104700-9161 ZEXEL test values diesel fuel-injection equipment 01.06.

22 20:39:54 Page 1

ZEXEL Ass'y No. 104700-9161

Bosch Ass'y No. 9 460 614 221
Bosch Typecode
Engine Type 4D56TCI
Manufacturer HYUNDAI
Edition date 30.04.09

1 Adjustment conditions
CAT Designation Unit Set value min. max. Actual values OT
Test oil ISO4113orSAEJ967
d
1404 Test oil
P Test oil temperature degC 45 45 50
Nozzle 105780-0060
Bosch type code NP-DN0SD1510
Nozzle holder 105780-2150
P Opening pressure MPa 13 13 13.3
P Opening pressure kgf/cm2 133 133 136
Injection pipe 157805-7320
P Injection pipe mm 2-6-450
Inside diameter - outside diameter - length (mm)
Joint assembly 157641-4720
Tube assembly 157641-4020
P Transfer pump pressure kPa 20 20 20
P Transfer pump pressure kgf/cm2 0.2 0.2 0.2
Direction of rotation (viewed from drive side) R
Right

2 Adjustment specification
2.1 Compensation resistor, compensation voltage comparison
Name Comp. resistor/voltage

Compensation resistance/compensation voltage comparison

A = Compensation resistor number
B= Compensation resistance
C = Compensation voltage delta U alpha soll
2.2 Pump chamber pressure
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P TCV duty (%) F TCV 60Hz % 100 100 100
P U alpha soll V 2.7 2.7 2.7
S Pump chamber pressure kPa 598 569 627
S Pump chamber pressure kgf/cm2 6.1 5.8 6.4
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 100 100 100
P TCV duty (%) F TCV 60Hz % 100 100 100
P U alpha soll V 2.7 2.7 2.7
C Pump chamber pressure kPa 294 294
C Pump chamber pressure kgf/cm2 3 3
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P TCV duty (%) F TCV 60Hz % 100 100 100
P U alpha soll V 2.7 2.7 2.7
C Pump chamber pressure kPa 598 559 637
C Pump chamber pressure kgf/cm2 6.1 5.7 6.5
CAT Designation Unit Set value min. max. Actual values OT

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
104700-9161 ZEXEL test values diesel fuel-injection equipment 01.06.22 20:39:54 Page 2

