Common Rail - EUI Catalog PDF

DIPACO Parts Catalog For
REBUILD THE FUTURE

Common Rail
Electronic Unit Injector/Unit Pump
Fuel Systems
DIPACO DIESEL PARTS - USA

105 East Parr Blvd. Reno, NV 89512 USA
Telephone: (775) 329-7511 Fax: (775) 329-9740 E-Mail: sales@dipaco.com Internet: www.dipaco.com
December 2004 Ver 1.6 REBUILD THE FUTURE 1

INTRODUCTION

An Employee Owned Company
Address
DIPACO, Inc.
105 East Parr Blvd.
Reno, Nevada 89512 USA
Phone: (775) 329-7511
Fax: (775) 329-9740
Toll Free Phone: (800) 648-4720
Toll Free Fax: (888) 320-7761
E-Mail: sales@dipaco.com
Internet: www.dipaco.com
W h a t w e o f f e r
Providing quality diesel parts since 1948
Comprehensive warranty
Competitive pricing
Excellence in customer service
Company representation before and after sales
Multi-skilled staff
Extended trading hours
Toll free phone and fax ordering
Full technical support
Quality commitment
Superior quality inventory
Same day shipping
Information
Copyright This catalog is in loose leaf form to
DIPACO, Inc., 2002. No part of this allow for continuous updating as we
publication may be reproduced in any add additional parts. For current
form by any means without written parts availability, please consult our
permission. current price list or contact DIPACO
or your DIPACO distributor.
This catalog is for reference

purposes only. DIPACO assumes
no responsibility or liability for any
errors or inaccuracies that may
appear in this publication. All
mention of OEM names and part
numbers is for reference only.
2 2
REBUILD THE FUTURE December 2004 Ver 1.6
TABLE OF CONTENTS

SUBJECT PAGE
Equipment Packages .......................................................................................................................... 4
Electronic Unit Injectors and Electronic Unit Pumps ........................................................ Section 1
Introduction ......................................................................................................................................... 1-1
Cam Box ............................................................................................................................................. 1-2
Cam Box Accessories ........................................................................................................................ 1-3
Cummins Celect ................................................................................................................................. 1-6
Detroit Diesel Series 50/60............................................................................................................... 1-10
Detroit Diesel Series 92 .................................................................................................................... 1-12
Caterpillar ......................................................................................................................................... 1-14
Bosch PDE80 ................................................................................................................................... 1-15
Bosch PDE30-PDE90 ...................................................................................................................... 1-16
Bosch PDE100 ................................................................................................................................. 1-18
Bosch PDE31 ................................................................................................................................... 1-20
Delphi ............................................................................................................................................... 1-22
Bosch PLD100-110 Type B .............................................................................................................. 1-25
Bosch PLD100 ................................................................................................................................. 1-26
Bosch PLD110 .................................................................................................................................. 1-27
Caterpillar & EDM (3500) ................................................................................................................. 1-29
Pop Test Adapters ............................................................................................................................ 1-30
Common Rail Fuel Systems ................................................................................................. Section 2
Electronic Simulator ........................................................................................................................... 2-1
Bosch CP-1 Fuel Pump ...................................................................................................................... 2-2
Delphi Fuel Pump ............................................................................................................................. 2-10
Siemens Fuel Pump ..........................................................................................................................2-11
Bosch Common Rail Injector ............................................................................................................ 2-12
Cummins ISBe Common Rail Injector .............................................................................................. 2-14
Delphi Common Rail Injector............................................................................................................ 2-16
Duramax/Isuzu Common Rail Injector.............................................................................................. 2-18
Denso............................................................................................................................................... 2-20
Fuel Line Kits .................................................................................................................................... 2-21
Diagnostic Tools ............................................................................................................................... 2-22
Dual Spring Injectors ............................................................................................................ Section 3
Test and Assembly Fixture ................................................................................................................. 3-2
Nozzles ................................................................................................................................... Section 4
Nozzles ............................................................................................................................................... 4-1
Test Bench Hardware and Accessories .............................................................................. Section 5
Test Bench Hardware and Accessories .............................................................................................. 5-1
December 2004 Ver 1.6 REBUILD THE FUTURE 3

REBUILD THE FUTURE
Equipment Packages

DIPACO REBUILD THE FUTURE equipment is available in several packages as well as individual
components. The modularity of the equipment allows you to purchase the equipment you need
today while knowing you can add additional components in the future without jeopardizing your initial
investment.
Below are the basic equipment packages.

CR/EUI EUI CP1 CP1/CP3 CP1 LARGE
FULL ONLY EUI EUI CP3 EUI/MUI
PART No. DESCRIPTION RTF25045 RTF25056 RTF25057 RTF25100 RTF25112 RTF25113
RTF25005 Simulator YES YES YES YES YES YES
RTF25007 Test Rail Kit YES YES YES YES
RTF25040 Camox Kit YES YES YES YES
RTF25041 Injector Quick Connector Kit YES YES YES YES
RTF25042 Filter Kit YES YES YES YES YES YES
RTF25052 CP3 Software Module YES YES YES
RTF25065 CP2 Software Module YES
RTF25066 Amp Meter Kit YES YES YES
RTF25067 Rail Element, CP2/ECD-U2 YES
RTF25068 Element Selector, CP2/ECD-U2 YES
RTF27000 Large Unit Injector Camox YES
RTF25008 Power Transformer YES YES YES YES YES YES
In addtion to the equipment packages listed above, we also have available an accessory kit for
companies looking to work on Cummins ISBe and Duramax 6600 engines. The accessory kit,
part number RTF25117, can be used with the above equipment packages RTF25045, RTF25057,
RTF25100, and RTF25112.
Following are the kit contents for RTF25117:

RTF25060 Transfer Pressure Adapter
RTF25069 Injector Wiring Harness
RTF25070 ISBe Injector Adapter
RTF25071 Torx Bit
RTF25081 ISBe Injector Quick Connector
RTF25086 Duramax Injector Quick Connector
RTF25094 Test Line
RTF25095 Test Line
D42411 Return Banjo
D42014 Return Hose
D2911235700 Banjo Bolt
028100248 Pressure Control Valve
4 4
REBUILD THE FUTURE December 2004 Ver 1.6
ELECTRONIC UNIT INJECTORS AND PUMPS
Section 1
Introduction

