Test Specifications

(Subject to alterations)
For Field Service only

REFERENCE NO. : TSS-TS-TATA 0..996 EDC

Edition : 09.2010
Replaces (edition) : 11.2005
Test oil : ISO 4113
Injection pump : 0 460 424 996
: VE4/12E1200R1052 3. TESTING
Customer : Tata Motors Ltd.
Engine model : TATA 497 TCIC BS III 3.1 Idling delivery quantity
Speed - min-1 (rpm) : 350
Application : LCV-TATA 709 Check-back voltage (mV) : 1500
Delivery quantity ( x ) : 6.5 - 11.5
TEST BENCH REQUIREMENTS in cm³ /500 strokes
o o
Test oil inlet temperature : 40 ± 1 C Maximum spread in cm³ (∆ ) : 2.5
Inlet pressure in bar : 0.35 ± 0.05 TV % : 100
Test injector : 1 688 901 114
Opening pressure in bar : 200 - 214
High pressure pipe : 9 681 030 729
(OD x ID x length) in mm : 6 x 2 x 450 3.2 Starting fuel delivery
Positioner adaptor cable : 0 986 612 442 Speed - min-1 (rpm) : 100
Timer travel measuring Device : 1 688 130 227 Check-back voltage (mV) : 2360
Injection timing locking Delivery quantity ( x ) : 36.0 - 56.0
Direction of rotation : Clockwise in cm³ /500 strokes
Plunger stroke in mm : 0.25 ± 0.02 TV % : 100
Drive shaft key way position
at BDC : A
Drive shaft key way position (at BDC) should be between Excess fuel stop/Shutoff
A & D (DV holders) and after injection timing locking Excess fuel limit : -
it should be inline with DV holder A Shutoff limit : -
1. SETTING
1.1 Timer travel 3.3 Shut off test
-1
Speed - min (rpm) : 950 Speed - min-1 (rpm) : 1200
Check-back voltage (mV) : 3600 Check-back voltage (mV) 1500
Timer travel in mm : 12.7 ± 0.2 Delivery quantity ( x ) : Maximum 1.5
TV % : 0 in cm³ /500 strokes
Shut off solenoid (ELAB) voltage: 0
TV % : 0
1.2 Vane pump pressure
Speed - min-1 (rpm) : 950
Check-back voltage (mV) : 3600
Vane pump pressure in bar : 9.8 ± 0.3
TV % : 0

1.3 Full load delivery

Speed - min-1 (rpm) : 950
Check-back voltage (mV) : 3600
Delivery quantity ( x ) : 49.0 ± 0.25
in cm³ /500 strokes
Maximum spread in cm³ (∆ ) : 1.8
TV % : 0

Contd…2
 -2-
TSS-TS-TATA 0..996 EDC
3.4 Shut off test
Speed - min-1 (rpm) : - 3.8 Fuel deliveries
Check-back voltage (mV) : -
Delivery quantity ( x ) : - Speed - min-1 (rpm) : 950
in cm³ /500 strokes Check-back voltage (mV) : 3600
Shut of solenoid (ELAB) voltage : - Delivery quantity ( x ) : (47.25 - 50.75)
TV % : - in cm³ /500 strokes
3.5 Timer travel TV % : 0
Speed - min-1 (rpm) : 950 Maximum spread in cm³ (∆ ) : 1.8
Check-back voltage (mV) : 3600 Speed - min-1 (rpm) : 500
Timer travel in mm : (12.1 - 13.3) Check-back voltage (mV) : 3030
TV % : 0 Delivery quantity ( x ) : 47.25 - 51.25
Speed - min-1 (rpm) : in cm³ /500 strokes
Check-back voltage (mV) : - TV % : 0
Timer travel in mm : -
TV % : - Speed - min-1 (rpm) : 1200
Speed - min-1 (rpm) : 1200 Check-back voltage (mV) : 3950
Check-back voltage (mV) : 3950 Delivery quantity ( x ) : 50.25 - 53.75
Timer travel in mm : 0 - 1.0 in cm³ /500 strokes
TV % : 100 TV % : 0
Speed - min-1 (rpm) : - Speed - min-1 (rpm) : -
Check-back voltage (mV) : - Check-back voltage (mV) : -
Timer travel in mm : - Delivery quantity ( x ) : -
TV % : - in cm³ /500 strokes
36 Vane pump pressure TV % : -
Speed - min-1 (rpm) : 950 Speed - min-1 (rpm) : -
Check-back voltage (mV) : 3600 Check-back voltage (mV) : -
Vane pump pressure in bar : (9.0 - 10.6) Delivery quantity ( x ) : -
TV % : 0 in cm³ /500 strokes
Speed - min-1 (rpm) : 300 TV % : -
Check-back voltage (mV) : 3950 Speed - min-1 (rpm) : -
Vane pump pressure in bar : 6.2 - 7.8 Check-back voltage (mV) : -
TV % : 0 Delivery quantity ( x ) : -
3.7 Overflow quantity in cm³ /500 strokes
Speed - min-1 (rpm) : 1200 TV % : -
Check-back voltage (mV) : 3950
Overflow quantity : 116.0 - 173.0 3.8 Solenoid
in cm³ /10 seconds Rated voltage : 12 V
TV % : 0
Speed - min-1 (rpm) : 500 4. ASSEMBLY AND SETTING DIMENSIONS
Check-back voltage (mV) : 3030 Description Specification
Overflow quantity : 116.0 - 162.0 K : 3.66 -3.74 mm
in cm³ /10 seconds KF : 8.2 - 8.6 mm
TV % : 0
Caution: Shut of solenoid (ELAB) to be connected with 12 V always unless specifically
mentioned while testing the pump.
Note: 3 X : Average of the cylinders
1 .Sl. No. of the operations indicate the sequence of operation.
2 .Values given in brackets are overchecking values
Applicable only for BOSCH/MICO test benches (~ 11 kW). 071009
These Test specifications should not be copied or transmitted to a third party without our written permission. All rights reserved.