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Calibration Charts

(All Models Including Arjun NOVO and 245 DI Orchard)

Copyright © 2012 Mahindra & Mahindra Ltd. All rights reserved. 1


INDEX (Move the Cursor over the Model to fetch Chart)
Mahindra YUVO REGULAR BS3
265 DI YUVO 265 DI
275 DI YUVO 275 DI TU
415 DI YUVO 295 DI
575 DI YUVO 475 DI
575 DI (1900 RPM)
575 DI (2300 RPM)
ARJUN NOVO 595 DI
ARJUN NOVO 605 DI - i (52 HP)
ARJUN NOVO 605 DI-i (57HP) ARJUN BS3A
REGULAR BS3A 555 DI
245 DI Orchard 445 DI
255 DI PP 605 DI (Rotary with 022 Injector Test Bench)
255 DI 605 DI (Rotary with 114 Injector Test Bench)
265 DI 605 DI (Inline Pump)
275 DI /265 DI PP ARJUN BS3
275 DI TU 555 DI
295, 395 & 405 DI Turbo 445 DI
415 DI 605 DI
475 DI
575 DI
585 PP
595 DI
Mahindra YUVO

Main Menu
REFERENCE NO

265 DI YUVO
Test Specifications
(subject to alternations)
For Field Service only
(B) ADJUSTMENT OF PUMP AND
GOVERNOR
GUIDE SLEEVE
TRAVEL
Control lever position : Free
: TSS-TS-MML-F..
REFERENCE NO Speed-min-1 (rpm) : 800
A2ZA00
Control rack travel in
Edition : 02.2016 : 0.3-0.7
mm
Replaces(edition) :- 1.MAXIMUM SPEED CONTROL (RATED
Test oil : 9 916 034 004 SPEED)
Revision :2 (without supplementry idling spring)
Combination No. : F002A2ZA00 Control lever position : 51.0±4.0°
Speed-min-1 (rpm) : 500
: PES 3 A 85 D 320 RS Boost pressure in bar :-
Injection pump
2000
Control rack travel in
: RSV 400...1000 A 5 C mm : 11.2-11.4
Governor
1793 R Speed-min-1 (rpm) : 1000
Customer : MAHINDRA Boost pressure in bar :-
Engine model : MDI1785 3AD Control rack travel in
: 10.45-10.55
Engine code :- mm
Application : 31hp Speed-min-1 (rpm) : 1055-1065
TEST BENCH REQUIREMENTS Boost pressure in bar :-
Control rack travel in
: 9.5
Test oil inlet mm
: 38°-42°C
temperature Speed-min-1 (rpm) : 1115-1145
Overflow valve : F002A10627 Boost pressure in bar :-
Inlet pressure in bar : 1.5 Control rack travel in
: 4.0
Test injector : 0681343009 mm
Opening pressure in bar : 172.0-175.0 Speed-min-1 (rpm) : 1250
High pressure pipe : 6X2X600 Boost pressure in bar :-
(ODXIDxlength) in mm Control rack travel in
: 0.3-1.4
mm
REFERENCE NO

2.FULL LOAD
(A) CALIBRATION OF PUMP WITHOUT DELIVERY
GOVERNOR ACTION Speed-min-1 (rpm) : 1000
Boost pressure in bar :-
Control rack travel in
Direction of rotation : Clockwise : 10.45-10.55
mm
Prestroke in mm : 3.45-3.55(3.4-3.6)
: 26.75-27.25(25.75-
Control rack position in Delivery quantity(x )
: 9.0-12.0 28.25)
mm
in cm³/500 strokes
Cam sequence : 1- 3 - 2
Maximum spread in cm³ : 1.5(3.5)
Cam displacement : 0-120-240° ±0.5°
3.TORQUE
Tappet clearance in mm : min 0.2
CONTROL
Injection Timing
:- Speed-min-1 (rpm) : 500
locking
Boost pressure in bar :-
BASIC SETTING
Control rack travel in
: 11.2-11.4
mm
Speed-min-1 (rpm) : 1000 Speed-min-1 (rpm) : 650
Control rack travel in Boost pressure in bar :-
: 10.45-10.55
mm Control rack travel in
Delivery quantity(x ) : 5.25-5.55 :11.2-11.4
mm
in cm³/100 strokes Speed-min-1 (rpm) : 500
Maximum spread in cm³ : 0.3(0.7) Boost pressure in bar :-
Control rack travel in
: 11.2-11.4
mm
Speed-min-1 (rpm) : 400 Speed-min-1 (rpm) : 650
Control rack travel in Boost pressure in bar :-
: 7.2-7.4
mm Control rack travel in
: 11.2-11.4
Delivery quantity(x ) : 0.95-1.35(0.75-1.55) mm
in cm/100 strokes Speed-min-1 (rpm) :-
Maximum spread in cm³ : 0.5(0.7) Boost pressure in bar :-
Control rack travel in
:-
mm
Speed-min-1 (rpm) : 1000
Boost pressure in bar :-
Control rack travel in
: 10.45-10.55
mm
Contd...2

TSS-TS-MML-F..A2ZA00
REFERENCE NO

6.MAXIMUM SPEED CONTROL (RATED


4. COURSE OF
SPEED)
DELIVERY
(with supplementary idling spring)
Speed-min-1 (rpm) : 500
Boost pressure in bar :-
: 21.25-22.75(20.25- Speed-min-1 (rpm) :-
Delivery quantity(x ) Control rack travel in
23.75) :-
mm
in cm³/500 strokes
Maximum spread in cm³ : 2.0(4.0)
7. GOVERNOR CUTTING IN SPEED
Speed-min-1 (rpm) : 650
Boost pressure in bar :- Speed-min-1 (rpm) : 1055-1065
: 24.75-26.25(23.75- Boost pressure in bar :-
Delivery quantity(x ) Control rack travel in
27.25) : 9.5
in cm³/500 strokes mm
Maximum spread in cm³ : 2.0(4.0)
While over checking ,if the cutting speed is above
Speed-min-1 (rpm) : 850
the rated speed and if,
Boost pressure in bar :- -the delivery values are within the overchecking
Delivery quantity(x ) :- tolerance
in cm³/500 strokes -control rack remains at full load position even at
Maximum spread in cm³ : - 50 min
Speed-min-1 (rpm) :- (rpm) less than the rated speed
Control rack travel in the cutting-in speed should be declared OK.
:-
mm 8. DEGREE OF IRREGULARY
Delivery quantity(x ) :- Speed-min-1 (rpm) : 1125-1155
in cm³/500 strokes Boost pressure in bar :-
Maximum spread in cm³ : - Control rack travel in
: 4.0
5. IDLING SPEED CONTROL (RATED mm
SPEED) No of notches : 20.0
Control lever position : 27.0±4.0° 9. STARTING
Speed-min-1 (rpm) : 400 TRAVEL
Control rack travel in Speed-min-1 (rpm) :-
: 7.2-7.4
mm Control rack travel in
:-
Speed-min-1 (rpm) : 100 mm
Control rack travel in Delivery quantity(x ) :-
: Minimum 19.0
mm in cm³/500 strokes
Speed-min-1 (rpm) : 400
Control rack travel in
: 7.2-7.4
mm
Speed-min-1 (rpm) : 520-580
REFERENCE NO

Control rack travel in 10.STARTING FUEL DELIVERY


: 2.0
mm Speed-min-1 (rpm) : 100
Control rack travel in
: 16.25-16.75
mm
Delivery quantity(x ) :-
in cm³/100 strokes

OTHER
INFORMATION
Element :- Adaption capsule :-
Delivery valve :-
Flyweight assembly :- Nozzle :-
Governor spring :- Opening pressure in bar : -
Note:
1. Sl.No.of the operations indicate the sequence of
3.(x):Average of the cylinders
operations.
2. Values given in brackets are overchecking
-
values

Applicable only for BOSCH and MICO Test benches 210116


These Test specifications should not be copied or transmitted to a
third party without our written permission.All rights reserved.
REFERENCE NO

275 DI YUVO
Test Specifications
(subject to alternations)
For Field Service only
(B) ADJUSTMENT OF PUMP AND
GOVERNOR
GUIDE SLEEVE
TRAVEL
Control lever position : Free
: TSS-TS-MML-F..
REFERENCE NO Speed-min-1 (rpm) : 800
A2ZA14
Control rack travel in
Edition : 04.2016 : 0.3-0.7
mm
Replaces(edition) :- 1.MAXIMUM SPEED CONTROL (RATED
Test oil : 9 916 034 004 SPEED)
Revision :3 (without supplementry idling spring)
Combination No. : F002A2ZA14 Control lever position : 44.0±4.0°
Speed-min-1 (rpm) : 500
: PES 3 A 85 D 320 RS Boost pressure in bar :-
Injection pump
2000
Control rack travel in
: RSV 400...1000 A 5 C mm : 11.8-12.2
Governor
1839 R Speed-min-1 (rpm) : 1000
Customer : MAHINDRA Boost pressure in bar :-
Engine model : DHE2235NA3A Control rack travel in
: 10.95-11.05
Engine code :- mm
Application : DHRUV Speed-min-1 (rpm) : 1040-1050
TEST BENCH REQUIREMENTS Boost pressure in bar :-
Control rack travel in
: 10.0
Test oil inlet mm
: 38°-42°C
temperature Speed-min-1 (rpm) : 1080-1110
Overflow valve : F002A10627 Boost pressure in bar :-
Inlet pressure in bar : 1.5 Control rack travel in
: 4.0
Test injector : 0681343009 mm
Opening pressure in bar : 172.0-175.0 Speed-min-1 (rpm) : 1250
High pressure pipe : 6X2X600 Boost pressure in bar :-
(ODXIDxlength) in mm Control rack travel in
: 0.3-1.4
mm
REFERENCE NO

2.FULL LOAD
(A) CALIBRATION OF PUMP WITHOUT DELIVERY
GOVERNOR ACTION Speed-min-1 (rpm) : 1000
Boost pressure in bar :-
Control rack travel in
Direction of rotation : Clockwise : 10.95-11.05
mm
Prestroke in mm : 3.65-3.75(3.6-3.8)
: 31.75-32.25(30.75-
Control rack position in Delivery quantity(x )
: 9.0-12.0 33.25)
mm
in cm³/500 strokes
Cam sequence : 1-3-2
Maximum spread in cm³ : 1.5(3.5)
Cam displacement : 0-120-240° ±0.5°
3.TORQUE
Tappet clearance in mm : min 0.2
CONTROL
Injection Timing
:- Speed-min-1 (rpm) : 500
locking
Boost pressure in bar :-
BASIC SETTING
Control rack travel in
: 11.8-12.2
mm
Speed-min-1 (rpm) : 1000 Speed-min-1 (rpm) : 700
Control rack travel in Boost pressure in bar :-
: 10.95-11.05
mm Control rack travel in
Delivery quantity(x ) : 6.25-6.55 :11.6-12.0
mm
in cm³/100 strokes Speed-min-1 (rpm) : 500
Maximum spread in cm³ : 0.3(0.7) Boost pressure in bar :-
Control rack travel in
: 11.8-12.2
mm
Speed-min-1 (rpm) : 400 Speed-min-1 (rpm) : 700
Control rack travel in Boost pressure in bar :-
: 7.1-7.3
mm Control rack travel in
: 11.6-12.0
Delivery quantity(x ) : 0.75-1.15(0.55-1.35) mm
in cm/100 strokes Speed-min-1 (rpm) :-
Maximum spread in cm³ : 0.5(0.7) Boost pressure in bar :-
Control rack travel in
:-
mm
Speed-min-1 (rpm) : 1000
Boost pressure in bar :-
Control rack travel in
: 10.95-11.05
mm
Contd...2

TSS-TS-MML-F..A2ZA14
REFERENCE NO

6.MAXIMUM SPEED CONTROL (RATED


4. COURSE OF SPEED)
DELIVERY (with supplementary idling spring)
Speed-min-1 (rpm) : 500
Boost pressure in bar :- Speed-min-1 (rpm) :-
Delivery quantity(x ) : 28.5-30.0(27.5-31.0) Control rack travel in
:-
in cm³/500 strokes mm
Maximum spread in cm³ : 2.0(4.0)
Speed-min-1 (rpm) : 700 7. GOVERNOR CUTTING IN SPEED
Boost pressure in bar :- Speed-min-1 (rpm) : 1040-1050
: 30.25-31.75(29.25- Boost pressure in bar :-
Delivery quantity(x )
32.75) Control rack travel in
in cm³/500 strokes : 10.0
mm
Maximum spread in cm³ : 2.0(4.0)
Speed-min-1 (rpm) : 800 While over checking ,if the cutting speed is above
Boost pressure in bar :- the rated speed and if,
Delivery quantity(x ) :- -the delivery values are within the overchecking
tolerance
in cm³/500 strokes
-control rack remains at full load position even at
Maximum spread in cm³ : -
50 min
Speed-min-1 (rpm) :- (rpm) less than the rated speed
Control rack travel in
:- the cutting-in speed should be declared OK.
mm
8. DEGREE OF IRREGULARY
Delivery quantity(x ) :-
in cm³/500 strokes Speed-min-1 (rpm) : 1090-1120
Maximum spread in cm³ : - Boost pressure in bar :-
Control rack travel in
5. IDLING SPEED CONTROL (RATED : 4.0
mm
SPEED)
No of notches : 12.0
Control lever position : 20.0±4.0°
9. STARTING
Speed-min-1 (rpm) : 400
TRAVEL
Control rack travel in
: 7.1-7.3 Speed-min-1 (rpm) :-
mm
Control rack travel in
Speed-min-1 (rpm) : 100 :-
mm
Control rack travel in Delivery quantity(x ) :-
: Minimum 19.0
mm
in cm³/500 strokes
Speed-min-1 (rpm) : 400
Control rack travel in
: 7.1-7.3
mm
Speed-min-1 (rpm) : 485-545
REFERENCE NO

Control rack travel in 10.STARTING FUEL DELIVERY


: 2.0
mm Speed-min-1 (rpm) : 100
Control rack travel in
: 16.0-16.5
mm
Delivery quantity(x ) :-
in cm³/100 strokes

OTHER
INFORMATION
Element :- Adaption capsule :-
Delivery valve :-
Flyweight assembly :- Nozzle :-
Governor spring :- Opening pressure in bar : -
Note:
1. Sl.No.of the operations indicate the sequence of
3.(x):Average of the cylinders
operations.
2. Values given in brackets are overchecking
-
values

Applicable only for BOSCH and MICO Test benches 130416


These Test specifications should not be copied or transmitted to a
third party without our written permission.All rights reserved.
REFERENCE NO

415 DI YUVO
Test Specifications
(subject to alternations)
For Field Service only
(B) ADJUSTMENT OF PUMP AND
GOVERNOR
GUIDE SLEEVE
TRAVEL
: TSS-TS-MML-F.. Control lever position : Free
REFERENCE NO Speed-min-1 (rpm) : 800
A2ZA10
Edition : 04.2016 Control rack travel in
: 0.3-0.7
Replaces(edition) :- mm
Test oil : 9 916 034 004 1.MAXIMUM SPEED CONTROL (RATED
SPEED)
Revision :4
(without supplementry idling spring)
Combination No. : F002A2ZA10 Control lever position : 51.0±4.0°

: PES 4 A 85 D 320 RS Speed-min-1 (rpm) : 500


Injection pump Boost pressure in bar :-
2000
: RSV 400...1000 A 5 C Control rack travel in : 11.3-11.5
Governor mm
1770 R
Speed-min-1 (rpm) : 1000
Customer : MAHINDRA
Boost pressure in bar :-
Engine model : MM2730N3AD
Control rack travel in
Engine code :- : 9.95-10.05
mm
Application : TRACTOR
Speed-min-1 (rpm) : 1035-1045
TEST BENCH REQUIREMENTS
Boost pressure in bar :-
Control rack travel in
Test oil inlet : 9.0
: 38°-42°C mm
temperature
Speed-min-1 (rpm) : 1095-1125
Overflow valve : F002A10627
Boost pressure in bar :-
Inlet pressure in bar : 1.5
Control rack travel in
Test injector : 0681343009 : 4.0
mm
Opening pressure in bar : 172.0-175.0
Speed-min-1 (rpm) : 1250
High pressure pipe : 6X2X600
Boost pressure in bar :-
(ODXIDxlength) in mm
Control rack travel in
: 0.3-1.4
mm
REFERENCE NO

2.FULL LOAD
(A) CALIBRATION OF PUMP WITHOUT DELIVERY
GOVERNOR ACTION Speed-min-1 (rpm) : 1000
Boost pressure in bar :-
Control rack travel in
Direction of rotation : Clockwise : 9.95-10.05
mm
Prestroke in mm : 3.65-3.75(3.6-3.8)
Delivery quantity(x ) : 24.5-25.0(23.5-26.0)
Control rack position in
: 9.0-12.0 in cm³/500 strokes
mm
Cam sequence : 1-3-4-2 Maximum spread in cm³ : 1.5(3.5)
Cam displacement : 0-90-180-270° ±0.5° 3.TORQUE
Tappet clearance in mm : min 0.2 CONTROL
Injection Timing Speed-min-1 (rpm) : 500
:- Boost pressure in bar :-
locking
BASIC SETTING Control rack travel in
: 11.3-11.5
mm
Speed-min-1 (rpm) : 700
Speed-min-1 (rpm) : 1000
Boost pressure in bar :-
Control rack travel in
: 9.95-10.05 Control rack travel in
mm :11.15-11.35
mm
Delivery quantity(x ) : 4.8-5.1
Speed-min-1 (rpm) : 500
in cm³/100 strokes Boost pressure in bar :-
Maximum spread in cm³ : 0.3(0.7) Control rack travel in
: 11.3-11.5
mm
Speed-min-1 (rpm) : 700
Speed-min-1 (rpm) : 400 Boost pressure in bar :-
Control rack travel in Control rack travel in
: 7.1-7.3 : 11.15-11.35
mm mm
Delivery quantity(x ) : 0.7-1.1(0.5-1.3) Speed-min-1 (rpm) :-
in cm/100 strokes Boost pressure in bar :-
Maximum spread in cm³ : 0.5(0.7) Control rack travel in
:-
mm
Speed-min-1 (rpm) : 1000
Boost pressure in bar :-
Control rack travel in
: 9.95-10.05
mm
Contd...2

TSS-TS-MML-F..A2ZA10
REFERENCE NO

6.MAXIMUM SPEED CONTROL (RATED


SPEED)
4. COURSE OF
(with supplementary idling spring)
DELIVERY
Speed-min-1 (rpm) : 500
Boost pressure in bar :- Speed-min-1 (rpm) :-
Control rack travel in
Delivery quantity(x ) : 22.0-23.5(21.0-24.5) :-
mm
in cm³/500 strokes
Maximum spread in cm³ : 2.0(4.0)
7. GOVERNOR CUTTING IN SPEED
Speed-min-1 (rpm) : 700
Speed-min-1 (rpm) : 1035-1045
Boost pressure in bar :-
Boost pressure in bar :-
Delivery quantity(x ) : 25.0-26.5(24.0-27.5)
Control rack travel in
in cm³/500 strokes : 9.0
mm
Maximum spread in cm³ : 2.0(4.0)
Speed-min-1 (rpm) : 800 While over checking ,if the cutting speed is above
Boost pressure in bar :- the rated speed and if,
Delivery quantity(x ) :- -the delivery values are within the overchecking
in cm³/500 strokes tolerance
Maximum spread in cm³ : - -control rack remains at full load position even at
50 min
Speed-min-1 (rpm) :-
(rpm) less than the rated speed
Control rack travel in
:- the cutting-in speed should be declared OK.
mm
Delivery quantity(x ) :- 8. DEGREE OF IRREGULARY
in cm³/500 strokes Speed-min-1 (rpm) : 1105-1135
Maximum spread in cm³ : - Boost pressure in bar :-
5. IDLING SPEED CONTROL (RATED Control rack travel in
: 4.0
SPEED) mm
Control lever position : 27.0±4.0° No of notches : 20.0
Speed-min-1 (rpm) : 400 9. STARTING
TRAVEL
Control rack travel in
: 7.1-7.3 Speed-min-1 (rpm) :-
mm
Control rack travel in
Speed-min-1 (rpm) : 100 :-
mm
Control rack travel in
: Minimum 19.0 Delivery quantity(x ) :-
mm
in cm³/500 strokes
Speed-min-1 (rpm) : 400
Control rack travel in
: 7.1-7.3
mm
Speed-min-1 (rpm) : 510-570
Control rack travel in
: 2.0
mm
REFERENCE NO

10.STARTING FUEL DELIVERY


Speed-min-1 (rpm) : 100
Control rack travel in
: 16.0-16.5
mm
Delivery quantity(x ) :-
in cm³/100 strokes

OTHER
INFORMATION
Element :- Adaption capsule :-
Delivery valve :-
Flyweight assembly :- Nozzle :-
Governor spring :- Opening pressure in bar : -
Note:
1. Sl.No.of the operations indicate the sequence of
3.(x):Average of the cylinders
operations.
2. Values given in brackets are overchecking
-
values

Applicable only for BOSCH and MICO Test benches 210116


These Test specifications should not be copied or transmitted to a
third party without our written permission.All rights reserved.
REFERENCE NO

575 DI YUVO
Test Specifications
(subject to alternations)
For Field Service only
(B) ADJUSTMENT OF PUMP AND
GOVERNOR
GUIDE SLEEVE
TRAVEL
Control lever position : Free
: TSS-TS-MML-F..
REFERENCE NO Speed-min-1 (rpm) : 800
A2ZA13
Control rack travel in
Edition : 04.2016 : 0.3-0.7
mm
Replaces(edition) :- 1.MAXIMUM SPEED CONTROL (RATED
Test oil : 9 916 034 004 SPEED)
Revision :3 (without supplementry idling spring)
Combination No. : F002A2ZA13 Control lever position : 51.0±4.0°
Speed-min-1 (rpm) : 500
: PES 4 A 85 D 320 RS Boost pressure in bar :-
Injection pump
2000
Control rack travel in
: RSV 400...1000 A 5 C mm : 11.7-12.0
Governor
1770 R Speed-min-1 (rpm) : 1000
Customer : MAHINDRA Boost pressure in bar :-
Engine model : DHE3045NA34 Control rack travel in
: 10.95-11.05
Engine code :- mm
Application : Tractor Speed-min-1 (rpm) : 1050-1060
TEST BENCH REQUIREMENTS Boost pressure in bar :-
Control rack travel in
: 10.0
Test oil inlet mm
: 38°-42°C
temperature Speed-min-1 (rpm) : 1110-1140
Overflow valve : F002A10627 Boost pressure in bar :-
Inlet pressure in bar : 1.5 Control rack travel in
: 4.0
Test injector : 0681343009 mm
Opening pressure in bar : 172.0-175.0 Speed-min-1 (rpm) : 1250
High pressure pipe : 6X2X600 Boost pressure in bar :-
(ODXIDxlength) in mm Control rack travel in
: 0.3-1.4
mm
REFERENCE NO

2.FULL LOAD
(A) CALIBRATION OF PUMP WITHOUT DELIVERY
GOVERNOR ACTION Speed-min-1 (rpm) : 1000
Boost pressure in bar :-
Control rack travel in
Direction of rotation : Clockwise : 10.95-11.05
mm
Prestroke in mm : 3.65-3.75(3.6-3.8)
: 30.25-30.75(29.25-
Control rack position in Delivery quantity(x )
: 9.0-12.0 31.75)
mm
in cm³/500 strokes
Cam sequence : 1-3-4-2
Maximum spread in cm³ : 1.5(3.5)
Cam displacement : 0-90-180-270° ±0.5°
3.TORQUE
Tappet clearance in mm : min 0.2
CONTROL
Injection Timing
:- Speed-min-1 (rpm) : 500
locking
Boost pressure in bar :-
BASIC SETTING
Control rack travel in
: 11.7-12.0
mm
Speed-min-1 (rpm) : 1000 Speed-min-1 (rpm) : 700
Control rack travel in Boost pressure in bar :-
: 10.95-11.05
mm Control rack travel in
Delivery quantity(x ) : 5.95-6.25 :11.7-11.9
mm
in cm³/100 strokes Speed-min-1 (rpm) : 500
Maximum spread in cm³ : 0.3(0.7) Boost pressure in bar :-
Control rack travel in
: 11.7-12.0
mm
Speed-min-1 (rpm) : 400 Speed-min-1 (rpm) : 700
Control rack travel in Boost pressure in bar :-
: 7.4-7.6
mm Control rack travel in
: 11.7-11.9
Delivery quantity(x ) : 0.7-1.1(0.5-1.3) mm
in cm/100 strokes Speed-min-1 (rpm) :-
Maximum spread in cm³ : 0.5(0.7) Boost pressure in bar :-
Control rack travel in
:-
mm
Speed-min-1 (rpm) : 1000
Boost pressure in bar :-
Control rack travel in
: 10.95-11.05
mm
Contd...2

TSS-TS-MML-F..A2ZA13
REFERENCE NO

6.MAXIMUM SPEED CONTROL (RATED


SPEED)
4. COURSE OF
(with supplementary idling spring)
DELIVERY
Speed-min-1 (rpm) : 500
Boost pressure in bar :- Speed-min-1 (rpm) :-
Control rack travel in
Delivery quantity(x ) : 26.0-27.5(25.0-28.5) :-
mm
in cm³/500 strokes
Maximum spread in cm³ : 2.0(4.0)
7. GOVERNOR CUTTING IN SPEED
Speed-min-1 (rpm) : 700
Speed-min-1 (rpm) : 1050-1060
Boost pressure in bar :-
Boost pressure in bar :-
Delivery quantity(x ) : 29.0-30.5(28.0-31.5)
Control rack travel in
in cm³/500 strokes : 10.0
mm
Maximum spread in cm³ : 2.0(4.0)
Speed-min-1 (rpm) : 900 While over checking ,if the cutting speed is above
Boost pressure in bar :- the rated speed and if,
Delivery quantity(x ) :- -the delivery values are within the overchecking
in cm³/500 strokes tolerance
Maximum spread in cm³ : - -control rack remains at full load position even at
50 min
Speed-min-1 (rpm) :-
(rpm) less than the rated speed
Control rack travel in
:- the cutting-in speed should be declared OK.
mm
Delivery quantity(x ) :- 8. DEGREE OF IRREGULARY
in cm³/500 strokes Speed-min-1 (rpm) : 1120-1150
Maximum spread in cm³ : - Boost pressure in bar :-
5. IDLING SPEED CONTROL (RATED Control rack travel in
: 4.0
SPEED) mm
Control lever position : 27.0±4.0° No of notches : 20.0
Speed-min-1 (rpm) : 400 9. STARTING
TRAVEL
Control rack travel in
: 7.4-7.6 Speed-min-1 (rpm) :-
mm
Control rack travel in
Speed-min-1 (rpm) : 100 :-
mm
Control rack travel in
: Minimum 19.0 Delivery quantity(x ) :-
mm
in cm³/500 strokes
Speed-min-1 (rpm) : 400
Control rack travel in
: 7.4-7.6
mm
Speed-min-1 (rpm) : 520-580
Control rack travel in
: 2.0
mm
REFERENCE NO