DIPACO DIESEL PARTS - USA, working with Corona Diesel of Italy,
is able to provide a full range of test equipment, repair equipment, and
parts for Electronic Unit Injectors and Electronic Unit Pumps. This
catalog is meant for reference and is not all inclusive of our parts and
equipment offerings.
The RTF25040 Cam Box and RTF25005

Electronic Simulator together form the heart
of a versatile testing system. The RTF25005
unit, when used with an appropriate test stand
and accessories, can perform a full range of
diagnostic tests on Common Rail fuel systems.
When joined with the RTF25040 Cam Box the
system can perform a full range of tests on most
Electronic Unit Injectors as well as Electronic
Unit Pumps. Unlike other cam boxes, the
RTF25040 can accept a wide variety of unit
injectors and unit pumps with its unique injector
block design. Another advantage is the system
works with most any test bench available.
Also available are cam box adapters for various

types of Electronic Unit Injectors and Electronic
Unit Pumps, adapters for use in performing
simple pop tests on unit injectors, tools for
rebuilding injectors and a growing range of
injector repair parts.
Temperatures can be a concern. During the RTF25040 Cam Box

short time needed to perform injector tests,
discharge temperatures can reach 600 C (1400 F). Minimum EUI/EUP Cam Box Test Bench
Do not use test benches with Bosch KMM Requirements
and KMA (except Bosch 815/KMA with VP44 Drive Motor: 12KW/15HP
conversion) fuel measurement units due to Test bench requires a 125MM bed height (Bosch
temperature issues. Do not use test benches standard) with a 30MM drive coupling
with a Hartridge VDM fuel measurement unit
because it requires a cylinder firing order. EUI/EUP Tests Performed
EUI Nozzle Opening Pressure, Atomization,
Spray Pattern, and Seat Leakage (using injector
adapter)
EUI/EUP Delivery at various RPM
December 2004 Ver 1.6 REBUILD THE FUTURE 1-1

Section 1 ELECTRONIC UNIT INJECTORS AND PUMPS
Cam Box

RTF25040 Cam Box

Minimum EUI/EUP Cam Box Test Bench Requirements
Drive Motor: 12KW/15HP
Test bench requires a 125MM bed height (Bosch standard)
with a 30MM drive coupling
EUI/EUP Tests Performed

EUI Nozzle Opening Pressure, Atomization, Spray Pattern,
and Seat Leakage (using injector adapter)
EUI/EUP Delivery at various RPM
1-2 REBUILD THE FUTURE December 2004 Ver 1.6

Section 1
Cam Box Accessories

RTF25040-1
Accumulator Retainer
Flange
RTF25040-2
Accumulator Flange
Retainer Screw
RTF25040-3
CR Pressure Valve

Large Cam Box

RTF27000
Large Injector Cam Box
The RTF27000 Cam Box is designed for testing large
unit injectors used in marine, railroad, and large industrial
applications. The RTF27000 is used together with the
RTF25005 Electronic Simulator. The RTF27000 can
presently test EMD EUI injectors and Caterpillar 3500
series injectors, both mechanical and electronic.
The kit includes the cam box shown below and the
accessories shown on page 1-5.
This cam box requires a minimum 15HP test bench.

Section 1
Large Cam Box Accessories

Injector Adapter
Caterpillar 3500
Mechanical
Injector Adapter
Caterpillar 3500
Electronic
Injector Adapter
EMD

Accessories

Cummins Celect

Applications:
L10

M11
N14
ISM
RTF26102 AVAILABLE NOZZLES

Cam Box Kit NOZZLE INJECTOR ENGINE
Individual cam box kit RTF26107 3070629 L10
parts are available. RTF26107 3070739 N14
RTF26107 3071534 L10
RTF26107 3073995 N14
RTF26107 3081314 N14
RTF26107 3081315 N14
RTF26107 3081317 L10
RTF26107 3652516 L10
RTF26107 3652541 N14
RTF26102-1 RTF26107 3652542 N14
Cam Box Screw RTF26108 3084589 M11
RTF26108 3087557 M11
RTF26108 3411752 M11
RTF26109 3083846 N14
RTF26109 3087733 N14
RTF26103 RTF26109 3087560 N14
Pop Test Adapter RTF26109 3411759 N14
L10 RTF26113 3411755 M11
M11 RTF26114 3411758 M11
ISM RTF26115 3087788 N14
RTF26115 3095086 N14
RTF26115 3411763 N14
RTF26115 3609796 N14
RTF26106 RTF26116 3088178 N14
Pop Test Adapter RTF26116 3411764 N14
N14 RTF26117 3073996 L10
RTF26117 3081318 L10
RTF26117 3652540 L10
RTF26122 3095040 M11
RTF26122 3411753 M11
RTF26126 3411385 N14
RTF26126 3411767 N14
RTF26127 3411381 N14
RTF26127 3411691 N14
RTF26127 3411765 N14
RTF26127 3411766 N14
RTF26128 3083848 N14
RTF26128 3087558 N14
RTF26128 3087734 N14
RTF26128 3411760 N14

