Ass'y No.

: 1 0 4 7 18040 7- 4
800 -1705 4 0
ENG. Type : A1 TCI
INJ. PUMP CALIBRATION DATA A kind of car: Starex
Drawing No. : 99 - 12 - 15 - 01 Company : HYUNDAI MOTORS
General Ass'y No. : KP-VE4/10F1900RNP Date : 1999. 12. 15.
Pre - Stroke : Pump rotation:Clockwise-viewed from drive side
1. Test Conditions
1-1 Nozzle ; 105780-0000(KP-DN12SD12T) 1-4 Injection pipe : 2mm6mm840mm
1-2 Nozzle holder : 105780-2080 1-5 Fuel oil temperature : 45 + 5
1-3 Nozzle opening pressure : 150+5 Kgf/ 1-6 Supply pump pressure : 0.2 Kgf/
2. Setting Pump speed Settings Charge air Difference
(r/min) pressure(mmHg) in delivery
2-1 Timing device travel 1,250 5.0 0.2 mm 55010
2-2 Supply pump pressure 1,250 6.0 0.3 Kgf/ 55010
2-3 Full load delivery(FULL) 1,250 69.31.0 cc/1000st 55010 6.5
750 63.01.0 cc/1000st 40010
750 49.91.0 cc/1000st 0
2-4 Idle speed regulation 375 16.01.5 cc/1000st 0 2.5
2-5 Start 100 65.0~85.0 cc/1000st 0
2-6 Full load speed regulation 2,575 24.43.0 cc/1000st 55010 9.0
2-7 Load-timer Adjustment 1,250 48.01.0 cc/1000st 55010
T = 4.00.2 55010

3. Test Specifications Charge air pressure(mmHg) 550 10

3-1 Timing device N = r/min 500 750 1,250 1,750 1,900
mm 1.30.4 2.80.4 5.00.2 7.20.4 7.90.4
3-2 Supply pump N = r/min 600 1,250 1,900
Kgf/ 4.30.3 6.00.3 7.70.3
3-3 Overflow delivery N = r/min 1,250 cc/1000st 420130 BCS Pressure 55010
3-4 Fuel injection quantities
Speed control lever Pump speed Fuel delivery Charge air 4.Dimensions
position (r/min) (cc/1000st) pressure (mmHg)
Full - load speed 600 (48.21.5) 0 K 3.30.1
750 (53.81.5) 26010 KF 5.80.1
1,000 (69.21.5) 55010 MS 1.20.1
1,750 (66.81.5) 55010 BCS
1,900 64.01.5 55010
2,000 (63.02.0) 55010 Control lever angle
2,300 (47.43.0) 55010 21 4
Switch OFF Magnet valve 375 M/V OFF Q = 0 0 A mm
Idling stop 410 (Measure) 0 38 5
700 Below 5.0 0 B mm
3-5 Solenoid valve Max. cut-in voltage 8V
Test voltage 12 14 V
DOOWON PRECISION INDUSTRY Co., Ltd. Service Department
DPICO 503-5,SHINSA-DONG,KANGNAM-GU,SEOUL,KOREA TEL:(02)510-72416, FAX:(02)510-7111
Ass'y No. : 104780-7540
 Load timer adjustment.
1.Adjust the governor shaft so that the clearance between the end of the
flange and the end of the governor shaft is approximately 3mm and then
lock the nut.

2.Load timer adjustment.

(1)Fix the control lever in the position satisfying the following
conditions:
Boost Pressure : 55010 mmHg
Pump speed : 1,250 r/min
Fuel injection quantity : 48.01.0 cc/1000st
(2)With the control lever positioned as described in (1) above adjust the
governor sleeve so that the timer reduction value (T) conforms to the
specified values (item 2-7)
T = 1722 Nm (1.72.2 Kg.m)

3.Confirmation of Timer Characteristics.

Fix the control lever in the position satisfying the following conditions
and confirm the timer stroke.
Control lever position Specified Values
Pump speed Fuel injection q'ty Boost pressure Timer stroke Timer reduction
(r/min) (cc/1000st) (mmHg) (mm) value (mm)
69.3 1.0 5.00.2
1,250 48.0 1.0 550 10 4.00.2 (1.0)
40.0 1.0 2.60.4 (2.4)
375 (16.0 1.5) 0 0

Potentiometer adjustment
Pump speed Control lever Fuel injection In-put Out-put Remark
(r/min) position Q'ty(cc/1000st) voltage voltage
- Idling - 10V (1.20.6) Check point
- Full speed - 10V 7.6 0.15 Adjusting point

In-put Line(+10 V)

Out-put Line

Ground Line

Ass'y No.: 104780-7540

W-CSD adjustment.
 1.Timer stroke adjustment
(1)Using the graph below to determine the timer stroke
(2)Adjust timer stroke adjusting screw so that the timer stroke
corresponds to value determined in note (1) above.

Cooling Control
Test Conditions water Timer stroke lever Remark
Temp() (mm) Position
Cooling water temp.: 20 0.6 0.2 Full load Adjusting point
A direction of upward -20 2.1 0.4 Full load Check point
(N = 500 r/min)
Cooling water temp.: 20 - Full load
A direction of upward -20 Measure Full load
(N = 100 r/min)

Ass'y No.: 104780-7540

W-CSD adjustment.
1. A idle spec of the cold time
A revolution Water temp.() RPM Lever angle Lever space(L) Remark
 volume of the 20 0 0.5 0 0.3 Adjust point
FAST idle lever -20 0.5 (7.8) (6.6)

2.W-FICD lever adjustment

(1) Insert a block gauge(thickness gauge) of L0.3mm thickness calulated from the
graph below idling stopper bolt and control lever
(2) Insert a block gauge(thickness gauge) of t=30.05mm thickness between W-FICD
lever and control lever , then adjust W-FICD lever and fix the bolt
where W-FICD lever and control lever are in contact.
T = 3.4 ~ 4.9 N.m (0.35 ~ 0.5Kgf-m)
Note : a) The temperature of the wax must be below 30 when adjusting.
b) Confirm that screw has a minium dimension of above 3 mm.

Ass'y No.: 104780-7540

Accelator link stroke adjustment.
Adjust the accelator link's stroke(32.91 mm) between the idling and full speed
position as shown as below.
 40

Difference
n delivery

6.5

2.5

9.0

55010

.30.1
.80.1
.20.1

angle
4
mm
5
mm

0
 uction
mm)

0)
4)

ark

point
g point

40
oint
nt

40

mark
st point

540