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 S/C RPM Requirements
1. Priming (C) 200 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. Delivery (C) 1250 Record delivery cm3.
11. Governor (S) 1420 1.5 to 2.0 cm3.
12. Gov. cut-off (C) 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)
Nomenclature
Part number: 8522A094A

Mark Part number Description Quantity Kit ?: Mark Part number Description Quantity Kit ?:
2 7185-775H Drive Shaft 66 7139-541 Transfer Pump Liner
4 NK1-22 Key 67 7135-108 Blades & Springs Kit
6 7182-40 Shoe Spacer - Long 86 6418-053A Nameplate
7 7182-557C Timing Plate 87 7185-849 Nameplate Rivet
8 7174-349A Timing Plate Screw 98 7022-180L Washer
9 7174-73B Governor Weight Cage 99 7185-950GB Sealing ring
11 7182-559 Split Ring 100 7174-842E Latch Valve Assy
12 7182-558 Spring Ring 102 7174-843A Latch Valve
14 7123-914G Governor Weight 103 7167-883B Latch Valve Body
15 5936-124 Thrust Washer 110 7174-844B Valve Spring
16 7123-818 X Thrust sleeve 111 7185-950ET O Ring
17 7135-72P Roller & Shoe Kit 112 7174-384A Adjusting Sleeve
22 7182-505 Shoe Retaining Plate 113 5936-208 Washer
23 7182-543 Catch Plate 114 7167-895 Latch Valve Lock Nut
24 7174-350A Catch Plate Screw 115 7167-893 Adjusting Screw
30 7182-708C Pump Housing 117 7022-180D Washer
32 7185-950GF O Ring 118 5334-280A Hex-head screw
33 7182-591 Dowel 120 5335-694 Stud
36 NOTE-53 Thrust Washer 122 7180-450 Gasket
37 7174-797 External circlip 123 7167-4 AA Hsg & Piston
38 7174-127A Oil Seal 128 7139-010B Spring
50 7182-507E Inner Bearing 132 7139-015 Internal Circlip
51 7174-67X Cam & Scroll Kit 133 7139-11G Spring Plate
55 7123-975 Cam screw 134 7123-293B Spring
56 7183-136K Head/Rotor, TP Rotor 136 7123-294B Spring
59 7185-815A Washer 137 7185-851W Shim
60 5335-684 Socket Head Screw 137 7185-851X Shim
63 7182-245A Transfer pump rotor 137 7185-851Y Washer
64 7185-950HD Sealing ring 3mm dia 137 7185-851Y Washer
65 7182-621J Meteringvalve Size A 138 7185-950BD Sealing ring
65 7182-621K Meteringvalve Size B 141 7167-301E X Spring cap

1
 Description : DPS Pumps (Ref 8522A094A)
Nomenclature
Part number: 8522A094A

Mark Part number Description Quantity Kit ?: Mark Part number Description Quantity Kit ?:
143 5936-355C Washer 230 7182-537B Control Bracket
144 7167-299 Hex-head screw 232 7182-530 M/Valve Ret Bracket
163 7185-950BD Sealing ring 233 7182-232B Governor Arm
165 7123-473H Piston hole plug 236 7174-29D Tab Washer
171 7182-423 Backing Ring 237 7185-859 Control Bracket Bolt
172 7185-950FR Sealing ring 244 7189-257 Ctrl Bracket Screw
173 7182-937A Hd Locating Fitting 248 7182-562 Locking washer
176 NC7-008 Ball * 249 7182-23 Stud
177 7022-180D Washer 253 7182-539 Spacer
178 5330-362 Cap nut 254 7182-540 Washer
185 7139-043 Sealing ring 255 7182-538 Spring Sleeve
186 7135-354A TP Endplate Kit 256 7182-532 Scroll Plate Spring
187 7180-147A Sandwich plate 258 7182-540 Washer
188 7123-439 Spring 259 7182-561 Control Bracket Stud
189 7180-453 Washer 261 7182-544 Shut-off Bar
190 7135-74BS X Sleeve & Piston 265A 7123-453J Single Spring Link
191 7123-15G Piston 271 7123-770G Throttle Shaft
193 7139-650G X Pressure adjuster 272 7123-94H Spring
195 7167-183B X Spring & Guide 278 7182-606A Spring
198 7180-879A Spring 280 7182-607 Spring Guide
199 7123-620A Filter 285 7185-950 Washer
200 7185-815K Washer 288 7123-726D Shut-off spindle
201 7133-37B Fuel connection 290 7185-950 Washer
202 7111-357H Protection Plug 294 7182-951 Gov Cover Gasket
212 5334-315F Screw 296 7182-501R Governor Cover
215 7180-238 Protection Cap 322 7123-728A Cap
216 7185-900W X Solenoid 323 7139-939 Spring Guide
219 7167-787 Spring 324 7167-899A Spring
221 7167-786 Washer 325 7123-724Q Throttle Lever
223 7167-785 Socket Head Screw 351 NW1-14Y1 Washer
225 5855-030HE Sealing ring 353 7174-637 Self Lock Nut

2
 Description : DPS Pumps (Ref 8522A094A)
Nomenclature
Part number: 8522A094A

Mark Part number Description Quantity Kit ?: Mark Part number Description Quantity Kit ?:
365 7139-937 Spring Guide 460 7180-357K X Pressure valve
366 7182-422 Lever Return Spring 465 7182-512 Clamping Plate
369 7123-725J Shut-Off Lever 466 7185-852A Union nut
372 NP1-5 Locking washer 467 7139-979 Protection Cap
373 NU9-8Z1 Nut 470 7185-950FP O Ring
375 7185-851P Washer 471 7174-723C Cover Plate
376 7174-336A Governor Cover Screw 472 7185-950FL O Ring
380 5936-208C Sealing Washer 473 7174-719A Cover Plate Plug
381 7174-917B Max Fuel Lock Nut 482 NW1-11Y1 Washer
382 7182-966A Max Speed Adj Screw 484 7174-725A Cover Plate Screw
383 7174-929B Protection Cap 580 7182-534 Excess Fuel Pin
384 5606-062 Lead Seal 581 7182-59 Pin Guide
386 7174-545 Washer 582 7182-542F Excess Fuel Spring
387 7185-854E Nut 583 7182-541 E-Clip
388 7174-594Q Max Speed Adj Screw 584 7185-950BF Sealing ring
389 7139-184 Protection Cap 585 7182-510 Piston Sleeve
390 5606-062 Lead Seal 586 NOTE-54 Excess Fuel Piston
392 7174-545 Washer 587 7185-950DW O Ring
393 7185-854E Nut 588 7182-963A Closing Plug
394 7174-594Q Max Speed Adj Screw 589 7182-511 Circlip
398 5936-208C Sealing Washer 9999 7135-122 Overhaul Kit
399 7174-917C Nut
400 7182-608 Anti-Stall Adj Screw
402 7185-815C Washer
403 7240-20B X Vent screw
404 7180-371 Vent screw
430 7185-815M Washer
431A 7139-854C Non-Return Valve
432 7111-357H Protection Plug
449 7167-978 Banjo
459 5936-332C Washer