mitics
DESCRIPTION
zexel lista de bombas inyectorasTRANSCRIPT
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1024ENGINE MODEL: 4HE1-TC
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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97210-054-0
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'
10
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*)
107492-1024 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
107492-1024 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)
107492-1024 4/11
Rac
k po
sitio
n (
mm
)
Idling adjustment
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
Boost compensator stroke: 1.35 ±0.1
Torque cam No. “ AF60”
Pump speed (r/min)
Confirm rack sensor Vist = 2.65±0.28
at supply voltage 5±0.01V , N =1000 r/min , R = R1 (15.1).
4. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+0.9
Approx.R1+0.3R1(15.1)
R2 [R1-2.15]
10.6± 1.0
0250-40 (650) 1000 (1150)
(1600)
1690
1810
14.0± 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
107492-1024 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]
R2-1.35
Approx. 31.3 {Approx. 235}
12.0± 1.3 {90± 10}
PushrodC
0
107492-1024 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 44.7 kPa {at least 335 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.96 b1 + tolerance
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
- 15.1 1,000 112 ± 1.6 ±4 Rack a1~a2(v)
Z 8.9±0.5 510 22 ± 1.5 ± 14 Rack c(v)
A R1(15.1) 1,000 112 ± 1 - Lever a1~a2(v)
B R1+0.9 1,200 (115) ± 2 - Lever b1~b2(v)
IApprox.
R1+0.3150 (200) - Lever c(v)
D* 15.3±0.1 1,200 (106) - Lever b1~b2(v)
107492-1024 7/11
5. Injection quantity
Cylinder variation
adjustment standardBasic
BasicBoost press. kPa{mmHg}Above 44.7{Above 335}
Cylinder variation
adjustment standard
Boost press. 0
Boost press. kPa{mmHg}Above 44.7 {Above 335 }Negative press. kPa{mmHg} 53.3 kPa{ 400 mmHg}
D*: Aneroid compensator actuator adjustment point
Boost press. kPa{mmHg}Above 44.7{Above 335}
107492-1024 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
107492-1024 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 44.7 kPa { 335 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
107492-1024 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 44.7 kPa
{at least 335 mmHg} boost pressure and confirm rack position is R1 = 15.1 mm and
fuel injection quantity is 112± 1 mm3/st at N = 1,000 r/min.
(2) Remove rack position measuring device.
(3) Attach rack sensor core to control rack.
At this time, hold control rack using a spanner (to prevent the rack from bending).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 44.7 kPa {at least 335 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 = 2.65±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
107492-1024 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
25°21′24″±
20′
13°±3°
(35°)
(96°)
(5°57′34″)
11. Drive Coupling Timing
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1025ENGINE MODEL: 4HE1-TC
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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97210-054-1
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'
10
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*)
107492-1025 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
107492-1025 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)
107492-1025 4/11
Rac
k po
sitio
n (
mm
)
Idling adjustment
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
Boost compensator stroke: 1.35 ±0.1
Torque cam No. “ AF60”
Pump speed (r/min)
Confirm rack sensor Vist = 2.65±0.28
at supply voltage 5±0.01V , N =1000 r/min , R = R1 (15.1).
4. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+0.9
Approx.R1+0.3R1(15.1)
R2 [R1-2.15]
10.6± 1.0
0250-40 (650) 1000 (1150)
(1600)
1690
1810
14.0± 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
107492-1025 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]
R2-1.35
Approx. 31.3 {Approx. 235}
12.0± 1.3 {90± 10}
PushrodC
0
107492-1025 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 44.7 kPa {at least 335 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.96 b1 + tolerance
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
- 15.1 1,000 112 ± 1.6 ±4 Rack a1~a2(v)
Z 8.9±0.5 510 22 ± 1.5 ± 14 Rack c(v)
A R1(15.1) 1,000 112 ± 1 - Lever a1~a2(v)
B R1+0.9 1,200 (115) ± 2 - Lever b1~b2(v)
IApprox.
R1+0.3150 (200) - Lever c(v)
D* 15.3±0.1 1,200 (106) - Lever b1~b2(v)
107492-1025 7/11
5. Injection quantity
Cylinder variation
adjustment standardBasic
BasicBoost press. kPa{mmHg}Above 44.7{Above 335}
Cylinder variation
adjustment standard
Boost press. 0
Boost press. kPa{mmHg}Above 44.7 {Above 335 }Negative press. kPa{mmHg} 53.3 kPa{ 400 mmHg}
D*: Aneroid compensator actuator adjustment point
Boost press. kPa{mmHg}Above 44.7{Above 335}
107492-1025 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
107492-1025 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 44.7 kPa { 335 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
107492-1025 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 44.7 kPa
{at least 335 mmHg} boost pressure and confirm rack position is R1 = 15.1 mm and
fuel injection quantity is 112± 1 mm3/st at N = 1,000 r/min.
(2) Remove rack position measuring device.
(3) Attach rack sensor core to control rack.
At this time, hold control rack using a spanner (to prevent the rack from bending).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 44.7 kPa {at least 335 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 = 2.65±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
107492-1025 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
25°21′24″±
20′
13°±3°
(35°)
(96°)
(5°57′34″)
11. Drive Coupling Timing
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1026ENGINE MODEL: 4HE1-TC
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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97210-054-1
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'
11
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*)
107492-1026 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
107492-1026 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)
107492-1026 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. Governor adjustment
4-1. Governor adjustment
Full load 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
107492-1026 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
107492-1026 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.96 b1 + tolerance
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)
107492-1026 7/11
5. Injection quantity
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}
107492-1026 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
107492-1026 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
107492-1026 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.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1026 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
25°21′24″±
20′
13°±3°
(35°)
(96°)
(5°57′34″)
11. Drive Coupling Timing
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1027ENGINE MODEL: 4HE1-TC
No.
Governor: 105934-0091
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2062 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97210-054-1
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'
11
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*)
107492-1027 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
107492-1027 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)
107492-1027 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. Governor adjustment
4-1. Governor adjustment
Full load 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
107492-1027 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
107492-1027 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.96 b1 + tolerance
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)
107492-1027 7/11
5. Injection quantity
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}
107492-1027 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
107492-1027 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
107492-1027 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.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1027 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
25°21′24″±
20′
13°±3°
(35°)
(96°)
(5°57′34″)
11. Drive Coupling Timing
105934-0091Governor: EP/RLD-MInjection pump: TCS4MD
107049-2063
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
Selector switch no.: 00 (for C/U 407910-303*)
Oil temperature: 40+5 °C
Company:
Assy No.: 107492-1028ENGINE MODEL: 4HE1-TC
No.
1. Test conditions
Date:
Pump rotation: counter clockwise (viewed from drive side)
kgf/cm2}
CONFIDENTIAL
INJECTION PUMP CALIBRATION DATA
20 Feb 2004
ISUZU
8-97210-054-1
Injection pipe: outer dia. 8 mm × inner dia. 3 mm length 600 mm
Nozzle opening pressure: 20.7 MPa {211 kgf/cm2}
Nozzle: 105780-0120 Nozzle holder: 105780-2190(Bosch type no. 1 688 901 990) (Bosch type no. 9 430 610 144)
Nozzle & nozzle holder assy: 105780-8250 (Bosch type no. 1 688 901 101)
Test oil: ISO4113 or SAE standard test oil {SAE J967d}
12
Transfer pump pressure: 255 kPa {2.6
2. Injection timing
Overflow valve opening pressure: 255 ± 34 kPa {2.6 ± 0.35 kgf/cm2}
1/11
Ambient temperature: 23±5 °C
DIGI switch no.: 11 (for C/U 407980-224*)
Pre-stroke: No. 1 plunger 4.0 ± 0.03 mm
Injection order: 1 3 , 1 4 , 1 290°± 15' 180°± 15' 270°± 15'
Plungers are numbered from Governor side.
Tappet clearance: Manually rotate camshaft 2 ~ 3 times and confirm that it rotates smoothly.
2/11107492-1028
3. Injection timing adjustment
(Refer to 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 counterweight 2 contacts 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 shim 1.
3-3 Individual cylinder's injection order adjustment
Adjust difference between each cylinder's injection angle based on that of No. 1 cylinder using
shim 1.
1
563
4
1
2
1. Setscrew installation 2. Pre-stroke adjustment3. Individual cylinder's injection
order adjustment
3/11107492-1028
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 No. 1 cylinder's output voltage for pre-stroke
lift values in table below.
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)
Advice
If measuring device (P/N 105782-6420) is removed, output voltage (a1, a2) must 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 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 lock-
nut to specified torque.
(3) Confirm solenoid switch operates at 14.5 - 0.1 V.
4/11107492-1028
4. Governor adjustment
4-1 Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw. Fully tighten adjusting nut.
Rac
k po
sitio
n (
mm
)
Pump speed (r/min)
Idling adjustment
10.0±0.110.5
Approx 8.97.8
6.6±0.1
3.9±0.3
0240
H J
400400
500475 880
Confirm rack sensor Vist = 2.55±0.28at supply voltage 5±0.01V, N = 1000 r/min, R = R1 (15.0).
Boost compensator stroke: 1.25±0.1
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
R1+0.9
Approx R1+0.3R1(15.0)
R2 [R1-2.15]
10.7±1.0
0250-40 (650) 1000 (1150) (1600)
16901810
13.9±0.1
Torque cam no. “AF60”
B
A
DI
5/11107492-1028
4-2 Boost compensator adjustment
(1) Select a push rod so C = 37.5±0.5 mm at full boost pressure. (C is distance from end face of
housing to top of lever.)
(2) Adjust boost compensator stroke using screw A (0 boost pressure position adjustment).
Adjust beginning of boost compensator operation by adjusting notch adjusting nut B.
CTop of lever Pushrod
Boost pressure inlet
A: Boost compensator stroke adjusting screw
Boost compensator spring
B: Notch adjusting nut
0
12.0±1.3 {90±10}
N = 500 r/min
R2 [R1-2.15]
Approx 28.7 {Approx 215}
Rac
k po
sitio
n (m
m)
Boost pressure kPa {mmHg}
R2-1.25
6/11107492-1028
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 timing cam adjusting point (point a in table below: Np = 900 r/min).
(4) Perform timing cam adjustment so output voltage is within range of a1 ~ a2 actually measured
for pre-stroke output voltage during injection timing adjustment in 3-4.
Adjusting point Pre-stroke (mm) Output voltage (actual) Remarks
a3.36 a1 + tolerance
3.10 a2 - tolerance
(5) Operate pump at timing cam confirmation point (point b in table below: Np = 1200 r/min).
(6) Confirm that pre-stroke output voltage is within range b1 ~ b2.
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.96 b1 + tolerance
2.76 b2 - tolerance
Pump speed (r/min)
900(500) 12000
3.7±0.03 (c)
4.0±0.03
3.36 (a1)
3.10 (a2)
2.96 (b1)
2.76 (b2)
2.0+0.03-0.10
Pre-stroke at stopper contact
Minimum advance angle adjustment stopper
Solenoid starting advance angle
b (confirmation point)
a (adjusting point)
Pre-stroke (Pre-stroke output voltage)
7/11107492-1028
5. Injection quantity
Adjustingpoint
Rackposition
(mm)
Pumpspeed(r/min)
Injection quantity(cm3 / 1000 strokes)
Max. variationbetween
cylinders (%)Fixed
Pre-strokeat
adjustmentRemarks
- 15.0 1000 109.5 ± 1.6 ±4 Rack a1 ~ a2(v) Basic Cylinder variation adjustment standard
Z 8.9±0.5 510 22 ± 1.5 ±14 Rack c(v) Cylinder variation adjustment standard
A R1(15.0) 1000 109.5 ± 1 - Lever a1 ~ a2(v) Basic Boost press. kPa {mmHg}Above 42.0 {Above 315}
B R1+0.9 1200 112.5 ± 4 - Lever b1 ~ b2(v) Boost press. kPa {mmHg}Above 42.0 {Above 315}
I [R1+0.3]±0.5 150 (180) - Lever c(v) Boost press. 0
D* 15.3±0.1 1200 (106) - Lever b1 ~ b2(v)
Boost press. kPa {mmHg}Above 42.0 {Above 315}Negative press. kPa {mmHg} 53.3 kPa {400 mmHg}
D*: Aneroid compensator actuator adjustment point
8/11107492-1028
6. FICD adjustment
(1) Stop 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 actuator 1 and set pump speed at 450 r/min.
(6) Gradually loosen set bolt 2 then fix bolt using nut when rack position is 8.7±0.1 mm.
(7) Apply above negative pressure several times and confirm FICD actuator is operating properly
and clearance between FICD actuator lever and speed control lever.
1+1mm
Speed control lever
FICD actuator lever
Tightening torque5 ~ 7 N.m {0.5 ~ 0.7 kgf.m}
1 2 3
9/11107492-1028
7. Aneroid compensator actuator adjustment (injection quantity decrease)
Note:
Set actuator after adjusting full rack position.
(1) Stop injection pump.
(2) Adjust wire nuts 1 so full load set lever contacts full load set bolt and aneroid compensator
actuator wire is not loose. Then, fix nuts 1.
(3) Apply 53.3 kPa {400 mmHg} negative pressure to aneroid compensator and set pump speed at
1200 r/min.
(4) Apply at least 42.0 kPa {315 mmHg} boost pressure to boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt 2 so control rack position
is 15.3±0.1 mm and fuel injection quantity is as specified. Then, fix set bolt 2.
Rac
k po
sitio
n (m
m)
Pump speed (r/min)
Stroke
D
Injection quantity decreaseadjustment point
Full load set bolt
Full load set lever
1
2
10/11107492-1028
8. Speed control lever angle 9. Stop lever angle
Stopper bolt H position
Hole (R42)
IdlingFull-speed
29.5°±3°30°±5°Hole (R41.3)
Normal Stop
45°±5°
22.5°±5°
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 = 1000 r/min.
(2) Remove rack position measuring device.
(3) Attach rack sensor core to control rack.
At this time, hold control rack using spanner (to prevent rack from bending).
Specified torque : 3.4 ~ 4.9 N.m {0.35 ~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9 ~ 8.8 N.m {0.7 ~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set to DC 5±0.01V.
(8) Apply at least 42.0 kPa {at least 315 mmHg} boost pressure, set pump speed at N = 1000 r/min,
and hold speed control lever against full speed stopper bolt.
(9) Confirm rack sensor output voltage from digital voltmeter (Vist = 2.55±0.28).
(10) Confirm that voltage changes when speed control lever is moved to idle and full sides.
Rac
k po
sitio
n (m
m)
Pump speed (r/min)
AR1
N
Rack position (mm)
Sen
sor
outp
ut v
olta
ge (
V)
R1
Vist
Set positionR = 1.5±0.2
11/11107492-1028
11. Drive coupling timing
L L
tt
Bracket mark Pump
Engine
Gear hole (Dia. 3 mm)
Gear's threaded hole
Gear side
Pump side
Check hole
Stamp on coupling and bracket(B.T.D.C. 8°)
Mark position of coupling at B.T.D.C. 13°
Timing setting (At pre-stroke 3.7±0.05 mm)
At No. 1 plunger's beginningof injection positionB.T.D.C.: 8°
13°07'30''±3°
(35°)
25°21'24''±20'(96°)
(5°5
7'34
'')
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1033ENGINE MODEL: 4HE1-TC N
No.
Governor: 105934-0080
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2071 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97210-057-0
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*)
107492-1033 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
107492-1033 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
a3.43 a1 + tolerance
3.17 a2 -tolerance
b2.85 b1 + tolerance
2.65 b2 -tolerance
(calculate from each specification)
107492-1033 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. Governor adjustment
4-1. Governor adjustment
Full load 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)
107492-1033 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
107492-1033 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
a3.43 a1 + tolerance
3.17 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.85 b1 + tolerance
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)
107492-1033 7/11
5. Injection quantity
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}
107492-1033 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
107492-1033 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
107492-1033 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).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1033 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
25°21′24″±
20′
13°±3°
(35°)
(96°)
(5°57′34″)
11. Drive Coupling Timing
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1034ENGINE MODEL: 4HE1-TC N
No.
Governor: 105934-0080
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2071 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97210-057-0
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*)
107492-1034 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
107492-1034 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
a3.43 a1 + tolerance
3.17 a2 -tolerance
b2.85 b1 + tolerance
2.65 b2 -tolerance
(calculate from each specification)
107492-1034 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. Governor adjustment
4-1. Governor adjustment
Full load 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)
107492-1034 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
107492-1034 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
a3.43 a1 + tolerance
3.17 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.85 b1 + tolerance
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)
107492-1034 7/11
5. Injection quantity
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}
107492-1034 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
107492-1034 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
107492-1034 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).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1034 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
25°21′24″±
20′
13°±3°
(35°)
(96°)
(5°57′34″)
11. Drive Coupling Timing
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1035ENGINE MODEL: 4HE1-TC N
No.
Governor: 105934-0081
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2072 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97210-057-1
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'
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*)
107492-1035 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
107492-1035 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
a3.43 a1 + tolerance
3.17 a2 -tolerance
b2.85 b1 + tolerance
2.65 b2 -tolerance
(calculate from each specification)
107492-1035 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. Governor adjustment
4-1. Governor adjustment
Full load 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)
107492-1035 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
107492-1035 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
a3.43 a1 + tolerance
3.17 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.85 b1 + tolerance
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)
107492-1035 7/11
5. Injection quantity
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}
107492-1035 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
107492-1035 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
107492-1035 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).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1035 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
25°21′24″±
20′
13°±3°
(35°)
(96°)
(5°57′34″)
11. Drive Coupling Timing
105934-0081Governor: EP/RLD-MInjection pump: TCS4MD
107049-2073
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
Selector switch no.: 00 (for C/U 407910-303*)
Oil temperature: 40+5 °C
Company:
Assy No.: 107492-1036ENGINE MODEL: 4HE1-TCN
No.
1. Test conditions
Date:
Pump rotation: counter clockwise (viewed from drive side)
kgf/cm2}
CONFIDENTIAL
INJECTION PUMP CALIBRATION DATA
20 Feb 2004
ISUZU
8-97210-057-1
Injection pipe: outer dia. 8 mm × inner dia. 3 mm length 600 mm
Nozzle opening pressure: 20.7 MPa {211 kgf/cm2}
Nozzle: 105780-0120 Nozzle holder: 105780-2190(Bosch type no. 1 688 901 990) (Bosch type no. 9 430 610 144)
Nozzle & nozzle holder assy: 105780-8250 (Bosch type no. 1 688 901 101)
Test oil: ISO4113 or SAE standard test oil {SAE J967d}
6
Transfer pump pressure: 255 kPa {2.6
2. Injection timing
Overflow valve opening pressure: 255 ± 34 kPa {2.6 ± 0.35 kgf/cm2}
1/11
Ambient temperature: 23±5 °C
DIGI switch no.: 11 (for C/U 407980-224*)
Pre-stroke: No. 1 plunger 4.0 ± 0.03 mm
Injection order: 1 3 , 1 4 , 1 290°± 15' 180°± 15' 270°± 15'
Plungers are numbered from Governor side.
Tappet clearance: Manually rotate camshaft 2 ~ 3 times and confirm that it rotates smoothly.
2/11107492-1036
3. Injection timing adjustment
(Refer to 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 counterweight 2 contacts 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 shim 1.
3-3 Individual cylinder's injection order adjustment
Adjust difference between each cylinder's injection angle based on that of No. 1 cylinder using
shim 1.
1
563
4
1
2
1. Setscrew installation 2. Pre-stroke adjustment3. Individual cylinder's injection
order adjustment
3/11107492-1036
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 No. 1 cylinder's output voltage for pre-stroke
lift values in table below.
Adjusting pointConfirmation point Pre-stroke (mm) Output voltage (actual) Remarks
a3.43 a1 + tolerance
3.17 a2 - tolerance
b2.85 b1 + tolerance
2.65 b2 - tolerance
(calculate from each specification)
Advice
If measuring device (P/N 105782-6420) is removed, output voltage (a1, a2) must 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 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 lock-
nut to specified torque.
(3) Confirm solenoid switch operates at 14.5 - 0.1 V.
4/11107492-1036
4. Governor adjustment
4-1 Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw. Fully tighten adjusting nut.
Boost compensator stroke: 1.1±0.1
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
R1+2.9
Approx R1+2.0
R1(12.9)
R3 [R1-0.6]+0.5-0.1
R2 [R1-0.6]
10.2±1.0
0250-40 (700)
700900 (1400) (1550)
16201775
(1050)
(1300)
14.0±0.1
Torque cam no. “AG00”
B
A
DI
Rac
k po
sitio
n (
mm
)
Pump speed (r/min)
Idling adjustment
10.0±0.110.5
Approx 8.57.8
6.6±0.1
3.9±0.3
0240
H J
400400
500475 880
Confirm rack sensor Vist = 2.13±0.28at supply voltage 5±0.01V, N = 900 r/min, R = R1 (12.9).
5/11107492-1036
4-2 Boost compensator adjustment
(1) Select a push rod so C = 37.5±0.5 mm at full boost pressure. (C is distance from end face of
housing to top of lever.)
(2) Adjust boost compensator stroke using screw A (0 boost pressure position adjustment).
Adjust beginning of boost compensator operation by adjusting notch adjusting nut B.
CTop of lever Pushrod
Boost pressure inlet
A: Boost compensator stroke adjusting screw
Boost compensator spring
B: Notch adjusting nut
0
10.7±1.3 {80±10}
N = 500 r/min
R2 [R1-0.6]
Approx 26.7 {Approx 200}
Rac
k po
sitio
n (m
m)
Boost pressure kPa {mmHg}
R2-1.1
6/11107492-1036
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 timing cam adjusting point (point a in table below: Np = 900 r/min).
(4) Perform timing cam adjustment so output voltage is within range of a1 ~ a2 actually measured
for pre-stroke output voltage during injection timing adjustment in 3-4.
Adjusting point Pre-stroke (mm) Output voltage (actual) Remarks
a3.43 a1 + tolerance
3.17 a2 - tolerance
(5) Operate pump at timing cam confirmation point (point b in table below: Np = 1450 r/min).
(6) Confirm that pre-stroke output voltage is within range b1 ~ b2.
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.85 b1 + tolerance
2.65 b2 - tolerance
Pump speed (r/min)
900(500) 14500
3.7±0.03 (c)
4.0±0.03
3.43 (a1)
3.17 (a2)
2.85 (b1)
2.65 (b2)
2.0+0.03-0.10
Pre-stroke at stopper contact
Minimum advance angle adjustment stopper
Solenoid starting advance angle
b (confirmation point)
a (adjusting point)
Pre-stroke (Pre-stroke output voltage)
7/11107492-1036
5. Injection quantity
Adjustingpoint
Rackposition
(mm)
Pumpspeed(r/min)
Injection quantity(cm3 / 1000 strokes)
Max. variationbetween
cylinders (%)Fixed
Pre-strokeat
adjustmentRemarks
- 12.9 900 81 ± 1.6 ±4 Rack a1 ~ a2(v) Basic Cylinder variation adjustment standard
Z 8.5±0.5 500 19 ± 1.5 ±14 Rack c(v) Cylinder variation adjustment standard
A R1(12.9) 900 81 ± 1 - Lever a1 ~ a2(v) Basic Boost press. kPa {mmHg}Above 40.0 {Above 300}
B R1+2.9 1450 102.5 ± 4 - Lever b1 ~ b2(v) Boost press. kPa {mmHg}Above 40.0 {Above 300}
I [R1+2.0]±0.5 150 (175) - Lever c(v) Boost press. 0
D* 15.2±0.1 1450 (96.5) - Lever b1 ~ b2(v)
Boost press. kPa {mmHg}Above 40.0 {Above 300}Negative press. kPa {mmHg} 53.3 kPa {400 mmHg}
D*: Aneroid compensator actuator adjustment point
8/11107492-1036
6. FICD adjustment
(1) Stop 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 actuator 1 and set pump speed at 450 r/min.
(6) Gradually loosen set bolt 2 then fix bolt using nut when rack position is 8.3±0.1 mm.
(7) Apply above negative pressure several times and confirm FICD actuator is operating properly
and clearance between FICD actuator lever and speed control lever.
1+1mm
Speed control lever
FICD actuator lever
Tightening torque5 ~ 7 N.m {0.5 ~ 0.7 kgf.m}
1 2 3
9/11107492-1036
7. Aneroid compensator actuator adjustment (injection quantity decrease)
Note:
Set actuator after adjusting full rack position.
