BasicBoost press. kPa｛mmHg｝Above 40.0｛Above 300｝

Cylinder variation

adjustment standard

Boost press. 0

Boost press. kPa｛mmHg｝Above 40.0 ｛Above 300 ｝Negative press. kPa｛mmHg｝ 53.3 kPa｛ 400 mmHg｝

D*: Aneroid compensator actuator adjustment point

Boost press. kPa｛mmHg｝Above 40.0｛Above 300｝

107492-1132 8/11

6. FICD Adjustment

(1) Stop the injection pump.

(2) Hold speed control lever against idling stopper bolt.

(3) Adjust clearance between FICD actuator lever and speed control lever to approx. 1+1mm.

(4) Loosen nut ③ and fully tighten FICD set bolt ② .

(5) Apply 53.3 kPa { 400 mmHg} negative pressure to the actuator ① and set the pump

speed at 450 r/min.

(6) Gradually loosen set bolt ② then fix bolt using nut when the rack position is 8.3±0.1 mm.

(7) Apply above negative pressure several times and confirm FICD actuator is operating

properly and clearance between FICD actuator lever and speed control lever.

Tightening torque

5 ～ 7 N.m {0.5 ～ 0.7 kgf.m}

FICD actuator lever

Speed control lever

②

1+1 mm

①

③

107492-1132 9/11

7. Aneroid compensator actuator adjustment ( injection quantity decrease )

Note:

Set this actuator after adjusting the full rack position.

(1) Stop injection pump.

(2) Adjust wire nut so full load set lever contacts full load set bolt and aneroid compensator

actuator wire is not loose. Then, fix the nut.

(3) Apply 53.3 kPa { 400 mmHg} negative pressure to aneroid compensator, set pump

speed at 1,450 r/min.

(4) Apply at least 40.0 kPa { 300 mmHg} boost pressure to the boost compensator.

(5) After operating full load set lever, adjust aneroid compensator set bolt so control rack

position is 15.2±0.1 mm and fuel injection quantity is as specified. Then, fix the set bolt.

Stroke

Injection quantity decrease

adjustment point

Full load set lever

Full load set bolt

D

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

B

A

107492-1132 10/11

8. Speed control lever angle 9. Stop lever angle

Hole(R42)Stopper bolt H position

Idling

Full-speedHole(R41.3)

Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29°± 3°

10. Rack Sensor Adjustment

(1) Before removing rack position measuring device, apply at least 40.0 kPa

{at least 300 mmHg} boost pressure and confirm rack position is R1 = 12.9 mm and

fuel injection quantity is 81± 1 mm3/st at N = 900 r/min.

(2) Remove rack position measuring device.

(3) Attach rack sensor core to control rack.

At this time, hold control rack using a spanner (to prevent the rack from bending).


(4) While pulling stop lever, install rack sensor to rack sensor core.

(5) Tighten two flange fixing screws.


(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.

(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.

(8) Apply at least 40.0 kPa {at least 300 mmHg} boost pressure, set pump speed at

N= 900 r/min, and hold speed control lever against the full speed stopper bolt.

(9) Confirm the rack sensor output voltage from the digital voltmeter. (Vist = 2.13±0.28)

(10) Confirm that the voltage changes when the speed control lever is moved to the idle and

full sides.

Rac

k po

sitio

n (m

m)

R1

N

Pump speed (r/min)

Sen

sor

outp

ut v

olta

ge (

V)

Vist

R1

Rack position (mm)

A

107492-1132 11/11

Timing setting

At No. 1 plunger’s beginning


B.T.D.C. : 8°

(At pre-stroke 3.7± 0.05mm)

Pump

Engine

Bracket mark

Gear hole (Dia. 3mm)

Gear’s threaded hole

Gear side

Pump side

Stamp on coupling and bracket

(B.T.D.C. 8°°°°°)

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

Check hole

28°35′14″±

20′

13°21′18″± 3°

(35°)

(96°)

(3°12′32″)

11. Drive Coupling Timing

Governor: EP/RED-IV105961-0071


Oil Temp. 40+5 °C


Service Department


Tel. (048)470-1559, Fax. (048)474-9856

Company:

Ass'y No.: 107691-0144ENGINE MODEL: FE6TA

No.

1. Test conditions

Date:


Injection pump: TC6MD

kgf/cm2 }

CONFIDENTIAL


18 Sep 2002

NISSAN DIESEL

16801 Z5607

107069-1460







8


1/4



37°±

5°

20°±

5°

3. Confirmation of RED-IV governor's output characteristics

[1] Rack sensor output characteristics(1) Measure the rack position R2 at PWM 72.5% and confirm that R2 = 15±1 mm.

(2) Measure the rack position R1 at PWM16.25% and confirm that R2 - R1 = 10±0.1 mm.

R1 R2

72.5%

16.25%

PWM (%)

Rack position (mm)

Switch box part no. 407980-4340

Control unit part no. 407915-0590

PWM72.5% rack position R2 = 15±1 (mm)

PWM16.25% rack characteristics R2 - R1 = 10±0.1 (mm)

R=1.0

Stop

Normal

R=20.0

107691-0144 2/4

Pre-stroke(mm)



5.1 ± 0.03 V1 = 1.2 ± 0.2 Confirmation


Note:




Injection order:

4. Injection timing


Plungers are numbered from the side.

1 5 , 1 3 , 1 6 , 1 2 , 1 4300°± 30'


Shim 3




Connector 1

Stopper pin 2


1 4 , 1 2 , 1 6 , 1 3 , 1 560°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'

[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.

[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.

