9320A070 MODY02 Edition: 4
Test Plan:
Vista T2359 9320A070 Issue Date:
MODY02
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: 2644H004 Setting Code: JR/2/2350
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 out and then 4.5 turns
in 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: 1.4 mm.
Boost stroke : 2.1 to 2.3 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 500 rpm 5 times.
Set boost pressure to 15.0 psi.
Open throttle.
2. Transfer Press. (S) 1100 90 to 92 psi
3. Delivery (S) 1100 90.0 ± 1.0 mm3/st.
4. Governor (S) 1210 12.0 to 20.0 mm3/st.
Stabilise. Cycle speed between 600 to 1240 rpm 5 times.
Stabilise and run at 1100 rpm until backleak temperature
is 38°C min.
5. Backleakage (C) 1100 Flow rate 500 to 1000 cm3/min.
6. Cambox Press. (C) 1100 5 to 11 psi.
7. Transfer Press. (S) 1100 Press at test(6 ) + 82.5to 83.5psi
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.
Energise ESOS
10. Advance (S) 500 0° (Datum advance gauge)
11. Advance (C) 750 0.3° Max.
12. Advance (C) 1050 0.8 to 1.2°.
13. Advance (C) 1100 0.8 to 1.2°.
1/4
9320A070 MODY02 Edition: 4
Test Plan:
Vista T2359 9320A070 Issue Date:
MODY02
ISO TEST PROCEDURE
Test Operation S/C RPM Requirements
Stop test machine.
Energise CA solenoid.
14. Advance (C) 700 3.8 to 5.5°.
De-energise CA solenoid.
15. Advance - (S) 1100 3.8to 4.2° 33.0to 37.0mm3/st.
Light load Adjust throttle/torque screw
& LLA valve.
Run test machine down to 0 rpm.
16. Advance - (C) 1100 3.8to 4.2° 35.0 ± 2.0mm3/st.
Light load Use throttle/Torque screw.
17. Advance - (C) 1100 7.8to 8.2° 20.0 ± 8.0mm3/st.
Light load Use throttle/Torque screw.
18. Advance - (C) 700 1.8to 2.2° 48.0 ± 7.0mm3/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
19. Torque Trimmer (S) 1100 Datum CPS reading to 0.0mm.
20. Torque Trimmer (S) 625 Adjust CPS to -0.2 to -0.4mm
CPS
21. Torque Trimmer (S) 690 Adjust CPS to 0.07 to 0.11mm
CPS
Run test machine down to 0 rpm.
Stabilise and run at 1150rpm for 2 seconds
22. Torque Trimmer (C) 1100 As test (19) ± 0.05 mm
CPS
23. Torque Trimmer (C) 775 Check CPS is 0.4 to 0.9mm
CPS
24. Torque Trimmer (C) 625 Check CPS is 0.0 to -0.8mm
CPS
25. Torque Trimmer (C) 1100 As test (22) ± 0.1 mm
CPS
Set boost pressure to zero.
26. Torque Trimmer (C) 1100 As test (25) - 1.75 ± 0.30 mm
CPS
Set boost pressure to 9.5 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 3.5 psi.
28. Torque Trimmer (C) 1100 As test (26) ± 0.2 mm
CPS
If correct continue with test (29), if not, adjust shimming
and then repeat test(s) (19 to 28 ).
Set boost pressure to zero.
Screw latch valve adjuster fully in.
29. Latch Valve S/C 250 CPS = -2.0 to -6.0 mm
If incorrect, adjust LV pre-load
& repeat test.
Run test machine down to 0 rpm.
30. Torque Trimmer (C) 220 Check CPS is 0.2 to 1.0mm
CPS
31. Torque Trimmer (C) 280 Check CPS is -2.0 to -6.0mm
CPS
If incorrect or adjusted, stop machine and repeat from test (29).
32. Delivery (C) 100 Minimum 75.0 mm3/st.
Close throttle.
33. Idle delivery (S) 405 12.0 to 16.0 mm3/st. Throttle closed.
34. Delivery (C) 510 Maximum 3.0 mm3/st.
Stop test machine.
Fit Max Fuel adjuster tool
Open throttle.
Set boost pressure to 15.0 psi.
35. Shut-off - (C) 500 De-energise solenoid, wait 5 seconds.
2/4
9320A070 MODY02 Edition: 4
Test Plan:
Vista T2359 9320A070 Issue Date:
MODY02
ISO TEST PROCEDURE
Test Operation S/C RPM Requirements
Solenoid Max. 2 mm3/st.
Run test machine down to 0 rpm.
Energise ESOS
36. Max. Delivery (S) 1100 90.0 ± 0.3 mm3/st.
Max. spread 5.0 mm3/st.
37. Delivery (C) 800 As test (36) + 10.5 ± 3.0 mm3/st.
38. Delivery (C) 1100 As test (36) ± 1 mm3/st.
39. Governor (S) 1190 12.0 to 16.0 mm3/st.
40. Gov. cut-off (C) 1240 Maximum 3.0 mm3/st.
41. Delivery (C) 1100 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 184.25°
speed (S) 1100 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 400 rpm 5 times.
Set boost pressure to 15.0 psi.
Open throttle.
Stabilise. Cycle speed between 600 to 1240 rpm 5 times.
Stabilise and run at 1100 rpm until backleak temperature
is 38°C min.
43. Advance (S) 500 0° (Datum advance gauge)
44. Advance (C) 1100 0.7 to 1.3°.
45. Advance (C) 750 0.5° Max.
46. Advance - (C) 1100 3.8to 4.2° 35.0 ± 4.0mm3/st.
Light load Use throttle/Torque screw.
47. Advance - (C) 1100 7.8to 8.2° 20.0 ± 10.0mm3/st.
Light load Use throttle/Torque screw.
48. Advance - (C) 700 1.8to 2.2° 48.0 ± 8.0mm3/st.
Light load Use throttle/Torque screw.
Stop test machine.
Fit CPS tool
Open throttle.
Energise CA solenoid.
49. Advance (C) 700 3.3 to 5.5°.
De-energise CA solenoid.
50. Torque Trimmer (S) 1100 Datum CPS reading to 0.0mm.
51. Torque Trimmer (C) 785 Check CPS is 0.4 to 0.9mm
CPS
52. Torque Trimmer (C) 615 Check CPS is 0.0 to -0.8mm
CPS
Set boost pressure to zero.
53. Torque Trimmer (C) 1100 Check CPS is -1.40 to -2.10mm
CPS
Move throttle lever to closed position for tests (54 ).
54. Delivery (C) 520 Maximum 3.0 mm3/st.
Open throttle.
55. Delivery (C) 100 Minimum 70.0 mm3/st.
Set boost pressure to 15 psi.
56. Shut-off - (C) 500 De-energise solenoid, wait 5 seconds.
3/4
9320A070 MODY02 Edition: 4
Test Plan:
Vista T2359 9320A070 Issue Date:
MODY02
ISO TEST PROCEDURE
Test Operation S/C RPM Requirements
Solenoid Max. 3.0 mm3/st.
Run test machine down to 0 rpm.
Energise ESOS
57. Gov. cut-off (C) 1240 Maximum 3.0 mm3/st.
Run test machine down to 1000 rpm.
58. Delivery (C) 1100 88.0 to 92.0 mm3/st.
59. Delivery (C) 800 As test (58) + 10.5 ± 4.0 mm3/st.
60. Dynamic timing Refer to SIN DT339
Piezo sensor, outlet U
Off-set angle 184.25°
speed (S) 1100 Trigger level 25 %
4/4