(1) Stop injection pump.
(2) Adjust wire nuts 1 so full load set lever contacts full load set bolt and aneroid compensator
actuator wire is not loose. Then, fix nuts 1.
(3) Apply 53.3 kPa {400 mmHg} negative pressure to aneroid compensator and set pump speed at
1450 r/min.
(4) Apply at least 40.0 kPa {300 mmHg} boost pressure to boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt 2 so control rack position
is 15.2±0.1 mm and fuel injection quantity is as specified. Then, fix set bolt 2.
Rac
k po
sitio
n (m
m)
Pump speed (r/min)
Stroke
D
Injection quantity decreaseadjustment point
Full load set bolt
Full load set lever
1
2
10/11107492-1036
8. Speed control lever angle 9. Stop lever angle
Stopper bolt H position
Hole (R42)
IdlingFull-speed
29°±3°30°±5°Hole (R41.3)
Normal Stop
45°±5°
22.5°±5°
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 spanner (to prevent rack from bending).
Specified torque : 3.4 ~ 4.9 N.m {0.35 ~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9 ~ 8.8 N.m {0.7 ~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set 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 full speed stopper bolt.
(9) Confirm rack sensor output voltage from digital voltmeter (Vist = 2.13±0.28).
(10) Confirm that voltage changes when speed control lever is moved to idle and full sides.
Rac
k po
sitio
n (m
m)
Pump speed (r/min)
AR1
N
Rack position (mm)
Sen
sor
outp
ut v
olta
ge (
V)
R1
Vist
Set positionR = 1.5±0.2
11/11107492-1036
11. Drive coupling timing
L L
tt
Bracket mark Pump
Engine
Gear hole (Dia. 3 mm)
Gear's threaded hole
Gear side
Pump side
Check hole
Stamp on coupling and bracket(B.T.D.C. 8°)
Mark position of coupling at B.T.D.C. 13°
Timing setting (At pre-stroke 3.7±0.05 mm)
At No. 1 plunger's beginningof injection positionB.T.D.C.: 8°
12°52'30''±3°
(35°)
25°21'24''±20'(96°)
(5°5
7'34
'')
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1045ENGINE MODEL: 4HE1-TCS
No.
Governor: 105934-0070
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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97210-050-0
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'
11
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*)
107492-1045 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
107492-1045 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 12 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 7.3 -0.1 V.
Adjusting pointConfirmation point
Pre-stroke (mm) Output voltage (actual) Remarks
a3.36 a1 + tolerance
3.10 a2 -tolerance
b2.72 b1 + tolerance
2.52 b2 -tolerance
(calculate from each specification)
107492-1045 4/11
Rac
k po
sitio
n (
mm
)
Idling adjustment
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
Boost compensator stroke: 1.35 ±0.1
Torque cam No. “ AF59”
Pump speed (r/min)
Confirm rack sensor Vist = 2.65±0.28
at supply voltage 5±0.01V , N =1000 r/min , R = R1 (15.1).
4. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+2.15Approx.R1+0.3
R1(15.1)
R2 [R1-2.15]
10.6± 1.0
0250-40 (650) 1000 (1350)
(1600)
1690
1810
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
(1450)
14.0± 0.1
107492-1045 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]
R2-1.35
Approx. 31.3 {Approx. 235}
12.0± 1.3 {90± 10}
PushrodC
0
107492-1045 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 44.7 kPa {at least 335 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 = 1,400 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.72 b1 + tolerance
2.52 b2 -tolerance
2.52 (b2)
2.72 (b1)
3.10 (a2)
3.36 (a1)
3.7± 0.03 (c)
4.0±0.03(500) 900 1,400
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
- 15.1 1,000 112 ± 1.6 ±4 Rack a1~a2(v)
Z 8.9±0.5 510 22 ± 1.5 ± 14 Rack c(v)
A R1(15.1) 1,000 112 ± 1 - Lever a1~a2(v)
BR1
+2.151,400 (123.5) ± 2 - Lever b1~b2(v)
IApprox.
R1+0.3150 (200) - Lever c(v)
D* 16.6±0.1 1,400 (115) - Lever b1~b2(v)
107492-1045 7/11
5. Injection quantity
Cylinder variation
adjustment standardBasic
BasicBoost press. kPa{mmHg}Above 44.7{Above 335}
Cylinder variation
adjustment standard
Boost press. 0
Boost press. kPa{mmHg}Above 44.7 {Above 335 }Negative press. kPa{mmHg} 53.3 kPa{ 400 mmHg}
D*: Aneroid compensator actuator adjustment point
Boost press. kPa{mmHg}Above 44.7{Above 335}
107492-1045 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
107492-1045 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 1,400 r/min.
(4) Apply at least 44.7 kPa { 335 mmHg} boost pressure to the boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt so control rack
position is 16.6±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
107492-1045 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 44.7 kPa
{at least 335 mmHg} boost pressure and confirm rack position is R1 = 15.1 mm and
fuel injection quantity is 112± 1 mm3/st at N = 1,000 r/min.
(2) Remove rack position measuring device.
(3) Attach rack sensor core to control rack.
At this time, hold control rack using a spanner (to prevent the rack from bending).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 44.7 kPa {at least 335 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 = 2.65±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
107492-1045 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
25°21′24″±
20′
13°±3°
(35°)
(96°)
(5°57′34″)
11. Drive Coupling Timing
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1046ENGINE MODEL: 4HE1-TCS
No.
Governor: 105934-0070
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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97210-050-1
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'
11
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*)
107492-1046 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
107492-1046 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 12 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 7.3 -0.1 V.
Adjusting pointConfirmation point
Pre-stroke (mm) Output voltage (actual) Remarks
a3.36 a1 + tolerance
3.10 a2 -tolerance
b2.72 b1 + tolerance
2.52 b2 -tolerance
(calculate from each specification)
107492-1046 4/11
Rac
k po
sitio
n (
mm
)
Idling adjustment
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
Boost compensator stroke: 1.35 ±0.1
Torque cam No. “ AF59”
Pump speed (r/min)
Confirm rack sensor Vist = 2.65±0.28
at supply voltage 5±0.01V , N =1000 r/min , R = R1 (15.1).
4. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+2.15Approx.R1+0.3
R1(15.1)
R2 [R1-2.15]
10.6± 1.0
0250-40 (650) 1000 (1350)
(1600)
1690
1810
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
(1450)
14.0± 0.1
107492-1046 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]
R2-1.35
Approx. 31.3 {Approx. 235}
12.0± 1.3 {90± 10}
PushrodC
0
107492-1046 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 44.7 kPa {at least 335 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 = 1,400 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.72 b1 + tolerance
2.52 b2 -tolerance
2.52 (b2)
2.72 (b1)
3.10 (a2)
3.36 (a1)
3.7± 0.03 (c)
4.0±0.03(500) 900 1,400
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
- 15.1 1,000 112 ± 1.6 ±4 Rack a1~a2(v)
Z 8.9±0.5 510 22 ± 1.5 ± 14 Rack c(v)
A R1(15.1) 1,000 112 ± 1 - Lever a1~a2(v)
BR1
+2.151,400 (123.5) ± 2 - Lever b1~b2(v)
IApprox.
R1+0.3150 (200) - Lever c(v)
D* 16.6±0.1 1,400 (115) - Lever b1~b2(v)
107492-1046 7/11
5. Injection quantity
Cylinder variation
adjustment standardBasic
BasicBoost press. kPa{mmHg}Above 44.7{Above 335}
Cylinder variation
adjustment standard
Boost press. 0
Boost press. kPa{mmHg}Above 44.7 {Above 335 }Negative press. kPa{mmHg} 53.3 kPa{ 400 mmHg}
D*: Aneroid compensator actuator adjustment point
Boost press. kPa{mmHg}Above 44.7{Above 335}
107492-1046 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
107492-1046 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 1,400 r/min.
(4) Apply at least 44.7 kPa { 335 mmHg} boost pressure to the boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt so control rack
position is 16.6±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
107492-1046 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 44.7 kPa
{at least 335 mmHg} boost pressure and confirm rack position is R1 = 15.1 mm and
fuel injection quantity is 112± 1 mm3/st at N = 1,000 r/min.
(2) Remove rack position measuring device.
(3) Attach rack sensor core to control rack.
At this time, hold control rack using a spanner (to prevent the rack from bending).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 44.7 kPa {at least 335 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 = 2.65±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
107492-1046 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
25°21′24″±
20′
13°±3°
(35°)
(96°)
(5°57′34″)
11. Drive Coupling Timing
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1047ENGINE MODEL: 4HE1-TCS
No.
Governor: 105934-0070
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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97210-050-1
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'
12
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*)
107492-1047 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
107492-1047 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 12 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 7.3 -0.1 V.
Adjusting pointConfirmation point
Pre-stroke (mm) Output voltage (actual) Remarks
a3.36 a1 + tolerance
3.10 a2 -tolerance
b2.72 b1 + tolerance
2.52 b2 -tolerance
(calculate from each specification)
107492-1047 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. “ AF59”
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. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+2.15Approx.R1+0.3
R1(15.0)
R2 [R1-2.15]
10.7± 1.0
0250-40 (650) 1000 (1350)
(1600)
1690
1810
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
(1450)
13.9± 0.1
107492-1047 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
107492-1047 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 = 1,400 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.72 b1 + tolerance
2.52 b2 -tolerance
2.52 (b2)
2.72 (b1)
3.10 (a2)
3.36 (a1)
3.7± 0.03 (c)
4.0±0.03(500) 900 1,400
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)
BR1
+2.151,400 (121.5) ± 2 - Lever b1~b2(v)
IApprox.
R1+0.3150 (180) - Lever c(v)
D* 16.6±0.1 1,400 (115) - Lever b1~b2(v)
107492-1047 7/11
5. Injection quantity
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}
107492-1047 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
107492-1047 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 1,400 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 16.6±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
107492-1047 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.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1047 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
25°21′24″±
20′
13°±3°
(35°)
(96°)
(5°57′34″)
11. Drive Coupling Timing
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1048ENGINE MODEL: 4HE1-TCS
No.
Governor: 105934-0071
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2062 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97210-050-1
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'
12
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*)
107492-1048 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
107492-1048 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 12 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 7.3 -0.1 V.
Adjusting pointConfirmation point
Pre-stroke (mm) Output voltage (actual) Remarks
a3.36 a1 + tolerance
3.10 a2 -tolerance
b2.72 b1 + tolerance
2.52 b2 -tolerance
(calculate from each specification)
107492-1048 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. “ AF59”
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. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+2.15Approx.R1+0.3
R1(15.0)
R2 [R1-2.15]
10.7± 1.0
0250-40 (650) 1000 (1350)
(1600)
1690
1810
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
(1450)
13.9± 0.1
107492-1048 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
107492-1048 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 = 1,400 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.72 b1 + tolerance
2.52 b2 -tolerance
2.52 (b2)
2.72 (b1)
3.10 (a2)
3.36 (a1)
3.7± 0.03 (c)
4.0±0.03(500) 900 1,400
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)
BR1
+2.151,400 (121.5) ± 2 - Lever b1~b2(v)
IApprox.
R1+0.3150 (180) - Lever c(v)
D* 16.6±0.1 1,400 (115) - Lever b1~b2(v)
107492-1048 7/11
5. Injection quantity
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}
107492-1048 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
107492-1048 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 1,400 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 16.6±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
107492-1048 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.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1048 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
25°21′24″±
20′
13°±3°
(35°)
(96°)
(5°57′34″)
11. Drive Coupling Timing
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1049ENGINE MODEL: 4HE1-TCS
No.
Governor: 105934-0071
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2063 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:14 Mar.2003
ISUZU8-97210-050-1
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'
13
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*)
107492-1049 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
107492-1049 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 12 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 7.3 -0.1 V.
Adjusting pointConfirmation point
Pre-stroke (mm) Output voltage (actual) Remarks
a3.36 a1 + tolerance
3.10 a2 -tolerance
b2.72 b1 + tolerance
2.52 b2 -tolerance
(calculate from each specification)
107492-1049 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. “ AF59”
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. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+2.15Approx.R1+0.3
R1(15.0)
R2 [R1-2.15]
10.7± 1.0
0250-40 (650) 1000 (1350)
(1600)
1690
1810
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
(1450)
13.9± 0.1
107492-1049 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
107492-1049 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 = 1,400 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.72 b1 + tolerance
2.52 b2 -tolerance
2.52 (b2)
2.72 (b1)
3.10 (a2)
3.36 (a1)
3.7± 0.03 (c)
4.0±0.03(500) 900 1,400
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)
BR1
+2.151,400 (121.5) ± 2 - Lever b1~b2(v)
IApprox.
R1+0.3150 (180) - Lever c(v)
D* 16.6±0.1 1,400 (115) - Lever b1~b2(v)
107492-1049 7/11
5. Injection quantity
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}
107492-1049 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
107492-1049 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 1,400 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 16.6±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
107492-1049 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.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1049 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
25°21′24″±
20′
13°07′30″± 3°
(35°)
(96°)
(5°57′34″)
11. Drive Coupling Timing
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1054ENGINE MODEL: 4HE1-TC N
No.
Governor: 105934-0080
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2071 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97210-051-0
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'
10
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*)
107492-1054 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
107492-1054 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 12 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 7.3 -0.1 V.
Adjusting pointConfirmation point
Pre-stroke (mm) Output voltage (actual) Remarks
a3.43 a1 + tolerance
3.17 a2 -tolerance
b2.85 b1 + tolerance
2.65 b2 -tolerance
(calculate from each specification)
107492-1054 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. Governor adjustment
4-1. Governor adjustment
Full load 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)
107492-1054 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
107492-1054 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
a3.43 a1 + tolerance
3.17 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.85 b1 + tolerance
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)
107492-1054 7/11
5. Injection quantity
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}
107492-1054 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
107492-1054 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
107492-1054 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).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1054 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
25°21′24″±
20′
13°±3°
(35°)
(96°)
(5°57′34″)
11. Drive Coupling Timing
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1055ENGINE MODEL: 4HE1-TC N
No.
Governor: 105934-0080
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2071 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97210-051-1
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'
10
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*)
107492-1055 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
107492-1055 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 12 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 7.3 -0.1 V.
Adjusting pointConfirmation point
Pre-stroke (mm) Output voltage (actual) Remarks
a3.43 a1 + tolerance
3.17 a2 -tolerance
b2.85 b1 + tolerance
2.65 b2 -tolerance
(calculate from each specification)
107492-1055 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. Governor adjustment
4-1. Governor adjustment
Full load 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)
107492-1055 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
107492-1055 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
a3.43 a1 + tolerance
3.17 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.85 b1 + tolerance
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)
107492-1055 7/11
5. Injection quantity
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}
107492-1055 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
107492-1055 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
107492-1055 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).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1055 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
25°21′24″±
20′
13°±3°
(35°)
(96°)
(5°57′34″)
11. Drive Coupling Timing
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1056ENGINE MODEL: 4HE1-TC N
No.
Governor: 105934-0081
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2072 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97210-051-1
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'
10
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*)
107492-1056 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
107492-1056 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 12 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 7.3 -0.1 V.
Adjusting pointConfirmation point
Pre-stroke (mm) Output voltage (actual) Remarks
a3.43 a1 + tolerance
3.17 a2 -tolerance
b2.85 b1 + tolerance
2.65 b2 -tolerance
(calculate from each specification)
107492-1056 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. Governor adjustment
4-1. Governor adjustment
Full load 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)
107492-1056 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
107492-1056 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
a3.43 a1 + tolerance
3.17 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.85 b1 + tolerance
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)
107492-1056 7/11
5. Injection quantity
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}
107492-1056 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
107492-1056 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
107492-1056 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).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1056 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
25°21′24″±
20′
13°±3°
(35°)
(96°)
(5°57′34″)
11. Drive Coupling Timing
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1057ENGINE MODEL: 4HE1-TC N
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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:14 Mar.2003
ISUZU8-97210-051-1
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'
11
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*)
107492-1057 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
107492-1057 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 12 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 7.3 -0.1 V.
Adjusting pointConfirmation point
Pre-stroke (mm) Output voltage (actual) Remarks
a3.43 a1 + tolerance
3.17 a2 -tolerance
b2.85 b1 + tolerance
2.65 b2 -tolerance
(calculate from each specification)
107492-1057 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. Governor adjustment
4-1. Governor adjustment
Full load 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)
107492-1057 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
107492-1057 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
a3.43 a1 + tolerance
3.17 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.85 b1 + tolerance
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)
107492-1057 7/11
5. Injection quantity
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}
107492-1057 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
107492-1057 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
107492-1057 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).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1057 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
25°21′24″±
20′
12°52′30″± 3°
(35°)
(96°)
(5°57′34″)
11. Drive Coupling Timing
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1063ENGINE MODEL: 4HE1-TCS
No.
Governor: 105934-0070
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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97210-056-0
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*)
107492-1063 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
107492-1063 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
b2.72 b1 + tolerance
2.52 b2 -tolerance
(calculate from each specification)
107492-1063 4/11
Rac
k po
sitio
n (
mm
)
Idling adjustment
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
Boost compensator stroke: 1.35 ±0.1
Torque cam No. “ AF59”
Pump speed (r/min)
Confirm rack sensor Vist = 2.65±0.28
at supply voltage 5±0.01V , N =1000 r/min , R = R1 (15.1).
4. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+2.15Approx.R1+0.3
R1(15.1)
R2 [R1-2.15]
10.6± 1.0
0250-40 (650) 1000 (1350)
(1600)
1690
1810
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
(1450)
14.0± 0.1
107492-1063 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]
R2-1.35
Approx. 31.3 {Approx. 235}
12.0± 1.3 {90± 10}
PushrodC
0
107492-1063 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 44.7 kPa {at least 335 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 = 1,400 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.72 b1 + tolerance
2.52 b2 -tolerance
2.52 (b2)
2.72 (b1)
3.10 (a2)
3.36 (a1)
3.7± 0.03 (c)
4.0±0.03(500) 900 1,400
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
- 15.1 1,000 112 ± 1.6 ±4 Rack a1~a2(v)
Z 8.9±0.5 510 22 ± 1.5 ± 14 Rack c(v)
A R1(15.1) 1,000 112 ± 1 - Lever a1~a2(v)
BR1
+2.151,400 (123.5) ± 2 - Lever b1~b2(v)
IApprox.
R1+0.3150 (200) - Lever c(v)
D* 16.6±0.1 1,400 (115) - Lever b1~b2(v)
107492-1063 7/11
5. Injection quantity
Cylinder variation
adjustment standardBasic
BasicBoost press. kPa{mmHg}Above 44.7{Above 335}
Cylinder variation
adjustment standard
Boost press. 0
Boost press. kPa{mmHg}Above 44.7 {Above 335 }Negative press. kPa{mmHg} 53.3 kPa{ 400 mmHg}
D*: Aneroid compensator actuator adjustment point
Boost press. kPa{mmHg}Above 44.7{Above 335}
107492-1063 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
107492-1063 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 1,400 r/min.
(4) Apply at least 44.7 kPa { 335 mmHg} boost pressure to the boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt so control rack
position is 16.6±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
107492-1063 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 44.7 kPa
{at least 335 mmHg} boost pressure and confirm rack position is R1 = 15.1 mm and
fuel injection quantity is 112± 1 mm3/st at N = 1,000 r/min.
(2) Remove rack position measuring device.
(3) Attach rack sensor core to control rack.
At this time, hold control rack using a spanner (to prevent the rack from bending).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 44.7 kPa {at least 335 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 = 2.65±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
107492-1063 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
25°21′24″±
20′
13°±3°
(35°)
(96°)
(5°57′34″)
11. Drive Coupling Timing
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1064ENGINE MODEL: 4HE1-TCS
No.
Governor: 105934-0070
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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97210-056-1
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'
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*)
107492-1064 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
107492-1064 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
b2.72 b1 + tolerance
2.52 b2 -tolerance
(calculate from each specification)
107492-1064 4/11
Rac
k po
sitio
n (
mm
)
Idling adjustment
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
Boost compensator stroke: 1.35 ±0.1
Torque cam No. “ AF59”
Pump speed (r/min)
Confirm rack sensor Vist = 2.65±0.28
at supply voltage 5±0.01V , N =1000 r/min , R = R1 (15.1).
4. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+2.15Approx.R1+0.3
R1(15.1)
R2 [R1-2.15]
10.6± 1.0
0250-40 (650) 1000 (1350)
(1600)
1690
1810
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
(1450)
14.0± 0.1
107492-1064 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]
R2-1.35
Approx. 31.3 {Approx. 235}
12.0± 1.3 {90± 10}
PushrodC
0
107492-1064 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 44.7 kPa {at least 335 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 = 1,400 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.72 b1 + tolerance
2.52 b2 -tolerance
2.52 (b2)
2.72 (b1)
3.10 (a2)
3.36 (a1)
3.7± 0.03 (c)
4.0±0.03(500) 900 1,400
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
- 15.1 1,000 112 ± 1.6 ±4 Rack a1~a2(v)
Z 8.9±0.5 510 22 ± 1.5 ± 14 Rack c(v)
A R1(15.1) 1,000 112 ± 1 - Lever a1~a2(v)
BR1
+2.151,400 (123.5) ± 2 - Lever b1~b2(v)
IApprox.
R1+0.3150 (200) - Lever c(v)
D* 16.6±0.1 1,400 (115) - Lever b1~b2(v)
107492-1064 7/11
5. Injection quantity
Cylinder variation
adjustment standardBasic
BasicBoost press. kPa{mmHg}Above 44.7{Above 335}
Cylinder variation
adjustment standard
Boost press. 0
Boost press. kPa{mmHg}Above 44.7 {Above 335 }Negative press. kPa{mmHg} 53.3 kPa{ 400 mmHg}
D*: Aneroid compensator actuator adjustment point
Boost press. kPa{mmHg}Above 44.7{Above 335}
107492-1064 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
107492-1064 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 1,400 r/min.
(4) Apply at least 44.7 kPa { 335 mmHg} boost pressure to the boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt so control rack
position is 16.6±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
107492-1064 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 44.7 kPa
{at least 335 mmHg} boost pressure and confirm rack position is R1 = 15.1 mm and
fuel injection quantity is 112± 1 mm3/st at N = 1,000 r/min.
(2) Remove rack position measuring device.
(3) Attach rack sensor core to control rack.
At this time, hold control rack using a spanner (to prevent the rack from bending).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 44.7 kPa {at least 335 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 = 2.65±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
107492-1064 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
25°21′24″±
20′
13°±3°
(35°)
(96°)
(5°57′34″)
11. Drive Coupling Timing
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1065ENGINE MODEL: 4HE1-TCS
No.
Governor: 105934-0070
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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97210-056-1
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'
6
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*)
107492-1065 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
107492-1065 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
b2.72 b1 + tolerance
2.52 b2 -tolerance
(calculate from each specification)
107492-1065 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. “ AF59”
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. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+2.15Approx.R1+0.3
R1(15.0)
R2 [R1-2.15]
10.7± 1.0
0250-40 (650) 1000 (1350)
(1600)
1690
1810
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
(1450)
13.9± 0.1
107492-1065 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
107492-1065 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 = 1,400 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.72 b1 + tolerance
2.52 b2 -tolerance
2.52 (b2)
2.72 (b1)
3.10 (a2)
3.36 (a1)
3.7± 0.03 (c)
4.0±0.03(500) 900 1,400
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)
BR1
+2.151,400 (121.5) ± 2 - Lever b1~b2(v)
IApprox.
R1+0.3150 (180) - Lever c(v)
D* 16.6±0.1 1,400 (115) - Lever b1~b2(v)
107492-1065 7/11
5. Injection quantity
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}
107492-1065 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
107492-1065 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 1,400 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 16.6±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
107492-1065 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.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1065 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
25°21′24″±
20′
13°±3°
(35°)
(96°)
(5°57′34″)
11. Drive Coupling Timing
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1066ENGINE MODEL: 4HE1-TCS
No.
