Test Plan: 8522A090

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Applic:
Fiat 8035.05.300
Issue No:
5
Date:
06/11/91
Pumps covered:
8522A090A
8522A091A
8522A092A

8522A093A

PUMP SPECIFICATION
Rotation:
Anti-Clockwise.
Governor type:
Mechanical all-speed.
Gov. Link Length:
40.75 0.3 mm.
Governor spring position :
2.
Plunger Diameter:
7,0 mm.
Drive Type:
Uprated with supported shaft.
Advance Type:
Automatic speed with start retard.
Transfer pressure adjuster in end plate.
Solenoid shut-off device, 12 volts.
Cambox pressurising valve.
Scroll plate max. fuel adjustment, hydraulic excess fuel device.
Notched timing disc on drive shaft.
ISO TEST CONDITIONS.
This data is only valid for the test conditions specified and the
following test benches: HA3000/HA2500/HA1150/HA1100MkII/HA875
HA700/HA400/AVM/PGM
Test Fluid:
ISO 4113 at 40 2C.
Inlet feed pressure:
0.1 bar
Nozzles:
ISO 4010.
Nozzle Opening Pressure:
172 + 3 - 0 bar.
H.P. pipes:
6 x 2 x 845 mm (ISO 4093.2).
PRE-TEST NOTES
A 2.5mm shim is fitted to the piston spring cap on assembly.
This must NOT be removed.
No additional shimming is required.
Connect cambox pressure gauge to vent screw.
Screw transfer pressure adjuster fully out and then 3.5 turns
in before commencing test.
Latch valve adjuster to be just below surface of locknut.
Fit auto-advance gauge and set to zero.
ISO TEST PROCEDURE
Test Operation
1.
Priming

S/C
(C)

RPM
200

Requirements
Obtain delivery from all injectors
and backleak.
2.
Stabilisation,
S/C*
750
52.0 2.0 mm3/st
initial setting
Run pump for 3 minutes to stabilise.
3.
Transfer Press. (C)
100 Minimum 0.4 bar, ( 6 psi).
4.
Cambox Press. (C)
850
0.1 to 0.3 bar(1.5 to 3.5 psi)
5.
Advance
(S)
850 5.5
(4.4
ust TP.
6.
Transfer Press. (C)
850
3.8 to 4.8 bar( 54 to 68psi)
7.
Advance-Full
(C)
1250 6.75 to 7.75, ( 5.4o 6.2m).
Remove pressure gauges and fit stop solenoid or plug.
Prime as at test (1).
8.
Back leakage. (C)
750 40 to 80 cm3 per 100 strokes.
Flow rate 300to 600 cm3/min.
9.
Max. Delivery (S)*
750
52.0 0.5 mm3/st.
Max. spread 4.0 mm3/st.
___________________
DELPHI Diesel Systems 2000

10.
11.
12.

Delivery
Governor
Gov. cut-off

(C)
(S)
(C)

1250 Record delivery cm3.

1420 1.5 to 2.0 cm3.
1520 Maximum 1.4 cm3.
(Reduce link length to lower limit if
fuel delivery is too high).
13. Delivery
(C)
1250 Throttle set as at (11),
Minimum as test (10) - 0.4cm3.
Run test machine down to 100 rpm and stop.
14. Latch valve
(S)
250 Screw latch valve adjuster fully in,
then screw out until advance reads
1.75 2.75( 1.4o 2.2m).
Lock adjuster.
Run test machine down to 100 rpm and stop.
15. Excess fuel
(C)
200 Minimum 16.0 cm3. Advance to read 0.
Move throttle lever to closed position for tests (16,17,18,19 ).
16. Idle delivery
(S)
325 2.0 to 2.5 cm3. Throttle closed.
17. Anti-stall
(S)
850 2.0 to 3.0 cm3.(Use 2000 strokes,ie
4 x 500 strokes). Lock screw.
18. Shut-off lever
(C)
325 Shut-off lever closed, Max. 0.8 cm3.
19. Shut-off (C)
325 De-energise solenoid, wait 5 seconds.
Solenoid
Max. 0.5 cm3.
20. Timing
S/C
Outlet 'U ', Pressure 55 bar
Offset 7.75 degrees against the
normal direction of pump rotation.
REFER TO STATEMENT AT END OF EXPLANATORY NOTES REGARDING MAXIMUM
FUEL AND SPEED SETTING AND VARIATIONS IN ENGINE PERFORMANCE.
___________________
DELPHI Diesel Systems 2000

