196000-3710 TICO

Parts List Page 1

Compo. P/N: 196000-3710 Assy P/N: 196000-3710

S M Illust.No. Part Name DENSO P/N Manu. P/N QTY I/C Start End Remarks
0 PUMP ASSY, INJECTI 196000-3710 22100-78230-71 01
1 HOUSING SUB-ASSY, 096110-0442 22301-22060-71 01
2 HEAD SUB-ASSY, DIS 096400-1730 22140-5C400 01
3 COVER SUB-ASSY, GO 096440-0590 22703-54132 01
S 4 SHAFT, DRIVE 096121-0070 22170-54180 01
S 5 RING SUB-ASSY, ROL 096180-0020 22108-54010 01
6 PUMP SUB-ASSY, FUE 096140-0030 22505-54010 01
7 GOVERNOR ASSY, TOR 096270-0780 22350-78200-71 01 STD-SP
S 8 SHAFT SUB-ASSY, GO 096450-0050 22740-21910-71 01 MARK 8
9 SOLENOID ASSY, FUE 096030-0520 22390-6A511 01 FCV,12V
9-1 O-RING 096049-0350 01 ID14.4
10 HOLDER SUB-ASSY, F 096260-0050 22741-54020 01
S 11 FLYWEIGHT, DISTRIB 096263-0030 22745-54010 04
12 SLEEVE, GOVERNOR 096252-0471 22316-54750 1C D0.60
12 SLEEVE, GOVERNOR 096252-0640 1C D0.65
12 SLEEVE, GOVERNOR 096252-1020 1C D0.55
S 13 WASHER, FLYWEIGHT 096265-0030 22753-54020 01 ROUND TYPE
S 15 WASHER, FLYWEIGHT 096265-0020 22753-54010 01 T1.30
16 NUT, GOVERNOR SHAF 096254-0050 22722-54470 01 M10,L SCREW
17 SHAFT SUB-ASSY, GO 096250-0030 22380-54020 01
18 O-RING 949140-2930 90099-14049 01 ID 8
19 BOLT, SOCKET 096449-0110 22395-56351 04 M6,L16
20 RING, GOVERNOR SLE 096255-0020 22147-54290 01
21 HOLDER, DELIVERY V 096425-0130 22131-54730 04
22 VALVE SUB-ASSY, DI 096420-0530 22104-56300 04
S 23 SPRING, DELIVERY V 096427-0010 22148-54010 04
24 GASKET, DELIVERY V 096426-0070 22149-56351 04
25 SEAT, DELIVERY VAL 096428-0010 22141-54010 04
S 26 CAMPLATE SUB-ASSY, 096230-0070 22130-54010 01
S 28 PLATE, PLUNGER, LW 096245-0020 22163-54010 01
S 29 PLATE, PLUNGER, UP 096244-0040 22162-54010 01
30 SPRING, COUPLING 096224-0040 22659-64150 01
31 COUPLING 096222-0020 22632-54010 01
32 GEAR, GOVERNOR DRI 096124-0030 22341-54010 01
33 JOINT, RUBBER 096126-0020 22169-54180 02
34 WASHER, DRIVE SHAF 096125-0010 22161-54010 01
S 35 COVER, FEED PUMP 096147-0040 22511-54020 01
36 KEY, WOODRUFF 949130-0260 90099-13017 01 T3.980
37 KEY, WOODRUFF 949130-0300 90099-13018 01 T4.023
38 NUT 949056-2390 90099-05166 01 0703 M14,L13.5
S 39 BEARING, BALL 949100-2860 90099-10148 01 OD8
S 40 SEAL, 0IL 096039-0040 22544-64740 01
41 PISTON, TIMER 096201-0770 22654-78219-71 01
42 SUB-PISTON, TIMER 096213-0020 22657-54010 01
43 PIN, TIMER SLIDE 096205-0020 22655-54010 01
44 STOPPER, TIMER SLI 096216-0120 22658-17840 01 L16.4
 Parts List Page 2

