TYPE: DP310 – 9520A500-509 ISSUE: 3 DATE: 24/07/2013

ENGINE: JCB 4.8Ltrs NA (BS 3) PAGE: 1/7

Rating: 55kW @ 2200 erpm

SERVICE TEST PLAN

Reference DP 310 – 9520A500-509S03

Customer JCB India Ltd.
Engine JCB 4.8 Ltrs NA (BS 3)
Rating 55kW @ 2200 erpm

Prepared by Checked by Approved by

T.GOPINATH S.PRAKASH M.G.BHASKAR

TYPE: DP310 – 9520A500-509 ISSUE: 3 DATE: 24/07/2013
ENGINE: JCB 4.8Ltrs NA (BS 3) PAGE: 2/7
Rating: 55kW @ 2200 erpm

Issue Date Amendments Notes

1. 11/02/2011 Release for Domestic market

Modified as per latest service testplan (Issue-5) issued by DDS

Changes:
Calibration Phase:
1. LLA check at 1100 rpm 41 to 44 mm3/st added
2. Governor setting rpm changed from 1175 to 1160
3. Governor cut off check rpm changed from 1240 to 1230
2. 11/06/2011
Overcheck Phase:
1. Cold advance specification changed from 8-10° to 6-10°
2. Governor setting sequenced after dynamic timing
3. Delivery check at 1100rpm added before and after governor
setting
4. Governor setting rpm changed from 1175 to 1160
5. Governor cut off check rpm changed from 1250 to 1230
Modified as per latest service testplan (Issue-7) issued by DDS

Changes:
Calibration Phase:
1. Latch valve setting changed to 315 rpm from 260 rpm.
2. Latch valve check points changed to 280 rpm from 220 rpm
& to 350 rpm from 280 rpm.
3. 24/07/2013 2. Idle speed setting changed to 440 rpm from 465 rpm.
3. Governor setting rpm changed to 1195 rpm from 1160 rpm.
4. Governor cutoff check changed to 1280 rpm from 1230 rpm.
Overcheck Phase:
5. Governor setting rpm changed to 1195 rpm from 1160 rpm.
6. Governor cutoff check changed to 1280 rpm from 1230 rpm.
TYPE: DP310 – 9520A500-509 ISSUE: 3 DATE: 24/07/2013
ENGINE: JCB 4.8Ltrs NA (BS 3) PAGE: 3/7
Rating: 55kW @ 2200 erpm

SERVICE TEST PLAN

Application/Engine JCB 4.8Ltrs NA (BS 3)

Issue No 3
Date 24/07/2013
Pumps Covered 9520A500-509
Type No. 1573

PUMP SPECIFICATION

Rotation Anti-Clockwise (4-Cylinder)

Governor type Mechanical all-speed
Gov. Link Length 41.5 ± 0.5 mm
Gov. Link Length 10.1 ± 0.5 mm
(DP 210 Workshop Manual Section 4.6.4)
Plunger Diameter 7.0 mm (4 off)
Drive Type Supported shaft
Transfer pressure Adjustable
Viscosity Compensator In end plate
Cam box Pressurizing valve
Advance Type Servo advance with Speed advance, LLA & CA
Torque trimmer
Solenoid voltage See Service instructions Note DT294

ISO TEST CONDITIONS

This data is only valid for the test

600 E
conditions specified and the following
test benches
Test Fluid ISO 4113 at 40± 2°C
Inlet feed pressure 5.0 psi
Back leak pressure 0.0 psi
Nozzles YDB286(BDLOS6844)
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-energized unless otherwise stated
Torque trimmer plug to be wound out until thread appears
Latch valve adjuster, if fitted, screw fully in then 8 turns out
Turn light load adjuster valve fully in then 1 turn out
Advance measurement on the cam ring
Backleak Flow pipe should not be connected to measuring unit unless otherwise stated
Calibrate LVDT gauge before use

Important: For delivery measurement, use higher number of counts to get accurate value.
TYPE: DP310 – 9520A500-509 ISSUE: 3 DATE: 24/07/2013
ENGINE: JCB 4.8Ltrs NA (BS 3) PAGE: 4/7
Rating: 55kW @ 2200 erpm

ISO TEST PROCEDURE

Test Operation S/C RPM Requirements

Warm-up Phase
1. Priming C 200 Obtain delivery from all injectors and Back leak
Close throttle
Stabilize. Cycle speed between 100 to 500rpm 3 times
Open Throttle
Put LLA Tool (R800EP) and ensure it is fully out
Connect LVDT gauge to the Advance port & Select Advance mode in LVDT Display unit
Leave open back leak connection (not to be connected to flow measurement)

