DP.A. FUEL PUMP — 6 71, Withdraw the splined shaft topether with the governor weight assembly. 72. Remove the ‘O° seal from drive shaft and seporate the weight assembly fiom the shaft 73. Remove the thrust sleeve, thrust washer, and the ‘weights from the weight carrier 74, Withdsaw the drive hub from the pump housing and ‘extract the olf seal using Tool, Part No. 7094/8934. "75, Any parts which ate showing any signs of scoring or ‘wear should be replaced, also all seals and gaskets should Dorepaced with new parts, a new drive bub oil seal, driving 1t onto its seat vw the spel ft ast No Sea SOA ie Perspex plug, Part No. 7144/13 in the seal If the seal is correctly seated a continouous black line will be seen JANUARY 1974 ‘where the seal is viewed through the (anged end of the plug. 77. Pass the mandrei of Tool, Part No. 714/894 through the weight carrier and fit the mandret into the base plate trapping the carrier between the shoulder on the mandrel and the upper face of the base plate. 78, Place the weights in position on the upper surface of the weight carer with the slot in each weight uppermost and nearest the mandrel, Each weight should tbe aligned with 2 carrier pocket and with iis inner end resting against the mandrel. 79, Place the thrst washer and then the thst sleeve on the and tod poston at he rr weit 30. Bxert downward presue om the this sleeve and the asembly wil enter the weight care, Withdraw the mandrel and remove the asembly from the baseplate of the tool Poe oe nb ough eo el he pe sing, seating the hub lange apunt the hous 82, With the governor weighs’ uppermost, insert the drive shat into he eight caver are threaded le firs) and ht anew" eal inthe groove in the surface of the shat, Protection ep, Part No. 704/900 should Be ed or he die alse when Big 0 5d he dive sat ad wiht sammy nt he ‘mp housing end engage the drive shat splines w ines in than oa of te dive ub. Eri postion eight cari tapped between the end face of he Arve hub anda shoulder onthe dive shat.84. Fit the support washer in the recess hetween the (wo sets of splines in the deve hub, and secure the driveshaft to the drive bub by fitting the spring washer and socket head dive shat screw. 5. Hold the drive hub with a special tool, Patt No, 144/773 and tighten the hub securing screw toa torque valye of 285 Ibsin. sing the adaptor Pari No, 714/261 and a standard torque wrench 86. Compress the timing ring withthe ctcip pliers and sei st against the shoulder in the ore of the pump housing. The scribed timing mark should be positioned in the centre of the inspection aperture in the housing. Rings without a timing matk should be positioned so that the open ends of the cnclip are at 180 degrees to the inspection aperture 87, Place the cam ting in postion against the ting ing, ‘The direction indicated by an a1toW on the visible face of the eam ring. should correspond withthe direction of pump rotuton marked on the nameplate BB. Secew the cam advance screw nto the cam ring and Lighten toa torque value of 300 lbshin. using the special adaptor Part No. 7244/1 25B ov » socket ands standard forque wiench, 89. Place the bottom adjusting plate in position on the pumping end distributing rotor NOTE: In the vortéet position of assembly the ‘cutout? fn the periphery of the adjusting plate is aligned with the “cut-out” in the periphery of the rotor, and the eccentsic slois in the adjusting plate are in line with the roller shoe guides. 90, Remove the corks retaining the win plungers inthe transverse bore in the rotor and insert the roller and shoe assemblies in the roller shoe guides. The contours of the projecting ears on the shoes should conform with the Contour of the ecceninc slots in the adjusting plate 91, Fit the top adjusting plate, engaging 10 lugs with the bottom adjusting plate, locating the wo plates one io the other wath the adjusting slot coincident with the scribed line 92, Secure the drive plate to the end of the rotar by fivting and lightly tightening the two drive plate serews. “The underside of the drive plate is recessed, 93. Fit the pumping and distobuting rotac in the bore of| the hydraulic head snd secure by fitting and lighiby Aightening the transfer pump r0% 94. Fit Tool Past No. 7184/262, to two of the high pressure outlets on the hydraube head and connect toa nozzle testing ouitit until a pressure of 30 aim, is ‘obtained snd ture the purnp rotor until dhe plunges and the roller shakes are" Forved 10 the maxionans, fut position, Set the voller te-roller dimension in severdanve with the lest specification by musing the adjusting plates 9S, Nekd she Jive plate wl Tool Pact No, 7884/744) and tighten the drive plate seiews wo v toague value ol T60 fos.fine on plunger, wath a dwmeter up te and Indding 7.5 mre, usiss sandued torque wrench, NOTE: Foe plunger diamerers larger than TS mn refer fo hical CAV, dealer for torque vate v6, Bssconneet the necle desing eat ané vemtove the Ssiirmup pipe trom the high pressure outers on the Inydrantic head DPA. FUEL PUMP ~ 7 97. Fit the external ‘O” seal on the hydraulic head and lubricate the portion of the head which fs into the sump housing 5. Slide the hydraulic head into the pump housing, engaging the spines on the inner end of the Give shat with those of the drive plate. Rotate the head and rotor ‘asombly 1 prevent damage wo the "seal as it enters the pump housing 99. Secute the hydiaulic head 10 the housing with the two locking screws. These screws should be left fingertight unt the advance device his been fited 100. Hold the drive hub with Tool, Pari No. 7144/773 and ughien the teansfer pump rotor toa torque valve of {65 Ws/in. using Tool, Patt No, 784/889, and a standard toaqae wrench 101. Fit the transfer pump liner in the countes bore in the end of the hydrault head und the pump vanes inthe slots of the transfer pump rotor. Rotate the liner to ensure thatthe vanes 46 not bind on the liner 102. Assemble the end plate as Tollows:- 403. Place the priming spring in the boxe of dhe end plate chamber 108" Fitnew washer (regulating sleeve 105. fasert the regulating psion into the bore of the regulating eve 106. Holding the regulating sleeve so that che larger diameter is uppermost, nsest the regaing spring absve the piston and then inser the spigoted end ot the sleeve plugita transier pressure rogutatar fitted 107. Pass the nylon iter over the seguioting valve assembly and fisert the assembly, small ed fist nto the end plate ensuring that che regulattig pistons retained within the 1opilting esse 108. Fit the elaining speing 109. Fina new °O" sel in the ovess in the end face of the hydrate head 110. Engage the dostct on the inner face 0 the end pate veh he soc th rane pp ter nd hen su the end plate to the hydraulic head by Trung the four end plate screws, Tighten srcws ta fone value of 48 Issn 11. On g pues fitted with 4 steel end plate procced as iollows Fit the sealing washer on dhe tue jnlet adapior and sctew it ite the eae plate Tighten 10 8 torque valve of 720 bin (8. Agen) Paes the gauze filter the Tis int apie and scchte pace. hy tune and Sightening the fl afer connserion 10 2 Torge sab wf 420 ba GANS hem.) 112i ar afumtum end plate Atied 6 the pr, ducn ue the dalle. sembly aegusice Fit anew washer to te fel let conngetis, aseimble te the end plate. and secure hy tightening te duet les oomgction fat tgs sale 6 TOUT. EELS Bg) HA Fauing the siomaate proces 9 tallow U1 Fat mew “0 scat to sho posters spring cap. tnd he piste plug wing protec ap, Part Nov TORS), TS. Sezew the piston plug inte the deme at the ed where te Heel pasa nts te cylindet Tyo. fisest UN piste the bof the sme sh counterbored ext vaitwards. nd ecu Hor Heed ot inovemeat TH Fav the mppes "0 scab on phe hvu Facatng bung wlvanes devise JANUARY 1974DP.A. FUEL PUMP 8 protecting the seal from damage by using the protection ‘ap, Part No. 7044/897. 118, Place the end steeb ballon its seating in the head locating fitting and then pass the fitting through the advance device housing. 119. Fit the lower ‘O° seal and the washer om the head locating fitting, protecting the seal by vsing protection ‘ap, Part No, 7044/18. 120. Place the sealing gasket in position against the pump housing. ¥21. Engage the cam advance screw with the piston, and serew the head loceting fitting into the hydraulic head ‘The advance device housing should be drawn onto the jointing face propiesively as the fling is tightened Minen's rubber jmting guket filed phen the head focsting fing to 3 torque value of 300 Jin. and when 2 cork gasket is fitted, 108 torque value of 3801 fin, 122. Tighten the two head locking screws 0 a torque value of 170 tb.fin, 123. Check for fteedom of movement, by moving the piston Y24, Insert the springs in the counterbored end of the piston and then fit the spring cap. 125. Fit the spring cap screw with the sealing washer and screw it into the spring cap. 126. Assemble "the governor linkage as. follows: Gnnotations tefer to illustration 2.2000+426). Derails for sant mechani of sieehansl powetnon A Thrust skove Swivel tok 8 Govern weighs 1M Conta ever © Gowtnot venta arm A Hhnk levee 2 aig spay puide © Moweng pr ‘Shot tur P Metermp tive © Shute shate Light soning Shuto tever S$. Contre broker 1 ding epeing Rotana sping 1 Goseraee spring 1 Dine shat ect ver 127, Engage the governor arma wish the governor bracket ahd cotnicct ie ww compuncnts wal) the small retaining spring. JANUARY 1974 128. Using protection cap, Past No. 7144/458A, ft the ower ‘O' seals to the throttle and ‘shut-off shafts, and using protection cap Part No. 7144/459A, fit the upper “0” seals. Pack the groove between the “O seals with ‘Shell Alvania, No.2 grease 129. Fit the idling spring on the shank of the idling guide. Pass the guide through the specified hoke in i governor arm and couple the governor spring to the guide. There are three holes in the governor ate; the forrest hole 0 be used if indicated in the relevant test specification. 