Section 1
Cummins Celect

Typical Injector View
REF PART DESCRIPTION QTY
1 - LINK 1 1
2 - LINK SOCKET
9
3 3081342 FOLLOWER 1
3 3081343 FOLLOWER 1 34
2
4 3072486 RETAINER RING 1
5 3078236 FOLLOWER SPRING 1
33
5 D3411340 FOLLOWER SPRING 1
6 3075659 BODY & PLUNGER 1 3
6 3075690 BODY & PLUNGER 1
- RTF26104 REPAIR KIT N14 1
- RTF26105 REPAIR KIT L10/M11/ISM 4 35
7 RTF26119 FUEL PASSAGE SCREW 1
8 RTF26120 FUEL PASSAGE WASHER 1
9 D3080811 RETAIN SCREW (N14) 2 5 16
10 RTF26121 BODY O-RING (L10/M11/ISM) 1
11 RTF26118 COIL & BARREL O-RING (GREEN) 2
12 D3070136 UPPER NUT O-RING (RED) 1 6
13 D3070137 MIDDLE NUT O-RING (WHITE) 1 7
14 D3070138 LOWER NUT O-RING (BLUE) 1
36
15 D3034408 COIL RETAINER NUT O-RING 1
16 RTF26125 WIRING HARNESS 1 8
11 (Inside Assy)
- RTF26125-1 CONNECTOR AND SEAL A/R 15
- RTF26125-2 WEDGE LOCK A/R
- RTF26125-3 SEAL A/R
- RTF26125-4 KIT A/R 17
- RTF26125-5 COVER A/R 10
17 - SPILL DEFLECTOR
18 RTF26100 BIAS SPRING .254 ID 1 18
18 RTF26123 BIAS SPRING .188 ID 1
11
19 D3071967 FILTER 1
20 D203426 ALIGNMENT PIN 2 19
- - PLUNGER & BARREL ASSY 1
21 - PLUNGER 1 21
22 - BARREL 1 24
23 3072819 CHECK CAGE 1 20
24 D3076068 CHECK BALL 1
25 - PRESSURE RELIEF VALVE 1 22 23
26 - SPRING
28
27 - NUT 1
28 RTF26101 PRESSURE SPRING 1 29 26
25
29 RTF26110-114 SPRING SEAT .114/.115 NO GROOVE A/R 30 27
29 RTF26110-118 SPRING SEAT .118/.119 1 GROOVE A/R
29 RTF26110-123 SPRING SEAT .123/.124 2 GROOVES A/R 31
30 RTF26111 SPRING CAGE
31 SEE PAGE 1-6 NOZZLE 1
32 - NUT (L10/M11) 1
33 - RETAINER (L10/M11) 1
34 - RETAIN SCREW (L10/M11/ISM) 1 32
35 - RETAINER (N14) 1
36 - STATOR 1
12
13
14

Cummins Celect

RTF26104 RTF26129
Repair Kit-N14 Injector Repair Kit
RTF26104-25 RTF26129-25
Repair Kit for 25 injectors Repair Kit for 25 injectors
RTF26105
Repair Kit-L10-M11
RTF26105-25
Repair Kit for 25 injectors
RTF26124
External Seal Kit
RTF26125
Wiring Harness
RTF26125-1
Connector and Seal
RTF26125-2
Wedge Lock
RTF26125-3
Seal
RTF26125-4
Kit
RTF26125-5
Cover

Section 1
Cummins Celect


Detroit Diesel

Applications:
Series 50

Series 60

Cam Box Kit NOZZLE INJECTOR ENGINE
Individual cam box kit RTF26211 5235575 Series 60
parts are available. RTF26212 5235580 Series 60
RTF26212 5236978 Series 50
RTF26213 5234970 Series 60
RTF26213 5235695 Series 60
RTF26213 5237320 Series 60
RTF26214 5234935 Series 60
RTF26215 5234870 Series 60
RTF26216 5234795 Series 60
RTF26201 RTF26216 5234945 Series 60
Pop Test Adapter RTF26217 5234785 Series 60
RTF26218 5234865 Series 60
RTF26219 5234940 Series 60
RTF26220 5235550 Series 50
RTF26220 5236977 Series 60

Section 1
Detroit Diesel

- RTF26209 INTERNAL SEAL KIT 1
2 RTF26202 O-RING (BROWN) 1
3 RTF26203 O-RING (RED) 1
4 RTF26204 O-RING 2
- RTF26210 EXTERNAL SEAL KIT 1
5 D5234699 O-RING 2
4
6 D5234701 O-RING 1
7 D5234702 O-RING 1 4
8 RTF26208 SPRING CAGE 1
9 RTF26207-122 .122/.123 NO OD GROOVE A/R
9 RTF26207-124 .124/.125 1 OD GROOVE A/R
9 RTF26207-126 .126/.127 2 OD GROOVES A/R
9 RTF26207-128 .128/.129 3 OD GROOVES A/R
- RTF26231 COMPLETE SEAL KIT A/R 6
- RTF26209 INTERNAL SEAL KIT A/R
- RTF26210 EXTERNAL SEAL KIT A/R 7
2

Detroit Diesel

Applications:
Series 92

RTF26230 RTF26209
Cam Box Kit S60 Internal Seal Kit
Individual cam box kit
parts are available. RTF26209-25
This kit must be used S60 Internal Seal Kit
with RTF26200-1 S60 for 25 injectors.
rocker arm.
RTF26210
S60 Internal Seal Kit
RTF26210-25
S60 Internal Seal Kit
for 25 injectors.

Section 1
Detroit Diesel


Caterpillar

Applications:
3176

3196
3406E
C-10
C-12
RTF26007 RTF26300
Pop Test Adapter External O-Ring Kit
3176/3196/C-10/C-12 3406E
RTF26301
External O-Ring Kit
3176/3196/C-10/C-12
RTF26013
Cam Box Kit RTF26034
Individual cam box kit Solenoid Repair Kit
parts are available. All Caterpillar except
3176C/3196/C-10/C-12 early 3176.
RTF26045
Cam Box Kit
3406E
RTF26200-1 S60 rocker
arm required.
RTF26200-1
S60 Rocker Arm
3406E
Use with RTF26045
Cam Box Kit.
This item is included in the
RTF26200 Cam Box Kit.

Section 1
Bosch PDE80

Applications:
Volkswagen
RTF26008
Pop Test Adapter
RTF26018
Cam Box Kit
parts are available.
RTF26025
External O-Ring Kit
See position 1 in diagram.
RTF26026
Internal O-Ring Kit
RTF26052
Alignment Pin Kit
See positions 11, 12 and
13 in diagram.
RTF26053
Nozzle Washer Kit
See positions 24 and 25
in diagram.
RTF26057
RTF26055 Solenoid Shim Kit
Injector Puller See position 10 in diagram.
RTF26058
Link Assembly
RTF26056 See position 3 in diagram.
Injector Holding Fixture
RTF26059
Nozzle Shim Kit

Bosch PDE30-PDE90

Applications:
Iveco Cursor 350

RTF26004
Pop Test Adapter
RTF26014
Cam Box Kit
RTF26040
Solenoid Regulator Kit
Kit contains 6 of each of
the following regulator
heights. Regulators are
also available separately.
14.60mm through 14.80mm
in .01mm increments.
RTF26040-1460 to
RTF26040-1480.

