Diesel Information

TECHNICAL APR1991

COMMERCIALLY CONFIDENTIAL D027(EN)

Testing Standards – All Pumps

SUBJECT:- Calibration Variations on Fuel Injection Pumps

1. INTRODUCTION

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It has been brought to our attention that some Distributors are finding difficulties satisfying customer
demands in respect of smoke levels and/or power output from equipment after having

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serviced/calibrated fuel injection pumps.

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Initial investigations have revealed that there are several incorrect nozzle holder/nozzle holder inlet

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connection combinations in use on test benches. The main purpose of this note is to clearly define the
acceptable combinations.
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2. TEST INJECTOR COMBINATIONS
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The only nozzle holder which is permissible for testing ALL CAV fuel injection pumps, which call for
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the use of orifice plates or ISO 4010 nozzles, is the ISO 7440.
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This holder is supplied by Lucas Hartridge and comes complete with either ISO 4010 nozzle or an
orifice plate depending on the part number requested. The complete injector is fitted with an ISO inlet
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connector into which is pressed an 'Edge filter'. This connector is stamped "ISO 7440".
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For the larger sized fuel injection pumps BDN8S2P nozzles are specified for the test bench. These
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nozzles can be used either in the above mentioned ISO 7440 holders, providing that they have a RED
identifying band (This band must NOT be added to unidentified holders), or in the older BKB50S533B
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holders.
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If the latter holders are used, extreme care must be exercised to ensure that the holders are
BKB50S533B and NOT BKB50SD533B. Use of the latter will result in incorrect calibration.
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NOTE: A mixture of ISO 7440 and BKB50S533B holders is not permitted on the test benches.

3. SERVICING POLICY
The ONLY servicing permissible on the test injectors is as follows:-

a) Changing the nozzle assembly for a similar NEW nozzle. Reconditioned nozzles MUST NOT
to be used.

b) Checking and resetting the injector opening pressure as specified in the test plan being used.

c) If fitted, the orifice plate may be removed and washed in a non-abrasive solution to remove
lacquer or other deposits. On no account should the plate be cleaned with abrasive
materials.

DELPHI Diesel Systems Ltd, Diesel Aftermarket, Spartan Close, Warwick, CV34 6AG, England.
Tel: [44] [0] 1926 472 900 Fax: [44] [0] 1926 472 901 © Delphi Diesel Systems Ltd
D027(EN) – Apr 91 - 2 of 2

Two final points to remember when calibrating Delphi equipment are:-

a) On receipt of a new Test Plan Index fiche (TP060 and TP200 ) the Explanatory Notes should
be read in order to familiarise oneself with any procedural/functional changes.

b) All figures quoted in test plans were obtained using Hartridge test benches. For the greatest
accuracy it is recommended that Hartridge test benches as specified in the Distributor
Standards F.I.E. workshop requirements publication be used for all service checking/setting.

Should one not be available two alternatives are permissible:

1. Where a specified test bench is not available then use a Hartridge Universal Calibrator in
conjunction with a test machine conforming to ISO 4008 Part 1 (Drive System requirements)
and having at least a 5kW (7,5 hp.) motor is recommended.

2. As 1 but use the machines calibration/measuring system.

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This final method, while accepted is the least preferred method and should only be used as a last

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resort.

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