9323A260 Issue No: 5

Test Plan
JCB 68.5 KW @ 2200 RPM (TC) Date: 00/00/00

PUMP SPECIFICATION
Rotation: Anti-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: 320/06738 Setting Code: .......
OEM Code: 320/06754 Setting Code: ....

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: 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 4.0 turns
out before commencing test
CA solenoid to be de-energised unless otherwise stated.
Torque trimmer plug to be wound out until thread appears.
Boost control initial shimming: 0.5 mm.
Boost stroke : 2.9 to 3.1 mm.
Latch valve adjuster, if fitted, screw fully in then
8 turns out
Turn light load adjuster valve fully in ,then 2 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 400 rpm 3 times.
Open throttle.
Set boost pressure to 15.0 psi.
2. Transfer Press. (S) 1100 84 to 86 psi
3. Delivery (S) 1150 84.3 ± 0.5 mm3/st.
4. Governor (S) 1280 12.0 to 16.0 mm3/st.
Stabilise. Cycle speed between 100 to 1260 rpm 2 times.
Stabilise and run at 1150 rpm until backleak temperature
is 38°C min.
5. Backleakage (C) 1100 Flow rate 450 to 950 cm3/min.
6. Cambox Press. (C) 1100 6 to 11 psi.
7. Transfer Press. (S) 1100 Press at test(6 ) + 78to 79psi
Run test machine down to 0 rpm.
8. Transfer Press. (C) 100 Minimum 12 psi.
9. Transfer Press (C) 1100 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) 750 0.5° Max.
12. Advance (C) 1050 1.8 to 2.2°.
13. Advance (C) 1100 1.8 to 2.2°.
Stop test machine.
Energise CA solenoid.
14. Advance (C) 700 7.0 to 9.5°.
De-energise CA solenoid.
15. Advance - (S) 1100 4.8to 5.2° 36.0to 40.0mm3/st.
Light load Adjust throttle/torque screw
& LLA valve.
Run test machine down to 0 rpm.
16. Advance - (C) 1100 4.8to 5.2° 38.0 ± 2.0mm3/st.
Light load Use throttle/Torque screw.
17. Advance - (C) 1100 1.0to 4.0° 51.5 ± 1.5mm3/st.
Light load Use throttle/Torque screw.
18. Advance - (C) 1100 7.3to 7.7° 30.0 ± 7.0mm3/st.
Light load Use throttle/Torque screw.
19. Advance - (C) 650 1.8to 2.2° 53.0 ± 8.0mm3/st.
Light load Use throttle/Torque screw.
Open throttle.
Stop test machine.
Fit CPS tool
Set boost pressure to 15.0 psi.
20. Torque Trimmer (S) 1200 Datum CPS reading to 0.0mm.
21. Torque Trimmer (S) 550 Adjust CPS to 0.05 to 0.15mm
CPS
22. Torque Trimmer (S) 640 Adjust CPS to -0.48 to -0.52mm
CPS
Run test machine down to 0 rpm.
23. Torque Trimmer (C) 1250 As test (20) ± 0.05 mm
CPS
24. Torque Trimmer (C) 700 Check CPS is -0.7 to -1.5mm
CPS
25. Torque Trimmer (C) 450 Check CPS is 0.8 to 1.6mm
CPS
26. Torque Trimmer (C) 1200 As test (23) ± 0.2 mm
CPS
Set boost pressure to zero.
27. Torque Trimmer (C) 1200 Check CPS is 1.8 to 2.4mm
CPS
Set boost pressure to 5.5 psi.
28. Torque Trimmer (C) 1200 As test (26) ± 0.2 mm
CPS
Set boost pressure to 1.0 psi.
29. Torque Trimmer (C) 1200 As test (27) ± 0.2 mm
CPS
Set boost pressure to zero.
Screw latch valve adjuster fully in.
30. Latch Valve S/C 260 CPS = 2.5 to 4.5 mm
If incorrect, adjust LV pre-load
& repeat test.
