Contents Page FUEL INJECTION PUMP 1. Function a 2. Dis-assembly 5 8, Inspection of parts 7 4. Assembly 8 5. Calibration 10 SNUBBER VALVE 1. Function 2 NOZZLE HOLDER AND NOZZLE 1. Function 13 2, Removal ofinjector from engine oyinderhead uy 8. Functional tests onnozze test stand “ 4. Dissastembly 15 5. Inspection ofparts 16 6. Assembly ” 7. _ Installation of injector on engine a ‘SPARE PARTS LIST FOR FUEL INJECTION PUMPS. 20 EXPLODED VIEW OF FUEL INJECTION PUMP a PF 1 WV... ‘SPARE PARTS LIST FOR NOZZLE HOLDER 2 EXPLODED VIEW OF NOZZLE HOLDER 23 KBA 242... COMPARISON OF MICO/ ABC/ ALCO 24 FUEL INJECTION EQUIPMENT SPARES ‘TEST SPECIFICATIONS 26 ‘SERVICE TOOLS FOR INJECTOR 27 Scanned with CamScannerFUEL INJECTION PUMP 10 Function MICO fuel injection pumps aro of singlo acting, Constant stroke and plunger typo with tho effective working stroke, however, boing adjustable. The pump consists primarily of a housing, delivery valve and spring, delivery valve holder, element (plunger and barrel assembly), Plunger spring, a geared control sleeve and ccontrol rack (rod) assembly. Tho pump element ‘comprises a barrel and a plunger, which are match assembled oa very close tolerance. ‘The fuel injection pump has three functions: + to raise the fuel oil pressure to a value, which willeficiently atomise the fuel + to supply the correct quantity of fuel to the injection nozzle commensurate with the power and speedrequiement ofthe engine. * to accurately time the delivery of the fuel for éfficient and economical operation of engine. Detvery Valve Holder Nut — ORing Delivery Valve Spring oma Delivery Valve Pump Housing Element Baffle Ring Control Rod Assembly Regulating Sleeve Upper Spring Plate ‘Screw Plunger Spring Plunger Guide Lower Spring Plate Suse Fig. 1. Cut section of fuel injection pump (ALCO/DLW Locomatives) Scanned with CamScannernee Fuol ail ontors the pump fom tho {vl ol hoador a file tho sump surrounding tho plungor barrel, Whon the plungor i a the bottom ofits soko (position 1), fuol lows through the barrel pors filing th spaco above the plungor and the cutaway area the helt. ‘As the plunger moves upward, fuel is pumped pack to the sump until barrel ports are closed. Further upward movement of plunger (position 2) raises the pressure ofthe rapped fuel. When pressure is sufficient to overcome the force fxerted on the delivery valve by the valve spring, the delivery valve opens and fuel is discharged into: the high-pressure pipe, leading to the injector. Further upward movement of the plunger increases fuel pressure to enable the injection to ocour: Delivery of fuel ceases when plunger helix opens the barrel ports (position 3). During the remaining movement of plunger, fuel spils into the sump. This termination of fuel delivery by he helix controls the quantity of fuel dolvered per stroke. The angular position of @ plunger, with respect to the barrel ports, determines the effective stroke and therefore, the quantity of fuel injected. The total length of the plunger stroke remains constant regardless of engine speed orload. ‘When the plunger is rotated to a position (8) where the vertical groove is aligned with the control port, no pressure can build up and ‘consequently, no uel willbe delivered, Tre angular postion ofthe plunger, with respect to the bare, is altered by a control sleeve, the lower end of the sleeve being slotted to engage the flange (vane) ofthe plunger. The upper end of control sleeve has an integral gearing, which ‘engages with the control rack. Movement ofthe ‘control rack by the engine governor rotates the a plunger, thereby varying the quantity of fuel delveredby the pump. 1. Barel 2 Barrel Port A Commencement [Maximum detivery "8-2. Control of fuel delivery by rotation of plunger Scanned with CamScanner2.0 21 Tho dolivory valvo provonts oxcoss draining of {uo from the dischargo lino. As tho plungor holix Uncovers the barrel ports, thore is a suddon pressure drop in the barrel resulting in tho closure of the valve due to higher pressure in the delivery pipe and delivery valve spring force. As the valve snaps into its seat, the prossuro ia reduced in the injection tubing to lower the ‘opening pressure of the nozzle. This action of the valve eliminates the possibilty of secondary injection (after dribble) from the nozzle, Tho sudden drop in pressure in the injection tubing is achieved by providing an accurate ‘ali piston atthe upper end ofthe delivery vale pin Fig. 3) When the plunger heli first uncovers the barel ports, the lower edge of the rele piston slides into the valve body and traps all fuel in the injection tube. Further movement of the valve to its seat increases the space available for fel in the tube and therefore reduces the fuel pressure, ‘The metered quantity of fuel from the injection pump passes through a shubber