Compo. P/N: 196000-3710 Assy P/N: 196000-3710

S M Illust.No. Part Name DENSO P/N Manu. P/N QTY I/C Start End Remarks
45 CLIP, TIMER 096211-0080 22656-17840 01 L/ DITCH
46 COVER, TIMER 096218-0040 22612-54020 01
47 COVER, TIMER 096218-0270 22612-56350 01
48 SPRING, TIMER, OUT 096208-2490 22615-78219-71A 1C K2.7
48 SPRING, TIMER, OUT 096208-2500 22615-78764-71A 1C K3.0
48 SPRING, TIMER, OUT 096208-2510 1C K3.3
49 CLIP, CONNECTOR SU 096029-0020 22172-54020 01
50 O-RING 096049-0400 22193-17840 02 ID27.5
S 51 PLUG, DISTRIBUTIVE 096417-0040 22176-54020 01
52 BOLT, DISTRIBUTIVE 096418-0020 22128-54010 01 M8,L19.7
53 GASKET, DELIVERY V 096426-0030 22149-56200 01 FOR HEAD PLUG
54 O-RING 096049-0510 22193-54772 01 ID30
S 55 SHEET, PLUNGER SPR 096247-0010 22145-54010 01
56 GUIDE SUB-ASSY, PL 096237-0010 22192-54010 02
57 SPRING, PLUNGER 096236-0030 22144-54180 02
58 SHEET, PLUNGER SPR 096246-0010 22143-54010 02
60 O-RING 949140-2980 90099-14053 01 ID60
62 SPRING, LEVER SUPP 096279-0010 22314-54010 02 K1.03
63 SMOKE SET SUB-ASSY 096480-0010 01
63-1 O-RING 096049-0470 22193-54771 01 ID7.5
64 NUT, HEXAGON 90166-06051 22138-73500-71 01 M6,L5
67 BOLT, SOCKET 096449-0020 22395-54010 04 M6,L35
68 SPRING, GOVERNOR I 096289-0020 22317-54010 01 K0.20
69 SHEET, GOVERNOR SP 096267-0030 22369-54010 01
70 SCREW SUB-ASSY, OV 096020-0030 22160-64010 01 W/FILTER
71 WASHER, AIR BLEEDE 090241-0010 22191-73600-71 05 T1.6
73 SCREW, COUNTERSUNK 949002-0420 90099-00723 02 M4,L28
74 SPRING, SPEED CONT 096261-0510 22726-78212-71 01
75 O-RING 096049-0300 22193-54770 01 ID 6.5
79 SPRING, RETURN 096444-0011 22322-54010 01
80 LEVER, ADJUSTING 096436-1970 22708-78300-71 1C MARK197
80 LEVER, ADJUSTING 096436-1980 22708-78301-71 1C 0401 MARK198
80 LEVER, ADJUSTING 096436-7320 1C B 0401 MARK732
80 LEVER, ADJUSTING 096436-7330 1C B 0401 MARK733
81 GASKET, GOVERNOR C 096446-0100 22774-54270 01
S 82 VALVE SUB-ASSY, RE 096160-0030 22180-54010 01
82-1 O-RING 096049-0180 22193-54561 01 ID10
82-2 O-RING 096049-0500 01 ID7.5
84 NUT, LOCK 096342-0010 22775-77121 01 M6,L5
85 SCREW, HOLLOW 949180-0770 90099-18022 01 M12,L43.5
86 BOLT, GOVERNOR LIN 096269-0020 22739-54020 02 M8,L19
87 NUT, CAP 949055-0300 90099-05161 01 M12
88 BOLT, SOCKET 096449-0070 22395-58200 04 M6,L45
91 WASHER, GOVERNOR T 096273-0140 22378-64010 01 T0.5
92 SHIM, PLUNGER SPRI 096248-0010 22182-54010 2C T0.5
92 SHIM, PLUNGER SPRI 096248-0020 22183-54010 2C T0.8
 Parts List Page 3