10.STARTING FUEL DELIVERY


Speed-min-1 (rpm) : 100
Control rack travel in
: 16.0-16.5
mm
Delivery quantity(x ) :-
in cm³/100 strokes

OTHER
INFORMATION
Element :- Adaption capsule :-
Delivery valve :-
Flyweight assembly :- Nozzle :-
Governor spring :- Opening pressure in bar : -
Note:
1. Sl.No.of the operations indicate the sequence of
3.(x):Average of the cylinders
operations.
2. Values given in brackets are overchecking
-
values

Applicable only for BOSCH and MICO Test benches 130416


These Test specifications should not be copied or transmitted to a
third party without our written permission.All rights reserved.
Arjun NOVO

Main Menu
REFERENCE NO Page 1 of 2
Test Specifications
ARJUN NOVO 605 DI-i (52HP) (subject to alternations)
For Field Service only

REFERENCE NO : TSS-TS-MML-F..A3Z007 (B) ADJUSTMENT OF PUMP AND GOVERNOR


Edition : 09.2014 GUIDE SLEEVE TRAVEL
Replaces(edition) :- Control lever position : Free
Test oil : F 002 S3E 001 Speed-min-1 (rpm) : 800
Revision :2 Control rack travel in mm : 0.3-0.7
1.MAXIMUM SPEED CONTROL (RATED SPEED)
Combination No. : F002A3Z007-EB40289300
(without supplementry idling spring)

Injection pump : PES4A85D320RS3500 Control lever position : 46.0±4.0°


Speed-min-1 (rpm) : 500
Governor : RSV400…1050A2C1742R Boost pressure in bar :-
Control rack travel in mm : 12.3-12.5
Customer : Mahindra & Mahindra, AFS
Speed-min-1 (rpm) : 1050
Engine model : NE4523A
Boost pressure in bar :-
Engine code :-
Control rack travel in mm : 11.95-12.05
Application : TRACTOR
TEST BENCH REQUIREMENTS Speed-min-1 (rpm) : 1100-1110
Boost pressure in bar :-

Test oil inlet temperature : 38°-42°C Control rack travel in mm : 11.0


Overflow valve : F002A10627 Speed-min-1 (rpm) : 1175-1205
Inlet pressure in bar : 1.5 Boost pressure in bar :-
Test injector : 0681343009 Control rack travel in mm : 4.0
Opening pressure in bar : 172.0-175.0 Speed-min-1 (rpm) : 1275
High pressure pipe : 6X2X600
Boost pressure in bar :-
(ODXIDxlength) in mm
Control rack travel in mm : 0.3-1.4
2.FULL LOAD DELIVERY
(A) CALIBRATION OF PUMP WITHOUT GOVERNOR ACTION
Speed-min-1 (rpm) : 1050
Boost pressure in bar :-
Direction of rotation : Clockwise Control rack travel in mm : 11.95-12.05
Prestroke in mm : 4.65-4.75(4.6-4.8) Delivery quantity(x ) : 27.0-27.5(26.0-28.5)
Control rack position in mm : 18.0-21.0 in cm³/500 strokes
Cam sequence : 1- 3- 4- 2 Maximum spread in cm³ : 1.5(3.5)
Cam displacement : 0-90-180-270° ±0.5° 3.TORQUE CONTROL
Tappet clearance in mm : min 0.2 Speed-min-1 (rpm) : 500
Injection Timing locking :- Boost pressure in bar :-
BASIC SETTING Control rack travel in mm : 12.3-12.5
Speed-min-1 (rpm) : 650
Speed-min-1 (rpm) : 1050 Boost pressure in bar :-
Control rack travel in mm : 11.95-12.05 Control rack travel in mm :12.0-12.2
Delivery quantity(x ) : 5.3-5.6 Speed-min-1 (rpm) : 500
in cm³/100 strokes Boost pressure in bar :-
Maximum spread in cm³ : 0.3(0.7) Control rack travel in mm : 12.3-12.5
Speed-min-1 (rpm) : 650
Boost pressure in bar :-
Speed-min-1 (rpm) : 400 Control rack travel in mm : 12.0-12.2
Control rack travel in mm : 8.6-8.8 Speed-min-1 (rpm) :-
Delivery quantity(x ) : 1.3-1.7(1.1-1.9) Boost pressure in bar :-
in cm/100 strokes Control rack travel in mm :-
Maximum spread in cm³ : 0.5(0.7) Speed-min-1 (rpm) : 1050
Boost pressure in bar :-
Control rack travel in mm : 11.95-12.05
Contd...2

file://\\banap61724\MSI\PDF\back up\F 750\New folder\TS-TSS-TS-MML-F..A3Z007-09.2014.htm 9/19/2014


REFERENCE NO
TSS-TS-MML-F..A3Z007 Page 2 of 2
4. COURSE OF DELIVERY 6.MAXIMUM SPEED CONTROL (RATED SPEED)
Speed-min-1 (rpm) : 500 (with supplementary idling spring)
Boost pressure in bar :-
Delivery quantity(x ) : 21.75-23.25(20.75-24.25) Speed-min-1 (rpm) :-
in cm³/500 strokes Control rack travel in mm :-
Maximum spread in cm³ : 2.0(4.0)
Speed-min-1 (rpm) : 650 7. GOVERNOR CUTTING IN SPEED
Boost pressure in bar :- Speed-min-1 (rpm) : 1100-1110
Delivery quantity(x ) : 22.0-23.5(21.0-24.5) Boost pressure in bar :-
in cm³/500 strokes Control rack travel in mm : 11.0
Maximum spread in cm³ : 2.0(4.0)
Speed-min-1 (rpm) :- While over checking ,if the cutting speed is above the rated speed and if,
Boost pressure in bar :- -the delivery values are within the overchecking tolerance
Delivery quantity(x ) :- -control rack remains at full load position even at 50 min
in cm³/500 strokes (rpm) less than the rated speed
Maximum spread in cm³ :- the cutting-in speed should be declared OK.
Speed-min-1 (rpm) :- 8. DEGREE OF IRREGULARY
Control rack travel in mm :- Speed-min-1 (rpm) : 1190-1220
Delivery quantity(x ) :- Boost pressure in bar :-
in cm³/500 strokes Control rack travel in mm : 4.0
Maximum spread in cm³ :- No of notches : 16.0
5. IDLING SPEED CONTROL (RATED SPEED) 9. STARTING TRAVEL
Control lever position : 23.0±4.0° Speed-min-1 (rpm) :-
-1
Speed-min (rpm) : 400 Control rack travel in mm :-
Control rack travel in mm : 8.6-8.8 Delivery quantity(x ) :-
in cm³/500 strokes
Speed-min-1 (rpm) : 100
Control rack travel in mm : Minimum 19.0 10.STARTING FUEL DELIVERY
Speed-min-1 (rpm) : 100
Speed-min-1 (rpm) : 400
Control rack travel in mm : 19.75-21.25
Control rack travel in mm : 8.6-8.8
Delivery quantity(x ) :-
Speed-min-1 (rpm) : 540-600
in cm³/100 strokes
Control rack travel in mm : 2.0

OTHER INFORMATION

Note:

1. Sl.No.of the operations indicate the sequence of operations. 3.(x):Average of the cylinders

2. Values given in brackets are overchecking values -

Applicable only for BOSCH and MICO Test benches 170714


These Test specifications should not be copied or transmitted to a third party without our written permission.All rights reserved.

file://\\banap61724\MSI\PDF\back up\F 750\New folder\TS-TSS-TS-MML-F..A3Z007-09.2014.htm 9/19/2014


ARJUN NOVO 605 DI-i (57HP) Test Specifications
(subject to alternations)
For Field Service only
 
 
REFERENCE NO : TSS-TS-MML F..969 (B) ADJUSTMENT OF PUMP AND GOVERNOR
 
Edition : 07.2013 GUIDE SLEEVE TRAVEL  
Replaces(edition) : 05.2013 Control lever position : Free  
 
Test oil : 9 916 034 004 Speed-min-1 (rpm) : 800  
Revision :4 Control rack travel in mm : 0.3-0.7  
 
  1.MAXIMUM SPEED CONTROL (RATED SPEED)
 
Combination No. : F002A0Z969-EB40.272.100    
  (without supplementry idling spring)  
   
 
Control lever position : 46.0±4.0°
Injection pump : PES 4 A 85 D 320 RS 3500  
 
Speed-min-1 (rpm) :-  
 
Governor : RSV 400...1050 A 2 C 1742 R Boost pressure in bar :-
   
Control rack travel in mm :-  
Customer : Mahindra & Mahindra Ltd.  
Speed-min-1 (rpm) : 1050
Engine model : NE 457 3A  
Boost pressure in bar :-  
Engine code :  
Control rack travel in mm : 12.95-13.05
 
Application : TRACTOR (605 DI)  
 
TEST BENCH REQUIREMENTS
Speed-min-1 (rpm) : 1095-1105  
  Boost pressure in bar :-
 
   
Test oil inlet temperature : 38°-42°C Control rack travel in mm : 12.0  
 
Overflow valve : F002A10627 Speed-min-1 (rpm) : 1180-1210
 
Inlet pressure in bar : 1.5 Boost pressure in bar :-  
Test injector : 0681343009 Control rack travel in mm : 4.0  
 
Opening pressure in bar : 172.0-175.0 Speed-min-1 (rpm) : 1300  
High pressure pipe : 6X2X600 Boost pressure in bar :-
 
(ODXIDxlength) in mm  
Control rack travel in mm : 0.3-1.4  
 
   
2.FULL LOAD DELIVERY
(A) CALIBRATION OF PUMP WITHOUT GOVERNOR ACTION  
Speed-min-1 (rpm) : 1050  
 
  Boost pressure in bar :-  
Direction of rotation : Clockwise  
Control rack travel in mm : 12.95-13.05
 
Prestroke in mm : 4.65-4.75(4.6-4.8) Delivery quantity(x ) : 31.75-32.25(30.75-33.25)  
Control rack position in mm : 18.0-21.0 in cm³/500 strokes  
Cam sequence : 1- 3- 4- 2
 
Maximum spread in cm³ : 1.5(2.5)  
 
Cam displacement : 0-90-180-270° ±0.5° 3.TORQUE CONTROL  
Tappet clearance in mm : min 0.2  
Speed-min-1 (rpm) :-
 
Injection Timing locking :-
 
Boost pressure in bar :-  
BASIC SETTING Control rack travel in mm :-  
   
  Speed-min-1 (rpm) :-
 
Speed-min-1 (rpm) : 1050 Boost pressure in bar :-  
Control rack travel in mm : 12.95-13.05 Control rack travel in mm :-  
 
Delivery quantity(x ) : 6.25-6.55 Speed-min-1 (rpm) : 500
 
in cm³/100 strokes Boost pressure in bar :-  
Maximum spread in cm³ : 0.3(0.5) Control rack travel in mm : 13.5-13.7  
   
Speed-min-1 (rpm) : 650
 
 
  Boost pressure in bar :-  
Speed-min-1 (rpm) : 400 Control rack travel in mm : 13.1-13.3  
 
Control rack travel in mm : 8.3-8.5 Speed-min-1 (rpm) :-  
Delivery quantity(x ) : 1.05-1.45(1.0-1.5) Boost pressure in bar :-  
in cm/100 strokes Control rack travel in mm :-  
 
Maximum spread in cm³ : 0.4(0.6) Speed-min-1 (rpm) : 1050  
Boost pressure in bar :-  
Control rack travel in mm : 12.95-13.05  
 
Contd...2
 
TSS-TS-MML F..969  
4. COURSE OF DELIVERY 6.MAXIMUM SPEED CONTROL (RATED SPEED)
Speed-min-1 (rpm) : 500 (with supplementary idling spring)
 
Boost pressure in bar :-  
Delivery quantity(x ) : 26.75-28.25(26.0-29.0) Speed-min-1 (rpm) :-
in cm³/500 strokes Control rack travel in mm :-
 
Maximum spread in cm³ : 1.75(3.0)  
Speed-min-1 (rpm) : 650 7. GOVERNOR CUTTING IN SPEED
Boost pressure in bar :- Speed-min-1 (rpm) : 1095-1105
Delivery quantity(x ) : 25.25-26.75(24.5-27.5) Boost pressure in bar :-
in cm³/500 strokes Control rack travel in mm : 12.0
Maximum spread in cm³ :1.75(3.0)  
Speed-min-1 (rpm) :- While over checking ,if the cutting speed is above the rated speed and if,
Boost pressure in bar :- -the delivery values are within the overchecking tolerance
Delivery quantity(x ) :- -control rack remains at full load position even at 50 min
in cm³/500 strokes (rpm) less than the rated speed
Maximum spread in cm³ :- the cutting-in speed should be declared OK.
 
Speed-min-1 (rpm) :- 8. DEGREE OF IRREGULARY
Control rack travel in mm :- Speed-min-1 (rpm) : 1195-1225
Delivery quantity(x ) :- Boost pressure in bar :-
in cm³/500 strokes Control rack travel in mm : 4.0
Maximum spread in cm³ :- No of notches : 16.0
 
5. IDLING SPEED CONTROL (RATED SPEED) 9. STARTING TRAVEL
Control lever position : 22.0±4.0° Speed-min-1 (rpm) :-
Speed-min-1 (rpm) : 400 Control rack travel in mm :-
Control rack travel in mm : 8.3-8.5 Delivery quantity(x ) :-

Speed-min-1 (rpm) : 100 in cm³/500 strokes

Control rack travel in mm : Minimum 19.0 10.STARTING FUEL DELIVERY


Speed-min-1 (rpm) : 100
Speed-min-1 (rpm) : 400
Control rack travel in mm : 19.75-21.25
Control rack travel in mm : 8.3-8.5
Delivery quantity(x ) :-
Speed-min-1 (rpm) : 525-585
in cm³/100 strokes
Control rack travel in mm : 2.0
 
OTHER INFORMATION
Element :- Adaption capsule :-
Delivery valve :-
Flyweight assembly :- Nozzle :-
Governor spring :- Opening pressure in bar :-
 
Note:
 
1. Sl.No.of the operations indicate the sequence of operations. 3.(x):Average of the cylinders
 
2. Values given in brackets are overchecking values -
 
 
 
 
 
 
 
 
Applicable only for BOSCH and MICO Test benches 160513
These Test specifications should not be copied or transmitted to a third party without our written permission.All rights reserved.
REGULAR BS3A

Main Menu
Test Specifications
245 DI Orchard (subject to alternations)
For Field Service only

REFERENCE NO : TSS-TS-MML F..835 (B) ADJUSTMENT OF PUMP AND GOVERNOR


Edition : 11.2011 GUIDE SLEEVE TRAVEL
Replaces(edition) :- Control lever position : Free
Test oil : F 002 S3E 001 Speed-min-1 (rpm) : 800
Revision :3 Control rack travel in mm : 0.3-0.7
1.MAXIMUM SPEED CONTROL (RATED SPEED)
Combination No. : F 002 A0Z 835-EB40.244.000
(without supplementry idling spring)

Injection pump : PES 2 A 85 D 320 RS 3500 Control lever position : 44.0±4.0°


Speed-min-1 (rpm) :-
Governor : RSV 325...900 A 1 C 1601 R Boost pressure in bar :-
Control rack travel in mm :-
Customer : M&M Ltd. (FES)- Swaraj Division
Speed-min-1 (rpm) : 900
Engine model : RV2XM+ - BS(Trem)IIIA
Boost pressure in bar :-
Engine code :-
Control rack travel in mm : 12.45-12.55
Application : TRACTOR
TEST BENCH REQUIREMENTS Speed-min-1 (rpm) : 940-950
Boost pressure in bar :-

Test oil inlet temperature : 38°-42°C Control rack travel in mm : 11.5


Overflow valve : F002A10627 Speed-min-1 (rpm) : 965-995
Inlet pressure in bar : 1.5 Boost pressure in bar :-
Test injector : 0681343009 Control rack travel in mm : 4.0
Opening pressure in bar : 172.0-175.0 Speed-min-1 (rpm) : 1150
High pressure pipe : 6X2X600 Boost pressure in bar :-
(ODXIDxlength) in mm
Control rack travel in mm : 0.3-1.4
2.FULL LOAD DELIVERY
(A) CALIBRATION OF PUMP WITHOUT GOVERNOR ACTION
Speed-min-1 (rpm) : 900
Boost pressure in bar :-
Direction of rotation : Clockwise Control rack travel in mm : 12.45-12.55
Prestroke in mm : 3.15-3.25(3.1-3.3) Delivery quantity(x ) : 36.5-37.0(35.5-38.0)
Control rack position in mm : 18.0-21.0 in cm³/500 strokes
Cam sequence : 1-2 Maximum spread in cm³ : 1.5(3.5)
Cam displacement : 0-90° ±0.5° 3.TORQUE CONTROL
Tappet clearance in mm : min 0.2 Speed-min-1 (rpm) :-
Injection Timing locking :- Boost pressure in bar :-
BASIC SETTING Control rack travel in mm :-
Speed-min-1 (rpm) :-
Speed-min-1 (rpm) : 900 Boost pressure in bar :-
Control rack travel in mm : 12.45-12.55 Control rack travel in mm :-
Delivery quantity(x ) : 7.2-7.5 Speed-min-1 (rpm) : 550
in cm³/100 strokes Boost pressure in bar :-
Maximum spread in cm³ : 0.3(0.7) Control rack travel in mm : 12.6-12.8
Speed-min-1 (rpm) : 800
Boost pressure in bar :-
Speed-min-1 (rpm) : 325 Control rack travel in mm : 12.4-12.6
Control rack travel in mm : 6.4-6.6 Speed-min-1 (rpm) :-
Delivery quantity(x ) : 0.85-1.25(0.65-1.45) Boost pressure in bar :-
in cm/100 strokes Control rack travel in mm :-
Maximum spread in cm³ : 0.5(0.7) Speed-min-1 (rpm) : 900
Boost pressure in bar :-
Control rack travel in mm : 12.45-12.55
Contd...2
TSS-TS-MML F..835
4. COURSE OF DELIVERY 6.MAXIMUM SPEED CONTROL (RATED SPEED)
Speed-min-1 (rpm) : 550 (with supplementary idling spring)
Boost pressure in bar :-
Delivery quantity(x ) : 30.75-32.25(29.75-33.25) Speed-min-1 (rpm) :-
in cm³/500 strokes Control rack travel in mm :-
Maximum spread in cm³ : 2.0(4.0)
Speed-min-1 (rpm) :- 7. GOVERNOR CUTTING IN SPEED
Boost pressure in bar :- Speed-min-1 (rpm) : 940-950
Delivery quantity(x ) :- Boost pressure in bar :-
in cm³/500 strokes Control rack travel in mm : 11.5
Maximum spread in cm³ :-
Speed-min-1 (rpm) :- While over checking ,if the cutting speed is above the rated speed and if,
Boost pressure in bar :- -the delivery values are within the overchecking tolerance
Delivery quantity(x ) :- -control rack remains at full load position even at 50 min
in cm³/500 strokes (rpm) less than the rated speed
Maximum spread in cm³ :- the cutting-in speed should be declared OK.
Speed-min-1 (rpm) :- 8. DEGREE OF IRREGULARY
Control rack travel in mm :- Speed-min-1 (rpm) : 970-1000
Delivery quantity(x ) :- Boost pressure in bar :-
in cm³/500 strokes Control rack travel in mm : 4.0
Maximum spread in cm³ :- No of notches : 10.0
5. IDLING SPEED CONTROL (RATED SPEED) 9. STARTING TRAVEL
Control lever position : 17.0±4.0° Speed-min-1 (rpm) :-
Speed-min-1 (rpm) : 325 Control rack travel in mm :-
Control rack travel in mm : 6.4-6.6 Delivery quantity(x ) :-
in cm³/500 strokes
Speed-min-1 (rpm) : 100
Control rack travel in mm : Minimum 19.0 10.STARTING FUEL DELIVERY
Speed-min-1 (rpm) :-
Speed-min-1 (rpm) : 325
Control rack travel in mm :-
Control rack travel in mm : 6.4-6.6
Delivery quantity(x ) :-
Speed-min-1 (rpm) : 365-425
in cm³/100 strokes
Control rack travel in mm : 2.0

OTHER INFORMATION

Note:

1. Sl.No.of the operations indicate the sequence of operations. 3.(x):Average of the cylinders

2. Values given in brackets are overchecking values

Applicable only for BOSCH and MICO Test benches 171111


These Test specifications should not be copied or transmitted to a third party without our written permission.All rights reserved.
REFERENCE NO

255 DI PP
(subject to alternations)
For Field Service only
REFERENCE NO : TSS-TS-MML F..927 (B) ADJUSTMENT OF PUMP AND GOVERNOR
Edition : 11.2012 GUIDE SLEEVE
Replaces(edition) :- TRAVEL
Test oil : 9 916 034 004 Control lever position : Free
Revision :5 -1 : 800
Speed-min (rpm)
: F002A0Z927- Control rack travel in mm : 0.3-0.7
Combination No.
E040.282.100 1.MAXIMUM SPEED CONTROL (RATED
: PES 2 A 90 D 320 RS SPEED)
Injection pump
2000 (without supplementry idling spring)
: RSV 400...1050 A 5 C Control lever position : 48.0±4.0°
Governor
1713 R -1 :-
Speed-min (rpm)
: Mahindra & Mahindra Boost pressure in bar :-
Customer
Ltd.
Control rack travel in mm : -
: 255ELS – MDI 1500 3A
Engine model Speed-min-1 (rpm) : 1050
(BSIII A)
Engine code :- Boost pressure in bar :-
Application : TRACTOR Control rack travel in mm : 10.95-11.05
TEST BENCH REQUIREMENTS Speed-min-1 (rpm) : 1090-1100
Boost pressure in bar :-
Test oil inlet temperature : 38°-42°C Control rack travel in mm : 10.0
Overflow valve : F002A10627
Speed-min-1 (rpm) : 1145-1175
Inlet pressure in bar : 1.5
Test injector : 0681343009 Boost pressure in bar :-
Opening pressure in bar : 172.0-175.0 Control rack travel in mm : 4.0
High pressure pipe : 6X2X600 Speed-min-1 (rpm) : 1340
(ODXIDxlength) in mm Boost pressure in bar :-
Control rack travel in mm : 0.3-1.4
(A) CALIBRATION OF PUMP WITHOUT 2.FULL LOAD
GOVERNOR ACTION DELIVERY
Speed-min-1 (rpm) : 1050
Direction of rotation : Clockwise Boost pressure in bar :-
Prestroke in mm : 2.95-3.05(2.9-3.1) Control rack travel in
Control rack position in : 10.95-11.05
: 9.0-12.0 mm
mm Delivery quantity(x ) : 32.25-32.75(31.25-33.75)
Cam sequence : 1-2 in cm³/500 strokes
Cam displacement : 0-90° ±0.5° Maximum spread in cm³ : 1.5(3.5)
Tappet clearance in mm : min 0.2 3.TORQUE CONTROL
Injection Timing locking : -
Speed-min-1 (rpm) :-
BASIC SETTING
Boost pressure in bar :-
Control rack travel in mm : -
Speed-min-1 (rpm) : 1050
Speed-min-1 (rpm) :-
Control rack travel in mm : 10.95-11.05 Boost pressure in bar :-
Delivery quantity(x ) : 6.35-6.65 Control rack travel in mm :-
in cm³/100 strokes
Speed-min-1 (rpm) : 500

1 of 3 6/11/2013 5:41 PM
REFERENCE NO file:///C:/Documents and Settings/jgg2ban/Local Settings/Temporary Intern...

Boost pressure in bar :-


Maximum spread in cm³ : 0.3(0.7) Control rack travel in mm : 11.4-11.6
Speed-min-1 (rpm) : 650
Boost pressure in bar :-
Speed-min-1 (rpm) : 400
Control rack travel in mm : 11.4-11.6
Control rack travel in mm : 7.2-7.4
Speed-min-1 (rpm) :-
Delivery quantity(x ) : 0.7-1.1(0.5-1.3)
Boost pressure in bar :-
in cm/100 strokes
Control rack travel in mm :-
Maximum spread in cm³ : 0.5(0.7)
Speed-min-1 (rpm) : 1050
Boost pressure in bar :-
Control rack travel in mm : 10.95-11.05
Contd...2

TSS-TS-MML F..927
4. COURSE OF 6.MAXIMUM SPEED CONTROL (RATED
DELIVERY SPEED)
-1 :- (with supplementary idling spring)
Speed-min (rpm)
Boost pressure in bar :-
Delivery quantity(x ) :- Speed-min-1 (rpm) :-
in cm³/500 strokes Control rack travel in mm : -
Maximum spread in cm³ : -
Speed-min-1 (rpm) : 650 7. GOVERNOR CUTTING IN SPEED
Boost pressure in bar :- Speed-min-1 (rpm) : 1090-1100
Delivery quantity(x ) : 28.75-30.25(27.75-31.25) Boost pressure in bar :-
in cm³/500 strokes Control rack travel in mm : 10.0
Maximum spread in cm³ : 2.0 (4.0)
While over checking ,if the cutting speed is above
Speed-min-1 (rpm) :-
the rated speed and if,
Boost pressure in bar :-
-the delivery values are within the overchecking
Delivery quantity(x ) :-
tolerance
in cm³/500 strokes -control rack remains at full load position even at 50
Maximum spread in cm³ : - min
Speed-min-1 (rpm) :- (rpm) less than the rated speed
Control rack travel in the cutting-in speed should be declared OK.
:-
mm 8. DEGREE OF IRREGULARY
Delivery quantity(x ) :-
Speed-min-1 (rpm) : 1175-1205
in cm³/500 strokes Boost pressure in bar :-
Maximum spread in cm³ : - Control rack travel in mm : 4.0
5. IDLING SPEED CONTROL (RATED SPEED) No of notches : 16.0
Control lever position : 22.0±4.0° 9. STARTING TRAVEL
-1 : 400
Speed-min (rpm) Speed-min-1 (rpm) :-
Control rack travel in mm : 7.2-7.4 Control rack travel in mm : -
-1 : 100
Speed-min (rpm) Delivery quantity(x ) :-
Control rack travel in mm : Minimum 19.0 in cm³/500 strokes
Speed-min-1 (rpm) : 400 10.STARTING FUEL DELIVERY
Control rack travel in mm : 7.2-7.4 Speed-min-1 (rpm) : 100
Speed-min-1 (rpm) : 550-610 Control rack travel in mm : 14.25-14.75
Delivery quantity(x ) :-

2 of 3 6/11/2013 5:41 PM
REFERENCE NO file:///C:/Documents and Settings/jgg2ban/Local Settings/Temporary Intern...