valve and high- pressure line, entering the nozalo holder at the pressure tube inlet connection. Drilled passages in the nozzle holder conduct fuel to the pressure chamber ofthe nozzle, ‘When the pressure of fuel acting on the pressure chamber exceeds the spring pressure, the nozzle valves forced fromits seat. Fuel then flows through the nozale spray holes until the fuel pump coases to deliver fuel. Fuel flow is then instantaneously and positively cut off, as the spring snaps the vale shut. Dis-assembly Before attempting to disassemble a fuel injection pump, make certain that the work bench and the tools are clean. Cover the bench with clean paper. Rinse the parts, as they are removed, in clean fuel oll. SOVASOL or white kerosene could also be used as an alternate cleaning medium. Number in brackets indicates the exploded view reference number frindividual components. Removal of plunger guide cap (7), plunger control sleeve (4) Place the pump in a dismanting fixture in an inverted position and force the plunger guide cup into the pump housing. Insert a piece of drill rod or heavy wire in the hole on the inside ofthe ‘pump bod to hold the plunger guide cup down, (Fig. 4) Remove the plunger guide cup retaining ring (Fig. 5) and force the plunger guide cup downto 5 Fi. 8. Removing the guide cup retaining ring Insert: Close-up of retaining ring Scanned with CamScanner{oreo on tho guide ls 20 tho corr io Oe gar guteCP cx at), pe and A the pump housing ig with upper spring plunger and keep it Lincthe lower seri unger sping (8) out e Remove contol seve a cxat (Fg. 6 Wash We separately ioprvert daa Delivery valve (21) anling fature in an the pump on a dis Peta poston. Wiha socket wrench, 1082” ry wae Pksing nut (8) (ig 7). While Teosning the nut oxet asirongand steady ul onthe wrench, Remove holding nut (Fig. 8) and delivery valve holder (20),Removethe delivery valve and valve body sa uni Ths unit can belted out ofthe purmphousing. Wash the delivery valve and valve body separately o prevent them from being damaged bycomingin contact with other parts. Caution: Never use a hammer to loosen or tighten the dalveryvae holding nut (18). Plunger barrel Remove plunger barrel by pushing tout through the deivery valve opening. The barrel is held in Position by means of a locating pin and corresponding slot on the barrel. The locating pin should not be removed. Wash barrel separately to prevent it from being damaged by coming in contact with other parts. Now ‘assemble the plunger and barrel fr protection against possible damage.* “Caution: Protection sleeve to be placed in between the ‘Plunger vane and the barrel to avoid damage to {he plunger top, Damage to the plunger top can ‘Cause seizure! stickiness ofthe element, Control rack (29) and bushings Remove control rack stop screw (27). Pu ontrolrack outofts bushings (Fig 9) 'm case bushings need 1 Suitable mandrel Allow i to fal replacement, using a Push in one side bushing and Ot HHOUGh the opening in the "© Pump housing, Remove the a ond bushingalsointhe same manner, Fig. 8-Removing delivery valve holding nut Scanned with CamScanner3.0 34 3.2 3.3 3.4 Inspection of parts Plunger guide cup (7) Replace plunger guide cup (7) ifthe indentation on the plunger and tappet seating surlace is more than 0.126 mm (0.005"), ‘The clearance between guide cup and the pump housing has no effect on pump performance. Replacement however, should be based on mechanical judgement. Plunger spring and spring seats Replace plunger spring it + cracked! nicked + corroded + surface coating damaged. Replace spring seat worn-out/ damaged. Plunger and barrel assembly (element) With constant use and abrasive action of extremely minute impurities in fue, the plunger ‘wears out, thus affecting the tightness of clement. Particularly ifthe wear! scoring mark is ‘considerably above the helix region of element plunger, the specified delivery quantity cannot be obtained and this will afect the engine performance. If there is considerable wear! scoring in the region above the helix ofthe element plunger and if specified values as per the Calibration Chart cannot be obtained, the element requires replacement. Occasionally, dark discolouration and pitting marks may be seen on the delivery valve seating surface bf the barrel f the surface shows only discolouration and no wear is noticed, the seating surface may be polished by using ‘mutton tallow’ or ‘clover compound A. After polishing, wash thoroughly in clean et ol It wearis observed, replace element. Element plunger and barrel are ‘match assembled’ and cannot be replaced individually. Delivery valve holding nut (18) Examine delvery valve holding nut for damaged threads orseat. Replace, fnecessary. Fig, 8. Removing the contol rack Scanned with CamScanner3.5 3.6 fap 3.8 3.9 4.0 41 Delivery valve holder (20) Examine for damage to high-prossure connecting threads. Examino tho seating surface. H necessary, lap the seating surface to remove any discolouration marks using ‘clover compound A\. After lapping, thoroughly wash dlvery valve holderin clean fuel oil Delivery valve spring (19) ‘The delivery valve spring must not be pitted or ‘racked nicked. Replaceit, necessary. Delivery valve (21) Examine the seating surfaces ofthe valve body that come into contact with barrel and delivery valve holder. Discolouration marks can be emoved by polishing with mutton tallow. 