P Pump speed r/min 2000 2000 2000

P TCV duty (%) F TCV 60Hz % 100 100 100
P U alpha soll V 2.7 2.7 2.7
C Pump chamber pressure kPa 735 686 784
C Pump chamber pressure kgf/cm2 7.5 7 8
2.3 Timer stroke
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P TCV duty (%) F TCV 60Hz % 100 100 100
P U alpha soll V 2.7 2.7 2.7
S Timer stroke mm 7.7 7.5 7.9
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 100 100 100
P TCV duty (%) F TCV 60Hz % 100 100 100
P U alpha soll V 2.7 2.7 2.7
C Timer stroke mm 1.8 0.3 3.3
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 350 350 350
P TCV duty (%) F TCV 60Hz % 100 100 100
P U alpha soll V 2.7 2.7 2.7
C Timer stroke mm 5.2 3.1 7.3
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P TCV duty (%) F TCV 60Hz % 100 100 100
P U alpha soll V 2.7 2.7 2.7
C Timer stroke mm 7.7 7.4 8
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P TCV duty (%) F TCV 60Hz % 70 70 70
P U alpha soll V 2.7 2.7 2.7
C Timer stroke mm 4 1.9 6.1
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2000 2000 2000
P TCV duty (%) F TCV 60Hz % 100 100 100
P U alpha soll V 2.7 2.7 2.7
C Timer stroke mm 9.75 9.3 10.2
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2000 2000 2000
P TCV duty (%) F TCV 60Hz % 0 0 0
P U alpha soll V 2.7 2.7 2.7
C Timer stroke mm 0 0 0
2.4 TPS output
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P TCV duty (%) F TCV 60Hz % 0 0 0
P U alpha soll V 2.7 2.7 2.7
S Vtps V 0.51 0.382 0.638
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P TCV duty (%) F TCV 60Hz % 0 0 0
P U alpha soll V 2.7 2.7 2.7
C Vtps V 0.51 0.382 0.638
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P TCV duty (%) F TCV 60Hz % 100 100 100
P U alpha soll V 2.7 2.7 2.7
C Vtps V 1.925 1.702 2.148
2.5 Overflow
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P TCV duty (%) F TCV 60Hz % 100 100 100
P U alpha soll V 2.7 2.7 2.7
C Overflow quantity cm3/min 550 420 680
2.6 Fuel injection quantities
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1250 1250 1250
P U alpha soll + dU alpha soll V 2.86 2.86 2.86
P TCV duty (%) F TCV 60Hz % 100 100 100
S Average injection quantity mm3/st. 72 71.5 72.5
S Difference in delivery mm3/st. 3.5 3.5
S = Setting value, C = Check value)
OT = Outside Tolerance (X is set)
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P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 375 375 375
P U alpha soll + dU alpha soll V 2 2 2
P TCV duty (%) F TCV 60Hz % 100 100 100
S Average injection quantity mm3/st. 14.8 11.8 17.8
S Difference in delivery mm3/st. 2.5 2.5
P Basic *
Remarks
Confirmation of difference in delivery
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2575 2575 2575
P U alpha soll + dU alpha soll V 1.96 1.96 1.96
P TCV duty (%) F TCV 60Hz % 100 100 100
S Average injection quantity mm3/st. 20.3 17.8 22.8
S Difference in delivery mm3/st. 5.5 5.5
P Basic *
Remarks
Confirmation of difference in delivery
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 100 100 100
P U alpha soll + dU alpha soll V 3.31 3.31 3.31
P TCV duty (%) F TCV 60Hz % 100 100 100
C Average injection quantity mm3/st. 67.9 57.9 77.9
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 375 375 375
P U alpha soll + dU alpha soll V 2 2 2
P TCV duty (%) F TCV 60Hz % 100 100 100
C Average injection quantity mm3/st. 14.8 11.8 17.8
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 500 500 500
P U alpha soll + dU alpha soll V 2.74 2.74 2.74
P TCV duty (%) F TCV 60Hz % 100 100 100
C Average injection quantity mm3/st. 51.2 48.7 53.7
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 750 750 750
P U alpha soll + dU alpha soll V 2.83 2.83 2.83
P TCV duty (%) F TCV 60Hz % 100 100 100
C Average injection quantity mm3/st. 63.1 60.6 65.6
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P U alpha soll + dU alpha soll V 2.87 2.87 2.87
P TCV duty (%) F TCV 60Hz % 100 100 100
C Average injection quantity mm3/st. 70.4 67.9 72.9
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1250 1250 1250
P U alpha soll + dU alpha soll V 2.86 2.86 2.86
P TCV duty (%) F TCV 60Hz % 100 100 100
C Average injection quantity mm3/st. 72 71 73
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1500 1500 1500
P U alpha soll + dU alpha soll V 2.82 2.82 2.82
P TCV duty (%) F TCV 60Hz % 100 100 100
C Average injection quantity mm3/st. 68.6 66.1 71.1
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1750 1750 1750
P U alpha soll + dU alpha soll V 2.8 2.8 2.8
P TCV duty (%) F TCV 60Hz % 100 100 100
C Average injection quantity mm3/st. 65.5 63 68
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1900 1900 1900
P U alpha soll + dU alpha soll V 2.77 2.77 2.77
P TCV duty (%) F TCV 60Hz % 100 100 100
C Average injection quantity mm3/st. 63.8 61.3 66.3
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2575 2575 2575
P U alpha soll + dU alpha soll V 1.96 1.96 1.96
P TCV duty (%) F TCV 60Hz % 100 100 100
C Average injection quantity mm3/st. 20.3 17.8 22.8
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2575 2575 2575
P U alpha soll + dU alpha soll V 1 1 1
S = Setting value, C = Check value)
OT = Outside Tolerance (X is set)
104700-9161 ZEXEL test values diesel fuel-injection equipment 01.06.22 20:39:54 Page 4