Control rack travel in mm : 2.0 in cm³/100 strokes

OTHER
INFORMATION
Element :- Adaption capsule :-
Delivery valve :-
Flyweight assembly :- Nozzle :-
Governor spring :- Opening pressure in bar :-
Note:
1. Sl.No.of the operations indicate the sequence of
3.(x):Average of the cylinders
operations.
2. Values given in brackets are overchecking values

Applicable only for BOSCH and MICO Test benches 211112


These Test specifications should not be copied or transmitted to a third party without our written
permission.All rights reserved.

3 of 3 6/11/2013 5:41 PM
REFERENCE NO Page 1 of 3

255 DI
Test Specifications
(subject to alternations)
For Field Service only
(B) ADJUSTMENT OF PUMP AND
GOVERNOR
GUIDE SLEEVE
TRAVEL
Control lever position : Free
REFERENCE NO : TSS-TS-MM F..743
Speed-min-1 (rpm) : 800
Edition : 05.2010 Control rack travel in
Replaces(edition):- : 0.3-0.7
mm
Test oil : 9 916 034 004 1.MAXIMUM SPEED CONTROL (RATED
Revision :2 SPEED)
: F002A0Z743- (without supplementry idling spring)
Combination No.
EA40.227.900 Control lever position : 47.0±4.0°
: PES 2 A 90 D 320 RS
Injection pump Speed-min-1 (rpm) :-
2000
Boost pressure in bar :-
: RSV 400...1050 A 5 C
Governor Control rack travel in
1602 R :-
mm
: Mahindra & Mahindra
Customer Speed-min-1 (rpm) : 1050
Ltd.
: MDI 1365N 3A (BSIII Boost pressure in bar :-
Engine model Control rack travel in
A) : 11.85-11.95
Engine code :- mm
Application : Tractor - (255 DI) Speed-min-1 (rpm) : 1090-1100
TEST BENCH REQUIREMENTS Boost pressure in bar :-
Control rack travel in
: 10.9
Test oil inlet mm
: 38°-42°C Speed-min-1 (rpm) : 1155-1185
temperature
Overflow valve : F002A10627 Boost pressure in bar :-
Inlet pressure in bar : 1.5 Control rack travel in
: 4.0
Test injector : 0681343009 mm
Opening pressure in bar : 172.0-175.0 Speed-min-1 (rpm) : 1350
High pressure pipe : 6X2X600 Boost pressure in bar :-
(ODXIDxlength) in mm Control rack travel in
: 0.3-1.4
mm
(A) CALIBRATION OF PUMP WITHOUT 2.FULL LOAD
GOVERNOR ACTION DELIVERY
Speed-min-1 (rpm) : 1050
Direction of rotation : Clockwise Boost pressure in bar :-
Prestroke in mm : 2.95-3.05(2.9-3.1) Control rack travel in
: 11.85-11.95
Control rack position in mm
: 9.0-12.0 Delivery quantity(x ) : 26.5-27.0(25.5-28.0)
mm
Cam sequence : 1-2 in cm³/500 strokes
Cam displacement : 0-90° ±0.5° Maximum spread in cm³ : 1.5(3.5)
Tappet clearance in mm : min 0.2 3.TORQUE
CONTROL
Injection Timing

file://C:\Documents and Settings\smn7ban\Local Settings\Temporary Internet Files\OLK... 12/28/2011


REFERENCE NO Page 2 of 3

locking :- Speed-min-1 (rpm) :-


BASIC SETTING Boost pressure in bar :-
Control rack travel in
:-
Speed-min-1 (rpm) : 1050 mm
Control rack travel in Speed-min-1 (rpm) :-
: 11.85-11.95 Boost pressure in bar :-
mm
Delivery quantity(x ) : 5.2-5.5 Control rack travel in
:-
in cm³/100 strokes mm
Maximum spread in cm³ : 0.3(0.7) Speed-min-1 (rpm) : 500
Boost pressure in bar :-
Control rack travel in
: 12.1-12.3
Speed-min-1 (rpm) : 400 mm
Control rack travel in Speed-min-1 (rpm) : 700
: 8.5-8.7 Boost pressure in bar :-
mm
Delivery quantity(x ) : 0.55-0.95(0.35-1.15) Control rack travel in
: 12.1-12.3
in cm/100 strokes mm
Maximum spread in cm³ : 0.5(0.7) Speed-min-1 (rpm) :-
Boost pressure in bar :-
Control rack travel in
:-
mm
Speed-min-1 (rpm) : 1050
Boost pressure in bar :-
Control rack travel in
: 11.85-11.95
mm
Contd...2

TSS-TS-MM F..743
6.MAXIMUM SPEED CONTROL (RATED
4. COURSE OF SPEED)
DELIVERY (with supplementary idling spring)
Speed-min-1 (rpm) : 500
Boost pressure in bar :- Speed-min-1 (rpm) :-
: 17.75-19.25(16.75- Control rack travel in
Delivery quantity(x ) :-
20.25) mm
in cm³/500 strokes
Maximum spread in cm³ : 2.0(4.0) 7. GOVERNOR CUTTING IN SPEED
Speed-min-1 (rpm) : 700 Speed-min-1 (rpm) : 1090-1100
Boost pressure in bar :- Boost pressure in bar :-
Delivery quantity(x ) : 23.0-24.5(22.0-25.5) Control rack travel in
: 10.9
in cm³/500 strokes mm
Maximum spread in cm³ : 2.0(4.0)
Speed-min-1 (rpm) :- While over checking ,if the cutting speed is above
Boost pressure in bar :- the rated speed and if,
-the delivery values are within the overchecking
Delivery quantity(x ) :-
tolerance
in cm³/500 strokes -control rack remains at full load position even at
Maximum spread in cm³ :- 50 min
Speed-min-1 (rpm) :- (rpm) less than the rated speed

file://C:\Documents and Settings\smn7ban\Local Settings\Temporary Internet Files\OLK... 12/28/2011


REFERENCE NO Page 3 of 3

Control rack travel in the cutting-in speed should be declared OK.


:-
mm 8. DEGREE OF IRREGULARY
Delivery quantity(x ) :- Speed-min-1 (rpm) : 1180-1210
in cm³/500 strokes Boost pressure in bar :-
Maximum spread in cm³ : - Control rack travel in
: 4.0
5. IDLING SPEED CONTROL (RATED mm
SPEED) No of notches : 16.0
Control lever position : 23.0±4.0° 9. STARTING
Speed-min-1 (rpm) : 400 TRAVEL
Control rack travel in
: 8.5-8.7 Speed-min-1 (rpm) :-
mm Control rack travel in
:-
Speed-min-1 (rpm) : 100 mm
Control rack travel in Delivery quantity(x ) :-
: Minimum 19.0
mm in cm³/500 strokes
Speed-min-1 (rpm) : 400 10.STARTING FUEL DELIVERY
Control rack travel in Speed-min-1 (rpm) : 100
: 8.5-8.7
mm Control rack travel in
Speed-min-1 (rpm) : 545-605 : 14.0-14.5
mm
Control rack travel in Delivery quantity(x ) :-
: 2.0
mm in cm³/100 strokes

OTHER
INFORMATION
Element :- Adaption capsule :-
Delivery valve :-
Flyweight assembly :- Nozzle :-
Governor spring :- Opening pressure in bar : -
Note:
1. Sl.No.of the operations indicate the sequence of
3.(x):Average of the cylinders
operations.
2. Values given in brackets are overchecking
values

Applicable only for BOSCH and MICO Test benches 190410


These Test specifications should not be copied or transmitted to a third party without our
written permission.All rights reserved.

file://C:\Documents and Settings\smn7ban\Local Settings\Temporary Internet Files\OLK... 12/28/2011


Test Specifications
265 DI (subject to alternations)
For Field Service only

REFERENCE NO : TSS-TS-MM F..736 (B) ADJUSTMENT OF PUMP AND GOVERNOR


Edition : 03.2011 GUIDE SLEEVE TRAVEL
Replaces(edition) : 04.2010 Control lever position : Free
Test oil : F 002 S3E 001 Speed-min-1 (rpm) : 800
Revision :2 Control rack travel in mm : 0.3-0.7
1.MAXIMUM SPEED CONTROL (RATED SPEED)
Combination No. : F 002 A0Z 736-EA40.227.800
(without supplementry idling spring)

Injection pump : PES 3 A 85 D 320 RS 2000 Control lever position : 40.0±4.0°


Speed-min-1 (rpm) :-
Governor : RSV 400...950 A 5 C 1598 R Boost pressure in bar :-
Control rack travel in mm :-
Customer : Mahindra & Mahindra Ltd.
Speed-min-1 (rpm) : 950
Engine model : MDI 1785 N 3A (BSIII A)
Boost pressure in bar :-
Engine code :-
Control rack travel in mm : 9.95-10.05
Application : Tractor-265 DI
TEST BENCH REQUIREMENTS Speed-min-1 (rpm) : 990-1000
Boost pressure in bar :-

Test oil inlet temperature : 38°-42°C Control rack travel in mm : 9.0


Overflow valve : F002A10627 Speed-min-1 (rpm) : 1025-1055
Inlet pressure in bar : 1.5 Boost pressure in bar :-
Test injector : 0681343009 Control rack travel in mm : 4.0
Opening pressure in bar : 172.0-175.0 Speed-min-1 (rpm) : 1200
High pressure pipe : 6X2X600 Boost pressure in bar :-
(ODXIDxlength) in mm
Control rack travel in mm : 0.3-1.4
2.FULL LOAD DELIVERY
(A) CALIBRATION OF PUMP WITHOUT GOVERNOR ACTION
Speed-min-1 (rpm) : 950
Boost pressure in bar :-
Direction of rotation : Clockwise Control rack travel in mm : 9.95-10.05
Prestroke in mm : 3.65-3.75(3.6-3.8) Delivery quantity(x ) : 25.75-26.25(24.75-27.25)
Control rack position in mm : 18.0-21.0 in cm³/500 strokes
Cam sequence : 1-3-2 Maximum spread in cm³ : 1.5(3.5)
Cam displacement : 0-120-240° ±0.5° 3.TORQUE CONTROL
Tappet clearance in mm : min 0.2 Speed-min-1 (rpm) :-
Injection Timing locking :- Boost pressure in bar :-
BASIC SETTING Control rack travel in mm :-
Speed-min-1 (rpm) :-
Speed-min-1 (rpm) : 950 Boost pressure in bar :-
Control rack travel in mm : 9.95-10.05 Control rack travel in mm :-
Delivery quantity(x ) : 5.05-5.35 Speed-min-1 (rpm) : 500
in cm³/100 strokes Boost pressure in bar :-
Maximum spread in cm³ : 0.3(0.7) Control rack travel in mm : 10.8-11.0
Speed-min-1 (rpm) : 700
Boost pressure in bar :-
Speed-min-1 (rpm) : 400 Control rack travel in mm : 10.8-11.0
Control rack travel in mm : 6.6-6.8 Speed-min-1 (rpm) :-
Delivery quantity(x ) : 0.6-1.0(0.4-1.2) Boost pressure in bar :-
in cm/100 strokes Control rack travel in mm :-
Maximum spread in cm³ : 0.5(0.7) Speed-min-1 (rpm) : 950
Boost pressure in bar :-
Control rack travel in mm : 9.95-10.05
Contd...2
TSS-TS-MM F..736
4. COURSE OF DELIVERY 6.MAXIMUM SPEED CONTROL (RATED SPEED)
Speed-min-1 (rpm) : 500 (with supplementary idling spring)
Boost pressure in bar :-
Delivery quantity(x ) : 20.25-21.75(19.25-22.75) Speed-min-1 (rpm) :-
in cm³/500 strokes Control rack travel in mm :-
Maximum spread in cm³ : 2.0(4.0)
Speed-min-1 (rpm) : 700 7. GOVERNOR CUTTING IN SPEED
Boost pressure in bar :- Speed-min-1 (rpm) : 990-1000
Delivery quantity(x ) : 24.75-26.25(23.75-27.25) Boost pressure in bar :-
in cm³/500 strokes Control rack travel in mm : 9.0
Maximum spread in cm³ : 2.0(4.0)
Speed-min-1 (rpm) :- While over checking ,if the cutting speed is above the rated speed and if,
Boost pressure in bar :- -the delivery values are within the overchecking tolerance
Delivery quantity(x ) :- -control rack remains at full load position even at 50 min
in cm³/500 strokes (rpm) less than the rated speed
Maximum spread in cm³ :- the cutting-in speed should be declared OK.
Speed-min-1 (rpm) :- 8. DEGREE OF IRREGULARY
Control rack travel in mm :- Speed-min-1 (rpm) : 1040-1070
Delivery quantity(x ) :- Boost pressure in bar :-
in cm³/500 strokes Control rack travel in mm : 4.0
Maximum spread in cm³ :- No of notches : 12.0
5. IDLING SPEED CONTROL (RATED SPEED) 9. STARTING TRAVEL
Control lever position : 19.0±4.0° Speed-min-1 (rpm) :-
Speed-min-1 (rpm) : 400 Control rack travel in mm :-
Control rack travel in mm : 6.6-6.8 Delivery quantity(x ) :-
in cm³/500 strokes
Speed-min-1 (rpm) : 100
Control rack travel in mm : Minimum 19.0 10.STARTING FUEL DELIVERY
Speed-min-1 (rpm) : 100
Speed-min-1 (rpm) : 400
Control rack travel in mm : 15.75-16.25
Control rack travel in mm : 6.6-6.8
Delivery quantity(x ) :-
Speed-min-1 (rpm) : 480-540
in cm³/100 strokes
Control rack travel in mm : 2.0

OTHER INFORMATION

Note:

1. Sl.No.of the operations indicate the sequence of operations. 3.(x):Average of the cylinders

2. Values given in brackets are overchecking values

Applicable only for BOSCH and MICO Test benches 250211


These Test specifications should not be copied or transmitted to a third party without our written permission.All rights reserved.
REFERENCE NO Page 1 of 3

275 DI / 265 DI PP
Test Specifications
(subject to alternations)
For Field Service only
(B) ADJUSTMENT OF PUMP AND
GOVERNOR
GUIDE SLEEVE
TRAVEL
Control lever position : Free
REFERENCE NO : TSS-TS-MML F..748 Speed-min-1 (rpm) : 800
Edition : 09.2011 Control rack travel in
: 0.3-0.7
Replaces(edition) : 05.2010 mm
Test oil : 9 916 034 004 1.MAXIMUM SPEED CONTROL (RATED
Revision :3 SPEED)
: F002A0Z748- (without supplementry idling spring)
Combination No.
E040.236.200 Control lever position : 40.0±4.0°
: PES 3 A 85 D 320 RS Speed-min-1 (rpm) :-
Injection pump
2000 Boost pressure in bar :-
: RSV 400...950 A 5 C Control rack travel in
Governor :-
1605 R mm
: Mahindra & Mahindra Speed-min-1 (rpm) : 950
Customer
Ltd. Boost pressure in bar :-
: MDI 1895 N 3A (BSIII Control rack travel in
Engine model : 11.65-11.75
A) mm
Engine code :- Speed-min-1 (rpm) : 990-1000
Application : Tractor-275 DI
Boost pressure in bar :-
TEST BENCH REQUIREMENTS Control rack travel in
: 10.7
mm
Test oil inlet Speed-min-1 (rpm) : 1035-1065
: 38°-42°C
temperature Boost pressure in bar :-
Overflow valve : F002A10627
Control rack travel in
Inlet pressure in bar : 1.5 : 4.0
mm
Test injector : 0681343009
Speed-min-1 (rpm) : 1220
Opening pressure in bar : 172.0-175.0
Boost pressure in bar :-
High pressure pipe : 6X2X600
Control rack travel in
(ODXIDxlength) in mm : 0.3-1.4
mm
2.FULL LOAD
(A) CALIBRATION OF PUMP WITHOUT DELIVERY
GOVERNOR ACTION
Speed-min-1 (rpm) : 950
Boost pressure in bar :-
Direction of rotation : Clockwise Control rack travel in
Prestroke in mm : 3.45-3.55(3.4-3.6) : 11.65-11.75
mm
Control rack position in : 28.75-29.25(27.75-
: 9.0-12.0 Delivery quantity(x )
mm 30.25)
Cam sequence : 1- 3 - 2 in cm³/500 strokes
Cam displacement : 0-120-240° ±0.5° Maximum spread in cm³ : 1.5(3.5)
Tappet clearance in mm : min 0.2
3.TORQUE

m orary t ...
REFERENCE NO Page 2 of 3

Injection Timing CONTROL


:-
locking Speed-min-1 (rpm) :-
BASIC SETTING Boost pressure in bar :-
Control rack travel in
:-
Speed-min-1 (rpm) : 950 mm
Control rack travel in Speed-min-1 (rpm) :-
: 11.65-11.75
mm Boost pressure in bar :-
Delivery quantity(x ) : 5.65-5.95 Control rack travel in
:-
in cm³/100 strokes mm
Maximum spread in cm³ : 0.3(0.7) Speed-min-1 (rpm) : 500
Boost pressure in bar :-
Control rack travel in
: 11.85-12.05
Speed-min-1 (rpm) : 400 mm
Control rack travel in Speed-min-1 (rpm) : 700
: 7.2-7.4 Boost pressure in bar :-
mm
Delivery quantity(x ) : 0.65-1.05(0.45-1.25) Control rack travel in
: 11.85-12.05
in cm/100 strokes mm
Maximum spread in cm³ : 0.5(0.7) Speed-min-1 (rpm) :-
Boost pressure in bar :-
Control rack travel in
:-
mm
Speed-min-1 (rpm) : 950
Boost pressure in bar :-
Control rack travel in
: 11.65-11.75
mm
Contd...2

TSS-TS-MML F..748
6.MAXIMUM SPEED CONTROL (RATED
4. COURSE OF SPEED)
DELIVERY (with supplementary idling spring)
Speed-min-1 (rpm) : 500
Boost pressure in bar :- Speed-min-1 (rpm) :-
: 20.25-21.75(19.25- Control rack travel in
Delivery quantity(x ) :-
22.75) mm
in cm³/500 strokes
Maximum spread in cm³ : 2.0(4.0) 7. GOVERNOR CUTTING IN SPEED
Speed-min-1 (rpm) : 700 Speed-min-1 (rpm) : 990-1000
Boost pressure in bar :- Boost pressure in bar :-
Delivery quantity(x ) : 24.0-25.5(23.0-26.5) Control rack travel in
: 10.7
in cm³/500 strokes mm
Maximum spread in cm³ : 2.0(4.0)
Speed-min-1 (rpm) :- While over checking ,if the cutting speed is above
Boost pressure in bar :- the rated speed and if,
-the delivery values are within the overchecking
Delivery quantity(x ) :-
tolerance
in cm³/500 strokes -control rack remains at full load position even at
Maximum spread in cm³ :- 50 min

file://C:\Documents and Settings\smn7ban\Local Settings\Temporary Internet Files\OLK... 12/28/2011


REFERENCE NO Page 3 of 3

Speed-min-1 (rpm) :- (rpm) less than the rated speed


Control rack travel in the cutting-in speed should be declared OK.
:-
mm 8. DEGREE OF IRREGULARY
Delivery quantity(x ) :- Speed-min-1 (rpm) : 1055-1085
in cm³/500 strokes Boost pressure in bar :-
Maximum spread in cm³ : - Control rack travel in
: 4.0
5. IDLING SPEED CONTROL (RATED mm
SPEED) No of notches : 12.0
Control lever position : 20.0±4.0° 9. STARTING
Speed-min-1 (rpm) : 400 TRAVEL
Control rack travel in Speed-min-1 (rpm) :-
: 7.2-7.4
mm Control rack travel in
:-
Speed-min-1 (rpm) : 100 mm
Control rack travel in Delivery quantity(x ) :-
: Minimum 19.0 in cm³/500 strokes
mm
Speed-min-1 (rpm) : 400 10.STARTING FUEL DELIVERY
Control rack travel in
: 7.2-7.4 Speed-min-1 (rpm) : 100
mm Control rack travel in
: 16.0-16.5
Speed-min-1 (rpm) : 490-550 mm
Control rack travel in
: 2.0 Delivery quantity(x ) :-
mm in cm³/100 strokes

OTHER
INFORMATION
Element :- Adaption capsule :-
Delivery valve :-
Flyweight assembly :- Nozzle :-
Governor spring :- Opening pressure in bar : -
Note:
1. Sl.No.of the operations indicate the sequence of
3.(x):Average of the cylinders
operations.
2. Values given in brackets are overchecking
values

Applicable only for BOSCH and MICO Test benches 141010


These Test specifications should not be copied or transmitted to a third party without our
written permission.All rights reserved.

file://C:\Documents and Settings\smn7ban\Local Settings\Temporary Internet Files\OLK... 12/28/2011


REFERENCE NO

275 DI TU
Test Specifications
(subject to alternations)
For Field Service only
(B) ADJUSTMENT OF PUMP AND
GOVERNOR
GUIDE SLEEVE
TRAVEL
REFERENCE NO : TSS-TS-MM F..734 Control lever position : Free
Edition : 02.2010 Speed-min-1 (rpm) : 800
Control rack travel in
Replaces(edition) :- : 0.3-0.7
mm
Test oil : 9 916 034 004
1.MAXIMUM SPEED CONTROL (RATED
Revision :1
SPEED)
: F002A0Z734- (without supplementry idling spring)
Combination No.
EA40.227.800
Control lever position : 43.0±4.0°
: PES 3 A 85 D 320 RS
Injection pump Speed-min-1 (rpm) :-
2000
Boost pressure in bar :-
: RSV 400...1050 A 5 C
Governor Control rack travel in
1596 R :-
mm
: Mahindra & Mahindra Speed-min-1 (rpm) : 1050
Customer
Ltd.
Boost pressure in bar :-
: MDI 1895 BN 3A
Engine model Control rack travel in
(BSIII A) : 10.65-10.75
Engine code :- mm
Application : Tractor -275 DI TU Speed-min-1 (rpm) : 1090-1100
TEST BENCH REQUIREMENTS Boost pressure in bar :-
Control rack travel in
: 9.7
mm
Test oil inlet
: 38°-42°C Speed-min-1 (rpm) : 1125-1155
temperature
Overflow valve : F002A10627 Boost pressure in bar :-
Inlet pressure in bar : 1.5 Control rack travel in
: 4.0
Test injector : 0681343009 mm
Opening pressure in bar : 172.0-175.0 Speed-min-1 (rpm) : 1310
High pressure pipe : 6X2X600 Boost pressure in bar :-
(ODXIDxlength) in mm Control rack travel in
: 0.3-1.4
mm
REFERENCE NO

2.FULL LOAD
(A) CALIBRATION OF PUMP WITHOUT DELIVERY
GOVERNOR ACTION Speed-min-1 (rpm) : 1050
Boost pressure in bar :-
Control rack travel in
Direction of rotation : Clockwise : 10.65-10.75
mm
Prestroke in mm : 3.15-3.25(3.1-3.3)
: 31.25-31.75(30.25-
Control rack position in Delivery quantity(x )
: 18.0-21.0 32.75)
mm
in cm³/500 strokes
Cam sequence : 1- 3- 2
Maximum spread in cm³ : 1.5(3.5)
Cam displacement : 0-120-240° ±0.5°
3.TORQUE
Tappet clearance in mm : min 0.2
CONTROL
Injection Timing
:- Speed-min-1 (rpm) :-
locking
Boost pressure in bar :-
BASIC SETTING
Control rack travel in
:-
mm
Speed-min-1 (rpm) : 1050 Speed-min-1 (rpm) :-
Control rack travel in Boost pressure in bar :-
: 10.65-10.75
mm Control rack travel in
Delivery quantity(x ) : 6.15-6.45 :-
mm
in cm³/100 strokes Speed-min-1 (rpm) : 500
Maximum spread in cm³ : 0.3(0.7) Boost pressure in bar :-
Control rack travel in
: 11.4-11.6
mm
Speed-min-1 (rpm) : 400 Speed-min-1 (rpm) : 700
Control rack travel in Boost pressure in bar :-
: 7.2-7.4
mm Control rack travel in
: 11.4-11.6
Delivery quantity(x ) : 0.8-1.2(0.6-1.4) mm
in cm/100 strokes Speed-min-1 (rpm) :-
Maximum spread in cm³ : 0.5(0.7) Boost pressure in bar :-
Control rack travel in
:-
mm
Speed-min-1 (rpm) : 1050
Boost pressure in bar :-
Control rack travel in
: 10.65-10.75
mm
Contd...2

