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BOSCH EP test values diesel fuel-injection equipment Test date Customer ID No. 07.01.

2009 Time: 14:15:50

Page: 1 Job. no.: ____________________ Serial no.: ____________________

PUMP AND CUSTOMER DATA PUMP DATA Edition Part no. Pump designation CUSTOMER DATA Customer Engine TEST PREREQUISITES CAT Designation Test oil Calibrating oil return temp. Inlet press. Test nozzle holder assembly Opening pressure Test pressure line Outside diameter x Inside diameter x Length Test line, injected quantity adjuster Test line (solenoid valve, start of injection) Shutoff solenoid SETTINGS/TEST SPECIFICATONS BASIC SETTING CAT Designation SUPPLY PUMP PRESSURE D speed D Check-back voltage S Supply pump pressure D TIMING DEVICE TRAVEL D speed D Check-back voltage S Timing device travel D FULL-LOAD DELIVERY D Temperature stabilization speed D Check-back voltage D Initial temperature D speed D Measurement temperature D Check-back voltage S Delivery CAT D D D D D D S S S CAT D D D D IDLE SETTING Designation Temperature stabilization speed Check-back voltage Initial temperature speed Check-back voltage Measurement temperature Delivery Spread Spread Timing device solenoid STARTING FUEL DELIVERY Designation Temperature stabilization speed Check-back voltage Initial temperature speed 12.06.01 0 460 404 977 VE4/10E2075R700 VW 1,9 l TDI

Unit C bar bar mm mm mm V

Set value ISO 4113 55 0.35 1 688 901 114 207.00 1 680 750 085 6.00 1.60 350.00 1469940521 1469940540 12

min. 54.50 0.30

max. 55.50 0.40

Actual values

OT

200.00 214.00

Unit rpm mV bar rpm mV mm 1/min mV C rpm C mV cm3/1000S. Unit 1/min mV C rpm mV C cm3/1000S. cm3/1000S. cm3/1000S. V Unit 1/min mV C rpm

Set value 500 2560.00 8.80 500 2560.00 10.20 2000 2500 61 750 57 2480.00 34.90 Set value 2000 2500 65 400 1800.00 61 10.40 3.00 4.00 12 Set value 2000 2500 65 100

min.

max.

Actual values 500 2560.00 500 2560.00 2000 2500 61 750 57 2480.00

OT

8.10

9.50

10.00

10.40

34.70 min.

35.10 max.

8.40

12.40

Actual values 2000 2500 65 400 1800.00 61

OT

min.

max.

Actual values 2000 2500 65 100

OT

CAT = Category (D = Default, S = Setting value, C = Check value) OT = Outside Tolerance (X is set)

BOSCH EP test values diesel fuel-injection equipment Customer ID No. Combination ID No. 0460404977

Page: 2

CAT D D S S CAT D D S S

Designation Check-back voltage Measurement temperature Delivery Timing device solenoid SHUTOFF TEST Designation speed Check-back voltage Delivery Shutoff solenoid

Unit mV C cm3/1000S. V Unit rpm mV cm3/1000S. V

Set value 2420.00 61 39.00 12 Set value 1000 4000.00 0.00 0.00

min. 34.00

max. 44.00

Actual values 2420.00 61

OT

min.

max.

Actual values 1000 4000.00

OT

ELECTRICAL TEST PIN ASSIGNMENT AS PER 0 986 611 929 (KDEP 1165) CAT Designation Unit POSITIONER TESTING D Test temperature C S Resistance, connections 4 and 7 Ohms D Test temperature C S Resistance, connections 4 and 7 Ohms S Resistance, connection 4 and ground Mohms S Resistance, connections 2 and 7 Mohms S Resistance, connections 4 and 6 Mohms S Resistance, connection 7 and ground Mohms HALF DIFFERENTIAL INDUCTIVE PICKUP Resistance, connections 1 and 3 Ohm Resistance, connections 2 and 3 Ohm Resistance, connections 1 and 2 Ohm Resistance, connection 1 and ground Mohms Resistance, connection 2 and ground Mohms Resistance, connection 3 and ground Mohms FUEL TEMPERATURE SENSOR D Test temperature C Resistance, connections 5 and 6 kohms D Test temperature C Resistance, connections 5 and 6 kohms Resistance, connection 5 and ground Mohms Resistance, connection 6 and ground Mohms SOLENOID VALVE START OF DELIVERY D Test temperature C Resistance, connections 1 and 2 Ohms D Test temperature C Resistance, connections 1 and 2 Ohms EXCESS-FUEL STOP/SHUTOFF STOP Excess-fuel stop mV Shutoff stop mV INJECTION-PUMP TEST SPECIFICATIONS ASSEMBLY AND ADJUSTMENT DIMENSIONS CAT Designation Unit Dimension K mm Dimension KF mm POMPE/ENGINE ASSIGNMENT S Plunger stroke mm S Outlet CAT D D S D D S TIMING DEVICE CURVE Designation speed Check-back voltage Timing device solenoid speed Check-back voltage Timing device travel Unit rpm mV V rpm mV mm