Section 1
Bosch PDE30-PDE90

1 - NOZZLE 1
2 RTF26061 EXTERNAL SEAL KIT 1 11
3 RTF26010 SPRING 1 8
- RTF26046 SPRING SEAT/INT. PLATE KIT 1
4 RTF26011 SPRING SEAT 1 6
5 RTF26012 INTERMEDIATE PLATE 1
6 - TAPPET O-RING 1 9
7 - SOLENOID 1 13
8 - NOZZLE NUT 1 11
9 - TAPPET 1 11
10 RTF26030 NOZZLE SHIM KIT A/R
11 RTF26029 SOLENOID O-RING KIT-EARLY 1
- LARGE WHITE O-RING 1
12
- LARGE BLACK O-RING 1
- GREEN O-RING 1 11
- WHITE O-RING 1 2
- RED O-RING 1
11 RTF26044 SOLENOID O-RING KIT-LATE 1 2
- LARGE BLACK O-RING 1 2
- GREEN O-RING 1 10
- WHITE O-RING 1
- RED O-RING 1 3
12 RTF26040 SOLENOID REGULATOR KIT A/R
12 RTF26040-SIZE 14.60mm to 14.80mm HEIGHT 1 4
5
- RTF26041 SOLENOID REG O-RING-EARLY 1
- RTF26060 SOLENOID REG O-RING-LATE 1 7
13 RTF26024 ARMATURE SCREW 1
1

Bosch PDE100

Applications:
Iveco Cursor 430

Iveco Stralis
Volvo D12A-380/420/460
Volvo D12C-380/420/460
Cam Box Kit AVAILABLE NOZZLES

Cam box components NOZZLE ENGINE
needed for this type of RTFDLLA155P572+P Volvo FH12 Euro I
injector are included with DLLA155P765 Use RTFDLLA155P872
the RTF25040 cam box. RTFDLLA155P872 Volvo FH12 Euro I-II
parts are available. RTF26040
Solenoid Regulator Kit
RTF26040-1460 to
RTF26040-1480
Kit contains 6 each of the
following regulator heights.
14.60mm through 14.80mm
in .01mm increments.
RTF26003 Regulators are also
Pop Test Adapter Euro1 available separately.
RTF26006
Pop Test Adapter Euro2

Section 1
Bosch PDE100

7 - SOLENOID 1 13
8 - NOZZLE NUT 1 11
9 - TAPPET 1 11
12
- GREEN O-RING 1 11
- WHITE O-RING 1 2
- RED O-RING 1
- GREEN O-RING 1 10
- WHITE O-RING 1
- RED O-RING 1 3
5
1

Bosch PDE31

Applications:
Scania DC 11.01 Scania DSC 11.01


Pop Test Adapter Euro1 NOZZLE ENGINE
RTFDLLA150P635 DC 11.02
RTFDLLA150P635 DC 11.03
RTFDLLA150P635 DSC 12.03
RTFDLLA150P635 DSC 12.05
DLLA150P847 DC12.01
DLLA150P847 DC12.09
RTF26006 DLLA150P847 DC16.01
Pop Test Adapter Euro2 DLLA150P848 DC11.03
DLLA150P848 DC11.04
DLLA150P848 DC12.02
DLLA150P848 DC16.02
RTF26020
Cam Box Kit
RTF26029
Solenoid Seal Kit Early
RTF26044
Solenoid Seal Kit
PDE31/100 Late
RTF26066
Internal/External
Seal Kit

Section 1
Bosch PDE31

2 RTF26066 INTERNAL/EXTERNAL SEAL KIT 1 11
7 - SOLENOID 1 13
8 - NOZZLE NUT 1 11
9 - TAPPET 1 11
12
- GREEN O-RING 1 11
- WHITE O-RING 1 2
- RED O-RING 1
- GREEN O-RING 1 10
- WHITE O-RING 1
- RED O-RING 1 3
5
1

Delphi

Applications:
Land Rover Discovery

RTF26009
Pop Test Adapter
RTF26017
Cam Box Kit
RTF26019
Injector Nut Tool

Section 1
Delphi


Delphi

Applications:
Volvo 420-460

John Deere
A3 Injector E1 Injector
Cam Box Kit AVAILABLE NOZZLES

Cam box components NOZZLE ENGINE
for Volvo applications RTFDLLA155P7154 Volvo FH12
are included with the Delphi LP004B
RTF25040 cam box.
Individual cam box kit RTF26001
parts are available. External O-Ring Kit
Volvo 420-460 Volvo, John Deere Use
with A3 injectors.
RTF26034
Solenoid Repair Kit
Volvo, John Deere
Use with A3 injectors.
Cam Box Kit
RTF26047 cam box.
John Deere
RTF26039
External O-Ring Kit
Volvo FH12 460 CV
Use with E1 injectors.
RTF26005
Pop Test Adapter
RTF26032
Intermediate Plate and
Spring Seat
Nozzle Shim Kit RTF26033

Available sizes in mm: Nozzle Shim Kit
0.20, 0.30, 0.40, 0.50, 0.60 Shim kit contains 20 pieces
each of the sizes listed.