130. Slide the spring retaining block, the linkage sprin dnd the spring reining washer onto the hook lever. Past the threaded end of the linkage hook through the governor arm, fit the pivot ballwasher and secure the assembly by fitting and tightening the securing rut, IRE, Altach the hook end of the lve to the metring vaive 132. Connect the free end of the governor spring to the ‘swivel link onthe thyottle shalt. Three. holes ate provided on the link: dhe one 10 be used is indicated in the relevant et speciation o in pump code. 133. Reverse the fixture in the sie. 134. Fit the assembled governor contro linkage on the pump housing, engaging the lower end of the governor frm with the thrust sleeve and inserting the metering valve inte position in the hydrate head. 138, Place the Keep plate into position on the governor contel Bracket Ht sew fa wothers onthe governor over studs, Pass the studs dhrongh the Keep plate and the bracket and screw thein tote the pump housing te secure the governor vonttul assembly. Lock tab washers Fit and tightea the screw at the end ot the bracket near the metering vase. 136. Bit the “shutoff lever Two diferent types of shutoff lever and ‘shutolt shaft ace in general se. Levers of early manufacture were of steel stp, whieh was bent 10 engage the cranked ‘shut-off shaft, Levers of later manufacture ore stamped (wom flat stel step. 137. “Shut-off shafts of earlier manufacture have a bearing at euch end in the governor control cover and in the upper face of the pump housing, Shafts of a ater manufacture have a single lengtliened bearing in the over conto coven “Shutoff levers of she “bentsirip” type ase Asembed the crank on the sbutlf sal aad then passed through the siot mn the overnin bracket 139, When two bearing shalt fitted im conjunction with the mire recent stamped “shucolt lever, tt is passed under a fab oo the control vover stud Tocking washer and must br engaged with the shat and passed through the slot in the bracket before the stud is fitted Liter (ype shu” bass can be placod in pesiton after the comol Bracket hus been secuved. snd ate engaged by the control shalt when the govenner cover is fitted 140. Set the internal Junerision between one governor comico} stud and the metering valve lever pip to dimension quoted in the test specification. Adjustment is made by screwing or unscrewing the mut en the end wl the hook lewes Light pressure shold be upphied co the governor gem to ald the merering valve in the Tully ‘open position, and the vermier gauge must be held paralle} tw the axis ef the pump.41. Fit the spring into the correct hole on the governor arm and also the throttle flak. The correct location can be determined from the following table Governing Arm | Throttle Ann > e 142. The correct code to which a particular pomp i set can be Adentiied by reference to the plate on be pump. EXAMPLE: The number is quoted ss A75/800/4/3030, This enables the purmp tobe st and the engine RPM set. -A75/800/4/3 ss fet engin Nice a afr Conde Stn a EC 00 Stokes Nenad eas oak Indicates pump tested Paro RPM, to be ‘with BENTISDI> used for seting somes maximum 143, Fit a new control cover gasket on the upper face of the pump housing. 194. If a ‘shut-of? shaft with a single bearing is to be fitted, press. the shaft into the control cover, sin protection cap, Part No. 7144/459A to protect the ‘O' teal. The peg shich engages the ‘shut-off bar must be close to the inside edge of the cover, DP.A. FUEL PUMP ~ 9 145. Press the throttle shaft into the cover, using the protection cap, Pert No. 7144/4594 10 protect the seals, and then slide the cover over the securing studs. Before ightoning the nuts on the securing studs ensure that the crank pin’ of the ‘shut-off shaft is engaged with the slot in the ‘shut-off lever. Tighten the muts to torque value of 40 Jin, (0.46 kg... 4, i the control levers onthe tote and “shutoft afi. 147. Replace the inspection cover complete with gasket and secure in place with the cover retaining screws. 146, The identification label on the pump indicates the correct direction of rotation of the pump. To check that the label has not been replaced upside dows, hold the ump, With the drive end pointing downwards The ters andl numeral on the Habel should then sead the Fight woy up. 149. Before fitting the fuel pump to the engine it should be tested using 2 suitable test machine, see page 14, D.P.A. PUMP WITH HYDRAULIC GOVERNOR 150. Remove the adjusting cover from the pump body and drain the fuel oil, 151, Remove the quill shaft and mount the pump oa the dismantling und aisembly fixture, Part No, 7244/155, and secure the fixture ina vice, 2.200.151 152. Remove the two screws holding the governor casing to the pump casing; withdraw the governor assembly snd discard the joint washer, JANUARY 1974DP.A. FUEL PUMP ~ 10 153. The eurrent ty plate beazed to the throttle shaft reversible governors have the stop sag renga ve 22000152 154. Before dismantling an eamly type governor sexe a line across the edge Of the stop plate, the verier plate and the throlte lever as a guide to correct asembly. Note wires the dot ff ie on ee right. 185. To dismantle the governor, proceed as follows: 156. Withdraw the shutoff sa 157, Remove the throte shaft 158. Withdraw the metering vale assembly. 159. Using too}, part: Number" 704/895 to hold the metering valve, remove he securing aut from the upper fend of the wave stem, Disnantle the shutoff washer, the ing spate If, te cone ene, he seig valve spring and the multi plate damper or the spr Hate whicver ied Pat P® “ume JANUARY 1974 NOTE: The idling stop and the maximum speed stop Screw positions are interchangeable. To avoid confusion, do not remove the screws unless renewal is necessery. 160. The edvance device must next be removed, as follow: 161. Reverse the fixture in the vice, to bring the advanced device uppermost. 162. Slacken the piston plug. Remove the spring cap and springs, 163. Unscrew the head locating fitting, remove cap nut sand withdraw the advance device housing as the fitting is ‘unserewed, 164, Remove the head locating fitting from the housing, taking care not t0 drop the sicel ball. Remove the ‘washer and fower oil seal. 165. Remove the piston plug and withdraw the piston, 166. Remove the “O" seal from the head locating fitting. 167, Unscrew the four screws holding the end plate to the hydraulic head, remove the end plate and the seal. 168. To dismantie the end plate, proceed 2s follows: 4169. Remove the fuel inlet connection and the spring fitted immediaicly below it 170, Remove the four hexagon head serews which secure ‘he end plate to the hydraulic head, also the damp plates 17, Liftoff the end plate and remove the synthetic 172. Invert the end plate and the complete regulating valve assembly will fll clear from the valve chamber. 175, Lift the fuel transfer pump blades from the slots in the rotor (see Fig. 2.200056) and withdraw the transfer ‘pump lines. 174, Remove the purnp outlet connections. 175. Hold the splined drive shaft with tool 744/733. and using tool 7044/889, slacken but do not remove, the iransfer pump rotor by turning in the direction indicated by the arrow on the rotor face. Ifthe rotor is unmarked, slacken in the direction of pump rotation 176, Remove the two head locking screws. 177. Remove the hydraulic head and rotor as an assembly. 178. Hold the drive plate with tool 7144/744 and slacken the two drive plate screws. 179. Remove the “O° seal from the periphery of the hydraulic head.180. Remove the tssnsfes pump rotor and separate pumping and distributor rotor from the hydraulic hed. Bo not aliow the cam rollers ia drop out. 181. Remove the duive plate screws to telease the drive plate. Dismaniie the top and bottom adjusting plates, the actuating rollers and the shoes from the rotor. Keep cach roller with is respective shoe. Immerse the rolers fond shoes in a bath of dean Foe el to protect them. 182. Retain the vin pumping plungers in the wansverse bore of the roior by two corks inserted in place of the getting cles The pump pangs ae ated tothe ore and should be retained cherem to prevent incoreest replacement. 183. Fit the rotor in the bore of the hydraulic head to protect the working surfaces. T&A, Remove the cam advance screw ftom the pump, susing too), patt_ number 7244/125B, Lightly tap the ‘blvancesciew before removal to fiee the eam ng. 185. Withdraw the cam ring. 186, Compress the liming sing with cixelip pliers and 187, Remove the retaining citeip from the drive shaft sing cirelip plievs DP.A. FUEL PUMP ~ 11 188, Withdraw the shaft from the pilot tube 189, All dismantled parts should be kept in a covered bath of clean fuel oll unt they are immediately required for reassembly. Then they must be assembled wet. Any parts showing signs of scoring or wear should be replaced also all seals and gaskets nist be seplaced with new pars, 199, ‘The pump should then be assembled in the’ Following sequence. 191. Slide the shaft into the pilot tube and secure # fn position with the cirlip. (No seals are fitted to the deive shaft on this type of drive), 192. Insert the guide dog, open end first, into the pump ‘end of the drive shaft, and line up the slot in the guide dog with the master spline on the drive shaft. The torsion bar aud end plate engage when fiting the pump ‘to the engine on the lest bench, 193. Compress the sming rng or cilip with the cp plies und seat against the shoulders inthe bore ofthe Pump housing. Rings dhould be positioned so tht the pen ends of he eilip ae at 180" to the inspection aperture. 184. Pisce the cam ring in position aginst the timing fing. The ditection indicated by the actow inthe sible faut of the cam ving must conform withthe diction of pump rotation matked on te name pate. Iss rw the cam afvance etter nd Uighien toa torque value of 25 Tbe (3.48 pm ig tHe spect took Part Now 7244/103 and estan iorque wrench, ‘Check the eam ring for freedom of ‘ovement after the same advance ste has been Sted JANUARY 1974DP.A. FUEL PUMP ~ 12 196, Place the bottom adjusting. plate in position, chamfered edge uppermost, on the pomping and distribution rotor with the small cu-out in dhe periphery ‘of the adjusting plate aligned with the cut-out flats in the rotor, and the eccentric slots in the plate in ine with the roller shoe guides. 197. Fit the rotor i the bore of the hydraulic head, secure it by fitting and parly tightening the Uansfer pump rotor 198, Remove the corks retaining the twin plungers in the transverse bore of the rotor. Insert the roller and shoe assemblies in the roller shor geides. The projecting ears ‘on the shoes must be placed in the eccentric slots on the ‘adjusting plates and the contour of the ears must Follow the contour of the slats. 199. Fit te cop adjusting plate, engage the lugs with the cut-outs in the bottom adjusting plate, locate the two ates yo hot the adjusting slot coincides with the 200. Secure the drive plate to the end of the rotor with the two drive plates screws parlly tightened, The underside of die drive plate is ecessed, and the holes are ‘machined 0 that the plate can be assetnbled in ony one way. 201. Fil tool No. 7144/2624 to two of the high pressure ‘outiet ports on the hydraulic head and connect it to 2 nozale testing unit, Operate the nozzle testing unit to raise the pressure to 30 atimospheres. Turn the pump rotor unt the plungers and rollers are foreed (0 the ‘maximum fuel position. Set the overall roller to reller {imension to the test specification figure by moving the adjusting plates. 