2. Transfer Pressure S 1100 Set TP 94 to 96 psi

74.0 ± 1.0 mm3/st

3. Delivery S 1100
[7.40 ± 0.1 cc/100st]
8 to 20 mm3/st
4. Governor S 1190
[0.8 to 2.0 cc/100st]
Stabilize. Cycle speed between 100 to 1200 rpm 2 times
Stabilize and run at 1100 rpm until backleak temperature is 38ºC min
Flow rate 400 to 900 cc/min
5. Back Leakage C 1100
(Connect back leak Flow Pipe)
Calibration Phase
Leave open backleak connection (not to be connected to flow measurement)
6. Cambox pressure C 1100 6 to 11 psi (If Fails change Backleak Valve)
7. Transfer Pressure S 1100 Pressure at test (6) + 86.0 to 88.0 psi
Run test machine down to 0 rpm
8. Transfer Pressure C 100 Minimum 12 psi
9. Transfer Pressure C 1100 As test (7) ± 1.0 psi
If incorrect repeat from test (6)
Stop test machine
Remove pressure gauges (cam box & TP)
Fit Start-Stop solenoid and Connect 12V
10. Advance S 500 0º (Datum advance gauge)
11. Advance C 750 0.5º Max
12. Advance C 1050 1.8 to 2.2º
13. Advance C 1100 1.8 to 2.2º
Stop test machine
Energize CA solenoid
14. Advance C 700 8.0 to 10º
De-energize CA solenoid
5.8 to 6.2º (Adjust LLA Tool/Throttle full open)
Check delivery 25.0 to 29.0 mm3/st
15. Advance – Light load S 1100 [2.5 to 2.9 cc/100st]
(Adjust needle valve, if required)
If fails change metering valve grading
Run test machine down to 0 rpm
8.8 to 9.2º (Adjust LLA Tool/Throttle full open)
16. Advance – Light load C 1100 Check delivery 12 to 28 mm3/st
[1.2 to 2.8 cc/100st]
TYPE: DP310 – 9520A500-509 ISSUE: 3 DATE: 24/07/2013
ENGINE: JCB 4.8Ltrs NA (BS 3) PAGE: 5/7
Rating: 55kW @ 2200 erpm

1.5 to 4.0º (Adjust LLA Tool/Throttle full open)

17. Advance – Light load C 1100 Check delivery 41 to 44 mm3/st
[4.1 to 4.4 cc/100st]
1.8 to 2.2º (Adjust LLA Tool/Throttle full open)
18. Advance – Light load C 650 Check delivery 33 to 53 mm3/st
[3.3 to 5.3 cc/100st]
If correct continue with test (19), if not , adjust shimming and repeat from test (15)
Stop test machine
Remove LLA Tool & Fit with Blank Screw
Remove LVDT gauge from advance port and fit CPS adaptor to LVDT gauge
Fit LVDT gauge to CPS port & select TT mode in LVDT display unit
Open throttle
19. Torque Trimmer S 1100 0 mm(Datum LVDT gauge)
20. Torque Trimmer S 550 Adjust TT Cam to 1.0 to 1.1 mm
Run test machine down to 0 rpm
Stabilize and run at 1125 rpm for 5 seconds
21. Torque Trimmer C 1100 As test (19) ± 0.05 mm
22. Torque Trimmer C 675 Check TT Gauge -0.2 to 0.2 mm
23. Torque Trimmer C 400 Check TT Gauge 2.00 to 2.40 mm
Screw latch valve adjuster fully in
TT 1.0 to 3.0 mm
24. Latch valve S 315
If incorrect, adjust latch valve preload & repeat test
Run test machine down to 0 rpm
25. Torque Trimmer C 280 Check TT Gauge -5.0 to -2.5 mm
26. Torque Trimmer C 350 Check TT Gauge 1.0 to 3.0 mm
Minimum 75.0 mm3/st
27. Delivery C 100
[Minimum 7.5 cc/100st]
If incorrect or adjusted, stop machine and repeat from test (24)
De-energise solenoid, wait 5 seconds.
28. Shut off solenoid C 500 Maximum 3.0 mm3/st
[Maximum 0.30 cc/100st]
Stop test machine
Energize solenoid
Close throttle
8.0 to 16.0 mm3/st (Adjust Idle screw)
29. Idle delivery S 440
[0.8 to 1.6 cc/100st]
Maximum 3.0 mm3/st
30. Delivery C 575
[Maximum 0.30 cc/100st]
Stop test machine
Remove LVDT Gauge from CPS & Fit Max fuel adjuster tool
Open throttle
73.8 ± 0.3 mm3/st
[7.38 ± 0.03 cc/100st]
31. Max Delivery S 1100
Max. Spread 5.0 mm3/st
[Max. Spread 0.5 cc/100st]
As test (31) + 3 ± 4 mm3/st
32. Delivery C 725
[As test (31) + 0.3 ± 0.4 cc/100st]
33. Delivery C 1100 Record delivery
12.0 to 16.0 mm3/st
34. Governor S 1195
[1.2 to 1.6 cc/100st]
TYPE: DP310 – 9520A500-509 ISSUE: 3 DATE: 24/07/2013
ENGINE: JCB 4.8Ltrs NA (BS 3) PAGE: 6/7
Rating: 55kW @ 2200 erpm