4 either the valve or valve body cannot be reused, the delivery valve assembly must be replaced. The valve and valve body are ‘match assombled’ and must never be replaced individual Control rack and sleeve Check the clearance between control rack and bushings. It shouldbe within 0.5 mm (0.020%). necessary, replace bushings/ control rack.” Move control rack by holding the sleeve firmly. ‘The control rack movement should be within 0.226 mm (0.008") Similarly move control rack by holding element plunger stationary Tho control rack movement should be within 0.38 mm (0.018"), necessary, replace control rack! sleeve. Baffle ring (22) ‘The baffle ring surrounds the barrel to prevent erosion of the pump housing as a result of a ‘sudden oil pressure when barrel ports are uncovered, Inspect batle ting for erosion. If excessive, replace bate ring ee Assembly Before assembling a fuel injection pump, wash all parts in clean fuel and assemble them when wet. Protective grease from new element ‘and delivery valve should be removed in petrol ‘thoroughly. Dip the element plunger and delivery valepinin clean fitered fuel before assembly Control rack bush tings Place the pump housing on an arby Dress in one bushing at a time tool (Fig. 10). oF press, with @ suitable Fig. 10. Pressingrin the control rack bushing Scanned with CamScannerAlter both tho bushings havo boon insorted, ream the bushings 10 18.25 to 18.27 mm (0.7185 to 0.7102"), Use areamer with euitablo guide (Fig 11). After roaming, thoroughly clean bushings and pump housing, 4.2 Plunger barrel Examine the barel seat in the pump housing. Donotattempt to refinish the barrel seat but remove dirt if there is any. The barrel seat must be tight, 50 that during pump operation, fue wil not leak past the seat into the spring cchamber. lace pump housing in a dismantling fiature in an upright postion. Insert element bartelinto pumphousing. Caution: Protection sleeve to be placed in between the plunger vane and the barrel to avoid damage to the plunger top. Damage to the plunger top can ° Gause seizure stickiness of the pump. ‘The element barrel is located by means of a pin pressed into the housing and a slot outside the barrel indicated by arrows in Fig. 12). After the barrels lowered fits seat, move the barrel up and down and rotate itsightly to ensure that itis, propery located. Thereafter, insert baffle ring around the element. Install delivery valve assembly and delivery valve spring into pump housing. Insert rubber 'O' ring (11) over the delvery valve holder. Place 'O' ring (12) on dolvery valve holding nut. Before insertion of ei “O'ring, smear a small quantty of vaseline or Fig. 12. Locating the element barre petroleum jelly onthe surface of'O'rings. Screw the holding nut into pump housing and then tighten it to a torque of 620-690 Nim (62-69 kgfm.or 450-500bs. ft) withatorque wrench Control rack and control sleeve Pace:the pump in the dismantling fiure in an inverted position. Slide control rack into its bushings rotating it, until the notched tooth is visible through the bottom opening of pump. Screw in the control rack stop screw and engage it with the | slot in the rack. Tighten the stop screw and put thelock-wire. Lower the control sleeve into the pump housing ‘and engage the rack so | that the notches on the | sleeve and rack are in line (Fig. 13), Fig. 18. Aligning marks 9 Scanned with CamScannerRE9 pungerandplngerguidecup == Install uppor spring eoat and plungor opring in pump housing. Position tho lowor spring saat to plungorand nsor plungorinto tho barrol go that thonotches on plungor flango (vano) and control sleovoarainine, Slide tho plungor guido cup into pump housing. Force the guide cup down against the spring pressure making certain thatthe plunger flange (ane) engages inthe slots in the control sleeve, Insert piece of dillrod or heavy wire inthe hole of the pump housing to hold the guide cup down, Install guide cup retaining ring; again force guide cup down and remove the dil rod. Release guide cup. General After the pump is completely assembled, check for free movement of control rack. The rack should slide freely. The pump is now ready for ® calibration, 5.0 Calibration ‘AI MICO fuel injection pumps are thoroughly tested for function, mounting dimensions, dativry values, ec, before despatch, ‘The calibration values specified for pumps (refer supplement - page 26) will hold good only if tested on Bosch calibration test bench with a suitable cambox. At the time of calioration of pump, the point of port closure is also marked ie, a matk is provided on pump plunger guide fang an aligning mark on the pump housing. On Pumps assembled with shorter plunger guide ‘cups, no separate matkng is provided on the cup, but the top edge of the plunger guide cup will serve as reference mark. The inspection windows coveredby a cover. 