202. Hold the drive plate with Toot, Pact mumber 714/748 and tighten the drive plate screws to a torque salue of 13.3 lbs/M. (185 kgm). where plunger ameter is op to 7.5 mun, then slacken and resighten to the ‘seme torque value. Drive plate screws must be ‘ightened evenly to avoid rotor distortion which can ‘ue sticking plungers. NOTE: For plunger diameters longer than 7.5 mm. ference mus be made to Jval CAV. deals for torque 203, Disconnect the nozzle testing outfits and remove the sucrup pipe from the high pressure outlets on the hydraulic head. JANUARY 1974 204, Fit an external ‘O" seal on the hydraulic head and lubricate the portion of the head which fits into the mehewang Fos Check thatthe guide dog sot i aligned with the mmaier spline onthe dive shaft Slide the hydric ead into the pimp housing and engage te drive shat pines find guide dog wth Oe guide plate spines and he two slote'n the face ofthe rotor. Rotate te head and rotor scemy to prt damage ote" ete 206. nsec the plot toc, Part No. 7144/S08B or /S08C {nto the metering valve bore to accurately locate the Iydraue head ts the pump casing. To determine the arret pilot tool 9 ft fw etenng valve bore, examine the hyatalic hesd between the delivery outlet adjacent to the metering valve bore if the hurber 6373 1s ttched ito the head use plot too! 71447508, When no umber it ethed into the head pilot tool 7144/5088 is the correct diameter fos the metering valve bore. 207. Secure the hydraulic hoad to the housing by the two heal Tosking serows only. Tighten these sexes Enger tight and remove te pilot tot 208, Hold the driveshaft with too 71487773 and wing tool 704/883, ughten the anser pump rotor to a lege of 5. (075 kgm 209. Fit the transfer pump inr inthe counter bore in the end of the hydrate heed and the pump vanes nthe slots in the tanser_pomp rotor. Rote the liner 10 nse that he vanes donot adn te liner. 210. Assemble the end plate ae follows FB ene z Seve aiing ring iter ne plate sleeve png Repulating sleeve Regulating spring Regulating piston Pring spring 22000210 23}1. Mace the priming spring i the bus of the end pate 212. Fit 4 new joint washer to the regulating sleeve, 213, Insert the regulating piston into the bore of the regulating sleeve214, Holding the regulating deeve 20 that the ager diameter is uppermost inset the spigoted end of the sleeve pug or transfer pressure regulator if ited 21S. Fast the nylon filter over the regulating valve aseinbly. sina end first, into. te ed plate ensuring thatthe seguating pision i retained win Whe repiating desve SHE the retaining spring. Fit « new washer on the inlet connecucn, scr Ht nto the end plate and lighly tighten. 2H Fit « new “0” sea in the recess in the end face of the hydiaic hea, 28, Engage the dowel on the ines face of the endplate ‘sth the oti the transfer pump ier and then secure the end plate and the clamp plates o the hydraulic head Sy fiting the four end plate screws tos torgue value of aC 58 kgm). 219. Fit'a new washer (0 the fuel inlet connection, semble (een ate aad sce by henge fuel tlt connection toa fygue vale oF 30% ts (015 kgm). 280 To resemble the Automatic Advance Device proceed us follows: EBT, Inver the: pump on the assembly fixture in the 322. Fit anew *O" sea to the piston sping cap and the piston plu, uxing protection eap 7044/89 Bo Serew the paston plug int the fuel passage end of ihe device. 2a: insert the piston inthe bore ofthis device with the ounterbored end oulwérds, Check for fsedom of Inovement 225, Bit the upper °O" seal on the head locating Biting, protect the seal from darmage withthe protection cap Soa? 226. Flace the steel ball on its seating in the head ining ng nd peng Sug te avance 357 Fit the “O° seal on the head locating Siting, wing the protection ap 7144/18 then ft the sce washer 228 Pace. the Sealing. gasket in. position against the pump eating, Jo. Engage the cam advance sew inthe piston, Screw te head focating Biting nto the hydraulic head. The advance. device shouldbe dram onto the joint face progressively es itis tightened. Fit the washer and cap futon the advance dette housing stud 230, Tighten the ead locating tng to a torque of 300 ibd, (has kp.) if a rubbor gakel is fed or 350 thin, (4.03 kgm.) where a cork gnsket is fed. On two Bolt ftments used on later models 350 Thin the tae Fog. Tgie he ap att ogi o 130 fbiin. 231, Tighten the wo head locking crews toa torque of TAB HE Coe hem * “ 232.” Move the piston 10. check “ovement of te advance device 353. Recheck the ligament of the head with the pilot iool. 25, tee the pigs the contort ison, Fit the spine cap 2855, Fit the sealing wisher to the spring cup sree 236, Tighten the spring cap and the piston plug 10 donque vale of 91 Bf 2.90 kgm) 237) Assemble the governor as Flows the freedom of DPA. FUEL PUMP ~ 13 238, Using Fig. 22000 — 153 as a guide, assemble the thin bottom washer on the metering valve stem, then the dished floating washer with the open face uppermost and then the stepped damper washer with the smaller dismeter uppermost. Fit the metering valve spring, the control sleeve (and the shim and idling spring if fitted) and finally the shut-off washer. Hold the metering valve With tool 7044/89S and screw the nut onto the thtead ‘of the metering valve stom and secure. 239. Insert the metering valve assembly into the metering valve orien the governor housing 240. Using protection cap. Part No. 7144/4580, and ‘7284/186, ft a new ‘0 seal to the throttle shaft, Insert the thts shaft into the goveroor owing with the eccentric lug uppermost, and engage between the toy Surface ofthe contol deeve andthe stuff washes. DAL. Fit a new °O° seal in the shut-off shaft, using protection cap 7144/11. Fit the stop plate (if’not 3 brazed on type), the vernier plate and the throttle arm te the throttle shaft, using the line scribed on the edge ‘of the plate for accurate location, Ensure thatthe hate shafts ot adertery verted through to 242, Press the ‘shutoff shaft into the housing ensuring that the “flat” engages the lower face of the shutoff washer. This can be accomplished by pressing the metediig valve stem fully into the housing when fiting the shait NOTE: DO NOT fit the “shut-off” shaft so that the lug engages above the “shutoff” washer. 243, Fit the “shutoff lover to the shaft and ensure that the shaft has not been rotated during fitting. 244. Fit a new jointing gasket on the face of the pump casing 245, ost the eee vab into the hydrate head and seat the governor aginst the joint face on the pump casing. Check that the governor is focated correctly and secure in place by fitting and tightening the two securing 246. Fit new inspection cover gasket then fit and secure the inspection cover, 247, The identification label on the pump body indicates the correct rotation of the pump. To check thatthe abel has not een incoreety ned hold the pump with the drive end downwards, the’ letering Should then read the Fight way up. 248. Altes an overhaul both mechanical and hydrauically governed D.P.A. pumps should be subjected to the following tests. A separate test plan, ‘quoting the dispatch numbers of the range of pumps to which Ht may be applied, is published for each different ‘ode! manufactured. PRESSURE TESTING 249. AM! pumps mus! be pressure tested after assembly boi ‘before and aftes being mounted on the test ‘machine. This is accomplished as follows: 250, Drain all fuel from the pump and connect an sir Tine to the purnp inlet connection. Do ensure thal ait supply is clean and free from water JANUARY 1974D.P.A, FUEL PUMP ~ 14 2St. Seal off the Jow pressure outlet connection on the ppuinp and completely iramorse pump in a bath of lean fuel ofl, On pumps fitied with the proportional pressurizing valve, which must be staled off when presure testing, take case not to disturb the joint between the outer connection and body of the valve which is seafed with “Loctite”. 252. Raise the ait pressure in the pump to 20 I fs. in Leave pump immersed in cil for 10 minutes (no visual observations to be made dung this period) 30 te allow any trapped air in external pockets — such as the tavitios in the end plate ~ to escape. 253. Observe for leaks after pump hus been immersed for 10 minutes, if the pump is not leaking reduce the it pressure to 2 psi. for 30 seconds: if there is still no leak Increase the pressure to 20 psi, If Une pump is stil leak free after 30 seconds it can be passed a satisfactory. NOTE 1: Mechanical governor pump with single piece drive shaft and two oil seals. In addition to the show, the outer ofl seal must be tested as described in Service Bulletin 6234 (SIN 12158) using tool 7144-760. NOTE 2: Hydraulic governor pumps without drive shaft ‘al seal, It is necessary to stop the oil leaking past the rive shalt whilst pressure testing, Use sealing cup "7144-890 which fits over the pilot tube. NOTE 3: Mechanically govemed pumps without drive shaft ol seal is necessary (o slop the oil leaking past the dive shat whi pressure esting, Too! 714760 may be used but it will be necessary to blank off the threaded connection (12 x 1.5 mm.) ofthe tool. SEAL TESTING 254, Certain mechanically governed pumps. have @ Single-piece drive shalt with to inward facing lipped oi} seus, The gap in the ciraip between the seas, line up with a tel tale hole n the pump body. The inner sea, nearest to the governor sleeve, is checked by the normal pressure test, leakage being indicated atthe tell fale hole 255. A special tool 7144/760 is used for testing the Outer seal, and this consists of a flanged cylinder with thtee fig studs, 9 air pressure connection and a sealing gasket. The tool is attached to the pump mounting flange and a supply of filtered air applied £0 the connection. The DPA, pump and the tool are Innmersed in a bath of fet cil and ale pressure applied at 4 Ib.jin? (0.28 kg.fom.*) for 20 seconds. Bubbles at the telltale hole will normally indicete an oi seal failure but first ensure that these are not caused by a faulty gasket. JANUARY 1974 CALIBRATING (see appropriste CAV, Test Plan on 19-23). 38: A sypial test machine, adapted for we with DP.A. pumps is shown below incorporating the following features: A. Vacsom gauge. B Transfer pressure pipe. Leakage meanuring yas uné wocks, D Feed pipe. Return pipes F Fucl cock ‘Special drive adaptor. 257. A set of high pressure pipes each 34 inchos (865 ‘ilimetrs) in length, 6 milimetres in diameter and of 2 Inllimetre Bore which coupled the outlet connections on the pump to matched set of injectors (type BDN 128012) set at 175 atmospheres opening pressure. 256, A fuel system which ensures an adequate fuel Supply at constant pressure at the pump inlet. Bevery 3 pump inlet should be a minimum flow of 1,000 cm? per minute, 3f this figue is not obtained is permissable to use 2 Ibn.” pressure feed. 259, One pressure gauge and one vacuum gauge for iesting the Output and efficiency of the transfer pump, 260. The following precautions must be observed whet testing the DPA. fas! pumps. 