Compo. P/N: 196000-3710 Assy P/N: 196000-3710

S M Illust.No. Part Name DENSO P/N Manu. P/N QTY I/C Start End Remarks
92 SHIM, PLUNGER SPRI 096248-0030 22184-54010 2C T1.0
92 SHIM, PLUNGER SPRI 096248-0040 22185-54010 2C T1.2
92 SHIM, PLUNGER SPRI 096248-0050 22186-54010 2C T1.5
92 SHIM, PLUNGER SPRI 096248-0060 22187-54010 2C T1.8
92 SHIM, PLUNGER SPRI 096248-0070 22188-54010 2C T2.0
92 SHIM, PLUNGER SPRI 096248-0080 22182-17010 2C T0.9
92 SHIM, PLUNGER SPRI 096248-0090 22182-17011 2C T1.1
92 SHIM, PLUNGER SPRI 096248-0100 22182-17012 2C T1.3
92 SHIM, PLUNGER SPRI 096248-0110 22182-17013 2C T1.4
93 WASHER, GOVERNOR G 096266-0100 22713-54010 1C T1.05
93 WASHER, GOVERNOR G 096266-0110 22714-54010 1C T1.25
93 WASHER, GOVERNOR G 096266-0120 22715-54010 1C T1.45
93 WASHER, GOVERNOR G 096266-0130 22716-54010 1C T1.65
93 WASHER, GOVERNOR G 096266-0140 22717-54010 1C T1.85
93 WASHER, GOVERNOR G 096266-0150 1C T1.55
93 WASHER, GOVERNOR G 096266-0160 1C T1.75
93 WASHER, GOVERNOR G 096266-0170 1C T2.05
93 WASHER, GOVERNOR G 096266-0270 1C T1.3
93 WASHER, GOVERNOR G 096266-0280 1C T1.4
93 WASHER, GOVERNOR G 096266-0290 1C T1.5
93 WASHER, GOVERNOR G 096266-0300 1C T1.6
93 WASHER, GOVERNOR G 096266-0310 1C T1.15
93 WASHER, GOVERNOR G 096266-0320 1C T1.2
93 WASHER, GOVERNOR G 096266-0330 1C T1.7
93 WASHER, GOVERNOR G 096266-0340 1C T1.8
94 PLUG, GOVERNOR SLE 096256-0410 22787-64642 1C L3.1
94 PLUG, GOVERNOR SLE 096256-0430 22787-54026 1C L3.3
94 PLUG, GOVERNOR SLE 096256-0450 22787-54028 1C L3.5
94 PLUG, GOVERNOR SLE 096256-0460 22787-54029 1C L3.6
94 PLUG, GOVERNOR SLE 096256-0470 22787-54030 1C L3.7
94 PLUG, GOVERNOR SLE 096256-0490 22787-54032 1C L3.9
94 PLUG, GOVERNOR SLE 096256-0510 22787-64640 1C L4.1
94 PLUG, GOVERNOR SLE 096256-0530 22787-54034 1C L4.3
94 PLUG, GOVERNOR SLE 096256-0580 22787-64663 1C L2.5
94 PLUG, GOVERNOR SLE 096256-0600 22787-64665 1C L2.7
94 PLUG, GOVERNOR SLE 096256-0620 22787-64667 1C L2.9
94 PLUG, GOVERNOR SLE 096256-0650 22787-54035 1C L4.5
94 PLUG, GOVERNOR SLE 096256-0670 22787-54036 1C L4.7
95 WASHER, TIMER SENS 096214-0040 22625-54271 2C T0.2
95 WASHER, TIMER SENS 096214-0050 22625-54272 2C T0.5
95 WASHER, TIMER SENS 096214-0060 22625-54273 2C T0.6
95 WASHER, TIMER SENS 096214-0070 22625-54274 2C T0.7
95 WASHER, TIMER SENS 096214-0080 22625-54275 2C T0.8
95 WASHER, TIMER SENS 096214-0090 22625-54276 2C T0.9
95 WASHER, TIMER SENS 096214-0100 22625-54277 2C T1.0
96 COLLAR, SMOKE SET 096448-0111 22749-54020 01
 Parts List Page 4

Compo. P/N: 196000-3710 Assy P/N: 196000-3710

S M Illust.No. Part Name DENSO P/N Manu. P/N QTY I/C Start End Remarks
97 SHIM, PLUNGER ADJU 096406-0020 22179-54010 1C T1.9
97 SHIM, PLUNGER ADJU 096406-0170 22179-54013 1C T2.2
97 SHIM, PLUNGER ADJU 096406-0270 22179-54015 1C T2.4
97 SHIM, PLUNGER ADJU 096406-0420 22179-54018 1C T2.7
97 SHIM, PLUNGER ADJU 096406-0520 22179-54020 1C T2.9
102 BOLT, HEXAGON, W/ 949045-0180 90099-04576 01 M6,L32
104 BOLT, SOCKET 096449-0140 22395-56350 02 M8,L16
105 BRACKET, IDLE UP 096438-2030 22178-78200-71 01
106 NIPPLE SUB-ASSY, S 092218-0190 22548-78250-71 01
107 E-RING 90577-02000 90096-90024 01 D2
112 BOLT, HEXAGON, W/ 949045-0190 90099-04946 01 M6,L40
115 WIRE SUB-ASSY 096045-0060 22751-54110 01
117 NUT 949056-1680 90179-06009 01 M6,L6.5
S 118 FILTER, SUB-ASSY 096530-0071 22602-56350-A 01
119 WASHER 096064-0110 22689-56350 01 T0.2
130 GASKET, DELIVERY V 096426-0130 22149-54771 02
INJECTION PUMP TEST SPECIFICATIONS 196000-3710
MANUFACTURER TOYOTA
INJECTION PUMP 196000-371#
ENGINE TYPE 1DZ VE4/10F1300RND371
VEHICLE MODEL FORK LIFT 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) 0.90 ± 0.10
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/cm2)
Nozzle Opening Pressure 14.7 ± 0.5 MPa ( 150 ± 5 kgf/cm2) 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
Lever Position Pump Speed Boost Pressure Fuel Delivery Max. Spread
in Delivery
(deg) (rpm)
(kPa) (mmHg) (mm3/st) (cc/200st) (mm3) (cc)

