mitics

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


3.10 a2 -tolerance

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


2.76 b2 -tolerance

2.76 (b2)

2.96 (b1)

3.10 (a2)

3.36 (a1)

3.7± 0.03 (c)

4.0±0.03(500) 900 1,200

2.0 ＋ 0.03－ 0.10

0

Adjustingpoint

Rackposition( mm )

Pumpspeed

( r/min )

Injection q'ty( cm3/100 strokes )

Max.variationbetweencylinders

FixedPre-stroke

at adjustmentRemarks

- 15.1 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.


(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


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

1/11


No.

Governor: 105934-0090

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97210-054-1

TCS4MD






side.



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

10



107492-1025 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1025 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.76 b2 -tolerance


107492-1025 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.35


12.0± 1.3 {90± 10}

PushrodC

0

107492-1025 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1025 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

25°21′24″±

20′

13°±3°

(35°)

(96°)

(5°57′34″)


Service Department


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

1/11


No.

Governor: 105934-0090

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97210-054-1

TCS4MD






side.



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

11



107492-1026 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1026 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.76 b2 -tolerance


107492-1026 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.25


12.0± 1.3 {90± 10}

PushrodC

0

107492-1026 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1026 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°




fuel injection quantity is 109.5± 1 mm3/st at N = 1,000 r/min.














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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

25°21′24″±

20′

13°±3°

(35°)

(96°)

(5°57′34″)


Service Department


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

1/11


No.

Governor: 105934-0091

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97210-054-1

TCS4MD






side.



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

11



107492-1027 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1027 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.76 b2 -tolerance


107492-1027 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.25


12.0± 1.3 {90± 10}

PushrodC

0

107492-1027 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1027 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

25°21′24″±

20′

13°±3°

(35°)

(96°)

(5°57′34″)


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


(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.





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


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



(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


3.10 a2 - tolerance


2.76 b2 - tolerance


Advice

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


(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.


(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


4-1 Governor 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


(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


A: Boost compensator stroke adjusting screw


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)



(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.



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.



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


Minimum advance angle adjustment stopper



a (adjusting point)

Pre-stroke (Pre-stroke output voltage)

7/11107492-1028


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}


8/11107492-1028

6. FICD adjustment




(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.


(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


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.



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}





(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


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:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97210-057-0

TCS4MD






side.



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

5



107492-1033 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1033 3/11






Advice


remeasured.



stopper.












3.17 a2 -tolerance


2.65 b2 -tolerance


107492-1033 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)


Torque cam No. “ AG00”

Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-0.6]

R2-1.1


10.7± 1.3 {80± 10}

PushrodC

0

107492-1033 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.17 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1033 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29°± 3°




fuel injection quantity is 81± 1 mm3/st at N = 900 r/min.











N= 900 r/min, and hold speed control lever against the full speed stopper bolt.



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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

25°21′24″±

20′

13°±3°

(35°)

(96°)

(5°57′34″)


Service Department


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

1/11


No.

Governor: 105934-0080

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97210-057-0

TCS4MD






side.



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

5



107492-1034 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1034 3/11






Advice


remeasured.



stopper.












3.17 a2 -tolerance


2.65 b2 -tolerance


107492-1034 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-0.6]

R2-1.1


10.7± 1.3 {80± 10}

PushrodC

0

107492-1034 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.17 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1034 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29°± 3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

25°21′24″±

20′

13°±3°

(35°)

(96°)

(5°57′34″)


Service Department


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

1/11


No.

Governor: 105934-0081

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97210-057-1

TCS4MD






side.



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

5



107492-1035 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1035 3/11






Advice


remeasured.



stopper.












3.17 a2 -tolerance


2.65 b2 -tolerance


107492-1035 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-0.6]

R2-1.1


10.7± 1.3 {80± 10}

PushrodC

0

107492-1035 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.17 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1035 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29°± 3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

25°21′24″±

20′

13°±3°

(35°)

(96°)

(5°57′34″)



107049-2073



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



Company:

Assy No.: 107492-1036ENGINE MODEL: 4HE1-TCN

No.

1. Test conditions

Date:


kgf/cm2}

CONFIDENTIAL


20 Feb 2004

ISUZU

8-97210-057-1






6


2. Injection timing


1/11




Injection order: 1 3 , 1 4 , 1 290°± 15' 180°± 15' 270°± 15'



2/11107492-1036





housing 1.












shim 1.

1

563

4

1

2


order adjustment

3/11107492-1036








3.17 a2 - tolerance


2.65 b2 - tolerance


Advice












4/11107492-1036




Advice



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


5/11107492-1036











0

10.7±1.3 {80±10}

N = 500 r/min

R2 [R1-0.6]


Rac

k po

sitio

n (m

m)


R2-1.1

6/11107492-1036









3.17 a2 - 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





a (adjusting point)


7/11107492-1036


Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)



cylinders (%)Fixed

Pre-strokeat

adjustmentRemarks

- 12.9 900 81 ± 1.6 ±4 Rack a1 ~ a2(v) Basic 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}



D* 15.2±0.1 1450 (96.5) - Lever b1 ~ b2(v)



8/11107492-1036

6. FICD adjustment









1+1mm

Speed control lever

FICD actuator lever


1 2 3

9/11107492-1036


Note:






1450 r/min.




Rac

k po

sitio

n (m

m)

Pump speed (r/min)

Stroke

D


Full load set bolt

Full load set lever

1

2

10/11107492-1036



Hole (R42)

IdlingFull-speed

29°±3°30°±5°Hole (R41.3)

Normal Stop

45°±5°

22.5°±5°



boost pressure and confirm rack position is R1 = 12.9 mm and fuel injection quantity is 81±1















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


11/11107492-1036


L L

tt

Bracket mark Pump

Engine



Gear side

Pump side

Check hole





12°52'30''±3°

(35°)

25°21'24''±20'(96°)

(5°5

7'34

'')

Service Department


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:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97210-050-0

TCS4MD






side.