261. Ensure that the test machine is set to run in the conesponding direction of rotation to. the. pump undergoing test, Revessl of the pump prevents entry of gland ere may eu rom ek of Sb. 3. Do not run the pump for tong perils at high speed with low fuel ouput. oo263. Do not run the pump for long periods with the Sehutoff control in the closed position. 264, The correct test machine adaptor plate must be used. A place with $0 mm, hole must never be used with 4 pump with 46 mm. spigot as seizure is probabie. 265, Standard sadiol high pressure connections must be fitted prior te testing. Iaformation is given in the test ata and explanatory notes. 266. Prime tho pump thoroughly before commencing {est aed at other times when indicated in the test plan. 267. To prime # pump, proceed as follows:- 268, Siacken the vent valves on the governor control ‘casing and the head locking serew. 269. Connect the fuel feed pipe to the pump inlet; Connect the back leakage pipe 270. Turn on the fuel supply to fitk dhe pump and run the pump at 100 spm. Wien fuel oil free from bubbles issues from the vent retighten the valve. D7}. Slacken the connections at the injector end of the high pressure pipes. 272, Run the pump st 100 zp. When the fuel oil free From bubbles. issues from all high pressure pipes, retighten all the connections. 273, Examine the pump after priming for ofl leaks at all jointing faces, connections and oil seals. Pumps raust be fie from jeaks both when running and when stationary. 274, Testing and adjastroent are effected by carrying out the senes of operations tabled in tine test plant in the specified onder. The purpose of each operation is indicated, and it will be noted that in addition to testing the overall efficiency of the pump, certzin other functions are checked independently PUMP OUTPUT 275. The fuel delivery i checked at one or more speeds ff rotation at full throttle by measuring the volume ppasing through each injector during 200 purmp eyeles, ‘The pump test dato quotes the average delivery, overall folesince and the maximum. petossable delivery variation (spread) between injectors. SHUT OFF CONTROL 276. This is checked by runing the pump at a specified speed (see test plan) with the ‘shut-ofP control closed. A aaximum fuel delivery is quoted. MAXIMUM FUEL SETTING 227, The maximum fuel delivery is checked at specified speed, with the throttle and the “shutoff” oatfols fully open. If the fuel debivery isnot within the specified limits, adjust as follows 278. Slacken the screws securing the inspection cover and drain the pump, 219. Remove the inspection covet. 280. Slacken the wo drive plate screws 281, Engage tool, Patt No. 774/875 with the slot in the periphery ofthe adjusting pat. 2Ea2: Adjuat the plate by lightly tapping the knurled end fof the took. The direetion in which the drive plate is turned to increase oF decrease fichng depends on the type of adjusting plates fited. FUEL PUMP — 35 283, Tighten the drive plave serews evenly to 18 lb/ft then slacken and setighten to a direct torque of 21 Ib. using the adaptor 7144/482, spanner 7144/5118 and a Sorque wrench. These torque figures are for use only, ‘when plunges up to 7.5 mm. diameter are used. 284, Replace and secure the inspection cover, refill the pump, vent as necessary and recheck the maximum fuel delivery, Repeat until the volumes are within the specified limits. NOTE: Adaptor 734/482 is used with the nomeranked fing spanner 7144/51} 07 SH1A. 285, The contre of the ring spanner must be 66 mm. ot 127 mm. from the contre of the adaptor. 286. The torque spanner and-ring spanner must be in line when tightening the serews, and care must be taken to ensore that the spanner does not contact the tide of the inspection aperture GOVERNOR TESTING 287. With the punsp running ata speed greater than half the waximam permissible speed of the engine to which i will be fitted, the maximum speed stop is adjusted unt a specified-fuel delivery is ebtsined, The volume of fuel specified is considerably Jess than the volume of fuel at the maximum fuel setting 288. The speed of rotation is then reduced and the fuel delivery should increase to 2 specified volume approximately equal fo the maximus fuel delivery. NOTE: Final governor setting must be carried out on the ‘engine, using a tachometer. "TRANSFER PUMP 289. Transfes pump vacuum is checked while running the pump at tow speed, with the twoway cock in the fuel feed pipe turned to the position whick cuts off the fuel supply and connects the pump inlet to the vacuum fuge, A geen depression must be attained in specified NOTE: The pump may eed to be recprimed after this test. 290. Transfer pressure is checked at one or more ‘specified speeds. A special alaptor Part No. 7044/892, is, screwed into the thread nonmally occupied by one of the head locking serews 10 enable a pipe to be fitted between the pump and the pressure gauge on the test machine. Transfer pressure can thus be fead directly from the gauge. JANUARY 1974D.P.A. FUEL PUMP ~ 16 SPEED ADVANCE DEVICE 291. The operation of this device is indicated on a special tool 7244/59 which consists of e gauge with 3 scale covering O~18° end a fecler pin 7244/70. To fit these tools, proceed as fllows:- 292, Remove the small screw ftom the piston spring cap 6 the advance device 293. Pass the threaded bush of the feeler pin assembly tinough the hole inthe tool bracket. 294, Insert the end of the plunger in the hole in the Spring cap and screw the bush into the spring cap bole, ‘This wil lamp the bracket between the spring exp and the shoulder on the threaded bush 295. Zoro the pauge by moving the scale relative to the pointer. 296, & specified advance must be obtained at a mumber OF diferent speeds of rotation, this checking the spoed at which the device becomes effective, and the speed st Which fall advance is obtained. 4297, Adjustment is made by incrasing or decreasing the thickness of shims Atted between the piston spring and the sprig cap. A single shim 05 millimetces in thickness is ted Guning manufacture and must not be removed. 298. On completion of these tests, the drive shaft screw of s mehaniealygovered pur tos be dackened snd Fahne dhe: tes co the feed tora vale of s/f. (3,3 kgm) where serew is 28,5 mem. lang, oF Pr tollt Got ket) where we 0 31.) me ong Ts js to prevent any risk of the serew slackening in service, JANUARY 1974 TIMING 299, ‘After testing, remove the pump from the test machine and drein by slackening the screws of the {inspection cover. Tighten the serews. Connect the st pipe 7144/2624 (Part Number 714/262) to the fi outlet specified on the test plan and {o the oullet diametrically opposite. Fit the relief valve 714/155 ‘Past Number 7144/262) to the stirrup pipe and connect, the complete tool through » high pressure pipe t0 a none eng nt ue of 30 atone applied bythe pup iowa the pump plongers apat ot the pump Seance Such movement brings the actuating rollers to a position. where they will strike the cam Jobes. When contact made, resistance to farther movement 1 encountered. ‘With the pump held in this position the timing ring 1 ‘moved until the seibed line on the ring aligned with a specified mark on the dive plate ‘301. The timing mark on the pump flange is made while ‘the pump is held in the same pesition. 302. Tool Number 7244/26 i set to the specified indexing figure and is then engaged with the splines on the pump drive shaft. The line is scribed by passing a seniber down the scribing guide-on the tool. NOTE: When timing mechanically governed pumps, i Imperive thatthe pumps own gull shat be fos to ‘compensate for any possible wear on the splines. DPA FUEL INJECTION PUMP (Refiting} 303. Rotate the engine flywheel in the normal direction of otation until its timing mark is aligned with the pointer in the flywheel housing timing aperture, The fiming marks on the flywheel are as follows:~ Uje~ Top dead centre. 216 ~ 26° BID. 220 ca. in, engines ~ Mechanical governor, 1/6 — 16° B.T.D.C. 330 cu, in. engines ~ Mechanical govemer. Sia "34° TDC. 330 ev, in, engines — Hydraulic governor, 1/2 ~ 12° B.T.DC. 330 cu. in, engines (turbocharged) Mechanical governor. 2/0 — 20° B.T.D.C, 330 cu. in. engines (turbocharged) Hydraulic eovernor. 30s, Fit he ionton bar indo, te sine om the timing ‘gear shaft coupling. care must be taken to line up wi ‘aster splines 305, Rotate the fuel pump shaft in the conect direction ‘until the master spline on the pump is parallel with the narrow edge of the torsion bar, cafe must be taken to ensure accurate alignment or ii will prove possible to noe te pep om te coupling, this wold dso means of accurately timing the engine. 506. Slide the fuel injection pump onto the splines, Aligning it with marks on the pump carrier and fit three ruts and washers which secure the pump to the cartier bracket, do not tighten at this time. 307. Remove the cover plate from the pump bi ‘nse that the timing mark on the pump rotor is aligned with the squared cnd of the ciclip. ive. ~ B— 330 eu. in. hydraulic governed pump. =D — 330.cu. in. mechanical governed pump. ~ G— 220 ca. in. mechanical governed pump.~~ 2:2000-907 (MECH. 330 eum 308. The engine must be held in the position detailed in passgraph 303, and the pump can be adjusted, i will be noted that the fixing studs enter into slots in the foel pump which sllows radial adjustment. The shaft will be hielé in @ fixed position by the engine and e radial mavenient of the fuel pump will enable the internal Luming marks to be aligned 309, Tighten the three pump securing wuts to a torque ff 14 fost 310. Fit the cover to the fuel pump and tighten to a torque of 7 Ibs/fl, seal the two screws with wire through the ‘wo holesin the screw heads, 31]. Mask the luel pump carver wi which will line up with the mark a scribed tine the fuel pump. DP.A. FUEL PUMP ~ 17 Should the 1uei pump carrier housing already have @ ‘ining snatk on, this cust be eradicated belore making a new mark 2200031 iim = 312, Refit the fuel injection pipes and fit the pipe lamps into. the original positigns to prevent vibrations. 313. Refit the coniral rods to the throttle arm. 314, Vent the entire fuel system. PRIMING AND VENTING THE FUEL SYSTEM 315, Whenever the fuel pipe lines ae disconnected, such ‘e when cleaning or renewing the filter elements, or if the fuel tank has boon allowed to run dry, 11 will be necessary to air vent the system belure aitempting to start the engine 316, Before priming and venting the system, ensure that the vent screws and surrounding areas ate’ thoroughly clean so that dirt or other foreign matter does not enter the system, Ensure also chat the glass howl of the pre-filter (if fitted) has been cleaned, and refilled with new fuel By operating the teed pump priming lever 317. Make provision for some spillage of fuel beneath engine and when an instruction calls for air free fuel, allow sufficient to bleed to achieve ths. 318, Ensure adequate Tuel is within the fuel tank and Stop cack is open, 318. Paragraps "320 co 328 refer to hydraulically ‘governed fuel pumps and paragraphs 326 to 330 reter 10 ‘mechanically governed fuel pumps. 