Full Load 14 ± 5° 900 — — 40.7 ± 0.5 8.1 ± 0.1 2.0 0.4

(Full)
High Speed 1410 — — 9.3 ± 3.0 1.9 ± 0.6 — —
3. ADJUSTMENT OF INTERNAL PRESSURE
Lever Position Pump Speed Boost Pressure Internal Pressure Remarks
(rpm) (kPa) (mmHg) (kPa) (kgf/cm2)

Full 400 — — 441.5 ± 29.5 4.5 ± 0.3 By the regulating valve

1200 — — 637.5 ± 29.5 6.5 ± 0.3

4. OVERFLOW QUANTITY CHECK

Lever Position Pump Speed Boost Pressure Overflow Quantity Remarks
(rpm) (kPa) (mmHg) (L/h) (cc/1000st)
Full 1200 — — 17 - 32 167 - 364
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)

Full 700 — — 0.85 ± 0.40

1200 — — 2.75 ± 0.40

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

2004.10.20
 196000-3710
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

Lever Pump Boost Pressure Fuel Delivery Max. Spread Remarks

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

Full 900 — — 40.7 ± 0.5 8.1 ± 0.1 2.0 0.4 By full load setting screw

1410 — — 9.3 ± 3.0 1.9 ± 0.6 — — By max. speed setting screw

1375 — — 23.7 ± 4.0 4.7 ± 0.8 — —

Less than Less than
1500 — — 3.0 0.6 — —

100 — — 56.5 ± 7.0 11.3 ± 1.4 6.0 1.2 By governor sleeve plug

400 — — 42.5 ± 6.5 8.5 ± 1.3 — — End of fuel quantity increase

500 — — 35.5 ± 2.0 7.1 ± 0.4 — —

1300 — — 47.0 ± 2.0 9.4 ± 0.4 — —

1200 — — A A — — A = Measurement

8. SETTING OF LOAD SENSING TIMER

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

Start of Load Sensing 1200 — — (A – 4.0) ± 2.0 (A – 0.8) ± 0.4 By governor shaft

End of Pressure Drop 1200 — — (A – 12.0) ± 2.0 (A – 2.4) ± 0.4 Check

Repeat Advance Angle

Check Points 1. Change of Piston Travel : 1.72 ± 0.40 mm (Pump speed 1200 rpm)

2. : mm

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

 196000-3710
9. SETTING OF ADJUSTING LEVER AT LOW SPEED
Lever Pump Boost Pressure Fuel Delivery Max. Spread Remarks
Position Speed in Delivery
(deg) (rpm) (kPa) (mm3/st) (cc/500st) (mm3) (cc)

– 18 ± 5° 390 — 8.0 ± 3.0 = B 4.0 ± 1.5 = B 2.0 1.0 Lever setting

(Idle)
Less than Less than
490 — 1.5 0.8 — —

250 — (B + 42.5) ± 4.0 (B + 21.3) ± 2.0 — —

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

Pump Speed Boost Pressure Fuel Delivery Remarks
(rpm) (kPa) (mmHg) (mm3/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. — : Not Applicable

Lever Position Pump Speed Boost Pressure Piston Travel Remarks
(rpm) (kPa) (mmHg) (mm)
— — — — — —

13. SETTING OF DIAPHRAGM FOR HEATER & POWER STEERING — : Not Applicable
Pump Speed Vacuum Pressure Fuel Delivery Remarks
(rpm) (kPa) (mmHg) (mm /st)3
(cc/500st)
— — — — — —

14. ADJUSTMENT OF POWER CONTROL — : Not Applicable

Lever Pump Speed Boost Pressure Fuel Delivery Remarks

Position (rpm) (kPa) (mmHg) (mm /st)
3
(cc/200st)
— — — — — — —
 196000-3710
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. Range of lever angle between idle and full lever position is 32 ± 5°.

2. After adgustment has been completed, delivery quantity must be 0 mm3/st (0 cc/200st)
when voltage at fuel cut solenoid is reduced to zero. (Pump Speed Np = 100 rpm)