INJECTION PUMP TEST SPECIFICATIONS 196000-5280

MANUFACTURER TOYOTA
I JECTION PUMP 196000-528#
ENGINE TYPE 1HZ VE6/10F1900RND528
VEHICLE MODEL LAND CRUISER ROTATION Clockwise viewed from GOVERNOR TYPE Maximum-minimum
drive side speed
RATED VOLTAGE 12V INJECTION ORDER A-B-C-D-E-F INJECTION INTERVAL 60° ± 30'
Dimension KF (mm) 5.90 ± 0.10 Dimension MS (mm) 0.29 ± 0.10
Dimension K (mm) 3.30 ± 0.15 Dimension PS (mm) 0.20 ± 0.02

1. TEST CONDITIONS
Nozzle 093400-0540 (DN12SD12A) Feed Pressure 19.6 kPa ( 0.2 kgf/cm2)
Nozzle Opening Pressure 14.7 ± 0.5 MPa ( 150 ± 5 kgf/cm 2) High Pressure Pipe Ø2 × Ø6 × 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
in Delivery
(deg) (rpm)
(kPa) (mmHg) (mm3/st) (cc/200st) (mm3) (cc)

Full Load 26 ± 5° 1200 80.0 600 62.2 ± 0.5 12.4 ± 0.1 2.0 0.4
(Full position)
High Speed 2300 80.0 600 27.2 ± 3.0 5.4 ± 0.6 — —

3. ADJUSTMENT OF INTERNAL PRESSURE Applying 0 V to T.C.V.

Lever Position Pump Speed Boost Pressure Internal Pressure Remarks
(rpm) (kPa) (mmHg) (kPa) (kgf/cm2)

Full 500 80.0 600 372.5 ± 29.5 3.8 ± 0.3 By the regulating valve

1900 80.0 600 790.0 ± 30.0 8.1 ± 0.3

4. OVERFLOW QUANTITY CHECK Applying 0 V to T.C.V.

Lever Position Pump Speed Boost Pressure Overflow Quantity Remarks
(rpm) (kPa) (mmHg) (L/h) (cc/1000st)
Full 2000 80.0 600 22 - 48 183 - 400
NOTE : The overflow valve belonging to the pump should be used checking.

5. ADJUSTMENT OF TIMER Applying 0 V to T.C.V.

Lever Position Pump Speed Boost Pressure Piston Travel Remarks
(rpm) (kPa) (mmHg) (mm)

Full 800 80.0 600 2.75 ± 0.40

1200 80.0 600 4.61 ± 0.40

1520 80.0 600 6.09 ± 0.40

1900 80.0 600 7.41 ± 0.24

NOTE : Hysteresis at each pump speed is less than 0.3 mm.

2004.05.10
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6. ADJUSTMENT OF BOOST COMPENSATOR Applying 0 V to T.C.V.

Lever Pump Boost Pressure Fuel Delivery Max. Spread Remarks

Speed in Delivery
Position (rpm) (kPa) (mmHg) (mm3/st) (cc/200st) (mm3) (cc)

Full 1200 80.0 600 62.5 ± 0.5 = A 12.4 ± 0.1 = A 2.0 0.4

1200 0 0 50.9 ± 1.0 10.2 ± 0.2 — — By eccentric cam

1200 21.3 160 54.5 ± 1.5 10.9 ± 0.3 — —

1200 32.0 240 58.8 ± 1.5 11.8 ± 0.3 — — By BCS spring

More than More than
1200 42.7 320 (A – 0.5) (A – 0.1) — —

7. ADJUSTMENT OF FUEL DELIVERY Applying 0 V to T.C.V.

Lever Pump Boost Pressure Fuel Delivery Max. Spread Remarks

Speed in Delivery
Position (rpm) (kPa) (mmHg) (mm3/st) (cc/200st) (mm3) (cc)