Governor: 105934-0071
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2062 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97210-056-1
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'
6
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*)
107492-1066 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
107492-1066 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
b2.72 b1 + tolerance
2.52 b2 -tolerance
(calculate from each specification)
107492-1066 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. “ AF59”
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. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+2.15Approx.R1+0.3
R1(15.0)
R2 [R1-2.15]
10.7± 1.0
0250-40 (650) 1000 (1350)
(1600)
1690
1810
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
(1450)
13.9± 0.1
107492-1066 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
107492-1066 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 = 1,400 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.72 b1 + tolerance
2.52 b2 -tolerance
2.52 (b2)
2.72 (b1)
3.10 (a2)
3.36 (a1)
3.7± 0.03 (c)
4.0±0.03(500) 900 1,400
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)
BR1
+2.151,400 (121.5) ± 2 - Lever b1~b2(v)
IApprox.
R1+0.3150 (180) - Lever c(v)
D* 16.6±0.1 1,400 (115) - Lever b1~b2(v)
107492-1066 7/11
5. Injection quantity
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}
107492-1066 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
107492-1066 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 1,400 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 16.6±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
107492-1066 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.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1066 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
25°21′24″±
20′
13°±3°
(35°)
(96°)
(5°57′34″)
11. Drive Coupling Timing
105934-0071Governor: EP/RLD-MInjection pump: TCS4MD
107049-2063
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
Selector switch no.: 00 (for C/U 407910-303*)
Oil temperature: 40+5 °C
Company:
Assy No.: 107492-1067ENGINE MODEL: 4HE1-TCS
No.
1. Test conditions
Date:
Pump rotation: counter clockwise (viewed from drive side)
kgf/cm2}
CONFIDENTIAL
INJECTION PUMP CALIBRATION DATA
20 Feb 2004
ISUZU
8-97210-056-1
Injection pipe: outer dia. 8 mm × inner dia. 3 mm length 600 mm
Nozzle opening pressure: 20.7 MPa {211 kgf/cm2}
Nozzle: 105780-0120 Nozzle holder: 105780-2190(Bosch type no. 1 688 901 990) (Bosch type no. 9 430 610 144)
Nozzle & nozzle holder assy: 105780-8250 (Bosch type no. 1 688 901 101)
Test oil: ISO4113 or SAE standard test oil {SAE J967d}
7
Transfer pump pressure: 255 kPa {2.6
2. Injection timing
Overflow valve opening pressure: 255 ± 34 kPa {2.6 ± 0.35 kgf/cm2}
1/11
Ambient temperature: 23±5 °C
DIGI switch no.: 11 (for C/U 407980-224*)
Pre-stroke: No. 1 plunger 4.0 ± 0.03 mm
Injection order: 1 3 , 1 4 , 1 290°± 15' 180°± 15' 270°± 15'
Plungers are numbered from Governor side.
Tappet clearance: Manually rotate camshaft 2 ~ 3 times and confirm that it rotates smoothly.
2/11107492-1067
3. Injection timing adjustment
(Refer to 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 counterweight 2 contacts 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 shim 1.
3-3 Individual cylinder's injection order adjustment
Adjust difference between each cylinder's injection angle based on that of No. 1 cylinder using
shim 1.
1
563
4
1
2
1. Setscrew installation 2. Pre-stroke adjustment3. Individual cylinder's injection
order adjustment
3/11107492-1067
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 No. 1 cylinder's output voltage for pre-stroke
lift values in table below.
Adjusting pointConfirmation point Pre-stroke (mm) Output voltage (actual) Remarks
a3.36 a1 + tolerance
3.10 a2 - tolerance
b2.72 b1 + tolerance
2.52 b2 - tolerance
(calculate from each specification)
Advice
If measuring device (P/N 105782-6420) is removed, output voltage (a1, a2) must 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 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 lock-
nut to specified torque.
(3) Confirm solenoid switch operates at 14.5 - 0.1 V.
4/11107492-1067
4. Governor adjustment
4-1 Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw. Fully tighten adjusting nut.
Boost compensator stroke: 1.25±0.1
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
R1+2.15Approx R1+0.3
R1(15.0)
R2 [R1-2.15]
10.7±1.0
0250-40 (650) 1000 (1350) (1450)
(1600)1690
13.9±0.1
Torque cam no. “AF59”
B
A DI
Rac
k po
sitio
n (
mm
)
Pump speed (r/min)
Idling adjustment
10.0±0.110.5
Approx 8.97.8
6.6±0.1
3.9±0.3
0240
H J
400400
500475 880
Confirm rack sensor Vist = 2.55±0.28at supply voltage 5±0.01V, N = 1000 r/min, R = R1 (15.0).
1810
5/11107492-1067
4-2 Boost compensator adjustment
(1) Select a push rod so C = 37.5±0.5 mm at full boost pressure. (C is distance from end face of
housing to top of lever.)
(2) Adjust boost compensator stroke using screw A (0 boost pressure position adjustment).
Adjust beginning of boost compensator operation by adjusting notch adjusting nut B.
CTop of lever Pushrod
Boost pressure inlet
A: Boost compensator stroke adjusting screw
Boost compensator spring
B: Notch adjusting nut
0
12.0±1.3 {90±10}
N = 500 r/min
R2 [R1-2.15]
Approx 28.7 {Approx 215}
Rac
k po
sitio
n (m
m)
Boost pressure kPa {mmHg}
R2-1.25
6/11107492-1067
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 timing cam adjusting point (point a in table below: Np = 900 r/min).
(4) Perform timing cam adjustment so output voltage is within range of a1 ~ a2 actually measured
for pre-stroke output voltage during injection timing adjustment in 3-4.
Adjusting point Pre-stroke (mm) Output voltage (actual) Remarks
a3.36 a1 + tolerance
3.10 a2 - tolerance
(5) Operate pump at timing cam confirmation point (point b in table below: Np = 1400 r/min).
(6) Confirm that pre-stroke output voltage is within range b1 ~ b2.
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.72 b1 + tolerance
2.52 b2 - tolerance
Pump speed (r/min)
900(500) 14000
3.7±0.03 (c)
4.0±0.03
3.36 (a1)
3.10 (a2)
2.72 (b1)
2.52 (b2)
2.0+0.03-0.10
Pre-stroke at stopper contact
Minimum advance angle adjustment stopper
Solenoid starting advance angle
b (confirmation point)
a (adjusting point)
Pre-stroke (Pre-stroke output voltage)
7/11107492-1067
5. Injection quantity
Adjustingpoint
Rackposition
(mm)
Pumpspeed(r/min)
Injection quantity(cm3 / 1000 strokes)
Max. variationbetween
cylinders (%)Fixed
Pre-strokeat
adjustmentRemarks
- 15.0 1000 109.5 ± 1.6 ±4 Rack a1 ~ a2(v) Basic Cylinder variation adjustment standard
Z 8.9±0.5 510 22 ± 1.5 ±14 Rack c(v) Cylinder variation adjustment standard
A R1(15.0) 1000 109.5 ± 1 - Lever a1 ~ a2(v) Basic Boost press. kPa {mmHg}Above 42.0 {Above 315}
B R1+2.15 1400 121.5 ± 4 - Lever b1 ~ b2(v) Boost press. kPa {mmHg}Above 42.0 {Above 315}
I [R1+0.3]±0.5 150 (180) - Lever c(v) Boost press. 0
D* 16.6±0.1 1400 (115) - Lever b1 ~ b2(v)
Boost press. kPa {mmHg}Above 42.0 {Above 315}Negative press. kPa {mmHg} 53.3 kPa {400 mmHg}
D*: Aneroid compensator actuator adjustment point
8/11107492-1067
6. FICD adjustment
(1) Stop 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 actuator 1 and set pump speed at 450 r/min.
(6) Gradually loosen set bolt 2 then fix bolt using nut when rack position is 8.7±0.1 mm.
(7) Apply above negative pressure several times and confirm FICD actuator is operating properly
and clearance between FICD actuator lever and speed control lever.
1+1mm
Speed control lever
FICD actuator lever
Tightening torque5 ~ 7 N.m {0.5 ~ 0.7 kgf.m}
1 2 3
9/11107492-1067
7. Aneroid compensator actuator adjustment (injection quantity decrease)
Note:
Set actuator after adjusting full rack position.
(1) Stop injection pump.
(2) Adjust wire nuts 1 so full load set lever contacts full load set bolt and aneroid compensator
actuator wire is not loose. Then, fix nuts 1.
(3) Apply 53.3 kPa {400 mmHg} negative pressure to aneroid compensator and set pump speed at
1400 r/min.
(4) Apply at least 42.0 kPa {315 mmHg} boost pressure to boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt 2 so control rack position
is 16.6±0.1 mm and fuel injection quantity is as specified. Then, fix set bolt 2.
Rac
k po
sitio
n (m
m)
Pump speed (r/min)
Stroke
D
Injection quantity decreaseadjustment point
Full load set bolt
Full load set lever
1
2
10/11107492-1067
8. Speed control lever angle 9. Stop lever angle
Stopper bolt H position
Hole (R42)
IdlingFull-speed
29.5°±3°30°±5°Hole (R41.3)
Normal Stop
45°±5°
22.5°±5°
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 = 1000 r/min.
(2) Remove rack position measuring device.
(3) Attach rack sensor core to control rack.
At this time, hold control rack using spanner (to prevent rack from bending).
Specified torque : 3.4 ~ 4.9 N.m {0.35 ~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9 ~ 8.8 N.m {0.7 ~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set to DC 5±0.01V.
(8) Apply at least 42.0 kPa {at least 315 mmHg} boost pressure, set pump speed at N = 1000 r/min,
and hold speed control lever against full speed stopper bolt.
(9) Confirm rack sensor output voltage from digital voltmeter (Vist = 2.55±0.28).
(10) Confirm that voltage changes when speed control lever is moved to idle and full sides.
Rac
k po
sitio
n (m
m)
Pump speed (r/min)
AR1
N
Rack position (mm)
Sen
sor
outp
ut v
olta
ge (
V)
R1
Vist
Set positionR = 1.5±0.2
11/11107492-1067
11. Drive coupling timing
L L
tt
Bracket mark Pump
Engine
Gear hole (Dia. 3 mm)
Gear's threaded hole
Gear side
Pump side
Check hole
Stamp on coupling and bracket(B.T.D.C. 8°)
Mark position of coupling at B.T.D.C. 13°
Timing setting (At pre-stroke 3.7±0.05 mm)
At No. 1 plunger's beginningof injection positionB.T.D.C.: 8°
13°07'30''±3°
(35°)
25°21'24''±20'(96°)
(5°5
7'34
'')
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1070ENGINE MODEL: 4HE1-XN
No.
Governor: 105934-0100
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2071 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97206-501-0
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'
2
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*)
107492-1070 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
107492-1070 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
a3.43 a1 + tolerance
3.17 a2 -tolerance
b2.85 b1 + tolerance
2.65 b2 -tolerance
(calculate from each specification)
107492-1070 4/11
Rac
k po
sitio
n (
mm
)
Idling adjustment
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
Boost compensator stroke: 0.8 ±0.1
Torque cam No. “ AG41”
Pump speed (r/min)
Confirm rack sensor Vist = 2.25±0.28
at supply voltage 5±0.01V , N =1000 r/min , R = R1 (13.5).
4. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+1.85
Approx.R1+1.5R1(13.5)
R2 [R1-1.4]
10.3± 1.0
0250-40 (700) 1000 (1400)
(1560)
1630
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
107492-1070 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 [R1-1.4]
R2-0.8
Approx. 24.7 {Approx. 185}
13.3± 1.3 {100± 10}
PushrodC
0
107492-1070 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 38.0 kPa {at least 285 mmHg}.
(3) Operate pump at the timing cam adjusting point
(point a in table below: Np = 900 r/min).
(4) Perform timing cam adjustment so output voltage is within range of a1 ~ a2 actually
measured for pre-stroke output voltage during injection timing adjustment in 3-4.
(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
a3.43 a1 + tolerance
3.17 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.85 b1 + tolerance
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
- 13.5 1,000 87 ± 1.6 ±4 Rack a1~a2(v)
Z 8.5±0.5 500 19 ± 1.5 ± 14 Rack c(v)
A R1(13.5) 1,000 87 ± 1 - Lever a1~a2(v)
BR1
+1.851,450 (98) ± 2 - Lever b1~b2(v)
IApprox.
R1+1.5150 (175) - Lever c(v)
D* 15.0±0.1 1,450 (94.5) - Lever b1~b2(v)
107492-1070 7/11
5. Injection quantity
Cylinder variation
adjustment standardBasic
BasicBoost press. kPa{mmHg}Above 38.0{Above 285}
Cylinder variation
adjustment standard
Boost press. 0
Boost press. kPa{mmHg}Above 38.0 {Above 285 }Negative press. kPa{mmHg} 53.3 kPa{ 400 mmHg}
D*: Aneroid compensator actuator adjustment point
Boost press. kPa{mmHg}Above 38.0{Above 285}
107492-1070 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
107492-1070 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 38.0 kPa { 285 mmHg} boost pressure to the boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt so control rack
position is 15.0±0.1 mm and fuel injection quantity is as specified. Then, fix the set bolt.
Stroke
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
107492-1070 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 38.0 kPa
{at least 285 mmHg} boost pressure and confirm rack position is R1 = 13.5 mm and
fuel injection quantity is 87± 1 mm3/st at N = 1,000 r/min.
(2) Remove rack position measuring device.
(3) Attach rack sensor core to control rack.
At this time, hold control rack using a spanner (to prevent the rack from bending).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 38.0 kPa {at least 285 mmHg} boost pressure, set pump speed at
N= 1,000 r/min, and hold speed control lever against the full speed stopper bolt.
(9) Confirm the rack sensor output voltage from the digital voltmeter. (Vist = 2.25±0.28)
(10) Confirm that the voltage changes when the speed control lever is moved to the idle and
full sides.
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
107492-1070 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
25°21′24″±
20′
13°±3°
(35°)
(96°)
(5°57′34″)
11. Drive Coupling Timing
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1071ENGINE MODEL: 4HE1-XN
No.
Governor: 105934-0100
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2071 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97211-812-0
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'
2
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*)
107492-1071 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
107492-1071 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
a3.43 a1 + tolerance
3.17 a2 -tolerance
b2.85 b1 + tolerance
2.65 b2 -tolerance
(calculate from each specification)
107492-1071 4/11
Rac
k po
sitio
n (
mm
)
Idling adjustment
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
Boost compensator stroke: 0.8 ±0.1
Torque cam No. “ AG41”
Pump speed (r/min)
Confirm rack sensor Vist = 2.25±0.28
at supply voltage 5±0.01V , N =1000 r/min , R = R1 (13.5).
4. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+1.85
Approx.R1+1.5R1(13.5)
R2 [R1-1.4]
10.3± 1.0
0250-40 (700) 1000 (1400)
(1560)
1630
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
107492-1071 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 [R1-1.4]
R2-0.8
Approx. 24.7 {Approx. 185}
13.3± 1.3 {100± 10}
PushrodC
0
107492-1071 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 38.0 kPa {at least 285 mmHg}.
(3) Operate pump at the timing cam adjusting point
(point a in table below: Np = 900 r/min).
(4) Perform timing cam adjustment so output voltage is within range of a1 ~ a2 actually
measured for pre-stroke output voltage during injection timing adjustment in 3-4.
(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
a3.43 a1 + tolerance
3.17 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.85 b1 + tolerance
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
- 13.5 1,000 87 ± 1.6 ±4 Rack a1~a2(v)
Z 8.5±0.5 500 19 ± 1.5 ± 14 Rack c(v)
A R1(13.5) 1,000 87 ± 1 - Lever a1~a2(v)
BR1
+1.851,450 (98) ± 2 - Lever b1~b2(v)
IApprox.
R1+1.5150 (175) - Lever c(v)
D* 15.0±0.1 1,450 (94.5) - Lever b1~b2(v)
107492-1071 7/11
5. Injection quantity
Cylinder variation
adjustment standardBasic
BasicBoost press. kPa{mmHg}Above 38.0{Above 285}
Cylinder variation
adjustment standard
Boost press. 0
Boost press. kPa{mmHg}Above 38.0 {Above 285 }Negative press. kPa{mmHg} 53.3 kPa{ 400 mmHg}
D*: Aneroid compensator actuator adjustment point
Boost press. kPa{mmHg}Above 38.0{Above 285}
107492-1071 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
107492-1071 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 38.0 kPa { 285 mmHg} boost pressure to the boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt so control rack
position is 15.0±0.1 mm and fuel injection quantity is as specified. Then, fix the set bolt.
Stroke
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
107492-1071 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 38.0 kPa
{at least 285 mmHg} boost pressure and confirm rack position is R1 = 13.5 mm and
fuel injection quantity is 87± 1 mm3/st at N = 1,000 r/min.
(2) Remove rack position measuring device.
(3) Attach rack sensor core to control rack.
At this time, hold control rack using a spanner (to prevent the rack from bending).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 38.0 kPa {at least 285 mmHg} boost pressure, set pump speed at
N= 1,000 r/min, and hold speed control lever against the full speed stopper bolt.
(9) Confirm the rack sensor output voltage from the digital voltmeter. (Vist = 2.25±0.28)
(10) Confirm that the voltage changes when the speed control lever is moved to the idle and
full sides.
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
107492-1071 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
25°21′24″±
20′
13°±3°
(35°)
(96°)
(5°57′34″)
11. Drive Coupling Timing
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1072ENGINE MODEL: 4HE1-XN
No.
Governor: 105934-0101
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2072 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97211-812-0
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'
2
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*)
107492-1072 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
107492-1072 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
a3.43 a1 + tolerance
3.17 a2 -tolerance
b2.85 b1 + tolerance
2.65 b2 -tolerance
(calculate from each specification)
107492-1072 4/11
Rac
k po
sitio
n (
mm
)
Idling adjustment
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
Boost compensator stroke: 0.8 ±0.1
Torque cam No. “ AG41”
Pump speed (r/min)
Confirm rack sensor Vist = 2.25±0.28
at supply voltage 5±0.01V , N =1000 r/min , R = R1 (13.5).
4. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+1.85
Approx.R1+1.5R1(13.5)
R2 [R1-1.4]
10.3± 1.0
0250-40 (700) 1000 (1400)
(1560)
1630
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
107492-1072 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 [R1-1.4]
R2-0.8
Approx. 24.7 {Approx. 185}
13.3± 1.3 {100± 10}
PushrodC
0
107492-1072 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 38.0 kPa {at least 285 mmHg}.
(3) Operate pump at the timing cam adjusting point
(point a in table below: Np = 900 r/min).
(4) Perform timing cam adjustment so output voltage is within range of a1 ~ a2 actually
measured for pre-stroke output voltage during injection timing adjustment in 3-4.
(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
a3.43 a1 + tolerance
3.17 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.85 b1 + tolerance
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
- 13.5 1,000 87 ± 1.6 ±4 Rack a1~a2(v)
Z 8.5±0.5 500 19 ± 1.5 ± 14 Rack c(v)
A R1(13.5) 1,000 87 ± 1 - Lever a1~a2(v)
BR1
+1.851,450 (98) ± 2 - Lever b1~b2(v)
IApprox.
R1+1.5150 (175) - Lever c(v)
D* 15.0±0.1 1,450 (94.5) - Lever b1~b2(v)
107492-1072 7/11
5. Injection quantity
Cylinder variation
adjustment standardBasic
BasicBoost press. kPa{mmHg}Above 38.0{Above 285}
Cylinder variation
adjustment standard
Boost press. 0
Boost press. kPa{mmHg}Above 38.0 {Above 285 }Negative press. kPa{mmHg} 53.3 kPa{ 400 mmHg}
D*: Aneroid compensator actuator adjustment point
Boost press. kPa{mmHg}Above 38.0{Above 285}
107492-1072 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
107492-1072 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 38.0 kPa { 285 mmHg} boost pressure to the boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt so control rack
position is 15.0±0.1 mm and fuel injection quantity is as specified. Then, fix the set bolt.
Stroke
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
107492-1072 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 38.0 kPa
{at least 285 mmHg} boost pressure and confirm rack position is R1 = 13.5 mm and
fuel injection quantity is 87± 1 mm3/st at N = 1,000 r/min.
(2) Remove rack position measuring device.
(3) Attach rack sensor core to control rack.
At this time, hold control rack using a spanner (to prevent the rack from bending).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 38.0 kPa {at least 285 mmHg} boost pressure, set pump speed at
N= 1,000 r/min, and hold speed control lever against the full speed stopper bolt.
(9) Confirm the rack sensor output voltage from the digital voltmeter. (Vist = 2.25±0.28)
(10) Confirm that the voltage changes when the speed control lever is moved to the idle and
full sides.
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
107492-1072 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
25°21′24″±
20′
13°±3°
(35°)
(96°)
(5°57′34″)
11. Drive Coupling Timing
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1080ENGINE MODEL: 4HE1-X
No.
Governor: 105934-0070
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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97212-182-0
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'
1
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*)
107492-1080 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
107492-1080 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 12 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 7.3 -0.1 V.
Adjusting pointConfirmation point
Pre-stroke (mm) Output voltage (actual) Remarks
a3.36 a1 + tolerance
3.10 a2 -tolerance
b2.72 b1 + tolerance
2.52 b2 -tolerance
(calculate from each specification)
107492-1080 4/11
Rac
k po
sitio
n (
mm
)
Idling adjustment
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
Boost compensator stroke: 1.35 ±0.1
Torque cam No. “ AF59”
Pump speed (r/min)
Confirm rack sensor Vist = 2.65±0.28
at supply voltage 5±0.01V , N =1000 r/min , R = R1 (15.1).
4. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+2.15Approx.R1+0.3
R1(15.1)
R2 [R1-2.15]
10.6± 1.0
0250-40 (650) 1000 (1350)
(1600)
1690
1810
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
(1450)
14.0± 0.1
107492-1080 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]
R2-1.35
Approx. 31.3 {Approx. 235}
12.0± 1.3 {90± 10}
PushrodC
0
107492-1080 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 44.7 kPa {at least 335 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 = 1,400 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.72 b1 + tolerance
2.52 b2 -tolerance
2.52 (b2)
2.72 (b1)
3.10 (a2)
3.36 (a1)
3.7± 0.03 (c)
4.0±0.03(500) 900 1,400
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
- 15.1 1,000 112 ± 1.6 ±4 Rack a1~a2(v)
Z 8.9±0.5 510 22 ± 1.5 ± 14 Rack c(v)
A R1(15.1) 1,000 112 ± 1 - Lever a1~a2(v)
BR1
+2.151,400 (123.5) ± 2 - Lever b1~b2(v)
IApprox.
R1+0.3150 (200) - Lever c(v)
D* 16.6±0.1 1,400 (115) - Lever b1~b2(v)
107492-1080 7/11
5. Injection quantity
Cylinder variation
adjustment standardBasic
BasicBoost press. kPa{mmHg}Above 44.7{Above 335}
Cylinder variation
adjustment standard
Boost press. 0
Boost press. kPa{mmHg}Above 44.7 {Above 335 }Negative press. kPa{mmHg} 53.3 kPa{ 400 mmHg}
D*: Aneroid compensator actuator adjustment point
Boost press. kPa{mmHg}Above 44.7{Above 335}
107492-1080 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
107492-1080 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 1,400 r/min.
(4) Apply at least 44.7 kPa { 335 mmHg} boost pressure to the boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt so control rack
position is 16.6±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
107492-1080 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 44.7 kPa
{at least 335 mmHg} boost pressure and confirm rack position is R1 = 15.1 mm and
fuel injection quantity is 112± 1 mm3/st at N = 1,000 r/min.
(2) Remove rack position measuring device.
(3) Attach rack sensor core to control rack.
At this time, hold control rack using a spanner (to prevent the rack from bending).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 44.7 kPa {at least 335 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 = 2.65±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
107492-1080 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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°06′26″±
20′
13°±3°
(35°)
(96°)
(3°12′32″)
11. Drive Coupling Timing
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1081ENGINE MODEL: 4HE1-X
No.
Governor: 105934-0070
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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97212-182-0
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'
2
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*)
107492-1081 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
107492-1081 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 12 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 7.3 -0.1 V.
Adjusting pointConfirmation point
Pre-stroke (mm) Output voltage (actual) Remarks
a3.36 a1 + tolerance
3.10 a2 -tolerance
b2.72 b1 + tolerance
2.52 b2 -tolerance
(calculate from each specification)
107492-1081 4/11
Rac
k po
sitio
n (
mm
)
Idling adjustment
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
Boost compensator stroke: 1.35 ±0.1
Torque cam No. “ AF59”
Pump speed (r/min)
Confirm rack sensor Vist = 2.65±0.28
at supply voltage 5±0.01V , N =1000 r/min , R = R1 (15.1).
4. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+2.15Approx.R1+0.3
R1(15.1)
R2 [R1-2.15]
10.6± 1.0
0250-40 (650) 1000 (1350)
(1600)
1690
1810
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
(1450)
14.0± 0.1
107492-1081 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]
R2-1.35
Approx. 31.3 {Approx. 235}
12.0± 1.3 {90± 10}
PushrodC
0
107492-1081 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 44.7 kPa {at least 335 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 = 1,400 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.72 b1 + tolerance
2.52 b2 -tolerance
2.52 (b2)
2.72 (b1)
3.10 (a2)
3.36 (a1)
3.7± 0.03 (c)
4.0±0.03(500) 900 1,400
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
- 15.1 1,000 112 ± 1.6 ±4 Rack a1~a2(v)
Z 8.9±0.5 510 22 ± 1.5 ± 14 Rack c(v)
A R1(15.1) 1,000 112 ± 1 - Lever a1~a2(v)
BR1
+2.151,400 (123.5) ± 2 - Lever b1~b2(v)
IApprox.
R1+0.3150 (200) - Lever c(v)
D* 16.6±0.1 1,400 (115) - Lever b1~b2(v)
107492-1081 7/11
5. Injection quantity
Cylinder variation
adjustment standardBasic
BasicBoost press. kPa{mmHg}Above 44.7{Above 335}
Cylinder variation
adjustment standard
Boost press. 0
Boost press. kPa{mmHg}Above 44.7 {Above 335 }Negative press. kPa{mmHg} 53.3 kPa{ 400 mmHg}
D*: Aneroid compensator actuator adjustment point
Boost press. kPa{mmHg}Above 44.7{Above 335}
107492-1081 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
107492-1081 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 1,400 r/min.
(4) Apply at least 44.7 kPa { 335 mmHg} boost pressure to the boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt so control rack
position is 16.6±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
107492-1081 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 44.7 kPa
{at least 335 mmHg} boost pressure and confirm rack position is R1 = 15.1 mm and
fuel injection quantity is 112± 1 mm3/st at N = 1,000 r/min.
(2) Remove rack position measuring device.
(3) Attach rack sensor core to control rack.
At this time, hold control rack using a spanner (to prevent the rack from bending).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 44.7 kPa {at least 335 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 = 2.65±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
107492-1081 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1082ENGINE MODEL: 4HE1-X
No.
Governor: 105934-0070
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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97212-182-0
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'
6
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*)
107492-1082 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
107492-1082 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 12 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 7.3 -0.1 V.
Adjusting pointConfirmation point
Pre-stroke (mm) Output voltage (actual) Remarks
a3.36 a1 + tolerance
3.10 a2 -tolerance
b2.72 b1 + tolerance
2.52 b2 -tolerance
(calculate from each specification)
107492-1082 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. “ AF59”
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. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+2.15Approx.R1+0.3
R1(15.0)
R2 [R1-2.15]
10.7± 1.0
0250-40 (650) 1000 (1350)
(1600)
1690
1810
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
(1450)
13.9± 0.1
107492-1082 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
107492-1082 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 = 1,400 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.72 b1 + tolerance
2.52 b2 -tolerance
2.52 (b2)
2.72 (b1)
3.10 (a2)
3.36 (a1)
3.7± 0.03 (c)
4.0±0.03(500) 900 1,400
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)
BR1
+2.151,400 (121.5) ± 2 - Lever b1~b2(v)
IApprox.
R1+0.3150 (180) - Lever c(v)
D* 16.6±0.1 1,400 (115) - Lever b1~b2(v)
107492-1082 7/11
5. Injection quantity
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}
107492-1082 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
107492-1082 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 1,400 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 16.6±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
107492-1082 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.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1082 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1083ENGINE MODEL: 4HE1-X
No.
Governor: 105934-0120
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2080 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97212-182-1
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'
7
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*)
107492-1083 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
107492-1083 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 12 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 7.3 -0.1 V.
Adjusting pointConfirmation point
Pre-stroke (mm) Output voltage (actual) Remarks
a3.36 a1 + tolerance
3.10 a2 -tolerance
b2.72 b1 + tolerance
2.52 b2 -tolerance
(calculate from each specification)
107492-1083 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. “ AH15”
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. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+2.15Approx.R1+0.3
R1(15.0)
R2 [R1-2.15]
10.7± 1.0
0300-40 (650) 1000 (1350)
(1600)
1690
1810
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
260
H J
(1450)
13.9± 0.1
107492-1083 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
107492-1083 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 = 1,400 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.72 b1 + tolerance
2.52 b2 -tolerance
2.52 (b2)
2.72 (b1)
3.10 (a2)
3.36 (a1)
3.7± 0.03 (c)
4.0±0.03(500) 900 1,400
2.0 + 0.03- 0.10
0
107492-1083 7/11
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)
BR1
+2.151,400 (121.5) ± 2 - Lever b1~b2(v)
IApprox.
R1+0.3150 (180) - Lever c(v)
D* 16.6±0.1 1,400 (115) - Lever b1~b2(v)
5. Injection quantity
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}
107492-1083 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
107492-1083 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 1,400 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 16.6±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
107492-1083 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.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1083 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1084ENGINE MODEL: 4HE1-X
No.
Governor: 105934-0120
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2063 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:14 Mar.2003
ISUZU8-97212-182-2
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'
8
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*)
107492-1084 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
107492-1084 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 12 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 7.3 -0.1 V.
Adjusting pointConfirmation point
Pre-stroke (mm) Output voltage (actual) Remarks
a3.36 a1 + tolerance
3.10 a2 -tolerance
b2.72 b1 + tolerance
2.52 b2 -tolerance
(calculate from each specification)
107492-1084 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. “ AH15”
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. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+2.15Approx.R1+0.3
R1(15.0)
R2 [R1-2.15]
10.7± 1.0
0300-40 (650) 1000 (1350)
(1600)
1690
1810
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
260
H J
(1450)
13.9± 0.1
107492-1084 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
107492-1084 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 = 1,400 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.72 b1 + tolerance
2.52 b2 -tolerance
2.52 (b2)
2.72 (b1)
3.10 (a2)
3.36 (a1)
3.7± 0.03 (c)
4.0±0.03(500) 900 1,400
2.0 + 0.03- 0.10
0
107492-1084 7/11
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)
BR1
+2.151,400 (121.5) ± 2 - Lever b1~b2(v)
IApprox.
R1+0.3150 (180) - Lever c(v)
D* 16.6±0.1 1,400 (115) - Lever b1~b2(v)
5. Injection quantity
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}
107492-1084 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
107492-1084 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 1,400 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 16.6±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
107492-1084 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.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1084 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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°36′18″±3°
(35°)
(96°)
(3°12′32″)
11. Drive Coupling Timing
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1090ENGINE MODEL: 4HE1-X
No.
Governor: 105934-0080
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2071 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97212-184-0
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'
1
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*)
107492-1090 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
107492-1090 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 12 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 7.3 -0.1 V.
Adjusting pointConfirmation point
Pre-stroke (mm) Output voltage (actual) Remarks
a3.43 a1 + tolerance
3.17 a2 -tolerance
b2.85 b1 + tolerance
2.65 b2 -tolerance
(calculate from each specification)
107492-1090 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. Governor adjustment
4-1. Governor adjustment
Full load 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)
107492-1090 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
107492-1090 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
a3.43 a1 + tolerance
3.17 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.85 b1 + tolerance
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)
107492-1090 7/11
5. Injection quantity
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}
107492-1090 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
107492-1090 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
107492-1090 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).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1090 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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°06′26″±
20′
13°±3°
(35°)
(96°)
(3°12′32″)
11. Drive Coupling Timing
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1091ENGINE MODEL: 4HE1-X
No.
Governor: 105934-0080
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2071 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97212-184-0
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'
2
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*)
107492-1091 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
107492-1091 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 12 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 7.3 -0.1 V.
Adjusting pointConfirmation point
Pre-stroke (mm) Output voltage (actual) Remarks
a3.43 a1 + tolerance
3.17 a2 -tolerance
b2.85 b1 + tolerance
2.65 b2 -tolerance
(calculate from each specification)
107492-1091 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. Governor adjustment
4-1. Governor adjustment
Full load 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)
107492-1091 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
107492-1091 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
a3.43 a1 + tolerance
3.17 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.85 b1 + tolerance
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)
107492-1091 7/11
5. Injection quantity
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}
107492-1091 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
107492-1091 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
107492-1091 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).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1091 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1092ENGINE MODEL: 4HE1-X
No.
Governor: 105934-0130
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2090 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97212-184-1
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'
4
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*)
107492-1092 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
107492-1092 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 12 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 7.3 -0.1 V.
Adjusting pointConfirmation point
Pre-stroke (mm) Output voltage (actual) Remarks
a3.43 a1 + tolerance
3.17 a2 -tolerance
b2.85 b1 + tolerance
2.65 b2 -tolerance
(calculate from each specification)
107492-1092 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. “ AH13”
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. Governor adjustment
4-1. Governor adjustment
Full load 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
0300-40 (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
260
H J
R3 [R1-0.6]+0.5-0.1
(1300)
700
E
(1050)
107492-1092 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
107492-1092 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
a3.43 a1 + tolerance
3.17 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.85 b1 + tolerance
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
107492-1092 7/11
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)
5. Injection quantity
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}
107492-1092 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
107492-1092 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
107492-1092 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).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1092 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1093ENGINE MODEL: 4HE1-X
No.
Governor: 105934-0130
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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:14 Mar.2003
ISUZU8-97212-184-2
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*)
107492-1093 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
107492-1093 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 12 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 7.3 -0.1 V.
Adjusting pointConfirmation point
Pre-stroke (mm) Output voltage (actual) Remarks
a3.43 a1 + tolerance
3.17 a2 -tolerance
b2.85 b1 + tolerance
2.65 b2 -tolerance
(calculate from each specification)
107492-1093 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. “ AH13”
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. Governor adjustment
4-1. Governor adjustment
Full load 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
0300-40 (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
260
H J
R3 [R1-0.6]+0.5-0.1
(1300)
700
E
(1050)
107492-1093 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
107492-1093 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
a3.43 a1 + tolerance
3.17 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.85 b1 + tolerance
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
107492-1093 7/11
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)
5. Injection quantity
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}
107492-1093 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
107492-1093 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
107492-1093 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).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1093 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1100ENGINE 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.
C O N F I D E N T I A L
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'
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*)
107492-1100 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
107492-1100 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)
107492-1100 4/11
Rac
k po
sitio
n (
mm
)
Idling adjustment
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
Boost compensator stroke: 1.35 ±0.1
Torque cam No. “ AF60”
Pump speed (r/min)
Confirm rack sensor Vist = 2.65±0.28
at supply voltage 5±0.01V , N =1000 r/min , R = R1 (15.1).
4. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+0.9
Approx.R1+0.3R1(15.1)
R2 [R1-2.15]
10.6± 1.0
0250-40 (650) 1000 (1150)
(1600)
1690
1810
14.0± 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
107492-1100 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]
R2-1.35
Approx. 31.3 {Approx. 235}
12.0± 1.3 {90± 10}
PushrodC
0
107492-1100 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 44.7 kPa {at least 335 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.96 b1 + tolerance
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
- 15.1 1,000 112 ± 1.6 ±4 Rack a1~a2(v)
Z 8.9±0.5 510 22 ± 1.5 ± 14 Rack c(v)
A R1(15.1) 1,000 112 ± 1 - Lever a1~a2(v)
B R1+0.9 1,200 (115) ± 2 - Lever b1~b2(v)
IApprox.
R1+0.3150 (200) - Lever c(v)
D* 15.3±0.1 1,200 (106) - Lever b1~b2(v)
107492-1100 7/11
5. Injection quantity
Cylinder variation
adjustment standardBasic
BasicBoost press. kPa{mmHg}Above 44.7{Above 335}
Cylinder variation
adjustment standard
Boost press. 0
Boost press. kPa{mmHg}Above 44.7 {Above 335 }Negative press. kPa{mmHg} 53.3 kPa{ 400 mmHg}
D*: Aneroid compensator actuator adjustment point
Boost press. kPa{mmHg}Above 44.7{Above 335}
107492-1100 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
107492-1100 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 44.7 kPa { 335 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
107492-1100 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 44.7 kPa
{at least 335 mmHg} boost pressure and confirm rack position is R1 = 15.1 mm and
fuel injection quantity is 112± 1 mm3/st at N = 1,000 r/min.
(2) Remove rack position measuring device.
(3) Attach rack sensor core to control rack.
At this time, hold control rack using a spanner (to prevent the rack from bending).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 44.7 kPa {at least 335 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 = 2.65±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
107492-1100 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
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.
C O N F I D E N T I A L
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. Governor adjustment
4-1. Governor adjustment
Full load 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.96 b1 + tolerance
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
5. Injection quantity
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.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
of injection position
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
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1102ENGINE MODEL: 4HE1-X
No.
Governor: 105934-0091
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2062 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.
C O N F I D E N T I A L
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*)
107492-1102 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
107492-1102 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)
107492-1102 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. Governor adjustment
4-1. Governor adjustment
Full load 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
107492-1102 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
107492-1102 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.96 b1 + tolerance
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)
107492-1102 7/11
5. Injection quantity
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}
107492-1102 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
107492-1102 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
107492-1102 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.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1102 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
105934-0091Governor: EP/RLD-MInjection pump: TCS4MD
107049-2063
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
Selector switch no.: 00 (for C/U 407910-303*)
Oil temperature: 40+5 °C
Company:
Assy No.: 107492-1103ENGINE MODEL: 4HE1-X
No.
1. Test conditions
Date:
Pump rotation: counter clockwise (viewed from drive side)
kgf/cm2}
CONFIDENTIAL
INJECTION PUMP CALIBRATION DATA
20 Feb 2004
ISUZU
8-97212-185-1
Injection pipe: outer dia. 8 mm × inner dia. 3 mm length 600 mm
Nozzle opening pressure: 20.7 MPa {211 kgf/cm2}
Nozzle: 105780-0120 Nozzle holder: 105780-2190(Bosch type no. 1 688 901 990) (Bosch type no. 9 430 610 144)
Nozzle & nozzle holder assy: 105780-8250 (Bosch type no. 1 688 901 101)
Test oil: ISO4113 or SAE standard test oil {SAE J967d}
6
Transfer pump pressure: 255 kPa {2.6
2. Injection timing
Overflow valve opening pressure: 255 ± 34 kPa {2.6 ± 0.35 kgf/cm2}
1/11
Ambient temperature: 23±5 °C
DIGI switch no.: 11 (for C/U 407980-224*)
Pre-stroke: No. 1 plunger 4.0 ± 0.03 mm
Injection order: 1 3 , 1 4 , 1 290°± 15' 180°± 15' 270°± 15'
Plungers are numbered from Governor side.
Tappet clearance: Manually rotate camshaft 2 ~ 3 times and confirm that it rotates smoothly.
2/11107492-1103
3. Injection timing adjustment
(Refer to 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 counterweight 2 contacts 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 shim 1.
3-3 Individual cylinder's injection order adjustment
Adjust difference between each cylinder's injection angle based on that of No. 1 cylinder using
shim 1.
1
563
4
1
2
1. Setscrew installation 2. Pre-stroke adjustment3. Individual cylinder's injection
order adjustment
3/11107492-1103
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 No. 1 cylinder's output voltage for pre-stroke
lift values in table below.
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)
Advice
If measuring device (P/N 105782-6420) is removed, output voltage (a1, a2) must 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 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 lock-
nut to specified torque.
(3) Confirm solenoid switch operates at 14.5 - 0.1 V.
4/11107492-1103
4. Governor adjustment
4-1 Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw. Fully tighten adjusting nut.
Boost compensator stroke: 1.25±0.1
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
R1+0.9
Approx R1+0.3R1(15.0)
R2 [R1-2.15]
10.7±1.0
0250-40 (650) 1000 (1150) (1600)
16901810
13.9±0.1
Torque cam no. “AF60”
B
A
DI
Rac
k po
sitio
n (
mm
)
Pump speed (r/min)
Idling adjustment
10.0±0.110.5
Approx 8.97.8
6.6±0.1
3.9±0.3
0240
H J
400400
500475 880
Confirm rack sensor Vist = 2.55±0.28at supply voltage 5±0.01V, N = 1000 r/min, R = R1 (15.0).
5/11107492-1103
4-2 Boost compensator adjustment
(1) Select a push rod so C = 37.5±0.5 mm at full boost pressure. (C is distance from end face of
housing to top of lever.)
(2) Adjust boost compensator stroke using screw A (0 boost pressure position adjustment).
Adjust beginning of boost compensator operation by adjusting notch adjusting nut B.
CTop of lever Pushrod
Boost pressure inlet
A: Boost compensator stroke adjusting screw
Boost compensator spring
B: Notch adjusting nut
0
12.0±1.3 {90±10}
N = 500 r/min
R2 [R1-2.15]
Approx 28.7 {Approx 215}
Rac
k po
sitio
n (m
m)
Boost pressure kPa {mmHg}
R2-1.25
6/11107492-1103
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 timing cam adjusting point (point a in table below: Np = 900 r/min).
(4) Perform timing cam adjustment so output voltage is within range of a1 ~ a2 actually measured
for pre-stroke output voltage during injection timing adjustment in 3-4.
Adjusting point Pre-stroke (mm) Output voltage (actual) Remarks
a3.36 a1 + tolerance
3.10 a2 - tolerance
(5) Operate pump at timing cam confirmation point (point b in table below: Np = 1200 r/min).
(6) Confirm that pre-stroke output voltage is within range b1 ~ b2.
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.96 b1 + tolerance
2.76 b2 - tolerance
Pump speed (r/min)
900(500) 12000
3.7±0.03 (c)
4.0±0.03
3.10 (a1)
3.36 (a2)
2.96 (b1)
2.76 (b2)
2.0+0.03-0.10
Pre-stroke at stopper contact
Minimum advance angle adjustment stopper
Solenoid starting advance angle
b (confirmation point)
a (adjusting point)
Pre-stroke (Pre-stroke output voltage)
7/11107492-1103
5. Injection quantity
Adjustingpoint
Rackposition
(mm)
Pumpspeed(r/min)
Injection quantity(cm3 / 1000 strokes)
Max. variationbetween
cylinders (%)Fixed
Pre-strokeat
adjustmentRemarks
- 15.0 1000 109.5 ± 1.6 ±4 Rack a1 ~ a2(v) Basic Cylinder variation adjustment standard
Z 8.9±0.5 510 22 ± 1.5 ±14 Rack c(v) Cylinder variation adjustment standard
A R1(15.0) 1000 109.5 ± 1 - Lever a1 ~ a2(v) Basic Boost press. kPa {mmHg}Above 42.0 {Above 315}
B R1+0.9 1200 112.5 ± 4 - Lever b1 ~ b2(v) Boost press. kPa {mmHg}Above 42.0 {Above 315}
I [R1+0.3]±0.5 150 (180) - Lever c(v) Boost press. 0
D* 15.3±0.1 1200 (106) - Lever b1 ~ b2(v)
Boost press. kPa {mmHg}Above 42.0 {Above 315}Negative press. kPa {mmHg} 53.3 kPa {400 mmHg}
D*: Aneroid compensator actuator adjustment point
8/11107492-1103
6. FICD adjustment
(1) Stop 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 actuator 1 and set pump speed at 450 r/min.
(6) Gradually loosen set bolt 2 then fix bolt using nut when rack position is 8.7±0.1 mm.
(7) Apply above negative pressure several times and confirm FICD actuator is operating properly
and clearance between FICD actuator lever and speed control lever.
1+1mm
Speed control lever
FICD actuator lever
Tightening torque5 ~ 7 N.m {0.5 ~ 0.7 kgf.m}
1 2 3
9/11107492-1103
7. Aneroid compensator actuator adjustment (injection quantity decrease)
Note:
Set actuator after adjusting full rack position.
(1) Stop injection pump.
(2) Adjust wire nuts 1 so full load set lever contacts full load set bolt and aneroid compensator
actuator wire is not loose. Then, fix nuts 1.
(3) Apply 53.3 kPa {400 mmHg} negative pressure to aneroid compensator and set pump speed at
1200 r/min.
(4) Apply at least 42.0 kPa {315 mmHg} boost pressure to boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt 2 so control rack position
is 15.3±0.1 mm and fuel injection quantity is as specified. Then, fix set bolt 2.
Rac
k po
sitio
n (m
m)
Pump speed (r/min)
Stroke
D
Injection quantity decreaseadjustment point
Full load set bolt
Full load set lever
1
2
10/11107492-1103
8. Speed control lever angle 9. Stop lever angle
Stopper bolt H position
Hole (R42)
IdlingFull-speed
29.5°±3°30°±5°Hole (R41.3)
Normal Stop
45°±5°
22.5°±5°
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 = 1000 r/min.
(2) Remove rack position measuring device.
(3) Attach rack sensor core to control rack.
At this time, hold control rack using spanner (to prevent rack from bending).
Specified torque : 3.4 ~ 4.9 N.m {0.35 ~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9 ~ 8.8 N.m {0.7 ~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set to DC 5±0.01V.
(8) Apply at least 42.0 kPa {at least 315 mmHg} boost pressure, set pump speed at N = 1000 r/min,
and hold speed control lever against full speed stopper bolt.
(9) Confirm rack sensor output voltage from digital voltmeter (Vist = 2.55±0.28).
(10) Confirm that voltage changes when speed control lever is moved to idle and full sides.
Rac
k po
sitio
n (m
m)
Pump speed (r/min)
AR1
N
Rack position (mm)
Sen
sor
outp
ut v
olta
ge (
V)
R1
Vist
Set positionR = 1.5±0.2
11/11107492-1103
11. Drive coupling timing
L L
tt
Bracket mark Pump
Engine
Gear hole (Dia. 3 mm)
Gear's threaded hole
Gear side
Pump side
Check hole
Stamp on coupling and bracket(B.T.D.C. 8°)
Mark position of coupling at B.T.D.C. 13°
Timing setting (At pre-stroke 3.7±0.05 mm)
At No. 1 plunger's beginningof injection positionB.T.D.C.: 8°
13°36'18''±3°
(35°)
28°35'14''±20'(96°)
(3°1
2'32
'')
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1110ENGINE MODEL: 4HE1-X
No.
Governor: 105934-0100
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2071 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97212-189-0
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'
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*)
107492-1110 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
107492-1110 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
a3.43 a1 + tolerance
3.17 a2 -tolerance
b2.85 b1 + tolerance
2.65 b2 -tolerance
(calculate from each specification)
107492-1110 4/11
Rac
k po
sitio
n (
mm
)
Idling adjustment
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
Boost compensator stroke: 0.8 ±0.1
Torque cam No. “ AG41”
Pump speed (r/min)
Confirm rack sensor Vist = 2.25±0.28
at supply voltage 5±0.01V , N =1000 r/min , R = R1 (13.5).
4. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+1.85
Approx.R1+1.5R1(13.5)
R2 [R1-1.4]
10.3± 1.0
0250-40 (700) 1000 (1400)
(1560)
1630
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
107492-1110 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 [R1-1.4]
R2-0.8
Approx. 24.7 {Approx. 185}
13.3± 1.3 {100± 10}
PushrodC
0
107492-1110 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 38.0 kPa {at least 285 mmHg}.
(3) Operate pump at the timing cam adjusting point
(point a in table below: Np = 900 r/min).
(4) Perform timing cam adjustment so output voltage is within range of a1 ~ a2 actually
measured for pre-stroke output voltage during injection timing adjustment in 3-4.
(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
a3.43 a1 + tolerance
3.17 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.85 b1 + tolerance
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
- 13.5 1,000 87 ± 1.6 ±4 Rack a1~a2(v)
Z 8.5±0.5 500 19 ± 1.5 ± 14 Rack c(v)
A R1(13.5) 1,000 87 ± 1 - Lever a1~a2(v)
BR1
+1.851,450 (98) ± 2 - Lever b1~b2(v)
IApprox.
R1+1.5150 (175) - Lever c(v)
D* 15.0±0.1 1,450 (94.5) - Lever b1~b2(v)
107492-1110 7/11
5. Injection quantity
Cylinder variation
adjustment standardBasic
BasicBoost press. kPa{mmHg}Above 38.0{Above 285}
Cylinder variation
adjustment standard
Boost press. 0
Boost press. kPa{mmHg}Above 38.0 {Above 285 }Negative press. kPa{mmHg} 53.3 kPa{ 400 mmHg}
D*: Aneroid compensator actuator adjustment point
Boost press. kPa{mmHg}Above 38.0{Above 285}
107492-1110 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
107492-1110 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 38.0 kPa { 285 mmHg} boost pressure to the boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt so control rack
position is 15.0±0.1 mm and fuel injection quantity is as specified. Then, fix the set bolt.