Description : DPS Pumps (Ref 8522A094A)

Part number: 8522A094A

Mark
2
4
6
7
8
9
11
12
14
15
16
17
22
23
24
30
32
33
36
37
38
50
51
55
56
59
60
63
64
65
65

Part number
7185-775H
NK1-22
7182-40
7182-557C
7174-349A
7174-73B
7182-559
7182-558
7123-914G
5936-124
7123-818
7135-72P
7182-505
7182-543
7174-350A
7182-708C
7185-950GF
7182-591
NOTE-53
7174-797
7174-127A
7182-507E
7174-67X
7123-975
7183-136K
7185-815A
5335-684
7182-245A
7185-950HD
7182-621J
7182-621K

Description
Drive Shaft
Key
Shoe Spacer - Long
Timing Plate
Timing Plate Screw
Governor Weight Cage
Split Ring
Spring Ring
Governor Weight
Thrust Washer
X Thrust sleeve
Roller & Shoe Kit
Shoe Retaining Plate
Catch Plate
Catch Plate Screw
Pump Housing
O Ring
Dowel
Thrust Washer
External circlip
Oil Seal
Inner Bearing
Cam & Scroll Kit
Cam screw
Head/Rotor, TP Rotor
Washer
Socket Head Screw
Transfer pump rotor
Sealing ring 3mm dia
Meteringvalve Size A
Meteringvalve Size B

Quantity

Kit ?:

Mark
66
67
86
87
98
99
100
102
103
110
111
112
113
114
115
117
118
120
122
123
128
132
133
134
136
137
137
137
137
138
141

Nomenclature

Part number
7139-541
7135-108
6418-053A
7185-849
7022-180L
7185-950GB
7174-842E
7174-843A
7167-883B
7174-844B
7185-950ET
7174-384A
5936-208
7167-895
7167-893
7022-180D
5334-280A
5335-694
7180-450
7167-4
7139-010B
7139-015
7139-11G
7123-293B
7123-294B
7185-851W
7185-851X
7185-851Y
7185-851Y
7185-950BD
7167-301E

Description
Transfer Pump Liner
Blades & Springs Kit
Nameplate
Nameplate Rivet
Washer
Sealing ring
Latch Valve Assy
Latch Valve
Latch Valve Body
Valve Spring
O Ring
Adjusting Sleeve
Washer
Latch Valve Lock Nut
Adjusting Screw
Washer
Hex-head screw
Stud
Gasket
AA Hsg & Piston
Spring
Internal Circlip
Spring Plate
Spring
Spring
Shim
Shim
Washer
Washer
Sealing ring
X Spring cap

Quantity

Kit ?:

Description : DPS Pumps (Ref 8522A094A)

Part number: 8522A094A

Mark
143
144
163
165
171
172
173
176
177
178
185
186
187
188
189
190
191
193
195
198
199
200
201
202
212
215
216
219
221
223
225

Part number
5936-355C
7167-299
7185-950BD
7123-473H
7182-423
7185-950FR
7182-937A
NC7-008
7022-180D
5330-362
7139-043
7135-354A
7180-147A
7123-439
7180-453
7135-74BS
7123-15G
7139-650G
7167-183B
7180-879A
7123-620A
7185-815K
7133-37B
7111-357H
5334-315F
7180-238
7185-900W
7167-787
7167-786
7167-785
5855-030HE