320. Canty out the following while operating the priming. lever on the fuel feed pump, 321, Slacken the injection pump feed pipe banjo screw and allow fuel to flow until free of air, Tighten the banjo serew, 322. Slacken plug in unused outlet of the main Alter bleed and then tighten plug 323. SJacken the vent screw on the injector pump hydraulic head. Slacken the vent screw on the govemor housing, When fuet, free from air, flows from the ‘wo vents, list Ughten the hydcaulic head vent screw, then the gowermor vent sciew, 324, Slacken the banjo screw on top of the main filter, ‘eed, then tighter screw. This operation should remove the alr from the dsive housing, the leak back pipe and the filter JANUARY 1974DP.A, FUEL PUMP — 18 325, Slucken any two high pressure injector pipe top ‘unions, crank the engine (which may run oa the other four ender), hen the won son a ue fe from air begins to flow. 326, Slacken the hexagonal headed bled (9/16in. AF.) ‘on fuel filter head (Reference A), operate priming lever, ‘on fuel lift pump (Reference €), at the same. time, ensure any emetgency stop fuel shutoff is deactivated, fand continue to operate priming lever until air free fuel flows from bleed, at which time, bleed should be se-tightened. 327, Siacken the hexagonal headed bied screw (5/16 in, AF) (Reference B) and opesate priming lever (Reference C) until ar free fuel is expelled from bleed serew. Leave % tuum open, crank for 5 seconds, then tighten, 328. Slacken the banjo pipe attachment (Reference E) scivate priming lever until air free fuel is expelled and Fea slightly slack at this point. NOTE: Omission of this operation will materially imerease cranking time. 329, Slacken one or more injector pipes at the injector end. and the fuel pump at No. 4 pressurising valve (Relesence D). JANUARY 1974 330. With the slackened pipes set stop lever to run Position, deactivate any automatic shutdown system and crank engine until air free fuel is expelled from the slackened pipes. Tighten all pipes to No. 4 injector and its essociated pressurising valve (Reference D), and attempt to start engine by cranking, and when engine commences to yun, retighien pressurising valve connection at (D) and No. 4 injector line at injector end. Operate speeder lever to required engine speed and check that no leaks exist in the fuel system. Stop engine. Wipe dean any spilt fuel on engine or equipment. IDLING ADJUSTMENT 331, The engine idling speed is contralied by 9 hhexagorrhead stop screw which contacts the throttle contro! lever on the governor housing. 332. With the engine at normal operating temperature, check the idling speed with « tachometer. If necessary. agjust the idling screw so that the engine idles at the specified speed 333. On vehicles equipped with an idling control knob ‘on the instrument panel, ensure that the knob is screwed right in-and that 2 small clearance exists between the nipple on the contol wie an the thot conte es, before adjusting the idling speed. MAXIMUM SPEED ADJUSTMENT 334, The engine maximum speed is set by # hexagon headed stop screw on the governor housing, This screw is encased by a cover which I sealed agains! uneuthonsed interference. 335, With the engine running at normal operating temperature. move the throttle control lever on the governor housing by hand to the maximum speed Position and check the engine speed with a tachometer. If the speed is not as specified, break the seal, remove the cover and adjust the screw. It is important that the specified maximum speed is not exceeded, therefore, this adjustment must not be attempted ‘without tachometer. Install and seak the cover.DPA. TEST DATA PLANS. Basic Punap Specifications 220 cu. in, engine with mechanically governed DPA fuel pump. “Types 3249380 to 3249760. Hydraulic head und transfer pump tines modified w provide for sel venting, Cambox pressurising valve ‘Automatte speed advance device. lke tation ooking on ding ea ated. dive with Testing shalt (ypes SEASS50 3349769 enly) Governor link length 53.5 mm. nominal 4 1.0 ram. (Types 3249380 _ 3249429 only). Governor tink length $3.5 mm, nominal £ 0.5 ap 1.0 mm. (Types 3248880 248589 only) Govetnor tink length 55.0: nm nominal 2 0 fn. (Types 8249760 3289769} Roller to vier dimension 49.9 ram. Plauger diameter 8.0 mre, (types 3269380 to 3249429) Planger diameter 9.0 min. (types 3269850 10 3249769), 330 cu. tn. engines with hydraulically governed DPA fuel pump. ‘Types 3266540 to 3266739. Automatic speed advanes device Transles pressure adjuster, Anti-bucklash torsion bar. ‘Clockwise ratation (looking on drive end), Roller to calter dimension 49.8 min. (49.7 com, ‘om types 3296730 to 3266739 only) Plunger diamewes 9.0 min 380 cu. in. engines with mechanteally governed DPA Huet punip. ‘Types 226870 1 326KHOD Uprated drive with fvatang shaft Automatic start setual with speed advanee devios Clockwise rozation (ooking on drive end), Governor tink length 33.0 nim, ominal 4 1.0 ‘mm, Roller to Roller dimension 4927 mm, Diamoter of Phuagers 9.0 nn DPA. FUEL PUMP — 19 Before Commencing Tests Fit sutoadvance measuring device and set the scale to 210. ‘Screw out antistall device (where fitted). ‘On hydraulically governed pumps, screw back transfer pressure adjuster in end plate 16 the minimum extent and then screw in 1% turns minimum. ‘Shimming of Automatic Speed Advance Device (3) AOS mm. shim is fitted to the piston spring cap on. assembly. This must not be removed. (2) The amount of additional shimming that may be ‘added (o meet test tequisements may vary from 0 19 3.0 nm, {GY On nydraulicaly governed pumps, the throttle lever ‘must point dewowards, Fuel incteate should be aftained by 2 clockwise movement of the lever when looking iveesly upon i, The ling setting screw & therefore the fone nearest 1 the ed plate and the maximum speed Selting serow isthe one nearest the pimp ange. NOTE: The governor setting speed quoted is for test purposes only, The goveruor maximum speed. screw ‘must be finaly set on the engine. JANUARY 1974DP.A. FUEL PUMP 20 3249380 3249390, 3249400 3249420 Test =s249389_| ~ 3249399 _| —szag4o9 | — 3249429 No._| Description RPM, Requitements Timing TOMER TOO Mx. TOU Has. 100 as “Fae eaivery from aT injectow ‘Rote tithe Tp ash 20 ine GOS tia) AE 2_|_ transfer pump vacuum 100 100 100, 100 Max time allowed 20 seconds 3 | “Transfer pressure 100, 100 100 100. 11 Ib/in? (0.8 kgem*) minirwum 4 | “Transfer pressure 3007 $00 800 800 65,0 SOT /in™ (4.6 to 5.6 kgjem?) 3] Cambox pressure 300 800. 800 800 4 fo 10 bin? (0.3 to 0.7 kglem®) 6 {Advance position 800 800 800 800 BE — FHF (Shim as requited) [FT Aavanee position TIO 1100 TIO 1100 3a [TE [Bick Teakawe 300" 300 300 300 $15 100 ce for 100 stroke time eyele Delivery tolerance 40 -0.2 ce 9 | Max, fuel delivery Set to code showa on pump Name Pate Spread between fines not to exceed 1.2 ce ‘Average delivery to be not less han 10_|_ Max. fuel delivery check 100 100« 100" 1007 average at (9) minus 2.5 ot Cucoft operation 11_| Shutoff lever closed 200 200 200 200 Average delivery not to exceed 0.8 ce Taroitle operation 12_| Throttle ever closed 200 200 200 200 ‘Average delivery not to exceed 1.9 c& 13] Fos delivery check 50 7300 50 1200 ‘Recon average delivery Set thioitle by maximum speed adjustment sew to 14 | Governor setting 650 1500 9s¢ 1270 sive maximum average delivery of 2.0 cc, No line toexceed 3:0 ce ‘With theotte set a8 (1a) averbge delivery to 15_| Fuel delivery check 00 1300 900 1200 be not less than average at (13} minus 0.4 e& ‘Spring position code = T 7 T Ts] Governor setting ‘AC Walt speed Hated gn Name Mate et Woe 10 phe average Gener TOS Tock stop serew [Timing Using outlet “U" (30 atin Pressuie) set Uiming sig to leer G" on Dave Plate ‘With the pump in this postion set indexing too} to 113° and setibe line on the housing flange 7] hee 50 seconds sass dratiig time and allow Fuel to settle for 15 soconds before taking reading JANUARY 1974D.P.A. FUEL PUMP 21 ‘sa9sso | 3249560 | 3249570 | a2agsz0 | 3240760 Test = 329559 | ~ 324969 | — 3249579 | 32a0580_| — 3240769 No._| Description RPM, Requizemnents Fost delivecy fiom al Tajectar 1 | Pong 160 100 109 100 200 and contsl cover vent ofie 2 “Transfer pressure 100 100, 100 100 100) 11 Ye/in? (038 kgfem*) minimum, 3] Cambox pressure 360 e0F 300 300. B07 66010 ofr (0.4 100.7 kglem) To Ravan setting 0 600 60 60 800 2H" to 3H Gham as required) Fal advance postion 30 300. 300 500 350 a | Transfer pressure 300 OTT 300 300 850TH | 60 10 80 lin HDL SK glen) Note ime to reach 30 in SO8inm} He 7 __| Transfer pomp vacuum 100 109 409 100 109 Max. time allowed 20 seconds Bf ack tenage. 60 2, 60 oO 600 $6100 ce for 160 stoke yas tine Delivery tolerance 00.2 cc. Spread 9 _| Max, fuel detivery Set to code shown on pump Name Plate™ between lines not to exceed 1.2 ce ‘Average delivery To be fot Tes that 10_| Max. fuel delivery eck 100 * 300 1007 oo" 100+ average at (9) minus 2.0 ce Cuioff operation 11_| Shutoff tever clowed 200 200 200 200, 200 Average delivery not to exceed 08 o& Throtile operation Sorew back aniistal Uevie and lack 12_| Throtle lever closed 200 200 200 200 200 “Average delivery not to exceed 1,0 62 13 | Foe deliver, check 900 1750] 500 1770 Tio TBE ‘Recoid average delivery Set throttle By maximum spend aljstmen Tew 14 | Govemor setting 90/810 | 640 1450 1170 900 to give max average delivery of 2.0 oe. No Jing to exceed 2.5 ce. Lock stop screw ‘With throtle st ax at (4) average 15 | Fel dativery chook 900/850 | 600 i270 1100 850 delivery to be not less than average et (13) _ sinus 0.4 ce ‘Spring position eode 3 TF Tea 4 + 7 To] Governor setting “Athall speed stated on Nase Pate ser thesitle to pve WeTage UeeNy TZU Tock stop srew Tis Tigo O° C0 rao ag TT "on DARE PE ‘With pamp in this position set indexing tool to 113° and seibe line on Housing Flange + | Uae 30 seconde ais Grassi tie and alow foe t sete for 15 seconds before taking vadiig FP Sw TO tbfie® 03510 07 kyle") __ FP} te 1 ibfia® (04 10 08 kelon) _ FET 1S 10 65 Boj” G2 10.4. glen”) FHT 3B to 78 bjwr (4.1 10 5.5 keer”) JANUARY 1974DPA. FUEL PUMP 22 3268780 3268790 3268800 Test 3268789 | ~ 3208799 | - 3268809 No, _|_ Description RFI. Requicements 1 _[ Priming TOO Max. 100 Max. TOO Max. Fuel delivery from all injectors "Note time to teach 16 in (406 min) Hig 2_| Trensfer pump vacuum too 400 100 Max time alowed 60 seconds 3_] Transfer pressure 100) 100 100, 11 Dbfin? (0 kgfers”) minimum F]Aavance position 20 200. 