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Section Ca.6: Description of The Fuel Injection Pump
Section Ca.6: Description of The Fuel Injection Pump
6
DESCRIPTION OF THE FUEL INJECTION PUMP
The injection pump is a single-cylinder, opposedplunger, inlet-metering, distributor-type pump fitted
with a mechanical flyweight-type governor and a hydraulically operated automatic advance mechanism. The
pump is flange-mounted on the rear of the engine front
mounting plate and is driven by the timing chain. A
splined quill shaft, having a master spline at each end
Fig. Ca.l
Main fuel filter air bleed points
1. Fuel cut-off tap.
2. Blanking plug.
3. Union screw.
Taxi. Issue 2. 55430
Ca
Fig. Ca.2
Fuel injection pump air bleed points
1. Union nut.
Fig. Ca.3
Section through the end plate and regulating valve
A.
B.
1.
2.
3.
4.
5.
6.
Priming.
Regulating.
Inlet connection.
Sleeve retaining spring.
Nylon filter.
Sleeve guide plug.
Regulating spring.
Regulating sleeve.
7. Regulating piston.
8. Piston retaining spring.
9. Fuel passage to transfer
pump inlet.
10. Regulating port.
11. Fuel passage to transfer
pump outlet.
Ca.5
Ca
Fig. Ca.4
Section through the fuel injection pump
1. Back-leakage connection.
2. Governor spring.
3. Metering valve.
4. End plate and regulating valve.
5. Transfer pump.
6. Hydraulic head.
7. Cam ring.
8. Automatic advance device.
9. Pumping plunger.
10. Drive plate.
11. Governor weight assembly.
Fig. Ca.5
Light-load advance device
Full load.
Low load.
Taxi. Issue2. 81968
A.
B.
1. Transfer pressure.
2. To pumping element.
Ca.
Fig. Ca.6
Mechanical governor
Governor weight.
Governor arm.
Shut-off bar.
Shut-offshaft.
Idling spring.
Governor spring.
Throttle shaft.
8. Linkage hook.
1.
2.
3.
4.
5.
6.
7.
9.
10.
11.
12.
13.
14.
15.
Metering port.
Metering valve,
Timing port.
Control bracket.
Drive shaft.
Thrust sleeve.
Weight retainer.
Ca
Fig. Ca.8
The injection cycle
A.
Inlet stroke.
B. Injection stroke.
1. Fuel inlet.
Section Ca.7
Fig. Ca.7
Maximum fuel adjustment
1. Top adjusting plate.
2. Roller shoe ear.
3. Roller.
Ca.8
Section Ca.8
DISMANTLING AND REASSEMBLING THE
FUEL INJECTION PUMP
Dismantling and servicing of the fuel injection pump
should only be carried out by specially trained personnel,
Fig. Ca.9
Checking the position of the injection pump timing
pointer, using timing gauge 18G 698
Ca.9
Ca
A51471
Fig. Ca.10
Holding the drive plate with spanner 18G 641 when
unscrewing the drive plate securing screws
Taxi. Issue3. 6394
Ca
Fig. Ca.ll
Removing the drive hub oil seal, using oil seal extractor
18G 658
Ca
!SA
Fig. Ca.12
Holding the drive hub with drive shaft screw assembly
tool 18G 659 while tightening the drive shaft screw
with torque adaptor 18G664 and torque wrench
18G 537
Ca.12
Fig. Ca.13
Assembling the governor weights, thrust washer, and
thrust sleeve into the weight retainer, using Service
tools 18G 661 and 18G 662
Fig. Ca.14
Assembly the top adjusting plate and the drive plate
with the slots in their peripheries aligned with the
scribed mark on the pumping end of the rotor
Taxi. Issue 4. 88664
Ca
Fig. Ca.15
Setting the roller-to-roller dimension, using a micrometer and Service tools 18G 109 A and 18G 653 A
Fig. Ca.16
Tightening the transfer pump rotor, using torque
wrench 18G536 and Service tools 18G 659 and 18G634
Ca.13
Ca
Fig. Ca.17
Setting the internal dimension between the metering
valve lever pin and the control cover stud with the
vernier heldparallel to the axis of the pump
lever pin and its nearest control cover stud to the length
given in GENERAL DATA, using a vernier gauge as
shown in Fig. Ca.17. Adjustment is made by slackening
or tightening the hook linkage nut. During this operation
light pressure should be applied to the governor arm
in the direction of the metering valve and the vernier
gauge should be held parallel to the pump axis.