Section 1
Delphi

4 RTF26032 INTER. PLATE AND SPRING SEAT 1
6 - SOLENOID 1 6
7 - NOZZLE NUT 1 11
8 - TAPPET 1 9
9 - SPRING 1 11
11 RTF26034 SOLENOID REPAIR KIT 1 11
11
2
10

Bosch PLD100-110 Type B

Applications:
Mack

Renault
DAF
KHD
RTF26021 RTF26024
Solenoid Screw Bit Solenoid Armature Screw
T20 Anti-tamper Torx Bit
RTF26035
RTF26022 External O-Ring Kit
Solenoid Repair Kit
RTF26062
Stop Kit
RTF26023
Cam Box Kit
Mack PLD Pumps
RTF26023-1
Adapter Flange
Mack PLD Pumps
If you own Cam Box Kit
RTF26015 or RTF26016
then you only need to
purchase this adapter
flange to test this injector.
RTF26023-2
Injector Adapter Block
RTF26023-3

Section 1
Bosch PLD100

Applications:
Freightliner
Mercedes Atego
Mercedes MBE900
RTF25084 RTF26016
External O-Ring Kit Cam Box Kit
RTF26062
Stop Kit
RTF26016-1
Adapter Flange
RTF26016-2
RTF26021
Solenoid Screw Bit
RTF26022
Solenoid Repair Kit
RTF26024
Solenoid Armature Screw

Bosch PLD110

Applications:
Freightliner

Mercedes Actros
Mercedes MBE4000

Quick Connector 21.5mm NOZZLE ENGINE
Use with Rilsan tubes RTFDLLA154P596++ Mercedes Actros
supplied in RTF25041.
RTF26022
Solenoid Repair Kit
RTF25085
External O-Ring Kit
Nozzle Shim Kit RTF25108

Available sizes in mm: Nozzle Shim Kit
0.80, 0.85, 0.90, 1.00, 1.05, Shim kit contains 20
1.10, 1.15, 1.20, 1.25, 1.30, pieces each of the size RTF26024
1.30, 1.35, 1.40, 1.45, 1.50, shown on the right. Solenoid Armature Screw
1.55, 1.60, 1.65, 1.70, 1.75,
1.80, 1.85, 1.90, 1.95, 2.00
RTF26062
RTF26015 Stop Kit
Cam Box Kit
RTF26015-1
Adapter Flange
RTF26016-2
RTF26021
Solenoid Screw Bit

Section 1
Bosch PLD110

2 RTF26032 INTER. PLATE AND SPRING SEAT 1
3 RTF26037 NOZZLE NUT 1
4 RTF25087 NOZZLE WASHER 1
5 RTF25108 NOZZLE SHIM A/R
6 RTF26038 SPRING 1
7 RTF26063 O-RING 1
7

Caterpillar And EDM

Applications:
EMD Electronic

Caterpillar 3500
Mechanical
Caterpillar 3500
Electronic
RTF27000 Injector Adapter

Large Injector Cam Box Caterpillar 3500
The RTF27000 Cam Box is designed for testing large Mechanical
unit injectors used in marine, railroad, and large industrial
applications. The RTF27000 is used together with the
RTF25005 Electronic Simulator. The RTF27000 can
presently test EMD EUI injectors and Caterpillar 3500
series injectors, both mechanical and electronic.
The kit includes the cam box shown below and the
accessories to the right. Injector Adapter
Caterpillar 3500
Electronic
Injector Adapter
EMD

Accessories
This cam box requires a minimum 15HP test bench.

Section 1
Pop Test Adapters

RTF26003 RTF26009
Pop Test Adapter Pop Test Adapter
Bosch PDE31-PDE100 Delphi and Landrover
Euro 1, Iveco, Volvo,
Scania
RTF26201
RTF26004
Pop Test Adapter
Pop Test Adapter
Detroit Series 50 and 60
Bosch PDE30-PDE90
Iveco
RTF26203
Pop Test Adapter
RTF26005 Cummins Celect
Pop Test Adapter L10, M11 and ISM
Delphi A3, Volvo and
John Deere
RTF26206
Pop Test Adapter
Cummins Celect
RTF26006 N14
Pop Test Adapter
Bosch PDE31-PDE100
Euro 2, Iveco, Volvo,
Scania
RTF26007
Pop Test Adapter
Caterpillar
3176/3196/C-10/C-12
RTF26008
Pop Test Adapter
Bosch PDE80
Volkswagen



COMMON RAIL FUEL SYSTEMS
Section 2
Electronic Simulator

DIPACO DIESEL PARTS - USA, working with Corona Diesel of Italy,

is able to provide a full range of test equipment, repair equipment,
and parts for Common Rail fuel systems. This catalog is meant for
reference and is not all inclusive of our parts and equipment offerings.
Minimum Test Bench Requirements

Drive Motor:
CP-1 4KW/5HP
CP-2/ECD-U2 15KW/20HP
CP-3 (7MM cam lift) 4KW/5HP. CP-3
(cam lift above 7MM) 7.5KW/10HP
Temperatures can be a concern. During the short

time needed to perform pump tests, discharge
temperatures can reach 600 C (1400 F). Do not
use test benches with Bosch KMM and KMA
(except Bosch 815/KMA with VP44 conversion)
fuel measurement units due to temperature issues.
Do not use test benches with a Hartridge VDM
fuel measurement unit because it requires a
cylinder firing order. CP-1 pumps are mounted on
a test bench with a VE mounting plate and a 20MM
drive coupling. For Mercedes CP-1 pumps a
DPA supported drive adapter (metric spline) and
DIPACO kit RTF25000. We recommend a Kevlar
reinforced Plexiglas shield be made to surround
the common rail system for technician safety. RTF25005 Electronic Simulator
Common Rail Fuel System Tests Performed When used with an appropriate test stand and
Pressure-Control Valve accessories, can perform a full range of diagnostic
Pump Leakage tests on CP-1 Type Common Rail fuel systems.
Inlet Safety Valve When joined with the RTF25052 (CP-3, Delphi,
Pump Delivery Volume Siemens) or RTF25065 (CP-2) add-on simulator
Pump Element Leakage the system will be able to perform a full range
Pump Element Shutoff Valve of tests on CP-2, CP-3, Delphi, and Siemens
Injector Bleed Orifice Valve Ball Seal Common Rail fuel systems. The RTF25005 unit
Injector Leakage comes with the cables, connectors, sensors, and
Injector Full Load Delivery other equipment needed to test many popular
Injector Partial Load Delivery Variation CP-1 systems. Additional connector kits for
Injector Opening Pressure, Atomization, Spray Mercedes CP-1 systems are available. An
Pattern, and Seat Leakage additional advantage is the system works with
Engine Rail Pressure Sensor most any test bench available.