P TCV duty (%) F TCV 60Hz % 100 100 100

C Average injection quantity mm3/st. 3 3
2.7 Magnet valve OFF
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1900 1900 1900
P U alpha soll + dU alpha soll V 2.77 2.77 2.77
P TCV duty (%) F TCV 60Hz % 100 100 100
C Average injection quantity cm3/min 0 0 0
2.8 Confirming NP sensor output
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 200 200 200
P TCV duty (%) F TCV 60Hz % 100 100 100
P U alpha soll V 2.7 2.7 2.7
C Speed output r/min N+-8
N=Measure the actual speed.
2.9 Checking fuel temperature sensor
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1250 1250 1250
P TCV duty (%) F TCV 60Hz % 100 100 100
P U alpha soll V 2.73 2.73 2.73
C Temperature output degC T+-5
Measure T = actual output temperature
2.10 Magnet
CAT Designation Unit Set value min. max. Actual values OT
C Max. applied voltage V 8 8 8
P Test voltage V 13 12 14

3 Assembly dimension
CAT Designation Unit Set value min. max. Actual values OT
S K dimension mm 3.3 3.2 3.4
S KF dimension mm 5.8 5.7 5.9
S Pre-stroke mm 0.1 0.08 0.12

4 Attachments' specification
4.1 Attachment specification 1
Name HARNESS & CONNECTOR

T.C.V. connector assembly specification

(1)Ensure the GE cable is not twisted at section A.
(2)Refer to diagram for direction of connector B.
(3)Route the TCV harnes C in the direction indicated by the arrows in the figure and install the co
nnector.
4.2 Attachment specification 2
Name HARNESS & CONNECTOR
a=(75deg)
L1=Max.2mm
L2=240+-10mm
L3=185+11-9mm
L4=185+11-9mm

Harness position specification

(1)Ensure each dimension is as shown in the diagram and fix the harness using the binders.
(2)Cut the binder leaving no more than L1 excess.
(3)Attach cover G to the GE, FCV, TCV and Q adjustment connectors.
(4)After completing all of the procedures, ensure no lead wires are exposed after routing the harn
ess.
A = GE, FCV, TCV, Q adjustment
B=NP
C=TPS
E = binder
G=Cover

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
104700-9161 ZEXEL test values diesel fuel-injection equipment 01.06.22 20:39:54 Page 5

4.3 Attachment specification 3

Name HARNESS & CONNECTOR
L1=Max.25mm
L2=Max.10mm
L3=345+-10mm
L4=(20mm)
L5=(30mm)
a=45deg

Corrugated tube assembly specification

(1)Align the end of the corrugated tube with clip A and fix it using black vinyl tape (L1, L2).
(2)Confirm that the dimension to the end of the corrugated tube C is L3, and fix it using black vin
yl tape (L4, L5).
(3)Refer to the illustration for the position of the corrugated tube slit.
A = binder
B = outside edge of binder
C = end of corrugated tube
D = position of corrugated tube's slit
4.4 Attachment specification 4
Name HARNESS & CONNECTOR
L1=320+-10mm
L2=5~15mm
T1=9.8~13.7N-m(1.0~1.4kgf-m)

Harness fixing specification

(1)Make the clearance between the clip J and the clip (B with metal end face) L1.
(2)Fix clip B using socket head bolt D. At this time, adjust to within the tolerance L1 so that the TP
S and NP harnesses in section A do not have excessive slack.
(3)Clip the GE cable and the FCV harness using clip E, and the TPS-NP harness using clip G.
(4)Attach the binder G after ensuring that the TPS cover H is not loose.
B = clip
D = socket head bolt
E = binder
G=Binder
H = TPS cover
J = binder
4.5 Attachment specification 5
Name HARNESS & CONNECTOR
L1=250+-10mm
L2=25+-10mm
L3=(20mm)
L4=(20mm)
L5=(10mm)

Vinyl tape assembly specification

Wrap with vinyl tape at position A in the figure.
4.6 Attachment specification 6
Name HARNESS & CONNECTOR
L1=20+-5mm

Marking application specification

(1)Ensure the corrugated tube is not twisted and then mark the position A shown in the figure.
(2)3) Mark at the two locations indicated in the figure ( viewed from the side of the pump and the t
op of the pump). The markings must be the dimensions shown and approx. 5 mm wide.
(3)2) Use indelible paint for steel.
A = white marking
B = End of tape binding

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)