Locate the idling spring on the idling spring guide.
Insert the guide into hole No. 2 in the governor arm
(Fig. Ca.6) and connect the governor spring to the idling
spring guide.
Insert the plain end of the shut-off bar into the slot
in the control bracket and position the shut-off bar under
the tab of the control cover stud locking washer.
Using protection cap 18G 564, fit the lower Oseal to
the shut-off shaft. Fit the upper 0seal, using protection
cap 18G 665. Pack the groove between the 0seals with
Shell Alvania No. 2 grease. Press the shut-off shaft into
its bore in the control cover. The peg which engages the
shut-off bar should be close to the inside edge of the
control cover, and should be left projecting slightly above
the control cover face.
Place a new control cover gasket in position on the
pump housing, ensuring that the locating tabs of the
gasket engage the slots under the keep plate. To ensure
satisfactory sealing this gasket should be soaked in Shell
Calibration Fluid C before assembly.
Fit new lower and upper 0seals to the throttle shaft,
using protection caps 18G 654 and 18G 665. Pack the
groove between the 0seals with Shell Alvania No. 2
grease. Connect the free end of the governor spring to
hole No. 2 (2-2-litre engine) or hole No. 1 (2.52-litre
engine) in the throttle shaft link (Fig. Ca.6).
Press the throttle shaft into its bore in the control
cover. Place the control cover in position on the control
cover studs. Ensure that the shut-off shaft peg engages
the shut-off bar and pull the shut-off shaft fully home
as the control cover is lowered onto the gasket. Fit new
sealing washers on the control cover studs and fit and
Taxi. Issue 4. 88664
Ca
Section Ca.9
TESTING AND ADJUSTING THE FUEL
INJECTION PUMP
After overhaul the fuel injection pump must be checked
functionally, and the maximum fuel output adjusted if
necessary. These tests and adjustments are carried out on
a power-driven test bench embodying the necessary
vacuum and pressure gauges and equipment to test the
fuel transfer pump and a graduated glass to measure the
injection pump back-leakage. In addition, the tools
mentioned in the following paragraphs are also required.
NOTE.-The following precautions must be observed
when testing the pump:
(1) Ensure that the power-driven test bench is set to run
in the direction of rotation of the injection pump, as
indicated by the arrow on the pump nameplate.
Serious damage may be caused to the pump if it is
run in the reverse direction.
(2) Ensure that the fuel flow at the pump inlet is not
less than 1,000 c.c./min. If this flow cannot be
obtained, a maximum feed pressure of 2 lb./sq. in.
(15 kg./cm.2) is permissible.
(3) Do not run the pump for long periods at high speed
with low fuel output.
(4) Do not run the pump for long periods with the shutoff control in the closed position.
After checking the direction of rotation mount the
pump on the test bench and connect up the drive. Fit
radial connections to the hydraulic head in place of the
banjo pipes. Using high-pressure pipes 6 mm. x 2 mm. x
865 mm. (34 in.) long, connect the radial connections to
a matched set of test nozzles. The test nozzles should be
Type BDN.12.SD.12 mounted in nozzle holders Type
BKB.50.SD.533b (formerly BKB.5O.SD.19b) and set to
open at 175 atmospheres.
Ensure that the pump throttle arm has the full range
of movement by unscrewing fully the idling and maximum
speed stop screws.
Remove the hydraulic head locking screw, not the one
incorporating the vent valve, and connect the pressure
gauge by means of a flexible pipe to transfer pressure
adaptor 18G 636, which is screwed into the head locking
screw hole.