00 FE 10 5K 5 Transfer pressure 7 700 700 48 10 62 Ib/in” G4 to 4a Kale?) [Advance postion: 7 706. 760 Baio BE (TT aaeanee postion TOU. TOOU. 1000. So OF | Transfer pressure 000. 1000 1606 38 to 72 ibfin® (4) to 5.1 Kafe) 9] Bick teakage 800 800 300 5 to 50 ce for 100 stroke time cycle Delivery tolerance +0 -02 ce to] Max fuel delivery Sot to code shown on pump Namie Plate® ‘Spread between lines not ta exceed 1.2 ce ‘Average delivery to BEROT Es Man b_| Max fuel delivery check 100" 100¢ 100 average at (10) mimus 1.5 ce Cut-off operation 12_| Shutoff ever closed 200 200. 200 Average delivery not to exezed 1.0 c¢ ‘Throttle operation 13_| Throttle lever closed 200 200 200 Average delivery not to exceed 08 ce 14] Fuel delivery check BU SOOPTO | TIOOTSOLTOOO | TasS AOI IO ‘Recond average delivery Set throttle by Twax. speed adjustment 15. | Governor setting ‘980)5601760 | 1180)820}1100 | 1 140}1120/1460 setew to give maximom average delivery ‘9f 20 ce, No ine to exceed 3.0 ce With throttle set as at (15) average delivery 16 _ | Fuel detives 930|sooi7i0 _| 11¢0}7s0;1000 | 1900/1000): 300 to be not less than average at (14) sninus 0.4 ce 25. Spring position code soar bo | afr} ifadala 17} Governor siting Chall speed stated on Name Plate set throws 10 ve average Celery of TOT Lock stop screw Te) Ting Using outlet "¥" GO atin, presnre) st ting Ang to Tevter "on Dave Plate. With pump this position set indexing tool to 331° and scribe line on Housing Flange, Uae SO seconds Past Weaning ie and allow Tusl to weite Tor 15 seconds before taking reading JANUARY 19742 aa Tae ae 5 E] mw PSese | -musw | Sane | "ses : ELA | nose a “| tenes 5 ghee Ose whe em“ rare SF : - Taras eae GHG 5 eT aL muutemmemcnm | vo | age | ao | | teas ne : Seabee i Ss geo 3 eS ame Pan rar oes rose Sanita pa pan meraronuiary pie pean Gin crane ep aA «| Raters on | ante vows | Steegnepeaue stato - il Sent aes ha aad _ 2 | Gata tilyern | 1 8 700 10 Fe OM 03 og MT [97] arene ran a a i (ase ee as ite Deity tin Oe 1a | a ae stip at own put ee et Spearmint send rc = se - ‘stage alive io be ois than ahora 11 ats Fuad tick | 1008 oor fa, 100 CIO) miner 2648, 0cc on 32730. 326729), aes | tlertiyea | 200 | amet x | pe en ttc O8 ise oka Se | wa | mantra | 20 - - . fsdyoike emcee Sense acne - aR ——— roar ta a sts + Sted t abaeT a oe want) usar [ost | suo | gemminw nengatey ote : oe Siena he Sixers TRC wT 1s | patton dea | roam | ron | un | noo | ean anageasaimed sc Eee Sr st | Bele ope | comic | aun} ome | me | Seong pemece nae me “iS fects” ett Watson a RATT a en Seueie ‘coreeninuming Sarthe Ne Le Sirona ac Locman bre I TG ST ROTTS ae - pian ng ke i Pe, | a TT an pane pos CE ARTS BETIS HET SETAE DTA False preorder tee ant tom oveg or Ta ian fae Tae Sok Kindecgewse | Cemating | Casas serpae | Cenreten Soe se pomp pi | ne En sere nan ee ee rojaconjan | ssmiae Gai) | en “megaane [pani aSuaiet [ae §iSeeion ——] eee isert 9@— sama ———F | figuvemm | reerissscey ant iiatinaet —— bearer | ‘tai ——_fomiar orig) ‘owanaeo ———[pesiart sie agar 2 Zn oe Fant ang i 4 [ie 3a excep lt sig mew wom (eo et ar 1 eo eTre ay rending instar bdwsaegert SIS hike To eger?)— = rapper [sited fs preter pre ORS" TR ugar Sere yak eel site iw fo pe am sep cave ATTIC ROWS WATTS2.20008 FUEL INJECTION PUMP INLINE TYPE INLINE TYPE FUEL INJECHION PUMP (Description) LThe Inline type of fuel injection pump used on 220 cu. in, engines is manufsetured by Simms (a), while that used On 330 cu, in engines is manufactured by C.A.V. ©). 2. Both types of pump are of the cam operated sprin feturn plunger design with a separate pumping element for each cylinder ‘of the engine. The elements are arranged in line and operated vertically by the camshaft and roller tappet arrangement within the pump housing. 3. The injection pomp has am eccentric on the camshall 40 operate the fuel lift pump, 4_ A pneumatic or mechanical type of governor can be fitted, the choice being dependent on the application for which the engine will be used. Operation of C.A.V. luvtine Fuel Pump 5. Pua! is supplied trom the fuel eft pump 40 a fuel od) Biter, after which itenters the fuel injection pump body. and then the pump element, whece the fet is pressurised and fed vis pipes to the injectors. 6 The stroke of each element plunger is constant and Aetermined by the pump camshsft; the effective Pumping movement however, depends on the relationship of the plunger to the barrel ports, 2200086 INLINE FUEL PUMP ~ 1 7.When the plunger is at the bottom of its stroke (see “a 2-20004-6), uel under pressure in the pump gallery flows trough the two pore to fl he rtenie ofthe are 8, As the plunger moves upwards, some of this fue is forced out of the ports, until the plunger reaches the position shown at ‘b”(22000A-6) when both ports are covered, 9. At this point further upward movement of the plunger increases the pressure on the fuel and causes the Aelivery valve 10 be opened, and the fuel enters the pipe connected to the injector 10. The pipe ond drilings in the injector are kept constantly’ fled, by previous operations of the plunge and detivesy valve, and the extra fuel forced in raises the pressure io the pipe until it iS sufficient to ft the Injector valve off its seal, This enables the fuel to be discharged as an atomised spray from the holes in the injector nozzle and penetrate the compressed sir charge in the combustion chamber. 11, The fuel discharge continues util the edge of the helical plunger recess uncovers the spill port (see ‘s* 2.20004.6) when the Fuel in the barrel fiows down the ‘ertical slot in the plunger and retumns through the spill port 10 the fuct gallery, 12, The resulting drop of pressune it the barrel allows the delivery valve to close (See 2.200049). In. closing the delivery valve draws a small quantity of fuel out of the pipe connected to the injector. This reduces the esdual pressure in the pipe and enables the injector valve t0 Snap quickly on its seat, thus preventing dabble into the combustion chamber. 13. The effective stroke of the plunger is varied by the movement of the pump control rod, which Simultanccusty rotates all the plungers within theie banels, 0 that a wide or narcow section between the top ‘of the plunger end the hefcal groove isin alignment with the spill port. Commencement of fuel delivery is therefore constant, but the end of the delivesy stroke ‘ill depend on the load and speed at which the engine is ‘operating, At ‘c),°8” and *e' (2.2000A-6) a plunger is shown in the position for fll load, haf toad and idling speeds respectively, whilst at °C the plunger is in the pasition required te stop the engine. 14, To enable the corteet intervals between the commencement uf delivery of fuel from the phungers to bbe maintained, the plungets can be cased or lowered by the adjustable tappets. Adjustment of the plungers 10 JANUARY 1974INLINE FUEL PUMP — 2 ‘ensure an equal detivery of fuel for a glven control rod position is effected by slackening the quadrant clamp serew and turning the plunger within the bamrel. These ‘operations, known as phasing and calibrating, eail for a high degree of skill by specially trained the use of specialised equipment, a otherwise be atternpted. sonnel and should not pan 22n00A.t4 Operation of Simms Inline Foel Pump 13, The Simms fuel injection purnp operates on the same principle a5 the C.A.V, pump but there are some exceptions. Fuel delivery is controlled inthe conventional manner by. the helix on the element plunger, but instead of having a vertical slot on its periphery the plunger is drilled along its axis, Rotation Of the phungess (0 vary the amount of fuel delivered is effected by forks clamped to the control rod and engaging ams projecting from the lower ends of the plunger. 16. Calibration is effected by slackening the camping screw in the control fork and moving the latter along the control Tod. Adjustment of the tappets for phasing the pump is carded out by exchanging spacers of greded {ilckness. These spacers a secured in the top of th tappet by a circlip. Clearance between the botiom: ofthe pitas andthe! eppet is controled by the use of ottom spring plates of graded thickness. Inline Fuel Injection Pump (Removal) 17. Thoroughly clean the area of engine which surcounds the fuel injection pump, this wll prevent the ingress of dirt into the fuel system. 18, Slacken the pinch bolt on the fuel pump coupling, access to this bolt 1 obtained through the coupling housing, it may be found necessary to rotate the engine before ¢ spanner can be fitted. JANUARY 1974 19, Remove all fuel pipes to the fuel infection pump and Jift pomp. Care should be taken to ensure that no dirt ‘enters the pump when the pipes are disconnected. Also remove the throttle linkage or pneumatic pipes as appropriate, 20. The two vertical bolts located underneath the fel injection pump support at the governor end must next bbe removed. Do not take the brackst from the engine oF the fuel injection pump wil be left unsupported. 21. Remove the four bolts which secure the fuel injection pump to the coupling housing and withdraw: ‘the fuel pump trom the engine. It may prove necessary to lever the coupling from the timing gear shaft, this will avoid any undue strain on the coupling. 22. Remove the key from the timing gear shaft Inline Fuel Injection Pump (inspection & Overhaul) 23, Dismanting, sembly testing and adjostment of the pump are operations which demand the services of specially trained personnel and the use of certain special fools and test apparatus. 24. Fuel injection equipment is manufactured to exiremely fine tolerances and for this reason the components must be Kept perfectly dean and not contaminated with dirt 25. Ideally, the bench top should have a surface of either linoleum or zinc piate, if these are uncbiainable a surface which can be casly cleaned and then covered with greaseproof paper. 26, It is important that all components pertaining to fesch element should be kept together in # separate container, filled with clean test off to facilitate correct teassembly, ‘These components include barrel and plunger, phunger spring, lower spring disc, delivery valve ‘and gute, delivery valve holder and tappet etc. 27, Under no circumstances should any component come into contact with files or scrapers, the use of siding pase is also to be avoided. ‘CAN. Inline Fue Injection 28. A calibration check should Aismantling, se page 8. 