Stroke
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
107492-1110 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 38.0 kPa
{at least 285 mmHg} boost pressure and confirm rack position is R1 = 13.5 mm and
fuel injection quantity is 87± 1 mm3/st at N = 1,000 r/min.
(2) Remove rack position measuring device.
(3) Attach rack sensor core to control rack.
At this time, hold control rack using a spanner (to prevent the rack from bending).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 38.0 kPa {at least 285 mmHg} boost pressure, set pump speed at
N= 1,000 r/min, and hold speed control lever against the full speed stopper bolt.
(9) Confirm the rack sensor output voltage from the digital voltmeter. (Vist = 2.25±0.28)
(10) Confirm that the voltage changes when the speed control lever is moved to the idle and
full sides.
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
107492-1110 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1111ENGINE MODEL: 4HE1-X
No.
Governor: 105934-0100
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2071 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97212-189-0
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'
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*)
107492-1111 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
107492-1111 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
a3.43 a1 + tolerance
3.17 a2 -tolerance
b2.85 b1 + tolerance
2.65 b2 -tolerance
(calculate from each specification)
107492-1111 4/11
Rac
k po
sitio
n (
mm
)
Idling adjustment
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
Boost compensator stroke: 0.8 ±0.1
Torque cam No. “ AG41”
Pump speed (r/min)
Confirm rack sensor Vist = 2.25±0.28
at supply voltage 5±0.01V , N =1000 r/min , R = R1 (13.5).
4. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+1.85
Approx.R1+1.5R1(13.5)
R2 [R1-1.4]
10.3± 1.0
0250-40 (700) 1000 (1400)
(1560)
1630
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
107492-1111 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 [R1-1.4]
R2-0.8
Approx. 24.7 {Approx. 185}
13.3± 1.3 {100± 10}
PushrodC
0
107492-1111 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 38.0 kPa {at least 285 mmHg}.
(3) Operate pump at the timing cam adjusting point
(point a in table below: Np = 900 r/min).
(4) Perform timing cam adjustment so output voltage is within range of a1 ~ a2 actually
measured for pre-stroke output voltage during injection timing adjustment in 3-4.
(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
a3.43 a1 + tolerance
3.17 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.85 b1 + tolerance
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
- 13.5 1,000 87 ± 1.6 ±4 Rack a1~a2(v)
Z 8.5±0.5 500 19 ± 1.5 ± 14 Rack c(v)
A R1(13.5) 1,000 87 ± 1 - Lever a1~a2(v)
BR1
+1.851,450 (98) ± 2 - Lever b1~b2(v)
IApprox.
R1+1.5150 (175) - Lever c(v)
D* 15.0±0.1 1,450 (94.5) - Lever b1~b2(v)
107492-1111 7/11
5. Injection quantity
Cylinder variation
adjustment standardBasic
BasicBoost press. kPa{mmHg}Above 38.0{Above 285}
Cylinder variation
adjustment standard
Boost press. 0
Boost press. kPa{mmHg}Above 38.0 {Above 285 }Negative press. kPa{mmHg} 53.3 kPa{ 400 mmHg}
D*: Aneroid compensator actuator adjustment point
Boost press. kPa{mmHg}Above 38.0{Above 285}
107492-1111 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
107492-1111 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 38.0 kPa { 285 mmHg} boost pressure to the boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt so control rack
position is 15.0±0.1 mm and fuel injection quantity is as specified. Then, fix the set bolt.
Stroke
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
107492-1111 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 38.0 kPa
{at least 285 mmHg} boost pressure and confirm rack position is R1 = 13.5 mm and
fuel injection quantity is 87± 1 mm3/st at N = 1,000 r/min.
(2) Remove rack position measuring device.
(3) Attach rack sensor core to control rack.
At this time, hold control rack using a spanner (to prevent the rack from bending).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 38.0 kPa {at least 285 mmHg} boost pressure, set pump speed at
N= 1,000 r/min, and hold speed control lever against the full speed stopper bolt.
(9) Confirm the rack sensor output voltage from the digital voltmeter. (Vist = 2.25±0.28)
(10) Confirm that the voltage changes when the speed control lever is moved to the idle and
full sides.
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
107492-1111 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1112ENGINE MODEL: 4HE1-X
No.
Governor: 105934-0101
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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:14 Mar.2003
ISUZU8-97212-189-1
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'
4
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*)
107492-1112 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
107492-1112 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
a3.43 a1 + tolerance
3.17 a2 -tolerance
b2.85 b1 + tolerance
2.65 b2 -tolerance
(calculate from each specification)
107492-1112 4/11
Rac
k po
sitio
n (
mm
)
Idling adjustment
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
Boost compensator stroke: 0.8 ±0.1
Torque cam No. “ AG41”
Pump speed (r/min)
Confirm rack sensor Vist = 2.25±0.28
at supply voltage 5±0.01V , N =1000 r/min , R = R1 (13.5).
4. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+1.85
Approx.R1+1.5R1(13.5)
R2 [R1-1.4]
10.3± 1.0
0250-40 (700) 1000 (1400)
(1560)
1630
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
107492-1112 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 [R1-1.4]
R2-0.8
Approx. 24.7 {Approx. 185}
13.3± 1.3 {100± 10}
PushrodC
0
107492-1112 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 38.0 kPa {at least 285 mmHg}.
(3) Operate pump at the timing cam adjusting point
(point a in table below: Np = 900 r/min).
(4) Perform timing cam adjustment so output voltage is within range of a1 ~ a2 actually
measured for pre-stroke output voltage during injection timing adjustment in 3-4.
(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
a3.43 a1 + tolerance
3.17 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.85 b1 + tolerance
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
- 13.5 1,000 87 ± 1.6 ±4 Rack a1~a2(v)
Z 8.5±0.5 500 19 ± 1.5 ± 14 Rack c(v)
A R1(13.5) 1,000 87 ± 1 - Lever a1~a2(v)
BR1
+1.851,450 (98) ± 2 - Lever b1~b2(v)
IApprox.
R1+1.5150 (175) - Lever c(v)
D* 15.0±0.1 1,450 (94.5) - Lever b1~b2(v)
107492-1112 7/11
5. Injection quantity
Cylinder variation
adjustment standardBasic
BasicBoost press. kPa{mmHg}Above 38.0{Above 285}
Cylinder variation
adjustment standard
Boost press. 0
Boost press. kPa{mmHg}Above 38.0 {Above 285 }Negative press. kPa{mmHg} 53.3 kPa{ 400 mmHg}
D*: Aneroid compensator actuator adjustment point
Boost press. kPa{mmHg}Above 38.0{Above 285}
107492-1112 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
107492-1112 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 38.0 kPa { 285 mmHg} boost pressure to the boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt so control rack
position is 15.0±0.1 mm and fuel injection quantity is as specified. Then, fix the set bolt.
Stroke
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
107492-1112 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 38.0 kPa
{at least 285 mmHg} boost pressure and confirm rack position is R1 = 13.5 mm and
fuel injection quantity is 87± 1 mm3/st at N = 1,000 r/min.
(2) Remove rack position measuring device.
(3) Attach rack sensor core to control rack.
At this time, hold control rack using a spanner (to prevent the rack from bending).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 38.0 kPa {at least 285 mmHg} boost pressure, set pump speed at
N= 1,000 r/min, and hold speed control lever against the full speed stopper bolt.
(9) Confirm the rack sensor output voltage from the digital voltmeter. (Vist = 2.25±0.28)
(10) Confirm that the voltage changes when the speed control lever is moved to the idle and
full sides.
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
107492-1112 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1120ENGINE MODEL: 4HE1-X
No.
Governor: 105934-0070
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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97212-186-0
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'
2
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*)
107492-1120 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
107492-1120 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
b2.72 b1 + tolerance
2.52 b2 -tolerance
(calculate from each specification)
107492-1120 4/11
Rac
k po
sitio
n (
mm
)
Idling adjustment
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
Boost compensator stroke: 1.35 ±0.1
Torque cam No. “ AF59”
Pump speed (r/min)
Confirm rack sensor Vist = 2.65±0.28
at supply voltage 5±0.01V , N =1000 r/min , R = R1 (15.1).
4. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+2.15Approx.R1+0.3
R1(15.1)
R2 [R1-2.15]
10.6± 1.0
0250-40 (650) 1000 (1350)
(1600)
1690
1810
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
(1450)
14.0± 0.1
107492-1120 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]
R2-1.35
Approx. 31.3 {Approx. 235}
12.0± 1.3 {90± 10}
PushrodC
0
107492-1120 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 44.7 kPa {at least 335 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 = 1,400 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.72 b1 + tolerance
2.52 b2 -tolerance
2.52 (b2)
2.72 (b1)
3.10 (a2)
3.36 (a1)
3.7± 0.03 (c)
4.0±0.03(500) 900 1,400
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
- 15.1 1,000 112 ± 1.6 ±4 Rack a1~a2(v)
Z 8.9±0.5 510 22 ± 1.5 ± 14 Rack c(v)
A R1(15.1) 1,000 112 ± 1 - Lever a1~a2(v)
BR1
+2.151,400 (123.5) ± 2 - Lever b1~b2(v)
IApprox.
R1+0.3150 (200) - Lever c(v)
D* 16.6±0.1 1,400 (115) - Lever b1~b2(v)
107492-1120 7/11
5. Injection quantity
Cylinder variation
adjustment standardBasic
BasicBoost press. kPa{mmHg}Above 44.7{Above 335}
Cylinder variation
adjustment standard
Boost press. 0
Boost press. kPa{mmHg}Above 44.7 {Above 335 }Negative press. kPa{mmHg} 53.3 kPa{ 400 mmHg}
D*: Aneroid compensator actuator adjustment point
Boost press. kPa{mmHg}Above 44.7{Above 335}
107492-1120 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
107492-1120 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 1,400 r/min.
(4) Apply at least 44.7 kPa { 335 mmHg} boost pressure to the boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt so control rack
position is 16.6±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
107492-1120 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 44.7 kPa
{at least 335 mmHg} boost pressure and confirm rack position is R1 = 15.1 mm and
fuel injection quantity is 112± 1 mm3/st at N = 1,000 r/min.
(2) Remove rack position measuring device.
(3) Attach rack sensor core to control rack.
At this time, hold control rack using a spanner (to prevent the rack from bending).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 44.7 kPa {at least 335 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 = 2.65±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
107492-1120 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1121ENGINE MODEL: 4HE1-X
No.
Governor: 105934-0070
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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97212-186-0
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'
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*)
107492-1121 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
107492-1121 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
b2.72 b1 + tolerance
2.52 b2 -tolerance
(calculate from each specification)
107492-1121 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. “ AF59”
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. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+2.15Approx.R1+0.3
R1(15.0)
R2 [R1-2.15]
10.7± 1.0
0250-40 (650) 1000 (1350)
(1600)
1690
1810
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
(1450)
13.9± 0.1
107492-1121 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
107492-1121 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 = 1,400 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.72 b1 + tolerance
2.52 b2 -tolerance
2.52 (b2)
2.72 (b1)
3.10 (a2)
3.36 (a1)
3.7± 0.03 (c)
4.0±0.03(500) 900 1,400
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)
BR1
+2.151,400 (121.5) ± 2 - Lever b1~b2(v)
IApprox.
R1+0.3150 (180) - Lever c(v)
D* 16.6±0.1 1,400 (115) - Lever b1~b2(v)
107492-1121 7/11
5. Injection quantity
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}
107492-1121 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
107492-1121 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 1,400 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 16.6±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
107492-1121 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.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1121 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1122ENGINE MODEL: 4HE1-X
No.
Governor: 105934-0071
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2062 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97212-186-0
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'
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*)
107492-1122 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
107492-1122 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
b2.72 b1 + tolerance
2.52 b2 -tolerance
(calculate from each specification)
107492-1122 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. “ AF59”
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. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+2.15Approx.R1+0.3
R1(15.0)
R2 [R1-2.15]
10.7± 1.0
0250-40 (650) 1000 (1350)
(1600)
1690
1810
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
(1450)
13.9± 0.1
107492-1122 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
107492-1122 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 = 1,400 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.72 b1 + tolerance
2.52 b2 -tolerance
2.52 (b2)
2.72 (b1)
3.10 (a2)
3.36 (a1)
3.7± 0.03 (c)
4.0±0.03(500) 900 1,400
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)
BR1
+2.151,400 (121.5) ± 2 - Lever b1~b2(v)
IApprox.
R1+0.3150 (180) - Lever c(v)
D* 16.6±0.1 1,400 (115) - Lever b1~b2(v)
107492-1122 7/11
5. Injection quantity
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}
107492-1122 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
107492-1122 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 1,400 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 16.6±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
107492-1122 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.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1122 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1123ENGINE MODEL: 4HE1-X
No.
Governor: 105934-0071
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2063 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:14 Mar.2003
ISUZU8-97212-186-1
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'
4
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*)
107492-1123 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
107492-1123 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
b2.72 b1 + tolerance
2.52 b2 -tolerance
(calculate from each specification)
107492-1123 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. “ AF59”
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. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+2.15Approx.R1+0.3
R1(15.0)
R2 [R1-2.15]
10.7± 1.0
0250-40 (650) 1000 (1350)
(1600)
1690
1810
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
(1450)
13.9± 0.1
107492-1123 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
107492-1123 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 = 1,400 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.72 b1 + tolerance
2.52 b2 -tolerance
2.52 (b2)
2.72 (b1)
3.10 (a2)
3.36 (a1)
3.7± 0.03 (c)
4.0±0.03(500) 900 1,400
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)
BR1
+2.151,400 (121.5) ± 2 - Lever b1~b2(v)
IApprox.
R1+0.3150 (180) - Lever c(v)
D* 16.6±0.1 1,400 (115) - Lever b1~b2(v)
107492-1123 7/11
5. Injection quantity
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}
107492-1123 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
107492-1123 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 1,400 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 16.6±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
107492-1123 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.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1123 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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°36′18″± 3°
(35°)
(96°)
(3°12′32″)
11. Drive Coupling Timing
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1130ENGINE MODEL: 4HE1-X
No.
Governor: 105934-0080
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2071 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:3 Mar.2003
ISUZU8-97212-188-0
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 )
Overflow valve opening pressure: 255 34 kPa { 2.6 0.35 kgf/cm2 }
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
Selector switch No. 00 (For C/U 407910-303*)
Digi switch No. 11 (For C/U 407980-224*)
1 3 , 1 4 , 1 290 15' 180 15' 270 15'
2
107492-1130 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
107492-1130 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
a3.43 a1 + tolerance
3.17 a2 -tolerance
b2.85 b1 + tolerance
2.65 b2 -tolerance
(calculate from each specification)
107492-1130 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. Governor adjustment
4-1. Governor adjustment
Full load 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)
107492-1130 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
107492-1130 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
a3.43 a1 + tolerance
3.17 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.85 b1 + tolerance
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)
107492-1130 7/11
5. Injection quantity
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}
107492-1130 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
107492-1130 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
107492-1130 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).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1130 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1131ENGINE MODEL: 4HE1-X
No.
Governor: 105934-0081
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2072 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97212-188-0
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'
2
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*)
107492-1131 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
107492-1131 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
a3.43 a1 + tolerance
3.17 a2 -tolerance
b2.85 b1 + tolerance
2.65 b2 -tolerance
(calculate from each specification)
107492-1131 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. Governor adjustment
4-1. Governor adjustment
Full load 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)
107492-1131 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
107492-1131 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
a3.43 a1 + tolerance
3.17 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.85 b1 + tolerance
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)
107492-1131 7/11
5. Injection quantity
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}
107492-1131 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
107492-1131 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
107492-1131 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).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1131 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
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.
C O N F I D E N T I A L
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
a3.43 a1 + tolerance
3.17 a2 -tolerance
b2.85 b1 + 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. Governor adjustment
4-1. Governor adjustment
Full load 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
a3.43 a1 + tolerance
3.17 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.85 b1 + tolerance
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
5. Injection quantity
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).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
of injection position
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
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1140ENGINE MODEL: 4HE1-X
No.
Governor: 105934-0070
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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97212-935-0
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'
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*)
107492-1140 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
107492-1140 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
b2.72 b1 + tolerance
2.52 b2 -tolerance
(calculate from each specification)
107492-1140 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. “ AF59”
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. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+2.15Approx.R1+0.3
R1(15.0)
R2 [R1-2.15]
10.7± 1.0
0250-40 (650) 1000 (1350)
(1600)
1690
1810
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
(1450)
13.9± 0.1
107492-1140 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
107492-1140 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 = 1,400 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.72 b1 + tolerance
2.52 b2 -tolerance
2.52 (b2)
2.72 (b1)
3.10 (a2)
3.36 (a1)
3.7± 0.03 (c)
4.0±0.03(500) 900 1,400
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)
BR1
+2.151,400 (121.5) ± 2 - Lever b1~b2(v)
IApprox.
R1+0.3150 (180) - Lever c(v)
D* 16.6±0.1 1,400 (115) - Lever b1~b2(v)
107492-1140 7/11
5. Injection quantity
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}
107492-1140 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
107492-1140 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 1,400 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 16.6±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
107492-1140 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.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1140 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1141ENGINE MODEL: 4HE1-X
No.
Governor: 105934-0071
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2062 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97212-935-0
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'
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*)
107492-1141 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
107492-1141 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
b2.72 b1 + tolerance
2.52 b2 -tolerance
(calculate from each specification)
107492-1141 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. “ AF59”
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. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+2.15Approx.R1+0.3
R1(15.0)
R2 [R1-2.15]
10.7± 1.0
0250-40 (650) 1000 (1350)
(1600)
1690
1810
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
(1450)
13.9± 0.1
107492-1141 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
107492-1141 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 = 1,400 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.72 b1 + tolerance
2.52 b2 -tolerance
2.52 (b2)
2.72 (b1)
3.10 (a2)
3.36 (a1)
3.7± 0.03 (c)
4.0±0.03(500) 900 1,400
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)
BR1
+2.151,400 (121.5) ± 2 - Lever b1~b2(v)
IApprox.
R1+0.3150 (180) - Lever c(v)
D* 16.6±0.1 1,400 (115) - Lever b1~b2(v)
107492-1141 7/11
5. Injection quantity
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}
107492-1141 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
107492-1141 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 1,400 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 16.6±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
107492-1141 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.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1141 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1142ENGINE MODEL: 4HE1-X
No.
Governor: 105934-0071
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2063 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:14 Mar.2003
ISUZU8-97212-935-1
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'
4
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*)
107492-1142 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
107492-1142 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
b2.72 b1 + tolerance
2.52 b2 -tolerance
(calculate from each specification)
107492-1142 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. “ AF59”
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. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+2.15Approx.R1+0.3
R1(15.0)
R2 [R1-2.15]
10.7± 1.0
0250-40 (650) 1000 (1350)
(1600)
1690
1810
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
(1450)
13.9± 0.1
107492-1142 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
107492-1142 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 = 1,400 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.72 b1 + tolerance
2.52 b2 -tolerance
2.52 (b2)
2.72 (b1)
3.10 (a2)
3.36 (a1)
3.7± 0.03 (c)
4.0±0.03(500) 900 1,400
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)
BR1
+2.151,400 (121.5) ± 2 - Lever b1~b2(v)
IApprox.
R1+0.3150 (180) - Lever c(v)
D* 16.6±0.1 1,400 (115) - Lever b1~b2(v)
107492-1142 7/11
5. Injection quantity
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}
107492-1142 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
107492-1142 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 1,400 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 16.6±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
107492-1142 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.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1142 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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°36′18″± 3°
(35°)
(96°)
(3°12′32″)
11. Drive Coupling Timing
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1150ENGINE MODEL: 4HE1-XS
No.
Governor: 105934-0070
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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97257-154-0
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'
1
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*)
107492-1150 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
107492-1150 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 12 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 7.3 -0.1 V.
Adjusting pointConfirmation point
Pre-stroke (mm) Output voltage (actual) Remarks
a3.36 a1 + tolerance
3.10 a2 -tolerance
b2.72 b1 + tolerance
2.52 b2 -tolerance
(calculate from each specification)
107492-1150 4/11
Rac
k po
sitio
n (
mm
)
Idling adjustment
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
Boost compensator stroke: 1.75 ±0.1
Torque cam No. “ AF59”
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. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+2.15
Approx.R1-0.2R1(15.0)
R2 [R1-2.15]
10.7± 1.0
0250-40 (650) 1000 (1350)
(1600)
1690
1810
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
(1450)
13.9± 0.1
107492-1150 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]
R2-1.75
Approx. 28.0 {Approx. 210}
4.7± 1.3 {35± 10}
PushrodC
0
107492-1150 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 41.3 kPa {at least 310 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 = 1,400 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.72 b1 + tolerance
2.52 b2 -tolerance
2.52 (b2)
2.72 (b1)
3.10 (a2)
3.36 (a1)
3.7± 0.03 (c)
4.0±0.03(500) 900 1,400
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)
BR1
+2.151,400 (121.5) ± 2 - Lever b1~b2(v)
IApprox.
R1-0.2150 (145) - Lever c(v)
D* 16.6±0.1 1,400 (115) - Lever b1~b2(v)
107492-1150 7/11
5. Injection quantity
Cylinder variation
adjustment standardBasic
BasicBoost press. kPa{mmHg}Above 41.3{Above 310}
Cylinder variation
adjustment standard
Boost press. 0
Boost press. kPa{mmHg}Above 41.3 {Above 310 }Negative press. kPa{mmHg} 53.3 kPa{ 400 mmHg}
D*: Aneroid compensator actuator adjustment point
Boost press. kPa{mmHg}Above 41.3{Above 310}
107492-1150 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
107492-1150 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 1,400 r/min.
(4) Apply at least 41.3 kPa { 310 mmHg} boost pressure to the boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt so control rack
position is 16.6±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
107492-1150 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 41.3 kPa
{at least 310 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.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 41.3 kPa {at least 310 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
107492-1150 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1151ENGINE MODEL: 4HE1-XS
No.
Governor: 105934-0071
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2062 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97257-154-0
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'
1
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*)
107492-1151 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
107492-1151 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 12 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 7.3 -0.1 V.
Adjusting pointConfirmation point
Pre-stroke (mm) Output voltage (actual) Remarks
a3.36 a1 + tolerance
3.10 a2 -tolerance
b2.72 b1 + tolerance
2.52 b2 -tolerance
(calculate from each specification)
107492-1151 4/11
Rac
k po
sitio
n (
mm
)
Idling adjustment
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
Boost compensator stroke: 1.75 ±0.1
Torque cam No. “ AF59”
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. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+2.15
Approx.R1-0.2R1(15.0)
R2 [R1-2.15]
10.7± 1.0
0250-40 (650) 1000 (1350)
(1600)
1690
1810
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
(1450)
13.9± 0.1
107492-1151 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]
R2-1.75
Approx. 28.0 {Approx. 210}
4.7± 1.3 {35± 10}
PushrodC
0
107492-1151 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 41.3 kPa {at least 310 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 = 1,400 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.72 b1 + tolerance
2.52 b2 -tolerance
2.52 (b2)
2.72 (b1)
3.10 (a2)
3.36 (a1)
3.7± 0.03 (c)
4.0±0.03(500) 900 1,400
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)
BR1
+2.151,400 (121.5) ± 2 - Lever b1~b2(v)
IApprox.
R1-0.2150 (145) - Lever c(v)
D* 16.6±0.1 1,400 (115) - Lever b1~b2(v)
107492-1151 7/11
5. Injection quantity
Cylinder variation
adjustment standardBasic
BasicBoost press. kPa{mmHg}Above 41.3{Above 310}
Cylinder variation
adjustment standard
Boost press. 0
Boost press. kPa{mmHg}Above 41.3 {Above 310 }Negative press. kPa{mmHg} 53.3 kPa{ 400 mmHg}
D*: Aneroid compensator actuator adjustment point
Boost press. kPa{mmHg}Above 41.3{Above 310}
107492-1151 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
107492-1151 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 1,400 r/min.