Connect the feed pipe, preferably of the transparent
type, to the fuel inlet connection on the injection pump
end plate. The vacuum gauge should be fitted, by means
of a T coupling, to the feed pipe.
Connect the inlet connection on the measuring-glass
to the drain connection on the pump housing and the
drain cock on the measuring-glass to the return pipe on
the test bench by means of flexible pipes.
Taxi. Issue 4. 6394
Fig. Ca.18
Checking the automatic advance device, using
advance gauge 18G 638 B
Ca
A9255
Fig. Ca.19
Adjusting the maximum fuel setting, using Service
tool 18G 656
Fig. Ca.20
The shut-off lever adjuster 18G697 mounted on the
fuel injection pump and test bench
Taxi. Issue4. 6394
Ca
Ca
Section Ca.10
ALTITUDE SETTINGS
Each vehicle leaves the Factory with its maximum fuel
setting adjusted for sea-level conditions. If the vehicle is
to be operated continuously above sea-level, adjustment
of the injection pump is necessary to set the maximum
fuel delivery to conform with the figures given in the
following table.
Moximum fuel output for 200
A57660.
Fig. Ca.22
Scribing the timing mark on the fuel injection pump
mounting flange, using Service tool 18G 648 A
Section Ca.12
LIFT PUMP
Follow the instructions given in Section C.l, but after
replacing the lift pump bleed the fuel system as described
in Section Ca.5.
Altitude
0 to 2,000 ft.
(0 to 600 m.)
6.4 to 6.6
C.C.
8.3 to 8.5
6.0 t o 6.2
C.C.
7.2 to 7.4
c.c.
6.6 to 6.8
c.c.
4.7 to 4.9
6.1 to 6.3
C.C.
c.c.
Section Ca.13
c.c.
Section Ca.11
FUEL INJECTORS
Follow the instructions given in Section C.6, noting
the following points.
Ca.18
Fuel delivery
Decrease the pump speed to 100 r.p.m. and check
the output. The average delivery for 200 shots
should now be not less than that obtained when
setting the pump maximum fuel output minus 1.5
C.C. When carrying out this test use 30 seconds
measuring-glass draining time and allow the test
oil to settle for 15seconds before taking a reading.
Ca.20
Ca
(5) Lift off the air cleaner body and intake hose as an
assembly. Note the rubber air seal between the
cleaner body and the intake manifold on the
engine.
Refitting
(6) Reverse the procedure in (1) to (5).
Section Ca.16
INJECTION PUMP (2.52-litre diesel engine)
The pump is as described in Sections Ca.6 and Ca.13,
but with a type number DPA 3249F520 and the setting
code stamped on the pump nameplate.
Later engines are fitted with a modified pump. This
pump is as described above, but with a type number
DPA 3342F110 and having two springs fitted to the
linkage hook instead of a single spring.
Removing and replacing
Follow the instructions in Section Ca.7, noting that the
correct injection timing for this pump is 23 B.T.D.C.
Maximum and idling speed adjustments
Follow the instructions given in Section Ca.13.
Section Ca.14
AIR CLEANER (Oil Bath Type)
Removing
(1) Release the clips and detach the air inlet tube and
the breather hose from the air cleaner body.
(2) Remove the screws retaining the air cleaner
assembly to the left-hand valance.
(3) Lift out the air cleaner assembly.
Refitting
(4) Reverse the procedure in (I) to (3).
Section Ca.15
AIR CLEANER (Dry Type)
Removing
(1) Remove the drive screw retaining the air intake
hose clip to the radiator frame.
(2) Release the clip and detach the breather hose from
the air cleaner intake.
(3) Remove the central wing nut, detach the air cleaner
top cover and remove the element.
(4) Release the air cleaner body from its support
bracket.
Ca.21
Ca
Test plan for pumps DPA 3249F520 and DPA 3342F110: Setting code A45/1200/4/3700
Test No.
l.
2.
1
I
4.
5.
6.
Description
R.P.M.
Requirements
Remarks
100
Transfer pressure
100
Transfer pressure
1,200
Advance position
1,200
to 2
Advance position
1,800
to
Backleakage
1,200
1,200
9.0
C.C.
average.