51 Procedure Mount the fuel injection pump on test bench (Fig. 14). Run the test bench and ensure that Airfreefuelis delivered through the test injector Increase the speed to 500 min’ (rpm), direction of rotation throughout calibration remaining Clockwise as viewed from the driving end, With Suitable scale and contol rack holding device, Push control rack towards'stop' and ensure that ‘here is no further movement. Thereatter, move {he control rack towards delivery postion by 20 mm inthe case of pump type PF 1 WV 180/53 nd 28 mm in the case of pump type PF 1 WV {17018 ignoring the marking on the control rack, 1 Check deivery quanti the value, as specied 0 Scanned with CamScannereS 5.2 ienot obtained, vary the position of control rack til pump dalvers specified quantiy. Holding the contol rack in this postion, add shims to tho pointe sothattindicatos: ‘30 mm on pump type PF 1 WV 150/65 ‘28 mm on pump type PF 1 WV 170/6 ‘Without making any further adjustment, check dalivery at a contol rack travel of 9 mm (idle positon). The pump should deliveras specified. ‘Stamp the total thickness of shims used on the pump housing near the pointer, after having erased the earlier stamping. Checking fuel delivery at zero control rack travel Move the control rack towards stop position and ‘engage the latch with the slot provided on the control rack. Run test bench at 200 min (rpm). ‘There should beno delivery Note that the calibration values shown on page 1 of supplement ae for reference purpose only In diesel service stations, where master pumps for ull fue’ and ‘ile fuel are availabe, before any repaired pump is taken for testing, the master pump values should be obtained on the test bench. After that the repaired pump shouldbe re-settothe same limits. IFitis not possible to calibrate the pump within the specified limits, the element or delivery valve ‘assembly may need replacement. The replacement of either or both of the above should providetheneeded correction. + Adjusting shims ‘The adjusting shims for control rack pointer are available in various thickness (refer page 22) " Scanned with CamScanner1.0 SNUBBER VALVE Function A snubber valve assembly is fitted on the fuel injection pump at the top of the delivery valve holderusing atubing union sleeve and nut, Itis basically a check valve that restricts fuel flow in the reverse direction through a small orice. Its function isto dampen shock waves traveling through the high-pressure line resulting from sudden closure of the delivery valve and the nozzle valve. Inspection and replacement of snubber valve + Visually inspect forcracks + Check or ree movement ofdiscby shaking + Examine the disc to see that itis not broken (by holding snubber valve assembly near a light source and looking through the snubber valve bore). Note that the office in the disc is considerably smaller than the bore in the snubber valve. ‘The snubber valve should be replaced if male and female cones are damaged/ worn out and/ orthe valve discis found broken. Replace complete assembly as individual parts arenot marketed. ———| NN in WSJ << QZ Snubber valve - part no. Scanned with CamScanneree NL a 1.0 1 1.2 NOZZLE HOLDER AND NOZZLE Function Nozzle holder ‘Tho fuel injection nozzle holdor conducte fuel ‘rom the pump, srubber valve and high prossuro discharge tubing to fuel injaction nozzle and provides a means of adjusting the nozzle valve ‘pening pressure, The nozzle alomises the fucl and directs it in a definite spray pattem into the engine combustion chamber. The major components of the nozzle holder are nozzle holder body (1), pressure adjusting spring (4), shims (compensating washers) (2), uide bush {@), intermediate disc (6) and nozzle capnut (7) {ee page 19) To adjust nozzle valve opening pressure, shims are used between nozzle holder body and guide ‘bush (spring cap), above the spring. The lower end of nozzle holder is ground and lapped to provide leak-proof and pressurestght seal with the lapped upper surface of intermediate disc (6). The lower surface of intermediate disc isalsolapped to provide a prossure tight sealing with the lapped surface of nozzle body. Nozzle holder and nozzle assembly will hereafter be referredto-sinjector. Nozzle ‘The fuel injection nozzles are the closed, hydraulically operated, differential type consisting of two parts nozzle body and nozzle valve (pin). Both these parts are made out of special heat-treated alloy steel to minimise wear ‘The nozzle valve and nozzle body are matched to form an assembly. These parts should not be exchanged individually but replaced only as an assembly. [At the tip of nozzle body are 9 spray holes through which fuel passes into the combustion ‘chamber, The spring loaded nozzle valve ‘controls the flow. Operation ‘The metered quantity of fuel from the injection pump enters the nozzle holder through the high-pressure inlet tube connection and flows through the drilled passages of nozzle holder ‘and nozzle body to the nozzle pressure chamber. When fuel pressure acting on the differential area exceeds the spring force to which the opening pressure is set, the valves lifted off its seat, Fuel flows through the nozzle spray holes ntithe fuel pump coases to deliver fuel. Figs injection nozle Scanned with CamScanner2.0 3.0 31 3.2 Tho fuel flow is then instantaneously and ‘cut off as tho spring pressure forces bbotween tho nozzle valve and nozzle body is necessary forlubrication. ‘The "leakage! fuel accumulates in the spring ccompariment. From the spring compartment, fuel drains out of the nozzle holder through aleak off passage, thus preventing the nozzle valve from becoming hydraulcaly locked. Removal of injector from engine cylinder head *+ Loosen high-pressure fuel line connection at ‘pump andnozzle holder. + Remove injector retaining stud nuts. + Remove retaining clamp and take out the injectorwith apuller. Note: There is no gasket between the nozzle holder capnut and the rolled sleeve in the oylinderhead, Cleaning Wipe all drt and loose carbon particles from injector with a clean cloth and clean the nozzle tipwitha brass wire brush. ss Functional tests on nozzle test ‘stand Mount the injector in a testing fixture and Connect to nozzle tester using suitable high- pressure pipe. Put the pressure gauge of nozzle {ester out of circuit by screwing in the shut off valve knob (clockwise direction). To flush the nozzle, operate the hand lever of {ester for about 10-12 strokes at the fastest possible lever speed, Tho nozsle should repeat (chatter) with a whistling tone and/ or spray in a well atomised form, Opening pressure test To check the opening pressure, bring the Pressure gauge in circuit by screwing out the Shut off valve knob (anticlockwise direction), Stowiy depress the hand lever until the nozse ‘sets the test oil and the pressure gauge Trading suddenly drops. At this stage, note own the pressure gauge reading, "indicates the injector opening pressure Fig. 2. Nozzle test stand Scanned with CamScanner3.3 3.4 4.0 HF tho opening prossure los botweon 266 kg(/om* (8600 psi) and 270 kgl/cm’ (8800 pai itisnot necessary tor0-s0t, , Seat tightness test Slowly operate tho hand lever of nozzle testor until the pointer in prossure gauge indicates 20 kgf/cm? less than the pening pressure recorded above, . For example, if opening pressure in as is condition is 260 kgf/cm’, hold the pressure at 240 kgf/cm’ for 10 seconds by slowly operati the hand lever, a ‘The nozzle is considered tight (good) ifno drop falls from the nozzle within 10 seconds, Wetness or formation of oil drop (which does ‘ot fall in 10 seconds) at the nozzle tip is acceptable. Spray pattern/ atomisation Put the pressure gauge out of circuit by screwing in the shut off valve (clockwise direction). Operate the nozzle tester hand lever at the fastest possible speed (4-6 strokes per ‘second). At this speed the spray should be well ‘atomised, the nozzle may or may not repeat audibly. If injector is satisfactory for seat tightness, spray pattern/ atomisation and opening pressure is lower than 256 kgl/om’ (3600 psi) re-set the opening pressure to 260-270 kgt/em* (8700 to 3800 psi) by changing the thickness of shims between nozzle holder body and the ‘guide bush (spring cap). Repeat seat tightness and spray pattern/atomisation tests. Absolute cleanliness is essential during .ssembly/ dis-assembly and testing of injectors. The working space must be free from dirtand chips. Dis-assembly Mount the itjector in a bench vice or suitable fixture, Unscrew the nozzle, capnut using @ socket wrench part no. HS! KDEP 77 (@ 689 034 038). Do not use a pipe wrench Lift the nozzle off the nozzle holder taking care that nozzle Aeedle does not drop out of the nozzle body. If nozzle is stuck in capnut due to excessive carbon formation, dive the nozzle out carefully with a brass rod, whose end conforms to the contour of nozzle tip. In order to protect the lapped surface of nozzle holder, screw on the ‘capnut to nozzle holder. 