Full 1200 80.0 600 62.2 ± 0.5 12.4 ± 0.1 2.0 0.4 By full load setting screw

Idle 2300 80.0 600 27.2 ± 3.0 5.4 ± 0.6 — — By max. speed setting screw

2200 80.0 600 48.3 ± 4.0 9.7 ± 0.8 — —

Less than Less than
2300 80.0 600 3.0 0.6 — —

Full 100 80.0 600 60.0 ± 10.0 12.0 ± 2.0 7.0 1.4 By governor sleeve plug

500 80.0 600 54.6 ± 2.0 10.9 ± 0.4 3.0 0.6

1500 80.0 600 62.7 ± 2.0 12.5 ± 0.4 3.0 0.6

1900 80.0 600 57.4 ± 2.5 11.5 ± 0.5 3.0 0.6

8. SETTING OF LOAD SENSING TIMER — : Not Applicable

Lever Position Pump Speed Boost Pressure Fuel Delivery Remarks
(rpm) (kPa) (mmHg) (mm3/st) (cc/200st)

Start of Load Sensing — — — — — —

End of Pressure Drop — — — — — —

Repeat Advance Angle — — — — — —

Check Points 1. — : — mm

2. — : — mm

3. Dimension of Governor Shaft : L = 1.15 ± 0.85 mm

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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) (mm3/st) (cc/500st) (mm3) (cc)

– 17 ± 5° 375 0 14.0 ± 1.5 = B 7.0 ± 0.8 = B — — Presetting

(0 mmHg)
(Idle position)
325 0 17.3 ± 1.5 8.7 ± 0.8 2.5 0.5 Lever setting
(0 mmHg)
More than More than
350 0 (B + 2.5) (B + 1.3) — —
(0 mmHg)

450 0 (B – 8.5) ± 2.5 (B – 4.3) ± 1.3 — —

(0 mmHg)

10. SETTING OF ADJUSTING LEVER AT PARTIAL RANGE — : Not Applicable

Pump Speed Boost Pressure Fuel Delivery Remarks
(rpm) (kPa) (mmHg) (mm3/st) (cc/500st)

— — — — — —

11. CHARACTERISTIC OF A.C.S.D. Applying 0 V to T.C.V.

Lever Pump Speed Boost Pressure Measuring Value Remarks
Position (rpm) (kPa) (mmHg)
Idle 325 0 0 0.71 ± 0.10 mm Piston Travel (Absolute)
325 0 0 3
0 mm /st Idle-up Quantity (cc/500st) (Additional from No.9)
Fuel temperature : 39 - 41°C

12. ADJUSTMENT OF T.C.V.

Lever Position Pump Speed Boost Pressure Piston Travel Remarks
(rpm) (kPa) (mmHg) (mm)
Full 1520 80.0 600 3.39 ± 0.20 With applying 12 (V)

13. SETTING OF DIAPHRAGM FOR HEATER & POWER STEERING — : Not Applicable
Pump Speed Vacuum Pressure Fuel Delivery Remarks
(rpm) (kPa) (mmHg) (mm3/st) (cc/500st)
— — — — — —

14. ADJUSTMENT OF POWER CONTROL — : Not Applicable

Lever Pump Speed Boost Pressure Fuel Delivery Remarks

Position (rpm) (kPa) (mmHg) (mm3/st) (cc/200st)
— — — — — — —
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15. ADJUSTMENT OF THROTTLE POSITION SENSOR Applying 0 V to T.C.V. Applying 5 ± 0.01 V to sensor.

Lever Position Pump Speed Boost Pressure Fuel Delivery Sensor Remarks
Output
(rpm) (kPa) (mmHg) (mm3/st) (cc/500st) Voltage (V)

— 1600 80.0 600 35.2 ± 0.5 17.6 ± 0.3 1.6 ± 0.025 Set point

Idle 0 0 0 — — 3.3 ± 0.5 Check point

Full 0 0 0 — — 0.62 ± 0.42 Check point

16. FINAL CHECK AFTER ADJUSTMENT

1. Lever position at idle is – 17 ± 5° and 26 ± 5° at full.
2. Resistance of pick-up tachometer must be 835 ± 185 ohms.
3. After adgustment has been completed, delivery quantity must be less than 3.0 mm3/st E2 VC VA
(0.6 cc/200st) when voltage at fuel cut solenoid is reduced to zero.
(Pump Speed Np = 100 rpm)

TCV +B
RPS Connector