PWM Rack position

5% 1 mm or less

95% 19 mm or above

Drive

107691-0144 3/4

Injection pump

Stamping position

Pre-stroke actuator



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)

PRack

position(mm)

PWM(%)

Pumpspeed(r/min)



cylinders (%)Remarks

P1 (11.3) 51.5 700 108 ± 1 ± 4 Basic

P2 (6.7) Approx 25.6 445 11 ± 1.8 ± 10

Pump speed(r/min)

Below 1150 1100 1300

Advanceangle (° )

Start 0 Below 0.3 Finish

4.0 ± 0.3


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.Tightening torque: 1.0 ~ 1.5 N•m {0.1 ~ 0.15 kgf•m}

2. Move the pre-stroke actuator clockwise (viewed from the drive side) to adjust it.


107691-0144 4/4









Pointer

Flywheel


Approx. 25°Coupling key groove position

Actuator: EP/RED-III 105956-0112


Oil Temp. 40+5 °C


Service Department


Tel. (048)470-1559, Fax. (048)474-9856

Company:


No.

1. Test conditions

Date:



kgf/cm2 }

CONFIDENTIAL


29 Oct 2002

ME301247

107069-0590







0


1/4


MITSUBISHI


3. RED-III governor


(Rack 19mm, Span 6mm)

When the rack sensor output voltages are V1 and V2, confirm that rack positions R1 and R2 are as

specified below.

Rack type 19 mm

Control unit no. 407910-3960

Output voltageV1 = (V2+0.9±0.0075)

V2 = 2.2±0.01

Rack position (mm)R2 = 11±1

R2 - R1 = 6±0.05

Rack position (mm)R1 R2

Out

put v

olta

ge (

V)

V1

V2

39°±5° R=20.0

Stop Normal

37°±5°

R=1.0

107691-2930 2/4

Pre-stroke(mm)



5.1 ± 0.03 V1 = 1.2 ± 0.2 Confirmation


Note:




Injection order:

4. Injection timing



1 5 , 1 3 , 1 6 , 1 2 , 1 4


Shim 3





Connector 1

Stopper 2

1 5 , 1 3 , 1 6 , 1 2 , 1 460°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'

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.Tightening torque: 1.0 ~ 1.5 N•m {0.1 ~ 0.15 kgf•m}

2. Move the pre-stroke actuator clockwise (viewed from the drive side) to adjust it.


Stamping position

Pre-stroke actuatorInjection pump

107691-2930 3/4



P1 V = 2.25 ± 0.01 (V) 3.1 ± 0.05 (mm)

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

PRack

position(mm)

Vist(V)

Pumpspeed(r/min)




P1 (12.5) 1.98 800 140 ± 1 ± 3 Basic

P2 (6.6) 2.9 ± 0.1 395 16.5 ± 1.8 ± 15

Pump speed(r/min)

Below1050 1000 1075

Advanceangle (° )

Start0 0 - 0.5 Finish

-1.5±0.5










Pointer

Flywheel




B.T.D.C.: 2°

107691-2930 4/4

7. Drive side rack sensor adjustment (-0620)• Threaded type rack sensor (For REDIII governor)


(2) When the governor side rack sensor output is VG, adjust the depth that the bobbin 1 is screwed in so

that the drive side rack sensor output voltage is VR±0.01V. Then, fix using the nut 5.

5

4 3

Pump end face

Apply red paint21


Governor side rack sensor output VG 1.60V

Drive side rack sensor output voltage VR±0.01V

(3) Reset the governor side rack sensor output at VG and confirm that the drive side rack sensor output

voltage is VR±0.01V.

(4) Attach the caution plate to the top of the joint 2 and apply red paint to the joint 2 and nut 5 join and to

the pump end face and joint 2 join.

Note:

When adjusting the depth that the bobbin 1 is screwed into the joint 2, the fully tightened position of the

bobbin is 9 threads (ie, 9 turns) from where it first engages the threads.


2V407912-1742

105782-6320

3V

407910-3032

407910-6010

407910-7210

Pre-stroke(mm)



5.1 ± 0.03 V1 = 1.2 ± 0.2 Confirmation


Note:




Injection order:

2. Injection timing




Shim 3


Oil Temp. 40+5 °C


Service Department


Tel. (048)470-1559, Fax. (048)474-9856

Company:

Ass'y No.: 107691-3570ENGINE MODEL: J08C-UJ


1. Test conditions

Date:



kgf/cm2 }

CONFIDENTIAL


29 Nov 2002

22040-2341B

107069-0740






1


1/6






Connector 1

Stopper 2

1 4 , 1 2 , 1 6 , 1 3 , 1 560°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'

HINO


107691-3570 2/6

Note:






Injection pump

Stamping position

Pre-stroke actuator

Adjustingpoint

PRack

position(mm)

Pumpspeed(r/min)




- P1 12.7 750 114.5 ± 3 ± 3.5 Rack Basic




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)


107691-3570 3/6



0190

275350 700

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

10.0

9.7+0.2-0.3

R1(12.7)

R1+1.1

0Below 225

(500)

(1300)

A

B

Rac

k po

sitio

n (m

m)

Pump speed (r/min)


R1+2.05

Approx R1+0.25

(800)

(950)

(1200) (1470)

1510

400

5.1±0.6

8.0Approx 8.2


Idling adjustment

Stop lever normal position setting: (18.0)


12.3±0.1

R2[R1-1.0]

9.3±1.0

1575

6.7±0.1

R2[R1-1.0]

R2-1.15

0

36.0±1.3 {270±10}


N = 300

Rac

k po

sitio

n (m

m)



I

(1050)

R1-0.25

650 (700)


Pump speed(r/min)

Below 1200 1150 1290

Advanceangle (° )


-1.5±0.3


107691-3570 4/6

Adjustingpoint

PRack

position(mm)

Pumpspeed(r/min)




A P1 R1(12.7) 750 114.5 ± 2 - Lever Boost press. kPa {mmHg} Above 62.0 {Above 465}




P1 V = 2.25 ± 0.01 (V) 3.1 ± 0.05 (mm)

P2 - -

(38°) ±3°


Idling


Stop lever angle

N=0, R=1.5±0.1

Stop

Full-speed

Normal

8.5°±5°

35°±5°

15°±5°

R=(18.0)Stopper bolt setting

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.

