Test Specifications

Test injector : 1688 901 114 (Subject to alterations)

Opening pressure : 207 bar For Field Service only

REFERENCE NO. TSS-TS-TCL 0..489 Customer Details

Tata Cummins Pvt.
Edition 12.2011 Customer Ltd.
Replaces (edition) - Engine model 6BTAA BSIII
0 460 426 489 - B 460
Injection pump 816 511 Application HCV-BSIII
VE 6 / 12 F 1250 R F002.S3E.001-H-
498-22 Test oil S/EFEP 170
Test Bench Requirements
Test oil inlet temperature 39° - 41° C Inlet pressure in bar 0.30 - 0.40
Test injector 1 688 901 114 Opening pressure in bar 207± 3.0
High pressure pipe H-S / EFEP 109 (OD x ID x length) in mm 6 x 2 x 450
Injection timing locking
Between C & D (DV
Direction of rotation Clock Wise Drive shaft key way position at BDC holders)
Drive shaft key way position after injection timing locking should
Plunger stroke in mm 1.25 ± 0.02 be inline with DV holder : D
1. SETTING
1.1 Timer travel 1.2 Vane Pump Pressure
-1 -1
Speed - min (rpm) 1200 Speed - min (rpm) 1200
Boost pressure in bar 1.0 Boost pressure in bar 1.0
Timer travel in mm 1.90 ± 0.20 Vane pump pressure in bar 6.80 ± 0.30
1.3 Full load Delivery 1.4 Idling Del.
-1 -1
Speed - min (rpm) 1050 Speed - min (rpm) 375
Boost pressure in bar 1.0 Boost pressure in bar 0.0
Del. Qty ( x ) in cm³ /500 strokes 45.50 ± 0.25 Del. Qty ( x ) in cm³ /500 strokes 13.00 ± 0.50
Maximum spread in cm³ (D ) 3.0 Maximum spread in cm³ (D ) 3.0
-1
Speed - min (rpm) 600 Residual delivery quantity
Boost pressure in bar 0.0 Speed - min-1 (rpm) -
Del. Qty ( x ) in cm³ /500 strokes 35.50 ± 0.25 Boost pressure in bar -
Speed - min-1 (rpm) 600 Del. Qty ( x ) in cm³ /500 strokes -
Boost pressure in bar 0.750 High Idling delivery quantity
-1
Del. Qty ( x ) in cm³ /500 strokes 46.00 ± 0.25 Speed - min (rpm) -
Boost pressure in bar -
Del Qty (x) in cm³ /500 strokes -
1.5 Maximum speed regulation 1.6 Starting fuel delivery
Speed - min-1 (rpm) 1425 Speed Min-¹ (RPM) 100
Boost pressure in bar 1.0 Boost pressure in bar 0.0
Del. Qty ( x ) in cm³ /500 strokes 14.50 ± 1.00 Del Qty (x) in cm³ /500 strokes 90.00 ± 12.50
1.7 Load dependent port closing (LFB) 1.8 Exhaust Gas Recirculation (EGR)setting point
Speed Min-¹ (RPM) 1150 Speed - min-1 (rpm) -
See procedure given below Del. Qty ( x ) in cm³ /500 strokes -
Input Voltage (V) -
Output Voltage (V) -
2. TESTING
2.1 Timer travel 2.2 Vane pump pressure
-1 -1
Speed - min (rpm) 1200 Speed - min (rpm) 1200
Boost pressure in bar 1.0 Boost pressure in bar 1.0
Timer travel in mm 1.30 - 2.50 Vane pump pressure in bar 6.00 - 7.60
-1 -1
Speed - min (rpm) - Speed - min (rpm) 700
Boost pressure in bar - Boost pressure in bar 1.0
Timer travel in mm - Vane pump pressure in bar 8.60 - 10.60 #
-1 -1
Speed - min (rpm) 700 Speed - min (rpm) -
Boost pressure in bar 1.0 Boost pressure in bar -
Timer travel in mm 3.70 - 5.10 # Vane pump pressure in bar -
-1 -1
Speed - min (rpm) - Speed - min (rpm) -
Boost pressure in bar - Boost pressure in bar -
Timer travel in mm - Vane pump pressure in bar -
(# With power (24 V) connected to KSB) (# With power (24 V) connected to KSB)
(Contd..)
TSS-TS-TCL 0..489
2.3 Overflow Qty