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

11



107492-1045 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1045 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.52 b2 -tolerance


107492-1045 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.35


12.0± 1.3 {90± 10}

PushrodC

0

107492-1045 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1045 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

25°21′24″±

20′

13°±3°

(35°)

(96°)

(5°57′34″)


Service Department


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

1/11


No.

Governor: 105934-0070

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97210-050-1

TCS4MD






side.



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

11



107492-1046 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1046 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.52 b2 -tolerance


107492-1046 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice




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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.35


12.0± 1.3 {90± 10}

PushrodC

0

107492-1046 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1046 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

25°21′24″±

20′

13°±3°

(35°)

(96°)

(5°57′34″)


Service Department


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

1/11


No.

Governor: 105934-0070

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97210-050-1

TCS4MD






side.



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

12



107492-1047 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1047 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.52 b2 -tolerance


107492-1047 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice




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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.25


12.0± 1.3 {90± 10}

PushrodC

0

107492-1047 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1047 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

25°21′24″±

20′

13°±3°

(35°)

(96°)

(5°57′34″)


Service Department


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

1/11


No.

Governor: 105934-0071

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97210-050-1

TCS4MD






side.



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

12



107492-1048 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1048 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.52 b2 -tolerance


107492-1048 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice




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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.25


12.0± 1.3 {90± 10}

PushrodC

0

107492-1048 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1048 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

25°21′24″±

20′

13°±3°

(35°)

(96°)

(5°57′34″)


Service Department


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

1/11


No.

Governor: 105934-0071

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:14 Mar.2003

ISUZU8-97210-050-1

TCS4MD






side.



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

13



107492-1049 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1049 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.52 b2 -tolerance


107492-1049 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice




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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.25


12.0± 1.3 {90± 10}

PushrodC

0

107492-1049 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1049 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

25°21′24″±

20′

13°07′30″± 3°

(35°)

(96°)

(5°57′34″)


Service Department


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

1/11


No.

Governor: 105934-0080

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97210-051-0

TCS4MD






side.



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

10



107492-1054 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1054 3/11






Advice


remeasured.



stopper.












3.17 a2 -tolerance


2.65 b2 -tolerance


107492-1054 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-0.6]

R2-1.1


10.7± 1.3 {80± 10}

PushrodC

0

107492-1054 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.17 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1054 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29°± 3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

25°21′24″±

20′

13°±3°

(35°)

(96°)

(5°57′34″)


Service Department


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

1/11


No.

Governor: 105934-0080

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97210-051-1

TCS4MD






side.



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

10



107492-1055 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1055 3/11






Advice


remeasured.



stopper.












3.17 a2 -tolerance


2.65 b2 -tolerance


107492-1055 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-0.6]

R2-1.1


10.7± 1.3 {80± 10}

PushrodC

0

107492-1055 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.17 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1055 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29°± 3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

25°21′24″±

20′

13°±3°

(35°)

(96°)

(5°57′34″)


Service Department


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

1/11


No.

Governor: 105934-0081

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97210-051-1

TCS4MD






side.



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

10



107492-1056 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1056 3/11






Advice


remeasured.



stopper.












3.17 a2 -tolerance


2.65 b2 -tolerance


107492-1056 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-0.6]

R2-1.1


10.7± 1.3 {80± 10}

PushrodC

0

107492-1056 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.17 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1056 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29°± 3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

25°21′24″±

20′

13°±3°

(35°)

(96°)

(5°57′34″)


Service Department


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

1/11


No.

Governor: 105934-0081

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:14 Mar.2003

ISUZU8-97210-051-1

TCS4MD






side.



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

11



107492-1057 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1057 3/11






Advice


remeasured.



stopper.












3.17 a2 -tolerance


2.65 b2 -tolerance


107492-1057 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-0.6]

R2-1.1


10.7± 1.3 {80± 10}

PushrodC

0

107492-1057 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.17 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1057 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29°± 3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

25°21′24″±

20′

12°52′30″± 3°

(35°)

(96°)

(5°57′34″)


Service Department


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

1/11


No.

Governor: 105934-0070

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97210-056-0

TCS4MD






side.



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

5



107492-1063 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1063 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.52 b2 -tolerance


107492-1063 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice




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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.35


12.0± 1.3 {90± 10}

PushrodC

0

107492-1063 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1063 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

25°21′24″±

20′

13°±3°

(35°)

(96°)

(5°57′34″)


Service Department


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

1/11


No.

Governor: 105934-0070

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97210-056-1

TCS4MD






side.



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

5



107492-1064 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1064 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.52 b2 -tolerance


107492-1064 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice




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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.35


12.0± 1.3 {90± 10}

PushrodC

0

107492-1064 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1064 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

25°21′24″±

20′

13°±3°

(35°)

(96°)

(5°57′34″)


Service Department


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

1/11


No.

Governor: 105934-0070

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97210-056-1

TCS4MD






side.



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

6



107492-1065 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1065 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.52 b2 -tolerance


107492-1065 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice




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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.25


12.0± 1.3 {90± 10}

PushrodC

0

107492-1065 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1065 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

25°21′24″±

20′

13°±3°

(35°)

(96°)

(5°57′34″)


Service Department


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

1/11


No.

Governor: 105934-0071

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97210-056-1

TCS4MD






side.



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

6



107492-1066 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1066 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.52 b2 -tolerance


107492-1066 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice




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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.25


12.0± 1.3 {90± 10}

PushrodC

0

107492-1066 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1066 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

25°21′24″±

20′

13°±3°

(35°)

(96°)

(5°57′34″)



107049-2063



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



Company:

Assy No.: 107492-1067ENGINE MODEL: 4HE1-TCS

No.

1. Test conditions

Date:


kgf/cm2}

CONFIDENTIAL


20 Feb 2004

ISUZU

8-97210-056-1






7


2. Injection timing


1/11




Injection order: 1 3 , 1 4 , 1 290°± 15' 180°± 15' 270°± 15'



2/11107492-1067





housing 1.












shim 1.