29. Annotations refer to 2.20004-29. '¢ carried out prior to1 Dalry vale holder 17 Oil sest 2 Delivery valve spring pep $B Comat, 3 Delivery vetee sping 1oKsy 4 Delivery valve 2OOit 3 sien § Dativery valve eet an join washer {Barrel hocking Stew and user 21 Carsnatt Goong 22 Cominatt nm “7 Plonger 22 Cove pate Plunger ares 2a Bran plug and waster 5 Upper spring plate 23Gonteal sleeve 19 Plunger sorine 26 Conuel roa 1) Loner spring plete 32 Sapper assembly 13 Tapoet adjusting stew ans locknut 14 Puro housing 13 Base sealing cu 16 Ena plate 2 Contra quadrant 228 Inspection cover 28 Guide block bolt ‘50 Ta waster 3) Guide block 30, Remove drain plug and washer (24) and drain the iubricating ol! from the Tower chamber of the purp housing (14). Ble Remove ‘the inspection cover (28) trom the pump using 32, Remove the feed pump or cover plate (23) and the excess fel device if fitted. 33, Mount the pump on the base plate, toot part number 7OM-6A and secure in a bench vice with the pamp hhousing vertical. 34. Tum the camshaft (18) and when each tappet ‘assembly (12) reaches maximum height insert a tappet Iter, tool part number 7144-122, between the lower sping plate (11)and he loot on he tppet sey AS 35, Wang the, counlig sraner, tot part member 11, to hold he pump halesoupling, esc the camshaft not with aboxspansees 36. Remove. the halfcoupling with the coupling exact fol pe nue 7B and remove key INLINE FUEL PUMP - 3 37. From the coupling end of the carwhaft remove the four bolts, spring washers and end plate (16). NOTE: The position of the small notch on the end of ‘the camshaft; this must be located at the same end of the pump on assembly. Hf the camshaft assembly is at variance with the nameplate symbol its application must bbe checked with the test data sheet 38. Remove governor, this is detailed on page 11 for ‘mechanical or page 14 Yor pneumatic governors 39. Withdraw the carishaft (18) complete with beatings (21) from the pump housing. 40. Remove the camshaft bearings (21) ond the inner tracks of the bearings from the camsheft using the extractor tool part number 71444364. Note end position and thickness when removing camshaft shims 2). ph xenon 41, Remove the outer tracks of the bearings from both end plaies using the collet type extrector, tool part ber 7145368 an then remo theo a ins 0) JANUARY 1974INLINE FUBL PUMP — 4 42, Turn the pump to a horizontal position. inspection Window uppermost wid securely lock the hase plate in the bench ce. 43, Using tool part oumber 704.815 tap the base sealing eups (15) into the cambox ad remove 44. Holding the tappet assembly (12) with the tappet holder, tool part number 7144-7434 exert a unward [pressure and withdraw tappet liter and then the tappet assembly 45. With tho element plunges forceps. tool pact number 7044-569, withdeaw the plunger (7) and lower spring plate (11) throowh the base sealing holes 46, Immerse the plunges (7) m a bath of clean tes cil to protect the suctaces frors damage. Place euch plunger it Sequence for assembly to its mated bartel. 47. Withdeaw de plunger spring (10) an upper spring plate (9), 48, Keep the control quadrant (22) locked to the control sleeve (25) and do not distusb the setting. 49, Ailer disengaging the control quadrant snd sleeve assembly from the contcol rod (26) slide the assembly From the plunger harel (3) 50. During complete dismantling it is conenient to camy out sequence 44 for cach cylinder in tun, followed by 45, 46, 47, 48 and 49 us a similar manner. keeping the components of each element assembly together ina small clear eomtaines SI" Tum the purnp hosing t0 the vertical position and securely lock in the bench vice 52, Remove guide hock bolt (29), tab washer (30) and Buide block (31), and Side the Contaob ved (26) from the pump housing. 53, Catelly unseiew the delivery valve holder (4) oF Gach element srom te pump Hourng an witha te jeivery valve spring (3), delivery salve spring pe and delivery valve (4), mire JANUARY 1974 2.20008-53 54, Remove delivery valve seat and joint washer (5) using the delivery salve extractor, toot part number 7144.903¢ $5 Asemble each delivery valve (4) 10 its mated Gelivery valye seat (5) and immesse i clean test oll to prevent dama 6, Unsere id vee bose and washer 2.20000.56 57. Pat plugs but (8) upwards and withdraw from lement bore is undem pump housing. Ensire the al by this operation,58, Assemble each plunger to its meted barrel and amen in dea i acmamted hwo 59. When pump is completely dismantled thorous Glean al components, Bo not ise sbraie or ty cleaning materials. 60. The pump components should be inspected for Scoring, pitting, corrosion and excesive wear. Discard defective parts 61. The following components should be carefully inspected for signs of overheating and must be changed if this has taken place the camshalt, camsheft bearings, outer and inner tracks, tappet roles and bearings 62. At each overhaul fit ew of seas, gaskets and sealing ‘washers. 63. The barrel seats in the pump housing must be Inspected for pitting oF other sigis of damage. IF the surfaces are damaged o: scored they should be lightly skimmed ith the lront bane ea ute, fo! part number 7144202. The minimum of material should be removed during this operation and in no steumstances ‘must this exceed 0.25 mm. total depth, 64, Check the controt quadrant and control rod for excessive wear on the teeth which gives the appearance of knife edging. New 22000864 © WORN-KNIFE EDGE 65. Contsol rod bushes must be checked for weer and ovality by fitting a new control rod. Comparison of the sliding fts will show the state of the bushes. 66. IF necessary worn bushes can be extracted after the locking rings have been removed with the bush locking key, tool part number 7044-658 and by using the control rod bush extractor, tool past number 7144-632, INLINE FUEL PUMP ~ 5 67. New control cod bushes and locking rings ean be ssvembled and secured using tools part numbers 7144-632, and 7044-658, and" must then be resmed indine. The freedom of the control rod depends en the accurate, alignment of the bushes. The final fit must permit the control rod to slide easily, but not loosely in the bushes. (68. A. special Long shanked reamer, tool part number “ou S6) fs wed in conanesion with ewo tamer Rules, fool part numbers 7044-562 and 7044-562A. These auides differ only in external diameter, 7084-5624 being the smaller, is a snug fit in the new bush before rearing and 7044-562 a snug fit after reaming. 69, Reamer guide 71044-5624 is fitted into one control tod bush, The shank of the reamer is then passed from the outside through the further bush, the pump housing and the core of the guide. Seeuse a wrench to the shank of the reamer and teem by carefully @rawingand-sotating in direction of the cutting edges through the bush, 10. This operation is epeated at the opposite end using the larger reamer guide 7044-562 fitfed in the newly seanied bush. On completion remove all swas? from the patnp housing. 71, When checking the elements, ell plungess should normally side down the barsels under their own weight. 72, ‘Thoroughly clean all components and prior to sssembly drain and dip in dean test oll, Do'not use gotton waste oF doth wipers of any kind 73. Mount the pump housing on the baseplate, toot part summer 7044-64, 74, Secure ina bench vice with the pump housing vertical, 75, Bit the plunger berrel (8) into its appropriate pump housing bore with the vertical groove in alignment with {he barrel locking screw hole. 76. Assemble borrel locking screw and washer (6) ensuring they engage in the plunger bartel grooves before tightening, When lightened it should still be possible to rove the plunger barrels (8) vertically until the locking screws contact the end of the groove 77. Fit a new joint washer to the delivery valve and seat (3), seating exch assembly on the upper face of the plunger barrel (8) by lightly tapping it into position using a dummy delivery valve holder and mallet. JANUARY 1974INLINE FUEL PUMP — 6 78, Care must be taken to ensure that the delivery vale and seat are located squstely, 79. A duramy delivery valve holder is made by machining the lower thread off a spare delivery valve holder tif the holder is an easy sliding 11 into the pump housing bore, 80. Assemble the delivery valve spring peg (2) and elivery valve spring (3) into each delivery valve holder {() and screw into position by hend. Bi. Using 6 torque spanner tighten all the delivery valve holders to S4-Nm (5.5 kgm. or 40 tb.ft.) when the pump is cold. 82, Tur the pump to a horizoniat postion, inspection window uppermost, 83. Dip each plonger (7) in clean test oil and using the element plunger forceps, tool part number 7044:569, carefully insert the plungers into their mating plunge? barrels (8) gently rotating each one several times. Rotation must he free, without binding 84, Put 2 picce of plastic o7 other suitable moteriak over the tappet bores 10 prevent the plungers from falling out 85. At this stage of the assembly, the pressure test for the clement. barrel seat leakage’ and! pump housing porosity can be carried out Barrel Seat Leakage & Pump Housing Porosity Test 86. Connect an air line to the fuel feed inlet 87, Blank off any openings in the fel galery which allow air to escape into the atmosphere. ‘88, Tum on the air supply, Make sure the pressure does not exceed 207 kNim? (2.1 kgiem? or 30 1b/in*). 89. Immerse, the pump in a both of clean test olf and examine the housing and barrel seat for leakage ‘90. Air bubbles will indicate the position of fuel leakage points and these must be cured belore proceeding further with the assembly. slight leak past the plunger can be ignored. NOTE: When it is necessary fo skim the barrel seats, remove ouly a light skim of material which must not ‘exceed 0.25 mm, using the element barrel seat cutter, tool part umber 7144-202. (Fig. 2.20004-63). 91. If an air supply is not aveilable carry out the following procedure using aC.A.V. nozzle setting oust, 92. Change the setting outhit standard, gauge for a 1379 Nim? (14.1 kpfem® oF O to 200 Tb/in®) geuge. 93. Wipe off all oll rom the housing and connect the nouale setting outfit to the pump fuel inlet using @ Stitable adaptor. Blank off sll venis subsequent to JE the te 94, Pump the nazz lpsting ovtfit up to & pressure of 207 ENP? (2.1 glem® oF SO in?) 85. Examine the housing for signs of oll fakege and repair as necessary 56, When the leakage cet is satisfactory completed remove the pieces of plastic covering the lappet bores and withdcaw all plungers Keeping them in ther correct sequence. ‘97. Mount the pump horizontally in the bench vice inspection window uppermast. 98. Slide the control rod (26) into the contsol sod ‘bushes and assemble the guide block (31) tab washer (30), guide block bott (29) nd tighten JANUARY 1974. 