Basic

107691-3570 5/6









Pointer

Flywheel



107691-3570 6/6









Note:




the joint).


Speed No 1250 r/min




6 1 2

5 4 3

Apply red paint

Pump end face


Pump end face

4 3


Ro

No Np

Rac

k po

sitio

n Output voltage

VR

Ro

Adjustment Np = No

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

Governor: EP/RED-IV105962-0220


Oil Temp. 40+5 °C


Service Department


Tel. (048)470-1559, Fax. (048)474-9856

Company:

Ass'y No.: 107691-3580ENGINE MODEL: JC8C-UK

No.

1. Test conditions

Date:



kgf/cm2 }

CONFIDENTIAL


7 May 2003

22040-2451B

107069-0750






2


1/4


HINO


3. Confirmation of RED-IV governor's output characteristics

[1] Rack sensor output characteristics(1) Measure the rack position R2 at PWM 72.5% and confirm that R2 = 15±1 mm.

(2) Measure the rack position R1 at PWM16.25% and confirm that R2 - R1 = 10±0.1 mm.

R1 R2

72.5%

16.25%

PWM (%)

Rack position (mm)

Switch box part no. 407980-4340

Control unit part no. 407915-0590

PWM72.5% rack position R2 = 15±1 (mm)

PWM16.25% rack characteristics R2 - R1 = 10±0.1 (mm)

R=1.0

Stop Normal

R=20.0


37° ±5°

18.5°±5°

107691-3580 2/4

Pre-stroke(mm)



5.1 ± 0.03 V1 = 1.2 ± 0.2 Confirmation


Note:




Injection order:

4. Injection timing


Plungers are numbered from the side.


Shim 3





Connector 1

Stopper 2

1 4 , 1 2 , 1 6 , 1 3 , 1 560°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'

[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.

[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.

PWM Rack position

5% 1 mm or less

95% 19 mm or above

Governor

107691-3580 3/4

Injection pump

Stamping position

Pre-stroke actuator



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)

PRack

position(mm)

PWM(%)

Pumpspeed(r/min)




P1 (11.8) 54.5 750 123.5 ± 2 ± 3.5 Basic

P2 (6.8) 26.3±2.8 440 -


Note:

1. Move the pre-stroke actuator fully clockwise (viewed from the drive side), and temporarily secure it to the actuator housing using the bolts.Tightening torque: 1.0 ~ 1.5 N•m {0.1 ~ 0.15 kgf•m}



Each cylinder 11 ± 1.1

Pump speed(r/min)

Below 1220 1170 1320-50POINTER stamping positionAdvance angle: 0°; Pump speed: 1170r/min

Advanceangle (° )

Start0 0- 0.3 Finish

-1.5±0.3

107691-3580 4/4








(Pre-stroke: 5.1±0.03 mm)


Pointer

Flywheel



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

B.T.D.C.: 3°


Pre-stroke(mm)



5.1 ± 0.03 V1 = 1.2 ± 0.2 Confirmation


Note:




Injection order:

2. Injection timing




Shim 3


Oil Temp. 40+5 °C


Service Department


Tel. (048)470-1559, Fax. (048)474-9856

Company:

Ass'y No.: 107691-3590ENGINE MODEL: J08C-UK


1. Test conditions

Date:



kgf/cm2 }

CONFIDENTIAL


29 Nov 2002

22040-2351B

107069-0760






2


1/6






Connector 1

Stopper 2

1 4 , 1 2 , 1 6 , 1 3 , 1 560°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'

HINO


107691-3590 2/6

Note:






Injection pump

Stamping position

Pre-stroke actuator

Adjustingpoint

PRack

position(mm)

Pumpspeed(r/min)




- P1 12.9 750 125 ± 3 ± 3.5 Rack Basic




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)


107691-3590 3/6



0190

275350 700

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

10.0

9.7+0.2-0.3

R1(12.9)

R1+0.4

0Below 225 (500) (1320)

A

B

Rac

k po

sitio

n (m

m)

Pump speed (r/min)


R1+2.45

Approx R1+0.4

750

(820)

(1200) (1475)

1520

400

5.1±0.6

8.0Approx 8.2


Idling adjustment



12.3±0.1R2[R1-1.15]

9.3±1.0

1585

6.7±0.1

R2[R1-1.15]

R2-0.95

0

38.0±1.3 {285±10}


N = 300

Rac

k po

sitio

n (m

m)



I

(910)


Pump speed(r/min)

Below 1180 1130 1260POINTER stamping positionAdvance angle: 0°; Pump speed: 1130r/min

Advanceangle (° )


-1.5±0.3


107691-3590 4/6

Adjustingpoint

PRack

position(mm)

Pumpspeed(r/min)





B P1 R1+2.45 1250 141.5 ± 6 - Lever Boost press. kPa {mmHg} Above 63.3 {Above 475}



P1 V = 2.25 ± 0.01 (V) 3.1 ± 0.05 (mm)

P2 - -

39°±3°


Idling


Stop lever angle

N=0, R=1.5±0.1

Stop

Full-speed

Normal

8.5° ±5°

35°±5°

15°±5°



Basic

107691-3590 5/6









Pointer

Flywheel



107691-3590 6/6









Note:




the joint).