TSS-TS-MM F..734
REFERENCE NO

6.MAXIMUM SPEED CONTROL (RATED


4. COURSE OF
SPEED)
DELIVERY
(with supplementary idling spring)
Speed-min-1 (rpm) : 500
Boost pressure in bar :-
: 23.75-25.25(22.75- Speed-min-1 (rpm) :-
Delivery quantity(x ) Control rack travel in
26.25) :-
mm
in cm³/500 strokes
Maximum spread in cm³ : 2.0(4.0)
7. GOVERNOR CUTTING IN SPEED
Speed-min-1 (rpm) : 700
Boost pressure in bar :- Speed-min-1 (rpm) : 1090-1100
: 27.75-29.25(26.75- Boost pressure in bar :-
Delivery quantity(x ) Control rack travel in
30.25) : 9.7
in cm³/500 strokes mm
Maximum spread in cm³ : 2.0(4.0)
While over checking ,if the cutting speed is above
Speed-min-1 (rpm) :-
the rated speed and if,
Boost pressure in bar :- -the delivery values are within the overchecking
Delivery quantity(x ) :- tolerance
in cm³/500 strokes -control rack remains at full load position even at
Maximum spread in cm³ : - 50 min
Speed-min-1 (rpm) :- (rpm) less than the rated speed
Control rack travel in the cutting-in speed should be declared OK.
:-
mm 8. DEGREE OF IRREGULARY
Delivery quantity(x ) :- Speed-min-1 (rpm) : 1140-1170
in cm³/500 strokes Boost pressure in bar :-
Maximum spread in cm³ : - Control rack travel in
: 4.0
5. IDLING SPEED CONTROL (RATED mm
SPEED) No of notches : 12.0
Control lever position : 19.0±4.0° 9. STARTING
Speed-min-1 (rpm) : 400 TRAVEL
Control rack travel in Speed-min-1 (rpm) :-
: 7.2-7.4
mm Control rack travel in
:-
Speed-min-1 (rpm) : 100 mm
Control rack travel in Delivery quantity(x ) :-
: Minimum 19.0
mm in cm³/500 strokes
Speed-min-1 (rpm) : 400
Control rack travel in
: 7.2-7.4
mm
Speed-min-1 (rpm) : 490-550
REFERENCE NO

Control rack travel in 10.STARTING FUEL DELIVERY


: 2.0
mm Speed-min-1 (rpm) : 100
Control rack travel in
: 16.0-16.5
mm
Delivery quantity(x ) :-
in cm³/100 strokes

OTHER
INFORMATION
Element :- Adaption capsule :-
Delivery valve :-
Flyweight assembly :- Nozzle :-
Governor spring :- Opening pressure in bar : -
Note:
1. Sl.No.of the operations indicate the sequence of
3.(x):Average of the cylinders
operations.
2. Values given in brackets are overchecking
values

Applicable only for BOSCH and MICO Test benches 300909


These Test specifications should not be copied or transmitted to a
third party without our written permission.All rights reserved.
REFERENCE NO Page 1 of 3

295,395 & 405 DI TC


Test Specifications
(subject to alternations)
For Field Service only
(B) ADJUSTMENT OF PUMP AND
GOVERNOR
GUIDE SLEEVE
TRAVEL
Control lever position : Free
REFERENCE NO : TSS-TS-MM F..735
Speed-min-1 (rpm) : 800
Edition : 03.2011 Control rack travel in
Replaces(edition) : 02.2010 : 0.3-0.7
mm
Test oil : 9 916 034 004 1.MAXIMUM SPEED CONTROL (RATED
Revision :3 SPEED)
: F002A0Z735- (without supplementry idling spring)
Combination No.
E040.238.300 Control lever position : 40.0±4.0°
: PES 3 A 85 D 320 RS
Injection pump Speed-min-1 (rpm) :-
2000
Boost pressure in bar :-
: RSV 400...950 A 5 C
Governor Control rack travel in
1597 R :-
mm
: Mahindra & Mahindra
Customer Speed-min-1 (rpm) : 950
Ltd.
: MDI 2050 N 3A (BSIII Boost pressure in bar :-
Engine model Control rack travel in
A) : 12.35-12.45
Engine code :- mm
Application : Tractor-275 DI TC Speed-min-1 (rpm) : 990-1000
TEST BENCH REQUIREMENTS Boost pressure in bar :-
Control rack travel in
: 11.4
Test oil inlet mm
: 38°-42°C Speed-min-1 (rpm) : 1040-1070
temperature
Overflow valve : F002A10627 Boost pressure in bar :-
Inlet pressure in bar : 1.5 Control rack travel in
: 4.0
Test injector : 0681343009 mm
Opening pressure in bar : 172.0-175.0 Speed-min-1 (rpm) : 1220
High pressure pipe : 6X2X600 Boost pressure in bar :-
(ODXIDxlength) in mm Control rack travel in
: 0.3-1.4
mm
(A) CALIBRATION OF PUMP WITHOUT 2.FULL LOAD
GOVERNOR ACTION DELIVERY
Speed-min-1 (rpm) : 950
Direction of rotation : Clockwise Boost pressure in bar :-
Prestroke in mm : 3.45-3.55(3.4-3.6) Control rack travel in
: 12.35-12.45
Control rack position in mm
: 9.0-12.0 Delivery quantity(x ) : 28.0-28.5(27.0-29.5)
mm
Cam sequence : 1- 3 - 2 in cm³/500 strokes
Cam displacement : 0-120-240° ±0.5° Maximum spread in cm³ : 1.5(3.5)
Tappet clearance in mm : min 0.2 3.TORQUE
CONTROL
Injection Timing

file://C:\Documents and Settings\smn7ban\Local Settings\Temporary Internet Files\OLK... 12/28/2011


REFERENCE NO Page 2 of 3

locking :- Speed-min-1 (rpm) :-


BASIC SETTING Boost pressure in bar :-
Control rack travel in
:-
Speed-min-1 (rpm) : 950 mm
Control rack travel in Speed-min-1 (rpm) :-
: 12.35-12.45 Boost pressure in bar :-
mm
Delivery quantity(x ) : 5.5-5.8 Control rack travel in
:-
in cm³/100 strokes mm
Maximum spread in cm³ : 0.3(0.7) Speed-min-1 (rpm) : 500
Boost pressure in bar :-
Control rack travel in
: 13.2-13.4
Speed-min-1 (rpm) : 400 mm
Control rack travel in Speed-min-1 (rpm) : 700
: 7.8-8.0 Boost pressure in bar :-
mm
Delivery quantity(x ) : 0.75-1.15(0.55-1.35) Control rack travel in
: 13.2-13.4
in cm/100 strokes mm
Maximum spread in cm³ : 0.5(0.7) Speed-min-1 (rpm) :-
Boost pressure in bar :-
Control rack travel in
:-
mm
Speed-min-1 (rpm) : 950
Boost pressure in bar :-
Control rack travel in
: 12.35-12.45
mm
Contd...2

TSS-TS-MM F..735
6.MAXIMUM SPEED CONTROL (RATED
4. COURSE OF SPEED)
DELIVERY (with supplementary idling spring)
Speed-min-1 (rpm) : 500
Boost pressure in bar :- Speed-min-1 (rpm) :-
Delivery quantity(x ) : 24.5-26.0(23.5-27.0) Control rack travel in
:-
in cm³/500 strokes mm
Maximum spread in cm³ : 2.0(4.0)
Speed-min-1 (rpm) : 700 7. GOVERNOR CUTTING IN SPEED
Boost pressure in bar :- Speed-min-1 (rpm) : 990-1000
: 28.25-29.75(27.25- Boost pressure in bar :-
Delivery quantity(x ) Control rack travel in
30.75) : 11.4
in cm³/500 strokes mm
Maximum spread in cm³ : 2.0(4.0)
Speed-min-1 (rpm) :- While over checking ,if the cutting speed is above
Boost pressure in bar :- the rated speed and if,
-the delivery values are within the overchecking
Delivery quantity(x ) :-
tolerance
in cm³/500 strokes -control rack remains at full load position even at
Maximum spread in cm³ :- 50 min
Speed-min-1 (rpm) :- (rpm) less than the rated speed

g s\ p y t Files\OLK...
REFERENCE NO Page 3 of 3

Control rack travel in the cutting-in speed should be declared OK.


:-
mm 8. DEGREE OF IRREGULARY
Delivery quantity(x ) :- Speed-min-1 (rpm) : 1060-1090
in cm³/500 strokes Boost pressure in bar :-
Maximum spread in cm³ : - Control rack travel in
: 4.0
5. IDLING SPEED CONTROL (RATED mm
SPEED) No of notches : 12.0
Control lever position : 19.0±4.0° 9. STARTING
Speed-min-1 (rpm) : 400 TRAVEL
Control rack travel in
: 7.8-8.0 Speed-min-1 (rpm) :-
mm Control rack travel in
:-
Speed-min-1 (rpm) : 100 mm
Control rack travel in Delivery quantity(x ) :-
: Minimum 19.0
mm in cm³/500 strokes
Speed-min-1 (rpm) : 400 10.STARTING FUEL DELIVERY
Control rack travel in Speed-min-1 (rpm) : 100
: 7.8-8.0
mm Control rack travel in
Speed-min-1 (rpm) : 500-560 : 16.0-16.5
mm
Control rack travel in Delivery quantity(x ) :-
: 2.0
mm in cm³/100 strokes

OTHER
INFORMATION
Element :- Adaption capsule :-
Delivery valve :-
Flyweight assembly :- Nozzle :-
Governor spring :- Opening pressure in bar : -
Note:
1. Sl.No.of the operations indicate the sequence of
3.(x):Average of the cylinders
operations.
2. Values given in brackets are overchecking
values

Applicable only for BOSCH and MICO Test benches 010311


These Test specifications should not be copied or transmitted to a third party without our
written permission.All rights reserved.

...
415 DI
Test Specifications
(subject to alternations)
For Field Service only
: TSS-TS-MML- (B) ADJUSTMENT OF PUMP AND
REFERENCE NO
F..A2ZA09 GOVERNOR
Edition : 11.2015 GUIDE SLEEVE
Replaces(edition) :- TRAVEL
Test oil : 9 916 034 004 Control lever position : Free
Revision :4 Speed-min-1 (rpm) : 800
Combination No. : F002A2ZA09 Control rack travel in
: 0.3-0.7
mm
: PES 4 A 85 D 320 1.MAXIMUM SPEED CONTROL
Injection pump
RS 2000 (RATED SPEED)
: RSV 400...950 A 5 (without supplementry idling spring)
Governor
C 1592 R
Customer : MAHINDRA Control lever position : 45.0±4.0°
Engine model : 415DI TREM IIIA Speed-min-1 (rpm) : 500
Engine code : Boost pressure in bar : -
Application : TRACTOR Control rack travel in
TEST BENCH REQUIREMENTS : 11.0-11.2
mm
Speed-min-1 (rpm) : 950
Test oil inlet Boost pressure in bar : -
: 38°-42°C
temperature Control rack travel in
Overflow valve : F002A10627 : 9.95-10.05
mm
Inlet pressure in bar : 1.5 Speed-min-1 (rpm) : 990-1000
Test injector : 0681343009 Boost pressure in bar : -
Opening pressure in
: 172.0-175.0 Control rack travel in
bar : 9.0
mm
High pressure pipe : 6X2X600
Speed-min-1 (rpm) : 1035-1065
(ODXIDxlength) in
mm Boost pressure in bar : -
Control rack travel in
: 4.0
mm
(A) CALIBRATION OF PUMP
Speed-min-1 (rpm) : 1200
WITHOUT GOVERNOR ACTION
Boost pressure in bar : -
Control rack travel in
Direction of rotation : Clockwise : 0.3-1.4
mm
Prestroke in mm : 3.65-3.75(3.6-3.8)
2.FULL LOAD
Control rack position
: 9.0-12.0 DELIVERY
in mm
Speed-min-1 (rpm) : 950
Cam sequence : 1-3-4-2
: 0-90-180-270° Boost pressure in bar : -
Cam displacement Control rack travel in
±0.5° : 9.95-10.05
Tappet clearance in mm
: min 0.2 Delivery quantity(x ) : 25.0-25.5(24.0-26.5)
mm
Injection Timing in cm³/500 strokes
:- Maximum spread in
locking : 1.5(3.5)
BASIC SETTING cm³
3.TORQUE
-1
Speed-min (rpm) : 950 CONTROL
Control rack travel in Speed-min-1 (rpm) : 500
: 9.95-10.05 Boost pressure in bar :-
mm
Delivery quantity(x ) : 4.9-5.2 Control rack travel in
: 11.0-11.2
in cm³/100 strokes mm
Maximum spread in Speed-min-1 (rpm) : 700
: 0.3(0.7) Boost pressure in bar :-
cm³
Control rack travel in
:11.0-11.2
mm
Speed-min-1 (rpm) : 400 Speed-min-1 (rpm) : 500
Control rack travel in Boost pressure in bar :-
: 6.9-7.1 Control rack travel in
mm : 11.0-11.2
Delivery quantity(x ) : 0.7-1.1(0.5-1.3) mm
in cm/100 strokes Speed-min-1 (rpm) : 700
Maximum spread in Boost pressure in bar :-
: 0.5(0.7) Control rack travel in
cm³ : 11.0-11.2
mm
Speed-min-1 (rpm) :-
Boost pressure in bar :-
Control rack travel in
:-
mm
Speed-min-1 (rpm) : 950
Boost pressure in bar :-
Control rack travel in
: 9.95-10.05
mm

Contd...2

TSS-TS-MML-F..A2ZA09
4. COURSE OF
DELIVERY 6.MAXIMUM SPEED CONTROL
Speed-min-1 (rpm) : 500 (RATED SPEED)
(with supplementary idling spring)
Boost pressure in bar : -
Delivery quantity(x ) : 21.5-23.0(20.5-24.0)
Speed-min-1 (rpm) : -
in cm³/500 strokes
Control rack travel in
Maximum spread in :-
: 2.0(4.0) mm
cm³
Speed-min-1 (rpm) : 700
Boost pressure in bar : - 7. GOVERNOR CUTTING IN SPEED
: 25.25-26.75(24.25- Speed-min-1 (rpm) : 990-1000
Delivery quantity(x ) Boost pressure in bar : -
27.75)
in cm³/500 strokes Control rack travel in
: 9.0
Maximum spread in mm
: 2.0(4.0)
cm³
Speed-min-1 (rpm) : 800 While over checking ,if the cutting speed is
Boost pressure in bar : - above the rated speed and if,
-the delivery values are within the
Delivery quantity(x ) : -
overchecking tolerance
in cm³/500 strokes
Maximum spread in -control rack remains at full load position
:-
cm³ even at 50 min
Speed-min-1 (rpm) :- (rpm) less than the rated speed
Control rack travel in the cutting-in speed should be declared OK.
:-
mm 8. DEGREE OF IRREGULARY
Delivery quantity(x ) :- Speed-min-1 (rpm) : 1045-1075
in cm³/500 strokes Boost pressure in bar : -
Maximum spread in Control rack travel in
:- : 4.0
cm³ mm
No of notches : 16.0
5. IDLING SPEED CONTROL (RATED 9. STARTING
SPEED) TRAVEL
Control lever position : 23.0±4.0° Speed-min-1 (rpm) : -
Speed-min-1 (rpm) : 400 Control rack travel in
:-
Control rack travel in mm
: 6.9-7.1
mm Delivery quantity(x ) : -
-1
Speed-min (rpm) : 100 in cm³/500 strokes
Control rack travel in 10.STARTING FUEL DELIVERY
: Minimum 19.0
mm Speed-min-1 (rpm) : 100
-1
Speed-min (rpm) : 400 Control rack travel in
: 16.0-16.5
Control rack travel in mm
: 6.9-7.1
mm Delivery quantity(x ) : -
Speed-min-1 (rpm) : 495-555 in cm³/100 strokes
Control rack travel in
: 2.0
mm

OTHER
INFORMATION
Element : Adaption capsule :
Delivery valve :
Flyweight assembly : Nozzle :
Opening pressure in
Governor spring : :
bar
Note:
1. Sl.No.of the operations indicate the
3.(x):Average of the cylinders
sequence of operations.
2. Values given in brackets are overchecking
values

Applicable only for BOSCH and MICO Test benches 091115


These Test specifications should not be copied or transmitted to a third party without
our written permission.All rights reserved.
Test Specifications
475 DI (subject to alternations)
For Field Service only

REFERENCE NO : TSS-TS-MML F..728 (B) ADJUSTMENT OF PUMP AND GOVERNOR


Edition : 10.2010 GUIDE SLEEVE TRAVEL
Replaces(edition) : 06.2010 Control lever position : Free
Test oil : F 002 S3E 001 Speed-min-1 (rpm) : 800
Revision :5 Control rack travel in mm : 0.3-0.7
1.MAXIMUM SPEED CONTROL (RATED SPEED)
Combination No. : F 002 A0Z 728-E040.229.200
(without supplementry idling spring)

Injection pump : PES 4 A 85 D 320 RS 2000 Control lever position : 45.0±4.0°


Speed-min-1 (rpm) :-
Governor : RSV 400...950 A 5 C 1592 R Boost pressure in bar :-
Control rack travel in mm :-
Customer : Mahindra & Mahindra Ltd.
Speed-min-1 (rpm) : 950
Engine model : MDI 2385 N 3A
Boost pressure in bar :-
Engine code :-
Control rack travel in mm : 10.35-10.45
Application : TRACTOR-475DI
TEST BENCH REQUIREMENTS Speed-min-1 (rpm) : 990-1000
Boost pressure in bar :-

Test oil inlet temperature : 38°-42°C Control rack travel in mm : 9.4


Overflow valve : F002A10627 Speed-min-1 (rpm) : 1040-1070
Inlet pressure in bar : 1.5 Boost pressure in bar :-
Test injector : 0681343009 Control rack travel in mm : 4.0
Opening pressure in bar : 172.0-175.0 Speed-min-1 (rpm) : 1225
High pressure pipe : 6X2X600 Boost pressure in bar :-
(ODXIDxlength) in mm
Control rack travel in mm : 0.3-1.4
2.FULL LOAD DELIVERY
(A) CALIBRATION OF PUMP WITHOUT GOVERNOR ACTION
Speed-min-1 (rpm) : 950
Boost pressure in bar :-
Direction of rotation : Clockwise Control rack travel in mm : 10.35-10.45
Prestroke in mm : 3.65-3.75(3.6-3.8) Delivery quantity(x ) : 27.0-27.5(26.0-28.5)
Control rack position in mm : 9.0-12.0 in cm³/500 strokes
Cam sequence : 1-3-4-2 Maximum spread in cm³ : 1.5(3.5)
Cam displacement : 0-90-180-270° ±0.5° 3.TORQUE CONTROL
Tappet clearance in mm : min 0.2 Speed-min-1 (rpm) :-
Injection Timing locking :- Boost pressure in bar :-
BASIC SETTING Control rack travel in mm :-
Speed-min-1 (rpm) :-
Speed-min-1 (rpm) : 950 Boost pressure in bar :-
Control rack travel in mm : 10.35-10.45 Control rack travel in mm :-
Delivery quantity(x ) : 5.3-5.6 Speed-min-1 (rpm) : 500
in cm³/100 strokes Boost pressure in bar :-
Maximum spread in cm³ : 0.3(0.7) Control rack travel in mm : 11.4-11.6
Speed-min-1 (rpm) : 700
Boost pressure in bar :-
Speed-min-1 (rpm) : 400 Control rack travel in mm : 11.4-11.6
Control rack travel in mm : 6.9-7.1 Speed-min-1 (rpm) :-
Delivery quantity(x ) : 0.7-1.1(0.5-1.3) Boost pressure in bar :-
in cm/100 strokes Control rack travel in mm :-
Maximum spread in cm³ : 0.5(0.7) Speed-min-1 (rpm) : 950
Boost pressure in bar :-
Control rack travel in mm : 10.35-10.45
Contd...2
TSS-TS-MML F..728
4. COURSE OF DELIVERY 6.MAXIMUM SPEED CONTROL (RATED SPEED)
Speed-min-1 (rpm) : 500 (with supplementary idling spring)
Boost pressure in bar :-
Delivery quantity(x ) : 22.25-23.75(21.25-24.75) Speed-min-1 (rpm) :-
in cm³/500 strokes Control rack travel in mm :-
Maximum spread in cm³ : 2.0(4.0)
Speed-min-1 (rpm) : 700 7. GOVERNOR CUTTING IN SPEED
Boost pressure in bar :- Speed-min-1 (rpm) : 990-1000
Delivery quantity(x ) : 26.75-28.25(25.75-29.25) Boost pressure in bar :-
in cm³/500 strokes Control rack travel in mm : 9.4
Maximum spread in cm³ : 2.0(4.0)
Speed-min-1 (rpm) :- While over checking ,if the cutting speed is above the rated speed and if,
Boost pressure in bar :- -the delivery values are within the overchecking tolerance
Delivery quantity(x ) :- -control rack remains at full load position even at 50 min
in cm³/500 strokes (rpm) less than the rated speed
Maximum spread in cm³ :- the cutting-in speed should be declared OK.
Speed-min-1 (rpm) :- 8. DEGREE OF IRREGULARY
Control rack travel in mm :- Speed-min-1 (rpm) : 1055-1085
Delivery quantity(x ) :- Boost pressure in bar :-
in cm³/500 strokes Control rack travel in mm : 4.0
Maximum spread in cm³ :- No of notches : 16.0
5. IDLING SPEED CONTROL (RATED SPEED) 9. STARTING TRAVEL
Control lever position : 23.0±4.0° Speed-min-1 (rpm) :-
Speed-min-1 (rpm) : 400 Control rack travel in mm :-
Control rack travel in mm : 6.9-7.1 Delivery quantity(x ) :-
in cm³/500 strokes
Speed-min-1 (rpm) : 100
Control rack travel in mm : Minimum 19.0 10.STARTING FUEL DELIVERY
Speed-min-1 (rpm) : 100
Speed-min-1 (rpm) : 400
Control rack travel in mm : 16.0-16.5
Control rack travel in mm : 6.9-7.1
Delivery quantity(x ) :-
Speed-min-1 (rpm) : 490-550
in cm³/100 strokes
Control rack travel in mm : 2.0

OTHER INFORMATION

Note:

1. Sl.No.of the operations indicate the sequence of operations. 3.(x):Average of the cylinders

2. Values given in brackets are overchecking values

Applicable only for BOSCH and MICO Test benches 041010


These Test specifications should not be copied or transmitted to a third party without our written permission.All rights reserved.
Test Specifications
575 DI (subject to alternations)
For Field Service only

REFERENCE NO : TSS-TS-MML F..729 (B) ADJUSTMENT OF PUMP AND GOVERNOR


Edition : 09.2010 GUIDE SLEEVE TRAVEL
Replaces(edition) : 08.2010 Control lever position : Free
Test oil : F 002 S3E 001 Speed-min-1 (rpm) : 800
Revision :8 Control rack travel in mm : 0.3-0.7
1.MAXIMUM SPEED CONTROL (RATED SPEED)
Combination No. : F 002 A0Z 729-EA40.215.700
(without supplementry idling spring)

Injection pump : PES 4 A 85 D 320 RS 2000 Control lever position : 43.0±4.0°


Speed-min-1 (rpm) :-
Governor : RSV 400...950 A 5 C 1591 R Boost pressure in bar :-
Control rack travel in mm :-
Customer : Mahindra & Mahindra Ltd.
Speed-min-1 (rpm) : 950
Engine model : MDI 2500 N 3A
Boost pressure in bar :-
Engine code :
Control rack travel in mm : 9.95-10.05
Application : Tractor-575 DI
TEST BENCH REQUIREMENTS Speed-min-1 (rpm) : 990-1000
Boost pressure in bar :-

Test oil inlet temperature : 38°-42°C Control rack travel in mm : 9.0


Overflow valve : F002A10627 Speed-min-1 (rpm) : 1035-1065
Inlet pressure in bar : 1.5 Boost pressure in bar :-
Test injector : 0681343009 Control rack travel in mm : 4.0
Opening pressure in bar : 172.0-175.0 Speed-min-1 (rpm) : 1225
High pressure pipe : 6X2X600 Boost pressure in bar :-
(ODXIDxlength) in mm
Control rack travel in mm : 0.3-1.4
2.FULL LOAD DELIVERY
(A) CALIBRATION OF PUMP WITHOUT GOVERNOR ACTION
Speed-min-1 (rpm) : 950
Boost pressure in bar :-
Direction of rotation : Clockwise Control rack travel in mm : 9.95-10.05
Prestroke in mm : 3.65-3.75(3.6-3.8) Delivery quantity(x ) : 28.85-29.15(27.75-30.25)
Control rack position in mm : 18.0-21.0 in cm³/500 strokes
Cam sequence : 1-3-4-2 Maximum spread in cm³ : 1.5(3.5)
Cam displacement : 0-90-180-270° ±0.5° 3.TORQUE CONTROL
Tappet clearance in mm : min 0.2 Speed-min-1 (rpm) :-
Injection Timing locking :- Boost pressure in bar :-
BASIC SETTING Control rack travel in mm :-
Speed-min-1 (rpm) :-
Speed-min-1 (rpm) : 950 Boost pressure in bar :-
Control rack travel in mm : 9.95-10.05 Control rack travel in mm :-
Delivery quantity(x ) : 5.65-5.95 Speed-min-1 (rpm) : 500
in cm³/100 strokes Boost pressure in bar :-
Maximum spread in cm³ : 0.3(0.7) Control rack travel in mm : 10.8-11.0
Speed-min-1 (rpm) : 700
Boost pressure in bar :-
Speed-min-1 (rpm) : 400 Control rack travel in mm : 10.8-11.0
Control rack travel in mm : 6.7-6.9 Speed-min-1 (rpm) :-
Delivery quantity(x ) : 0.75-1.15(0.55-1.35) Boost pressure in bar :-
in cm/100 strokes Control rack travel in mm :-
Maximum spread in cm³ : 0.5(0.7) Speed-min-1 (rpm) : 950
Boost pressure in bar :-
Control rack travel in mm : 9.95-10.05
Contd...2
TSS-TS-MML F..729
4. COURSE OF DELIVERY 6.MAXIMUM SPEED CONTROL (RATED SPEED)
Speed-min-1 (rpm) : 500 (with supplementary idling spring)
Boost pressure in bar :-
Delivery quantity(x ) : 25.5-27.0(24.5-28.0) Speed-min-1 (rpm) :-
in cm³/500 strokes Control rack travel in mm :-
Maximum spread in cm³ : 2.0(4.0)
Speed-min-1 (rpm) : 700 7. GOVERNOR CUTTING IN SPEED
Boost pressure in bar :- Speed-min-1 (rpm) : 990-1000
Delivery quantity(x ) : 29.5-31.0(28.5-32.0) Boost pressure in bar :-
in cm³/500 strokes Control rack travel in mm : 9.0
Maximum spread in cm³ : 2.0(4.0)
Speed-min-1 (rpm) :- While over checking ,if the cutting speed is above the rated speed and if,
Boost pressure in bar :- -the delivery values are within the overchecking tolerance
Delivery quantity(x ) :- -control rack remains at full load position even at 50 min
in cm³/500 strokes (rpm) less than the rated speed
Maximum spread in cm³ :- the cutting-in speed should be declared OK.
Speed-min-1 (rpm) :- 8. DEGREE OF IRREGULARY
Control rack travel in mm :- Speed-min-1 (rpm) : 1050-1080
Delivery quantity(x ) :- Boost pressure in bar :-
in cm³/500 strokes Control rack travel in mm : 4.0
Maximum spread in cm³ :- No of notches : 16.0
5. IDLING SPEED CONTROL (RATED SPEED) 9. STARTING TRAVEL
Control lever position : 23.0±4.0° Speed-min-1 (rpm) :-
Speed-min-1 (rpm) : 400 Control rack travel in mm :-
Control rack travel in mm : 6.7-6.9 Delivery quantity(x ) :-
in cm³/500 strokes
Speed-min-1 (rpm) : 100
Control rack travel in mm : Minimum 19.0 10.STARTING FUEL DELIVERY
Speed-min-1 (rpm) : 100
Speed-min-1 (rpm) : 400
Control rack travel in mm : 16.0-16.5
Control rack travel in mm : 6.7-6.9
Delivery quantity(x ) :-
Speed-min-1 (rpm) : 490-550
in cm³/100 strokes
Control rack travel in mm : 2.0

