REFERENCE NO : TSS-TS-MML F..728 Edition : 01.2012 Replaces(edition) : 10.2010 Test oil : F 002 S3E 001 Revision : 6 Combination No. : F 002 A0Z 728-E040.229.200 Injection pump : PES 4 A 85 D 320 RS 2000 Governor : RSV 400...950 A 5 C 1592 R Customer : Mahindra & Mahindra Ltd. Engine model : MDI 2385 N 3A Engine code : - Application : TRACTOR-475DI TEST BENCH REQUIREMENTS Test oil inlet temperature : 38°-42°C Overflow valve : F002A10627 Inlet pressure in bar : 1.5 Test injector : 0681343009 Opening pressure in bar : 172.0-175.0 High pressure pipe : 6X2X600 (ODXIDxlength) in mm (A) CALIBRATION OF PUMP WITHOUT GOVERNOR ACTION Direction of rotation : Clockwise Prestroke in mm : 3.65-3.75(3.6-3.8) Control rack position in mm : 9.0-12.0 Cam sequence : 1-3-4-2 Cam displacement : 0-90-180-270° ±0.5° Tappet clearance in mm : min 0.2 Injection Timing locking : - BASIC SETTING Speed-min-1 (rpm) : 950 Control rack travel in mm : 10.35-10.45 Delivery quantity(x ) : 5.3-5.6 in cm³/100 strokes Maximum spread in cm³ : 0.3(0.7) Speed-min-1 (rpm) : 400 Control rack travel in mm : 6.9-7.1 Delivery quantity(x ) : 0.7-1.1(0.5-1.3) in cm/100 strokes Maximum spread in cm³ : 0.5(0.7) (B) ADJUSTMENT OF PUMP AND GOVERNOR GUIDE SLEEVE TRAVEL Control lever position : Free Speed-min-1 (rpm) : 800 Control rack travel in mm : 0.3-0.7 1.MAXIMUM SPEED CONTROL (RATED SPEED) (without supplementry idling spring) Control lever position : 45.0±4.0° 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 mm : 10.35-10.45 Speed-min-1 (rpm) : 990-1000 Boost pressure in bar : - Control rack travel in mm : 9.4 Speed-min-1 (rpm) : 1040-1070 Boost pressure in bar : - Control rack travel in mm : 4.0 Speed-min-1 (rpm) : 1225 Boost pressure in bar : - Control rack travel in mm : 0.3-1.4 2.FULL LOAD DELIVERY Speed-min-1 (rpm) : 950 Boost pressure in bar : - Control rack travel in mm : 10.35-10.45 Delivery quantity(x ) : 27.0-27.5(26.0-28.5) in cm³/500 strokes Maximum spread in cm³ : 1.5(3.5) 3.TORQUE CONTROL Speed-min-1 (rpm) : - Boost pressure in bar : - Control rack travel in mm : - Speed-min-1 (rpm) : - Boost pressure in bar : - Control rack travel in mm :- Speed-min-1 (rpm) : 500 Boost pressure in bar : - Control rack travel in mm : 11.4-11.6 Speed-min-1 (rpm) : 700 Boost pressure in bar : - Control rack travel in mm : 11.4-11.6 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 mm : 10.35-10.45 Contd...2 TSS-TS-MML F..728 4. COURSE OF DELIVERY Speed-min-1 (rpm) : 500 Boost pressure in bar : - Delivery quantity(x ) : 22.25-23.75(21.25-24.75) in cm³/500 strokes Maximum spread in cm³ : 2.0(4.0) Speed-min-1 (rpm) : 700 Boost pressure in bar : - Delivery quantity(x ) : 26.75-28.25(25.75-29.25) in cm³/500 strokes Maximum spread in cm³ : 2.0(4.0) Speed-min-1 (rpm) : - Boost pressure in bar : - Delivery quantity(x ) : - in cm³/500 strokes Maximum spread in cm³ : - Speed-min-1 (rpm) : - Control rack travel in mm : - Delivery quantity(x ) : - in cm³/500 strokes Maximum spread in cm³ : - 5. IDLING SPEED CONTROL (RATED SPEED) Control lever position : 23.0±4.0° Speed-min-1 (rpm) : 400 Control rack travel in mm : 6.9-7.1 Speed-min-1 (rpm) : 100 Control rack travel in mm : Minimum 19.0 Speed-min-1 (rpm) : 400 Control rack travel in mm : 6.9-7.1 Speed-min-1 (rpm) : 490-550 Control rack travel in mm : 2.0 6.MAXIMUM SPEED CONTROL (RATED SPEED) (with supplementary idling spring) Speed-min-1 (rpm) : - Control rack travel in mm : - 7. GOVERNOR CUTTING IN SPEED Speed-min-1 (rpm) : 990-1000 Boost pressure in bar : - Control rack travel in mm : 9.4 While over checking ,if the cutting speed is above the rated speed and if, -the delivery values are within the overchecking tolerance -control rack remains at full load position even at 50 min (rpm) less than the rated speed the cutting-in speed should be declared OK. 8. DEGREE OF IRREGULARY Speed-min-1 (rpm) : 1055-1085 Boost pressure in bar : - Control rack travel in mm : 4.0 No of notches : 16.0 9. STARTING TRAVEL Speed-min-1 (rpm) : - Control rack travel in mm : - Delivery quantity(x ) : - in cm³/500 strokes 10.STARTING FUEL DELIVERY Speed-min-1 (rpm) : 100 Control rack travel in mm : 16.0-16.5 Delivery quantity(x ) : - in cm³/100 strokes