Speed No 1250 r/min




6 1 2

5 4 3

Apply red paint

Pump end face


Pump end face

4 3


Ro

No Np

Rac

k po

sitio

n Output voltage

VR

Ro

Adjustment Np = No

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

Pre-stroke(mm)



5.1 ± 0.03 V1 = 1.2 ± 0.2 Confirmation


Note:




Injection order:

2. Injection timing




Shim 3


Oil Temp. 40+5 °C


Service Department


Tel. (048)470-1559, Fax. (048)474-9856

Company:

Ass'y No.: 107691-3630ENGINE MODEL: J08C-UK


1. Test conditions

Date:



kgf/cm2 }

CONFIDENTIAL


29 Nov 2002

22040-2371A

107069-0760






2


1/6






Connector 1

Stopper 2

1 4 , 1 2 , 1 6 , 1 3 , 1 560°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'

HINO


107691-3630 2/6

Note:






Injection pump

Stamping position

Pre-stroke actuator

Adjustingpoint

PRack

position(mm)

Pumpspeed(r/min)




- P1 12.9 750 125 ± 3 ± 3.5 Rack Basic




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)


107691-3630 3/6



0190

275350 700

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

10.0

9.7+0.2-0.3

R1(12.9)

R1+0.4

0Below 225 (500) (1320)

A

B

Rac

k po

sitio

n (m

m)

Pump speed (r/min)


R1+2.45

Approx R1+0.4

750

(820)

(1200) (1475)

1520

400

5.1±0.6

8.0Approx 8.2


Idling adjustment



12.3±0.1R2[R1-1.15]

9.3±1.0

1585

6.7±0.1

R2[R1-1.15]

R2-0.95

0

38.0±1.3 {285±10}


N = 300

Rac

k po

sitio

n (m

m)



I

(910)


Pump speed(r/min)

Below 1180 1130 1260

Advanceangle (° )


-1.5±0.3


107691-3630 4/6

Adjustingpoint

PRack

position(mm)

Pumpspeed(r/min)





B P1 R1+2.45 1250 141.5 ± 6 - Lever Boost press. kPa {mmHg} Above 63.3 {Above 475}



P1 V = 2.25 ± 0.01 (V) 3.1 ± 0.05 (mm)

P2 - -

39°±3°


Idling


Stop lever angle

N=0, R=1.5±0.1

Stop

Full-speed

Normal

8.5° ±5°

35°±5°

15°±5°



POINTER stamping positionAdvance angle: 0°; Pump speed: 1130r/min

Basic

107691-3630 5/6









Pointer

Flywheel



107691-3630 6/6









Note:




the joint).


Speed No 1250 r/min




6 1 2

5 4 3

Apply red paint

Pump end face


Pump end face

4 3


Ro

No Np

Rac

k po

sitio

n Output voltage

VR

Ro

Adjustment Np = No

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

Pre-stroke(mm)



5.1 ± 0.03 V1 = 1.2 ± 0.2 Confirmation


Note:




Injection order:

2. Injection timing




Shim 3


Oil Temp. 40+5 °C


Service Department


Tel. (048)470-1559, Fax. (048)474-9856

Company:

Ass'y No.: 107691-3690ENGINE MODEL: J08C-UL


1. Test conditions

Date:



kgf/cm2 }

CONFIDENTIAL


10 Feb 2003

22040-2320B

107069-0740






1


1/6






Connector 1

Stopper 2

1 4 , 1 2 , 1 6 , 1 3 , 1 560°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'

HINO


107691-3690 2/6

Note:






Injection pump

Stamping position

Pre-stroke actuator

Adjustingpoint

PRack

position(mm)

Pumpspeed(r/min)




- P1 11.9 750 102 ± 3 ± 3.5 Rack Basic




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)


107691-3690 3/6


0190

275350 700

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

10.0

9.7+0.2-0.3

R1(11.9)Approx R1+1.75

0Below 225 650 (1300)

A

B

Rac

k po

sitio

n (m

m)

Pump speed (r/min)


R1+2.05

(700)

(800)

(1200) (1460)

1485

400

5.1±0.6

8.0Approx 8.2


Idling adjustment



R1-0.1R2[R1-0.35]

9.1±1.0

1550

6.7±0.1

R2[R1-0.35]

R2-1.0

0

37.3±1.3 {280±10}


N = 300

Rac

k po

sitio

n (m

m)



11.9±0.1

(530)

I

H J



Pump speed(r/min)

Below 1150 1100 1250-50

Advanceangle (° )


-1.5±0.3


107691-3690 4/6

Adjustingpoint

PRack

position(mm)

Pumpspeed(r/min)








P1 V = 2.25 ± 0.01 (V) 3.1 ± 0.05 (mm)

P2 - -

35.5° ±3°


Idling

Stop lever angle

N=0, R=1.5±0.1

Stop

Full-speed

Normal

8.5°±5°

35°±5°

15°±5°



Basic


107691-3690 5/6









Pointer

Flywheel



107691-3690 6/6









Note:




the joint).


Speed No 1250 r/min




6 1 2

5 4 3

Apply red paint

Pump end face


Pump end face

4 3


Ro

No Np

Rac

k po

sitio

n Output voltage

VR

Ro

Adjustment Np = No

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



Oil Temp. 40+5 °C

Company:


No.

1. Test conditions

Date:



kgf/cm2 }

CONFIDENTIAL


17 Aug 2004

ME302925

107069-0590







0


1/4


MITSUBISHI


3. RED-III governor




specified below.

Rack type 19 mm



V2 = 2.2±0.01


R2 - R1 = 6±0.05


Out

put v

olta

ge (

V)

V1

V2

37°±5° R=20.0

Stop Normal

33.5° ±5°

R=1.0



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

107691-7020 2/4

Pre-stroke(mm)



5.1 ± 0.03 V1 = 1.2 ± 0.2 Confirmation


Note:




Injection order:

4. Injection timing




Shim 3





Connector 1

Stopper 2

1 5 , 1 3 , 1 6 , 1 2 , 1 460°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'

Note:


2. Move the pre-stroke actuator Counter clockwise (viewed from the drive side) to adjust it.


Stamping position


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)

PRack

position(mm)

Vist(V)

Pumpspeed(r/min)




P1 (12.5) 1.98 800 140 ± 1 ± 3 Basic

P2 (6.6) 2.9 ± 0.1 395 16.5 ± 1.8 ± 15

Pump speed(r/min)

Below1050 1000 1075

Advanceangle (° )


-1.5±0.5










Pointer

Flywheel




B.T.D.C.: 2°

107691-7020 4/4





5

4 3

Pump end face

Apply red paint21








Note:




2V407912-1742

105782-6320

3V

407910-3032

407910-6010

407910-7210



Oil Temp. 40+5 °C

Company:


No.