1

563

4

1

2


order adjustment

3/11107492-1067








3.10 a2 - tolerance


2.52 b2 - tolerance


Advice












4/11107492-1067




Advice



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


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


1810

5/11107492-1067











0

12.0±1.3 {90±10}

N = 500 r/min

R2 [R1-2.15]


Rac

k po

sitio

n (m

m)


R2-1.25

6/11107492-1067









3.10 a2 - 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





a (adjusting point)


7/11107492-1067


Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)



cylinders (%)Fixed

Pre-strokeat

adjustmentRemarks






D* 16.6±0.1 1400 (115) - Lever b1 ~ b2(v)



8/11107492-1067

6. FICD adjustment









1+1mm

Speed control lever

FICD actuator lever


1 2 3

9/11107492-1067


Note:






1400 r/min.




Rac

k po

sitio

n (m

m)

Pump speed (r/min)

Stroke

D


Full load set bolt

Full load set lever

1

2

10/11107492-1067



Hole (R42)

IdlingFull-speed

29.5°±3°30°±5°Hole (R41.3)

Normal Stop

45°±5°

22.5°±5°


















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


11/11107492-1067


L L

tt

Bracket mark Pump

Engine



Gear side

Pump side

Check hole





13°07'30''±3°

(35°)

25°21'24''±20'(96°)

(5°5

7'34

'')

Service Department


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:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97206-501-0

TCS4MD






side.



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

2



107492-1070 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1070 3/11






Advice


remeasured.



stopper.












3.17 a2 -tolerance


2.65 b2 -tolerance


107492-1070 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-1.4]

R2-0.8


13.3± 1.3 {100± 10}

PushrodC

0

107492-1070 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.17 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1070 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29°± 3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

25°21′24″±

20′

13°±3°

(35°)

(96°)

(5°57′34″)


Service Department


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

1/11


No.

Governor: 105934-0100

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97211-812-0

TCS4MD






side.



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

2



107492-1071 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1071 3/11






Advice


remeasured.



stopper.












3.17 a2 -tolerance


2.65 b2 -tolerance


107492-1071 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-1.4]

R2-0.8


13.3± 1.3 {100± 10}

PushrodC

0

107492-1071 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.17 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1071 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29°± 3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

25°21′24″±

20′

13°±3°

(35°)

(96°)

(5°57′34″)


Service Department


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

1/11


No.

Governor: 105934-0101

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97211-812-0

TCS4MD






side.



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

2



107492-1072 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1072 3/11






Advice


remeasured.



stopper.












3.17 a2 -tolerance


2.65 b2 -tolerance


107492-1072 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-1.4]

R2-0.8


13.3± 1.3 {100± 10}

PushrodC

0

107492-1072 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.17 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1072 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29°± 3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

25°21′24″±

20′

13°±3°

(35°)

(96°)

(5°57′34″)


Service Department


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:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97212-182-0

TCS4MD






side.



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

1



107492-1080 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1080 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.52 b2 -tolerance


107492-1080 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice




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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.35


12.0± 1.3 {90± 10}

PushrodC

0

107492-1080 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1080 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°06′26″±

20′

13°±3°

(35°)

(96°)

(3°12′32″)


Service Department


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

1/11


No.

Governor: 105934-0070

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97212-182-0

TCS4MD






side.



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

2



107492-1081 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1081 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.52 b2 -tolerance


107492-1081 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice




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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.35


12.0± 1.3 {90± 10}

PushrodC

0

107492-1081 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1081 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°35′14″±

20′

13°28′48″±3°

(35°)

(96°)

(3°12′32″)


Service Department


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

1/11


No.

Governor: 105934-0070

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97212-182-0

TCS4MD






side.



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

6



107492-1082 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1082 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.52 b2 -tolerance


107492-1082 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice




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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.25


12.0± 1.3 {90± 10}

PushrodC

0

107492-1082 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1082 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°35′14″±

20′

13°28′48″±3°

(35°)

(96°)

(3°12′32″)


Service Department


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

1/11


No.

Governor: 105934-0120

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97212-182-1

TCS4MD






side.



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

7



107492-1083 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1083 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.52 b2 -tolerance


107492-1083 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)


Torque cam No. “ AH15”

Pump speed (r/min)






Advice




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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.25


12.0± 1.3 {90± 10}

PushrodC

0

107492-1083 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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)


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1083 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°35′14″±

20′

13°28′48″±3°

(35°)

(96°)

(3°12′32″)


Service Department


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

1/11


No.

Governor: 105934-0120

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:14 Mar.2003

ISUZU8-97212-182-2

TCS4MD






side.



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

8



107492-1084 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1084 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.52 b2 -tolerance


107492-1084 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice




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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.25


12.0± 1.3 {90± 10}

PushrodC

0

107492-1084 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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)


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1084 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°35′14″±

20′

13°36′18″±3°

(35°)

(96°)

(3°12′32″)


Service Department


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

1/11


No.

Governor: 105934-0080

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97212-184-0

TCS4MD






side.



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

1



107492-1090 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1090 3/11






Advice


remeasured.



stopper.












3.17 a2 -tolerance


2.65 b2 -tolerance


107492-1090 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-0.6]

R2-1.1


10.7± 1.3 {80± 10}

PushrodC

0

107492-1090 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.17 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1090 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29°± 3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°06′26″±

20′

13°±3°

(35°)

(96°)

(3°12′32″)


Service Department


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

1/11


No.

Governor: 105934-0080

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97212-184-0

TCS4MD






side.



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

2



107492-1091 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1091 3/11






Advice


remeasured.



stopper.












3.17 a2 -tolerance


2.65 b2 -tolerance


107492-1091 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-0.6]

R2-1.1


10.7± 1.3 {80± 10}

PushrodC

0

107492-1091 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.17 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1091 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29°± 3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°35′14″±

20′

13°28′48″± 3°

(35°)

(96°)

(3°12′32″)


Service Department


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

1/11


No.

