Test Specifications

(Subject to alterations)
For Field Service only
REFERENCE NO. : TSS-TS-TCL 0..489 1.4 Idling delivery
Edition : 05.2009 Speed - min-1 (rpm) : 375
Replaces (edition) : - Boost pressure in bar 0
Test oil : F 002 S3E 001 Delivery quantity ( x ) : 14.0± 0.5
Injection pump : 0 460 426 489-B460816511-03 in cm³ /500 strokes
: VE6/12F1250R498-22 Maximum spread in cm³ (') : 3.0
Customer : Tata Cummins Pvt. Ltd.
Engine model : 6BTAA BSIII 1.5 Maximum speed regulation
-1
Application : Vehicular (HCV) -BS III Speed - min (rpm) : 1425
Boost pressure in bar 1.0
TEST BENCH REQUIREMENTS Delivery quantity ( x ) : 26.5 ± 1.0
o o
Test oil inlet temperature : 38 - 42 C in cm³ /500 strokes
Inlet pressure in bar : 0.30 - 0.40
Test injector : 1 688 901 022 1.6 Starting fuel delivery
Opening pressure in bar : 130 - 133 Speed - min-1 (rpm) : 100
High pressure pipe : H-S/EFEP 109 Delivery quantity ( x ) : 100.0 ± 12.5
(OD x ID x length) in mm : 6 x 2 x 450 in cm³ /500 strokes
Injection timing locking 1.7 Load dependent port closing (LFB)
Direction of rotation : Clockwise Speed - min-1 (rpm) : 1150
Plunger stroke in mm : 1.25 ± 0.02 See procedure given below
Drive shaft key way position 2. TESTING
at BDC : Between C & D (DV holders) 2.1 Timer travel
Drive shaft key way position after injection timing locking Speed - min-1 (rpm) : 1000
should be inline with DV holderD Boost pressure in bar : 1.0
1. SETTING Timer travel in mm : 0.1 - 1.3
1.1 Timer travel Speed - min-1 (rpm) : 1200
-1
Speed - min (rpm) : 1200 Boost pressure in bar : 1.0
Boost pressure in bar : 1.0 Timer travel in mm : (1.3 - 2.5)
Timer travel in mm : 1.9 ± 0.2 Speed - min-1 (rpm) : 700
1.2 Vane pump pressure Boost pressure in bar : 0
Speed - min-1 (rpm) : 1200 Timer travel in mm : 3.4 - 4.8 #
Boost pressure in bar : 1.0 (# With power (24 V) connected to KSB)
Vane pump pressure in bar : 6.5 ± 0.3 2.2 Vane pump pressure
1.3 Full load delivery Speed - min-1 (rpm) : 1200
-1
Speed - min (rpm) : 1050 Boost pressure in bar : 1.0
Boost pressure in bar : 1.0 Vane pump pressure in bar : (5.7 - 7.3)
Delivery quantity ( x ) : 95.0 ± 0.25 Speed - min-1 (rpm) : 700
in cm³ /500 strokes Boost pressure in bar : 0
Maximum spread in cm³ (') : 3.0 Vane pump pressure in bar : 9.0 - 11.2 #
-1
Speed - min (rpm) : 600 (# With power (24 V) connected to KSB)
Boost pressure in bar : 0 2.3 Overflow quantity
Delivery quantity ( x ) : 67.2 ± 0.25 Speed - min-1 (rpm) : 1250
in cm³ /500 strokes Boost pressure in bar : 1.0
Overflow quantity : 114.0 - 198.0
-1
Speed - min (rpm) : 600 in cm³ /10 seconds
Boost pressure in bar : 0.75 Speed - min-1 (rpm) : -
Delivery quantity ( x ) : 82.5 ± 0.25 Boost pressure in bar : -
in cm³ /500 strokes Overflow quantity : -
in cm³ /10 seconds

Contd…2
TSS-TS-TCL 0..489 -2-
-1
2.4 Fuel deliveries Speed - min (rpm) : -
End stop Boost pressure in bar : -
Control lever position : Maximum Delivery quantity ( x ) : -
in cm³ /500 strokes
Speed - min-1 (rpm) : 1050 Speed - min-1 (rpm) : -
Boost pressure in bar : 1.0 Boost pressure in bar : -
Delivery quantity ( x ) : (93 - 97) Delivery quantity ( x ) : -
in cm³ /500 strokes in cm³ /500 strokes
Idle stop
-1
Speed - min (rpm) : 600 Control lever position : Idling position
-1
Boost pressure in bar : 0.75 Speed - min (rpm) : 375
Delivery quantity ( x ) : (80.25 - 84.75) Delivery quantity ( x ) : (10 - 18)
in cm³ /500 strokes in cm³ /500 strokes
Speed - min-1 (rpm) : 470
-1
Speed - min (rpm) : 600 Delivery quantity ( x ) : Maximum 1.5
Boost pressure in bar : 0 in cm³ /500 strokes
Delivery quantity ( x ) : (64.95 - 69.45) Electrical shutoff (solenoid)
in cm³ /500 strokes (By disconnecting solenoid switch)
Control lever position : Idling position
-1
Speed - min (rpm) : 1250 Speed - min-1 (rpm) : 375
Boost pressure in bar : 1.0 Boost pressure in bar : 0
Delivery quantity ( x ) : (87 - 91.5) Delivery quantity ( x ) : Maximum 1.5
in cm³ /500 strokes in cm³ /500 strokes
Maximum spread in cm³ (') : 2.5
-1
Speed - min (rpm) : 1425 Mechanical shutoff
Boost pressure in bar : 1.0 (By operating stop lever)
-1
Delivery quantity ( x ) : (22.5 - 30.5) Speed - min (rpm) : 1250
in cm³ /500 strokes Boost pressure in bar : 1.0
Delivery quantity ( x ) : Maximum 1.5
-1
Speed - min (rpm) : 1500 in cm³ /500 strokes
Boost pressure in bar : 1.0 2.5 Solenoid
Delivery quantity ( x ) : Maximum 1.5 Rated voltage : 24 V
in cm³ /500 strokes
3. ASSEMBLY AND SETTING DIMENSIONS
Speed - min-1 (rpm) : - Description
Boost pressure in bar : - K : 3.64 - 3.76 mm
Delivery quantity ( x ) : - KF : 8.2 - 8.6 mm
in cm³ /500 strokes MS1 : 1.06 - 1.31 mm
OTHER INFORMATION :
Caution: KSB solenoid should be disconnected while calibrating the pump at all points except where indicated.

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 pressurebegins 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.
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 and MICO test benches 270409
These Test specifications should not be copied or transmitted to a third party without our written permission. All rights reserved.