Section 2 COMMON RAIL FUEL SYSTEMS
Bosch CP-1 Fuel Pump

8
25
27 24
7 26 26
29 30 5 28
27 2 3
4 3
1 9 20/21/22/23
14/15/16/17/18/19
36
12
6 10 11 34
35 13
31/32/33
REF PART DESCRIPTION QTY REF PART DESCRIPTION QTY

1 - HIGH PRESSURE OUTLET 1 24 - ELEMENT COVER 3
2 RTF25016 CAMSHAFT-SINGLE OIL SEAL 1 25 RTF25046 ELEMENT COVER SCREW 12
2 RTF25017 CAMSHAFT-DUAL OIL SEAL 1 26 RTF25030 WASHER 2
2 RTF25037 CAMSHAFT (MERCEDES) 1 27 RTF25031 INLET/OUTLET TUBE 2
3 RTF25036 CAMSHAFT BUSHING KIT 1 - RTF25032 PUMP O-RING/SEAL KIT (EARLY) 1
4 RTF25018 CAM LOBE 1 - RTF25092 PUMP O-RING/SEAL KIT (LATE) 1
5 - COVER 1 28 - FRONT SEAL 1
6 RTF25019 PRESSURE REGULATOR SCREW 2 29 - FRONT COVER O-RING 1
7 RTF25021 SAFETY VALVE ASSY 1 30 - FRONT COVER O-RING 1
7 RTF25038 SAFETY VALVE ASSY (MERC) 1 31 - PRESSURE REG O-RING 1
8 RTF25020 COVER SCREW 3 32 - PRESSURE REG SEAL RING 1
9 RTF25022 WASHER 1 33 - PRESSURE REG O-RING 1
10 - PRESSURE REGULATOR 1 34 - COVER ALIGN PIN O-RING 6
11 RTF25054 PRESSURE REGULATOR GSKT 1 35 - COVER ALIGN PIN SEAL RING 6
12 RTF25025 ELEMENT COVER ALIGN PIN 3 36 - COVER SEAL RING (EARLY) 3
13 RTF25023 075/080 WASHER 3 36 - COVER SEAL RING (LATE) 3
13 RTF25024 065/075 WASHER 3 - - COVER SEAL RING (LATE) 3
14 RTF25047 RETAINER DISCHARGE BALL 3 - RTF25053 PRESSURE REG SEAL KIT 1
15 RTF25026 DISCHARGE BALL 3 31 - PRESSURE REG O-RING 1
16 - VALVE BLOCK 3 32 - PRESSURE REG SEAL RING 1
17 RTF25121 SUCTION VALVE 3 33 - PRESSURE REG O-RING 1
18 RTF25027 SUCTION VALVE SPRING 3 - RTF25034 CONE WASHER KIT 1
19 RTF25048 RETAINER SUCTION VALVE 3 13 RTF25023 075/080 WASHER 12
20 RTF25122 ELEMENT SPIDER 3 13 RTF25024 065/075 WASHER 12
21 RTF25080 CLIP 3 - RTF25033 FRONT SEAL KIT (MERCEDES) 1
22 RTF25015 ELEMENT SPRING 3 28 - FRONT SEAL 1
23 RTF25029 PUMP ELEMENT 6.5 3 - - MOUNTING O-RING 1
23 RTF25028 PUMP ELEMENT 7.0 3 - RTF25101 ELMNT SHUTOFF VALVE O-RING 1
23 RTF25123 PUMP ELEMENT 7.5 3

Section 2

RTF25000 RTF25111
Mercedes CP-1 Test Kit CP-1 Screw Kit
Metric Spline Zinc plated screws for
RTF25000-A element covers, front
Mercedes CP-1 Test Kit cover, and pressure
Imperial Spline regulator. Screws
For use with Mercedes should be replaced every
CP-1 common rail fuel time pump is repaired.
systems. Includes 12-RTF25046,
3-RTF25020, and
RTF25001 2-RTF25019.
Camshaft Bushing
Tool Kit
Tools for removing and
installing camshaft
bushings. Kit also
includes 5 RTF25036
bushing kits.
RTF25002
Swivel Vise Mounting Kit
Includes bracket and
rotating plate for mounting
non-Mercedes fuel pumps.
RTF25003
Swivel Vise
RTF25050
Swivel Vise Adapter
Mercedes
Rotating plate for
mounting Mercedes fuel
pumps in RTF25002
Swivel Vise. Included
in RTF25000 and
RTF25000-A.


Applications:
Renault

Mitsibushi
RTF25065
Add-on Module
RTF25066
Amperage Meter Kit
RTF25067
Rail Element
RTF25068
Element Selector

Section 2

Applications:
CP3-70
CP3-80
CP3-110
Duramax 6600
Cummins ISBe
RTF25088 RTF25124
Internal O-Ring and Seal Front Seal Kit
Kit CP3-70
CP3-110
Duramax 6600
Cummins ISBe
COMING
Element Valve
RTF25089 CP3-70
Internal O-Ring and Seal
Kit
CP3-70
COMING
Element Plug
RTF25090 CP3-70
Internal O-Ring and Seal
Kit
CP3-80
COMING
RTF25091 Element Plug
Internal O-Ring and Seal CP3-80 and CP3-110
Kit See diagram #1 page 2-8
CP3-70
No Supply Pump
COMING
Element Valve
CP3-80 and CP3-110
RTF25102 See diagram #2 page 2-8
CP3-70 Screw Kit
RTF25103
CP3-80/110 Screw Kit
Zinc plated screws for

element covers, front
cover, and pressure
regulator. Screws should
be replaced every time
pump is repaired.


