9520A420 Issue No: 1

Test Plan
Perkins vista 83.0 KW @ 230 Date: 00/00/00

PUMP SPECIFICATION
Rotation: Clockwise.
Governor type: Mechanical all-speed.
Gov. Link Length: 41.5 ± 0.5 mm.
Gov. Link Length: 10.1 ± 0.5 mm.
(DP210 Workshop Manual Section 4.6.4)
Plunger Diameter: 7.0 mm (4 off).
Drive Type: Supported shaft.
Transfer pressure: adjustable.
Viscosity compensating device in end plate.
Cambox pressurising valve.
Servo Advance with:
- Speed advance, LLA & CA
Torque trimmer.
Boost control.
Solenoid voltage: See Service Instruction Note DT294.
OEM Code: 2644C311 Setting Code: -/2/2490
OEM Code: 2644C336 Setting Code: -/2/2490

ISO TEST CONDITIONS.

This data is only valid for the test conditions specified and the
following test benches: HA3000/HA2500/HA700/AVM/PGM
Test Fluid: ISO 4113 at 40 ± 2°C.
Inlet feed pressure: 5.0 psi
Backleak pressure: 0.0 psi
Nozzles: YDB287 (BDL0S6889)
Nozzle Opening Pressure: 172 + 3 - 0 bar.
Nozzle Holder: ISO 7440 + YDB288 Edge filter assy.
H.P. pipes: 6 x 1.8 x 450 mm

PRE-TEST NOTES
Screw transfer pressure adjuster fully in and then 4.5 turns
out before commencing test
No additional shimming is required.
CA solenoid to be de-energised unless otherwise stated.
Torque trimmer plug to be wound out until thread appears.
Boost control initial shimming: 1.5 mm.
Boost stroke : 5.7 to 5.9 mm.
Latch valve adjuster, if fitted, screw fully in then
8 turns out
Turn light load adjuster valve fully in ,then 1 turns out.