1. Test conditions

Date:



kgf/cm2 }

CONFIDENTIAL


19 May 2006

ME304583

107069-0590







0


1/4


MITSUBISHI


3. RED-III governor




specified below.

Rack type 19 mm



V2 = 2.2±0.01


R2 - R1 = 6±0.05


Out

put v

olta

ge (

V)

V1

V2

37°±5° R=20.0

Stop Normal

33.5° ±5°

R=1.0



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

107691-7040 2/4

Pre-stroke(mm)



5.1 ± 0.03 V1 = 1.2 ± 0.2 Confirmation


Note:




Injection order:

4. Injection timing




Shim 3





Connector 1

Stopper 2

1 5 , 1 3 , 1 6 , 1 2 , 1 460°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'

Note:


2. Move the pre-stroke actuator Counter clockwise (viewed from the drive side) to adjust it.


Stamping position


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)

PRack

position(mm)

Vist(V)

Pumpspeed(r/min)




P1 (12.5) 1.98 800 140 ± 1 ± 3 Basic

P2 (6.6) 2.9 ± 0.1 395 16.5 ± 1.8 ± 15

Pump speed(r/min)

Below1050 1000 1075

Advanceangle (° )


-1.5±0.5










Pointer

Flywheel




B.T.D.C.: 2°

107691-7040 4/4





5

4 3

Pump end face

Apply red paint21








Note:




2V407912-1742

105782-6320

3V

407910-3032

407910-6010

407910-7210

DIGI switch no.: 17 (for C/U 407980-224*)




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

Pre-stroke(mm)



5.6 ± 0.03 V1 = 1.2 ± 0.2 Confirmation


Note:




Injection order:

2. Injection timing

Pre-stroke: No. 1 plunger 5.6 ± 0.03 mm


1 5 , 1 3 , 1 6 , 1 2 , 1 460°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'


Shim 3

Company:

Assy No.: 107692-2086ENGINE MODEL: 6D16T5


1. Test conditions

Date:

Pump rotation: Countor clockwise (viewed from drive side)


kgf/cm2}

CONFIDENTIAL


10 Apr 2006

MITSUBISHI

ME075629

107069-0120



Nozzle: 105780-0120 Nozzle holder: 105780-2190(Bosch type no. 1 688 901 990) (Bosch type no. )

Nozzle & nozzle holder assy: 105780-8250 (Bosch type no. 1 688 901 101)


8


1/6






Connector 1

Stopper 2


107692-2086 2/6

Note:




2. Move the pre-stroke actuator counterclockwise (viewed from the drive side) to adjust it.


Injection pump

Stamping position

Pre-stroke actuator

Adjustingpoint

PRack

position(mm)

Pumpspeed(r/min)




- P1 13.4 700 122 ± 2 ± 3 Rack Basic Cylinder variation adjustment standard

Z P2 Approx7.7 510 10.5 ± 1.8 ± 15 Rack Cylinder variation adjustment standard



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)

107692-2086 3/6


If not indicated, the rack position allowance is ± 0.05 mm.Full load adjustment

Idling adjustment

Torque cam no. ‘AC34’

Boost compensator stroke: (1.4)±0.1

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

Rac

k po

sitio

n (m

m)

Pump speed (r/min)

R2[R1-1.3]

(R2-1.4)

0

8.0±1.3 {60±10}


N = 250

Rac

k po

sitio

n (m

m)



0

185275

290900

9.5

9.2+0.2-0.3

325

2.4±0.5

7.5

Approx 7.7

6.1±0.1

R1(13.4)

R1+1.3

0Below 225

(1310)

A

BR1+1.55

Approx R1-0.8

700(1270) (1450)

1530

R2[R1-1.3]

9.2±0.1

1590

I

(1030)(380)

D

C

12.0±1.0

(320)

400

H J


107692-2086 4/6

Adjustingpoint

PRack

position(mm)

Pumpspeed(r/min)




A P1 R1(13.4) 700 122 ± 1 - Lever Boost pressure kPa {mmHg} Above 36.0 {Above 270}

B P1 R1+1.55 1350 (113) ± 2 - Lever Boost pressure kPa {mmHg} Above 36.0 {Above 270}

C P1 (R2-1.4) 250 69 ± 2 - Lever Boost pressure 0

D P1 (R1-0.55) 550 (118.5) ± 2 - Lever Boost pressure kPa {mmHg} Above 36.0 {Above 270}



P1 V = 2.25 ± 0.01 (V) 3.6 ± 0.03 (mm)

P2 - -

Basic

39.5°±

3°


Idling


Stop lever angle

Stop

Full-speed

Normal

30°±5°

41°±5°

4°±5°

Set the stopper bolt at R=3.5±0.3,N=0 Confirm that injection does not occur.

107692-2086 5/6

8. Rack sensor adjustment (-0620)

Note: Do not operate the aneroid compensator if installed.

(1)Fix the speed control lever in the FULL position.

(2) Set the speed at N r/min and the rack position at R. (If equipped with a boost compensator, apply boost

pressure.)

(3)Adjust the bobbin 1 so that the rack sensor output voltage is VR±0.01.

(4)Apply red paint to the joint 2 and nut 3 join and to the joint 2 and pump end face join.