(4) Apply at least 41.3 kPa { 310 mmHg} boost pressure to the boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt so control rack
position is 16.6±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
107492-1151 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 41.3 kPa
{at least 310 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.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 41.3 kPa {at least 310 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
107492-1151 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1152ENGINE MODEL: 4HE1-XS
No.
Governor: 105934-0140
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2062 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:12 Feb.2002
ISUZU8-97257-154-1
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*)
107492-1152 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
107492-1152 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 12 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 7.3 -0.1 V.
Adjusting pointConfirmation point
Pre-stroke (mm) Output voltage (actual) Remarks
a3.36 a1 + tolerance
3.10 a2 -tolerance
b2.72 b1 + tolerance
2.52 b2 -tolerance
(calculate from each specification)
107492-1152 4/11
Rac
k po
sitio
n (
mm
)
Idling adjustment
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
Boost compensator stroke: 2.1 ±0.1
Torque cam No. “ AH20”
Pump speed (r/min)
Confirm rack sensor Vist = 2.763±0.28
at supply voltage 5±0.01V , N =1000 r/min , R = R1 (15.3).
4. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+2.15
Approx.R1-0.05R1(15.3)
R2 [R1-2.15]
11.9± 1.0
0300-40 (650) 1000 (1350)
(1600)
1690
1775
A
B
D
C
I
10.510.0± 0.1
Approx.9.0
7.8
6.6± 0.1
3.9± 0.3
0 880500
475
400
400
240
H J
(1450)
14.2± 0.1
107492-1152 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]
R2-2.1
Approx. 24.7 {Approx. 185}
5.3± 1.3 {40± 10}
PushrodC
0
107492-1152 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 38.0 kPa {at least 285 mmHg}.
(3) Operate pump at the timing cam adjusting point
(point a in table below: Np = 900 r/min).
(4) Perform timing cam adjustment so output voltage is within range of a1 ~ a2 actually
measured for pre-stroke output voltage during injection timing adjustment in 3-4.
(5) Operate the pump at the timing cam confirmation point
(point b in table below: Np = 1,400 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.72 b1 + tolerance
2.52 b2 -tolerance
2.52 (b2)
2.72 (b1)
3.10 (a2)
3.36 (a1)
3.7± 0.03 (c)
4.0±0.03(500) 900 1,400
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
- 15.3 1,000 109 ± 1.6 ±4 Rack a1~a2(v)
Z 9.0±0.5 540 15.5 ± 1.5 ± 14 Rack c(v)
A R1(15.3) 1,000 109 ± 1 - Lever a1~a2(v)
BR1
+2.151,400 121 ± 4 - Lever b1~b2(v)
IApprox.
R1-0.05150 (145) - Lever c(v)
D* 16.9±0.1 1,400 (115) ± 2 - Lever b1~b2(v)
107492-1152 7/11
5. Injection quantity
Cylinder variation
adjustment standardBasic
BasicBoost press. kPa{mmHg}Above 38.0{Above 285}
Cylinder variation
adjustment standard
Boost press. 0
Boost press. kPa{mmHg}Above 38.0 {Above 285}Negative press. kPa{mmHg} 53.3 kPa{ 400 mmHg}
D*: Aneroid compensator actuator adjustment point
Boost press. kPa{mmHg}Above 38.0{Above 285}
107492-1152 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 9.0±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
107492-1152 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 1,400 r/min.
(4) Apply at least 38.0 kPa { 285 mmHg} boost pressure to the boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt so control rack
position is 16.9±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
107492-1152 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°±3°
30°± 5°
10. Rack Sensor Adjustment
(1) Before removing rack position measuring device, apply at least 38.0 kPa
{at least 285 mmHg} boost pressure and confirm rack position is R1 = 15.3 mm and
fuel injection quantity is 109± 1 mm3/st at N = 1,000 r/min.
(2) Remove rack position measuring device.
(3) Attach rack sensor core to control rack.
At this time, hold control rack using a spanner (to prevent the rack from bending).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 38.0 kPa {at least 285 mmHg} boost pressure, set pump speed at
N= 1,000 r/min, and hold speed control lever against the full speed stopper bolt.
(9) Confirm the rack sensor output voltage from the digital voltmeter. (Vist = 2.763±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
107492-1152 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
105934-0140Governor: EP/RLD-MInjection pump: TCS4MD
107049-2063
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
Selector switch no.: 00 (for C/U 407910-303*)
Oil temperature: 40+5 °C
Company:
Assy No.: 107492-1153ENGINE MODEL: 4HE1-XS
No.
1. Test conditions
Date:
Pump rotation: counter clockwise (viewed from drive side)
kgf/cm2}
CONFIDENTIAL
INJECTION PUMP CALIBRATION DATA
20 Feb 2004
ISUZU
8-97257-154-2
Injection pipe: outer dia. 8 mm × inner dia. 3 mm length 600 mm
Nozzle opening pressure: 20.7 MPa {211 kgf/cm2}
Nozzle: 105780-0120 Nozzle holder: 105780-2190(Bosch type no. 1 688 901 990) (Bosch type no. 9 430 610 144)
Nozzle & nozzle holder assy: 105780-8250 (Bosch type no. 1 688 901 101)
Test oil: ISO4113 or SAE standard test oil {SAE J967d}
4
Transfer pump pressure: 255 kPa {2.6
2. Injection timing
Overflow valve opening pressure: 255 ± 34 kPa {2.6 ± 0.35 kgf/cm2}
1/11
Ambient temperature: 23±5 °C
DIGI switch no.: 11 (for C/U 407980-224*)
Pre-stroke: No. 1 plunger 4.0 ± 0.03 mm
Injection order: 1 3 , 1 4 , 1 290°± 15' 180°± 15' 270°± 15'
Plungers are numbered from Governor side.
Tappet clearance: Manually rotate camshaft 2 ~ 3 times and confirm that it rotates smoothly.
2/11107492-1153
3. Injection timing adjustment
(Refer to 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 counterweight 2 contacts 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 shim 1.
3-3 Individual cylinder's injection order adjustment
Adjust difference between each cylinder's injection angle based on that of No. 1 cylinder using
shim 1.
1
563
4
1
2
1. Setscrew installation 2. Pre-stroke adjustment3. Individual cylinder's injection
order adjustment
3/11107492-1153
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 No. 1 cylinder's output voltage for pre-stroke
lift values in table below.
Adjusting pointConfirmation point Pre-stroke (mm) Output voltage (actual) Remarks
a3.36 a1 + tolerance
3.10 a2 - tolerance
b2.72 b1 + tolerance
2.52 b2 - tolerance
(calculate from each specification)
Advice
If measuring device (P/N 105782-6420) is removed, output voltage (a1, a2) must 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 output voltage (c) at this time.
3-6 Solenoid switch adjustment
(1) Apply 12 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 lock-
nut to specified torque.
(3) Confirm solenoid switch operates at 7.3 - 0.1 V.
4/11107492-1153
4. Governor adjustment
4-1 Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw. Fully tighten adjusting nut.
Boost compensator stroke: 2.1±0.1
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
R1+2.15
Approx R1-0.05R1(15.3)
R2 [R1-2.15]
11.9±1.0
0300-40 (650) 1000 (1350) (1450)
(1600)1690
14.2±0.1
Torque cam no. “AH20”
B
A D
I
Rac
k po
sitio
n (
mm
)
Pump speed (r/min)
Idling adjustment
10.0±0.110.5
Approx 9.07.8
6.6±0.1
3.9±0.3
0240
H J
400400
500475 880
Confirm rack sensor Vist = 2.763±0.28at supply voltage 5±0.01V, N = 1000 r/min, R = R1 (15.3).
1775
5/11107492-1153
4-2 Boost compensator adjustment
(1) Select a push rod so C = 37.5±0.5 mm at full boost pressure. (C is distance from end face of
housing to top of lever.)
(2) Adjust boost compensator stroke using screw A (0 boost pressure position adjustment).
Adjust beginning of boost compensator operation by adjusting notch adjusting nut B.
CTop of lever Pushrod
Boost pressure inlet
A: Boost compensator stroke adjusting screw
Boost compensator spring
B: Notch adjusting nut
0
5.3±1.3 {40±10}
N = 500 r/min
R2 [R1-2.15]
Approx 24.7 {Approx 185}
Rac
k po
sitio
n (m
m)
Boost pressure kPa {mmHg}
R2-2.1
6/11107492-1153
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 38.0 kPa {at least 285 mmHg}.
(3) Operate pump at timing cam adjusting point (point a in table below: Np = 1000 r/min).
(4) Perform timing cam adjustment so output voltage is within range of a1 ~ a2 actually measured
for pre-stroke output voltage during injection timing adjustment in 3-4.
Adjusting point Pre-stroke (mm) Output voltage (actual) Remarks
a3.36 a1 + tolerance
3.10 a2 - tolerance
(5) Operate pump at timing cam confirmation point (point b in table below: Np = 1400 r/min).
(6) Confirm that pre-stroke output voltage is within range b1 ~ b2.
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.72 b1 + tolerance
2.52 b2 - tolerance
Pump speed (r/min)
900(500) 14000
3.7±0.03 (c)
4.0±0.03
3.36 (a1)
3.10 (a2)
2.72 (b1)
2.52 (b2)
2.0+0.03-0.10
Pre-stroke at stopper contact
Minimum advance angle adjustment stopper
Solenoid starting advance angle
b (confirmation point)
a (adjusting point)
Pre-stroke (Pre-stroke output voltage)
7/11107492-1153
5. Injection quantity
Adjustingpoint
Rackposition
(mm)
Pumpspeed(r/min)
Injection quantity(cm3 / 1000 strokes)
Max. variationbetween
cylinders (%)Fixed
Pre-strokeat
adjustmentRemarks
- 15.3 1000 109 ± 1.6 ±4 Rack a1 ~ a2(v) Basic Cylinder variation adjustment standard
Z 9.0±0.5 540 15.5 ± 1.5 ±14 Rack c(v) Cylinder variation adjustment standard
A R1(15.3) 1000 109 ± 1 - Lever a1 ~ a2(v) Basic Boost press. kPa {mmHg}Above 38.0 {Above 285}
B R1+2.15 1400 121 ± 4 - Lever b1 ~ b2(v) Boost press. kPa {mmHg}Above 38.0 {Above 285}
I [R1-0.05]±0.5 150 (145) - Lever c(v) Boost press. 0
D* 16.9±0.1 1400 (115) - Lever b1 ~ b2(v)
Boost press. kPa {mmHg}Above 38.0 {Above 285}Negative press. kPa {mmHg} 53.3 kPa {400 mmHg}
D*: Aneroid compensator actuator adjustment point
8/11107492-1153
6. FICD adjustment
(1) Stop 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 actuator 1 and set pump speed at 450 r/min.
(6) Gradually loosen set bolt 2 then fix bolt using nut when rack position is 9.0±0.1 mm.
(7) Apply above negative pressure several times and confirm FICD actuator is operating properly
and clearance between FICD actuator lever and speed control lever.
1+1mm
Speed control lever
FICD actuator lever
Tightening torque5 ~ 7 N.m {0.5 ~ 0.7 kgf.m}
1 2 3
9/11107492-1153
7. Aneroid compensator actuator adjustment (injection quantity decrease)
Note:
Set actuator after adjusting full rack position.
(1) Stop injection pump.
(2) Adjust wire nuts 1 so full load set lever contacts full load set bolt and aneroid compensator
actuator wire is not loose. Then, fix nuts 1.
(3) Apply 53.3 kPa {400 mmHg} negative pressure to aneroid compensator and set pump speed at
1400 r/min.
(4) Apply at least 38.0 kPa {285 mmHg} boost pressure to boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt 2 so control rack position
is 16.9±0.1 mm and fuel injection quantity is as specified. Then, fix set bolt 2.
Rac
k po
sitio
n (m
m)
Pump speed (r/min)
Stroke
D
Injection quantity decreaseadjustment point
Full load set bolt
Full load set lever
1
2
10/11107492-1153
8. Speed control lever angle 9. Stop lever angle
Stopper bolt H position
Hole (R42)
Idling
Full-speed
30°±5°30.5°±3°
Hole (R41.3)
Normal Stop
45°±5°
22.5°±5°
10. Rack sensor adjustment
(1) Before removing rack position measuring device, apply at least 38.0 kPa {at least 285 mmHg}
boost pressure and confirm rack position is R1 = 15.3 mm and fuel injection quantity is 109±1
mm3/st at N = 1000 r/min.
(2) Remove rack position measuring device.
(3) Attach rack sensor core to control rack.
At this time, hold control rack using spanner (to prevent rack from bending).
Specified torque : 3.4 ~ 4.9 N.m {0.35 ~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9 ~ 8.8 N.m {0.7 ~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set to DC 5±0.01V.
(8) Apply at least 38.0 kPa {at least 285 mmHg} boost pressure, set pump speed at N = 1000 r/min,
and hold speed control lever against full speed stopper bolt.
(9) Confirm rack sensor output voltage from digital voltmeter (Vist = 2.763±0.28).
(10) Confirm that voltage changes when speed control lever is moved to idle and full sides.
Rac
k po
sitio
n (m
m)
Pump speed (r/min)
AR1
N
Rack position (mm)
Sen
sor
outp
ut v
olta
ge (
V)
R1
Vist
Set positionR = 1.5±0.2
11/11107492-1153
11. Drive coupling timing
L L
tt
Bracket mark Pump
Engine
Gear hole (Dia. 3 mm)
Gear's threaded hole
Gear side
Pump side
Check hole
Stamp on coupling and bracket(B.T.D.C. 8°)
Mark position of coupling at B.T.D.C. 13°
Timing setting (At pre-stroke 3.7±0.05 mm)
At No. 1 plunger's beginningof injection positionB.T.D.C.: 8°
13°36'18''±3°
(35°)
28°35'14''±20'(96°)
(3°1
2'32
'')
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1160ENGINE MODEL: 4HE1-XS
No.
Governor: 105934-0110
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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97225-432-1
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'
1
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*)
107492-1160 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
107492-1160 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 3.84 ~ 3.90. 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
a3.70 a1 + tolerance
3.44 a2 -tolerance
b3.24 b1 + tolerance
3.04 b2 -tolerance
(calculate from each specification)
107492-1160 4/11
Idling adjustment
Rac
k po
sitio
n (
mm
)
Pump speed (r/min)
Confirm rack sensor Vist = 2.77±0.28
at supply voltage 5±0.01V , N =1000 r/min , R = R1 (16.1).
4. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
10.510.0± 0.1
Approx.8.7
7.8
6.6± 0.1
4.3± 0.5
0 750500
475
400
400
240
H J
Rac
k po
sitio
n (
mm
)
Pump speed (r/min)
Boost compensator stroke: 1.65 ±0.1
Torque cam No. “ AG80”
R1+0.45
Approx.R1+0.05R1(16.1)
R2 [R1-2.55]
13.2± 1.0
0250-40 (650) 1000 (1085) 1300
1400
A
B
D
(1180)
14.75± 0.1
107492-1160 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 = 400 r/min
R2 [R1-2.55]
R2-1.65
Approx. 30.7 {Approx. 230}
12.0± 1.3 {90± 10}
PushrodC
0
107492-1160 6/11
4-3 Timing cam adjustment (Timing cam No:510)
(1) Hold speed control lever against full speed stopper bolt.
(2) Supply boost pressure of at least 44.0 kPa {at least 330 mmHg}.
(3) Operate pump at the timing cam adjusting point
(point a in table below: Np = 1,000 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
a3.70 a1 + tolerance
3.44 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b3.24 b1 + tolerance
3.04 b2 -tolerance
3.04 (b2)
3.24 (b1)
3.44 (a2)
3.70 (a1)
3.87±0.03 (c)
4.0±0.03(800) 1,000 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
- 16.1 1,000 124 ± 1.6 ±4 Rack a1~a2(v)
Z 8.7±0.5 585 14 ± 1.5 ± 14 Rack c(v)
A R1(16.1) 1,000 124 ± 1 - Lever a1~a2(v)
BR1
+0.451,150 123.5 ± 4 - Lever b1~b2(v)
I
Approx.
R1
+0.05
150 (225) - Lever c(v)
D*16.15
±0.11,150 (118.5) - Lever b1~b2(v)
107492-1160 7/11
5. Injection quantity
Cylinder variation
adjustment standardBasic
BasicBoost press. kPa{mmHg}Above 44.0{Above 330}
Cylinder variation
adjustment standard
Boost press. kPa{mmHg}Above 44.0 {Above 330 }Negative press. kPa{mmHg} 53.3 kPa{ 400 mmHg}
D*: Aneroid compensator actuator adjustment point
Boost press. kPa{mmHg}Above 44.0{Above 330}
Boost press. 0
107492-1160 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 8.1±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
107492-1160 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 1,150 r/min.
(4) Apply at least 44.0 kPa { 330 mmHg} boost pressure to the boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt so control rack
position is 16.15± 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
107492-1160 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,
N=0
StopNormal
45°±5°
22.5°±5°
32°±5°
23°± 3°
10. Rack Sensor Adjustment
(1) Before removing rack position measuring device, apply at least 44.0 kPa
{at least 330 mmHg} boost pressure and confirm rack position is R1 = 16.1 mm and
fuel injection quantity is 124± 1 mm3/st at N = 1,000 r/min.
(2) Remove rack position measuring device.
(3) Attach rack sensor core to control rack.
At this time, hold control rack using a spanner (to prevent the rack from bending).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 44.0 kPa {at least 330 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 = 2.77±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
107492-1160 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
B.T.D.C. : 9°
(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. 9°°°°°)
Mark position of coupling at B.T.D.C. 13°°°°°
Check hole
28°05′14″±
20′
12°58′48″± 3°
(35°)
(96°)
(3°12′32″)
11. Drive Coupling Timing
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1161ENGINE MODEL: 4HE1-XS
No.
Governor: 105934-0111
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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97225-432-1
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'
1
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*)
107492-1161 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
107492-1161 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 3.84 ~ 3.90. 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
a3.70 a1 + tolerance
3.44 a2 -tolerance
b3.24 b1 + tolerance
3.04 b2 -tolerance
(calculate from each specification)
107492-1161 4/11
Rac
k po
sitio
n (
mm
)
Idling adjustment
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
Boost compensator stroke: 1.65 ±0.1
Torque cam No. “ AG80”
Pump speed (r/min)
Confirm rack sensor Vist = 2.77±0.28
at supply voltage 5±0.01V , N =1000 r/min , R = R1 (16.1).
4. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+0.45
Approx.R1+0.05R1(16.1)
R2 [R1-2.55]
13.2± 1.0
0250-40 (650) 1000 (1085) 1300
1400
A
B
D
10.510.0± 0.1
Approx.8.7
7.8
6.6± 0.1
4.3± 0.5
0 750500
475
400
400
240
H J
(1180)
14.75± 0.1
107492-1161 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 = 400 r/min
R2 [R1-2.55]
R2-1.65
Approx. 30.7 {Approx. 230}
12.0± 1.3 {90± 10}
PushrodC
0
107492-1161 6/11
4-3 Timing cam adjustment (Timing cam No:510)
(1) Hold speed control lever against full speed stopper bolt.
(2) Supply boost pressure of at least 44.0 kPa {at least 330 mmHg}.
(3) Operate pump at the timing cam adjusting point
(point a in table below: Np = 1,000 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
a3.70 a1 + tolerance
3.44 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b3.24 b1 + tolerance
3.04 b2 -tolerance
3.04 (b2)
3.24 (b1)
3.44 (a2)
3.70 (a1)
3.87±0.03 (c)
4.0±0.03(800) 1,000 1,200
2.0 + 0.03- 0.10
0
107492-1161 7/11
Adjustingpoint
Rackposition( mm )
Pumpspeed
( r/min )
Injection q'ty( cm3/100 strokes )
Max.variationbetweencylinders
FixedPre-stroke
at adjustmentRemarks
- 16.1 1,000 124 ± 1.6 ±4 Rack a1~a2(v)
Z 8.7±0.5 585 14 ± 1.5 ± 14 Rack c(v)
A R1(16.1) 1,000 124 ± 1 - Lever a1~a2(v)
BR1
+0.451,150 123.5 ± 4 - Lever b1~b2(v)
I
Approx.
R1
+0.05
150 (225) - Lever c(v)
D*16.15
±0.11,150 (118.5) - Lever b1~b2(v)
5. Injection quantity
Cylinder variation
adjustment standardBasic
BasicBoost press. kPa{mmHg}Above 44.0{Above 330}
Cylinder variation
adjustment standard
Boost press. kPa{mmHg}Above 44.0 {Above 330 }Negative press. kPa{mmHg} 53.3 kPa{ 400 mmHg}
D*: Aneroid compensator actuator adjustment point
Boost press. kPa{mmHg}Above 44.0{Above 330}
Boost press. 0
107492-1161 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 8.1±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
107492-1161 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 1,150 r/min.
(4) Apply at least 44.0 kPa { 330 mmHg} boost pressure to the boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt so control rack
position is 16.15± 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
107492-1161 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,
N=0
StopNormal
45°±5°
22.5°±5°
32°±5°
23°± 3°
10. Rack Sensor Adjustment
(1) Before removing rack position measuring device, apply at least 44.0 kPa
{at least 330 mmHg} boost pressure and confirm rack position is R1 = 16.1 mm and
fuel injection quantity is 124± 1 mm3/st at N = 1,000 r/min.
(2) Remove rack position measuring device.
(3) Attach rack sensor core to control rack.
At this time, hold control rack using a spanner (to prevent the rack from bending).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 44.0 kPa {at least 330 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 = 2.77±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
107492-1161 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
B.T.D.C. : 9°
(At pre-stroke 3.7± 0.05mm)
Pump
Engine
Bracket mark
Gear hole (Dia. 3mm)
Gear’s threaded hole
Gear side
Pump side
Mark position of coupling at B.T.D.C. 13°°°°°
Check hole
28°05′14″±
20′
12°58′48″± 3°
(35°)
(96°)
(3°12′32″)
11. Drive Coupling Timing
Stamp on coupling and bracket
(B.T.D.C. 9°°°°°)
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1162ENGINE MODEL: 4HE1-XS
No.
Governor: 105934-0112
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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97225-432-1
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'
2
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*)
107492-1162 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
107492-1162 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 3.84 ~ 3.90. 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
a3.70 a1 + tolerance
3.44 a2 -tolerance
b3.24 b1 + tolerance
3.04 b2 -tolerance
(calculate from each specification)
107492-1162 4/11
Rac
k po
sitio
n (
mm
)
Idling adjustment
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
Boost compensator stroke: 1.65 ±0.1
Torque cam No. “ AG80”
Pump speed (r/min)
Confirm rack sensor Vist = 2.77±0.28
at supply voltage 5±0.01V , N =1000 r/min , R = R1 (16.1).
4. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
[R1+0.45]
Approx.R1+0.05R1(16.1)
R2 [R1-2.55]
13.2± 1.0
0250-40 (650) 1000 (1085) 1300
1400
A
B
D
10.510.0± 0.1
Approx.8.7
7.8
6.6± 0.1
4.3± 0.5
0 750500
475
400
400
240
H J
(1180)
14.75± 0.1
+0.05-0.15
107492-1162 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 = 400 r/min
R2 [R1-2.55]
R2-1.65
Approx. 30.7 {Approx. 230}
12.0± 1.3 {90± 10}
PushrodC
0
107492-1162 6/11
4-3 Timing cam adjustment (Timing cam No:510)
(1) Hold speed control lever against full speed stopper bolt.
(2) Supply boost pressure of at least 44.0 kPa {at least 330 mmHg}.
(3) Operate pump at the timing cam adjusting point
(point a in table below: Np = 1,000 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
a3.70 a1 + tolerance
3.44 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b3.24 b1 + tolerance
3.04 b2 -tolerance
3.04 (b2)
3.24 (b1)
3.44 (a2)
3.70 (a1)
3.87±0.03 (c)
4.0±0.03(800) 1,000 1,200
2.0 + 0.03- 0.10
0
107492-1162 7/11
Adjustingpoint
Rackposition( mm )
Pumpspeed
( r/min )
Injection q'ty( cm3/100 strokes )
Max.variationbetweencylinders
FixedPre-stroke
at adjustmentRemarks
- 16.1 1,000 124 ± 1.6 ±4 Rack a1~a2(v)
Z 8.7±0.5 585 14 ± 1.5 ± 14 Rack c(v)
A R1(16.1) 1,000 124 ± 1 - Lever a1~a2(v)
B
R1+0.45
+0.05
-0.15
1,150 123.5 ± 4 - Lever b1~b2(v)
IApprox.