Governor: 105934-0130

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97212-184-1

TCS4MD






side.



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

4



107492-1092 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1092 3/11






Advice


remeasured.



stopper.












3.17 a2 -tolerance


2.65 b2 -tolerance


107492-1092 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-0.6]

R2-1.1


10.7± 1.3 {80± 10}

PushrodC

0

107492-1092 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.17 a2 -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 )



FixedPre-stroke


- 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)


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1092 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29°± 3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°35′14″±

20′

13°28′48″± 3°

(35°)

(96°)

(3°12′32″)


Service Department


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

1/11


No.

Governor: 105934-0130

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:14 Mar.2003

ISUZU8-97212-184-2

TCS4MD






side.



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

5



107492-1093 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1093 3/11






Advice


remeasured.



stopper.












3.17 a2 -tolerance


2.65 b2 -tolerance


107492-1093 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-0.6]

R2-1.1


10.7± 1.3 {80± 10}

PushrodC

0

107492-1093 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.17 a2 -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 )



FixedPre-stroke


- 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)


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1093 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29°± 3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°35′14″±

20′

13°21′18″± 3°

(35°)

(96°)

(3°12′32″)


Service Department


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

1/11


No.

Governor: 105934-0090

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97212-185-0

TCS4MD






side.



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

3



107492-1100 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1100 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.76 b2 -tolerance


107492-1100 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.35


12.0± 1.3 {90± 10}

PushrodC

0

107492-1100 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1100 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°35′14″±

20′

13°28′48″±3°

(35°)

(96°)

(3°12′32″)


Service Department


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

1/11


No.

Governor: 105934-0090

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97212-185-0

TCS4MD






side.



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

5



107492-1101 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1101 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.76 b2 -tolerance


107492-1101 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.25


12.0± 1.3 {90± 10}

PushrodC

0

107492-1101 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


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

Z 8.9±0.5 510 22 ± 1.5 ± 14 Rack c(v)

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

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

IApprox.

R1＋0.3150 (180) - Lever c(v)

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

107492-1101 7/11


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1101 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°35′14″±

20′

13°28′48″±3°

(35°)

(96°)

(3°12′32″)


Service Department


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

1/11


No.

Governor: 105934-0091

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97212-185-0

TCS4MD






side.



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

5



107492-1102 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1102 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.76 b2 -tolerance


107492-1102 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.25


12.0± 1.3 {90± 10}

PushrodC

0

107492-1102 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1102 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°35′14″±

20′

13°28′48″±3°

(35°)

(96°)

(3°12′32″)



107049-2063



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



Company:

Assy No.: 107492-1103ENGINE MODEL: 4HE1-X

No.

1. Test conditions

Date:


kgf/cm2}

CONFIDENTIAL


20 Feb 2004

ISUZU

8-97212-185-1






6


2. Injection timing


1/11




Injection order: 1 3 , 1 4 , 1 290°± 15' 180°± 15' 270°± 15'



2/11107492-1103





housing 1.












shim 1.

1

563

4

1

2


order adjustment

3/11107492-1103








3.10 a2 - tolerance


2.76 b2 - tolerance


Advice












4/11107492-1103




Advice



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


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


5/11107492-1103











0

12.0±1.3 {90±10}

N = 500 r/min

R2 [R1-2.15]


Rac

k po

sitio

n (m

m)


R2-1.25

6/11107492-1103









3.10 a2 - 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





a (adjusting point)


7/11107492-1103


Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)



cylinders (%)Fixed

Pre-strokeat

adjustmentRemarks






D* 15.3±0.1 1200 (106) - Lever b1 ~ b2(v)



8/11107492-1103

6. FICD adjustment









1+1mm

Speed control lever

FICD actuator lever


1 2 3

9/11107492-1103


Note:






1200 r/min.




Rac

k po

sitio

n (m

m)

Pump speed (r/min)

Stroke

D


Full load set bolt

Full load set lever

1

2

10/11107492-1103



Hole (R42)

IdlingFull-speed

29.5°±3°30°±5°Hole (R41.3)

Normal Stop

45°±5°

22.5°±5°


















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


11/11107492-1103


L L

tt

Bracket mark Pump

Engine



Gear side

Pump side

Check hole





13°36'18''±3°

(35°)

28°35'14''±20'(96°)

(3°1

2'32

'')

Service Department


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

1/11


No.

Governor: 105934-0100

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97212-189-0

TCS4MD






side.



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

3



107492-1110 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1110 3/11






Advice


remeasured.



stopper.












3.17 a2 -tolerance


2.65 b2 -tolerance


107492-1110 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-1.4]

R2-0.8


13.3± 1.3 {100± 10}

PushrodC

0

107492-1110 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.17 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1110 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29°± 3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°35′14″±

20′

13°28′48″± 3°

(35°)

(96°)

(3°12′32″)


Service Department


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

1/11


No.

Governor: 105934-0100

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97212-189-0

TCS4MD






side.



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

3



107492-1111 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1111 3/11






Advice


remeasured.



stopper.












3.17 a2 -tolerance


2.65 b2 -tolerance


107492-1111 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-1.4]

R2-0.8


13.3± 1.3 {100± 10}

PushrodC

0

107492-1111 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.17 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1111 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29°± 3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°35′14″±

20′

13°28′48″± 3°

(35°)

(96°)

(3°12′32″)


Service Department


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

1/11


No.

Governor: 105934-0101

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:14 Mar.2003

ISUZU8-97212-189-1

TCS4MD






side.



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

4



107492-1112 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1112 3/11






Advice


remeasured.



stopper.












3.17 a2 -tolerance


2.65 b2 -tolerance


107492-1112 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-1.4]

R2-0.8


13.3± 1.3 {100± 10}

PushrodC

0

107492-1112 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.17 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1112 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29°± 3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°35′14″±

20′

13°21′18″± 3°

(35°)

(96°)

(3°12′32″)


Service Department


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

1/11


No.

Governor: 105934-0070

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97212-186-0

TCS4MD






side.



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

2



107492-1120 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1120 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.52 b2 -tolerance


107492-1120 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice




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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.35


12.0± 1.3 {90± 10}

PushrodC

0

107492-1120 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1120 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°35′14″±

20′

13°28′48″± 3°

(35°)

(96°)

(3°12′32″)


Service Department


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

1/11


No.

Governor: 105934-0070

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97212-186-0

TCS4MD






side.



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

3



107492-1121 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1121 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.52 b2 -tolerance


107492-1121 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice




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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.25


12.0± 1.3 {90± 10}

PushrodC

0

107492-1121 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1121 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°35′14″±

20′

13°28′48″± 3°

(35°)

(96°)

(3°12′32″)


Service Department


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

1/11


No.

Governor: 105934-0071

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97212-186-0

TCS4MD






side.



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

3



107492-1122 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1122 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.52 b2 -tolerance


107492-1122 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice




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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.25


12.0± 1.3 {90± 10}

PushrodC

0

107492-1122 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1122 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°35′14″±

20′

13°28′48″± 3°

(35°)

(96°)

(3°12′32″)


Service Department


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

1/11


No.

Governor: 105934-0071

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:14 Mar.2003

ISUZU8-97212-186-1

TCS4MD






side.



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

4



107492-1123 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1123 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.52 b2 -tolerance


107492-1123 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice




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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.25


12.0± 1.3 {90± 10}

PushrodC

0

107492-1123 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1123 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°35′14″±

20′

13°36′18″± 3°

(35°)

(96°)

(3°12′32″)


Service Department


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

1/11


No.

Governor: 105934-0080

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:3 Mar.2003

ISUZU8-97212-188-0

TCS4MD





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


side.



Selector switch No. 00 (For C/U 407910-303*)


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

2

107492-1130 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1130 3/11






Advice


remeasured.



stopper.












3.17 a2 -tolerance


2.65 b2 -tolerance


107492-1130 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-0.6]

R2-1.1


10.7± 1.3 {80± 10}

PushrodC

0

107492-1130 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.17 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1130 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29°± 3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°35′14″±

20′

13°28′48″± 3°

(35°)

(96°)

(3°12′32″)


Service Department


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

1/11


No.

Governor: 105934-0081

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97212-188-0

TCS4MD






side.



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

2



107492-1131 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1131 3/11






Advice


remeasured.



stopper.












3.17 a2 -tolerance


2.65 b2 -tolerance


107492-1131 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-0.6]

R2-1.1


10.7± 1.3 {80± 10}

PushrodC

0

107492-1131 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.17 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1131 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29°± 3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°35′14″±

20′

13°28′48″± 3°

(35°)

(96°)

(3°12′32″)


Service Department


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

1/11


No.

Governor: 105934-0081

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:18 Mar.2003

ISUZU8-97212-188-1

TCS4MD






side.



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

3



107492-1132 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1132 3/11






Advice


remeasured.



stopper.












3.17 a2 -tolerance


2.65 b2 -tolerance


107492-1132 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-0.6]

R2-1.1


10.7± 1.3 {80± 10}

PushrodC

0

107492-1132 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.17 a2 -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 )



FixedPre-stroke


- 12.9 900 81 ± 1.6 ±4 Rack a1～a2(v)

Z 8.5±0.5 500 19 ± 1.5 ± 14 Rack c(v)

A R1(12.9) 900 81 ± 1 - Lever a1～a2(v)

B R1＋2.9 1,450 (102.5) ± 2 - Lever b1～b2(v)

IApprox.

R1＋2.0150 (175) - Lever c(v)

D* 15.2±0.1 1,450 (96.5) - Lever b1～b2(v)

107492-1132 7/11


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1132 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29°± 3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°35′14″±

20′

13°21′18″± 3°

(35°)

(96°)

(3°12′32″)


Service Department


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

1/11


No.

Governor: 105934-0070

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97212-935-0

TCS4MD






side.



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

3



107492-1140 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1140 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.52 b2 -tolerance


107492-1140 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice




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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.25


12.0± 1.3 {90± 10}

PushrodC

0

107492-1140 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1140 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°35′14″±

20′

13°28′48″± 3°

(35°)

(96°)

(3°12′32″)


Service Department


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

1/11


No.

Governor: 105934-0071

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97212-935-0

TCS4MD






side.



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

3



107492-1141 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1141 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.52 b2 -tolerance


107492-1141 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice




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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.25


12.0± 1.3 {90± 10}

PushrodC

0

107492-1141 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1141 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°35′14″±

20′

13°28′48″± 3°

(35°)

(96°)

(3°12′32″)


Service Department


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

1/11


No.

Governor: 105934-0071

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:14 Mar.2003

ISUZU8-97212-935-1

TCS4MD






side.



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

4



107492-1142 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1142 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.52 b2 -tolerance


107492-1142 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice




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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.25


12.0± 1.3 {90± 10}

PushrodC

0

107492-1142 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1142 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°35′14″±

20′

13°36′18″± 3°

(35°)

(96°)

(3°12′32″)


Service Department


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:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97257-154-0

TCS4MD






side.



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

1



107492-1150 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1150 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.52 b2 -tolerance


107492-1150 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.75


4.7± 1.3 {35± 10}

PushrodC

0

107492-1150 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1150 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°35′14″±

20′

13°28′48″±3°

(35°)

(96°)

(3°12′32″)


Service Department


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

1/11


No.

Governor: 105934-0071

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97257-154-0

TCS4MD






side.



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

1



107492-1151 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1151 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.52 b2 -tolerance


107492-1151 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.75


4.7± 1.3 {35± 10}

PushrodC

0

107492-1151 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1151 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°35′14″±

20′

13°28′48″±3°

(35°)

(96°)

(3°12′32″)


Service Department


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

1/11


No.

Governor: 105934-0140

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:12 Feb.2002

ISUZU8-97257-154-1

TCS4MD






side.