1

2 3

Constant voltage



Speed N 1350 r/min

Rack position R R1+1.55 mm


2V407912-1742

105782-6320

3V

407910-3032

407910-6010

407910-7210


107692-2086 6/6


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





At No. 1 plunger’s beginning of injection position(Pre-stroke: 5.6±0.03mm)

B.T.D.C.: 2°


Pointer

Flywheel




ZEXEL Ass'y No. 107692-2170Bosch Ass'y No.Bosch TypecodeEngine Type 6D16T5Manufacturer MITSUBISHIEdition date 10/04/06 (8)



...P Test Oil Temperature degC 40 40 45

Nozzle and nozzle holder 105780-8250Bosch type code 1 688 901 101Nozzle 105780-0120Bosch type code 1 688 901 990Nozzle holder 105780-2190

P Opening Pressure MPa 20.7P Opening Pressure kgf/cm2 211

Injection pipe mm 8-3-600Outer diameter - inner diameter - length (mm)

Overflow valve 131424-8420P Overflow valve opening pressure kPa 255 221 289P Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95P Tester oil delivery pressure kPa 255 255 255P Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6P PS/ACT control unit part no. 407980-224*P Digi switch no. 17

Direction of rotation (viewed from drive side) LLeft

2 Adjustment specification2.1 Injection timing adjustmentCAT Designation Unit Set value min. max. Actual values OT

P Direction of rotation (viewed from drive side) LLeft

P Injection order 1-5-3-6-2-4S Pre-stroke mm 5.6 5.57 5.63P Beginning of injection position NO.1

Governor sideS Difference between angles 1 deg. 60 59.75 60.25




Cyl.1-2S Difference between angles 5 deg. 300 299.75 300.25

Cal 1-42.2 Injection quantity adjustmentCAT Designation Unit Set value min. max. Actual values OT

P Adjusting point -P Rack position 13.4P Pump speed r/min 700 700 700S Average injection quantity mm3/st. 122 120 124S Max variation between cylinders % 0 -3 3P Basic *P Fixing the rack *P PS407980-224* V 2.25+-0.01P PS407980-224* mm 3.6+-0.05P Standard for adjustment of the maximum var

iation between cylinders*



CAT Designation Unit Set value min. max. Actual values OTP Adjusting point ZP Rack position 7.7+-0.5P Pump speed r/min 510 510 510S Average injection quantity mm3/st. 10.5 8.7 12.3S Max variation between cylinders % 0 -15 15P Fixing the rack *P PS407980-224* V V1+0.05+-0.01P PS407980-224* mm 5.5+-0.03P Standard for adjustment of the maximum var

iation between cylinders*

RemarksRefer to items regarding the pre-stroke actuator

CAT Designation Unit Set value min. max. Actual values OTP Adjusting point AP Rack position R1(13.4)P Pump speed r/min 700 700 700S Average injection quantity mm3/st. 122 121 123P Basic *P Fixing the lever *P Boost pressure kPa 36 36P Boost pressure mmHg 270 270P PS407980-224* V 2.25+-0.01P PS407980-224* mm 3.6+-0.05

CAT Designation Unit Set value min. max. Actual values OTP Adjusting point BP Rack position R1+1.55P Pump speed r/min 1350 1350 1350S Average injection quantity mm3/st. 113 109 117P Fixing the lever *P Boost pressure kPa 36 36P Boost pressure mmHg 270 270P PS407980-224* V 2.25+-0.01P PS407980-224* mm 3.6+-0.05

CAT Designation Unit Set value min. max. Actual values OTP Adjusting point CP Rack position (R2-1.4)P Pump speed r/min 250 250 250S Average injection quantity mm3/st. 69 67 71P Fixing the lever *P Boost pressure kPa 0 0 0P Boost pressure mmHg 0 0 0P PS407980-224* V 2.25+-0.01P PS407980-224* mm 3.6+-0.05

CAT Designation Unit Set value min. max. Actual values OTP Adjusting point DP Rack position (R1-0.55)P Pump speed r/min 550 550 550S Average injection quantity mm3/st. 118.5 114.5 122.5P Fixing the lever *P Boost pressure kPa 36 36P Boost pressure mmHg 270 270P PS407980-224* V 2.25+-0.01P PS407980-224* mm 3.6+-0.05



2.3 Governor adjustmentName

T1=AC34BCL=(1.4)+-0.1mm

N:Pump speedR:Rack position (mm)(1)Torque cam stamping: T1(2)Tolerance for racks not indicated: +-0.05mm.(3)Boost compensator stroke: BCL

2.4 Boost compensator adjustmentCAT Designation Unit Set value min. max. Actual values OT

P Pump speed r/min 250 250 250P Rack position (R2-1.4)S Boost pressure kPa 8 6.7 9.3S Boost pressure mmHg 60 50 70

CAT Designation Unit Set value min. max. Actual values OTP Pump speed r/min 250 250 250P Rack position R2(R1-1.3)S Boost pressure kPa 22.7 22.7 22.7

AboutS Boost pressure mmHg 170 170 170

About



2.5 Speed control lever angleName


aa=38mm F:Full speedI:Idle(1)Use the hole at R = aa(2)Stopper bolt set position 'H'

2.6 Stop lever angleName

a=4deg+-5degb=(31deg)c=41deg+-5deg

aa=47mmbb=17.4mmcc=3.5+-0.3mmdd=0r/min

N:Pump normalS:Stop the pump.(1)Use the hole at R = aa(2)Normal engine position (equivalent to R = bb).(3)Set the stopper bolt at rack position = cc and speed = dd and confirm non-injection



2.7 Timing settingName

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

aa=2degbb=5.6+-0.03mm

(1)Pump vertical direction(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 to 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 sequence1. 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 flywheel are matching.4. If they are not matching, erase the alignment mark on the flywheel side, and stamp an alignment 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 injection position.

