INJECTION PUMP TEST SPECIFICATIONS 196000-5170,1,2

MANUFACTURER DONGFENG CHAOYANG INJECTION 196000-517#

ENGINE TYPE QD32TI PUMP VE4/11F1800RND517
VEHICLE MODEL TRACK 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) 6.40 ± 0.10 Dimension MS (mm) 2.00 ± 0.10
Dimension K (mm) 3.30 ± 0.15 Dimension PS (mm) 0.11 ± 0.02
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 14 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 1.5 ± 5° 1000 80.0 600 60.1 ± 0.5 12.0 ± 0.1 4.0 0.8
(Full position)
High Speed 2350 80.0 600 31.9 ± 1.5 6.4 ± 0.3 — —
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 1000 80.0 600 490.0 ± 70.0 5.0 ± 0.7 By the regulating valve
Less than Less than
2000 80.0 600 960.0 9.8 Applying 6 ± 0.1 V to T.C.V.

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 1800 80.0 600 17.0 - 43.0 160 - 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 1000 80.0 600 2.94 ± 0.20

1500 80.0 600 5.10 ± 0.20

1800 80.0 600 6.41 ± 0.20

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

2005.11.16
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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 1000 80.0 600 60.1 ± 0.5 = A 12.0 ± 0.1 = A 4.0 0.8 By full load setting screw

2350 80.0 600 31.9 ± 1.5 6.4 ± 0.3 — — By max. speed setting screw

2200 80.0 600 58.2 ± 8.0 11.6 ± 1.6 — —

Less than Less than
2600 80.0 600 3.0 0.6 — —
+ 20.0 +4.0
100 0 0 84.0 – 15.0
16.8 – 3.0 12.0 2.4 By governor sleeve plug
Less than Less than
250 0 0 50.0 10.0 — — End of fuel quantity increase

1500 80.0 600 68.7 ± 1.5 13.7 ± 0.3 — —

Less than Less than
1700 80.0 600 (B + 2.0) (B + 0.4) — —

1800 80.0 600 69.6 ± 1.5 = B 13.9 ± 0.3 = B 4.0 0.8

Less than Less than
1900 80.0 600 (B - 1.0) (B - 0.2) — —

2000 80.0 600 64.0 ± 10.0 12.8 ± 2.0 — —

2100 80.0 600 62.0 ± 10.0 12.4 ± 2.0 — —

Less than Less than
1000 100.0 750 (A + 1.0) (A + 0.2) — —
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 1000 80.0 600 60.1 ± 0.5 12.0 ± 0.1 4.0 0.8 By full load setting screw

500 0 0 44.3 ± 0.5 8.9 ± 0.1 — —

500 22.7 170 46.9 ± 0.75 9.4 ± 0.15 — —

500 29.3 220 50.6 ± 1.0 10.1 ± 0.2 — —

500 80.0 600 56.5 ± 2.0 11.3 ± 0.4 — —

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

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

Start of Load Sensing 1800 80.0 600 (B – 9.5) ± 1.5 (B – 1.9) ± 0.3 By governor shaft

End of Pressure Drop 1800 80.0 600 45.3 ± 1.5 9.1 ± 0.3 Check

Repeat Advance Angle — — — — —

Check Points 1. Piston Travel at End of Pressure Drop : 5.41 ± 0.40 mm (Pump speed 1800rpm)

2. Piston Travel at End of Pressure Drop : 5.41 ± 0.20 mm (Pump speed 1800rpm)

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

*1 : The point where internal pump pressure begins to rise.

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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) 3
(mm /st) (cc/500st) (mm3) (cc)

– 34.5 ± 5° 375 0 9.5 ± 1.0 4.8 ± 0.5 2.5 1.3 Lever setting
(Idle position)
Less than Less than
700 0 0.5 0.3 — —

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. — : Not Applicable

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)
Full 1000 80 600 4.45 ± 0.40
2000 80 600 6.90 ± 0.40 Max. advance angle

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 Remarks
Output
(rpm) (kPa) (mmHg) (mm3/st) (cc/500st) Voltage (V)

— — — — — — — —

16. FINAL CHECK AFTER ADJUSTMENT

1. Lever position at idle is – 34.5 ± 5° and 1.5 ± 5° at full.

2. After adgustment has been completed, delivery quantity must be 0mm3/st (0cc/200st) when
voltage at fuel cut solenoid is reduced to zero.
(Pump Speed Np = 100rpm at full lever position, Applying 6 ± 0.1 V to T.C.V.)