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

3



107492-1152 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1152 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.52 b2 -tolerance


107492-1152 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-2.1


5.3± 1.3 {40± 10}

PushrodC

0

107492-1152 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



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｝



107492-1152 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30.5°±3°

30°± 5°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°35′14″±

20′

13°28′48″±3°

(35°)

(96°)

(3°12′32″)



107049-2063



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



Company:

Assy No.: 107492-1153ENGINE MODEL: 4HE1-XS

No.

1. Test conditions

Date:


kgf/cm2}

CONFIDENTIAL


20 Feb 2004

ISUZU

8-97257-154-2






4


2. Injection timing


1/11




Injection order: 1 3 , 1 4 , 1 290°± 15' 180°± 15' 270°± 15'



2/11107492-1153





housing 1.












shim 1.

1

563

4

1

2


order adjustment

3/11107492-1153








3.10 a2 - tolerance


2.52 b2 - tolerance


Advice












4/11107492-1153




Advice



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


1775

5/11107492-1153











0

5.3±1.3 {40±10}

N = 500 r/min

R2 [R1-2.15]


Rac

k po

sitio

n (m

m)


R2-2.1

6/11107492-1153









3.10 a2 - 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





a (adjusting point)


7/11107492-1153


Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)



cylinders (%)Fixed

Pre-strokeat

adjustmentRemarks


Z 9.0±0.5 540 15.5 ± 1.5 ±14 Rack c(v) Cylinder variation adjustment standard


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)



8/11107492-1153

6. FICD adjustment









1+1mm

Speed control lever

FICD actuator lever


1 2 3

9/11107492-1153


Note:






1400 r/min.




Rac

k po

sitio

n (m

m)

Pump speed (r/min)

Stroke

D


Full load set bolt

Full load set lever

1

2

10/11107492-1153



Hole (R42)

Idling

Full-speed

30°±5°30.5°±3°

Hole (R41.3)

Normal Stop

45°±5°

22.5°±5°


















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


11/11107492-1153


L L

tt

Bracket mark Pump

Engine



Gear side

Pump side

Check hole





13°36'18''±3°

(35°)

28°35'14''±20'(96°)

(3°1

2'32

'')

Service Department


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

1/11


No.

Governor: 105934-0110

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97225-432-1

TCS4MD






side.



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

1



107492-1160 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1160 3/11






Advice


remeasured.



stopper.












3.44 a2 -tolerance


3.04 b2 -tolerance


107492-1160 4/11

Idling adjustment

Rac

k po

sitio

n (

mm

)

Pump speed (r/min)






Advice



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)



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 400 r/min

R2 [R1-2.55]

R2-1.65


12.0± 1.3 {90± 10}

PushrodC

0

107492-1160 6/11

4-3 Timing cam adjustment (Timing cam No:510)




(point a in table below: Np = 1,000 r/min).








a (adjusting point)


stopper


Pump speed (r/min)




3.44 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard




Boost press. 0

107492-1160 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:









position is 16.15± 0.1 mm and fuel injection quantity is as specified. Then, fix the set

bolt.

Stroke


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



Idling


Set the position

R=1.5± 0.2,

N=0

StopNormal

45°±5°

22.5°±5°

32°±5°

23°± 3°


















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



B.T.D.C. : 9°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 9°°°°°)


Check hole

28°05′14″±

20′

12°58′48″± 3°

(35°)

(96°)

(3°12′32″)


Service Department


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

1/11


No.

Governor: 105934-0111

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97225-432-1

TCS4MD






side.



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

1



107492-1161 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1161 3/11






Advice


remeasured.



stopper.












3.44 a2 -tolerance


3.04 b2 -tolerance


107492-1161 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 400 r/min

R2 [R1-2.55]

R2-1.65


12.0± 1.3 {90± 10}

PushrodC

0

107492-1161 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.44 a2 -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 )



FixedPre-stroke


- 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)


Cylinder variation



Cylinder variation

adjustment standard




Boost press. 0

107492-1161 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










bolt.

Stroke


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



Idling


Set the position

R=1.5± 0.2,

N=0

StopNormal

45°±5°

22.5°±5°

32°±5°

23°± 3°


















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



B.T.D.C. : 9°


Pump

Engine

Bracket mark



Gear side

Pump side


Check hole

28°05′14″±

20′

12°58′48″± 3°

(35°)

(96°)

(3°12′32″)



(B.T.D.C. 9°°°°°)

Service Department


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

1/11


No.

Governor: 105934-0112

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97225-432-1

TCS4MD






side.



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

2



107492-1162 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1162 3/11






Advice


remeasured.



stopper.












3.44 a2 -tolerance


3.04 b2 -tolerance


107492-1162 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



[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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 400 r/min

R2 [R1-2.55]

R2-1.65


12.0± 1.3 {90± 10}

PushrodC

0

107492-1162 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.44 a2 -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 )



FixedPre-stroke


- 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)


Cylinder variation



Cylinder variation

adjustment standard




Boost press. 0

107492-1162 8/11

6. FICD Adjustment






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.



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


Note:










bolt.

Stroke


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



Idling


Set the position

R=1.5± 0.2,

N=0

StopNormal

45°±5°

22.5°±5°

32°±5°

23°± 3°


















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



B.T.D.C. : 9°


Pump

Engine

Bracket mark



Gear side

Pump side


Check hole

28°05′14″±

20′

12°58′48″± 3°

(35°)

(96°)

(3°12′32″)



(B.T.D.C. 9°°°°°)

Service Department


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

1/11


No.

Governor: 105934-0113

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Nov.2001

ISUZU8-97225-432-1

TCS4MD






side.



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

2



107492-1163 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1163 3/11






Advice


remeasured.



stopper.












3.44 a2 -tolerance


3.04 b2 -tolerance


107492-1163 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



[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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 400 r/min

R2 [R1-2.55]

R2-1.65


12.0± 1.3 {90± 10}

PushrodC

0

107492-1163 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.44 a2 -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 )



FixedPre-stroke


- 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)


Cylinder variation



Cylinder variation

adjustment standard




Boost press. 0

107492-1163 8/11

6. FICD Adjustment






speed at 450 r/min.


mm.



