92

9520A190
Perkins Vista 74.5 KW @ 22

Test Plan

Issue No: 3 Date: 00/00/00

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

See Service Instruction Note DT294. 2644B347 Setting Code: 2644B352 Setting Code:

-/2/2360 -/2/2360

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 2C. Inlet feed pressure: 5.0 psi Backleak pressure: 0.0 psi Nozzles: YDB286 (BDL0S6844) 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: Boost stroke : Latch valve adjuster, if fitted, screw fully in then 8 turns out Turn light load adjuster valve fully in ,then 1 turns out.

1.5 mm. 5.0 to 5.2 mm.

ISO TEST PROCEDURE

Test 1. Operation Priming S/C (C) 200 RPM Requirements 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) 1100 90 to 92 psi --- 92 3. Delivery (S) 1100 91.5 1.0 mm3/st. --- 92 4. Governor (S) 1200 8.0 to 20.0 mm3/st. --- 17 Stabilise. Cycle speed between 100 to 1300 rpm 2 times. Stabilise and run at 1100 rpm until backleak temperature is 38C min. 5. Back leakage. (C) 1100 Flow rate 500 to 1000 cm3/min. --- 800 6. Cambox Press. (C) 1100 7 to 11 psi --- 10 7. Transfer Press. (C) 1100 Press at test(6 ) + 82.0 to 84.0psi --- 92 Run test machine down to 0 rpm. 8. Transfer Press. (C) 100 Minimum 12 psi. --- 18 9. Transfer Press (C) 1100 As test (7 ) 1.0 psi --- 92 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) --- 0 11. Advance (C) 750 0.7 Max. 12. Advance (C) 1050 2.8 to 3.2. 2.8 to 3.2. 13. Advance (C) 1100 Stop test machine. Energise CA solenoid. 3.3 to 5.5. 14. Advance (C) 700 De-energise CA solenoid. 15. Advance (S) 1100 4.8 to 5.2 44.0 to 48.0mm3/st Light load Adjust throttle/torque screw & LLA valve. Run test machine down to 0 rpm. 16. Advance (C) 1100 9.8 to 10.2 30.0 8.0mm/3st. Light load Use throttle/Torque screw. 700 1.8 to 2.2 66.0 8.0mm/3st. 17. Advance (C) Light load Use throttle/Torque screw. If correct continue with test (18), 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. Torque Trimmer (S) 1100 Datum CPS reading to 0.0mm. 18. 19. Torque Trimmer (S) 700 Adj CPS to 0.74 to 0.80mm CPS Run test machine down to 0 rpm. Stabilise and run at 1150rpm for 2 secs 20. Torque Trimmer (C) 1100 As test (18) 0.05 mm CPS 21. Torque Trimmer (C) 650 Check CPS is +0.30 to +0.70mm CPS 22. Torque Trimmer (C) 1100 As test (20) 0.1 mm CPS Set boost pressure to zero. 23. Torque Trimmer (C) 1100 As test (22) - 3.5 0.3 mm CPS Set boost pressure to 10.0 psi. 24. Torque Trimmer (C) 1100 As test (22) 0.3 mm CPS If correct continue with test (25), if not, adjust shimming and then repeat test(s) (18 to 24 ). Set boost pressure to 3.0 psi. 25. Torque Trimmer (C) 1100 As test (23) 0.2 mm CPS If correct continue with test (26), if not, adjust shimming and then repeat test(s) (18 to 25 ). Set boost pressure to zero. Screw latch valve adjuster fully in. 26. Latch Valve (C) 280 CPS = - 2.0 to - 10.0 mm If incorrect, adjust LV pre-load & repeat test Run test machine down to 0 rpm. 27. Torque Trimmer (C) 250 As test (26) + 3.0 5.0 mm CPS 28. Torque Trimmer (C) 300 As test (27) - 5.0 3.0 mm CPS If incorrect or adjusted, stop machine and repeat from test (26). 29. Delivery (C) 100 Minimum 70.0 mm3/st. 30. Shut-off (C) 500 De-energise solenoid, wait 5 seconds. Solenoid Max. 3.0 mm3/st. Stop test machine. Close throttle. 31. Idle delivery (S) 430 12.0 to 16.0 mm3/st. Throttle closed. 32. 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. 33. Max. Delivery (S) 1100 91.5 0.3 mm3/st. Max. spread 5.0 mm3/st. 34. Delivery S/C 700 As test (33) + 12.0 2.0 mm3/st. 35. Delivery (C) 1100 Record delivery mm3/st.

Set boost pressure to zero. 36. Delivery Set boost pressure to 15.0 psi. 37. Delivery 38. Governor 39. Gov. cut-off 40. Delivery 41. Dynamic timing

(C) (C) (S) (C) (C)

500 1100 1180 1235 1100

71.5 to 77.5 mm3/st. Record delivery mm3/st. 12.0 to 16.0 mm3/st. Maximum 3.0 mm3/st. Throttle as test (38). Minimum as test (37) - 1.0 mm3/st. Refer to SIN DT339 Piezo sensor, outlet U Off-set angle 184.60 Trigger level 25 %

speed (S) 1100 . 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 400 rpm 3 times. Set boost pressure to 15.0 psi. Open throttle. Stabilise. Cycle speed between 100 to 1240 rpm 3 times. Stabilise and run at 1100 rpm until backleak temperature is 38C min. 42. Gov. cut-off (C) 1250 Maximum 4.0 mm3/st. Fully unscrew the Maximum speed adjusting screw. 43. Advance (S) 500 0 (Datum advance gauge) 44. Advance (C) 700 0.6 Max. 45. Advance (C) 1100 2.7 to 3.3. 46. Advance (C) 1100 4.8 to 5.2 46.0 4.0mm/3st. Light load Use throttle/Torque screw. 47. Advance (C) 1100 9.8 to 10.2 30.0 10.0mm/3st. Light load Use throttle/Torque screw. 48. Advance (C) 700 1.8 to 2.2 66.0 10.0mm/3st. Light load Use throttle/Torque screw. Stop test machine. Energise CA solenoid. 49. Advance (C) 700 3.3 to 5.5. De-energise CA solenoid. Set boost pressure to zero. Move throttle lever to closed position for tests (50 ). 50. Delivery (C) 560 Maximum 4.0 mm3/st. Open throttle. 51. Delivery (C) 100 Minimum 60.0 mm3/st. 52. 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. 53. Delivery (C) 1100 88.5 to 94.5 mm3/st. 54. Delivery (C) 700 As test (53) + 12.0 4.0 mm3/st. Set boost pressure to zero. 55. Delivery (C) 500 71.5 to 77.5 mm3/st. Set boost pressure to 15.0 psi. 56. Governor (S) 1180 12.0 to 16.0 mm3/st. 57. Gov. cut-off (C) 1235 Maximum 4.0 mm3/st. 58. Dynamic timing Refer to SIN DT339 Piezo sensor, outlet U Off-set angle 184.60 speed (S) 1100 Trigger level 25 %