2.9 Pre-stroke actuator adjustment2.9.1 Adjustment valueCAT Designation Unit Set value min. max. Actual values OT

P CU407980-224* *P Actuator retarding type *P Supply voltage V 24 23.5 24.5P Ambient temperature degC 23 18 28



P Pre-stroke mm 2.5 2.45 2.55S Output voltage V 2.83 2.82 2.84P Adjustment *

CAT Designation Unit Set value min. max. Actual values OTP CU407980-224* *P Supply voltage V 24 23.5 24.5P Ambient temperature degC 23 18 28P Pre-stroke mm 5.6 5.57 5.63S Output voltage V 1.2 1 1.4P Confirmation *

RemarksOutput voltage V1

CAT Designation Unit Set value min. max. Actual values OTP CU407980-224* *P Supply voltage V 24 23.5 24.5P Ambient temperature degC 23 18 28S Output voltage V 3.05 3.05P Confirmation of operating range *

2.9.2 Actuator type (MD-TICS)Name

A : Stopper pinB: Connector

2.9.3 Shim position indication (MD-TICS)Name

C:Shim



2.9.4 Adjusting method and stamping positionName

A:Sealing positionB:Pre-stroke actuator1. 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 adjust 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 and housing side.




2.10.1 Additional device 1Name RACK SENSOR

N1=1350r/minRa=R1(13.4)+1.55mm

(VR) measurement voltage(I) Part number of the control unit(G) Apply red paint.(H): End surface of the pump1. Rack sensor adjustment (-0620)(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)



2.10.2 Additional device 2Name SPEED SENSOR

L=0.8~1mm (A) Flyweight projection(B) Pickup sensor(c) Lock nutSpeed sensor installation(1)Install the speed sensor so that the clearance between the sensor and the flyweight projectionis L.(This gap is the gap when the pickup sensor is returned 1 turn from where it contacts the flyweight tooth.)



Service Department


Tel. (048)470-1559, Fax. (048)474-9856

Company:

Ass'y No.: 108622-0106ENGINE MODEL: PF6TC

No. Governor: EP/RED-III pre-stroke actuator:

1. Test conditions

Date:


Injection pump: TC6HD105952-1140 159600-0420

kgf/cm2 }

CONFIDENTIAL


3 Jul 2002

NISSAN DIESEL

16801 96618

108062-3182







5


1/3

DIGI Switch No. 31(For C/U 407980-224*)


R=20.0

Stop Normal

R=1.0 37°±5°

20°±5°

3. RED-III governor




specified below.

Rack type 19 mm



V2 = 2.2±0.01


R2 - R1 = 6±0.05


Out

put v

olta

ge (

V)

V1

V2

108622-0106 2/3

Injection order:

4. Injection timing

Pre-stroke: No.1 Plunger 6.4 ± 0.03mm V

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

Note: Perform at voltage

1 4 , 1 2 , 1 6 , 1 3 , 1 560°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'


• Pre-stroke: h1 = 6.4±0.03 mm (when the timing sleeve is pushed up using the jig)

• Connector angle when tightening the eccentric pin: 8°30'±30'

• Power supply voltage: 24±0.5 V

• Ambient temperature: 23±5° C

• Adjustment and confirmation

Adjustment Confirmation Confirmation Confirmation

Pre-stroke (mm) 4.0±0.05 h1 = 6.4±0.03 Below 3.4 Operation

Sensor output (V) 2.45±0.01 V1 = 1.2±0.2 3 - 0.02 Above 3.05

Pre-stroke actuator

Stamp aligning mark on housing


108622-0106 3/3



7. Timing setting

At adjustment pre-stroke6.3±0.03(mm) (V=[V1+0.05]±0.01(V))

Rackposition

(mm)

Vist(mm)

Pumpspeed(r/min)




(16.1) 1.43 600 192 ± 2 ± 4 Basic

(8.6) Approx.2.6 300 13.3 ± 1 ± 10


At adjustment pre-stroke4.0±0.05(mm) (V=2.45±0.01(V))


Service Department


Tel. (048)470-1559, Fax. (048)474-9856

Company:



1. Test conditions

Date:



kgf/cm2 }

CONFIDENTIAL


3 Jul 2002

MITSUBISHI

ME121502

108062-3192







1


1/3



3. RED-III governor




specified below.

Rack type 15 mm



V2 = 1.8±0.01


R2 - R1 = 6±0.05


Out

put v

olta

ge (

V)

V1

V2

R=16.0

Stop Normal

R=1.029°±5°

19°±5°

108622-2080 2/3

Injection order:

4. Injection timing


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











Pre-stroke actuator


1 5 , 1 3 , 1 6 , 1 2 , 1 460°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'


108622-2080 3/3


Rackposition

(mm)

Vist(mm)

Pumpspeed(r/min)




(12.3) 1.53 650 155.5 ± 1 ± 2 Basic

(7.1) Approx.2.6 370 20 ± 2 ± 15


At adjustment pre-stroke 3.2±0.05(mm) (V=2.45±0.01(V))

Approx. 44°

Damper

Pointer

3° ±3° Stamp an aligning mark on the damper to align with the pointer groove.



8. Timing setting

7. Drive side rack sensor adjustment (RED-III governor)

(1) With the injection pump stopped, set the REDIII governor’s Vist to the value shown in the table below.

(2) Adjust the bobbin 1 so that the drive side rack sensor's output voltage is VR±0.01, then fix using the

nut 3.

(3) Apply red paint to the joint 2 - nut 3 join and to the joint 2 - pump end face join.

Rack sensor supply voltage 5±0.01V

Speed N 0r/min

REDIII governor Vist 1.00V



2V407912-1742

105782-6320

3V

407910-3032

407910-6010

407910-7210

1 23

Apply red paint

Pump end face


Service Department


Tel. (048)470-1559, Fax. (048)474-9856

Company:



1. Test conditions

Date:



kgf/cm2 }

CONFIDENTIAL


3 Jul 2002

MITSUBISHI

ME121502

108062-3192







1


1/3



3. RED-III governor




specified below.