Maximum 3.0 mm3/st

35. Governor cut-off C 1280
[Maximum 0.3 cc/100st]
As test (33) – 1.0 mm3/st (Minimum)
36. Delivery C 1100
[As test (33) - 0.1 cc/100st (Minimum)]
Refer to SIN DT339
Piezo sensor, outlet U
37. Dynamic timing S 1100
Off-set angle 275.9°
Trigger level 25%
ISO OVERCHECK PROCEDURE
The Over check 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-energize unless otherwise stated
No adjustments to be made unless otherwise stated
Unlock Drive shaft Lock bolt
Close throttle
Stabilize Cycle speed between 100 to 500 rpm 3 times
Open throttle
Stabilize Cycle speed between 100 to 1250 rpm 2 times
Stabilize and run at 1100 rpm until back leak temperature is 38°C min

Over check Phase

Remove CPS adaptor from LVDT Gauge & Connect LVDT gauge to advance port
Select Advance mode in LVDT display unit
Open throttle
3.0 mm3/st (Maximum)
38. Governor Cut-off C 1290
[0.3 cc/100st (Maximum)]
Fully unscrew maximum speed adjusting screw
39. Advance S 500 0°(Datum advance Gauge)
40. Advance C 730 0.5°(Maximum)
41. Advance C 1075 1.8° to 2.2°
5.8° to 6.2°
24.0 to 30.0 mm3/st
42. Advance – Light Load C 1100
[2.4 to 3.0 cc/100st]
(Adjust LLA Tool/Throttle full open)
8.8° to 9.2°
11 to 29.0 mm3/st
43. Advance – Light Load C 1100
[1.1 to 2.9 cc/100st]
(Adjust LLA Tool/Throttle full open)
1.8° to 2.2°
32.0 to 54.0 mm3/st
44. Advance – Light Load C 650
[3.2 to 5.4 cc/100st]
(Adjust LLA Tool/Throttle full open)
Stop test machine
Energise CA solenoid
45. Advance C 710 8.0 to 10.0°
TYPE: DP310 – 9520A500-509 ISSUE: 3 DATE: 24/07/2013
ENGINE: JCB 4.8Ltrs NA (BS 3) PAGE: 7/7
Rating: 55kW @ 2200 erpm

De-energise CA solenoid
Stop test machine
Remove LVDT gauge from advance port and fit CPS adaptor to LVDT gauge
Remove max fuel adjuster and fit LVDT gauge to CPS port
Select TT mode in LVDT display unit
46. Torque Trimmer S 1100 0.0 mm (Datum LVDT gauge)
47. Torque Trimmer C 685 Check TT gauge = -0.2 to 0.2 mm
48. Torque Trimmer C 390 Check TT gauge = 2.0 to 2.4 mm
Move throttle lever to closed position
3.0 mm3/st (Maximum)
49. Delivery C 585
[0.3 cc/100st (Maximum)]
Open throttle
70.0 mm3/st (Minimum)
50. Delivery C 100
[7.0 cc/100st (Minimum)]
De-Energize solenoid, wait 5 seconds
51. Shut Off Solenoid C 500 Max 3.0 mm3/st
[Max 0.3 cc/100st]
Energise solenoid
Run test machine down to 0 rpm
71.8 to 75.8 mm3/st
52. Delivery C 1100
[7.18 to 7.58 cc/100st]
As test (52) + 3 ± 5.0 mm3/st
53. Delivery C 725
[As test (52) + 0.3 ± 0.5 cc/100st]
As test (52) ± 2.0 mm3/st
54. Delivery C 1100
[As test (52) ± 0.2 cc/100st]
Refer to SIN DT339
Piezo sensor, outlet U
55. Dynamic timing S 1100
Off-set angle 275.9°
Trigger level 25%
56. Delivery C 1100 Record delivery
12.0 to 16.0 mm3/st
57. Governor S 1195
[1.2 to 1.6 cc/100st]
3.0 mm3/st (Maximum)
58. Governor cut-off C 1280
[0.3 cc/100st (Maximum)]
As test (56) – 1.0 mm3/st (Minimum)
59. Delivery C 1100
[As test (56) - 0.1 cc/100st (Minimum)]