INJECTION PUMP TEST SPECIFICATIONS 196000-3520
MANUFACTURER TOYOTA 196000-352#
INJECTION PUMP
ENGINE TYPE 3L VE4/10F1950RND 352
VEHICLE MODEL HILUX/ ROTATION Clockwise viewed GOVERNOR TYPE All speed
4 RUNNER from drive side
RATED VOLTAGE 12V INJECTION ORDER A-B-C -D INJECTION INTERVAL 90° ± 30'
Dimension KF (mm ) 5.50 ± 0.10 Dim ension MS (mm ) 0.40 ± 0.10
Dimension K (m m) 3.30 ± 0.10 Dim ension PS (m m) —
1. TEST CONDITIONS
Nozzle 093400-0540 (DN12SD12A) Feed Pressure 19.6 kPa ( 0.2 kgf/cm 2 )
Nozzle Opening Pressure 14.7 ± 0.5 MPa ( 150 ± 5 kgf/cm 2) High Pressure Pipe Ø2 X Ø6 X 840 mm
Test Oil SAE J967 (ISO4113) Fuel Temperature 40 - 45 °C (104 - 113°F)
NOTE : Apply 6 volts DC across the fuel cut solenoid during adjustment.
2. PRE-ADJUSTMENT Applying 0 V to T.C.V.
Lever Position Pump Speed Boost Pressure Fuel Delivery Max. Spread
(deg) (rpm) in Delivery
(kPa) (mm Hg) (m m 3 /st) (cc/200st) (m m 3 ) (cc)
Full Load 28.5 ± 5° 1200 — — 55.6 ± 0.5 11.1 ± 0.1 2.0 0.4
(Full)
High Speed 2200 — — 27.0 ± 2.5 5.4 ± 0.5 — —
NOTE : Dimension of Governor Shaft, L = about 2.5 mm
3. ADJUSTM ENT OF INTERNAL PRESSURE Applying 0 V to T.C.V.
Lever Position Pum p Speed Boost Pressure Internal Pressure Remarks
(rpm) (kPa) (m mHg) (kPa) (kgf/cm 2)
Full 500 — — 343.5 ± 29.5 3.5 ± 0.3 By the regulating valve
1900 — — 637.0 ± 29.0 6.5 ± 0.3
4. OVERFLOW QUANTITY CHECK Applying 0 V to T.C.V.
Lever Position Pum p Speed Boost Pressure Overflow Quantity Remarks
(rpm) (kPa) (m mHg) (L/h) (cc/1000st)
Full 2200 — — 22 - 48 167 - 364
NOTE : The overflow valve belonging to the pump should be used checking.
5. ADJUSTM ENT OF TIM ER Applying 0 V to T.C.V.
Lever Position Pum p Speed Boost Pressure Piston Travel Remarks
(rpm) (kPa) (m mHg) (mm)
Full 800 — — 1.90 ± 0.40
1200 — — 3.30 ± 0.40
2000 — — 6.20 ± 0.40
2450 — — 7.30 ± 0.24 M ax. piston travel
NOTE : Hysteresis at each pum p speed is less than 0.3 mm .
196000-3520
6. ADJUSTMENT OF BOOST COMPENSATOR — : Not Applicable
Lever Pump Boost Pressure Fuel Delivery M ax. Spread Rem arks
Position Speed in Delivery
(rpm )
(kPa) (mmHg) (m m 3 /st) (cc/200st) (mm 3) (cc)