8 Scanned with CamScanner44 4.2 4.3 5.0 51 hholderbody and clean themin clean fuel oil, Cleaning of nozzle Soak nozzle in clean fuel oil/ kerosene and withdraw the nozzle valve (needle pin) from nozzle body. If the needle cannot be withdrawn easily, soak nozzle in kerosene for a few hours. If nozzle needle is stil sticky, it is advisable to scrap the nozzle. Such nozzles may not function satisfactorily even if the needle is removed somehow. Examine nozzle needle for damaged or rough nozzle needle seat. Also examine the nozzle body for damaged or carboned seat and clogged spray hole. fnocessary, soak nozzle in kerosene. Clogged nozzle spray holes Blow clean and dry compressed air into nozzle body. If necessary clean the spray holes (Fig, 3) with nozzle cleaning wire (refer supplement for details) The cleaning wire should not break into the hole because it is difficult to remove the broken piece. Nozzle body To clean the nozzle body use an oil collecting groove cleaner and nozzle seat scraper available innozze cleaning kit (Fig. 4). — Inspection of parts Nozzleslide test ‘After having removed all traces of foreign material rinse nozzle needle and body in fitered test ol, Holding the nozzle body almost vertical, pullout nozzle needle by one third ofits engaged (Guide) length. When released, the nozzle needle should slide down to the seat with its own weight (Fig. 6). "nozzle needle sticks in the body, smear a tle mutton tallow on the needle guide and hold it in the chuck of a lapping motor. Run the lapping ‘motor and move nozzle body over the needle, imparting ‘back and forth’ and rotary motion. While carrying out this operation nozzle, needle should not touch its seat in the body. Wash ozzle needle and body in clean test oll and ‘epeatthe slidetest. Nozzle holder body (1) The lapped pressure surface should be free of Cracks, Scratches, pitting marks etc, that may fause an improper seal between the nozzle holder and the intermediate piece. Clean with ‘est oll and blow with ‘clean and dry’ Fig. 5. Fall test Scanned with CamScanner‘compressed air, Chock the cae hroads for any 5.3 Nozzle capnut (7) Remove carbon deposits from inner and outer surfaces. Examine for cracks, damage to threads and seatn ; ing surface. Replace, if peels place, if 5.4 _ Pressure adjusting spring (4) Replace the spring itis nicked, pitted or worn ut. If spring is condemned for wear on the outer surface of the spring col, determine the cause and rectly. 5.5 Spring seat (3) Replace spring seat it is rough or badly worn out. 5.6 Spindle (lower spring seat) (5) Replace, if broken, cracked or excessively worn out. 5.7 Intermediate disc (6) Replace intermediate disc if found cracked or if indentation at the nozzle seating end exceeds 0.125 mm. _ 6.0 Assembly 61 — Cleaningofnozzle If using a new nozzle, remove the preservative coating and wash the nozzle thoroughly in clean petrol ~Djpthenozzle body and needleinfiteredtest of andassemble. Nozzle needle and body are ‘match assembled’. ‘Therefore they should not be interchanged with those of other nozzles, 6.2 Slidetest +. Dipthenozzleneedieinfiteredtest oilandineert + intonozzle body. Holdiig the nozzle body almost vertical, pull out the needle up to maximum one third of its fengaged (guide) length. When released, the nozzle should slide down to its seat by its own weight. Wash all the nozzle holder components = thoroughly incleantestoil. 6.3 Mount nozale holder body () in holding Fate ale end’ upwards. Insert shims (2), spring seat (3) and spring (4 in the body. Keep Spindle with guide bush (6) and intermediate doe (6) on the protruding end of spring ” with ‘90% — Scanned with CamScanner7.0 ‘Assemble nozzle ovor tho intermodiato dive: sorow on tho nozzlo capnut by hand and ccentraliso tho nozzle, Tighten the nozzlo capnut to 130-150 Num (13- 15 kglim of 94-109 Ibs.) torque with a suitable boxspannerand torque wrench (Fig. 6). Remove the injector from fiture and carry out the functional tests. + Fitmentand flushing: Same as 3. + Opening pressure test: Same as3.2 Ifthe injector is new or new nozzle holder spring ‘and nozzle have been used, set the opening pressure to 275+10 kgt/cm® (3800 to 4050 psi). Re-setting pressure for injector (with used nozzle holder spring and nozzle) is 260-270 kat/om (3700 to 3800 psi). + Seattightness test: Same as 3.3 + Repetition (chatter) and spray pattern test (for new nozzle) Good repetition in the entire range of attainable lever speed. Lowest-test speed is one downward stroke/ second. Occasional/ small non-repeating anges are of no significance and should not be the criteria for rejection. At fast lever speeds, good repetition is indicated by well atomised spray. Spray pattern/ atomisation ‘At lower test speeds, the atomisation is coarse (non-homogeneous). At fast lever speeds te spray is compact and finely atomised. Installation of injector on engine *+ Clean nozzle hole in cyinder head. + Position the rubber 'O' ring around the nozzle holder. + Place the injector in cylinder head and position itwith the locating dowel. + Apply the injector retaining clamp so that the clamp bearing surface is directly over the centre line of the nozzle holder. Tighten the clamp nuts, hand tight until the clamp is parallelto the head surface. Insert fuel injection tube at the side, making sure that upset cone enters conical seat on the side of the nozzle holder body. Tighten the clamp nuts, hand tight until the clamp is parallelto the head surface. Fig. 6. Tightening the nozzle capnut with torque wrench Scanned with CamScanner7A Centering of Nozzle & checking truerunning Itis very important that the injector, centralised, uring the assembly of Care is taken that the nozzle is To achieve a true running of 0.3 mm, the centering sleeve (part no, 9 689 084 100) has beenused (Fig. 7). Further, using the true running gauge (part no, F 002 H81 508), check the true running of the nozzle (Fig. 8). Note: Failure to follow the above Procedure can lead to side thrust on the nozzle, which can lead tothe breakage of nozzle. Fig. 7. To achieve true running of 0.3 m coanoco LY on e (F002 H1 608) Fig. 8. For checking the true running of nozzle use gauge (part no. F 002 H31 508) Scanned with CamScannerSPARE PARTS LIST FOR FUEL INJECTION PUMPS Types: a. 9410035 000-PF 1 WV 150/5flted to ALCO 251 B-16 Vee Diesel Engine b, 94100095001 -PF1 WV 170/6 fitted to ALCO 251 D/6 Cylinder Diesel Engine Fig. Description of spare parts Partno, No.in ng each 1 Pump housing 9411 085 208 1 >2 Elementfor -9410035 000 9411 038401 1 -9.410036 001 9411 038 402 1 34 Regulating sleeve 9.411 036300 1 , ls Upper spring late 9411 030508 7 é Plunger spring ‘9411 084600 1 Plunger guide cup 19411 030504 1 8 Lower springplate 9411 030104 1 10 Springing 9411 084602 1 >it "Oring 9411 080201 1 >i2 ‘Oring 9411 030 202 1 4 Screw 9411 033.400 1 ® 18 Nut 9411 088302 1 19 Delivery valve spring 94110346011 20 Delivery valve holder 9411 038301 1 >a Delivery valve for -9410035 000 9411 038503 1 b __-9410035001 9411 038.505 1 22 Baffle ring 9411 030 208 1 24 Sorew 9910501 152 2 25 Pointer 9411 080000 4 26 Latch 19.411 032003 i 20 Screw 9411 038.401 4 8 ‘Shims yi a -0.1 mmthick 9.411 030 105 b -0.2mmthick 9.411 030 106 Q © -0.25mmthick ‘9411030107 2 4 -0.5mmthick 9411030108 | asrequired @ —-O.8mmthick 9411030109 1 mm thick 9411030110 9g -20mmthick 9411030111 329 Controlrackassembly 9411 086 000 1 >20/* Controlrackbushing 9.411 080336 2 30 Screw 2910022 196 2 3t Washer for 30 1410 107 005 2 [32 Inspection cover ‘9411 080002 1 33 Gasketfor32 ‘8411 080008 i 3° Banjoboltforfueliniet ‘9411 088.407 1 *Notilustrated > Parts subject to wear and tear Scanned with CamScannerEXPLODED VIEW OF FUEL INJECTION PUMP PF 1 WV... 9 410 035... Oo) -OG or a OMD0OO Scanned with CamScannerSPARE PARTS LIST FOR NOZZLE HOLDER Types: 0.431 919 008/ KBA 242 72 19.490 081 902/ KBA 242 T10 Fig. Descriptionofspareparts Spareparts —_-Spareparts, No.in oy forKBA242T2 for KBA242T10 each 1 Nozzle holder body 9431 035 132 1 2 ‘Compensating washer 2 OSmmthick 2430 100600 - b 0.35mmthick 2.480 100601 2 cc OAmmthick 2490 100602 : : 6 0.45 mmthick 2490 100603 . © OSmmthick 2490100604 9431090125" { 08Smmthick 2.430 100608 : ssrequired|] BO @ @ 0.6mmthick 2.430 100606 : hh 1Ommthick 2490103008 9431 080126" i 20mmthick 2.430 103.006 : k 04 mmthick @ 2430100607 9431030 123" w | ate = earanoe ° 3 Springseat 2480120000 9491080128" 1 (Washer) or 9.431 030 129" 1 4 Spring 2434619008 —9.431034601* ’ | 38 Intermediate dise 2430136000 9431030120 1 7 Nozzle capnut 2433314087 9.431 083320 1 . >B Nozzlefor a -251B 16Veeengine 9430083800 9490039300. 1 DLIS7T1194 —DL1S7T 1194 9 b +251 D6 CyLengine 9490033901 9430033301 1 DLIS7TH41 LAST Hat “Interchangeable with corresponding ABC parts Nozzle is not supplied along with the nozzle holder ané f ‘number engraved on the nozzle. >Parts subject to wearand tear id hence to be ordered separately, Please state order — Scanned with CamScannerEXPLODED VIEW OF NOZZLE HOLDER KBA 242... Pray Ci S 2 @e ° “eo Ss iS 4 =e © i Wy UW) Scanned with CamScannerCOMPARISON OF MICO/ABC/ALCO FUEL INJECTION EQUIPMENT SPARES - iCOequivaiont SSCS : Fig.no.asshown Partnumber Description nico asm, Has eto view drawing 922008 GATEIG at 1410 107008 Washer 26200162 APFACO 150 A T4016 941035000 Pump for 251 8 T520016S _APFICO 150 PFW 18015 T4016F 2921267 __8C76286-2A 2 9.411 038.401 Pump elementfor 2518 2321294 GU 76106 | Gu76153 7 9411 080604 Plunger guide cup 72821904 GU76114 +2922384_ +WA7646 9 9411 030 104 Lower spring plate 7 2921316 _GU76144 5 9411 080503 Upper spring plate 2321326 GA1060 2 9411030202 “O'ring between housing : 2321927 GA76214 and nut +2821325_ +RG 1047 7 9411 080201 "Oring between nutand