RTF25052 RTF25072
Electronic Simulator Camshaft Bushing
Add-on Module Tool Kit
Tools for removing and
installing camshaft
RTF25058 bushings.
Swivel Vise Adapter
RTF25073
Inlet and Return Fitting
Socket
RTF25059
CP3 Tappet Lifter
Tool Kit
For all CP3 pumps
except Duramax 6600
RTF25114
CP3 Tappet Lifter
Tool Kit
Duramax 6600 only
RTF25060
Transfer Pressure
Connector
RTF25118
RTF25066 CP3 Inlet Metering Valve
Amperage Meter Kit Disassembly Tool
0281002488
Pressure-Control Valve
RTF25126
RTF25071 Camshaft Bushing Tool
Element Plug Torx Bit Duramax 6600 only

Section 2



(View A-See Page 2-9)
A
1

1 - ELEMENT PLUG CP3-80/CP3-110 1
2 - ELEMENT VALVE CP3-80/CP3-110 1

Section 2

View A

Delphi Fuel Pump

Applications:
Ford: Focus, Mondeo & Transit Van

Hyundia
Jaguar X-Type
Nissan
Peugeot
Renault: Clio & Kangoo
RTF25052 CDFDPF
Electronic Simulator RTF
Add-on Module Flange
Ford Focus
RTF25061
Transfer Pressure
Connector
RTF25066
Amperage Meter Kit
RTF25079
Pressure Connector
Cable
RTF25127
Test Bench Mounting
Flange
Renault Clio
CDF2
Flange
Ford Focus

Section 2
Denso Fuel Pump-HP2

Applications:
Ford Transit Van
Mazda
Nissan
Toyota
ACME11
RTF
Add-on Module
HP2
RTF25066
Amperage Meter Kit
RTF25128
Swivel Vise Adapter
HP2 & HP3 High
Pressure Pumps
RTF25129
Test Bench Mounting
Flange
HP2 & HP3 High
Pressure Pumps
555-HP2
RTF
HP2
CD1700-2
RTF
CDRHP2
RTF

Denso Fuel Pump-HP3

Applications:
John Deere 4045H

John Deere 6068H
ACME12
RTF
Add-on Module
HP3
RTF25128
Swivel Vise Adapter
HP2 & HP3
High Pressure Pumps
RTF25129
Test Bench Mounting
Flange
HP2 & HP3
High Pressure Pumps

Section 2
Siemens Fuel Pump

Applications:
Peugeot
RTF25052
Add-on Module
RTF25066
Amperage Meter Kit
CD1700-A
RTF
555-6A
RTF
555-6B
RTF

Bosch Common Rail Injector

RTF25051 RTF25132
Armature Retainer Tool Injector Seat Cleaning
Tool
RTF25063
19mm Injector
Extraction Tool
RTF25064
19mm Injector Holding
Assembly/Disassembly
Block
RTF25130
Installation Tool for
RTF25082 Seal Ring
RTF25131
Injector Removal
Adapter Tool
To be used with a slide
hammer.

Section 2
Bosch Common Rail Injector

1 RTF25013 SOLENOID O-RING 1
2 RTF25083 SPHERICAL VALVE 1
3 RTF25082 WASHER 1
4 RTF25049 WASHER 1
5 - SPRING 1
6 - SPRING SEAT 1
7 RTF25055 ALIGNMENT PIN 2
8 RTF25014 NOZZLE NUT (19MM) 1
1
8 RTF25116 NOZZLE NUT (17MM) 1
9 RTF25087 NOZZLE WASHER (MERCEDES) 1
9 RTF25104 NOZZLE WASHER (FIAT & BMW) 1
2
9 RTF25133 NOZZLE WASHER (PEUGEOT) 1
10 RTF25134 NOZZLE SHIM 1.2mm A/R
10 RTF25136 NOZZLE SHIM 1.4mm A/R 3
20 RTF25049 WASHER 1 4
10
5
6
7
8
9
20

Cummins ISBe Common Rail Injector

Applications:
Cummins ISBe

Iveco
Renault
MAN
Autocar
RTF25051
Armature Retainer Tool
RTF25070
RTF25069
Wiring Harness
RTF25081
Quick Connector 21.5mm
Use with Rilsan tubes
Order in multiples of
injectors that can be tested.
RTF25094
Test Fuel Line
8mm x 2mm x150mm Injectors
14 x 14 line nuts

Section 2
Cummins ISBe Common Rail Injector

1 RTF25106 SOLENOID O-RING 2
2 - NOZZLE NUT 1
3 RTF25105 INLET TUBE O-RING 1
4 RTF25055 ALIGNMENT PIN 2
5 - SPRING SEAT 1 1
6 - SHIM KIT A/R
7 - INLET TUBE 1
8 - ADAPTER 1
9 RTF25082 WASHER 1
9 RTF25140 WASHER-ALUMINUM 1
10 - O-RING 1
11 - WASHER 1
12 RTF25083 SPHERICAL VALVE 1
13 RTF25107 NOZZLE WASHER 1
12
1
11
10
7
8
4
6
5
13

Delphi Common Rail Injector

RTF25074
Wiring Harness

Section 2
Delphi Common Rail Injector


Duramax/Isuzu Common Rail Injector

Applications:
GM Duramax 6600

RTF25069 Injector Testing Leak-off

Wiring Harness Hardware
D42014 (2) Leak-off Hose
D42411 (4) Banjo
D2911235700 (4) Bolt
Using the above hardware
will allow for injector
leak-off when testing four
Duramax 6600 injectors.
RTF25086
Duramax 6600
RTF25094
Test Fuel Line
14 x 14 line nuts

Section 2
Duramax/Isuzu Common Rail Injector


Denso ECD-U2 Injector

Applications:
Komatsu SAA 6D125

Isuzu Duramax 7800
RTF25069
Wiring Harness
RTF26064
Adapter
injectors that can be
tested. (Komatsu Only)
RTF26065
Quick Connector
RTF25081

Section 2
Fuel Line Kits

All fuel line kits are constructed using special fuel
line material able to handle 2,000 bar (28,000 PSI)
pressure. Kits include the line from pump to rail
and lines for each injector.
RTF25109
Mercedes Vito
Fuel Line Kit
200/220
RTF25110
Mercedes Sprinter
Fuel Line Kit
270

Diagnostic Tools

RTF25004
Manometer
0-1500 Bar
RTF25062
On-Engine Diagnostic Kit
Test the efficiency of
the fuel pump. Includes
manometer, manual
pressure control, and
a rail pressure sensor
controller.
RTF26042
For Pop Testing
Common Rail Injectors
Bosch
RTF26043
For Pop Testing
Common Rail Injectors
Delphi

DUAL SPRING INJECTORS
Section 3
RTF26050
Test and Assembly
Fixture
Includes injector holding
fixtures and nozzle
measurement tool.