— — — — — — — — —
7. ADJUSTM ENT OF FUEL DELIVERY Applying 0 V to T.C.V.
Lever Pump Boost Pressure Fuel Delivery M ax. Spread Rem arks
Speed in Delivery
Position (rpm ) (kPa) (mmHg) (m m 3 /st) (cc/200st) (mm 3) (cc)
Full 1200 — — 55.6 ± 0.5 = A 11.1 ± 0.1 = A 2.0 0.4 By full load setting screw
2200 — — 27.0 ± 2.5 5.4 ± 0.5 — — By max. speed setting screw
2000 — — 47.2 ± 4.0 9.4 ± 0.8 — —
Les s than Les s than
2450 — — 5.0 1.0 — —
100 — — 70.0 ± 10.0 14.0 ± 2.0 6.0 1.2 By governor sleeve plug
500 — — 51.7 ± 3.0 10.3 ± 0.6 2.5 0.5
1900 — — 50.2 ± 2.8 10.0 ± 0.6 2.5 0.5
8. SETTING OF LOAD SENSING TIMER Applying 0 V to T.C.V.
Lever Position Pump Speed Boost Pressure Fuel Delivery Rem arks
3
(rpm) (kPa) (mm Hg) (mm /st) (cc/200st)
Start of Load Sensing 1200 — — (A – 5.0) ± 2.0 (A – 1.0) ± 0.4 By governor shaft
End of Pressure Drop 1200 — — 41.6 ± 1.0 8.3 ± 0.2 Check
Check Points 1. Change of Piston Travel : 1.68 ± 0.50 m m (Pump speed 1200 rpm )
2. Dimension of Governor Shaft : L = 1.15 ± 0.85 mm
196000-3520
9. SETTING OF ADJUSTING LEVER AT LOW SPEED Applying 0 V to T.C.V.
Lever Pump Boost Pressure Fuel Delivery Max. Spread Remarks
Position Speed in Delivery
(deg) (rpm ) (kPa) (mm /st)3
(cc/500st) 3
(m m ) (cc)
– 15.5 ± 5° 350 — 19.6 ± 1.5 = B 9.8 ± 0.8 = B 1.7 0.9 Lever setting
(Idle)
425 — (B – 12.5) ± 2.5 (B – 6.3) ± 1.3 — —
10. SETTING OF ADJUSTING LEVER AT PARTIAL RANGE — : Not Applicable
Pump Speed Boost Pressure Fuel Delivery Remarks
(rpm) (kPa) (mm Hg) (mm 3 /st) (cc/500st)
— — — — — —
11. CHARACTERISTIC OF A.C.S.D. Applying 0 V to T.C.V.
Lever Position Pump Speed Boost Pressure Measuring Value Remarks
(rpm) (kPa) (mmHg)
Idle 350 — — 0.34 ± 0.10 mm Piston Travel
350 — — 0 m m 3/st Idle-up Quantity (0 cc/500st)
Fuel temperature : 39 - 41°C
12. ADJUSTMENT OF T.C.V.
Lever Position Pump Speed Boost Pressure Piston Travel Remarks
(rpm) (kPa) (mmHg) (mm )
At End Pressure 1200 — — 3.30 ± 0.70 W ith applying 6 ± 0.1 (V)
Drop
13. SETTING OF DIAPHRAGM FOR HEATER & POW ER STEERING — : Not Applicable
Pump Speed Vacuum Pressure Fuel Delivery Remarks
(rpm) (kPa) (m mHg) (m m 3 /st) (cc/500st)
— — — — — —
14. ADJUSTMENT OF POW ER CONTROL — : Not Applicable
Lever Position Pump Speed Boos t Pressure Fuel Delivery Remarks
(rpm) (kPa) (mmHg) (mm 3 /st) (cc/200st)
— — — — — — —
196000-3520
15. ADJUSTMENT OF THROTTLE POSITION SENSOR — : Not Applicable
Lever Position Pump Speed Boost Pressure Fuel Delivery Sensor Rem arks
Output
(rpm) (kPa) (mmHg) 3
(m m /st) (cc/500st) Voltage (V)
— — — — — — — —
16. FINAL CHECK AFTER ADJUSTMENT
1. Range of lever angle between idle and full lever position is 44 ± 3°.
2. Resistance of pick-up tachometer must be 810 ± 160 ohm s.
3. After adgustm ent has been completed, delivery quantity must be 0 m m 3 /st (0 cc/200st)
when voltage at fuel cut solenoid is reduced to zero. (Pum p Speed Np = 100 rpm)