Set value 22.5 0.7 60.0 0.775 1.0 1.0 1.0 1.0 5.7 5.7 11.4 1.0 1.0 1.0 22.5 2.6 60.0 0.75 1.0 1.0 22.5 15.8 60.0 18.25 4385 750

min. 15.0 0.4 50.0 0.450

max. 30.0 1.0 70.0 1.100

Actual values

OT

4.9 4.9 9.8

6.5 6.5 13.0

15.0 1.2 50.0 0.30

30.0 4.0 70.0 1.20

15.0 14.3 50.0 15.50 4120 650

30.0 17.3 70.0 21.00 4650 850

Set value 3.7 8.4 0.85 A Set value 1500 1500.00 12 300 2560.00 8.10

min. 3.6 8.2 0.83

max. 3.8 8.6 0.87

Actual values

OT

min.

max.

Actual values 1500 1500.00 300 2560.00

OT

5.60

10.60

CAT = Category (D = Default, S = Setting value, C = Check value) OT = Outside Tolerance (X is set)

BOSCH EP test values diesel fuel-injection equipment Customer ID No. Combination ID No. 0460404977

Page: 3

CAT D D S CAT D D S D D S CAT D D D D D D S D D D D D D S CAT D D D D D D S D D D D D D S D D D D D D S

Designation Timing device travel speed Check-back voltage Timing device travel Timing device travel SUPPLY PUMP PRESSURE CURVE Designation speed Check-back voltage Supply pump pressure speed Check-back voltage Supply pump pressure OVERFLOW Designation Temperature stabilization speed Check-back voltage Initial temperature speed Check-back voltage Measurement temperature Delivery Delivery Temperature stabilization speed Check-back voltage Initial temperature speed Check-back voltage Measurement temperature Delivery Delivery FUEL DELIVERY CURVE Designation Temperature stabilization speed Check-back voltage Initial temperature speed Check-back voltage Measurement temperature Delivery Delivery Temperature stabilization speed Check-back voltage Initial temperature speed Check-back voltage Measurement temperature Delivery Delivery Temperature stabilization speed Check-back voltage Initial temperature speed Check-back voltage Measurement temperature Delivery Delivery

Unit mm rpm mV mm mm Unit rpm mV bar rpm mV bar Unit 1/min mV C rpm mV C cm3/10s. cm3/10s. 1/min mV C rpm mV C cm3/10s. cm3/10s. Unit 1/min mV C rpm mV C cm3/1000S. cm3/1000S. 1/min mV C rpm mV C cm3/1000S. cm3/1000S. 1/min mV C rpm mV C cm3/1000S. cm3/1000S.

Set value 8.10 2050 3890.00 12.30 12.30 Set value 2050 3890.00 11.40 300 2560.00 7.30 Set value 2000 2500 61 500 2560.00 57 52.00 52.00 100 2500 51 2050 3890.00 53 58.00 58.00 Set value 100 2500 51 2050 3890.00 53 50.40 50.40 2000 2500 61 500 2560.00 57 43.30 43.30 2000 2500 61 750 2480.00 57 34.90 34.90

min. 4.30 11.60 11.50 min. 10.60 6.10 min.

max. 11.90 13.00 13.10 max. 12.20 8.50 max.

Actual values 2050 3890.00

OT

Actual values 2050 3890.00 300 2560.00

OT

37.00 32.00

67.00 72.00

Actual values 2000 2500 61 500 2560.00 57 100 2500 51 2050 3890.00 53

OT

43.00 38.00 min.

73.00 78.00 max.

49.20 48.60

51.60 52.20

Actual values 100 2500 51 2050 3890.00 53 2000 2500 61 500 2560.00 57 2000 2500 61 750 2480.00 57

OT

42.00 41.30

44.60 45.30

34.70 33.60

35.10 36.20

CAT = Category (D = Default, S = Setting value, C = Check value) OT = Outside Tolerance (X is set)