ISO TEST PROCEDURE

Test Operation S/C RPM Requirements
1. Priming (C) 200 Obtain delivery from all injectors
and backleak.
Close throttle.
Stabilise. Cycle speed between 100 to 500 rpm 3 times.
Set boost pressure to 15.0 psi.
Open throttle.
2. Transfer Press. (S) 1150 90 to 92 psi
3. Delivery (S) 1150 109.0 ± 0.5 mm3/st.
4. Governor (S) 1300 12.0 to 16.0 mm3/st.
Stabilise. Cycle speed between 100 to 1310 rpm 2 times.
Stabilise and run at 1150 rpm until backleak temperature
is 38°C min.
5. Back leakage. (C) 1150 Flow rate 500 to 1000 cm3/min.
6. Cambox Press. (C) 1150 6 to 10 psi
7. Transfer Press. (C) 1150 Press at test(6 ) + 82.0 to 84.0psi
Run test machine down to 0 rpm.
8. Transfer Press. (C) 100 Minimum 12 psi.
9. Transfer Press (C) 1150 As test (7 ) ± 1.0 psi
If incorrect repeat from test (6 ).
Stop test machine.
Remove pressure gauges and fit stop solenoid or plug.
10. Advance (S) 500 0° (Datum advance gauge)
11. Advance (C) 700 0.6° Max.
12. Advance (C) 1050 1.3 to 1.7°.
13. Advance (C) 1150 1.3 to 1.7°.
Stop test machine.
Energise CA solenoid.
14. Advance (C) 700 3.3 to 5.5°.
De-energise CA solenoid.
15. Advance - (S) 1150 4.8 to 5.2° 47.0 to 51.0mm3/st
Light load Adjust throttle/torque screw
& LLA valve.
Run test machine down to 0 rpm.
16. Advance - (C) 1150 4.8 to 5.2° 49.0 ± 2.0mm3/st.
Light load Use throttle/Torque screw.
17. Advance - (C) 1150 8.8 to 9.2° 35.0 ± 8.0mm3/st.
Light load Use throttle/Torque screw.
18. Advance - (C) 700 1.8 to 2.2° 72.0 ± 8.0mm3/st.
Light load Use throttle/Torque screw.
If correct continue with test (19), if not, adjust shimming
and then repeat test(s) (from test 15).
Open throttle.
Stop test machine.
Fit CPS tool
Set boost pressure to 15.0 psi.
19. Torque Trimmer (S) 1150 Datum CPS reading to 0.0mm.
20. Torque Trimmer (S) 700 Adj CPS to -0.65 to -0.71mm
CPS
Run test machine down to 0 rpm.
Stabilise and run at 1175rpm for 5 secs
21. Torque Trimmer (C) 1150 As test (19) ± 0.05 mm
CPS
22. Torque Trimmer (C) 950 Check CPS is +0.20 to -0.20mm
CPS
23. Torque Trimmer (C) 525 Check CPS is -0.8 to -1.2mm
CPS
24. Torque Trimmer (C) 1100 As test (21) ± 0.1 mm
CPS
Set boost pressure to zero.
25. Torque Trimmer (C) 1100 As test (24) - 4.10 ± 0.30 mm
CPS
Set boost pressure to 8.5 ± 0.3 psi.
26. Torque Trimmer (C) 1100 As test (24) ± 0.3 mm
CPS
If correct continue with test (27), if not, adjust shimming
and then repeat test(s) (19 to 26 ).
Set boost pressure to 1.0 ± 0.3 psi.
27. Torque Trimmer (C) 1100 As test (25) ± 0.2 mm
CPS
If correct continue with test (28), if not, adjust shimming
and then repeat test(s) (19 to 27 ).
Set boost pressure to zero.
Screw latch valve adjuster fully in.
28. Latch Valve (C) 280 CPS = - 3.0 to - 7.0 mm
If incorrect, adjust LV pre-load
& repeat test
Run test machine down to 0 rpm.
29. Torque Trimmer (C) 250 As test (28) + 3.0 ± 5.0 mm
CPS
30. Torque Trimmer (C) 300 As test (29) - 5.0 ± 3.0 mm
CPS
If incorrect or adjusted, stop machine and repeat from test (28).
31. Delivery (C) 100 Minimum 60.0 mm3/st.
32. Shut-off - (C) 500 De-energise solenoid, wait 5 seconds.
Solenoid Max. 3.0 mm3/st.
Stop test machine.
Close throttle.
33. Idle delivery (S) 450 12.0 to 16.0 mm3/st. Throttle closed.
34. Delivery (C) 550 Maximum 3.0 mm3/st.
Stop test machine.
Fit Max Fuel adjuster tool
Open throttle.
Set boost pressure to 15.0 psi.
35. Max. Delivery (S) 1150 109.0 ± 0.5 mm3/st.
Max. spread 5.0 mm3/st.
36. Delivery S/C 700 As test (35) + 3.0 ± 1.0 mm3/st.
Set boost pressure to zero.
37. Delivery (C) 500 71.0 to 77.0 mm3/st.
Set boost pressure to 15.0 ± 0.2 psi.
38. Delivery (C) 1150 Record delivery mm3/st.
39. Governor (S) 1280 12.0 to 16.0 mm3/st.
40. Gov. cut-off (C) 1330 Maximum 3.0 mm3/st.
41. Delivery (C) 1150 Throttle as test (39).
Minimum as test (38) - 1.0 mm3/st.
42. Dynamic timing Refer to SIN DT339
Piezo sensor, outlet U
Off-set angle 182.50°
speed (S) 1150 Trigger level 25 %
.
ISO OVERCHECK PROCEDURE
.
The Overcheck section of this plan has been developed in
conjunction with the Original Equipment Manufacturer.
Providing all values are achieved, the pump settings will
maintain the original homologated engine performance. Failure to
attain any one of the values will indicate a pump setting or
function failure and require further investigation.
.
PRE-OVERCHECK NOTES
Dynamic timing - record zero angle - (refer to DT339)
Drive shaft lock bolt to remain locked until zero angle
recorded.
CA advance motor to be de-energised unless otherwise stated.
No adjustments to be made unless otherwise stated.
Close throttle.
Stabilise. Cycle speed between 100 to 500 rpm 3 times.
Set boost pressure to 15.0 psi.
Open throttle.
Stabilise. Cycle speed between 100 to 1290 rpm 2 times.
Stabilise and run at 1200 rpm until backleak temperature
is 38°C min.
43. Gov. cut-off (C) 1330 Maximum 3.0 mm3/st.
Fully unscrew the Maximum speed adjusting screw.
44. Advance (S) 500 0° (Datum advance gauge)
45. Advance (C) 700 0.7° Max.
46. Advance (C) 1150 1.2 to 1.8°.
47. Advance - (C) 1150 4.8 to 5.2° 49.0 ± 4.0mm3/st.
Light load Use throttle/Torque screw.
48. Advance - (C) 1150 8.8 to 9.2° 35.0 ± 9.0mm3/st.
Light load Use throttle/Torque screw.
49. Advance - (C) 700 1.8 to 2.2° 72.0 ± 10.0mm3/st.
Light load Use throttle/Torque screw.
Stop test machine.
Energise CA solenoid.
50. Advance (C) 700 3.5 to 5.5°.
De-energise CA solenoid.
Set boost pressure to zero.
Move throttle lever to closed position for tests (51 ).
51. Delivery (C) 550 Maximum 3.0 mm3/st.
Open throttle.
52. Delivery (C) 100 Minimum 60.0 mm3/st.
53. Shut-off - (C) 500 De-energise solenoid, wait 5 seconds.
Solenoid Max. 3.0 mm3/st.
Run test machine down to 0 rpm.
Set boost pressure to 15.0 psi.
Run test machine down to 1100 rpm.
54. Delivery (C) 1150 106.0 to 112.0 mm3/st.
55. Delivery (C) 700 As test (54) + 2.0 ± 3.0 mm3/st.
Set boost pressure to zero.
56. Delivery (C) 500 70.0 to 78.0 mm3/st.
Set boost pressure to 15.0 psi.
57. Governor (S) 1280 12.0 to 16.0 mm3/st.
58. Gov. cut-off (C) 1330 Maximum 3.0 mm3/st.
59. Dynamic timing Refer to SIN DT339
Piezo sensor, outlet U
Off-set angle 182.50°
speed (S) 1150 Trigger level 25 %