R1+0.05150 (225) - Lever c(v)
D*16.15
±0.11,150 (118.5) - Lever b1~b2(v)
5. Injection quantity
Cylinder variation
adjustment standardBasic
BasicBoost press. kPa{mmHg}Above 44.0{Above 330}
Cylinder variation
adjustment standard
Boost press. kPa{mmHg}Above 44.0 {Above 330 }Negative press. kPa{mmHg} 53.3 kPa{ 400 mmHg}
D*: Aneroid compensator actuator adjustment point
Boost press. kPa{mmHg}Above 44.0{Above 330}
Boost press. 0
107492-1162 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 8.45± 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
107492-1162 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 1,150 r/min.
(4) Apply at least 44.0 kPa { 330 mmHg} boost pressure to the boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt so control rack
position is 16.15± 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
107492-1162 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,
N=0
StopNormal
45°±5°
22.5°±5°
32°±5°
23°± 3°
10. Rack Sensor Adjustment
(1) Before removing rack position measuring device, apply at least 44.0 kPa
{at least 330 mmHg} boost pressure and confirm rack position is R1 = 16.1 mm and
fuel injection quantity is 124± 1 mm3/st at N = 1,000 r/min.
(2) Remove rack position measuring device.
(3) Attach rack sensor core to control rack.
At this time, hold control rack using a spanner (to prevent the rack from bending).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 44.0 kPa {at least 330 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 = 2.77±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
107492-1162 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
B.T.D.C. : 9°
(At pre-stroke 3.7± 0.05mm)
Pump
Engine
Bracket mark
Gear hole (Dia. 3mm)
Gear’s threaded hole
Gear side
Pump side
Mark position of coupling at B.T.D.C. 13°°°°°
Check hole
28°05′14″±
20′
12°58′48″± 3°
(35°)
(96°)
(3°12′32″)
11. Drive Coupling Timing
Stamp on coupling and bracket
(B.T.D.C. 9°°°°°)
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1163ENGINE MODEL: 4HE1-XS
No.
Governor: 105934-0113
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2062 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Nov.2001
ISUZU8-97225-432-1
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'
2
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*)
107492-1163 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
107492-1163 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 3.84 ~ 3.90. 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
a3.70 a1 + tolerance
3.44 a2 -tolerance
b3.24 b1 + tolerance
3.04 b2 -tolerance
(calculate from each specification)
107492-1163 4/11
Rac
k po
sitio
n (
mm
)
Idling adjustment
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
Boost compensator stroke: 1.65 ±0.1
Torque cam No. “ AG80”
Pump speed (r/min)
Confirm rack sensor Vist = 2.77±0.28
at supply voltage 5±0.01V , N =1000 r/min , R = R1 (16.1).
4. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
[R1+0.45]
Approx.R1+0.05R1(16.1)
R2 [R1-2.55]
13.2± 1.0
0250-40 (650) 1000 (1085) 1300
1400
A
B
D
10.510.0± 0.1
Approx.8.7
7.8
6.6± 0.1
4.3± 0.5
0 750500
475
400
400
240
H J
(1180)
14.75± 0.1
+0.05-0.15
107492-1163 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 = 400 r/min
R2 [R1-2.55]
R2-1.65
Approx. 30.7 {Approx. 230}
12.0± 1.3 {90± 10}
PushrodC
0
107492-1163 6/11
4-3 Timing cam adjustment (Timing cam No:510)
(1) Hold speed control lever against full speed stopper bolt.
(2) Supply boost pressure of at least 44.0 kPa {at least 330 mmHg}.
(3) Operate pump at the timing cam adjusting point
(point a in table below: Np = 1,000 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
a3.70 a1 + tolerance
3.44 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b3.24 b1 + tolerance
3.04 b2 -tolerance
3.04 (b2)
3.24 (b1)
3.44 (a2)
3.70 (a1)
3.87±0.03 (c)
4.0±0.03(800) 1,000 1,200
2.0 + 0.03- 0.10
0
107492-1163 7/11
Adjustingpoint
Rackposition( mm )
Pumpspeed
( r/min )
Injection q'ty( cm3/100 strokes )
Max.variationbetweencylinders
FixedPre-stroke
at adjustmentRemarks
- 16.1 1,000 124 ± 1.6 ±4 Rack a1~a2(v)
Z 8.7±0.5 585 14 ± 1.5 ± 14 Rack c(v)
A R1(16.1) 1,000 124 ± 1 - Lever a1~a2(v)
B
R1+0.45
+0.05
-0.15
1,150 123.5 ± 4 - Lever b1~b2(v)
IApprox.
R1+0.05150 (225) - Lever c(v)
D*16.15
±0.11,150 (118.5) - Lever b1~b2(v)
5. Injection quantity
Cylinder variation
adjustment standardBasic
BasicBoost press. kPa{mmHg}Above 44.0{Above 330}
Cylinder variation
adjustment standard
Boost press. kPa{mmHg}Above 44.0 {Above 330 }Negative press. kPa{mmHg} 53.3 kPa{ 400 mmHg}
D*: Aneroid compensator actuator adjustment point
Boost press. kPa{mmHg}Above 44.0{Above 330}
Boost press. 0
107492-1163 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 8.45± 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
107492-1163 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 1,150 r/min.
(4) Apply at least 44.0 kPa { 330 mmHg} boost pressure to the boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt so control rack
position is 16.15± 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
107492-1163 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,
N=0
StopNormal
45°±5°
22.5°±5°
32°±5°
23°± 3°
10. Rack Sensor Adjustment
(1) Before removing rack position measuring device, apply at least 44.0 kPa
{at least 330 mmHg} boost pressure and confirm rack position is R1 = 16.1 mm and
fuel injection quantity is 124± 1 mm3/st at N = 1,000 r/min.
(2) Remove rack position measuring device.
(3) Attach rack sensor core to control rack.
At this time, hold control rack using a spanner (to prevent the rack from bending).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 44.0 kPa {at least 330 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 = 2.77±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
107492-1163 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
B.T.D.C. : 9°
(At pre-stroke 3.7± 0.05mm)
Pump
Engine
Bracket mark
Gear hole (Dia. 3mm)
Gear’s threaded hole
Gear side
Pump side
Mark position of coupling at B.T.D.C. 13°°°°°
Check hole
28°05′14″±
20′
12°58′48″± 3°
(35°)
(96°)
(3°12′32″)
11. Drive Coupling Timing
Stamp on coupling and bracket
(B.T.D.C. 9°°°°°)
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1164ENGINE MODEL: 4HE1-XS
No.
Governor: 105934-0113
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2063 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:27 Aug.2003
ISUZU8-97225-432-2
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'
4
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*)
107492-1164 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
107492-1164 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 3.84 ~ 3.90. 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
a3.70 a1 + tolerance
3.44 a2 -tolerance
b3.24 b1 + tolerance
3.04 b2 -tolerance
(calculate from each specification)
107492-1164 4/11
Rac
k po
sitio
n (
mm
)
Idling adjustment
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
Boost compensator stroke: 1.65 ±0.1
Torque cam No. “ AG80”
Pump speed (r/min)
Confirm rack sensor Vist = 2.77±0.28
at supply voltage 5±0.01V , N =1000 r/min , R = R1 (16.1).
4. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
[R1+0.45]
Approx.R1+0.05R1(16.1)
R2 [R1-2.55]
13.2± 1.0
0250-40 (650) 1000 (1085) 1300
1400
A
B
D
10.510.0± 0.1
Approx.8.7
7.8
6.6± 0.1
4.3± 0.5
0 750500
475
400
400
240
H J
(1180)
14.75± 0.1
+0.05-0.15 I
107492-1164 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 = 400 r/min
R2 [R1-2.55]
R2-1.65
Approx. 30.7 {Approx. 230}
12.0± 1.3 {90± 10}
PushrodC
0
107492-1164 6/11
4-3 Timing cam adjustment (Timing cam No:510)
(1) Hold speed control lever against full speed stopper bolt.
(2) Supply boost pressure of at least 44.0 kPa {at least 330 mmHg}.
(3) Operate pump at the timing cam adjusting point
(point a in table below: Np = 1,000 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
a3.70 a1 + tolerance
3.44 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b3.24 b1 + tolerance
3.04 b2 -tolerance
3.04 (b2)
3.24 (b1)
3.44 (a2)
3.70 (a1)
3.87±0.03 (c)
4.0±0.03(800) 1,000 1,200
2.0 + 0.03- 0.10
0
107492-1164 7/11
Adjustingpoint
Rackposition( mm )
Pumpspeed
( r/min )
Injection q'ty( cm3/100 strokes )
Max.variationbetweencylinders
FixedPre-stroke
at adjustmentRemarks
- 16.1 1,000 124 ± 1.6 ±4 Rack a1~a2(v)
Z 8.7±0.5 585 14 ± 1.5 ± 14 Rack c(v)
A R1(16.1) 1,000 124 ± 1 - Lever a1~a2(v)
B
R1+0.45
+0.05
-0.15
1,150 123.5 ± 4 - Lever b1~b2(v)
IApprox.
R1+0.05150 (225) - Lever c(v)
D*16.15
±0.11,150 (118.5) - Lever b1~b2(v)
5. Injection quantity
Cylinder variation
adjustment standardBasic
BasicBoost press. kPa{mmHg}Above 44.0{Above 330}
Cylinder variation
adjustment standard
Boost press. kPa{mmHg}Above 44.0 {Above 330 }Negative press. kPa{mmHg} 53.3 kPa{ 400 mmHg}
D*: Aneroid compensator actuator adjustment point
Boost press. kPa{mmHg}Above 44.0{Above 330}
Boost press. 0
107492-1164 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 8.45± 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
107492-1164 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 1,150 r/min.
(4) Apply at least 44.0 kPa { 330 mmHg} boost pressure to the boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt so control rack
position is 16.15± 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
107492-1164 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,
N=0
StopNormal
45°±5°
22.5°±5°
32°±5°
23°± 3°
10. Rack Sensor Adjustment
(1) Before removing rack position measuring device, apply at least 44.0 kPa
{at least 330 mmHg} boost pressure and confirm rack position is R1 = 16.1 mm and
fuel injection quantity is 124± 1 mm3/st at N = 1,000 r/min.
(2) Remove rack position measuring device.
(3) Attach rack sensor core to control rack.
At this time, hold control rack using a spanner (to prevent the rack from bending).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 44.0 kpa {at least 330 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 = 2.77±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
107492-1164 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
B.T.D.C. : 9°
(At pre-stroke 3.87± 0.05mm)
Pump
Engine
Bracket mark
Gear hole (Dia. 3mm)
Gear’s threaded hole
Gear side
Pump side
Mark position of coupling at B.T.D.C. 13°°°°°
Check hole
28°05′
14″±
20′
12°38′18″± 3°
(35°)
(96°)
(3°
12′
32″)
11. Drive Coupling Timing
Stamp on coupling and bracket
(B.T.D.C. 9°°°°°)
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1170ENGINE MODEL: 4HE1-XN
No.
Governor: 105934-0150
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2072 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:12 Feb.2002
ISUZU8-97321-399-0
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'
1
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*)
107492-1170 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
107492-1170 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 12 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 7.3 -0.1 V.
Adjusting pointConfirmation point
Pre-stroke (mm) Output voltage (actual) Remarks
a3.43 a1 + tolerance
3.17 a2 -tolerance
b2.85 b1 + tolerance
2.65 b2 -tolerance
(calculate from each specification)
107492-1170 4/11
Rac
k po
sitio
n (
mm
)
Idling adjustment
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
Boost compensator stroke: 1.5 ±0.1
Torque cam No. “ AH22”
Pump speed (r/min)
Confirm rack sensor Vist = 2.249±0.28
at supply voltage 5±0.01V , N =900 r/min , R = R1 (13.0).
4. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+2.9
Approx.R1+2.1
R1(13.0)
R2 [R1-0.6]
10.1± 1.0
0300-40 (700) 900 (1400)
(1550)
1630
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
(1050)
107492-1170 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]
R2-1.5
Approx. 23.3 {Approx. 175}
5.3± 1.3 {40± 10}
PushrodC
0
107492-1170 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 36.7 kPa {at least 275 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
a3.43 a1 + tolerance
3.17 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.85 b1 + tolerance
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
- 13.0 900 80 ± 1.6 ±4 Rack a1~a2(v)
Z 8.5 ± 0.5 540 14 ± 1.5 ± 14 Rack c(v)
A R1(13.0) 900 80 ± 1 - Lever a1~a2(v)
B R1+2.9 1,450 101.5 ± 4 - Lever b1~b2(v)
IApprox.
R1+2.1150 (165) - Lever c(v)
D* 15.3±0.1 1,450 (95.5) - Lever b1~b2(v)
107492-1170 7/11
5. Injection quantity
Cylinder variation
adjustment standardBasic
BasicBoost press. kPa{mmHg}Above 36.7{Above 275}
Cylinder variation
adjustment standard
Boost press. 0
Boost press. kPa{mmHg}Above 36.7 {Above 275 }Negative press. kPa{mmHg} 53.3 kPa{ 400 mmHg}
D*: Aneroid compensator actuator adjustment point
Boost press. kPa{mmHg}Above 36.7{Above 275}
107492-1170 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 8.5±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
107492-1170 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 36.7 kPa { 275 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
107492-1170 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 36.7 kPa
{at least 275 mmHg} boost pressure and confirm rack position is R1 = 13.0 mm and
fuel injection quantity is 80± 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).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 36.7 kPa {at least 275 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 = 2.249±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
107492-1170 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1171ENGINE MODEL: 4HE1-XN
No.
Governor: 105934-0150
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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:18 Mar.2003
ISUZU8-97321-399-1
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'
1
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*)
107492-1171 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
107492-1171 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 12 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 7.3 -0.1 V.
Adjusting pointConfirmation point
Pre-stroke (mm) Output voltage (actual) Remarks
a3.43 a1 + tolerance
3.17 a2 -tolerance
b2.85 b1 + tolerance
2.65 b2 -tolerance
(calculate from each specification)
107492-1171 4/11
Rac
k po
sitio
n (
mm
)
Idling adjustment
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
Boost compensator stroke: 1.5 ±0.1
Torque cam No. “ AH22”
Pump speed (r/min)
Confirm rack sensor Vist = 2.249±0.28
at supply voltage 5±0.01V , N =900 r/min , R = R1 (13.0).
4. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+2.9
Approx.R1+2.1
R1(13.0)
R2 [R1-0.6]
10.1± 1.0
0300-40 (700) 900 (1400)
(1550)
1630
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
(1050)
107492-1171 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]
R2-1.5
Approx. 23.3 {Approx. 175}
5.3± 1.3 {40± 10}
PushrodC
0
107492-1171 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 36.7 kPa {at least 275 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
a3.43 a1 + tolerance
3.17 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.85 b1 + tolerance
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
- 13.0 900 80 ± 1.6 ±4 Rack a1~a2(v)
Z 8.5 ± 0.5 540 14 ± 1.5 ± 14 Rack c(v)
A R1(13.0) 900 80 ± 1 - Lever a1~a2(v)
B R1+2.9 1,450 101.5 ± 4 - Lever b1~b2(v)
IApprox.
R1+2.1150 (165) - Lever c(v)
D* 15.3±0.1 1,450 (95.5) - Lever b1~b2(v)
107492-1171 7/11
5. Injection quantity
Cylinder variation
adjustment standardBasic
BasicBoost press. kPa{mmHg}Above 36.7{Above 275}
Cylinder variation
adjustment standard
Boost press. 0
Boost press. kPa{mmHg}Above 36.7 {Above 275 }Negative press. kPa{mmHg} 53.3 kPa{ 400 mmHg}
D*: Aneroid compensator actuator adjustment point
Boost press. kPa{mmHg}Above 36.7{Above 275}
107492-1171 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 8.5±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
107492-1171 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 36.7 kPa { 275 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
107492-1171 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 36.7 kPa
{at least 275 mmHg} boost pressure and confirm rack position is R1 = 13.0 mm and
fuel injection quantity is 80± 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).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 36.7 kPa {at least 275 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 = 2.249±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
107492-1171 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1180ENGINE MODEL: 4HE1-X
No.
Governor: 105934-0120
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2080 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:8 Jan.2002
ISUZU8-97329-171-0
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'
0
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*)
107492-1180 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
107492-1180 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 12 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 7.3 -0.1 V.
Adjusting pointConfirmation point
Pre-stroke (mm) Output voltage (actual) Remarks
a3.36 a1 + tolerance
3.10 a2 -tolerance
b2.72 b1 + tolerance
2.52 b2 -tolerance
(calculate from each specification)
107492-1180 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. “ AH15”
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. Governor adjustment
4-1. Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw.
Fully tighten the adjusting nut.
R1+2.15Approx.R1+0.3
R1(15.0)
R2 [R1-2.15]
10.7± 1.0
0300-40 (650) 1000 (1350)
(1600)
1690
1810
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
260
H J
(1450)
13.9± 0.1
107492-1180 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
107492-1180 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 = 1,400 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
a3.36 a1 + tolerance
3.10 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.72 b1 + tolerance
2.52 b2 -tolerance
2.52 (b2)
2.72 (b1)
3.10 (a2)
3.36 (a1)
3.7± 0.03 (c)
4.0±0.03(500) 900 1,400
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)
BR1
+2.151,400 121.5 ± 4 - Lever b1~b2(v)
IApprox.
R1+0.3150 (180) - Lever c(v)
D* 16.6±0.1 1,400 (115) - Lever b1~b2(v)
107492-1180 7/11
5. Injection quantity
Cylinder variation
adjustment standardBasic
BasicBoost press. kPa{mmHg}Above 42.0{Above 315}
Cylinder variation
adjustment standard
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}
Boost press. 0
107492-1180 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
107492-1180 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 1,400 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 16.6±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
107492-1180 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.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1180 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
25°21′24″±
20′
13°±3°
(35°)
(96°)
(5°57′34″)
11. Drive Coupling Timing
105934-0120Governor: EP/RLD-MInjection pump: TCS4MD
107049-2063
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
Selector switch no.: 00 (for C/U 407910-303*)
Oil temperature: 40+5 °C
Company:
Assy No.: 107492-1181ENGINE MODEL: 4HE1-X
No.
1. Test conditions
Date:
Pump rotation: counter clockwise (viewed from drive side)
kgf/cm2}
CONFIDENTIAL
INJECTION PUMP CALIBRATION DATA
20 Feb 2004
ISUZU
8-97329-171-0
Injection pipe: outer dia. 8 mm × inner dia. 3 mm length 600 mm
Nozzle opening pressure: 20.7 MPa {211 kgf/cm2}
Nozzle: 105780-0120 Nozzle holder: 105780-2190(Bosch type no. 1 688 901 990) (Bosch type no. 9 430 610 144)
Nozzle & nozzle holder assy: 105780-8250 (Bosch type no. 1 688 901 101)
Test oil: ISO4113 or SAE standard test oil {SAE J967d}
1
Transfer pump pressure: 255 kPa {2.6
2. Injection timing
Overflow valve opening pressure: 255 ± 34 kPa {2.6 ± 0.35 kgf/cm2}
1/11
Ambient temperature: 23±5 °C
DIGI switch no.: 11 (for C/U 407980-224*)
Pre-stroke: No. 1 plunger 4.0 ± 0.03 mm
Injection order: 1 3 , 1 4 , 1 290°± 15' 180°± 15' 270°± 15'
Plungers are numbered from Governor side.
Tappet clearance: Manually rotate camshaft 2 ~ 3 times and confirm that it rotates smoothly.
2/11107492-1181
3. Injection timing adjustment
(Refer to 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 counterweight 2 contacts 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 shim 1.
3-3 Individual cylinder's injection order adjustment
Adjust difference between each cylinder's injection angle based on that of No. 1 cylinder using
shim 1.
1
563
4
1
2
1. Setscrew installation 2. Pre-stroke adjustment3. Individual cylinder's injection
order adjustment
3/11107492-1181
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 No. 1 cylinder's output voltage for pre-stroke
lift values in table below.
Adjusting pointConfirmation point Pre-stroke (mm) Output voltage (actual) Remarks
a3.36 a1 + tolerance
3.10 a2 - tolerance
b2.72 b1 + tolerance
2.52 b2 - tolerance
(calculate from each specification)
Advice
If measuring device (P/N 105782-6420) is removed, output voltage (a1, a2) must 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 output voltage (c) at this time.
3-6 Solenoid switch adjustment
(1) Apply 12 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 lock-
nut to specified torque.
(3) Confirm solenoid switch operates at 7.3 - 0.1 V.
4/11107492-1181
4. Governor adjustment
4-1 Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw. Fully tighten adjusting nut.
Boost compensator stroke: 1.25±0.1
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
R1+2.15Approx R1+0.3
R1(15.0)
R2 [R1-2.15]
10.7±1.0
0300-40 (650) 1000 (1350) (1450)
(1600)1690
13.9±0.1
Torque cam no. “AH15”
B
A DI
Rac
k po
sitio
n (
mm
)
Pump speed (r/min)
Idling adjustment
10.0±0.110.5
Approx 8.97.8
6.6±0.1
3.9±0.3
0260
H J
400400
500475 880
Confirm rack sensor Vist = 2.55±0.28at supply voltage 5±0.01V, N = 1000 r/min, R = R1 (15.0).
1810
5/11107492-1181
4-2 Boost compensator adjustment
(1) Select a push rod so C = 37.5±0.5 mm at full boost pressure. (C is distance from end face of
housing to top of lever.)
(2) Adjust boost compensator stroke using screw A (0 boost pressure position adjustment).
Adjust beginning of boost compensator operation by adjusting notch adjusting nut B.
CTop of lever Pushrod
Boost pressure inlet
A: Boost compensator stroke adjusting screw
Boost compensator spring
B: Notch adjusting nut
0
12.0±1.3 {90±10}
N = 500 r/min
R2 [R1-2.15]
Approx 28.7 {Approx 215}
Rac
k po
sitio
n (m
m)
Boost pressure kPa {mmHg}
R2-1.25
6/11107492-1181
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 timing cam adjusting point (point a in table below: Np = 900 r/min).
(4) Perform timing cam adjustment so output voltage is within range of a1 ~ a2 actually measured
for pre-stroke output voltage during injection timing adjustment in 3-4.
Adjusting point Pre-stroke (mm) Output voltage (actual) Remarks
a3.36 a1 + tolerance
3.10 a2 - tolerance
(5) Operate pump at timing cam confirmation point (point b in table below: Np = 1400 r/min).
(6) Confirm that pre-stroke output voltage is within range b1 ~ b2.
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.72 b1 + tolerance
2.52 b2 - tolerance
Pump speed (r/min)
900(500) 14000
3.7±0.03 (c)
4.0±0.03
3.36 (a1)
3.10 (a2)
2.72 (b1)
2.52 (b2)
2.0+0.03-0.10
Pre-stroke at stopper contact
Minimum advance angle adjustment stopper
Solenoid starting advance angle
b (confirmation point)
a (adjusting point)
Pre-stroke (Pre-stroke output voltage)
7/11107492-1181
5. Injection quantity
Adjustingpoint
Rackposition
(mm)
Pumpspeed(r/min)
Injection quantity(cm3 / 1000 strokes)
Max. variationbetween
cylinders (%)Fixed
Pre-strokeat
adjustmentRemarks
- 15.0 1000 109.5 ± 1.6 ±4 Rack a1 ~ a2(v) Basic Cylinder variation adjustment standard
Z 8.9±0.5 510 22 ± 1.5 ±14 Rack c(v) Cylinder variation adjustment standard
A R1(15.0) 1000 109.5 ± 1 - Lever a1 ~ a2(v) Basic Boost press. kPa {mmHg}Above 42.0 {Above 315}
B R1+2.15 1400 121.5 ± 4 - Lever b1 ~ b2(v) Boost press. kPa {mmHg}Above 42.0 {Above 315}
I [R1+0.3]±0.5 150 (180) - Lever c(v) Boost press. 0
D* 16.6±0.1 1400 (115) - Lever b1 ~ b2(v)
Boost press. kPa {mmHg}Above 42.0 {Above 315}Negative press. kPa {mmHg} 53.3 kPa {400 mmHg}
D*: Aneroid compensator actuator adjustment point
8/11107492-1181
6. FICD adjustment
(1) Stop 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 actuator 1 and set pump speed at 450 r/min.