OTHER INFORMATION

Note:

1. Sl.No.of the operations indicate the sequence of operations. 3.(x):Average of the cylinders

2. Values given in brackets are overchecking values

Applicable only for BOSCH and MICO Test benches 020910


These Test specifications should not be copied or transmitted to a third party without our written permission.All rights reserved.
REFERENCE NO Page 1 of 3

585 PP
Test Specifications
(subject to alternations)
For Field Service only
(B) ADJUSTMENT OF PUMP AND
GOVERNOR
  GUIDE SLEEVE
TRAVEL
  Control lever position  : Free
  REFERENCE NO  : Provisional   Speed-min-1  (rpm)  : 800
  Control rack travel in 
  Edition  : Provisional  : 0.3-0.7
mm
  Replaces(edition)  : -
  1.MAXIMUM SPEED CONTROL (RATED 
  Test oil  : 9 916 034 004
SPEED)
  Revision  : 5
     (without supplementry idling spring)
  Combination No.  : F002A2ZA15   Control lever position  : 49.0±4.0°
-1  : 500
 : PES 4 A 85 D 320 RS    Speed-min   (rpm)
  Injection pump   Boost pressure in bar  : -
2000
 : RSV 400...1050 A 5 C    Control rack travel in   : 11.9-12.1
  Governor mm
1841 R
  Speed-min-1  (rpm)  : 1050
  Customer  : MAHINDRA
  Engine model  : MDI3050ENA3A   Boost pressure in bar  : -
  Engine code  : -   Control rack travel in 
 : 10.95-11.05
mm
  Application  : 585DI
  Speed-min-1  (rpm)  : 1085-1095
  TEST BENCH REQUIREMENTS
  Boost pressure in bar  : -
  Control rack travel in 
  Test oil inlet   : 10.0
 : 38°-42°C mm
temperature
  Overflow valve  : F002A10627   Speed-min-1  (rpm)  : 1130-1160
  Inlet pressure in bar  : 1.5   Boost pressure in bar  : -
  Test injector  : 0681343009   Control rack travel in 
 : 4.0
  Opening pressure in bar  : 172.0-175.0 mm
  High pressure pipe  : 6X2X600   Speed-min-1  (rpm)  : 1300
  (ODXIDxlength) in mm   Boost pressure in bar  : -
  Control rack travel in 
 : 0.3-1.4
(A) CALIBRATION OF PUMP WITHOUT mm
GOVERNOR ACTION   2.FULL LOAD
DELIVERY
  Direction of rotation  : Clockwise   Speed-min-1  (rpm)  : 1050
  Boost pressure in bar  : -
  Prestroke in mm  : 3.65-3.75(3.6-3.8)
  Control rack travel in 
  Control rack position in   : 10.95-11.05
 : 9.0-12.0 mm
mm
  Cam sequence  :  1-3-4-2   Delivery quantity(x  )  : 30.0-30.0(30.0-30.0)
  Cam displacement  :  0-90-180-270° ±0.5°   in cm³/500 strokes
  Tappet clearance in mm  : min 0.2   Maximum spread in cm³ : null
  Injection Timing    3.TORQUE
 : - CONTROL
locking

file://C:\Users\205865\AppData\Local\Microsoft\Windows\Temporary Internet Files\Con... 01/09/2016


REFERENCE NO Page 2 of 3

  BASIC SETTING   Speed-min-1  (rpm)  : 500


  Boost pressure in bar  : -
  Speed-min-1  (rpm)  : 1050   Control rack travel in 
 : 11.9-12.1
  Control rack travel in  mm
 : 10.95-11.05
mm   Speed-min-1  (rpm)  : 700
  Delivery quantity(x  )  : 5.85-6.15   Boost pressure in bar  : -
  in cm³/100 strokes   Control rack travel in 
 :11.9-12.1
  Maximum spread in cm³  : null mm
  Speed-min-1  (rpm)  : 500
  Boost pressure in bar  : -
  Speed-min-1  (rpm)  : 400   Control rack travel in 
 : 11.9-12.1
  Control rack travel in  mm
 : 7.2-7.4
mm   Speed-min-1  (rpm)  : 700
  Delivery quantity(x  )  : 0.85-0.85(0.85-0.85)   Boost pressure in bar  : -
  in cm/100 strokes   Control rack travel in 
 : 11.9-12.1
  Maximum spread in cm³  : null mm
  Speed-min-1  (rpm)  : -
  Boost pressure in bar  : -
  Control rack travel in 
 : -
mm
  Speed-min-1  (rpm)  : 1050
  Boost pressure in bar  : -
  Control rack travel in 
 : 10.95-11.05
mm
Contd...2

Provisional
  6.MAXIMUM SPEED CONTROL (RATED 
SPEED)
  4. COURSE OF        (with supplementary idling spring)
DELIVERY
  Speed-min-1  (rpm)  : 500
  Speed-min-1  (rpm)  : -
  Boost pressure in bar  : -
  Control rack travel in 
  Delivery quantity(x  )  : 25.0-25.0(25.0-25.0)  : -
mm
  in cm³/500 strokes
  Maximum spread in cm³  : null
  7. GOVERNOR CUTTING IN SPEED  
  Speed-min-1  (rpm)  : 700
  Speed-min-1  (rpm)  : 1085-1095
  Boost pressure in bar  : -
  Boost pressure in bar  : -
  Delivery quantity(x  )  : 28.0-28.0(28.0-28.0)   Control rack travel in 
  in cm³/500 strokes  : 10.0
mm
  Maximum spread in cm³  : null
  Speed-min-1  (rpm)  : 900   While over checking ,if the cutting speed is above 
  Boost pressure in bar  : - the rated speed and if,
  Delivery quantity(x  )  : -   -the delivery values are within the overchecking
  in cm³/500 strokes tolerance
  Maximum spread in cm³  : -   -control rack remains at full load position even at
50 min
  Speed-min-1  (rpm)  : -
    (rpm) less than the rated speed  

file://C:\Users\205865\AppData\Local\Microsoft\Windows\Temporary Internet Files\Con... 01/09/2016


REFERENCE NO Page 3 of 3

  Control rack travel in     the cutting-in speed should be declared OK.


 : -
mm   8. DEGREE OF IRREGULARY
  Delivery quantity(x  )  : -   Speed-min-1  (rpm)  : 1135-1165
  in cm³/500 strokes   Boost pressure in bar  : -
  Maximum spread in cm³  : -   Control rack travel in 
 : 4.0
  5. IDLING SPEED CONTROL (RATED mm
SPEED)   No of notches  : 16.0
  Control lever position  : 23.0±4.0°   9. STARTING 
  Speed-min-1  (rpm)  : 400 TRAVEL
  Control rack travel in 
 : 7.2-7.4   Speed-min-1  (rpm)  : -
mm   Control rack travel in 
 : -
  Speed-min-1  (rpm)  : 100 mm
  Control rack travel in    Delivery quantity(x  )  : -
 : Minimum 19.0
mm   in cm³/500 strokes
  Speed-min-1  (rpm)  : 400   10.STARTING FUEL DELIVERY
  Control rack travel in    Speed-min-1  (rpm)  : 100
 : 7.2-7.4
mm   Control rack travel in 
  Speed-min-1  (rpm)  : 495-555  : 16.0-16.5
mm
  Control rack travel in    Delivery quantity(x  )  : -
 : 2.0
mm   in cm³/100 strokes
 

  OTHER
  
INFORMATION
  Element  : -   Adaption capsule  : -
  Delivery valve  : -   
  Flyweight assembly  : -   Nozzle  : -
  Governor spring  : -   Opening pressure in bar  : -
  Note:
  1. Sl.No.of the operations indicate the sequence of 
  3.(x):Average of the cylinders
operations.
  2. Values given in brackets are overchecking 
-
values

  -

  Applicable only for BOSCH and MICO Test benches 140716


  These Test specifications should not be copied or transmitted to a third party without our 
written permission.All rights reserved.

file://C:\Users\205865\AppData\Local\Microsoft\Windows\Temporary Internet Files\Con... 01/09/2016


REFERENCE NO

595 DI
Test Specifications
(subject to alternations)
For Field Service only
(B) ADJUSTMENT OF PUMP AND
GOVERNOR
GUIDE SLEEVE
TRAVEL
: PROVISIONAL Control lever position : Free
REFERENCE NO
CHART Speed-min-1 (rpm) : 800
: PROVISIONAL Control rack travel in
Edition : 0.3-0.7
CHART mm
Replaces(edition) : 1.MAXIMUM SPEED CONTROL (RATED
Test oil : 9 916 034 004 SPEED)
Revision :0 (without supplementry idling spring)
Combination No. : F002A0Z874 Control lever position : 50.04.0
Speed-min-1 (rpm) :-
: PES 4 A 85 D 320 RS Boost pressure in bar :-
Injection pump
3593
Control rack travel in
: RSV 350...1050 A 1 C mm :-
Governor
1432 R Speed-min-1 (rpm) : 1050
: Mahindra & Mahindra Boost pressure in bar :-
Customer
Ltd. Control rack travel in
Engine model : MDI 3000TC 3A : 12.45-12.55
mm
Engine code : Speed-min-1 (rpm) : 1090-1100
Application : TRACTOR-595TC
Boost pressure in bar :-
TEST BENCH REQUIREMENTS Control rack travel in
: 11.5
mm
Test oil inlet Speed-min-1 (rpm) : 1115-1145
: 38-42C
temperature Boost pressure in bar :-
Overflow valve : F002A10627
Control rack travel in
Inlet pressure in bar : 1.5 : 4.0
mm
Test injector : 0681343009 Speed-min-1 (rpm) : 1300
Opening pressure in bar : 172.0-175.0
Boost pressure in bar :-
High pressure pipe : 6X2X600
Control rack travel in
(ODXIDxlength) in mm : 0.3-1.4
mm
REFERENCE NO

2.FULL LOAD
(A) CALIBRATION OF PUMP WITHOUT DELIVERY
GOVERNOR ACTION Speed-min-1 (rpm) : 1050
Boost pressure in bar :-
Control rack travel in
Direction of rotation : Clockwise : 12.45-12.55
mm
Prestroke in mm : 4.65-4.75(4.6-4.8)
: 32.75-33.25(31.75-
Control rack position in Delivery quantity(x )
: 9.0-12.0 34.25)
mm
in cm/500 strokes
Cam sequence : 1- 3- 4- 2
Maximum spread in cm : 1.5(3.5)
Cam displacement : 0-90-180-270 0.5
3.TORQUE
Tappet clearance in mm : min 0.2
CONTROL
Injection Timing
:- Speed-min-1 (rpm) :-
locking
Boost pressure in bar :-
BASIC SETTING
Control rack travel in
:-
mm
Speed-min-1 (rpm) : 1050 Speed-min-1 (rpm) :-
Control rack travel in Boost pressure in bar :-
: 12.45-12.55
mm Control rack travel in
Delivery quantity(x ) : 6.45-6.75 :-
mm
in cm/100 strokes Speed-min-1 (rpm) : 500
Maximum spread in cm : 0.3(0.7) Boost pressure in bar :-
Control rack travel in
: 14.7-14.9
mm
Speed-min-1 (rpm) : 375 Speed-min-1 (rpm) : 650
Control rack travel in Boost pressure in bar :-
: 9.1-9.3
mm Control rack travel in
: 13.7-13.9
Delivery quantity(x ) : 0.75-1.15(0.55-1.35) mm
in cm/100 strokes Speed-min-1 (rpm) :-
Maximum spread in cm : 0.5(0.7) Boost pressure in bar :-
Control rack travel in
:-
mm
Speed-min-1 (rpm) : 1050
Boost pressure in bar :-
Control rack travel in
: 12.45-12.55
mm
Contd...2

PROVISIONAL CHART
REFERENCE NO

6.MAXIMUM SPEED CONTROL (RATED


4. COURSE OF SPEED)
DELIVERY (with supplementary idling spring)
Speed-min-1 (rpm) :-
Boost pressure in bar :- Speed-min-1 (rpm) :-
Delivery quantity(x ) :- Control rack travel in
:-
in cm/500 strokes mm
Maximum spread in cm :-
Speed-min-1 (rpm) : 650 7. GOVERNOR CUTTING IN SPEED
Boost pressure in bar :- Speed-min-1 (rpm) : 1090-1100
: 31.25-32.75(30.25- Boost pressure in bar :-
Delivery quantity(x )
33.75) Control rack travel in
in cm/500 strokes : 11.5
mm
Maximum spread in cm : 2.0(4.0)
Speed-min-1 (rpm) :- While over checking ,if the cutting speed is above
Boost pressure in bar :- the rated speed and if,
Delivery quantity(x ) :- -the delivery values are within the overchecking
tolerance
in cm/500 strokes
-control rack remains at full load position even at
Maximum spread in cm : -
50 min
Speed-min-1 (rpm) :- (rpm) less than the rated speed
Control rack travel in
:- the cutting-in speed should be declared OK.
mm
8. DEGREE OF IRREGULARY
Delivery quantity(x ) :-
in cm/500 strokes Speed-min-1 (rpm) : 1130-1160
Maximum spread in cm : - Boost pressure in bar :-
Control rack travel in
5. IDLING SPEED CONTROL (RATED : 4.0
mm
SPEED)
No of notches : 12.0
Control lever position : 21.04.0
9. STARTING
Speed-min-1 (rpm) : 375
TRAVEL
Control rack travel in
: 9.1-9.3 Speed-min-1 (rpm) :-
mm
Control rack travel in
Speed-min-1 (rpm) : 100 :-
mm
Control rack travel in Delivery quantity(x ) :-
: Minimum 19.0
mm
in cm/500 strokes
Speed-min-1 (rpm) : 375
Control rack travel in
: 9.1-9.3
mm
Speed-min-1 (rpm) : 470-530
REFERENCE NO

Control rack travel in 10.STARTING FUEL DELIVERY


: 2.0
mm Speed-min-1 (rpm) : 100
Control rack travel in
: 19.75-21.25
mm
Delivery quantity(x ) : 4.3-6.3(5.3-5.3)
in cm/100 strokes

OTHER
INFORMATION
Element :- Adaption capsule :-
Delivery valve :-
Flyweight assembly :- Nozzle :-
Governor spring :- Opening pressure in bar : -
Note:
1. Sl.No.of the operations indicate the sequence of
3.(x):Average of the cylinders
operations.
2. Values given in brackets are overchecking
values

Applicable only for BOSCH and MICO Test benches 230311


These Test specifications should not be copied or transmitted to a
third party without our written permission.All rights reserved.
ARJUN BS3A

Main Menu
REFERENCE NO

555 DI
Test Specifications
(subject to alternations)
For Field Service only
(B) ADJUSTMENT OF PUMP AND
GOVERNOR
GUIDE SLEEVE
TRAVEL
: PROVISIONAL Control lever position : Free
REFERENCE NO
CHART Speed-min-1 (rpm) : 800
: PROVISIONAL Control rack travel in
Edition : 0.3-0.7
CHART mm
Replaces(edition) : 1.MAXIMUM SPEED CONTROL (RATED
Test oil : 9 916 034 004 SPEED)
Revision :0 (without supplementry idling spring)
Combination No. : F002A0Z873 Control lever position : 55.04.0
Speed-min-1 (rpm) :-
: PES 4 A 95 D 320 RS Boost pressure in bar :-
Injection pump
2000
Control rack travel in
: RSV 400...1050 A 1 C mm :-
Governor
1673 R Speed-min-1 (rpm) : 1050
Customer : MAHINDRA Boost pressure in bar :-
Engine model : 555DI Control rack travel in
: 9.95-10.05
Engine code : mm
Application : TRACTOR Speed-min-1 (rpm) : 1090-1100
TEST BENCH REQUIREMENTS Boost pressure in bar :-
Control rack travel in
: 9.0
Test oil inlet mm
: 38-42C
temperature Speed-min-1 (rpm) : 1115-1145
Overflow valve : F002A10627 Boost pressure in bar :-
Inlet pressure in bar : 1.5 Control rack travel in
: 4.0
Test injector : 0681343009 mm
Opening pressure in bar : 172.0-175.0 Speed-min-1 (rpm) : 1310
High pressure pipe : 6X2X600 Boost pressure in bar :-
(ODXIDxlength) in mm Control rack travel in
: 0.3-1.4
mm
REFERENCE NO

2.FULL LOAD
(A) CALIBRATION OF PUMP WITHOUT DELIVERY
GOVERNOR ACTION Speed-min-1 (rpm) : 1050
Boost pressure in bar :-
Control rack travel in
Direction of rotation : Clockwise : 9.95-10.05
mm
Prestroke in mm : 4.15-4.25(4.1-4.3)
Delivery quantity(x ) : 34.5-35.5(33.5-36.5)
Control rack position in
: 9.0-12.0 in cm/500 strokes
mm
Cam sequence : 1- 3- 4- 2 Maximum spread in cm : 1.8(4.0)
Cam displacement : 0-90-180-270 0.5 3.TORQUE
Tappet clearance in mm : min 0.2 CONTROL
Injection Timing Speed-min-1 (rpm) :-
:- Boost pressure in bar :-
locking
BASIC SETTING Control rack travel in
:-
mm
Speed-min-1 (rpm) :-
Speed-min-1 (rpm) : 1050
Boost pressure in bar :-
Control rack travel in
: 9.95-10.05 Control rack travel in
mm :-
mm
Delivery quantity(x ) : 6.85-7.15
Speed-min-1 (rpm) : 500
in cm/100 strokes Boost pressure in bar :-
Maximum spread in cm : 0.4(0.8) Control rack travel in
: 11.0-11.2
mm
Speed-min-1 (rpm) : 650
Speed-min-1 (rpm) : 400 Boost pressure in bar :-
Control rack travel in Control rack travel in
: 7.4-7.6 : 11.0-11.2
mm mm
Delivery quantity(x ) : 0.65-1.05(0.4-1.3) Speed-min-1 (rpm) :-
in cm/100 strokes Boost pressure in bar :-
Maximum spread in cm : 0.6(0.9) Control rack travel in
:-
mm
Speed-min-1 (rpm) : 1050
Boost pressure in bar :-
Control rack travel in
: 9.95-10.05
mm
Contd...2

PROVISIONAL CHART
Test Specifications
445 DI (subject to alternations)
For Field Service only

REFERENCE NO : TSS-TS-MM F..765 (B) ADJUSTMENT OF PUMP AND GOVERNOR


Edition : 05.2010 GUIDE SLEEVE TRAVEL
Replaces(edition) :- Control lever position : Free
Test oil : F 002 S3E 001 Speed-min-1 (rpm) : 800
Revision :2 Control rack travel in mm : 0.5
1.MAXIMUM SPEED CONTROL (RATED SPEED)
Combination No. : F 002 A0Z 765-E040.244.300
(without supplementry idling spring)

Injection pump : PES 3 A 95 D 320 RS 2000 Control lever position : 56.0±4.0°


Speed-min-1 (rpm) :-
Governor : RSV 400...1050 A 1 C 1431 R Boost pressure in bar :-
Control rack travel in mm :-
Customer : Mahindra & Mahindra Ltd.
Speed-min-1 (rpm) : 1050
Engine model : NE 342 BSIII A
Boost pressure in bar :-
Engine code :-
Control rack travel in mm : 10.25-10.35
Application : TRACTOR-445DI
TEST BENCH REQUIREMENTS Speed-min-1 (rpm) : 1090-1100
Boost pressure in bar :-

Test oil inlet temperature : 38°-42°C Control rack travel in mm : 9.3


Overflow valve : F002A10627 Speed-min-1 (rpm) : 1110-1140
Inlet pressure in bar : 1.5 Boost pressure in bar :-
Test injector : 0681343009 Control rack travel in mm : 4.0
Opening pressure in bar : 172.0-175.0 Speed-min-1 (rpm) : 1325
High pressure pipe : 6X2X600 Boost pressure in bar :-
(ODXIDxlength) in mm
Control rack travel in mm : 0.3-1.4
2.FULL LOAD DELIVERY
(A) CALIBRATION OF PUMP WITHOUT GOVERNOR ACTION
Speed-min-1 (rpm) : 1050
Boost pressure in bar :-
Direction of rotation : Clockwise Control rack travel in mm : 10.25-10.35
Prestroke in mm : 3.75-3.85(3.7-3.9) Delivery quantity(x ) : 36.0-37.0(35.0-38.0)
Control rack position in mm : 9.0-12.0 in cm³/500 strokes
Cam sequence :1-3-2 Maximum spread in cm³ : 1.8(4.0)
Cam displacement : 0 -120- 240° ±0.5° 3.TORQUE CONTROL
Tappet clearance in mm : min 0.2 Speed-min-1 (rpm) :-
Injection Timing locking :- Boost pressure in bar :-
BASIC SETTING Control rack travel in mm :-
Speed-min-1 (rpm) :-
Speed-min-1 (rpm) : 1050 Boost pressure in bar :-
Control rack travel in mm : 10.25-10.35 Control rack travel in mm :-
Delivery quantity(x ) : 7.15-7.45 Speed-min-1 (rpm) : 500
in cm³/100 strokes Boost pressure in bar :-
Maximum spread in cm³ : 0.4(0.8) Control rack travel in mm : 11.5-11.7
Speed-min-1 (rpm) : 700
Boost pressure in bar :-
Speed-min-1 (rpm) : 400 Control rack travel in mm : 11.5-11.7
Control rack travel in mm : 7.6-7.8 Speed-min-1 (rpm) :-
Delivery quantity(x ) : 0.7-1.1(0.45-1.35) Boost pressure in bar :-
in cm/100 strokes Control rack travel in mm :-
Maximum spread in cm³ : 0.6(0.9) Speed-min-1 (rpm) : 1050
Boost pressure in bar :-
Control rack travel in mm : 10.25-10.35
Contd...2
REFERENCE NO

6.MAXIMUM SPEED CONTROL (RATED


SPEED)
4. COURSE OF
(with supplementary idling spring)
DELIVERY
Speed-min-1 (rpm) :-
Boost pressure in bar :- Speed-min-1 (rpm) :-
Control rack travel in
Delivery quantity(x ) :- :-
mm
in cm/500 strokes
Maximum spread in cm : -
7. GOVERNOR CUTTING IN SPEED
Speed-min-1 (rpm) : 650
Speed-min-1 (rpm) : 1090-1100
Boost pressure in bar :-
Boost pressure in bar :-
Delivery quantity(x ) : 33.5-35.5(32.5-36.5)
Control rack travel in
in cm/500 strokes : 9.0
mm
Maximum spread in cm : 2.5 (4.0)
Speed-min-1 (rpm) :- While over checking ,if the cutting speed is above
Boost pressure in bar :- the rated speed and if,
Delivery quantity(x ) :- -the delivery values are within the overchecking
in cm/500 strokes tolerance
Maximum spread in cm : - -control rack remains at full load position even at
50 min
Speed-min-1 (rpm) :-
(rpm) less than the rated speed
Control rack travel in
:- the cutting-in speed should be declared OK.
mm
Delivery quantity(x ) :- 8. DEGREE OF IRREGULARY
in cm/500 strokes Speed-min-1 (rpm) : 1145-1175
Maximum spread in cm : - Boost pressure in bar :-
5. IDLING SPEED CONTROL (RATED Control rack travel in
: 4.0
SPEED) mm
Control lever position : 27.04.0 No of notches : 18.0
Speed-min-1 (rpm) : 400 9. STARTING
TRAVEL
Control rack travel in
: 7.4-7.6 Speed-min-1 (rpm) :-
mm
Control rack travel in
Speed-min-1 (rpm) : 100 :-
mm
Control rack travel in
: Minimum 19.0 Delivery quantity(x ) :-
mm
in cm/500 strokes
Speed-min-1 (rpm) : 400
Control rack travel in
: 7.4-7.6
mm
Speed-min-1 (rpm) : 570-630
Control rack travel in
: 2.0
mm
REFERENCE NO

10.STARTING FUEL DELIVERY


Speed-min-1 (rpm) : 100
Control rack travel in
: 19.75-21.25
mm
Delivery quantity(x ) :-
in cm/100 strokes

OTHER
INFORMATION
Element :- Adaption capsule :-
Delivery valve :-
Flyweight assembly :- Nozzle :-
Governor spring :- Opening pressure in bar : -
Note:
1. Sl.No.of the operations indicate the sequence of
3.(x):Average of the cylinders
operations.
2. Values given in brackets are overchecking
values

Applicable only for BOSCH and MICO Test benches 210311


These Test specifications should not be copied or transmitted to a
third party without our written permission.All rights reserved.
605 DI
(Rotary with 022 Injector Test Bench) Test Specifications
(Subject to alternations)
For Field Service Only