Spread between lines not
to exceed 1.0 C.C.
58 to 78 lb./sq. in.
(4.1to 5.5 kg./cm.2)
7.
8.
9.
I1
I
I1
Cut-off operation
Throttle operation
C.C.
Throttle lever fully closed and antistall screw unscrewed and locked.
Record delivery
1,650
12.
Governor setting
1,850
13.
1,650
Average delivery as in
test 1 1 minus 0.4 C.C.
11.
14.
Governor setting
1,850
~~
~~
Ca.22
40.
41.
42.
43.
Description
End plate.
Locating pin.
Screw for end plate.
Stud for end plate.
Nut for stud.
Piston retaining spring.
Regulating piston.
Regulating sleeve.
Washer for sleeve.
Filter.
Regulating plug.
Regulating spring.
Sleeve retaining spring.
Inlet connection.
Washer for inlet connection.
Transfer pump rotor.
Transfer pump blade.
Transfer pump liner.
Transfer pump seal.
Hydraulic head and rotor assembly.
Rotor plug.
Washer for plug.
Hydraulic head seal.
Banjo pipe.
Bolt for banjo pipe.
Washer for bolt.
Fuel feed pipe connection.
Olive for fuel feed pipe.
Hydraulic head locking screw.
Washer for screw.
Hydraulic head vent screw assembly.
Vented locking screw for hydraulic head.
Vent screw.
Adjusting plate (bottom).
Roller shoe.
Roller
Adjusting plate (top).
Drive plate.
Drive plate screw.
Cam ring.
Locating circlip for cam ring.
Governor weight.
Retainer for governor weights.
No.
44.
45.
46.
47.
48.
49.
50.
51.
52.
53.
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
78.
79.
80.
81.
82.
83.
84.
85.
Description
Thrust sleeve.
Thrust washer.
Drive shaft.
Drive shaft seal.
Drive shaft screw.
Spring washer for screw.
Support washer.
Drive hub.
Drive hub seal.
Quill shaft.
Pump housing.
Gasket for control cover.
Cover-plate.
Gasket for cover-plate.
Screw for cover-plate.
Washer for screw (shakeproof).
Drain connection.
Washer for connection.
Governor arm.
Spring for governor arm.
Keep plate.
Tab washer.
Control bracket.
Screw for bracket.
Tab washer for screw.
Stud for control cover.
Nut for stud.
Washer for stud.
Linkage nut.
Pivot ball washer.
Linkage washer.
Linkage hook.
Linkage spring.
Spring retainer.
Metering valve.
Shut-off bar.
Shut-off Shaft.
Seal for shut-off shaft.
Shut-off lever.
Dust cap for shaft.
Washer for shaft.
Nut for shaft.
No.
86.
87.
88.
89.
90.
91.
92.
93.
94.
95.
96.
97.
98.
99.
100.
101.
102.
103.
104.
105.
106.
107.
108.
109.
110.
111.
112.
113.
114.
115.
116.
117.
118.
119.
120.
121.
122.
123.
124.
125.
126.
127.
Description
Throttle shaft.
Seal for throttle shaft.
Dust cap for shaft.
Nut for shaft.
Throttle arm.
Governor spring.
Guide for idling spring.
Control cover.
Adjusting screw.
Washer for adjusting screw.
Locknut for screw.
Locking sleeve.
Adaptor for sleeve.
Vent screw.
Vent screw body.
Washer for vent screw body.
Adjustment screw for metering valve.
Washer for nut.
Locknut.
Sealing cap.
Automatic advance device housing and piston.
Gasket for housing.
Stud for housing.
Cap nut for stud.
Washer for cap nut.
Cam advance screw.
Piston plug.
Seal for plug.
Piston spring cap.
Seal for cap.
Screw for cap.
Washer for screw.
Head locating bolt.
Slide washer.
Maximum advance stop.
Spring for stop.
Shim washer for spring.
Washer for head locating bolt.
Joint washer for pump mounting flange.
Washer for nut.
Nut for injection pump mounting bolt.
Idling spring.