Speed Min-¹ (RPM) 1250 Speed Min-¹ (RPM) -
Boost pressure in bar 1.0 Boost pressure in bar -
Overflow Qty in cm³ /10 seconds 108 - 192 Overflow Qty in cm³ /10 seconds -
2.4 Fuel deliveries
End stop Idle Del Qty
Control lever position Maximum Control lever position Idling position
Speed - min-1 (rpm) 1250 Low Idle Del.Qty
-1
Boost pressure in bar 1.0 Speed - min (rpm) 375
Del. Qty ( x ) in cm³ /500 strokes 38.55 - 43.05 Boost pressure in bar 0.0
Speed - min-1 (rpm) 600 Del. Qty ( x ) in cm³ /500 strokes 9.00 - 17.00
Boost pressure in bar 0.0 Residual Del. Qty
-1
Del. Qty ( x ) in cm³ /500 strokes 33.25 - 37.75 Speed - min (rpm) -
Speed - min-1 (rpm) 600 Boost pressure in bar -
Boost pressure in bar 0.750 Del. Qty ( x ) in cm³ /500 strokes -
Del. Qty ( x ) in cm³ /500 strokes 43.75 - 48.25 High Idle Del.Qty
Speed - min-1 (rpm) 1050 Speed - min-1 (rpm) 470
Boost pressure in bar 1.0 Boost pressure in bar 0.0
Del. Qty ( x ) in cm³ /500 strokes 43.50 - 47.50 Del. Qty ( x ) in cm³ /500 strokes 0.00 - 1.50
Speed - min-1 (rpm) - Electrical Shutoff (by disconnecting Solenoid switch)
Boost pressure in bar - Control lever position Idling position
-1
Del. Qty ( x ) in cm³ /500 strokes - Speed - min (rpm) 375
Speed - min-1 (rpm) 1425 Boost pressure in bar 0.0
Boost pressure in bar 1.0 Del. Qty ( x ) in cm³ /500 strokes 0.00 - 1.50
Del. Qty ( x ) in cm³ /500 strokes 10.50 - 18.50 Mechanical Shutoff (by Operating Stop Lever)
-1 -1
Speed - min (rpm) 1500 Speed - min (rpm) 1250
Boost pressure in bar 1.0 Boost pressure in bar 1.0
Del. Qty ( x ) in cm³ /500 strokes 0.00 - 1.50 Del. Qty ( x ) in cm³ /500 strokes 0.00 - 1.50
Exhaust Gas Recirculation (EGR) Maximum spread in cm³ (D ) -
-1
Speed - min (rpm) - Solenoid Voltage
Del. Qty ( x ) in cm³ /500 strokes - Rated voltage (KSB) 24V
Input Voltage (V) -
Output Voltage (V) -
3. ASSEMBLY AND SETTING DIMENSIONS :
Description Specification Description Specification
K 3.64 - 3.76 mm MS1 1.06 - 1.31 mm
KF 8.2 - 8.6 mm
Sl No. of the operations indicate the sequence of operation
X : Average of the cylinders
Caution: Always KSB to be disconnected while testing the pump unless specifically mentioned.
PROCEDURE FOR SETTING OF LOAD DEPENDENT PORT CLOSING (LFB)
- Adjusting governor shaft: (See 9.1 and 9.7 of VE pump Repair & Testing booklet)
Before start of calibration, screw-in governor shaft until there is a gap of approximately 3 mm from the housing flange to the
end face of governor shaft. Then calibrate pump as per calibration chart. (from 1.1 to 1.6)
- Setting load dependent port closing operation 1.7.
Loosen the lock nut of the governor shaft. Run the test bench at the specified speed (as per 1.7). Keep the control lever in
maximum position.
Screw-out governor shaft slowly till the vane pump pressure begins to fall.
Then screw-in governor shaft again by 1/8 of a turn. Lock the governor shaft by tightening the lock nut to the specified
torque.
Remarks
Applicable only for BOSCH test benches
These Test Specifications should not be copied or transmitted to a third party without our written permission.
All rights reserved
30112011