REFERENCE NO TSS-TS-MML VE 0...506


Edition 08.2011 Test oil F002.S3E.001-H-S/EFEP 170
Replaces (edition) - Customer M&M - FES
Injection pump 0460.424.506-B 460 816 726 Engine model NE457 trem3A
VE4/12F1000R1142-1 Application Tractor - (605DI 57 HP)
TEST BENCH REQUIREMENTS
Test oil inlet temperature 39° - 41° C Inlet pressure in bar 0.30 - 0.40
Test injector 1 688 901 022 Opening pressure in bar 180 - 183
High pressure pipe H-S / EFEP 109 (OD x ID x length) in mm 6 x 2 x 450
Injection timing locking
Direction of rotation Clock Wise Drive shaft key way position at BDC Between A & D (DV holders)
Plunger stroke in mm 0.7 ± 0.02 Drive shaft key way position after injection timing locking should be
inline with DV holder : A
1. SETTING
1.1 Timer Travel 1.2 Vane Pump Pressure
Speed Min-¹(RPM) 900 Speed Min-¹(RPM) 900
Boost pressure in bar - Boost pressure in bar -
Timer travel in mm 1.10 ± 0.20 Timer travel in mm 5.30 ± 0.30
1.3 Full load delivery 1.4 Idling delivery quantity
Speed Min-¹ (RPM) 1000 Speed Min-¹ (RPM) 400
Boost pressure in bar - Boost pressure in bar -
Del Qty (x) in cm³ /500 strokes 35.50 ± 0.25 Del Qty (x) in cm³ /500 strokes 5.00 ± 0.50
Maximum spread in cm³ 2.0 Maximum spread in cm³ 3.0
Speed Min-¹ (RPM) - Residual delivery quantity
Boost pressure in bar - Speed Min-¹ (RPM) -
Del Qty (x) in cm³ /500 strokes - Boost pressure in bar -
Speed Min-¹ (RPM) - Del Qty (x) in cm³ /500 strokes -
Boost pressure in bar - High Idling delivery quantity
Del Qty (x) in cm³ /500 strokes - Speed Min-¹ (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) 1075 Speed Min-¹ (RPM) 100
Boost pressure in bar - Boost pressure in bar -
Del Qty (x) in cm³ /500 strokes 5.00 ± 1.00 Del Qty (x) in cm³ /500 strokes 41.00 ± 12.50
1.7 Load dependent port closing (LFB) 1.8 Exhaust Gas Recirculation (EGR)setting point
Speed Min-¹ (RPM) - 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
Speed Min-¹ (RPM) 900 Speed Min-¹ (RPM) 900
Boost pressure in bar - Boost pressure in bar -
Timer travel in mm 0.70 - 1.50 Vane pump pressure in bar 4.60 - 6.00
Speed Min-¹ (RPM) 1000 Speed Min-¹ (RPM) 600
Boost pressure in bar - Boost pressure in bar -
Timer travel in mm 1.10 - 1.90 Vane pump pressure in bar 7.3 - 9.7#
Speed Min-¹ (RPM) 600 Speed Min-¹ (RPM) -
Boost pressure in bar - Boost pressure in bar -
Timer travel in mm 5.40 - 7.40# Vane pump pressure in bar -
Speed Min-¹ (RPM) - Speed Min-¹ (RPM) -
Boost pressure in bar - Boost pressure in bar -
Timer travel in mm - Vane pump pressure in bar -
(# With power (12 V) connected to KSB) (# With power (12 V) connected to KSB)
TSS-TS-MML VE 0...506
2.3 Overflow Qty
Speed Min-¹ (RPM) 1000 Speed Min-¹ (RPM) -
Boost pressure in bar - Boost pressure in bar -
Overflow Qty in cm³ /10 seconds 117 - 184 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) 500 Low idle Del Qty
Boost pressure in bar - Speed Min-¹ (RPM) 400
Del Qty (x) in cm³ /500 strokes 27.50 - 31.50 Boost pressure in bar -
Speed Min-¹ (RPM) 1000 Del Qty (x) in cm³ /500 strokes 2.00 - 8.00
Boost pressure in bar - Residual Del Qty
Del Qty (x) in cm³ /500 strokes 34.00 - 37.00 Speed Min-¹ (RPM) -
Speed Min-¹ (RPM) 725 Boost pressure in bar -
Boost pressure in bar - Del Qty (x) in cm³ /500 strokes -
Del Qty (x) in cm³ /500 strokes 31.75 - 35.75 High Idling Del Qty
Speed Min-¹ (RPM) 1075 Speed Min-¹ (RPM) 500
Boost pressure in bar - Boost pressure in bar -
Del Qty (x) in cm³ /500 strokes 2.00 - 8.00 Del Qty (x) in cm³ /500 strokes 0.00 - 1.50
Speed Min-¹ (RPM) 1125 Electrical shutoff (by disconnecting solenoid switch)
Boost pressure in bar - Control lever position Idling Position
Del Qty (x) in cm³ /500 strokes 0.00 - 1.50 Speed Min-¹ (RPM) 415
Speed Min-¹ (RPM) - Boost pressure in bar -
Boost pressure in bar - Del Qty (x) in cm³ /500 strokes 0.00 - 1.50
Del Qty (x) in cm³ /500 strokes - Maximum spread in cm³ -
Speed Min-¹ (RPM) - Mechanical shutoff (By operating stop lever)
Boost pressure in bar - Speed Min-¹ (RPM) 1000
Del Qty (x) in cm³ /500 strokes - Boost pressure in bar -
Speed Min-¹ (RPM) - Del Qty (x) in cm³ /500 strokes 0.00 - 1.50
Boost pressure in bar - Maximum spread in cm³ -
Del Qty (x) in cm³ /500 strokes - Exhaust Gas Recirculation (EGR)
Speed Min-¹ (RPM) - Speed Min-¹ (RPM) -
Boost pressure in bar - Del Qty (x) in cm³ /500 strokes -
Del Qty (x) in cm³ /500 strokes - Input voltage(V) -
Output voltage(V) -
2.5 Solenoid
Rated voltage (ELAB) 12 V Rated voltage (KSB) 12 V
3. ASSEMBLY AND SETTING DIMENSIONS :
Description Specification
K 3.64 - 3.76 mm
KF 8.2 - 8.6 mm
MS1 0.65 - 1.05 MM
NOTE:
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.

Remarks
Pl. note the change in the test injector OPENING PRESSURE
08272011
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
605 DI Test Specifications
(Rotay with 114 Injector Test Bench) (Subject to alterations)
For Field Service only
REFERENCE NO. : TSS-TS-MML 0..506 1.4 Idling delivery
Edition : 06.2011 Speed - min-1 (rpm) : 435
Replaces (edition) : 03.2011 Delivery quantity ( x ) : 6.0± 0.5
Test oil : F 002 S3E 001 in cm³ /500 strokes
Injection pump : 0 460 424 506 Maximum spread in cm³ (') : 3.0
VE4/12F1000R1142-1 1.5 Maximum speed regulation
B 460 816 726 01 Speed - min-1 (rpm) : 1100
VE 4/12F 1000 RV1672601 Boost pressure in bar -
Delivery quantity ( x ) : 6.5± 0.5
in cm³ /500 strokes
Maximum spread in cm³ (') : -
Customer : Mahindra & Mahindra Ltd. 1.6 Starting fuel delivery
Engine model : NE 457 3A Speed - min-1 (rpm) : 100
Application : Tractor 605 DI Delivery quantity ( x ) : 55.0 ± 12.5
in cm³ /500 strokes
TEST BENCH REQUIREMENTS 1.7 Load dependent port closing (LFB)
o o
Test oil inlet temperature : 38 - 42 C Speed - min-1 (rpm) : -
Inlet pressure in bar : 0.30 - 0.40 Not applicable
Test injector : 1 688 901 114 1.8 Exhaust Gas Recirculation (EGR)setting point
Opening pressure in bar : 204 - 210 Speed - min-1 (rpm) : -
High pressure pipe : H-S/EFEP 109 Delivery quantity ( x ) : -
(OD x ID x length) in mm : 6 x 2 x 450 in cm³ /500 strokes
Injection timing locking 2. TESTING
Direction of rotation : Clockwise
Plunger stroke in mm : 0.7± 0.02 2.1 Timer travel
Drive shaft key way position Speed - min-1 (rpm) : 1000
at BDC : Between A & D (DV holders) Timer travel in mm : 1.5 - 2.3
Drive shaft key way position after injection timing locking Speed - min-1 (rpm) : 900
should be inline with DV holder A Timer travel in mm : 1.0 - 1.8)
1. SETTING Speed - min-1 (rpm) : -
1.1 Timer travel Timer travel in mm : -
Speed - min-1 (rpm) : 900 Speed - min-1 (rpm) : 600
Boost pressure in bar : - Timer travel in mm : 5.9 - 7.9 #
Timer travel in mm : 1.4± 0.2 # measured by connecting the power supply (12 V) to KSB
1.2 Vane pump pressure 2.2 Vane pump pressure
Speed - min-1 (rpm) : 900 Speed - min-1 (rpm) : 900
Boost pressure in bar : - Vane pump pressure in bar : (5.1 - 6.5)
Vane pump pressure in bar : 5.8± 0.3 Speed - min-1 (rpm) : 600
1.3 Full load delivery Vane pump pressure in bar : 9.1 - 11.5 #
Speed - min-1 (rpm) : 1000 # measured by connecting the power supply (12 V) to KSB
Boost pressure in bar : - 2.3 Overflow quantity
Delivery quantity ( x ) : 21.25 ± 0.25 Speed - min-1 (rpm) : 1000
in cm³ /500 strokes Boost pressure in bar : -
Maximum spread in cm³ (') : 2.0 Overflow quantity : 116 - 184
Speed - min-1 (rpm) : - in cm³ /10 seconds
Boost pressure in bar : - Speed - min-1 (rpm) : -
Delivery quantity ( x ) : - Boost pressure in bar : -
in cm³ /500 strokes Overflow quantity : -
Maximum spread in cm³ (') : - in cm³ /10 seconds

Contd…2
REFERENCE NO

605 DI Inline
Test Specifications
xt

(subject to alternations)
For Field Service only

(B) ADJUSTMENT OF PUMP AND


GOVERNOR
: PROVISIONAL
REFERENCE NO GUIDE SLEEVE
CHART
TRAVEL
Edition : PROVISIONAL
Control lever position : Free
Replaces(edition) :
Speed-min-1 (rpm) : 800
Test oil : 9 916 034 004 Control rack travel in
Revision :2 : 0.3-0.7
mm
: F002A0Z969- 1.MAXIMUM SPEED CONTROL (RATED
Combination No.
EB40.272.100 SPEED)
: PES 4 A 85 D 320 (without supplementry idling spring)
Injection pump
RS 3500 Control lever position : 46.0±4.0°
: RSV 400...1050 A 2 Speed-min-1 (rpm) : -
Governor
C 1742 R Boost pressure in bar : -
: Mahindra & Control rack travel in
Customer : -
Mahindra Ltd. mm
Engine model : NE 457 3A Speed-min-1 (rpm) : 1050
Engine code :- Boost pressure in bar : -
Application : TRACTOR-(605 DI) Control rack travel in
: 12.95-13.05
TEST BENCH REQUIREMENTS mm
Speed-min-1 (rpm) : 1095-1105
Test oil inlet Boost pressure in bar : -
: 38°-42°C
temperature Control rack travel in
Overflow valve : F002A10627 : 12.0
mm
Inlet pressure in bar : 1.5 Speed-min-1 (rpm) : 1180-1210
Test injector : 0681343009 Boost pressure in bar : -
Opening pressure in Control rack travel in
: 172.0-175.0 : 4.0
bar mm
High pressure pipe : 6X2X600 :
Speed-min-1 (rpm) 1300
(ODXIDxlength) in
mm Boost pressure in bar : -
Control rack travel in
: 0.3-1.4
mm

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REFERENCE NO

2.FULL LOAD
(A) CALIBRATION OF PUMP WITHOUT DELIVERY
GOVERNOR ACTION Speed-min-1 (rpm) : 1050
Boost pressure in bar : -
Control rack travel in
Direction of rotation : Clockwise : 12.95-13.05
mm
Prestroke in mm : 4.65-4.75(4.6-4.8)
: 32.35-32.65(31.25-
Control rack position Delivery quantity(x )
: 18.0-21.0 33.75)
in mm
in cm³/500 strokes
Cam sequence : 1- 3- 4- 2
Maximum spread in
: 0-90-180-270° : 1.5(3.5)
Cam displacement cm³
±0.5°
3.TORQUE
Tappet clearance in
: min 0.2 CONTROL
mm
Speed-min-1 (rpm) :-
Injection Timing
:- Boost pressure in bar : -
locking
Control rack travel in
BASIC SETTING :-
mm
Speed-min-1 (rpm) :-
-1
Speed-min (rpm) : 1050 Boost pressure in bar : -
Control rack travel in Control rack travel in
: 12.95-13.05 :-
mm mm
Delivery quantity(x ) : 6.35-6.65 Speed-min-1 (rpm) : 500
in cm³/100 strokes Boost pressure in bar : -
Maximum spread in Control rack travel in
: 0.3(0.7) : 13.6-13.8
cm³ mm
Speed-min-1 (rpm) : 650
Boost pressure in bar : -
Speed-min-1 (rpm) : 400 Control rack travel in
Control rack travel in : 13.0-13.2
: 7.9-8.1 mm
mm Speed-min-1 (rpm) :-
Delivery quantity(x ) : 1.05-1.45(0.85-1.65) Boost pressure in bar : -
in cm/100 strokes Control rack travel in
Maximum spread in :-
: 0.5(0.7) mm
cm³ Speed-min-1 (rpm) : 1050
Boost pressure in bar : -
Control rack travel in
: 12.95-13.05
mm
Contd...2

PROVISIONAL CHART

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REFERENCE NO

4. COURSE OF
DELIVERY
Speed-min-1 (rpm) : 500 6.MAXIMUM SPEED CONTROL (RATED
Boost pressure in bar : - SPEED)
: 26.75-28.25(25.75- (with supplementary idling spring)
Delivery quantity(x )
29.25)
in cm³/500 strokes Speed-min-1 (rpm) :-
Maximum spread in Control rack travel in
: 2.0(4.0) :-
cm³ mm
Speed-min-1 (rpm) : 650
Boost pressure in bar : - 7. GOVERNOR CUTTING IN SPEED
: 25.25-26.75(24.25- Speed-min-1 (rpm) : 1095-1105
Delivery quantity(x )
27.75) Boost pressure in bar : -
in cm³/500 strokes Control rack travel in
Maximum spread in : 12.0
: 2.0 (4.0) mm
cm³
Speed-min-1 (rpm) :- While over checking ,if the cutting speed is
Boost pressure in bar : - above the rated speed and if,
Delivery quantity(x ) : - -the delivery values are within the
in cm³/500 strokes overchecking tolerance
Maximum spread in -control rack remains at full load position
:- even at 50 min
cm³
Speed-min-1 (rpm) :- (rpm) less than the rated speed
Control rack travel in the cutting-in speed should be declared OK.
:-
mm 8. DEGREE OF IRREGULARY
Delivery quantity(x ) : - Speed-min-1 (rpm) : 1195-1225
in cm³/500 strokes Boost pressure in bar : -
Maximum spread in Control rack travel in
:- : 4.0
cm³ mm
5. IDLING SPEED CONTROL (RATED No of notches : 16.0
SPEED) 9. STARTING
Control lever position : 22.0±4.0° TRAVEL
Speed-min-1 (rpm) : 400 Speed-min-1 (rpm) :-
Control rack travel in Control rack travel in
: 7.9-8.1 :-
mm mm
Speed-min-1 (rpm) : 100 Delivery quantity(x ) : -
Control rack travel in in cm³/500 strokes
: Minimum 19.0
mm
Speed-min-1 (rpm) : 400

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REFERENCE NO

Control rack travel in 10.STARTING FUEL DELIVERY


: 7.9-8.1
mm Speed-min-1 (rpm) : 100
Speed-min-1 (rpm) : 520-580 Control rack travel in
: 19.75-21.25
Control rack travel in mm
: 2.0
mm Delivery quantity(x ) : -
in cm³/100 strokes

OTHER
INFORMATION
Element :- Adaption capsule :-
Delivery valve :-
Flyweight assembly :- Nozzle :-
Opening pressure in
Governor spring :- :-
bar
Note:
1. Sl.No.of the operations indicate the
3.(x):Average of the cylinders
sequence of operations.
2. Values given in brackets are overchecking
values

Applicable only for BOSCH and MICO Test benches 100413


These Test specifications should not be copied or transmitted
to a third party without our written permission.All rights
reserved.

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REGULAR BS3

Main Menu
265 DI
Test Specifications
(subject to alternations)
For Field Service only

REFERENCE NO : ASA-TS-MML F_603P (B) ADJUSTMENT OF PUMP AND GOVERNOR


Edition : 11.2007(PROVISIONAL) GUIDE SLEEVE TRAVEL
Replaces(edition) :- Control lever position : Free
Test oil : F 002 S3E 001 Speed-min-1 (rpm) : 800
Revision :0 Control rack travel in mm : 0.3-0.7
1.MAXIMUM SPEED CONTROL (RATED SPEED)
Combination No. : F 002 A0Z 603-E 040 196 300
(without supplementry idling spring)

Injection pump : PES 3 A 85 D 320 RS 2000 Control lever position : 40.0±4.0°


Speed-min-1 (rpm) :-
Governor : RSV 400...950 A 5 C 1509 R Boost pressure in bar :-
Control rack travel in mm :-
Customer : Mahindra & Mahindra Ltd.
Speed-min-1 (rpm) : 950
Engine model : MDI 2050
Boost pressure in bar :-
Engine code :-
Control rack travel in mm : 9.95-10.05
Application : Tractor 265 DI
TEST BENCH REQUIREMENTS Speed-min-1 (rpm) : 990-1000
Boost pressure in bar :-

Test oil inlet temperature : 38°-42°C Control rack travel in mm : 9.0


Overflow valve : F002A10627 Speed-min-1 (rpm) : 1020-1050
Inlet pressure in bar : 1.5 Boost pressure in bar :-
Test injector : 0681343009 Control rack travel in mm : 4.0
Opening pressure in bar : 172.0-175.0 Speed-min-1 (rpm) : 1250
High pressure pipe : 6X2X600 Boost pressure in bar :-
(ODXIDxlength) in mm
Control rack travel in mm : 0.3-1.4
2.FULL LOAD DELIVERY
(A) CALIBRATION OF PUMP WITHOUT GOVERNOR ACTION
Speed-min-1 (rpm) : 950
Boost pressure in bar :-
Direction of rotation : Clockwise Control rack travel in mm : 9.95-10.05
Prestroke in mm : 3.65-3.75(3.6-3.8) Delivery quantity(x ) : 25.75-26.25(24.75-27.25)
Control rack position in mm : 9.0-12.0 in cm³/500 strokes
Cam sequence : 1-3-2 Maximum spread in cm³ : 1.5(3.5)
Cam displacement : 0-120-240° ±0.5° 3.TORQUE CONTROL
Tappet clearance in mm : min 0.2 Speed-min-1 (rpm) :-
Injection Timing locking :- Boost pressure in bar :-
BASIC SETTING Control rack travel in mm :-
Speed-min-1 (rpm) :-
Speed-min-1 (rpm) : 950 Boost pressure in bar :-
Control rack travel in mm : 9.95-10.05 Control rack travel in mm :-
Delivery quantity(x ) : 5.05-5.35 Speed-min-1 (rpm) : 650
in cm³/100 strokes Boost pressure in bar :-
Maximum spread in cm³ : 0.3(0.7) Control rack travel in mm : 10.8-11.0
Speed-min-1 (rpm) : 800
Boost pressure in bar :-
Speed-min-1 (rpm) : 400 Control rack travel in mm : 10.0-10.2
Control rack travel in mm : 6.7-6.9 Speed-min-1 (rpm) :-
Delivery quantity(x ) : 0.8-1.2(0.6-1.4) Boost pressure in bar :-
in cm/100 strokes Control rack travel in mm :-
Maximum spread in cm³ : 0.5(0.7) Speed-min-1 (rpm) : 950
Boost pressure in bar :-
Control rack travel in mm : 9.95-10.05
Contd...2
ASA-TS-MML F_603P
4. COURSE OF DELIVERY 6.MAXIMUM SPEED CONTROL (RATED SPEED)
Speed-min-1 (rpm) : 650 (with supplementary idling spring)
Boost pressure in bar :-
Delivery quantity(x ) : 24.25-25.75(23.25-26.75) Speed-min-1 (rpm) :-
in cm³/500 strokes Control rack travel in mm :-
Maximum spread in cm³ : 2.0(4.0)
Speed-min-1 (rpm) :- 7. GOVERNOR CUTTING IN SPEED
Boost pressure in bar :- Speed-min-1 (rpm) : 990-1000
Delivery quantity(x ) :- Boost pressure in bar :-
in cm³/500 strokes Control rack travel in mm : 9.0
Maximum spread in cm³ :-
Speed-min-1 (rpm) :- While over checking ,if the cutting speed is above the rated speed and if,
Boost pressure in bar :- -the delivery values are within the overchecking tolerance
Delivery quantity(x ) :- -control rack remains at full load position even at 50 min
in cm³/500 strokes (rpm) less than the rated speed
Maximum spread in cm³ :- the cutting-in speed should be declared OK.
Speed-min-1 (rpm) :- 8. DEGREE OF IRREGULARY
Control rack travel in mm :- Speed-min-1 (rpm) : 1060-1090
Delivery quantity(x ) :- Boost pressure in bar :-
in cm³/500 strokes Control rack travel in mm : 4.0
Maximum spread in cm³ :- No of notches : 12.0
5. IDLING SPEED CONTROL (RATED SPEED) 9. STARTING TRAVEL
Control lever position : 19.0±4.0° Speed-min-1 (rpm) :-
Speed-min-1 (rpm) : 400 Control rack travel in mm :-
Control rack travel in mm : 6.7-6.9 Delivery quantity(x ) :-
in cm³/500 strokes
Speed-min-1 (rpm) :-
Control rack travel in mm : Minimum - 10.STARTING FUEL DELIVERY
Speed-min-1 (rpm) : 100
Speed-min-1 (rpm) : 400
Control rack travel in mm : 14.0-14.5
Control rack travel in mm : 6.7-6.9
Delivery quantity(x ) : 5.75-6.75(5.5-7.0)
Speed-min-1 (rpm) : 615-675
in cm³/100 strokes
Control rack travel in mm : 2.0

OTHER INFORMATION

Note:

1. Sl.No.of the operations indicate the sequence of operations. 3.(x):Average of the cylinders

2. Values given in brackets are overchecking values

Applicable only for BOSCH and MICO Test benches 021206


These Test specifications should not be copied or transmitted to a third party without our written permission.All rights reserved.
Test Specifications
275 DI TU (subject to alternations)
For Field Service only

REFERENCE NO : TSS-TS-MML F_607 (B) ADJUSTMENT OF PUMP AND GOVERNOR


Edition : 09.2009 GUIDE SLEEVE TRAVEL
Replaces(edition) :- Control lever position : Free
Test oil : F 002 S3E 001 Speed-min-1 (rpm) : 800
Revision :2 Control rack travel in mm : 0.3-0.7
1.MAXIMUM SPEED CONTROL (RATED SPEED)
Combination No. : F 002 A0Z 607- E B40 195 700
(without supplementry idling spring)

Injection pump : PES 3 A 85 D 320 RS 2000 Control lever position : 44.0±4.0°


Speed-min-1 (rpm) :-
Governor : RSV 375...1050 A 5 C 1511 R Boost pressure in bar :-
Control rack travel in mm :-
Customer : Mahindra & Mahindra Ltd.
Speed-min-1 (rpm) : 1050
Engine model : MDI 2050 B Trem III
Boost pressure in bar :-
Engine code :-
Application Control rack travel in mm : 10.55-10.65
: TRACTOR-275 TU DI
TEST BENCH REQUIREMENTS Speed-min-1 (rpm) : 1090-1100
Boost pressure in bar :-