(6) Gradually loosen set bolt 2 then fix bolt using nut when rack position is 8.7±0.1 mm.
(7) Apply above negative pressure several times and confirm FICD actuator is operating properly
and clearance between FICD actuator lever and speed control lever.
1+1mm
Speed control lever
FICD actuator lever
Tightening torque5 ~ 7 N.m {0.5 ~ 0.7 kgf.m}
1 2 3
9/11107492-1181
7. Aneroid compensator actuator adjustment (injection quantity decrease)
Note:
Set actuator after adjusting full rack position.
(1) Stop injection pump.
(2) Adjust wire nuts 1 so full load set lever contacts full load set bolt and aneroid compensator
actuator wire is not loose. Then, fix nuts 1.
(3) Apply 53.3 kPa {400 mmHg} negative pressure to aneroid compensator and set pump speed at
1400 r/min.
(4) Apply at least 42.0 kPa {315 mmHg} boost pressure to boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt 2 so control rack position
is 16.6±0.1 mm and fuel injection quantity is as specified. Then, fix set bolt 2.
Rac
k po
sitio
n (m
m)
Pump speed (r/min)
Stroke
D
Injection quantity decreaseadjustment point
Full load set bolt
Full load set lever
1
2
10/11107492-1181
8. Speed control lever angle 9. Stop lever angle
Stopper bolt H position
Hole (R42)
IdlingFull-speed
29.5°±3°30°±5°Hole (R41.3)
Normal Stop
45°±5°
22.5°±5°
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 = 1000 r/min.
(2) Remove rack position measuring device.
(3) Attach rack sensor core to control rack.
At this time, hold control rack using spanner (to prevent rack from bending).
Specified torque : 3.4 ~ 4.9 N.m {0.35 ~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9 ~ 8.8 N.m {0.7 ~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set to DC 5±0.01V.
(8) Apply at least 42.0 kPa {at least 315 mmHg} boost pressure, set pump speed at N = 1000 r/min,
and hold speed control lever against full speed stopper bolt.
(9) Confirm rack sensor output voltage from digital voltmeter (Vist = 2.55±0.28).
(10) Confirm that voltage changes when speed control lever is moved to idle and full sides.
Rac
k po
sitio
n (m
m)
Pump speed (r/min)
AR1
N
Rack position (mm)
Sen
sor
outp
ut v
olta
ge (
V)
R1
Vist
Set positionR = 1.5±0.2
11/11107492-1181
11. Drive coupling timing
L L
tt
Bracket mark Pump
Engine
Gear hole (Dia. 3 mm)
Gear's threaded hole
Gear side
Pump side
Check hole
Stamp on coupling and bracket(B.T.D.C. 8°)
Mark position of coupling at B.T.D.C. 13°
Timing setting (At pre-stroke 3.7±0.05 mm)
At No. 1 plunger's beginningof injection positionB.T.D.C.: 8°
13°07'30''±3°
(35°)
25°21'24''±20'(96°)
(5°5
7'34
'')
Service Department
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572 Japan
Tel. (048)470-1559, Fax. (048)474-9856
1/11
Ass'y No.: 107492-1190ENGINE MODEL: 4HE1-X
No.
Governor: 105934-0130
1. Test condition
Date:
Pump rotation:
Injection pump: 107049-2090 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.
C O N F I D E N T I A L
INJ. PUMP CALIBRATION DATA
Company:8 Jan.2002
ISUZU8-97329-172-0
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'
0
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*)
107492-1190 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
107492-1190 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 12 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 7.3 -0.1 V.
Adjusting pointConfirmation point
Pre-stroke (mm) Output voltage (actual) Remarks
a3.43 a1 + tolerance
3.17 a2 -tolerance
b2.85 b1 + tolerance
2.65 b2 -tolerance
(calculate from each specification)
107492-1190 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. “ AH13”
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. Governor adjustment
4-1. Governor adjustment
Full load 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
0300-40 (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
260
H J
R3 [R1-0.6]+0.5-0.1
(1300)
700
E
(1050)
107492-1190 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
107492-1190 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
a3.43 a1 + tolerance
3.17 a2 -tolerance
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.85 b1 + tolerance
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 ± 4 - 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)
107492-1190 7/11
5. Injection quantity
Cylinder variation
adjustment standardBasic
BasicBoost press. kPa{mmHg}Above 40.0{Above 300}
Cylinder variation
adjustment standard
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}
Boost press. 0
107492-1190 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
107492-1190 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
107492-1190 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).
Specified torque : 3.4~~~~~ 4.9 N.m {0.35~~~~~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9~~~~~ 8.8 N.m {0.7~~~~~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set it to DC 5± 0.01V.
(8) Apply at least 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
107492-1190 11/11
Timing setting
At No. 1 plunger’s beginning
of injection position
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
25°21′24″±
20′
13°±3°
(35°)
(96°)
(5°57′34″)
11. Drive Coupling Timing
105934-0130Governor: EP/RLD-MInjection pump: TCS4MD
107049-2073
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
Selector switch no.: 00 (for C/U 407910-303*)
Oil temperature: 40+5 °C
Company:
Assy No.: 107492-1191ENGINE MODEL: 4HE1-X
No.
1. Test conditions
Date:
Pump rotation: counter clockwise (viewed from drive side)
kgf/cm2}
CONFIDENTIAL
INJECTION PUMP CALIBRATION DATA
20 Feb 2004
ISUZU
8-97329-172-0
Injection pipe: outer dia. 8 mm × inner dia. 3 mm length 600 mm
Nozzle opening pressure: 20.7 MPa {211 kgf/cm2}
Nozzle: 105780-0120 Nozzle holder: 105780-2190(Bosch type no. 1 688 901 990) (Bosch type no. 9 430 610 144)
Nozzle & nozzle holder assy: 105780-8250 (Bosch type no. 1 688 901 101)
Test oil: ISO4113 or SAE standard test oil {SAE J967d}
1
Transfer pump pressure: 255 kPa {2.6
2. Injection timing
Overflow valve opening pressure: 255 ± 34 kPa {2.6 ± 0.35 kgf/cm2}
1/11
Ambient temperature: 23±5 °C
DIGI switch no.: 11 (for C/U 407980-224*)
Pre-stroke: No. 1 plunger 4.0 ± 0.03 mm
Injection order: 1 3 , 1 4 , 1 290°± 15' 180°± 15' 270°± 15'
Plungers are numbered from Governor side.
Tappet clearance: Manually rotate camshaft 2 ~ 3 times and confirm that it rotates smoothly.
2/11107492-1191
3. Injection timing adjustment
(Refer to 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 counterweight 2 contacts 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 shim 1.
3-3 Individual cylinder's injection order adjustment
Adjust difference between each cylinder's injection angle based on that of No. 1 cylinder using
shim 1.
1
563
4
1
2
1. Setscrew installation 2. Pre-stroke adjustment3. Individual cylinder's injection
order adjustment
3/11107492-1191
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 No. 1 cylinder's output voltage for pre-stroke
lift values in table below.
Adjusting pointConfirmation point Pre-stroke (mm) Output voltage (actual) Remarks
a3.43 a1 + tolerance
3.17 a2 - tolerance
b2.85 b1 + tolerance
2.65 b2 - tolerance
(calculate from each specification)
Advice
If measuring device (P/N 105782-6420) is removed, output voltage (a1, a2) must 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 output voltage (c) at this time.
3-6 Solenoid switch adjustment
(1) Apply 12 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 lock-
nut to specified torque.
(3) Confirm solenoid switch operates at 7.3 - 0.1 V.
4/11107492-1191
4. Governor adjustment
4-1 Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw. Fully tighten adjusting nut.
Boost compensator stroke: 1.1±0.1
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
R1+2.9
Approx R1+2.0
R1(12.9)
R3 [R1-0.6]+0.5-0.1
R2 [R1-0.6]
10.2±1.0
0300-40 (700)
700900 (1400) (1550)
16201775
(1050)
(1300)
14.0±0.1
Torque cam no. “AH13”
B
A
DI
Rac
k po
sitio
n (
mm
)
Pump speed (r/min)
Idling adjustment
10.0±0.110.5
Approx 8.57.8
6.6±0.1
3.9±0.3
0260
H J
400400
500475 880
Confirm rack sensor Vist = 2.13±0.28at supply voltage 5±0.01V, N = 900 r/min, R = R1 (12.9).
5/11107492-1191
4-2 Boost compensator adjustment
(1) Select a push rod so C = 37.5±0.5 mm at full boost pressure. (C is distance from end face of
housing to top of lever.)
(2) Adjust boost compensator stroke using screw A (0 boost pressure position adjustment).
Adjust beginning of boost compensator operation by adjusting notch adjusting nut B.
CTop of lever Pushrod
Boost pressure inlet
A: Boost compensator stroke adjusting screw
Boost compensator spring
B: Notch adjusting nut
0
10.7±1.3 {80±10}
N = 500 r/min
R2 [R1-0.6]
Approx 26.7 {Approx 200}
Rac
k po
sitio
n (m
m)
Boost pressure kPa {mmHg}
R2-1.1
6/11107492-1191
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 timing cam adjusting point (point a in table below: Np = 900 r/min).
(4) Perform timing cam adjustment so output voltage is within range of a1 ~ a2 actually measured
for pre-stroke output voltage during injection timing adjustment in 3-4.
Adjusting point Pre-stroke (mm) Output voltage (actual) Remarks
a3.43 a1 + tolerance
3.17 a2 - tolerance
(5) Operate pump at timing cam confirmation point (point b in table below: Np = 1450 r/min).
(6) Confirm that pre-stroke output voltage is within range b1 ~ b2.
Confirmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.85 b1 + tolerance
2.65 b2 - tolerance
Pump speed (r/min)
900(500) 14500
3.7±0.03 (c)
4.0±0.03
3.43 (a1)
3.17 (a2)
2.85 (b1)
2.65 (b2)
2.0+0.03-0.10
Pre-stroke at stopper contact
Minimum advance angle adjustment stopper
Solenoid starting advance angle
b (confirmation point)
a (adjusting point)
Pre-stroke (Pre-stroke output voltage)
7/11107492-1191
5. Injection quantity
Adjustingpoint
Rackposition
(mm)
Pumpspeed(r/min)
Injection quantity(cm3 / 1000 strokes)
Max. variationbetween
cylinders (%)Fixed
Pre-strokeat
adjustmentRemarks
- 12.9 900 81 ± 1.6 ±4 Rack a1 ~ a2(v) Basic Cylinder variation adjustment standard
Z 8.5±0.5 500 19 ± 1.5 ±14 Rack c(v) Cylinder variation adjustment standard
A R1(12.9) 900 81 ± 1 - Lever a1 ~ a2(v) Basic Boost press. kPa {mmHg}Above 40.0 {Above 300}
B R1+2.9 1450 102.5 ± 4 - Lever b1 ~ b2(v) Boost press. kPa {mmHg}Above 40.0 {Above 300}
I [R1+2.0]±0.5 150 (175) - Lever c(v) Boost press. 0
D* 15.2±0.1 1450 (96.5) - Lever b1 ~ b2(v)
Boost press. kPa {mmHg}Above 40.0 {Above 300}Negative press. kPa {mmHg} 53.3 kPa {400 mmHg}
D*: Aneroid compensator actuator adjustment point
8/11107492-1191
6. FICD adjustment
(1) Stop 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 actuator 1 and set pump speed at 450 r/min.
(6) Gradually loosen set bolt 2 then fix bolt using nut when rack position is 8.3±0.1 mm.
(7) Apply above negative pressure several times and confirm FICD actuator is operating properly
and clearance between FICD actuator lever and speed control lever.
1+1mm
Speed control lever
FICD actuator lever
Tightening torque5 ~ 7 N.m {0.5 ~ 0.7 kgf.m}
1 2 3
9/11107492-1191
7. Aneroid compensator actuator adjustment (injection quantity decrease)
Note:
Set actuator after adjusting full rack position.
(1) Stop injection pump.
(2) Adjust wire nuts 1 so full load set lever contacts full load set bolt and aneroid compensator
actuator wire is not loose. Then, fix nuts 1.
(3) Apply 53.3 kPa {400 mmHg} negative pressure to aneroid compensator and set pump speed at
1450 r/min.
(4) Apply at least 40.0 kPa {300 mmHg} boost pressure to boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt 2 so control rack position
is 15.2±0.1 mm and fuel injection quantity is as specified. Then, fix set bolt 2.
Rac
k po
sitio
n (m
m)
Pump speed (r/min)
Stroke
D
Injection quantity decreaseadjustment point
Full load set bolt
Full load set lever
1
2
10/11107492-1191
8. Speed control lever angle 9. Stop lever angle
Stopper bolt H position
Hole (R42)
IdlingFull-speed
29°±3°30°±5°Hole (R41.3)
Normal Stop
45°±5°
22.5°±5°
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 spanner (to prevent rack from bending).
Specified torque : 3.4 ~ 4.9 N.m {0.35 ~ 0.5 kgf.m}
(4) While pulling stop lever, install rack sensor to rack sensor core.
(5) Tighten two flange fixing screws.
Specified torque : 6.9 ~ 8.8 N.m {0.7 ~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set 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 full speed stopper bolt.
(9) Confirm rack sensor output voltage from digital voltmeter (Vist = 2.13±0.28).
(10) Confirm that voltage changes when speed control lever is moved to idle and full sides.
Rac
k po
sitio
n (m
m)
Pump speed (r/min)
AR1
N
Rack position (mm)
Sen
sor
outp
ut v
olta
ge (
V)
R1
Vist
Set positionR = 1.5±0.2
11/11107492-1191
11. Drive coupling timing
L L
tt
Bracket mark Pump
Engine
Gear hole (Dia. 3 mm)
Gear's threaded hole
Gear side
Pump side
Check hole
Stamp on coupling and bracket(B.T.D.C. 8°)
Mark position of coupling at B.T.D.C. 13°
Timing setting (At pre-stroke 3.7±0.05 mm)
At No. 1 plunger's beginningof injection positionB.T.D.C.: 8°
12°52'30''±3°
(35°)
25°21'24''±20'(96°)
(5°5
7'34
'')
105934-0071Governor: EP/RLD-MInjection pump: TCS4MD
107049-2063
Selector switch no.: 00 (for C/U 407910-303*)
Oil temperature: 40+5 °C
Company:
Assy No.: 107492-1200ENGINE MODEL: 4HE1-TC
No.
1. Test con di tions
Date:
Pump rotation: counter clockwise (viewed from drive side)
kgf/cm2}
CONFIDENTIAL
INJECTION PUMP CALIBRATION DATA
10 Sep 2007
ISUZU
8-98024-252-0
Injection pipe: outer dia. 8 mm × inner dia. 3 mm length 600 mm
Nozzle opening pressure: 20.7 MPa {211 kgf/cm2}
Nozzle: 105780-0120 Nozzle holder: 105780-2190(Bosch type no. 1 688 901 990) (Bosch type no. 9 430 610 144)
Nozzle & nozzle holder assy: 105780-8250 (Bosch type no. 1 688 901 101)
Test oil: ISO4113 or SAE standard test oil {SAE J967d}
2
Transfer pump pressure: 255 kPa {2.6
2. Injection timing
Overfl ow valve opening pressure: 255 ± 34 kPa {2.6 ± 0.35 kgf/cm2}
1/11
Ambient temperature: 23±5 °C
DIGI switch no.: 11 (for C/U 407980-224*)
Pre-stroke: No. 1 plunger 4.0 ± 0.03 mm
Injection order: 1 3 , 1 4 , 1 290°± 15' 180°± 15' 270°± 15'
Plungers are numbered from Governor side.
Tappet clearance: Manually rotate camshaft 2 ~ 3 times and confi rm that it rotates smooth ly.
Bosch CorporationAutomotive Aftermarket Division
3-4-1 Kitano, Niiza-shi, Saitama-ken, 352-8572, JAPAN
Tel. 81-48-475-2521 Fax. 81-48-475-2520
2/11107492-1200
3. Injection timing adjustment
(Refer to 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 counterweight 2 contacts housing's pressfi tted 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 shim 1.
3-3 Individual cylinder's injection order adjustment
Adjust difference between each cylinder's injection angle based on that of No. 1 cylinder using
shim 1.
1
563
4
1
2
1. Setscrew installation 2. Pre-stroke adjustment3. Individual cylinder's injection
order adjustment
3/11107492-1200
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 No. 1 cylinder's output voltage for pre-stroke
lift values in table below.
Adjusting pointConfi rmation point Pre-stroke (mm) Output voltage (actual) Remarks
a3.36 a1 + tolerance
3.10 a2 - tolerance
b2.72 b1 + tolerance
2.52 b2 - tolerance
(calculate from each specifi cation)
Advice
If measuring device (P/N 105782-6420) is removed, output voltage (a1, a2) must 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 specifi ed torque.
(3) Measure 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 lock-
nut to specifi ed torque.
(3) Confi rm solenoid switch operates at 14.5 - 0.1 V.
4/11107492-1200
4. Governor adjustment
4-1 Governor adjustment
Full load adjustment
Advice
Loosen timing cam and lock screw. Fully tighten adjusting nut.
Boost compensator stroke: 1.05±0.1
Pump speed (r/min)
Rac
k po
sitio
n (
mm
)
R1+2.15Approx R1+0.5
R1(14.5)
R2 [R1-2.15]
10.7±1.0
0250-40 (650) 1000 (1350) (1450)
(1610)1690
13.9±0.1
Torque cam no. “AF59”
B
A DI
Rac
k po
sitio
n (
mm
)
Pump speed (r/min)
Idling adjustment
10.0±0.110.5
Approx 8.97.8
6.6±0.1
3.9±0.3
0240
H J
400400
500475 880
Confi rm rack sensor Vist = 2.62±0.28at supply voltage 5±0.01V, N = 1000 r/min, R = R1 (14.5).
1810
5/11107492-1200
4-2 Boost compensator adjustment
(1) Select a push rod so C = 37.5±0.5 mm at full boost pressure. (C is distance from end face of
housing to top of lever.)
(2) Adjust boost compensator stroke using screw A (0 boost pressure position adjustment).
Adjust beginning of boost compensator operation by adjusting notch adjusting nut B.
CTop of lever Pushrod
Boost pressure inlet
A: Boost compensator stroke adjusting screw
Boost compensator spring
B: Notch adjusting nut
0
12.0±1.3 {90±10}
N = 500 r/min
R2 [R1-2.15]
Approx 26.0 {Approx 195}
Rac
k po
sitio
n (m
m)
Boost pressure kPa {mmHg}
R2-1.05
6/11107492-1200
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 39.3 kPa {at least 295 mmHg}.
(3) Operate pump at timing cam adjusting point (point a in table below: Np = 900 r/min).
(4) Perform timing cam adjustment so output voltage is within range of a1 ~ a2 actually measured
for pre-stroke output voltage during injection timing adjustment in 3-4.
Adjusting point Pre-stroke (mm) Output voltage (actual) Remarks
a3.36 a1 + tolerance
3.10 a2 - tolerance
(5) Operate pump at timing cam confi rmation point (point b in table below: Np = 1400 r/min).
(6) Confi rm that pre-stroke output voltage is within range b1 ~ b2.
Confi rmation point Pre-stroke (mm) Output voltage (actual) Remarks
b2.72 b1 + tolerance
2.52 b2 - tolerance
Pump speed (r/min)
900(500) 14000
3.7±0.03 (c)
4.0±0.03
3.36 (a1)
3.10 (a2)
2.72 (b1)
2.52 (b2)
2.0+0.03-0.10
Pre-stroke at stopper contact
Minimum advance angle adjustment stopper
Solenoid starting advance angle
b (confi rmation point)
a (adjusting point)
Pre-stroke (Pre-stroke output voltage)
7/11107492-1200
5. Injection quantity
Adjustingpoint
Rackposition
(mm)
Pumpspeed(r/min)
Injection quantity(cm3 / 1000 strokes)
Max. variationbetween
cylinders (%)Fixed
Pre-strokeat
adjustmentRemarks
- 14.5 1000 105.5 ± 1.6 ±4 Rack a1 ~ a2(v) Basic Cylinder variation adjustment standard
Z 8.9±0.5 510 22 ± 1.5 ±14 Rack c(v) Cylinder variation adjustment standard
A R1(14.5) 1000 105.5 ± 1 - Lever a1 ~ a2(v) Basic Boost press. kPa {mmHg}Above 39.3 {Above 295}
B R1+2.15 1400 117 ± 4 - Lever b1 ~ b2(v) Boost press. kPa {mmHg}Above 39.3 {Above 295}
I [R1+0.5]±0.5 150 (170) - Lever c(v) Boost press. 0
D* 16.1±0.1 1400 (110.5) - Lever b1 ~ b2(v)
Boost press. kPa {mmHg}Above 39.3 {Above 295}Negative press. kPa {mmHg} 53.3 kPa {400 mmHg}
D*: Aneroid compensator actuator adjustment point
8/11107492-1200
6. FICD adjustment
(1) Stop 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 actuator 1 and set pump speed at 450 r/min.
(6) Gradually loosen set bolt 2 then fi x bolt using nut when rack position is 8.7±0.1 mm.
(7) Apply above negative pressure several times and confi rm FICD actuator is operating properly
and clearance between FICD actuator lever and speed control lever.
1+1mm
Speed control lever
FICD actuator lever
Tightening torque5 ~ 7 N.m {0.5 ~ 0.7 kgf.m}
1 2 3
9/11107492-1200
7. Aneroid compensator actuator adjustment (injection quantity decrease)
Note:
Set actuator after adjusting full rack position.
(1) Stop injection pump.
(2) Adjust wire nuts 1 so full load set lever contacts full load set bolt and aneroid compensator
actuator wire is not loose. Then, fi x nuts 1.
(3) Apply 53.3 kPa {400 mmHg} negative pressure to aneroid compensator and set pump speed at
1400 r/min.
(4) Apply at least 39.3 kPa {295 mmHg} boost pressure to boost compensator.
(5) After operating full load set lever, adjust aneroid compensator set bolt 2 so control rack position
is 16.1±0.1 mm and fuel injection quantity is as specifi ed. Then, fi x set bolt 2.
Rac
k po
sitio
n (m
m)
Pump speed (r/min)
Stroke
D
Injection quantity decreaseadjustment point
Full load set bolt
Full load set lever
1
2
10/11107492-1200
8. Speed control lever angle 9. Stop lever angle
Stopper bolt H position
Hole (R42)
IdlingFull-speed
29.5°±3°30°±5°Hole (R41.3)
Normal Stop
45°±5°
22.5°±5°
10. Rack sensor adjustment
(1) Before removing rack position measuring device, apply at least 39.3 kPa {at least 295 mmHg}
boost pressure and confi rm rack position is R1 = 14.5 mm and fuel injection quantity is 105.5±
1 mm3/st at N = 1000 r/min.
(2) Remove rack position measuring device.
(3) Attach rack sensor core to control rack.
At this time, hold control rack using spanner (to prevent rack from bending).
Specifi ed 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 fl ange fi xing screws.
Specifi ed torque : 6.9 ~ 8.8 N.m {0.7 ~ 0.9 kgf.m}
(6) Connect rack sensor wire harness to constant voltage power supply and digital voltmeter.
(7) Turn constant voltage power supply power switch ON and set to DC 5±0.01V.
(8) Apply at least 39.3 kPa {at least 295 mmHg} boost pressure, set pump speed at N = 1000
r/min, and hold speed control lever against full speed stopper bolt.
(9) Confi rm rack sensor output voltage from digital voltmeter (Vist = 2.62±0.28).
(10) Confi rm that voltage changes when speed control lever is moved to idle and full sides.
Rac
k po
sitio
n (m
m)
Pump speed (r/min)
AR1
N
Rack position (mm)
Sen
sor
outp
ut v
olta
ge (
V)
R1
Vist
Set positionR = 1.5±0.2
11/11107492-1200
11. Drive coupling timing
L L
tt
Bracket mark Pump
Engine
Gear hole (Dia. 3 mm)
Gear's threaded hole
Gear side
Pump side
Check hole
Stamp on coupling and bracket(B.T.D.C. 8°)
Mark position of coupling at B.T.D.C. 13°
Timing setting (At pre-stroke 3.7±0.05 mm)
At No. 1 plunger's beginningof injection positionB.T.D.C.: 8°
13°36'18''±3°
(35°)
28°35'14''±20'(96°)
(3°1
2'32
'')