Section 3 DUAL SPRING INJECTORS


NOZZLES
Section 4

Section 4 NOZZLES


TEST BENCH HARDWARE AND ACCESSORIES
Section 5
RTF25007 RTF25081
Test Bench Rail Kit Quick Connector 21.5mm
RTF25086
Duramax 6600
RTF25041 Use with Rilsan tubes
Injector Connector Kit supplied in RTF25041.
Six quick connectors for
use with 17mm and 19mm RTF25093
injectors on test stand. Test Fuel Line
12 x 14 line nuts
RTF25094
Test Fuel Line
RTF25075 14 x 14 line nuts
Fuel Measurement
RTF25095
Accumulator Adapter
Test Fuel Line
Hartridge 1100/2500
8mm x 2mm x 200mm Pump/sensor/rail
14 x 14 line nuts CP2 & ECD-U2
RTF25076
Fuel Measurement RTF25096
Accumulator Adapter Test Fuel Line
8mm x 2mm x94mm Pump/sensor/rail
Hartridge AVM
12 x 14 line nuts
RTF25077 RTF25097
Fuel Measurement Test Fuel Line
Accumulator Adapter 8mm x 2mm x94mm Pump/sensor/rail
Bosch 815/KMA 12 x 12 line nuts
RTF25078 RTF25098
Test Bench Base Test Fuel Line
Adapter (Set of 2) 8mm x 2mm x 94mm Pump/sensor/rail
Hartridge 14 x 14 line nuts
RTF25099
Test Fuel Line
8mm x 2mm x 200mm Pump/sensor/rail
12 x 14 line nuts

Section 5 TEST BENCH HARDWARE AND ACCESSORIES


TEST BENCH HARDWARE AND ACCESSORIES
Section 5
RTF25120
Common Rail
Injector Test Cabinet
RTF25141
Extention Cable
RTF25142
Extention Cable

Section 5 TEST BENCH HARDWARE AND ACCESSORIES


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DIPACO Parts Catalog For

REBUILD THE FUTURE

DIPACO DIESEL PARTS - USA

December 2004 Ver 1.6 REBUILD THE FUTURE 1

This catalog is for reference

December 2004 Ver 1.6 REBUILD THE FUTURE 3

Below are the basic equipment packages.

Following are the kit contents for RTF25117:

The RTF25040 Cam Box and RTF25005

Also available are cam box adapters for various

Temperatures can be a concern. During the RTF25040 Cam Box

December 2004 Ver 1.6 REBUILD THE FUTURE 1-1

RTF25040 Cam Box

EUI/EUP Tests Performed

1-2 REBUILD THE FUTURE December 2004 Ver 1.6

December 2004 Ver 1.6 REBUILD THE FUTURE 1-3

This cam box requires a minimum 15HP test bench.

1-4 REBUILD THE FUTURE December 2004 Ver 1.6

Large Injector Cam Box

December 2004 Ver 1.6 REBUILD THE FUTURE 1-5

RTF26102 AVAILABLE NOZZLES

1-6 REBUILD THE FUTURE December 2004 Ver 1.6

December 2004 Ver 1.6 REBUILD THE FUTURE 1-7

1-8 REBUILD THE FUTURE December 2004 Ver 1.6

December 2004 Ver 1.6 REBUILD THE FUTURE 1-9

RTF26200 AVAILABLE NOZZLES

1-10 REBUILD THE FUTURE December 2004 Ver 1.6

December 2004 Ver 1.6 REBUILD THE FUTURE 1-11

1-12 REBUILD THE FUTURE December 2004 Ver 1.6

December 2004 Ver 1.6 REBUILD THE FUTURE 1-13

1-14 REBUILD THE FUTURE December 2004 Ver 1.6

December 2004 Ver 1.6 REBUILD THE FUTURE 1-15

1-16 REBUILD THE FUTURE December 2004 Ver 1.6

December 2004 Ver 1.6 REBUILD THE FUTURE 1-17

Cam Box Kit AVAILABLE NOZZLES

1-18 REBUILD THE FUTURE December 2004 Ver 1.6

December 2004 Ver 1.6 REBUILD THE FUTURE 1-19

RTF26003 AVAILABLE NOZZLES

1-20 REBUILD THE FUTURE December 2004 Ver 1.6

December 2004 Ver 1.6 REBUILD THE FUTURE 1-21

1-22 REBUILD THE FUTURE December 2004 Ver 1.6

December 2004 Ver 1.6 REBUILD THE FUTURE 1-23

Cam Box Kit AVAILABLE NOZZLES

Nozzle Shim Kit RTF26033

1-24 REBUILD THE FUTURE December 2004 Ver 1.6

December 2004 Ver 1.6 REBUILD THE FUTURE 1-25

1-26 REBUILD THE FUTURE December 2004 Ver 1.6

December 2004 Ver 1.6 REBUILD THE FUTURE 1-27

RTF25081 AVAILABLE NOZZLES

Nozzle Shim Kit RTF25108

1-28 REBUILD THE FUTURE December 2004 Ver 1.6

December 2004 Ver 1.6 REBUILD THE FUTURE 1-29

RTF27000 Injector Adapter

Large Injector Cam Box

This cam box requires a minimum 15HP test bench.

1-30 REBUILD THE FUTURE December 2004 Ver 1.6

December 2004 Ver 1.6 REBUILD THE FUTURE 1-31

1-32 REBUILD THE FUTURE December 2004 Ver 1.6

DIPACO DIESEL PARTS - USA, working with Corona Diesel of Italy,

Minimum Test Bench Requirements

Temperatures can be a concern. During the short

December 2004 Ver 1.6 REBUILD THE FUTURE 2-1

REF PART DESCRIPTION QTY REF PART DESCRIPTION QTY