Test oil inlet temperature : 38°-42°C Control rack travel in mm : 9.6


Overflow valve : F002A10627 Speed-min-1 (rpm) : 1125-1155
Inlet pressure in bar : 1.5 Boost pressure in bar :-
Test injector : 0681343009 Control rack travel in mm : 4.0
Opening pressure in bar : 172.0-175.0 Speed-min-1 (rpm) : 1310
High pressure pipe : 6X2X600 Boost pressure in bar :-
(ODXIDxlength) in mm
Control rack travel in mm : 0.3-1.4
2.FULL LOAD DELIVERY
(A) CALIBRATION OF PUMP WITHOUT GOVERNOR ACTION
Speed-min-1 (rpm) : 1050
Boost pressure in bar :-
Direction of rotation : Clockwise Control rack travel in mm : 10.55-10.65
Prestroke in mm : 3.15-3.25(3.1-3.3) Delivery quantity(x ) : 30.75-31.25(29.75-32.25)
Control rack position in mm : 9.0-12.0 in cm³/500 strokes
Cam sequence : 1- 3- 2 Maximum spread in cm³ : 1.5(3.5)
Cam displacement : 0-120-240° ±0.5° 3.TORQUE CONTROL
Tappet clearance in mm : min 0.2 Speed-min-1 (rpm) :-
Injection Timing locking :- Boost pressure in bar :-
BASIC SETTING Control rack travel in mm :-
Speed-min-1 (rpm) :-
Speed-min-1 (rpm) : 1050 Boost pressure in bar :-
Control rack travel in mm : 10.55-10.65 Control rack travel in mm :-
Delivery quantity(x ) : 6.05-6.35 Speed-min-1 (rpm) : 630
in cm³/100 strokes Boost pressure in bar :-
Maximum spread in cm³ : 0.3(0.7) Control rack travel in mm : 11.2-11.4
Speed-min-1 (rpm) : 800
Boost pressure in bar :-
Speed-min-1 (rpm) : 400 Control rack travel in mm : 10.65-10.85
Control rack travel in mm : 6.6-6.8 Speed-min-1 (rpm) :-
Delivery quantity(x ) : 0.65-1.05(0.45-1.25) Boost pressure in bar :-
in cm/100 strokes Control rack travel in mm :-
Maximum spread in cm³ : 0.5(0.7) Speed-min-1 (rpm) : 1050
Boost pressure in bar :-
Control rack travel in mm : 10.55-10.65
Contd...2
TSS-TS-MML F_607
4. COURSE OF DELIVERY 6.MAXIMUM SPEED CONTROL (RATED SPEED)
Speed-min-1 (rpm) : 630 (with supplementary idling spring)
Boost pressure in bar :-
Delivery quantity(x ) : 26.25-27.75(25.25-28.75) Speed-min-1 (rpm) :-
in cm³/500 strokes Control rack travel in mm :-
Maximum spread in cm³ : 2.0(4.0)
Speed-min-1 (rpm) :- 7. GOVERNOR CUTTING IN SPEED
Boost pressure in bar :- Speed-min-1 (rpm) : 1090-1100
Delivery quantity(x ) :- Boost pressure in bar :-
in cm³/500 strokes Control rack travel in mm : 9.6
Maximum spread in cm³ :-
Speed-min-1 (rpm) :- While over checking ,if the cutting speed is above the rated speed and if,
Boost pressure in bar :- -the delivery values are within the overchecking tolerance
Delivery quantity(x ) :- -control rack remains at full load position even at 50 min
in cm³/500 strokes (rpm) less than the rated speed
Maximum spread in cm³ :- the cutting-in speed should be declared OK.
Speed-min-1 (rpm) :- 8. DEGREE OF IRREGULARY
Control rack travel in mm :- Speed-min-1 (rpm) : 1145-1175
Delivery quantity(x ) :- Boost pressure in bar :-
in cm³/500 strokes Control rack travel in mm : 4.0
Maximum spread in cm³ :- No of notches : 13.0
5. IDLING SPEED CONTROL (RATED SPEED) 9. STARTING TRAVEL
Control lever position : 19.0±4.0° Speed-min-1 (rpm) :-
-1
Speed-min (rpm) : 400 Control rack travel in mm :-
Control rack travel in mm : 6.6-6.8 Delivery quantity(x ) :-
in cm³/500 strokes
Speed-min-1 (rpm) : 100
Control rack travel in mm : Minimum 19.0 10.STARTING FUEL DELIVERY
Speed-min-1 (rpm) : 100
Speed-min-1 (rpm) : 400
Control rack travel in mm : 16.0-16.5
Control rack travel in mm : 6.6-6.8
Delivery quantity(x ) :-
Speed-min-1 (rpm) : 520-580
in cm³/100 strokes
Control rack travel in mm : 2.0

OTHER INFORMATION

Note:

1. Sl.No.of the operations indicate the sequence of operations. 3.(x):Average of the cylinders

2. Values given in brackets are overchecking values

Applicable only for BOSCH and MICO Test benches 010909


These Test specifications should not be copied or transmitted to a third party without our written permission.All rights reserved.
REFERENCE NO

295 DI
Test Specifications
(subject to alternations)
For Field Service only
(B) ADJUSTMENT OF PUMP AND
GOVERNOR
GUIDE SLEEVE
TRAVEL
: PROVISIONAL Control lever position : Free
REFERENCE NO Speed-min-1 (rpm) : 800
CHART
Edition : Control rack travel in
: 0.3-0.7
Replaces(edition) : mm
Test oil : 9 916 034 004 1.MAXIMUM SPEED CONTROL (RATED
SPEED)
Revision :2
(without supplementry idling spring)
Combination No. : EB40201300 Control lever position : 40.0±4.0°

: PES 3 A 95 D 320 RS Speed-min-1 (rpm) :-


Injection pump Boost pressure in bar :-
3500
: RSV 400...950 A 5 C 1 Control rack travel in :-
Governor mm
R
Speed-min-1 (rpm) : 950
Customer : MAHINDRA
Boost pressure in bar :-
Engine model : 295 DI
Control rack travel in
Engine code : : 11.95-12.05
mm
Application : 41hp
Speed-min-1 (rpm) : 990-1000
TEST BENCH REQUIREMENTS
Boost pressure in bar :-
Control rack travel in
Test oil inlet : 11.0
: 38°-42°C mm
temperature
Speed-min-1 (rpm) : 1035-1065
Overflow valve : F002A10627
Boost pressure in bar :-
Inlet pressure in bar : 1.5
Control rack travel in
Test injector : 0681343009 : 4.0
mm
Opening pressure in bar : 172.0-175.0
Speed-min-1 (rpm) : 1200
High pressure pipe : 6X2X600
Boost pressure in bar :-
(ODXIDxlength) in mm
Control rack travel in
: 0.3-1.4
mm
REFERENCE NO

2.FULL LOAD
(A) CALIBRATION OF PUMP WITHOUT DELIVERY
GOVERNOR ACTION Speed-min-1 (rpm) : 950
Boost pressure in bar :-
Control rack travel in
Direction of rotation : Clockwise : 11.95-12.05
mm
Prestroke in mm : 4.05-4.15(4.0-4.2)
Delivery quantity(x ) : 37.5-38.5(36.5-39.5)
Control rack position in
: 18.0-21.0 in cm³/500 strokes
mm
Cam sequence : 1-3-2 Maximum spread in cm³ : 1.8(4.0)
Cam displacement : 0-120-240° ±0.5° 3.TORQUE
Tappet clearance in mm : min 0.2 CONTROL
Injection Timing Speed-min-1 (rpm) :-
:- Boost pressure in bar :-
locking
BASIC SETTING Control rack travel in
:-
mm
Speed-min-1 (rpm) :-
Speed-min-1 (rpm) : 950
Boost pressure in bar :-
Control rack travel in
: 11.95-12.05 Control rack travel in
mm :-
mm
Delivery quantity(x ) : 7.45-7.75
Speed-min-1 (rpm) : 700
in cm³/100 strokes Boost pressure in bar :-
Maximum spread in cm³ : 0.4(0.8) Control rack travel in
: 12.2-12.4
mm
Speed-min-1 (rpm) : 800
Speed-min-1 (rpm) : 400 Boost pressure in bar :-
Control rack travel in Control rack travel in
: 8.4-8.6 : 12.05-12.25
mm mm
Delivery quantity(x ) : 0.8-1.2(0.55-1.45) Speed-min-1 (rpm) :-
in cm/100 strokes Boost pressure in bar :-
Maximum spread in cm³ : 0.6(0.9) Control rack travel in
:-
mm
Speed-min-1 (rpm) : 950
Boost pressure in bar :-
Control rack travel in
: 11.95-12.05
mm
Contd...2

PROVISIONAL CHART
REFERENCE NO

6.MAXIMUM SPEED CONTROL (RATED


SPEED)
4. COURSE OF
(with supplementary idling spring)
DELIVERY
Speed-min-1 (rpm) : 700
Boost pressure in bar :- Speed-min-1 (rpm) :-
Control rack travel in
Delivery quantity(x ) : 32.0-34.0(31.0-35.0) :-
mm
in cm³/500 strokes
Maximum spread in cm³ : 2.5(4.0)
7. GOVERNOR CUTTING IN SPEED
Speed-min-1 (rpm) :-
Speed-min-1 (rpm) : 990-1000
Boost pressure in bar :-
Boost pressure in bar :-
Delivery quantity(x ) :-
Control rack travel in
in cm³/500 strokes : 11.0
mm
Maximum spread in cm³ : -
Speed-min-1 (rpm) : 900 While over checking ,if the cutting speed is above
Boost pressure in bar :- the rated speed and if,
Delivery quantity(x ) :- -the delivery values are within the overchecking
in cm³/500 strokes tolerance
Maximum spread in cm³ : - -control rack remains at full load position even at
50 min
Speed-min-1 (rpm) :-
(rpm) less than the rated speed
Control rack travel in
:- the cutting-in speed should be declared OK.
mm
Delivery quantity(x ) :- 8. DEGREE OF IRREGULARY
in cm³/500 strokes Speed-min-1 (rpm) : 1060-1090
Maximum spread in cm³ : - Boost pressure in bar :-
5. IDLING SPEED CONTROL (RATED Control rack travel in
: 4.0
SPEED) mm
Control lever position : 19.0±4.0° No of notches : 12.0
Speed-min-1 (rpm) : 400 9. STARTING
TRAVEL
Control rack travel in
: 8.4-8.6 Speed-min-1 (rpm) :-
mm
Control rack travel in
Speed-min-1 (rpm) : 100 :-
mm
Control rack travel in
: Minimum 19.0 Delivery quantity(x ) :-
mm
in cm³/500 strokes
Speed-min-1 (rpm) : 400
Control rack travel in
: 8.4-8.6
mm
Speed-min-1 (rpm) : 510-570
Control rack travel in
: 2.0
mm
REFERENCE NO

10.STARTING FUEL DELIVERY


Speed-min-1 (rpm) : 100
Control rack travel in
: 17.25-17.75
mm
Delivery quantity(x ) : 8.25-9.75(8.0-10.0)
in cm³/100 strokes

OTHER
INFORMATION
Element : Adaption capsule :
Delivery valve :
Flyweight assembly : Nozzle :
Governor spring : Opening pressure in bar :
Note:
1. Sl.No.of the operations indicate the sequence of
3.(x):Average of the cylinders
operations.
2. Values given in brackets are overchecking
values

Applicable only for BOSCH and MICO Test benches


These Test specifications should not be copied or transmitted to a
third party without our written permission.All rights reserved.
475 DI Test Specifications
(subject to alternations)
For Field Service only

REFERENCE NO : ASA-TS-MML -F_570 (B) ADJUSTMENT OF PUMP AND GOVERNOR


Edition : 08.2007 GUIDE SLEEVE TRAVEL
Replaces(edition) :- Control lever position : Free
Test oil : F 002 S3E 001 Speed-min-1 (rpm) : 800
Revision :0 Control rack travel in mm : 0.3-0.7
1.MAXIMUM SPEED CONTROL (RATED SPEED)
Combination No. : F 002 A0Z 570-E 040 194 000
(without supplementry idling spring)

Injection pump : PES 4A 85D 320 RS 2000 Control lever position : 43.0±4.0°
Speed-min-1 (rpm) :-
Governor : RSV 425...950 A 5 C 1478 R Boost pressure in bar :-
Control rack travel in mm :-
Customer : Mahindra & Mahindra Ltd.
Speed-min-1 (rpm) : 950
Engine model : MDI 2700 Trem III
Boost pressure in bar :-
Engine code :
Control rack travel in mm : 12.05-12.15
Application : 475 DI-TRACTOR
TEST BENCH REQUIREMENTS Speed-min-1 (rpm) : 990-1000
Boost pressure in bar :-

Test oil inlet temperature : 38°-42°C Control rack travel in mm : 11.1


Overflow valve : F002A10627 Speed-min-1 (rpm) : 1045-1075
Inlet pressure in bar : 1.5 Boost pressure in bar :-
Test injector : 0681343009 Control rack travel in mm : 4.0
Opening pressure in bar : 172.0-175.0 Speed-min-1 (rpm) : 1225
High pressure pipe : 6X2X600 Boost pressure in bar :-
(ODXIDxlength) in mm
Control rack travel in mm : 0.3-1.4
2.FULL LOAD DELIVERY
(A) CALIBRATION OF PUMP WITHOUT GOVERNOR ACTION
Speed-min-1 (rpm) : 950
Boost pressure in bar :-
Direction of rotation : Clockwise Control rack travel in mm : 12.05-12.15
Prestroke in mm : 3.25-3.35(3.2-3.4) Delivery quantity(x ) : 28.5-29.0(27.5-30.0)
Control rack position in mm : 16.0-19.0 in cm³/500 strokes
Cam sequence : 1-3-4-2 Maximum spread in cm³ : 1.5(3.5)
Cam displacement : 0-90-180-270° ±0.5° 3.TORQUE CONTROL
Tappet clearance in mm : min 0.2 Speed-min-1 (rpm) :-
Injection Timing locking :- Boost pressure in bar :-
BASIC SETTING Control rack travel in mm :-
Speed-min-1 (rpm) :-
Speed-min-1 (rpm) : 950 Boost pressure in bar :-
Control rack travel in mm : 12.05-12.15 Control rack travel in mm :-
Delivery quantity(x ) : 5.6-5.9 Speed-min-1 (rpm) :-
in cm³/100 strokes Boost pressure in bar :-
Maximum spread in cm³ : 0.3(0.7) Control rack travel in mm :-
Speed-min-1 (rpm) :-
Boost pressure in bar :-
Speed-min-1 (rpm) : 425 Control rack travel in mm :-
Control rack travel in mm : 5.6-5.8 Speed-min-1 (rpm) :-
Delivery quantity(x ) : 0.65-1.05(0.45-1.25) Boost pressure in bar :-
in cm/100 strokes Control rack travel in mm :-
Maximum spread in cm³ : 0.5(0.7) Speed-min-1 (rpm) :-
Boost pressure in bar :-
Control rack travel in mm :-
Contd...2
ASA-TS-MML -F_570 08.2007 2
4. COURSE OF DELIVERY 6.MAXIMUM SPEED CONTROL (RATED SPEED)
Speed-min-1 (rpm) : 700 (with supplementary idling spring)
Boost pressure in bar :-
Delivery quantity(x ) : 24.5-26.0(23.5-27.0) Speed-min-1 (rpm) :-
in cm³/500 strokes Control rack travel in mm :-
Maximum spread in cm³ : 2.0(4.0)
Speed-min-1 (rpm) :- 7. GOVERNOR CUTTING IN SPEED
Boost pressure in bar :- Speed-min-1 (rpm) : 990-1000
Delivery quantity(x ) :- Boost pressure in bar :-
in cm³/500 strokes Control rack travel in mm : 11.1
Maximum spread in cm³ :-
Speed-min-1 (rpm) :- While over checking ,if the cutting speed is above the rated speed and if,
Boost pressure in bar :- -the delivery values are within the overchecking tolerance
Delivery quantity(x ) :- -control rack remains at full load position even at 50 min
in cm³/500 strokes (rpm) less than the rated speed
Maximum spread in cm³ :- the cutting-in speed should be declared OK.
Speed-min-1 (rpm) :- 8. DEGREE OF IRREGULARY
Control rack travel in mm :- Speed-min-1 (rpm) : 1060-1090
Delivery quantity(x ) :- Boost pressure in bar :-
in cm³/500 strokes Control rack travel in mm : 4.0
Maximum spread in cm³ :- No of notches : 15.0
5. IDLING SPEED CONTROL (RATED SPEED) 9. STARTING TRAVEL
Control lever position : 22.0±4.0° Speed-min-1 (rpm) :-
Speed-min-1 (rpm) : 425 Control rack travel in mm :-
Control rack travel in mm : 5.6-5.8 Delivery quantity(x ) :-
in cm³/500 strokes
Speed-min-1 (rpm) : 100
Control rack travel in mm : Minimum 19.0 10.STARTING FUEL DELIVERY
Speed-min-1 (rpm) : 100
Speed-min-1 (rpm) : 425
Control rack travel in mm : 16.0-16.5
Control rack travel in mm : 5.6-5.8
Delivery quantity(x ) :-
Speed-min-1 (rpm) : 490-550
in cm³/100 strokes
Control rack travel in mm : 2.0

Note:

1. Sl.No.of the operations indicate the sequence of operations. 3.(x):Average of the cylinders

2. Values given in brackets are overchecking values

Applicable only for BOSCH and MICO Test benches 251005


These Test specifications should not be copied or transmitted to a third party without our written permission.All rights reserved.
575 DI (1900 rpm)
Delphi-TVS PRODUCT COS No. STP2A300AC02
Mannur CUSTOMER OVERCHECK PART 1 of 1
SPECIFICATION ISSUE 2
PUMP No.: G8973A300A SERVICE CODING: ----

ENGINE DETAILS :

CUSTOMER : MAHINDRA & MAHINDRA APPLICATION : TRACTOR


ENGINE : MM 575 TREM 3 GOVERNING : 8 - 15 %
RATING : 44.5 hp @ 1900 E rpm ASA Ref : M&M: M65B3A
CUSTOMER Ref :

RELEASE STATUS

TARGET √ FORMAL †
PREPARED BY - B.Venkatarama krishnan DATE - 24/08/2007

Master Pump details:


Production Master : 008 CAI (48.5 mm3/str +/- 1) on production machine (PE-75168 and PE-75170)
Eng and QA Master : 010 CAI (47.7 mm3/str +/- 1) on production machine (PE-75168 and PE-75170)

DATE - 24/08/2007

TEST CONDITIONS

TEST MACHINE :PE1060 FEED PRESSURE : 1m head B/LEAK PRES. zero

NOZZLES : BDLOS6844 FLOW BAND: 11.2 TO 11.8 GPH N.O.P.: 178 bar

INJECTION PIPES : 6 x 1.75 x 450 CODE : R732/10EP

ADVANCE GAUGE : R732/4LY DATUM : 0 0 @ 500 RPM

ROTATION : CLOCKWISE LOOKING ON DRIVE END

* - All other checks as per Production test plan and Quality test plan
* - Leak checks to be conducted as per spec PS 25 unless otherwise stated.
√ Items of change throughout the document are indicated by this symbol.
DIMENSIONAL CHECKS (If required) :
As per the outline drawing as mentioned in the parts list

ISSUED BY : Engineering Dept


Delphi-TVS PRODUCT COS No. STP2A300AC02
Mannur CUSTOMER OVERCHECK PART 1 of 1
SPECIFICATION ISSUE 2
PUMP No.: G8973A300A SERVICE CODING: ----

AUDIT CHECK POINTS :

TP5

FUEL DELIVERY (F) F2


TRANSFER PRESSURE (TP)
TP1
F3
GF1
F1 TP2
BF2
BF3
GF2 TP3
BF1 LIGHT LOAD ADVANCE (LLA)
LLA1
LLA2
SF1 IF1
FAST IDLE FUEL A1

A2 CB1
TP4 CB2
GF3
IF2 CAMBOX PRES. (CB)
GF4
IF3 A3 ADVANCE (A)
A/STALL FUEL

SPEED PRPM SPEED PRPM

ITEM RPM TARGET √ ITEM RPM TARGET √


A1 950 0 0 +/- 0.5 LLA1 950 2.90 – 3.10 AT 12 – 20 mm3/STR

F2 950 TO MASTER +/- 2.0 mm3/str IF2 375 7.5 – 12.5 mm3/str
SET USING IDLE SCREW
SF1 100 30 mm3/STR MIN IF3 600 4 mm3/str MAX
GF3 1050 9 – 14 mm3/str
GF4 1200 7 mm3/str MAX

TIMING REFERENCE PUMP NUMBER : NA CODE :

TIMING STATIC DYNAMIC LOCKSHAFT

ANGLE: 200 ± 0.50


PORT : X

ELECTRIC SHUT OFF CHECK

SPEED : 400 RPM


DELIVERY POST SHUT OFF : 4 mm3/str MAX
Number : DATE : 24/08/2007 APPROVED : M.G.Bhaskar
SHEET : 2 of 3 FILE :\DI project\Mahindra\ MM575BS3\Test plans\...
Delphi-TVS PRODUCT COS No. STP2A300AC02
Mannur CUSTOMER OVERCHECK PART 1 of 1
SPECIFICATION ISSUE 2
PUMP No.: G8973A300A SERVICE CODING: ----

THROTTLE SHUT OFF LIMITS - NA

SPEED : RPM
DELIVERY POST SHUT OFF : mm3/st MAX

EXHAUST BRAKE LEVER LIMITS NA

SPEED : RPM
DELIVERY POST SHUT OFF : mm3/st MAX

ANTI-STALL CHECKS NA

SPEED : RPM
DELIVERY POST SHUT OFF : mm3/st MAX

MODIFICATIONS
ISSUE DATE Signature Remarks if any

1 18/05/2007 Release

2 24/08/2007 Change in Master Pump delivery setting at 950 rpm


Based on new PPAP certified FIP 121 EAI.

ADDITIONAL REQUIREMENTS:
ADVANCE MEASUREMENT TO BE TAKEN FROM CAM NOTCH, ON SIDE OF PUMP.
CAM ADVANCE TRAVEL 0.61mm = 1 DEG

Number : DATE : 24/08/2007 APPROVED : M.G.Bhaskar


SHEET : 3 of 3 FILE :\DI project\Mahindra\ MM575BS3\Test plans\...
575 DI (2300 rpm)
Delphi-TVS PRODUCT COS No. STPA111AC03
Mannur CUSTOMER OVERCHECK PART 1 of 1
SPECIFICATION ISSUE 3
PUMP No.: G8973A111A SERVICE CODING: ----

ENGINE DETAILS :

CUSTOMER : MAHINDRA & MAHINDRA APPLICATION : TRACTOR


ENGINE : MM 575 TREM 3 GOVERNING : 5-9 %
RATING : 47.5 hp @ 2300 E rpm ASA Ref : M&M: M37B3B
CUSTOMER Ref :

RELEASE STATUS

TARGET √ FORMAL †
PREPARED BY - I.Prabhu santiago DATE - 27/09/2005

Master Pump details:


Production Master : 011 BYI (38.7 mm3/str +/- 1) on production machine (780M-06, 780M-14 and PE-75170)
Eng and QA Master : 010 BYI (38.9 mm3/str +/- 1) on production machine (780M-06, 780M-14 and PE-75170)

DATE - 27/09/2005

TEST CONDITIONS

TEST MACHINE :HA780/PE1060 FEED PRESSURE : 1m head B/LEAK PRES. zero

NOZZLES : BDL110S6133/1 FLOW BAND: 7.5 – 8.0 GPH N.O.P.: 225 bar

INJECTION PIPES : 6 x 1.75 x 450 CODE : R732/10EP

ADVANCE GAUGE : R732/4LY DATUM : 0 0 @ 500 RPM

ROTATION : CLOCKWISE LOOKING ON DRIVE END

* - All other checks as per Production test plan and Quality test plan
* - Leak checks to be conducted as per spec PS 25 unless otherwise stated.
√ Items of change throughout the document are indicated by this symbol.
DIMENSIONAL CHECKS (If required) :
As per the outline drawing as mentioned in the parts list

ISSUED BY : Engineering Dept


Number : DATE : 27/09/2005 APPROVED : Sriramkumar
SHEET : 1 of 3 FILE :\DI project\Mahindra\ MM575BS3\Test plans\...
Delphi-TVS PRODUCT COS No. STPA111AC03
Mannur CUSTOMER OVERCHECK PART 1 of 1
SPECIFICATION ISSUE 3
PUMP No.: G8973A111A SERVICE CODING: ----

AUDIT CHECK POINTS :

TP5

FUEL DELIVERY (F) F2


TRANSFER PRESSURE (TP)
TP1
F3
GF1
F1 TP2
BF2
BF3
GF2 TP3
BF1 LIGHT LOAD ADVANCE (LLA)
LLA1
LLA2
SF1 IF1
FAST IDLE FUEL A1

A2 CB1
TP4 CB2
GF3
IF2 CAMBOX PRES. (CB)
GF4
IF3 A3 ADVANCE (A)
A/STALL FUEL

SPEED PRPM SPEED PRPM

ITEM RPM TARGET √ ITEM RPM TARGET √


A1 1150 1 0 +/- 0.5 LLA1 1150 2.90 – 3.10 AT 13 – 19 mm3/STR

A2 700 0 0 +/- 0.5

F2 1150 TO MASTER +/- 2.0 mm3/str IF2 400 4 – 7 mm3/str


SET USING IDLE SCREW
SF1 100 24 mm3/STR MIN IF3 700 3 mm3/str MAX
GF3 1250 17 – 21 mm3/str
GF4 1300 7 mm3/str MAX

TIMING REFERENCE PUMP NUMBER : NA CODE :

TIMING STATIC DYNAMIC LOCKSHAFT

ANGLE: 200 ± 0.50


PORT : X

ELECTRIC SHUT OFF CHECK


Number : DATE : 27/09/2005 APPROVED : Sriramkumar
SHEET : 2 of 3 FILE :\DI project\Mahindra\ MM575BS3\Test plans\...
Delphi-TVS PRODUCT COS No. STPA111AC03
Mannur CUSTOMER OVERCHECK PART 1 of 1
SPECIFICATION ISSUE 3
PUMP No.: G8973A111A SERVICE CODING: ----

SPEED : 400 RPM


DELIVERY POST SHUT OFF : 4 mm3/str MAX

THROTTLE SHUT OFF LIMITS - NA

SPEED : RPM
DELIVERY POST SHUT OFF : mm3/st MAX

EXHAUST BRAKE LEVER LIMITS NA

SPEED : RPM
DELIVERY POST SHUT OFF : mm3/st MAX

ANTI-STALL CHECKS NA

SPEED : RPM
DELIVERY POST SHUT OFF : mm3/st MAX

MODIFICATIONS
ISSUE DATE Signature Remarks if any

1 04/08/2005 Release
2 05/08/2005 Master delivery changed to meet customer
requirement of 47.5 hp
3 27/09/2005 Master delivery on Master FIPs changed for mean
power requirement

ADDITIONAL REQUIREMENTS:
ADVANCE MEASUREMENT TO BE TAKEN FROM CAM NOTCH, ON SIDE OF PUMP.
CAM ADVANCE TRAVEL 0.61mm = 1 DEG

Number : DATE : 27/09/2005 APPROVED : Sriramkumar


SHEET : 3 of 3 FILE :\DI project\Mahindra\ MM575BS3\Test plans\...
595 DI
Air Cleaner & Fuel System - Fuel Injection Pump Calibration Chart
Test Specifications
MICO (Subject to alterations)
Bosch Group For Field Service only
Mahindra Super Turbo 595 DI Sarpanch (Calibration Chart)
REFERENCE NO. : SSE-TS-MML 3.19 (B) ADJUSTMENT OF PUMP AND GOVERNOR
Edition : 10.1999
GUIDE SLEEVE TRAVEL
Replaces (edition : -
Control lever position : Free
Test oil : 9 916 034 004
Speed - min-1 (rpm) : 800
Combination : F 002 A0Z 143-E A40 0806 00 Control rack travel
Injection Pump : PES 4A 95D 320RS 2969 in mm : 0.3 - 0.7

88 Governor : RSV 425... 1050 A1C 1000 R 1. MAXIMUM SPEED CONTROL (RATED SPEED)
Customer : Mahindra & Mahindra Ltd. (without supplementary idling spring)

Engine model : MDI - 3000TC Control lever position : 610 ± 40


Engine code : 59113 Speed - min-1 (rpm) : 1050
Control rack travel
Application : Tractor
in mm : 9.7
TEST BENCH REQUIREMENTS Speed - min-1 (rpm) : 1110 - 1120
Test oil inlet Control rack travel
temperature : 380 - 420 C in mm : 8.7
Overflow valve : 9 451 037 430 Speed - min-1 (rpm) : 1130 - 1160
Control rack travel
Inlet pressure in bar : 1.5 in mm : 4.0
Test injector : 0 681 343 009 Speed - min-1 (rpm) : 1350
Opening pressure Control track travel
in bar : 172 - 176 in mm : 0.3 - 1.4
High Pressure pipe : 6 x 1.8 x 385
(OD x ID x length) in mm 2. FULL LOAD DELIVERY
Speed - min-1 (rpm) : 1050
(A) CALIBRATION OF PUMP WITHOUT GOVERNOR Boost pressure in bar : -
ACTION
Control rack travel
Direction of rotation : Clockwise in mm : 9.7
-
Delivery quantity (x)
Prestroke in mm : 3.25 - 3.35 (3.20 - 3.40)
Control rack in cm3/ 500 strokes : 35.8 - 36.3 (34.6 - 37.8)
position in mm : 9 - 12 Maximum spread
Cam sequence : 1-3-4-2 in cm3 (Δ) : 1.8 (4.0)
Cam displacement : 900 ± 0.50 Speed - min-1 (rpm) : -
Tappet clearance Boost pressure in bar : -
in mm : Min 0.2 Control rack travel
in mm : -
BASIC SETTING -
Delivery quantity (x)
Speed - min-1 (rpm) : 1050 in cm3 / 500 strokes : -
Control rack Maximum spread
travel in mm : 9.7 in cm3 (Δ) : -
-
Delivery quantity(x)
3
in cm / 100 strokes : 7.4 - 7.6 3. TORQUE CONTROL
Maximum spread Speed - min-1 (rpm) : Not applicable
in cm3 (Δ) : 0.4 (0.8) Control rack travel
in mm : -
-1
Speed - min (rpm) : -
Speed - min-1 (rpm) : 425 Control rack travel
Control rack travel in mm : -
in mm : 6.0 Speed - min-1 (rpm) : -
-
Delivery quantity (x) Control rack travel
3
in cm / 100 strokes : 0.4 - 0.8 (0.2 -1.1) in mm : -
Maximum spread
in cm3 (Δ) : 0.6 (0.9)

1st Version 2nd set.pmd 88 6/3/2006, 11:18 AM


Air Cleaner & Fuel System - Fuel Injection Pump Calibration Chart
SSE-TS-MML 3.19

4. COURSE OF DELIVERY 7. GOVERNOR CUTTING IN SPEED


Speed - min-1 (rpm) : 750 Speed - min-1 (rpm) : 1110 - 1120
Boost pressure in bar : - Control rack travel
-
Delivery quantity (x) in mm : Less by 1 mm from full pad
in cm3 / 500 strokes : 32.5 - 33 (31.3 - 34.3) control rack travel
Maximum spread
in cm3 (Δ) : 2.5 (4.0) While over checking, if the cutting-in speed is above the
Speed - min-1 (rpm) : - reated speed and if,
Boost pressure in bar : - - the delivery values are within the overchecking
-
Delivery quantity (x) : - tolerance
in cm3 / 500 strokes - control rack remains at full load position even at
Maximum spread 50 min-1 (rpm) less than the rated speed
in cm3 (Δ) : - the cutting-in speed should be declared OK.

