104700-9023 ZEXEL test values diesel fuel-injection equipment 29.10.

20 15:02:39 Page 1

ZEXEL Ass'y No. 104700-9023

Bosch Ass'y No. 9 460 613 463
Bosch Typecode
Engine Type 4D56T
Manufacturer HYUNDAI
Edition date 21.04.09

1 Adjustment conditions
CAT Designation Unit Set value min. max. Actual values OT
Test oil ISO4113orSAEJ967
d
1404 Test oil
P Test oil temperature degC 45 45 50
Nozzle 105780-0060
Bosch type code NP-DN0SD1510
Nozzle holder 105780-2150
P Opening pressure MPa 13 13 13.3
P Opening pressure kgf/cm2 133 133 136
Injection pipe 157805-7320
P Injection pipe mm 2-6-450
Inside diameter - outside diameter - length (mm)
Joint assembly 157641-4720
Tube assembly 157641-4020
P Transfer pump pressure kPa 20 20 20
P Transfer pump pressure kgf/cm2 0.2 0.2 0.2
Direction of rotation (viewed from drive side) R
Right

2 Adjustment specification
2.1 Compensation resistor, compensation voltage comparison
Name Comp. resistor/voltage

Compensation resistance/compensation voltage comparison

A = Compensation resistor number
B= Compensation resistance
C = Compensation voltage delta U alpha soll
2.2 Pump chamber pressure
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P TCV duty (%) F TCV 60Hz % 100 100 100
P U alpha soll V 2.7 2.7 2.7
S Pump chamber pressure kPa 598.5 569 628
S Pump chamber pressure kgf/cm2 6.1 5.8 6.4
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 100 100 100
P TCV duty (%) F TCV 60Hz % 100 100 100
P U alpha soll V 2.7 2.7 2.7
C Pump chamber pressure kPa 294 294
C Pump chamber pressure kgf/cm2 3 3
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P TCV duty (%) F TCV 60Hz % 100 100 100
P U alpha soll V 2.7 2.7 2.7
C Pump chamber pressure kPa 598.5 559 638
C Pump chamber pressure kgf/cm2 6.1 5.7 6.5
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2000 2000 2000
S = Setting value, C = Check value)
OT = Outside Tolerance (X is set)
104700-9023 ZEXEL test values diesel fuel-injection equipment 29.10.20 15:02:39 Page 2

P TCV duty (%) F TCV 60Hz % 100 100 100

P U alpha soll V 2.7 2.7 2.7
C Pump chamber pressure kPa 736 687 785
C Pump chamber pressure kgf/cm2 7.5 7 8
2.3 Timer stroke
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P TCV duty (%) F TCV 60Hz % 100 100 100
P U alpha soll V 2.7 2.7 2.7
S Timer stroke mm 7.7 7.5 7.9
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 100 100 100
P TCV duty (%) F TCV 60Hz % 100 100 100
P U alpha soll V 2.7 2.7 2.7
C Timer stroke mm 1.8 0.3 3.3
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 350 350 350
P TCV duty (%) F TCV 60Hz % 100 100 100
P U alpha soll V 2.7 2.7 2.7
C Timer stroke mm 5.2 3.1 7.3
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P TCV duty (%) F TCV 60Hz % 100 100 100
P U alpha soll V 2.7 2.7 2.7
C Timer stroke mm 7.7 7.4 8
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P TCV duty (%) F TCV 60Hz % 70 70 70
P U alpha soll V 2.7 2.7 2.7
C Timer stroke mm 4 1.9 6.1
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2000 2000 2000
P TCV duty (%) F TCV 60Hz % 100 100 100
P U alpha soll V 2.7 2.7 2.7
C Timer stroke mm 9.75 9.3 10.2
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2000 2000 2000
P TCV duty (%) F TCV 60Hz % 0 0 0
P U alpha soll V 2.7 2.7 2.7
C Timer stroke mm 0 0 0
2.4 TPS output
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P TCV duty (%) F TCV 60Hz % 0 0 0
P U alpha soll V 2.7 2.7 2.7
S Vtps V 0.51 0.382 0.638
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P TCV duty (%) F TCV 60Hz % 0 0 0
P U alpha soll V 2.7 2.7 2.7
C Vtps V 0.51 0.382 0.638
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P TCV duty (%) F TCV 60Hz % 100 100 100
P U alpha soll V 2.7 2.7 2.7
C Vtps V 1.925 1.702 2.148
2.5 Overflow
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P TCV duty (%) F TCV 60Hz % 100 100 100
P U alpha soll V 2.7 2.7 2.7
C Overflow quantity cm3/min 550 420 680
2.6 Fuel injection quantities
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1250 1250 1250
P U alpha soll + dU alpha soll V 2.73 2.73 2.73
P TCV duty (%) F TCV 60Hz % 100 100 100
S Average injection quantity mm3/st. 63.3 62.8 63.8
S Difference in delivery mm3/st. 3.5 3.5
P Basic *
S = Setting value, C = Check value)
OT = Outside Tolerance (X is set)
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CAT Designation Unit Set value min. max. Actual values OT