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


Note:










bolt.

Stroke


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



Idling


Set the position

R=1.5± 0.2,

N=0

StopNormal

45°±5°

22.5°±5°

32°±5°

23°± 3°


















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



B.T.D.C. : 9°


Pump

Engine

Bracket mark



Gear side

Pump side


Check hole

28°05′14″±

20′

12°58′48″± 3°

(35°)

(96°)

(3°12′32″)



(B.T.D.C. 9°°°°°)

Service Department


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

1/11


No.

Governor: 105934-0113

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:27 Aug.2003

ISUZU8-97225-432-2

TCS4MD






side.



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

4



107492-1164 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1164 3/11






Advice


remeasured.



stopper.












3.44 a2 -tolerance


3.04 b2 -tolerance


107492-1164 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



[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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 400 r/min

R2 [R1-2.55]

R2-1.65


12.0± 1.3 {90± 10}

PushrodC

0

107492-1164 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.44 a2 -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 )



FixedPre-stroke


- 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)


Cylinder variation



Cylinder variation

adjustment standard




Boost press. 0

107492-1164 8/11

6. FICD Adjustment






speed at 450 r/min.


mm.



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


Note:










bolt.

Stroke


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



Idling


Set the position

R=1.5± 0.2,

N=0

StopNormal

45°±5°

22.5°±5°

32°±5°

23°± 3°














(8) Apply at least 44.0 kpa {at least 330 mmHg} boost pressure, set pump speed at




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



B.T.D.C. : 9°


Pump

Engine

Bracket mark



Gear side

Pump side


Check hole

28°05′

14″±

20′

12°38′18″± 3°

(35°)

(96°)

(3°

12′

32″)



(B.T.D.C. 9°°°°°)

Service Department


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

1/11


No.

Governor: 105934-0150

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:12 Feb.2002

ISUZU8-97321-399-0

TCS4MD






side.



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

1



107492-1170 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1170 3/11






Advice


remeasured.



stopper.












3.17 a2 -tolerance


2.65 b2 -tolerance


107492-1170 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-0.6]

R2-1.5


5.3± 1.3 {40± 10}

PushrodC

0

107492-1170 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.17 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1170 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29°± 3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°35′14″±

20′

13°28′48″± 3°

(35°)

(96°)

(3°12′32″)


Service Department


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

1/11


No.

Governor: 105934-0150

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:18 Mar.2003

ISUZU8-97321-399-1

TCS4MD






side.



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

1



107492-1171 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1171 3/11






Advice


remeasured.



stopper.












3.17 a2 -tolerance


2.65 b2 -tolerance


107492-1171 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-0.6]

R2-1.5


5.3± 1.3 {40± 10}

PushrodC

0

107492-1171 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.17 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard

Boost press. 0




107492-1171 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29°± 3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

28°35′14″±

20′

13°21′18″± 3°

(35°)

(96°)

(3°12′32″)


Service Department


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

1/11


No.

Governor: 105934-0120

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:8 Jan.2002

ISUZU8-97329-171-0

TCS4MD






side.



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

0



107492-1180 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1180 3/11






Advice


remeasured.



stopper.












3.10 a2 -tolerance


2.52 b2 -tolerance


107492-1180 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice




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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-2.15]

R2-1.25


12.0± 1.3 {90± 10}

PushrodC

0

107492-1180 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.10 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard




Boost press. 0

107492-1180 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29.5°±3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

25°21′24″±

20′

13°±3°

(35°)

(96°)

(5°57′34″)



107049-2063



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



Company:


No.

1. Test conditions

Date:


kgf/cm2}

CONFIDENTIAL


20 Feb 2004

ISUZU

8-97329-171-0






1


2. Injection timing


1/11




Injection order: 1 3 , 1 4 , 1 290°± 15' 180°± 15' 270°± 15'



2/11107492-1181





housing 1.












shim 1.

1

563

4

1

2


order adjustment

3/11107492-1181








3.10 a2 - tolerance


2.52 b2 - tolerance


Advice












4/11107492-1181




Advice



Pump speed (r/min)

Rac

k po

sitio

n (

mm

)


R1(15.0)

R2 [R1-2.15]

10.7±1.0

0300-40 (650) 1000 (1350) (1450)

(1600)1690

13.9±0.1


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


1810

5/11107492-1181











0

12.0±1.3 {90±10}

N = 500 r/min

R2 [R1-2.15]


Rac

k po

sitio

n (m

m)


R2-1.25

6/11107492-1181









3.10 a2 - 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





a (adjusting point)


7/11107492-1181


Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)



cylinders (%)Fixed

Pre-strokeat

adjustmentRemarks






D* 16.6±0.1 1400 (115) - Lever b1 ~ b2(v)



8/11107492-1181

6. FICD adjustment









1+1mm

Speed control lever

FICD actuator lever


1 2 3

9/11107492-1181


Note:






1400 r/min.




Rac

k po

sitio

n (m

m)

Pump speed (r/min)

Stroke

D


Full load set bolt

Full load set lever

1

2

10/11107492-1181



Hole (R42)

IdlingFull-speed

29.5°±3°30°±5°Hole (R41.3)

Normal Stop

45°±5°

22.5°±5°


















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


11/11107492-1181


L L

tt

Bracket mark Pump

Engine



Gear side

Pump side

Check hole





13°07'30''±3°

(35°)

25°21'24''±20'(96°)

(5°5

7'34

'')

Service Department


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

1/11


No.

Governor: 105934-0130

1. Test condition

Date:

Pump rotation:


kgf/cm2 }

2. Injection timing


Injection order:





Company:8 Jan.2002

ISUZU8-97329-172-0

TCS4MD






side.



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

0



107492-1190 2/11







stopper pin.


mm.













order adjustment

1

2

4

563

107492-1190 3/11






Advice


remeasured.



stopper.