5. IDLING SPEED CONTROL (RATED SPEED) 8. DEGREE OF IRREGULARITY


Control lever position : 310 ±40 Speed - min-1 (rpm) : 1150 - 1180
Speed - min-1 (rpm) :
425 Control rack travel
in mm : 4.0
Control rack travel
in mm : 8.2 No of notches : -18
Speed - min-1 (rpm) :
100
Control rack travel 9. STARTING TRAVEL
in mm : Minimum 19.0 Speed - min-1 (rpm) : 100
Speed - min-1 (rpm) :
425 Control rack travel
Control rack travel in mm : 19.5 - 21.0
in mm : 5.8 - 6.2
Speed - min-1 (rpm) : 540 - 600 10. STARTING FUEL DELIVERY
Control rack travel Speed - min-1 (rpm) : -
in mm : 2.0 Control rack travel
in mm : -
6. MAXIMUM SPEED CONTROL (RATED SPEED) -
Delivery quantity (x)
(without supplementary idling spring)
in cm3 / 500 strokes : -
Speed - min-1 (rpm) : -
Control rack travel
in mm : -
Speed - min-1 (rpm) : -
Control rack travel
in mm : -

OTHER INFORMATION :
Element : F 002 B10 528 Adaption capsule : 9 430 034 281
Delivery valve : 9 411 038 576
Flyweight assembly : 1 428 194 019 Nozzle :
Governor spring : 1 424 650 005 Opening pressure
in bar : 250 - 258

Note :
1. Sl. No. of the operations indicate the sequence of operations
2. Values given in brackets are overchecking values
3. x- : Average of the cylinders
E0999

Applicable only for BOSCH and MICO test benches


These Test specifications should not be copied or transmitted to a third party without our written permission. All rights reserved.

1st Version 2nd set.pmd 89 6/3/2006, 11:18 AM


ARJUN BS3

Main Menu
REFERENCE NO
555 DI
Test Specifications
(subject to alternations)
For Field Service only

: STS-TS-MML (B) ADJUSTMENT OF PUMP AND


REFERENCE NO GOVERNOR
F_492
Edition : 06.2005 GUIDE SLEEVE
TRAVEL
Replaces(edition) :-
Control lever position : Free
Test oil : 9 916 034 004
Speed-min-1 (rpm) : 800
Revision :1
Control rack travel in
: F002A0Z492-E 040 : 0.3-0.7
Combination No. mm
185 900 1.MAXIMUM SPEED CONTROL (RATED
: PES 4 A 95 D 320 SPEED)
Injection pump
RS 2000 (without supplementry idling spring)
: RSV 400...1050 A 1 Control lever position : 55.0±4.0°
Governor
C 1431 R Speed-min-1 (rpm) : -
: Mahindra & Boost pressure in bar : -
Customer
Mahindra Ltd.
Control rack travel in
Engine model : NE452 : -
mm
Engine code : 59166 Speed-min-1 (rpm) : 1050
: TRACTOR-555 DI
Application Boost pressure in bar : -
(Domestic) - Arjun
Control rack travel in
TEST BENCH REQUIREMENTS : 8.55-8.65
mm
Speed-min-1 (rpm) : 1090-1100
Test oil inlet
: 38°-42°C Boost pressure in bar : -
temperature
Overflow valve : F002A10627 Control rack travel in
: 7.6
mm
Inlet pressure in bar : 1.5
Speed-min-1 (rpm) : 1105-1135
Test injector : 0681343009
Opening pressure in Boost pressure in bar : -
: 172.0-175.0 Control rack travel in
bar : 4.0
High pressure pipe : 6X2X600 mm
(ODXIDxlength) in Speed-min-1 (rpm) : 1280
mm Boost pressure in bar : -
Control rack travel in
: 0.3-1.4
mm

file:///C|/Documents and Settings/098726/Local Set....Outlook/EY2ZSHQI/Calibration Chart -555DI BS3.htm (1 of 4) [7/5/2012 11:55:22 AM]
REFERENCE NO

2.FULL LOAD
(A) CALIBRATION OF PUMP WITHOUT DELIVERY
GOVERNOR ACTION Speed-min-1 (rpm) : 1050
Boost pressure in bar :-
Control rack travel in
Direction of rotation : Clockwise : 8.55-8.65
mm
Prestroke in mm : 4.35-4.45(4.3-4.5)
Delivery quantity(x ) : 29.0-30.0(28.0-31.0)
Control rack position
: 9.0-12.0 in cm³/500 strokes
in mm
Cam sequence : 1- 3- 4- 2 Maximum spread in
: 1.8(4.0)
cm³
: 0-90-180-270°
Cam displacement 3.TORQUE
±0.5°
Tappet clearance in CONTROL
: min 0.2 Speed-min-1 (rpm) :-
mm
Injection Timing Boost pressure in bar :-
:-
locking Control rack travel in
:-
BASIC SETTING mm
Speed-min-1 (rpm) :-
Boost pressure in bar :-
Speed-min-1 (rpm) : 1050
Control rack travel in
Control rack travel in :-
: 8.55-8.65 mm
mm
Speed-min-1 (rpm) : 500
Delivery quantity(x ) : 5.75-6.05
Boost pressure in bar :-
in cm³/100 strokes
Control rack travel in
Maximum spread in : 10.1-10.3
: 0.4(0.8) mm
cm³
Speed-min-1 (rpm) : 700
Boost pressure in bar :-
Control rack travel in
Speed-min-1 (rpm) : 400 : 9.7-9.9
mm
Control rack travel in
: 7.0-7.2 Speed-min-1 (rpm) :-
mm
Boost pressure in bar :-
Delivery quantity(x ) : 0.6-1.0(0.35-1.25)
Control rack travel in
in cm/100 strokes :-
mm
Maximum spread in
: 0.6(0.9) Speed-min-1 (rpm) : 1050
cm³
Boost pressure in bar :-
Control rack travel in
: 8.55-8.65
mm
Contd...2

STS-TS-MML F_492

file:///C|/Documents and Settings/098726/Local Set....Outlook/EY2ZSHQI/Calibration Chart -555DI BS3.htm (2 of 4) [7/5/2012 11:55:22 AM]
REFERENCE NO

4. COURSE OF 6.MAXIMUM SPEED CONTROL (RATED


DELIVERY SPEED)
Speed-min-1 (rpm) :- (with supplementary idling spring)
Boost pressure in bar : -
Delivery quantity(x ) : - Speed-min-1 (rpm) :-
in cm³/500 strokes Control rack travel in
:-
Maximum spread in mm
:-
cm³
Speed-min-1 (rpm) : 700 7. GOVERNOR CUTTING IN SPEED
Boost pressure in bar : - Speed-min-1 (rpm) : 1090-1100
Delivery quantity(x ) : 30.0-32.0(29.0-33.0) Boost pressure in bar : -
in cm³/500 strokes Control rack travel in
Maximum spread in : 7.6
: 2.5 (4.0) mm
cm³
Speed-min-1 (rpm) :- While over checking ,if the cutting speed is
Boost pressure in bar : - above the rated speed and if,
Delivery quantity(x ) : - -the delivery values are within the
in cm³/500 strokes overchecking tolerance
Maximum spread in -control rack remains at full load position
:- even at 50 min
cm³
Speed-min-1 (rpm) :- (rpm) less than the rated speed
Control rack travel in the cutting-in speed should be declared OK.
:-
mm 8. DEGREE OF IRREGULARY
Delivery quantity(x ) : - Speed-min-1 (rpm) : 1120-1150
in cm³/500 strokes Boost pressure in bar : -
Maximum spread in Control rack travel in
:- : 4.0
cm³ mm
5. IDLING SPEED CONTROL (RATED No of notches : 18.0
SPEED) 9. STARTING
Control lever position : 26.0±4.0° TRAVEL
Speed-min-1 (rpm) : 400 Speed-min-1 (rpm) :-
Control rack travel in Control rack travel in
: 7.0-7.2 :-
mm mm
Speed-min-1 (rpm) : 100 Delivery quantity(x ) : -
Control rack travel in in cm³/500 strokes
: Minimum 19.0
mm
Speed-min-1 (rpm) : 400
Control rack travel in
: 7.0-7.2
mm
Speed-min-1 (rpm) : 555-615

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REFERENCE NO

Control rack travel in 10.STARTING FUEL DELIVERY


: 2.0
mm Speed-min-1 (rpm) : 100
Control rack travel in
: 19.75-21.25
mm
Delivery quantity(x ) : -
in cm³/100 strokes

OTHER
INFORMATION
Element : Adaption capsule :
Delivery valve :
Flyweight assembly : Nozzle :
Opening pressure in
Governor spring : :
bar
Note:
1. Sl.No.of the operations indicate the
3.(x):Average of the cylinders
sequence of operations.
2. Values given in brackets are overchecking
values

Applicable only for BOSCH and MICO Test benches 170605


These Test specifications should not be copied or transmitted
to a third party without our written permission.All rights
reserved.

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REFERENCE NO

445 DI
Test Specifications
(subject to alternations)
For Field Service only

(B) ADJUSTMENT OF PUMP AND


: STS-TS-MML GOVERNOR
REFERENCE NO
F_490_P GUIDE SLEEVE
Edition : 06.2005 TRAVEL
Replaces(edition) :- Control lever position : Free
Test oil : 9 916 034 004 Speed-min-1 (rpm) : 800
Revision :1 Control rack travel in
: 0.5
: F002A0Z490- E B40 mm
Combination No. 1.MAXIMUM SPEED CONTROL (RATED
177 800
SPEED)
: PES 3 A 95 D 320
Injection pump (without supplementry idling spring)
RS 2000
: RSV 400...1050 A 1 Control lever position : 56.0±4.0°
Governor :
C 1431 R Speed-min-1 (rpm) -
: Mahindra & Boost pressure in bar : -
Customer
Mahindra Ltd. Control rack travel in
: -
: NE 342 (445 DI) - mm
Engine model
Domestic Speed-min-1 (rpm) : 1050
Engine code : 59154 Boost pressure in bar : -
: TRACTOR-445 DI Control rack travel in
Application : 10.15-10.25
(Domestic) - Arjun mm
TEST BENCH REQUIREMENTS Speed-min-1 (rpm) : 1095-1105
Boost pressure in bar : -
Test oil inlet Control rack travel in
: 38°-42°C : 9.2
temperature mm
Overflow valve : F002A10627 :
Speed-min-1 (rpm) 1125-1145
Inlet pressure in bar : 1.5
Boost pressure in bar : -
Test injector : 0681343009
Control rack travel in
Opening pressure in : 4.0
: 172.0-175.0 mm
bar
Speed-min-1 (rpm) : 1300
High pressure pipe : 6X2X600
(ODXIDxlength) in Boost pressure in bar : -
mm Control rack travel in
: 0.3-1.4
mm

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REFERENCE NO

2.FULL LOAD
(A) CALIBRATION OF PUMP WITHOUT DELIVERY
GOVERNOR ACTION Speed-min-1 (rpm) : 1050
Boost pressure in bar :-
Control rack travel in
Direction of rotation : Clockwise : 10.15-10.25
mm
Prestroke in mm : 3.75-3.85(3.7-3.9)
Delivery quantity(x ) : 34.5-35.5(33.5-36.5)
Control rack position
: 9.0-12.0 in cm³/500 strokes
in mm
Cam sequence :1-3-2 Maximum spread in
: 1.8(4.0)
cm³
Cam displacement : 0 -120- 240° ±0.5°
3.TORQUE
Tappet clearance in
: min 0.2 CONTROL
mm
Injection Timing Speed-min-1 (rpm) :-
:- Boost pressure in bar :-
locking
BASIC SETTING Control rack travel in
:-
mm
Speed-min-1 (rpm) :-
Speed-min-1 (rpm) : 1050
Boost pressure in bar :-
Control rack travel in
: 10.15-10.25 Control rack travel in
mm :-
mm
Delivery quantity(x ) : 6.85-7.15
Speed-min-1 (rpm) : 600
in cm³/100 strokes Boost pressure in bar :-
Maximum spread in Control rack travel in
: 0.4(0.8) : 11.3-11.5
cm³ mm
Speed-min-1 (rpm) : 800
Boost pressure in bar :-
Speed-min-1 (rpm) : 400 Control rack travel in
Control rack travel in : 10.9-11.1
: 7.9-8.1 mm
mm Speed-min-1 (rpm) :-
Delivery quantity(x ) : 0.7-1.1(0.45-1.35) Boost pressure in bar :-
in cm/100 strokes Control rack travel in
Maximum spread in :-
: 0.6(0.9) mm
cm³ Speed-min-1 (rpm) : 1050
Boost pressure in bar :-
Control rack travel in
: 10.15-10.25
mm
Contd...2

STS-TS-MML F_490_P

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REFERENCE NO

4. COURSE OF 6.MAXIMUM SPEED CONTROL (RATED


DELIVERY SPEED)
Speed-min-1 (rpm) :- (with supplementary idling spring)
Boost pressure in bar : -
Delivery quantity(x ) : - Speed-min-1 (rpm) :-
in cm³/500 strokes Control rack travel in
:-
Maximum spread in mm
:-
cm³
Speed-min-1 (rpm) : 800 7. GOVERNOR CUTTING IN SPEED
Boost pressure in bar : - Speed-min-1 (rpm) : 1095-1105
Delivery quantity(x ) : 35.5-37.5(34.5-38.5) Boost pressure in bar : -
in cm³/500 strokes Control rack travel in
Maximum spread in : 9.2
: 2.5 (4.0) mm
cm³
Speed-min-1 (rpm) :- While over checking ,if the cutting speed is
Boost pressure in bar : - above the rated speed and if,
Delivery quantity(x ) : - -the delivery values are within the
in cm³/500 strokes overchecking tolerance
Maximum spread in -control rack remains at full load position
:- even at 50 min
cm³
Speed-min-1 (rpm) :- (rpm) less than the rated speed
Control rack travel in the cutting-in speed should be declared OK.
:-
mm 8. DEGREE OF IRREGULARY
Delivery quantity(x ) : - Speed-min-1 (rpm) : 1155-1185
in cm³/500 strokes Boost pressure in bar : -
Maximum spread in Control rack travel in
:- : 4.0
cm³ mm
5. IDLING SPEED CONTROL (RATED No of notches : 18.0
SPEED) 9. STARTING
Control lever position : 28.0±4.0° TRAVEL
Speed-min-1 (rpm) : 400 Speed-min-1 (rpm) :-
Control rack travel in Control rack travel in
: 7.9-8.1 :-
mm mm
Speed-min-1 (rpm) : 100 Delivery quantity(x ) : -
Control rack travel in in cm³/500 strokes
: Minimum 19.0
mm
Speed-min-1 (rpm) : 400
Control rack travel in
: 7.9-8.1
mm

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REFERENCE NO

Speed-min-1 (rpm) : 585-645 10.STARTING FUEL DELIVERY


Control rack travel in Speed-min-1 (rpm) : 100
: 2.0
mm Control rack travel in
: 19.75-21.25
mm
: 13.15-14.65(12.9-
Delivery quantity(x )
14.9)
in cm³/100 strokes

OTHER
INFORMATION
Element : Adaption capsule :
Delivery valve :
Flyweight assembly : Nozzle :
Opening pressure in
Governor spring : :
bar
Note:
1. Sl.No.of the operations indicate the
3.(x):Average of the cylinders
sequence of operations.
2. Values given in brackets are overchecking
values

Applicable only for BOSCH and MICO Test benches 190205


These Test specifications should not be copied or transmitted
to a third party without our written permission.All rights
reserved.

file:///C|/Documents and Settings/098726/Local Set...Outlook/EY2ZSHQI/Calibration Chart -445 DI BS3.htm (4 of 4) [7/5/2012 11:54:47 AM]
REFERENCE NO

605 DI
Test Specifications
(subject to alternations)
For Field Service only

: STS-TS-MML (B) ADJUSTMENT OF PUMP AND


REFERENCE NO GOVERNOR
F_491_P
Edition : 06.2005 GUIDE SLEEVE
TRAVEL
Replaces(edition) :-
Control lever position : Free
Test oil : 9 916 034 004
Speed-min-1 (rpm) : 800
Revision :0
Control rack travel in
: F002A0Z491-E B40 : 0.3-0.7
Combination No. mm
180 500 1.MAXIMUM SPEED CONTROL (RATED
: PES 4 A 95 D 320 SPEED)
Injection pump
RS 2000 (without supplementry idling spring)
: RSV 400...1050 A 1 Control lever position : 55.0±4.0°
Governor
C 1431 R Speed-min-1 (rpm) : -
: Mahindra & Boost pressure in bar : -
Customer
Mahindra Ltd.
Control rack travel in
Engine model : NEF 457 -Domestic : -
mm
Engine code : 59250 Speed-min-1 (rpm) : 1050
: TRACTOR-605 DI
Application Boost pressure in bar : -
(Domestic) - Arjun
Control rack travel in
TEST BENCH REQUIREMENTS : 9.95-10.05
mm
Speed-min-1 (rpm) : 1090-1100
Test oil inlet
: 38°-42°C Boost pressure in bar : -
temperature
Overflow valve : F002A10627 Control rack travel in
: 9.0
mm
Inlet pressure in bar : 1.5
Speed-min-1 (rpm) : 1115-1145
Test injector : 0681343009
Opening pressure in Boost pressure in bar : -
: 172.0-175.0 Control rack travel in
bar : 4.0
High pressure pipe : 6X2X600 mm
(ODXIDxlength) in Speed-min-1 (rpm) : 1315
mm Boost pressure in bar : -
Control rack travel in
: 0.3-1.4
mm

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REFERENCE NO

2.FULL LOAD
(A) CALIBRATION OF PUMP WITHOUT DELIVERY
GOVERNOR ACTION Speed-min-1 (rpm) : 1050
Boost pressure in bar :-
Control rack travel in
Direction of rotation : Clockwise : 9.95-10.05
mm
Prestroke in mm : 4.35-4.45(4.3-4.5)
Delivery quantity(x ) : 33.0-34.0(32.0-35.0)
Control rack position
: 9.0-12.0 in cm³/500 strokes
in mm
Cam sequence : 1- 3- 4- 2 Maximum spread in
: 1.8(4.0)
cm³
: 0-90-180-270°
Cam displacement 3.TORQUE
±0.5°
Tappet clearance in CONTROL
: min 0.2 Speed-min-1 (rpm) :-
mm
Injection Timing Boost pressure in bar :-
:-
locking Control rack travel in
:-
BASIC SETTING mm
Speed-min-1 (rpm) :-
Boost pressure in bar :-
Speed-min-1 (rpm) : 1050
Control rack travel in
Control rack travel in :-
: 9.95-10.05 mm
mm
Speed-min-1 (rpm) : 600
Delivery quantity(x ) : 6.55-6.85
Boost pressure in bar :-
in cm³/100 strokes
Control rack travel in
Maximum spread in : 10.8-11.0
: 0.4(0.8) mm
cm³
Speed-min-1 (rpm) : 700
Boost pressure in bar :-
Control rack travel in
Speed-min-1 (rpm) : 400 : 10.6-10.8
mm
Control rack travel in
: 7.6-7.8 Speed-min-1 (rpm) :-
mm
Boost pressure in bar :-
Delivery quantity(x ) : 0.6-1.0(0.35-1.25)
Control rack travel in
in cm/100 strokes :-
mm
Maximum spread in
: 0.6(0.9) Speed-min-1 (rpm) : 1050
cm³
Boost pressure in bar :-
Control rack travel in
: 9.95-10.05
mm
Contd...2

STS-TS-MML F_491_P

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REFERENCE NO

4. COURSE OF
DELIVERY 6.MAXIMUM SPEED CONTROL (RATED
Speed-min-1 (rpm) :- SPEED)
Boost pressure in bar :- (with supplementary idling spring)
Delivery quantity(x ) :-
in cm³/500 strokes Speed-min-1 (rpm) :-
Maximum spread in Control rack travel in
:- :-
cm³ mm
Speed-min-1 (rpm) : 700
Boost pressure in bar :- 7. GOVERNOR CUTTING IN SPEED
: 28.75-30.75(27.75- Speed-min-1 (rpm) : 1090-1100
Delivery quantity(x )
31.75) Boost pressure in bar : -
in cm³/500 strokes Control rack travel in
: 9.0
Maximum spread in mm
: 2.5 (4.0)
cm³
Speed-min-1 (rpm) :- While over checking ,if the cutting speed is
Boost pressure in bar : - above the rated speed and if,
Delivery quantity(x ) : - -the delivery values are within the
in cm³/500 strokes overchecking tolerance
-control rack remains at full load position
Maximum spread in
:- even at 50 min
cm³
(rpm) less than the rated speed
Speed-min-1 (rpm) :-
Control rack travel in the cutting-in speed should be declared OK.
:- 8. DEGREE OF IRREGULARY
mm
Delivery quantity(x ) : - Speed-min-1 (rpm) : 1150-1180
in cm³/500 strokes Boost pressure in bar : -
Maximum spread in Control rack travel in
:- : 4.0
cm³ mm
5. IDLING SPEED CONTROL (RATED No of notches : 18.0
SPEED) 9. STARTING
Control lever position : 27.0±4.0° TRAVEL
Speed-min-1 (rpm) : 400 Speed-min-1 (rpm) :-
Control rack travel in Control rack travel in
: 7.6-7.8 :-
mm mm
Speed-min-1 (rpm) : 100 Delivery quantity(x ) : -
Control rack travel in in cm³/500 strokes
: Minimum 19.0
mm
Speed-min-1 (rpm) : 400
Control rack travel in
: 7.6-7.8
mm

file:///C|/Documents and Settings/098726/Local Set....Outlook/EY2ZSHQI/Calibration Chart -605DI BS3.htm (3 of 4) [7/5/2012 11:55:49 AM]
REFERENCE NO

Speed-min-1 (rpm) : 570-630 10.STARTING FUEL DELIVERY


Control rack travel in Speed-min-1 (rpm) : 100
: 2.0
mm Control rack travel in
: 19.75-21.25
mm
Delivery quantity(x ) : -
in cm³/100 strokes

OTHER
INFORMATION
Element : Adaption capsule :
Delivery valve :
Flyweight assembly : Nozzle :
Opening pressure in
Governor spring : :
bar
Note:
1. Sl.No.of the operations indicate the
3.(x):Average of the cylinders
sequence of operations.
2. Values given in brackets are overchecking
values

Applicable only for BOSCH and MICO Test benches 101204


These Test specifications should not be copied or transmitted
to a third party without our written permission.All rights
reserved.

file:///C|/Documents and Settings/098726/Local Set....Outlook/EY2ZSHQI/Calibration Chart -605DI BS3.htm (4 of 4) [7/5/2012 11:55:49 AM]