5 Test Specifications

(Subject to alterations)
For Field Service only
REFERENCE NO. : STS-TS-MML 2.52 k1 1.4 Idling delivery
Edition : 03.2006 Speed - min-1 (rpm) : 450
Replaces (edition) : 04.2005 Delivery quantity ( x ) : 7.5 ± 0.5
Test oil : F 002 S3E 001 in cm³ /500 strokes
Injection pump : 0 460 414 251-VE4/11F1600R85Maximum spread in cm³ (') : 2.5
(B 460 816 011) 1.5 Maximum speed regulation
Speed - min-1 (rpm) : 1800
Boost pressure in bar -
Delivery quantity ( x ) : 26.5± 0.5
in cm³ /500 strokes
Maximum spread in cm³ (') : -
Customer : Mahindra & Mahindra Ltd. 1.6 Starting fuel delivery
Engine model : MDI 3200 TCI BSII Speed - min-1 (rpm) : 100
Engine code : 82143 Delivery quantity ( x ) : 50.0 ± 12.5
Application : MUV, Pick-up 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 : 1 688 901 022 1.8 Exhaust Gas Recirculation (EGR)setting point
Opening pressure in bar : 130 - 133 Speed - min-1 (rpm) : 450
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 Input voltage : 4.7 ± 0.5 V
Direction of rotation : Clockwise Output voltage : 0.4 ± 0.05 V
Plunger stroke in mm : 1.17 ± 0.02 Voltage to be set by keeping the control lever in idling
Drive shaft key way position position
at BDC : Between A & D (DV holders)
Drive shaft key way position after injection timing locking 2. TESTING
should be inline with DV holder A 2.1 Timer travel
1. SETTING Speed - min-1 (rpm) : 1350
1.1 Timer travel Timer travel in mm : (1.9 - 2.9)
Speed - min-1 (rpm) : 1350 Speed - min-1 (rpm) : 1600
Boost pressure in bar : - Timer travel in mm : 3.1 - 4.3
Timer travel in mm : 2.4 ± 0.2 Speed - min-1 (rpm) : -
1.2 Vane pump pressure Timer travel in mm : -
-1
Speed - min (rpm) : 1350 2.2 Vane pump pressure
Boost pressure in bar : - Speed - min-1 (rpm) : -
Vane pump pressure in bar : 7.3 ± 0.5 Vane pump pressure in bar : -
1.3 Full load delivery Speed - min-1 (rpm) : 1350
Speed - min-1 (rpm) : 1200 Vane pump pressure in bar : (6.5 - 8.1)
Boost pressure in bar : - 2.3 Overflow quantity
Delivery quantity ( x ) : 58.5± 0.5 Speed - min-1 (rpm) : 1600
in cm³ /500 strokes Boost pressure in bar : -
Maximum spread in cm³ (') : 2.5 Overflow quantity : 119 - 203
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
 STS-TS-MML 2.52 k1 -2-

2.4 Fuel deliveries Electrical shutoff (solenoid)

End stop (By disconnecting solenoid switch)
Control lever position : Maximum Control lever position : Idling position

Speed - min-1 (rpm) : 1200 Speed - min-1 (rpm) : 450

Boost pressure in bar : - Boost pressure in bar : -
Delivery quantity ( x ) : (56.50 - 60.50) Delivery quantity ( x ) : Maximum 1.5
in cm³ /500 strokes in cm³ /500 strokes
Speed - min-1 (rpm) : 1600 Maximum spread in cm³ (') : 2.5
Boost pressure in bar : - Mechanical shutoff
Delivery quantity ( x ) : 54.75 - 59.25 (By operating stop lever)
in cm³ /500 strokes Speed - min-1 (rpm) : -
Speed - min-1 (rpm) : 600 Boost pressure in bar : -
Boost pressure in bar : - Delivery quantity ( x ) : -
Delivery quantity ( x ) : 40.5 - 44.5 in cm³ /500 strokes
in cm³ /500 strokes Maximum spread in cm³ (') : -
Speed - min-1 (rpm) : 1800 Exhaust Gas Recirculation (EGR)
Boost pressure in bar : - Speed - min-1 (rpm) : -
Delivery quantity ( x ) : (23.5 - 29.5) Delivery quantity ( x ) : -
in cm³ /500 strokes in cm³ /500 strokes
Speed - min-1 (rpm) : - Input voltage : -
Boost pressure in bar : - Output voltage : -
Delivery quantity ( x ) : - -
in cm³ /500 strokes -
Speed - min-1 (rpm) : - -
Boost pressure in bar : - Speed - min-1 (rpm) : 450
Delivery quantity ( x ) : - Input voltage : 4.7 ± 0.5 V
in cm³ /500 strokes Output voltage : 0.4 ± 0.5 V
Idle stop (tio be checked by control lever in idling position)

Control lever position : Idling position

2.5 Solenoid
Speed - min-1 (rpm) : 450 Rated voltage : 12 V
Delivery quantity ( x ) : (4.5 - 10.5) 3. ASSEMBLY AND SETTING DIMENSIONS
in cm³ /500 strokes Description
Speed - min-1 (rpm) : - K : 3.64 - 3.76 mm
Delivery quantity ( x ) : - KF : 8.2 - 8.6 mm
in cm³ /500 strokes MS1 : 0.95 - 1.22 mm

Note: 3 X : Average of the cylinders

1 .Sl. No. of the operations indicate the sequence of operation.
2 .Values given in brackets are overchecking values
Applicable only for BOSCH and MICO test benches 100106
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