Run test machine down to 0 rpm.
31. Torque Trimmer (C) 220 Check CPS is -0.5 to -2.5mm
CPS
32. Torque Trimmer (C) 280 Check CPS is 2.5 to 4.5mm
CPS
If incorrect or adjusted, stop machine and repeat from test (30).
33. Delivery (C) 100 Minimum 75.0 mm3/st.
34. Shut-off - (C) 500 De-energise solenoid, wait 5 seconds.
Solenoid Max. 2.0 mm3/st.
Stop test machine.
Energise ESOS
Close throttle.
35. Idle delivery (S) 420 12.0 to 16.0 mm3/st. Throttle closed.
36. Delivery (C) 540 Maximum 3.0 mm3/st.
Stop test machine.
Fit Max Fuel adjuster tool
Open throttle.
Set boost pressure to 15.0 psi.
37. Max. Delivery (S) 1150 84.3 ± 0.3 mm3/st.
Max. spread 5.0 mm3/st.
38. Delivery (C) 700 As test (37) + 9 ± 3 mm3/st.
39. Delivery (C) 1150 As test (37) ± 1.0 mm3/st.
Set boost pressure to zero.
40. Delivery (C) 1200 As test (39) - 13.0 ± 5.0 mm3/st.
Set boost pressure to 15.0 ± 0.5 psi.
41. Dynamic timing Refer to SIN DT339
Piezo sensor, outlet U
Off-set angle 274.0°
speed (S) 1150 Trigger level 25 %
42. Delivery (C) 1100 Record delivery mm3/st.
43. Governor (S) 1235 12.0 to 16.0 mm3/st.
44. Gov. cut-off (C) 1320 Maximum 3.0 mm3/st.
45. Delivery (C) 1100 Throttle as test (43).
Minimum as test (42) - 1.0 mm3/st.
.
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 1280 rpm 5 times.
Stabilise and run at 1100 rpm until backleak temperature
is 38°C min.
46. Gov. cut-off (C) 1320 Maximum 3.0 mm3/st.
Fully unscrew the Maximum speed adjusting screw.
47. Advance (S) 500 0° (Datum advance gauge)
48. Advance (C) 1100 1.7 to 2.3°.
49. Advance (C) 750 0.7° Max.
50. Advance - (C) 1100 4.8to 5.2° 38.0 ± 4.0mm3/st.
Light load Use throttle/Torque screw.
51. Advance - (C) 1100 7.3to 7.7° 30.0 ± 9.0mm3/st.
Light load Use throttle/Torque screw.
52. Advance - (C) 650 1.8to 2.2° 53.0 ± 10mm3/st.
Light load Use throttle/Torque screw.
Stop test machine.
Energise CA solenoid.
53. Advance (C) 700 6 to 10°.
De-energise CA solenoid.
Open throttle.
Fit CPS tool
Set boost pressure to 15.0 psi.
54. Torque Trimmer (S) 1150 Datum CPS reading to 0.0mm.
55. Torque Trimmer (C) 725 Check CPS is -0.7 to -1.5mm
CPS
56. Torque Trimmer (C) 425 Check CPS is 0.8 to 1.6mm
CPS
Set boost pressure to zero.
57. Torque Trimmer (C) 1150 As test (54) + 2.1 ± 0.4 mm
CPS
Close throttle.
58. Delivery (C) 540 Maximum 3.0 mm3/st.
Open throttle.
59. Delivery (C) 100 Minimum 75.0 mm3/st.
60. Shut-off - (C) 500 De-energise solenoid, wait 5 seconds.
Solenoid Max. 3.0 mm3/st.
Run test machine down to 0 rpm.
Energise ESOS
Set boost pressure to 15.0 psi.
61. Delivery (C) 1100 81.0 to 87.0 mm3/st.
62. Delivery (C) 700 As test (61) + 9.0 ± 4.0 mm3/st.
63. Dynamic timing Refer to SIN DT339
Piezo sensor, outlet U
 Off-set angle 274.0°
speed (S) 1150 Trigger level 25 %
64. Delivery (C) 1100 Record delivery mm3/st.
65. Governor (S) 1235 12.0 to 16.0 mm3/st.
66. Gov. cut-off (C) 1320 Maximum 3.0 mm3/st.
67. Delivery (C) 1100 Throttle as test (65).
Minimum as test (64) - 1.0 mm3/st.