3.17 a2 -tolerance


2.65 b2 -tolerance


107492-1190 4/11

Rac

k po

sitio

n (

mm

)

Idling adjustment

Pump speed (r/min)

Rac

k po

sitio

n (

mm

)



Pump speed (r/min)






Advice



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







nut B.


A Boost compensator




Top of lever


Rac

k po

sitio

n (

mm

) N = 500 r/min

R2 [R1-0.6]

R2-1.1


10.7± 1.3 {80± 10}

PushrodC

0

107492-1190 6/11













a (adjusting point)


stopper


Pump speed (r/min)




3.17 a2 -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 )



FixedPre-stroke


- 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


Cylinder variation



Cylinder variation

adjustment standard




Boost press. 0

107492-1190 8/11

6. FICD Adjustment






speed at 450 r/min.




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


Note:










Stroke


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



Idling


Set the position

R=1.5± 0.2

StopNormal

45°±5°

22.5°±5°

30°±5°

29°± 3°


















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



B.T.D.C. : 8°


Pump

Engine

Bracket mark



Gear side

Pump side


(B.T.D.C. 8°°°°°)


Check hole

25°21′24″±

20′

13°±3°

(35°)

(96°)

(5°57′34″)



107049-2073



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



Company:


No.

1. Test conditions

Date:


kgf/cm2}

CONFIDENTIAL


20 Feb 2004

ISUZU

8-97329-172-0






1


2. Injection timing


1/11




Injection order: 1 3 , 1 4 , 1 290°± 15' 180°± 15' 270°± 15'



2/11107492-1191





housing 1.












shim 1.

1

563

4

1

2


order adjustment

3/11107492-1191








3.17 a2 - tolerance


2.65 b2 - tolerance


Advice












4/11107492-1191




Advice



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


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


5/11107492-1191











0

10.7±1.3 {80±10}

N = 500 r/min

R2 [R1-0.6]


Rac

k po

sitio

n (m

m)


R2-1.1

6/11107492-1191









3.17 a2 - 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





a (adjusting point)


7/11107492-1191


Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)



cylinders (%)Fixed

Pre-strokeat

adjustmentRemarks






D* 15.2±0.1 1450 (96.5) - Lever b1 ~ b2(v)



8/11107492-1191

6. FICD adjustment









1+1mm

Speed control lever

FICD actuator lever


1 2 3

9/11107492-1191


Note:






1450 r/min.




Rac

k po

sitio

n (m

m)

Pump speed (r/min)

Stroke

D


Full load set bolt

Full load set lever

1

2

10/11107492-1191



Hole (R42)

IdlingFull-speed

29°±3°30°±5°Hole (R41.3)

Normal Stop

45°±5°

22.5°±5°


















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


11/11107492-1191


L L

tt

Bracket mark Pump

Engine



Gear side

Pump side

Check hole





12°52'30''±3°

(35°)

25°21'24''±20'(96°)

(5°5

7'34

'')


107049-2063



Company:

Assy No.: 107492-1200ENGINE MODEL: 4HE1-TC

No.

1. Test con di tions

Date:


kgf/cm2}

CONFIDENTIAL


10 Sep 2007

ISUZU

8-98024-252-0






2


2. Injection timing

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

1/11




Injection order: 1 3 , 1 4 , 1 290°± 15' 180°± 15' 270°± 15'


Tappet clearance: Manually rotate camshaft 2 ~ 3 times and confi rm that it rotates smooth ly.

Bosch CorporationAutomotive Aftermarket Division


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

2/11107492-1200





housing 1.

(2) -1. Screw in setscrew 3 until counterweight 2 contacts housing's pressfi tted stopper pin.











shim 1.

1

563

4

1

2


order adjustment

3/11107492-1200






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


3.10 a2 - tolerance


2.52 b2 - tolerance

(calculate from each specifi cation)

Advice





3.73. Then, tighten locknut to specifi ed torque.





nut to specifi ed torque.

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

4/11107492-1200




Advice



Pump speed (r/min)

Rac

k po

sitio

n (

mm

)


R1(14.5)

R2 [R1-2.15]

10.7±1.0

0250-40 (650) 1000 (1350) (1450)

(1610)1690

13.9±0.1


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











0

12.0±1.3 {90±10}

N = 500 r/min

R2 [R1-2.15]


Rac

k po

sitio

n (m

m)


R2-1.05

6/11107492-1200









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


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




b (confi rmation point)

a (adjusting point)


7/11107492-1200


Adjustingpoint

Rackposition

(mm)

Pumpspeed(r/min)



cylinders (%)Fixed

Pre-strokeat

adjustmentRemarks




B R1+2.15 1400 117 ± 4 - Lever b1 ~ b2(v) Boost press. kPa {mmHg}Above 39.3 {Above 295}


D* 16.1±0.1 1400 (110.5) - Lever b1 ~ b2(v)



8/11107492-1200

6. FICD adjustment






(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


1+1mm

Speed control lever

FICD actuator lever


1 2 3

9/11107492-1200


Note:




actuator wire is not loose. Then, fi x nuts 1.


1400 r/min.



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


Full load set bolt

Full load set lever

1

2

10/11107492-1200



Hole (R42)

IdlingFull-speed

29.5°±3°30°±5°Hole (R41.3)

Normal Stop

45°±5°

22.5°±5°



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.




Specifi ed torque : 3.4 ~ 4.9 N.m {0.35 ~ 0.5 kgf.m}


(5) Tighten two fl ange fi xing screws.

Specifi ed torque : 6.9 ~ 8.8 N.m {0.7 ~ 0.9 kgf.m}



(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


11/11107492-1200


L L

tt

Bracket mark Pump

Engine



Gear side

Pump side

Check hole





13°36'18''±3°

(35°)

28°35'14''±20'(96°)

(3°1

2'32

'')

mitics

Documents

solenoid switch adjustment1

cylinders injection

setscrew pn

prestroke adjustmentadjust

injection pump

cylinders prestrokeis

prestroke adjustment3

selector switch