FOR MAGASA F113 10HP (Bomboleo)

INJECTION PUMP TEST SPECIFICATIONS 096500-3090

INJECTION PUMP 096500-3090 (VE4/12E2100RND309) Rotation Clockwise viewed from drive side
MANUFACTURER TOYOTA
ENGINE TYPE 1KZ-TE Injection Order A-B-C-D
VEHICLE MODEL HILUX/4 RUNNER Injection Interval 90
GOVERNOR TYPE Electronic control Rated Voltage 14 0.1 V
TIMER Electronic control Dimension KF (mm) 6.10 0.10
Pump Select Switch No. (ECD Controller) 2 Dimension K (mm) 3.30 0.10

1. TEST CONDITIONS
1) Nozzle 093400-3230 (DN12SD12A) 4) Feed Pressure 19.6 kPa ( 0.2 kg/cm2)
2) Nozzle Opening Pressure 14.7 0.2 MPa ( 150 2 kg/cm2) 5) High Pressure Pipe 2 6 840 mm
3) Test Oil SAE J967 (ISO4113) 6) Inlet Fuel Temperature 40 - 43 C (104 - 109.4 F)

2. INSPECTION OF FUEL TEMPERATURE SENSOR

ECD CONTROLLER SETTING
Pump
Speed Display Injection Duty Pump Sensor Resistance
Remarks
(rpm) Selector Quantity Ratio Select (k )
Command Command Switch

Fuel
Temperat REC OFF 1.85 1.50

3. INSPECTION OF Ne SENSOR
ECD CONTROLLER SETTING
Pump Sensor Output
Speed Display Injection Duty Pump Voltage Remarks
(rpm) Selector Quantity Ratio Select (V)
Command Command Switch

50 Np REC OFF 0.1 or more

4. BREAK-IN DRIVE
ECD CONTROLLER SETTING
Pump
Speed Display Injection Duty Pump Check Remarks
(rpm) Selector Quantity Ratio Select
Command Command Switch

0 SPV OFF 940 0 REC OFF Setting

No fuel leaks, no abnormal noise, and no Drive more than 5 minutes.
2000 SPEED 940 0 REC OFF abnormal temperature rising.

5. INTERNAL PRESSURE
ECD CONTROLLER SETTING
Pump
Speed Display Injection Duty Pump Internal Pressure
Remarks
(rpm) Selector Quantity Ratio Select (kg/cm2)
Command Command Switch

0 SPV OFF 940 0 REC OFF

2000 SPEED 940 0 REC OFF 9.25 0.15 (906.9 14.7 kPa) Adjust by Regulating Valve
100 SPV OFF A5A 0 REC OFF 2.00 or more (196 kPa) Confirmation

6. OVERFLOW QUANTITY
ECD CONTROLLER SETTING
Pump Overflow
Speed Display Injection Duty Pump Quantity Remarks
(rpm) Selector Quantity Ratio Select (cc/1000st)
Command Command Switch

0 SPV OFF 940 0 REC OFF

2000 SPEED 940 0 REC OFF 375 - 583 If its out of specification, change overflow valve.
2003.01.27
FOR MAGASA F113 10HP (Bomboleo) 096500-3090

7. ADJUSTMENT OF TIMER (Always stop pump when changing the first digit of injection quantity command.)
ECD CONTROLLER SETTING
Pump
Display Injection Duty Pump Timer Stroke
Speed Remarks
Selector Quantity Ratio Select (mm)
(rpm)
Command Command Switch

2000 Timer Adjust 000 0 REC OFF 10.30 0.24

500 Timer Adjust 100 0 REC OFF 10.30 0.24
500 Timer Adjust 200 50 REC OFF 3.00 2.50
500 Timer Adjust 300 100 REC OFF 0
200 Timer Adjust 400 0 REC OFF 3.60 or more Internal Pressure : 4.3 kgf/cm2 or more (421.0 kPa)
100 Timer Adjust 500 0 REC OFF 0.40 or more Internal Pressure : 2.0 kgf/cm2 or more (196.0 kPa)

NOTE : Adjustment should be done by Timer Adjust Shim.

8. PRESETTING FOR CAM ANGLE ADJUSTMENT

ECD CONTROLLER SETTING
Target
Pump Display Injection Quantity Duty Pump Quantity Dealer Original
Speed Selector Command Ratio Select [ND - CPS] Remarks
(cc/200stcyl.)
(rpm) Command Switch (cc/200stcyl.)
First Second Third
digit digit digit
0 SPV OFF 9 8 A 100 REC OFF
400 SPL 9 8 A 100 REC OFF 3.32 0.20 2.13 0.20

If Q is out of Target
400 SPV OFF 9 100 REC OFF Quantity with 9, 8, A, adjust
2nd. and 3rd. digits to get
"Target Quantity".

400 SPL 9 100 REC OFF 3.32 0.20 2.13 0.20 Re-measurement

When the correction value is raised by 1 level,

the injection quantity is increased approx. 0.2 - 0.3 mm3/st (0.04 - 0.06 cc/200st).

