INJECTION PUMP TEST SPECIFICATIONS

MANUFACTURER MITSUBISHI
INJECTION PUMP 196000-5501
ENGINE TYPE S4S-DT VE4/12F1250RND550
VEHICLE MODEL INDUSTRIAL ROTATION Clockwise viewed from GOVERNOR TYPE All speed
drive side
RATED VOLTAGE 12V INJECTION ORDER A-B-C-D INJECTION INTERVAL 90° ± 30'
Dimension KF (mm) 5.90 ± 0.10 Dimension MS (mm) 0.50 ± 0.05
Dimension K (mm) 3.30 ± 0.10 Dimension PS (mm) —
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 × 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
(deg) (rpm) in Delivery
(kPa) (mmHg) (mm3/st) (cc/200st) (mm3) (cc)

Full Load 36 ± 5° 800 — — 97.8 ± 1.5 19.6 ± 0.3 3.0 0.6

(Full position)
High Speed 1430 — — 24.7 ± 5.0 4.9 ± 1.0 — —
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/cm 2)

Full 1250 — — 482.5 ± 29.5 4.9 ± 0.3 By the regulating valve

Less than Less than
Idle 1430 — — 902.0 9.2 TCV ON

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 1250 — — 28 - 54 373 - 720
NOTE : The overflow valve belonging to the pump should be used checking.

5. ADJUSTMENT OF TIMER
Lever Position Pump Speed Boost Pressure Piston Travel Remarks
(rpm) (kPa) (mmHg) (mm)
More than
Full 950 — — 0.22 TCV OFF

1000 — — 0.82 ± 0.40 TCV OFF

1250 — — 1.85 ± 0.40 TCV OFF

Idle 1000 — — 4.66 ± 0.60 TCV ON

1250 — — 4.90 ± 0.40 TCV ON

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

2008.08.27
 196000-5501
6. ADJUSTMENT OF BOOST COMPENSATOR — : Not Applicable

Lever Pump Boost Pressure Fuel Delivery Max. Spread Remarks

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

— — — — — — — — —

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 800 — — 97.8 ± 1.5 19.6 ± 0.3 3.0 0.6 By full load setting screw

1430 — — 24.7 ± 5.0 4.9 ± 1.0 — — By max. speed setting screw

Less than Less than
1520 — — 3.0 0.6 — —

100 — — 87.0 ± 12.0 17.4 ± 2.4 10.0 2.0 By governor sleeve plug
Less than Less than
280 — — 80.0 16.0 — — End of fuel quantity increase

700 — — 90.3 ± 4.0 18.1 ± 0.8 — —

650 — — 80.5 ± 4.0 16.1 ± 0.8 — —

1050 — — 106.4 ± 4.0 21.3 ± 0.8 — —

1250 — — 114.5 ± 3.5 = A 22.9 ± 0.7 = A — —

8. SETTING OF LOAD SENSING TIMER Applying 0 V to T.C.V

Lever Position Pump Speed Boost Pressure Fuel Delivery Remarks
3
(rpm) (kPa) (mmHg) (mm /st) (cc/200st)

Start of Load Sensing 1250 — — (A – 12.0) ± 2.0 (A – 2.4) ± 0.4 By governor shaft
Less than Less than
1 End of Pressure Drop 1 1250 — — 50.0 10.0 Refer to check points 1.

More than More than

2 End of Pressure Drop 2 1250 — — 84.5 16.9 Refer to check points 1.

3 Repeat Advance Angle 1 1250 — — 27.0 ± 2.0 5.4 ± 0.4 Refer to check points 2.

4 Repeat Advance Angle 2 — — — — — —

Less than
1. Piston Travel at End of Pressure Drop : 0.40 mm (Pump speed 1250 rpm)

2. Piston Stroke Repeat Advance Angle : 2.30 ± 0.60 mm (Pump speed 1250 rpm)
Check Points
3. — : — mm —
4. Dimension of Governor Shaft : L = 1.15 ± 0.85 mm

Note: Set the adjusting lever position according to the conditions for "Start of Load Sensing". Under the aforementioned
conditions, gradually return the adjusting lever to the idle side, and verify the fuel delivery quantity and timer stroke for
items 1 through 3 in order.
 196000-5501
9. SETTING 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) 3
(mm /st) (cc/500st) (mm3) (cc)
Lever setting
– 15 ± 5° 595 — 5.0 ± 2.0 = B 2.5 ± 1.0 = B 3.0 1.5
(Idle position)
470 — B + 50.0 B + 25.0 — —
Less than Less than
670 — 2.0 1.0 — —

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

Pump Speed Boost Pressure Fuel Delivery Remarks
3
(rpm) (kPa) (mmHg) (mm /st) (cc/500st)

— — — — — —

11. CHARACTERISTIC OF A.C.S.D.

Lever Pump Speed Boost Pressure Measuring Value Remarks
Position (rpm) (kPa) (mmHg)
— — — — — —

Fuel temperature : 39 - 41°C (102 - 106°F)

12. ADJUSTMENT OF T.C.V. Applying 6 ± 0.1 V to T.C.V.

Lever Position Pump Speed Boost Pressure Piston Travel Remarks
(rpm) (kPa) (mmHg) (mm)
— 1250 — — 2.67 ± 0.70 Q = 67.3 ± 21.3 mm 3/st (13.5 ± 4.3
cc/200st)

13. SETTING OF DIAPHRAGM FOR HEATER & POWER STEERING — : Not Applicable

Pump Speed Vacuum Pressure Fuel Delivery Remarks

3
(rpm) (kPa) (mmHg) (mm /st) (cc/500st)
— — — — — —

14. ADJUSTMENT OF POWER CONTROL — : Not Applicable

Lever Pump Speed Boost Pressure Fuel Delivery Remarks

Position
(rpm) (kPa) (mmHg) 3
(mm /st) (cc/200st)
— — — — — — —
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15. ADJUSTMENT OF THROTTLE POSITION SENSOR — : Not Applicable

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

— ― ― ― ― ― ― —

16. FINAL CHECK AFTER ADJUSTMENT

1. Range of lever angle between idle and full lever position is 36 ± 5°.(fig.1)

2. After adgustment has been completed, delivery quantity must be 5.0 mm3/st or less (1.0
cc/200st) when voltage at fuel cut solenoid is reduced to zero. (Pump Speed Np = 100 rpm at
full lever position, Applying 6.0 ± 0.1 V to T.C.V.)

Idle 0° Full

fig.1