P Pump speed r/min 375 375 375
P U alpha soll + dU alpha soll V 1.81 1.81 1.81
P TCV duty (%) F TCV 60Hz % 100 100 100
S Average injection quantity mm3/st. 7.3 4.3 10.3
S Difference in delivery mm3/st. 2.5 2.5
P Basic *
Remarks
Confirmation of difference in delivery
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2300 2300 2300
P U alpha soll + dU alpha soll V 1.81 1.81 1.81
P TCV duty (%) F TCV 60Hz % 100 100 100
S Average injection quantity mm3/st. 19.4 16.9 21.9
S Difference in delivery mm3/st. 5.5 5.5
P Basic *
Remarks
Confirmation of difference in delivery
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 100 100 100
P U alpha soll + dU alpha soll V 2.9 2.9 2.9
P TCV duty (%) F TCV 60Hz % 100 100 100
C Average injection quantity mm3/st. 50.3 40.3 60.3
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 375 375 375
P U alpha soll + dU alpha soll V 1.81 1.81 1.81
P TCV duty (%) F TCV 60Hz % 100 100 100
C Average injection quantity mm3/st. 7.3 4.3 10.3
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 500 500 500
P U alpha soll + dU alpha soll V 2.59 2.59 2.59
P TCV duty (%) F TCV 60Hz % 100 100 100
C Average injection quantity mm3/st. 51.8 49.3 54.3
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 750 750 750
P U alpha soll + dU alpha soll V 2.71 2.71 2.71
P TCV duty (%) F TCV 60Hz % 100 100 100
C Average injection quantity mm3/st. 60.2 57.7 62.7
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1250 1250 1250
P U alpha soll + dU alpha soll V 2.1 2.1 2.1
P TCV duty (%) F TCV 60Hz % 100 100 100
C Average injection quantity mm3/st. 29 24 34
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1250 1250 1250
P U alpha soll + dU alpha soll V 2.5 2.5 2.5
P TCV duty (%) F TCV 60Hz % 100 100 100
C Average injection quantity mm3/st. 49.8 44.8 54.8
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1250 1250 1250
P U alpha soll + dU alpha soll V 2.73 2.73 2.73
P TCV duty (%) F TCV 60Hz % 100 100 100
C Average injection quantity mm3/st. 63.3 62.3 64.3
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1900 1900 1900
P U alpha soll + dU alpha soll V 2.56 2.56 2.56
P TCV duty (%) F TCV 60Hz % 100 100 100
C Average injection quantity mm3/st. 53.2 50.7 55.7
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2300 2300 2300
P U alpha soll + dU alpha soll V 1.81 1.81 1.81
P TCV duty (%) F TCV 60Hz % 100 100 100
C Average injection quantity mm3/st. 19.4 16.9 21.9
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2450 2450 2450
P U alpha soll + dU alpha soll V 1 1 1
P TCV duty (%) F TCV 60Hz % 100 100 100
C Average injection quantity mm3/st. 3 3
2.7 Magnet valve OFF
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1900 1900 1900
P U alpha soll + dU alpha soll V 2.56 2.56 2.56
S = Setting value, C = Check value)
OT = Outside Tolerance (X is set)
104700-9023 ZEXEL test values diesel fuel-injection equipment 29.10.20 15:02:39 Page 4

P TCV duty (%) F TCV 60Hz % 100 100 100

C Average injection quantity cm3/min 0 0 0
2.8 Confirming NP sensor output
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 200 200 200
P TCV duty (%) F TCV 60Hz % 100 100 100
P U alpha soll V 2.7 2.7 2.7
C Speed output r/min N+-8
N=Measure the actual speed.
2.9 Checking fuel temperature sensor
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1250 1250 1250
P TCV duty (%) F TCV 60Hz % 100 100 100
P U alpha soll V 2.73 2.73 2.73
C Temperature output degC T+-5
Measure T = actual output temperature
2.10 Magnet
CAT Designation Unit Set value min. max. Actual values OT
C Max. applied voltage V 8 8 8
P Test voltage V 13 12 14

3 Assembly dimension
CAT Designation Unit Set value min. max. Actual values OT
S K dimension mm 3.3 3.2 3.4
S KF dimension mm 5.9 5.8 6
S Pre-stroke mm 0.1 0.08 0.12

4 Attachments' specification
4.1 Attachment specification 1
Name HARNESS & CONNECTOR

TCV connector assembly specification

(1)Ensure the GE cable is not twisted at section A.
(2)Refer to the figure for the direction of connector clip B.
(3)Route the TCV harness in the direction indicated by the arrows in the figure and install the con
nector C.
4.2 Attachment specification 2
Name HARNESS & CONNECTOR
L1=15+-5mm

Connector and binder assembly specification

(1)For D's connector, adjust the position of the protective tube to L1 and install.
(2)Assemble the connectors and clips in the order A, B, C, D, E, F, G and H.
(3)Fix the GE cable and the FCV cable using the binder C.
(4)Clip the GE cable, the F.C.V., the T.P.S. P/U and the T.P.S harnesses using clip H.
A:Push type clip
B:F.C.V. harness
C:Clip (be careful of installation direction)
D:G.E. Connector
E:Q adjustment connector
F:P/U Connector
G:T.P.S. Connector
H:Binder
I:Protective tube

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)