Description
Washer
Hex-head screw
Sealing ring
Piston hole plug
Backing Ring
Sealing ring
Hd Locating Fitting
Ball
*
Washer
Cap nut
Sealing ring
TP Endplate Kit
Sandwich plate
Spring
Washer
X Sleeve & Piston
Piston
X Pressure adjuster
X Spring & Guide
Spring
Filter
Washer
Fuel connection
Protection Plug
Screw
Protection Cap
X Solenoid
Spring
Washer
Socket Head Screw
Sealing ring

Quantity

Kit ?:

Mark
230
232
233
236
237
244
248
249
253
254
255
256
258
259
261
265A
271
272
278
280
285
288
290
294
296
322
323
324
325
351
353

Nomenclature

Part number
7182-537B
7182-530
7182-232B
7174-29D
7185-859
7189-257
7182-562
7182-23
7182-539
7182-540
7182-538
7182-532
7182-540
7182-561
7182-544
7123-453J
7123-770G
7123-94H
7182-606A
7182-607
7185-950
7123-726D
7185-950
7182-951
7182-501R
7123-728A
7139-939
7167-899A
7123-724Q
NW1-14Y1
7174-637

Description
Control Bracket
M/Valve Ret Bracket
Governor Arm
Tab Washer
Control Bracket Bolt
Ctrl Bracket Screw
Locking washer
Stud
Spacer
Washer
Spring Sleeve
Scroll Plate Spring
Washer
Control Bracket Stud
Shut-off Bar
Single Spring Link
Throttle Shaft
Spring
Spring
Spring Guide
Washer
Shut-off spindle
Washer
Gov Cover Gasket
Governor Cover
Cap
Spring Guide
Spring
Throttle Lever
Washer
Self Lock Nut

Quantity

Kit ?:

Description : DPS Pumps (Ref 8522A094A)

Part number: 8522A094A

Mark
365
366
369
372
373
375
376
380
381
382
383
384
386
387
388
389
390
392
393
394
398
399
400
402
403
404
430
431A
432
449
459

Part number
7139-937
7182-422
7123-725J
NP1-5
NU9-8Z1
7185-851P
7174-336A
5936-208C
7174-917B
7182-966A
7174-929B
5606-062
7174-545
7185-854E
7174-594Q
7139-184
5606-062
7174-545
7185-854E
7174-594Q
5936-208C
7174-917C
7182-608
7185-815C
7240-20B
7180-371
7185-815M
7139-854C
7111-357H
7167-978
5936-332C

Description
Spring Guide
Lever Return Spring
Shut-Off Lever
Locking washer
Nut
Washer
Governor Cover Screw
Sealing Washer
Max Fuel Lock Nut
Max Speed Adj Screw
Protection Cap
Lead Seal
Washer
Nut
Max Speed Adj Screw
Protection Cap
Lead Seal
Washer
Nut
Max Speed Adj Screw
Sealing Washer
Nut
Anti-Stall Adj Screw
Washer
X Vent screw
Vent screw
Washer
Non-Return Valve
Protection Plug
Banjo
Washer

Quantity

Kit ?:

Mark
460
465
466
467
470
471
472
473
482
484
580
581
582
583
584
585
586
587
588
589
9999

Nomenclature

Part number
7180-357K
7182-512
7185-852A
7139-979
7185-950FP
7174-723C
7185-950FL
7174-719A
NW1-11Y1
7174-725A
7182-534
7182-59
7182-542F
7182-541
7185-950BF
7182-510
NOTE-54
7185-950DW
7182-963A
7182-511
7135-122

Description
X Pressure valve
Clamping Plate
Union nut
Protection Cap
O Ring
Cover Plate
O Ring
Cover Plate Plug
Washer
Cover Plate Screw
Excess Fuel Pin
Pin Guide
Excess Fuel Spring
E-Clip
Sealing ring
Piston Sleeve
Excess Fuel Piston
O Ring
Closing Plug
Circlip
Overhaul Kit

Quantity

Kit ?: