FOR EPS-575

kg/cm
2
) mm
INJECTION PUMP TEST SPECIFICATIONS
1. TEST CONDITIONS
1) Nozzle
2) Nozzle Opening Pressure
3) Test Oil
4) Feed Pressure
5) High Pressure Pipe
6) Inlet Fuel Temperature
4. BREAK-IN DRIVE
ECD CONTROLLER SETTING
Display
Selector
Injection
Quantity
Command
Duty
Ratio
Command
Check Remarks
2. INSPECTION OF FUEL TEMPERATURE SENSOR
Sensor Resistance
(k )
Sensor Output
Voltage
(V)
3. INSPECTION OF Ne SENSOR
Pump
Speed
(rpm)
ECD CONTROLLER SETTING
Display
Selector
Injection
Quantity
Command
Duty
Ratio
Command
Pump
Select
Switch
Remarks
ECD CONTROLLER SETTING
Display
Selector
Injection
Quantity
Command
Duty
Ratio
Command
Remarks
kg/cm
2
)
Pump
Select
Switch
Pump
Select
Switch
Rated Voltage
Pump Select Switch No. (ECD Controller)
Dimension KF (mm)
Dimension K (mm)
Injection Order
Injection Interval
Rotation
096500-3090
096500-3090 (VE4/12E2100RND309)
Electronic control
Electronic control
Clockwise viewed from drive side
A - B - C - D
90
TOYOTA
1KZ-TE
HILUX/4 RUNNER
14 0.1 V
6.10 0.10
3.30 0.10 2
093400-3230 (DN12SD12A)
150 2
SAE J967 (ISO4113)
0.2
2 6 840
40 - 43 C (104 - 109.4 F)

Fuel
Temperat
REC OFF 1.85 1.50
50 Np REC OFF 0.1 or more
INJECTION PUMP
MANUFACTURER
ENGINE TYPE
VEHICLE MODEL
GOVERNOR TYPE
TIMER
0
2000
SPV OFF
SPEED
940
940
0
0
REC OFF
REC OFF

No fuel leaks, no abnormal noise, and no

abnormal temperature rising.
Setting
Drive more than 5 minutes.
5. INTERNAL PRESSURE
Pump
Speed
(rpm)
Pump
Speed
(rpm)
ECD CONTROLLER SETTING
Display
Selector
Injection
Quantity
Command
Duty
Ratio
Command
Internal Pressure
(kg/cm
2
)
Remarks
Pump
Select
Switch
Pump
Speed
(rpm)
0
2000
SPV OFF
SPEED
940
940
0
0
REC OFF
REC OFF

9.25 0.15 (906.9 14.7 kPa) Adjust by Regulating Valve

6. OVERFLOW QUANTITY
ECD CONTROLLER SETTING
Display
Selector
Injection
Quantity
Command
Duty
Ratio
Command
Overflow
Quantity
(cc/1000st)
Remarks
Pump
Select
Switch
Pump
Speed
(rpm)
0
2000
SPV OFF
SPEED
940
940
0
0
REC OFF
REC OFF

375 - 583 If its out of specification, change overflow valve.

100 SPV OFF A5A 0 REC OFF 2.00 or more (196 kPa) Confirmation
14.7 0.2
19.6
( MPa
( kPa
2003.01.27
FOR EPS-575

19.47 1.00

19.47 1.00
7. ADJUSTMENT OF TIMER
Timer Stroke
(mm)
ECD CONTROLLER SETTING
Display
Selector
Injection
Quantity
Command
Duty
Ratio
Command
Remarks
9. ADJUSTMENT OF CAM ANGLE
Target Angle
(CA)
[Data on Display]
Pump
Speed
(rpm)
Remarks
8. PRESETTING FOR CAM ANGLE ADJUSTMENT
NOTE : Select "REC ON" position after "Target Angle" is gotten.
When the correction value is raised by 1 level,
the injection quantity is increased approx. 0.2 - 0.3 mm
3
/st (0.04 - 0.06 cc/200st).
: Never forget removing pressure sensor from piping.
Pump
Speed
(rpm)
ECD CONTROLLER SETTING
Display
Selector
Duty
Ratio
Command
Remarks
Injection Quantity
Command
First
digit
Second
digit
Third
digit
ECD CONTROLLER SETTING
Display
Selector
Duty
Ratio
Command
Injection Quantity
Command
First
digit
Second
digit
Third
digit
Pump
Select
Switch
Pump
Select
Switch
Pump
Select
Switch
Dealer Original
(mm
3
/stcyl.)
Target
Quantity
[ND - CPS]
(cc/200stcyl.)
(Always stop pump when changing the first digit of injection quantity command.)
Pump
Speed
(rpm)
2000
500
500
500
200
100
Timer Adjust
Timer Adjust
Timer Adjust
Timer Adjust
Timer Adjust
Timer Adjust
000
100
200
300
400
500
0
0
50
100
0
0
REC OFF
REC OFF
REC OFF
REC OFF
REC OFF
REC OFF
10.30 0.24
10.30 0.24
3.00 2.50
0
3.60 or more
0.40 or more
Internal Pressure : 4.3 kgf/cm
2
or more (421.0 kPa)
Internal Pressure : 2.0 kgf/cm
2
or more (196.0 kPa)
0
400
400
400
SPV OFF
SPL
SPV OFF
SPL
9
9
9
9
8
8
A
A
100
100
100
100