delivery valve holder ® o 2821688 HG761142A 7 ‘9417 085 208 Pumphousing togetherwith 18 11No.9411 033.302 Nut J Inividualparts of 4 2Nos.2910501 152 Screw | ABC pump housing 27 1No.9411033.401 Screw }eannotbe replaced 30 2Nos.2910022196 Screw | withcorresponding 14 1No.9411 033.400 _ Screw | MICO parts 282184941 _HP-76356 20 (9411 083301 Delivery valveholder 2321955 PO76I0 25 (9411 080000 Pointer 2821968 VA76I98A 21 9414 038505 Delivery vale for251D 2321983 SP76114 18 9411 034601 Delivery valve spring 2921878 RD 76205A 29 9411036000" Controlrackassembly 23214451 SV7656 4 9411086300" __Reguiatingsloeve 2921464 RG7624 10 8411 034602 ‘Spring ring 292153 OV76203 32 ‘9411 030002 Inspection cover o:e@ 2922088 _GA76269 33 9411 030003, Gasket : 2922084 SP 76141 8 9.411 034600 Piungerspring 23001641 8G 7678 - 9411 030836 ‘Controlrackbushing 2922662 _ LH762 26 9.411 032003, Latch 2402466__VATEI94A 9.411037 400 ‘Snubbervalve 4231051-1 ADL I67 (0430039301 Nozzle for 251 D TM822-6 DLAs7 T1141 4820021 APFICQH7O 50488 9410035001 4920021-1 APF1CQ170 PF1WV170/6 ——_ Pumpfor251D T5048C 4321001 BC 76356A 2 (9411 088 402 Elementfor251D 223102189 ADL 167 19430033300 TMe21-6 DLIB7T 1194 Nozzlefor2518 "> 22372410-2. AKK242 0431 519003 T5700 KBA24272 or Nozale holder for 251 B&D 9430031 302 — Scanned with CamScannerCOMPARISON OF MICO/ABC/ALCO FUEL INJECTION EQUIPMENT SPARES MICO equivalent ALCO ABCno. Fig.no.asshown Partnumber Description Cat.no. inthe exploded view drawing 23210318 SR7629-2 28 ‘9.411 030106 23210319 SR7629-7 28 9.411.030 111 23210321 SR7629-1 28 9411 030 105 23210822 SR7629-3 28 9.411 030107 23210323 SR7629-4 28 9411 080 108 23210324 SR7629-5 28 ‘9411 030109 [23210325 SR7629-6 28 9411 030 110 Shim 23213611 VA76196A a 9411 038503 Delivery valve for 2518 24010442 : (9411 033407 Banjo bolt MICO baffle ring 9.411 030 208 cannot be used with ABC pump housing but ABC ring can be used with MICO pump housing, + If MICO control rack assembly has to be used on ABC pump, regulating sleeve should also be replaced with that of MICO and vice-versa. Scanned with CamScannerTEST SPECIFICATIONS Test equipment Testbench Cambox Testinjector Nozzle High pressure pipe Test conditions Inlet pressure foréalbration Ciltemperature Testoil MICO/ Bosch make 82421 1900 0681 343 005 (EFEP 218) 0681 443 016 3115 23674 8x 2x950mm (outer dia x wall thickness x length) osto1 402°C isons Calibration Values (Applicable only when tested on MICO/ Bosch test bench) Pumptype Testinjector —_Controlrack ‘opening position min’ (rpm) Delivery quantity pressure (mm) (cm’/300 strokes) kgt/em* PFI WV 150/5 17248 9 500 70.5-76.5 (645-825) 9410035000 30 500 999-411 (887-423) PF1WV170/6 17248 9 500 90-100 (86-104) 9.410035 001 28 500 465-489 (462-492) Notes: (a) Values given in brackets are overchecking values. (0) Applicable only for MICO and Bosch test benches, {(c) Maximum shims at pointer tobe 4 mm. BDC dimension (a) :6.5 0.05 mm BDC dimension is the distance from the pump mounting surface to the top of the pump drive push rod or roller tappet in BDC position. See sketch alongside. This dimension must be maintained while mounting the pump on the testbench. Caution: Teppet Measurement of BDC dimension Itis absolutely essential o ensure maintenance of BDC dimension both on the calibration test bench as wollas onthe pump mounting block on the engine. Failure to adherence willresultin: + Damage tothe housing by way of spigot breakage ifthe BDC dimensionis more + Damage tothe control sleeve! element plunger in caseitis less Scanned with CamScannerSERVICE TOOLS FOR INJECTOR Sno. Description Designation Application Nozzle cleaning / testing 1 03-KDEP 2900 Forcleaning ll nozzles 9680034001 2 Nozzlecleaning wire (0.8mm) 03-KDEP 2900/11/1 ForDL157T 1134 nozzles 9681 033.209 3 Nozzle cleaningwire (0.85mm) 03-KDEP.2900/19/1 For DL157T 1141 nozzles 9681 033.210 4 Nozzlesnesdielift gauge H-S/KDEP1 For checking nozzle needle ft 9689035001 +Feeler +H-S/KDEP 1/4 9681033211 5 Dialgauge Range Oto 10mm Forusein conjunction with Least count 0.01 mm nozzle needle lift gauge (Tobe procured locally) [6 Mattontaiow FT19V1 Forgeneraluse | 5700262000 7 Nozzle centering sleeve HS/KDEP 128 Forcentering the nozzle 9.689034 100 while assembing nthe | NHbody |B Twerunninggauge +~—-—«~FOO2HS1508 ‘Go/no go gauge for checking the truerunning of the nozzle during injector assembly | Nozzle testing 1 Nozzle tester Bosch : EFEP 60... MICO: H-S/KDEP99 or H-S/KDEP 99A 2 High-pressure pipe 03-A1-EF 8040/24 For connecting injector to (M14x 1.5mm capnutson 9681 030 703 the nozzle tester both sides) 7 3 Fixture for injector H-S/KDEP 66 For holding the injector | g 9689033034 while testing | 4 Socketwrench H-S/KDEP 77 For loosening/ tightening 9689034038 nozzle capnut 5 Testoil 9916034004 For testing nozzles | Scanned with CamScanner