Rack type 15 mm



V2 = 1.8±0.01


R2 - R1 = 6±0.05


Out

put v

olta

ge (

V)

V1

V2

R=16.0

Stop Normal

R=1.029°±5°

19°±5°

108622-2081 2/3

Injection order:

4. Injection timing


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











Pre-stroke actuator


1 5 , 1 3 , 1 6 , 1 2 , 1 460°± 15' 120°± 15' 180°± 15' 240°± 15' 300°± 15'


108622-2081 3/3


Rackposition

(mm)

Vist(mm)

Pumpspeed(r/min)




(12.3) 1.53 650 155.5 ± 1 ± 2 Basic

(7.1) Approx.2.6 370 20 ± 2 ± 15


At adjustment pre-stroke 3.2±0.05(mm) (V=2.45±0.01(V))

Approx. 44°

Damper

Pointer

3° ±3° Stamp an aligning mark on the damper to align with the pointer groove.



8. Timing setting

7. Drive side rack sensor adjustment (RED-III governor)

(1) With the injection pump stopped, set the REDIII governor’s Vist to the value shown in the table below.

(2) Adjust the bobbin 1 so that the drive side rack sensor's output voltage is VR±0.01, then fix using the

nut 3.

(3) Apply red paint to the joint 2 - nut 3 join and to the joint 2 - pump end face join.

Rack sensor supply voltage 5±0.01V

Speed N 0r/min

REDIII governor Vist 1.00V



2V407912-1742

105782-6320

3V

407910-3032

407910-6010

407910-7210

1 23

Apply red paint

Pump end face

Robert BoschGmbH

Stuttgart /

.............:.............:

................:

..............:......:

1Kundendienstvorschrift

Alle Rechte bei ROBERT BOSCH GmbH, auch für den Fall von Schutzrechtsanmeldungen.Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

StatusTest Specification

mecanically-governedDistributor pumps

PV-No.Change

PageDate of print

2

....................................: mm 0,75

1 688 901 027 ...................:...........................................:

...............................................:........................................:

6,00ISONORM 35,00

2,00 450 mmx x

± 5,00 kPa.......................................: 0,50

25,0 0,3±±.........................:

°CMPa

55

overflow quantity at pump (l/h)

supply pump pressure (MPa)

timing device travel (mm) N

full-load start-quantity (mm³/H)

full-load (mm³/H)

speed regulation breakaway (mm³/H)

idle (mm³/H)

electric shut-off (mm³/H)

LFB-quantity (mm³/H)

LFB timing device travel (mm) N

control lever spacing, -angle

USMUUSMO

PKUPSUPSEP

SVKUSVEPSVO

STAMSTO

VUVEPVO

AB1

LEPLK

SPE1SPE2

DQ2Q4Q3

DS2DS3S4

YaYb

4001100

100400900

100900

1100

100250

400800

1100

1280

430500

430430

110011001100

110011001100

00

1200

1200

00

000

0

00

00

000

000

±±

±±±

±±

±±

±±±

±

±±

±±

±±±

±±±

±±

mmmm

8,0 10,0

0,09 0,07 0,07

0,8 0,6 0,6

15,0 10,0

4,0 3,0 3,0

1,5

6,0 1,5

1,5 1,5

6,0 0,5 0,5

0,1 0,5 0,6

2,0 3,0

3,5

6,0

5,0

n

1/min

KSB

V

TV

%

1212

121212

121212

1212

121212

12

1212

00

121212

121212

ELAB

V

a i

22,0 47,0

0,40 0,55 0,70

3,8 1,2 2,6

95,0 118,0

115,5 108,5 92,0

1,5

10,0 1,5

1,5 1,5

-14,0 27,5 47,5

-0,6 -0,7 3,4

38,9 43,0

0 460 426 357 ..............................:pump VE 6 / 12 F 1100 L 936

85NEF

Traktoren..............: 5,9

kWl

:

..............:...............:A460907012

Iveco-Fiat504047351

............................:

..............................:.............................:

Customer Drawing

CustomerCustomer Order no.

EnginePowerpist. swept vol.Application

test conditions

Remarks:

4vorläufig

22.07.20041 469 426 357

01.03.2005 08:44

calibr. nozzle-and-holder assemblytest fuel-injection tubingcalibrating oil

overflow restriction

calibration-oil inlet pressurecalibration oil Overflow temperatureopening pressure

Testpoint

Index Sollwert/Tolerance

distribution DA-Sollwert/Tolerance

LDA-Pressure

hPa

Robert BoschGmbH

Stuttgart /

.............:.............:

................:

..............:......:

2Kundendienstvorschrift

Alle Rechte bei ROBERT BOSCH GmbH, auch für den Fall von Schutzrechtsanmeldungen.Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns.

StatusTest Specification

mecanically-governedDistributor pumps

PV-No.Change

PageDate of print

2

Nr.Kundenwuensch-Leerlauf und AbregeldrehzahlAenderungNeue Serienreferenzpumpe Nr. 424 890Anpassung nach der FeW Statistik vom 07.11.02Einstellversuch - PSEP auf 7,0 barErstausgabe nach Ref.pp. LV 15330 - Nr. 191 509

22.07.04

23.10.0311.11.0216.10.0221.08.02

FeW/FAV2/P

MICO/DVEMICO/DVEMICO/DVEMICO/DVE

FeW/FAV2/P-Bk

MICO/DVE-AkMICO/DVE-AkMICO/DVE-AkMICO/DVE-Ak

4

3210

Changes:

Pumpe mit Kolben-KSB und Badewanne LFB, Pumpe mit EDC Ueberstroemventil.SVKU Messreihenfolge : von obere Drehzahl auf "null" fahren, 15 secunden warten, KKSB ELAB spannenund SVKU Weg messen. DS bei Teillastmenge Q3 messen.

4vorläufig

22.07.20041 469 426 357

01.03.2005 08:44

Change Date Dept. Name

K = 3,7 +- 0,06 mm MS1 = 0,81 +- 0,1 mm Ausl. A = 1,10 +- 0,02 mm

zexel calibration data

Documents

test conditionsdate

pump assy

ef85119a test oil

sae standard test oil

pump rotation

bolt adjustment type

test data16059490use1605

shim adjustment type