3.32 0.20

3.32 0.20
If Q is out of Target
Quantity with 9, 8, A, adjust
2nd. and 3rd. digits to get
"Target Quantity".
Re-measurement
REC OFF
REC OFF
REC OFF
REC OFF
NOTE : Adjustment should be done by Timer Adjust Shim.
0
to
400
400
Cam
Angle
Cam
Angle
0
0
0 0 REC OFF
REC OFF
Adjust 2nd. and 3rd. digits to get "Target
Angle".
100
100
096500-3090
6.04 0.50
6.04 0.50
FOR EPS-575
62.94 2.00
18.27 0.80
53.48 1.20
73.08 1.30
50.38 1.00
102.88 1.50
52.58 1.00
112.52 1.30
30.84 1.10
88.50 1.50
86.47 3.30
37.15 3.00
3.00 or less
62.94 2.00
18.27 0.80
53.48 1.20
73.08 1.30
50.38 1.00
102.88 1.50
52.58 1.00
112.52 1.30
30.84 1.10
88.50 1.50

2.5

2.5

2.5

2.5

2.5

2.5

2.5

2.5
10. ADJUSTMENT OF FUEL DELIVERY
Pump
Speed
(rpm)
ECD CONTROLLER SETTING
Duty
Ratio
Command
Outlet Fuel
Temperature
(C)
Max.
Spread In
Delivery
(mm
3
/st)
When the correction value is raised by 1 level, the injection quantity
is increased approx. 0.2 - 0.3 mm
3
/stcyl (0.04 - 0.06 cc/200stcyl).
Display
Selector
12. CHECK POINT
Pump
Select
Switch
11. RECONFIRMATION OF FUEL DELIVERY
( )
NOTE : Adjust 2nd. and 3rd. degits of "Injection Volume Command Value" switch to get target quantity.
13. NOTE
Injection
Quantity
Command
Dealer Original
(mm
3
/stcyl.)
Target Quantity
[ND - CPS]
(cc/200stcyl.)
Timing mark re-marking position :
100
350
350
500
700
700
1000
1000
1800
1800
Q Adjust
Q Adjust
Q Adjust
Q Adjust
Q Adjust
Q Adjust
Q Adjust
Q Adjust
Q Adjust
Q Adjust
000
100
200
300
400
500
600
700
800
900
0
0
0
0
0
0
0
0
0
0
REC OFF
REC OFF
REC OFF
REC OFF
REC OFF
REC OFF
REC OFF
REC OFF
REC OFF
REC OFF
12.58 0.40
3.78 0.16
10.62 0.24
14.36 0.26
10.32 0.20
10.25 0.15 cc/100st
10.80 0.20
11.02 0.13 cc/100st
6.88 0.22
18.74 0.30
42.0 5.0
42.0 5.0
42.0 5.0
42.0 5.0
45.0 5.0
45.0 5.0
45.0 5.0
45.0 5.0
48.5 5.0
48.5 5.0
Pump
Speed
(rpm)
ECD CONTROLLER SETTING
Duty
Ratio
Command
Outlet Fuel
Temperature
(C)
Max.
Spread In
Delivery
(mm
3
/st)
Display
Selector
Pump
Select
Switch
Injection
Quantity
Command
Dealer Original
(mm
3
/stcyl.)
Target Quantity
[ND - CPS]
(cc/200stcyl.)
100
350
350
500
700
700
1000
1000
1800
1800
000
100
200
300
400
500
600
700
800
900
0
0
0
0
0
0
0
0
0
0
REC OFF
REC OFF
REC OFF
REC OFF
REC OFF
REC OFF
REC OFF
REC OFF
REC OFF
REC OFF
12.58 0.40
3.78 0.16
10.62 0.24
14.36 0.26
10.32 0.20
10.25 0.15 cc/100st
10.80 0.20
11.02 0.13 cc/100st
6.88 0.22
18.74 0.30
42.0 5.0
42.0 5.0
42.0 5.0
42.0 5.0
45.0 5.0
45.0 5.0
45.0 5.0
45.0 5.0
48.5 5.0
48.5 5.0
Confirm
Confirm
Confirm
Confirm
Confirm
Confirm
Confirm
Confirm
Confirm
Confirm
Pump
Speed
(rpm)
ECD CONTROLLER SETTING
Duty
Ratio
Command
Outlet Fuel
Temperature
(C)
Display
Selector
Pump
Select
Switch
Injection
Quantity
Command
Dealer Original
(mm
3
/stcyl.)
Target Quantity
[ND - CPS]
(cc/200stcyl.)
2000
2300
2000
Confirm
Confirm
Confirm
A00
B00
C00
0
0
0
REC OFF
REC OFF
REC OFF
16.76 0.66
7.12 0.60
0.60 or less
49.0 6.0
50.0 6.0
51.0 6.0
Based on cylinder B, cam lift distance (plunger) should be 2.39 mm
096500-3090