9. ADJUSTMENT OF CAM ANGLE

ECD CONTROLLER SETTING
Pump Display Injection Quantity Duty Pump Target Angle
Speed Selector Command Ratio Select (CA) Remarks
(rpm) Command Switch [Data on Display]
First Second Third
digit digit digit

0 Cam
to Angle 0 0 0 100 REC OFF 6.36 0.5
400
Cam Adjust 2nd. and 3rd. digits to get "Target
400 Angle 0 100 REC OFF 6.36 0.5 Angle".

NOTE : Select "REC ON" position after "Target Angle" is gotten.

: Never forget removing pressure sensor from piping.
FOR MAGASA F113 10HP (Bomboleo) 096500-3090

10. ADJUSTMENT OF FUEL DELIVERY ( When the correction value is raised by 1 level, the injection quantity
3
is increased approx. 0.2 - 0.3 mm /stcyl (0.04 - 0.06 cc/200stcyl). )
ECD CONTROLLER SETTING Max.
Pump Target Quantity Spread In Outlet Fuel
Display Injection Duty Pump Dealer Original
Speed [ND - CPS] Delivery Temperature
Selector Quantity Ratio Select (cc/200stcyl.)
(rpm) (cc/200stcyl.) (cc) (C)
Command Command Switch

100 Q Adjust 000 0 REC OFF 12.58 0.40 11.34 0.40 42.0 5.0
350 Q Adjust 100 0 REC OFF 3.78 0.16 3.31 0.16 0.50 42.0 5.0
350 Q Adjust 200 0 REC OFF 10.62 0.24 10.30 0.24 42.0 5.0
500 Q Adjust 300 0 REC OFF 14.36 0.26 13.83 0.26 0.50 42.0 5.0
700 Q Adjust 400 0 REC OFF 10.32 0.20 9.90 0.20 45.0 5.0
700 Q Adjust 500 0 REC OFF 10.25 0.15 cc/100st 10.02 0.15 cc/100st 45.0 5.0
1000 Q Adjust 600 0 REC OFF 10.80 0.20 10.13 0.20 45.0 5.0
1000 Q Adjust 700 0 REC OFF 11.02 0.13 cc/100st 10.69 0.13 cc/100st 0.50 45.0 5.0
1800 Q Adjust 800 0 REC OFF 6.88 0.22 6.46 0.22 48.5 5.0
1800 Q Adjust 900 0 REC OFF 18.74 0.30 18.58 0.30 0.50 48.5 5.0

NOTE : Adjust 2nd. and 3rd. degits of "Injection Volume Command Value" switch to get target quantity.

11. RECONFIRMATION OF FUEL DELIVERY

ECD CONTROLLER SETTING Max.
Pump Target Quantity Spread In Outlet Fuel
Display Injection Duty Pump Dealer Original
Speed [ND - CPS] Delivery Temperature
Selector Quantity Ratio Select (cc/200stcyl.)
(rpm) (cc/200stcyl.) (cc) (C)
Command Command Switch

100 Confirm 000 0 REC OFF 12.58 0.40 11.34 0.40 42.0 5.0
350 Confirm 100 0 REC OFF 3.78 0.16 3.31 0.16 0.50 42.0 5.0
350 Confirm 200 0 REC OFF 10.62 0.24 10.30 0.24 42.0 5.0
500 Confirm 300 0 REC OFF 14.36 0.26 13.83 0.26 0.50 42.0 5.0
700 Confirm 400 0 REC OFF 10.32 0.20 9.90 0.20 45.0 5.0
700 Confirm 500 0 REC OFF 10.25 0.15 cc/100st 10.02 0.15 cc/100st 45.0 5.0
1000 Confirm 600 0 REC OFF 10.80 0.20 10.13 0.20 45.0 5.0
1000 Confirm 700 0 REC OFF 11.02 0.13 cc/100st 10.69 0.13 cc/100st 0.50 45.0 5.0
1800 Confirm 800 0 REC OFF 6.88 0.22 6.46 0.22 48.5 5.0
1800 Confirm 900 0 REC OFF 18.74 0.30 18.58 0.30 0.50 48.5 5.0

12. CHECK POINT

ECD CONTROLLER SETTING
Pump Target Quantity Outlet Fuel
Speed Display Injection Duty Pump [ND - CPS] Dealer Original Temperature
(rpm) Selector Quantity Ratio Select (cc/200stcyl.) (cc/200stcyl.) (C)
Command Command Switch

2000 Confirm A00 0 REC OFF 16.76 0.66 16.04 0.66 49.0 6.0
2300 Confirm B00 0 REC OFF 7.12 0.60 6.95 0.60 50.0 6.0
2000 Confirm C00 0 REC OFF 0.60 or less Less than 0.60 51.0 6.0

13. NOTE
Timing mark re-marking position : Based on cylinder B, cam lift distance (plunger) should be 2.39 mm