99. Centeaise the control rod (26) lengthvways in the pamp housing by aligning the dell indentations ‘equidistant at each end with the pump housing 100. If the control quandcants (27) have been removed fiom the control sleeves (25), they should be assembled, taking care that the sertbed lines on the sleeve and quadrant are aligned before the clamping serew is figitened. The quadrant lug should be in ine with the adjusting holes on the quadrant sleeve. New quadrants wil not be seribed and the damping sre heads should always be pesitioned towards the governor. 101. Molding the quadrant lugs vertical, sie the control sleeve astembly onto the plunger bartel (8) engaging He teeth of the quadrant and control sod so. that the quadrant i in mid travel postion HOD. Check that the control rod has complete freedom ‘of movernent after fiting each sleeve. 103, Side tke upper spring plate (9) onto the top of the canirol eeve (28) and seat auist the shoulder in the pomp housing 104. Assemble whe plunger springs (10) in_ position gains the upper spring ples, 10S, Dip ip clean test oll snd asemble the lower spring plates (11) und. phingers (7) to their mated bares, through the pomp housing base sealing holes, using tie element plunger forceps, too! park number 7044-568,106. Using the tappet bolder, tool part number 7144-7434, align the tappet assembly (12) in a horizontal position with the tappet bore in the pump housing. 107, Engage the hexagon ofthe head clearance adjusting screw on the tappet assembly (12) with the hexagon in the bore of the lower spring plat (11). 108, Correctly assembled, the plunger helix will be at tho front facing the inspection window. 169. Press. the tappet assembly upwards against the plunger spring unt i is posible to insert tappet lifter, {ool part number 7144-122, under the lower spring plate (11), Withdraw the tappet Bolder. NOTE: Operations 101 to 107 ste applied to each element, 110, Assemble new oil seals (17) to both end plates. Replace the off seal shims (20) and press in the outer ‘racks of the camshaft bearings. LIL. Assemble the camshaft end float adjustment shims {@2) of equal thickness to each end of the camshaft (18). 112, Fit the bearing inner tracks to the camishaft (18). 103, Fre the camshaft bearings (21) onto the eating inner tracks. 314. Assemble and seeuse the governor housing or one «end plate to the pump housing. 11S. With reference’ to the test date sheet locate the small notch on the camshaft at the correct end of the pemy N16" Fit protection cap, toot part number 1044-684 and pass the camshaft through the pump housing end plate ‘without damaging the oll sea. H17. Remove the protection cap and fit it 10 the ‘opposite end of the camshaft, INLINE FUEL PUMP 7 118. Slide remaining end camshaft without damaging Spring washecs and bolts, 119. Remove the protection cap from the camshaft. 120. Check the carnshaft end float using the camshaft end play gauge, tool part number 7044-634. late over the protected oil seal and secure with, 121, The camshaft end play gauge consists of 2 steot barrel and thimble, The bartel is graduated from 1 t0 10 ‘mu, The thimible is graduated in hundredths of a mm. ation 122, Tum the thimble to zero om the barrel and screw the gauge securely onto the end of the camshaft. 123, Strike the end of the gauge squarely and firmly with @ hide mallet to position the camshaft at the further end ofits movement. 124. Turn the thimble til it lightly touches the end plate snd take a reading. 125. Stike the Opposite end of the camshaft squarely and firmly with @hide mallet, 126. Tusn the thimble clockwise until it lightly touches thc end plate and take a second reading, 127. The difference between the two readings gives the dimension of the camshatt end float. 128. The end float must be within 0.05 to 0.15 mm, and is controlled by the thickness of the shims between the inner bearing tracks and the shoulders on the camshaft, Make sure the full end float of the camshatt is measured, 129. If shimming is required, it must be arranged equally teach end of the camshaft 130. When the end float i within the specified limits ox the camsbaft several times by hand to ensure i is ree. 131. With the key (19) securely fitted into the slot in the camihall (18), semble the haltcoupling and secure with spring washer and out, using the coupling spamner, tool part number 7044-11 snd box spanner. 132. Compete the assembly of the gavemor if Atte. 133, Withdraw (he teppet iifters after rotating the camshaft till each cam is top detd centre for each Seren. 134, Turn the camshaft by hand and at the same time move the conttol sod backwards and forwards through its full travel, There musi be no tighiness or binding with the control rod or camshaft in any position. JANUARY 1974INLINE FUEL PUMP ~ 8 138. For convenience the plunger head clearance can now be set, for details see section on Phasing. 136, Fit 4 new set of base sealing cups (15) into the pump housing base using the base dosing plug punch, {ool part number 70448154. 137. ‘The base sealing cups must be inserted by the shouldered end of the punch to ensure they aré set to the correct depth in the pump housing base. 138, Remove the pump from the assembly plate. 139, Assemble the blanking cover plate (23) drain plug ‘and washer (24) and the excess fuel device, if specified. 140. Assemble the inspection cover (28) and a new gasket. Use Cascosel MLL68 adhesive to fix the gasket to the cover before assembly to the pump housing. When Cascostl is not avalable a good quality grease can be used, ARANOLEDWARDSON ADHESIVES LTD RIVERSIDE HOUSE. AMWELL END WARE HERTS. PUMP TESTING 141. The injection pump must accurately meter minute quantities of fel under all conditions of engine load and speed, and it must deliver the fuel to each cylinder at the exact time at which the engine sequites it. To ensure these functions are catsied out elficenty, each CAN. fuel injection pump is tested and accurately adjusted before it leaves the works. 142. The final setting is indicated by a line sribed across each quadrant and control sleeve 143, After a pump has been overhauled it should be tested and re-adjusted before iti fitted to the engine. 144. The test data required to adjust and set a pump for its purticular application is published by CAN. in the form of test plans. It is essential that reference be made to the particular test plan before any attempt is made to seta pump. 145. Special equipment is requirod to carry out the tests comeety and it fs recommended that the wosk is done by aCANV. agent, 146. Purnp testing is carried out in two parts PHASING nd CALIBRATION. 147. Phasing consists of adjusting the pumping elements 0 that they start to inject fueh at the correct angular intervel in camshaft degsees. The interval for inline pumps is 360 degrees camshaft angle divided by the number of elements in the pamp. 148, [tis also necessary to determine the point st which the adjustment has to be made. This isthe ‘port closed’ position the point at which the ising plunger doses the ports through which fuel has entered the element barrel, 149. The injection of fuel into the engine begins after the port closes, fllowing an interval which depends on lunger diameter, cam prof, speed of camshaft, pipe th, the setting of the injector spring and volume of ing valve, 150. Calibrating the pump consists of making an ‘Shustnent for te egg 6 ha oul Hom ach pumping line JANUARY 1974 4151. When the pump is working, the output of each element depends on the position of the helical edge of the phunger helix in relation to the spill port of the barrel, a pesition which can be varied by turning the ‘plunger in the barrel. 152, When the engine and pump are running, the ‘governor moves the control rod, (umning the quadrants, ‘control sleeves and plungers together. 153. For adjustment each element must be calibrated separtely, Phasing the injection Pur 154. Adjustment of the phe of AA pumps i effected by increasing or decreasing the head clearances of the plunger in its barrel by means of the tappet adjustment Screw. During this adjustment the plunger et the top of its travel must NOT strike against the bottom face of the delivery valve seating or considerable damage will result, 155. Adjustment is correct when the plunger at top dead centre has a head clearance of 0.5 £0.15 mm. unlessa Afferent figure is given in the test plan, 336, The flowing tools ee wvalable for tapes fjustment: ‘Tappet adjusting spanner ~ tool part number 7044-914, sppet lockmut spanner — too! patt number 7144-180. ‘Tappet liter ~ tool part number 7144-122. 157. Adjustment is made by dackening the tappet fookpat and turing the lowe sping pete which as small notches to take justing spanner, factmumber 704g914. PP, ane 158. Remove the inspection cover (28) and excess fuel dovice if ited, 1$9. Fit control rod indicator and set to ze10, After setting the zet0 position open the contrl rod to 10 mm. and Jock the indicator by means of the knurled locking screw. 160. Secure the injection pump to a suitable test bench, 161. Set plunger head clearance if not already caried ‘out on assembly. 162. The dzection of the camshaft rotation and the amount of head clearance is detalled on the pump test plan, these instructions must be strictly followed. 163. Remove the delivery valve holder (1), delivery valve spring pee (2). delivery valve spring (3), delivery valve (4) and delivery valve seat and joint washer (5).164, Set the plunger head clearance gauge, tool part number 7044-838 to ze70 on a surface plate and serew it into the tapped hole normally occupied by No. 1 delivery valve holder until the stem touches the top of the element baste, 165. Turn the camshaft until the top dead centre mark ‘on the coupling is aligned with the vertical line om the bearing end plate. No. I plunger is now at top dead centre, 166. Loosen the tappet lock aunt (13) using the tappet looknut spanner, tool part number 1144280. 167. With the stem of the plunger head clearence gauge resting on the top face of the element plunger, carefully raise or lover the lower spring plate by the tappet sjostng screw, using tappet adjusting spante, tol pat snumber 7046514 until the gauge repisters the required head clerance, 168, Tighten the tappet fork. 169. Remove the plunger head clearance gauge from No, F element. Replace delivery valve seat complete with joint washer (5) on the upper face of its appropriate junger bartel (8) and seat the delivery valve seat by dy tapping it into positon vsing 2 dummy delivery valve holder and mallet 170. This operation mst be carried out whenever the dlvery valve seats are returned to the pump housing. 171. Care must be taken to ensure that the delivery valve and seat are located squarely. 172. A dummy delivery valve holder is made by ‘machining the Tower thread off 2 spure delivery valve holder til the holder is an easy sting fit into the pump. housing bore. BE ey Do not replace the delivery valve (4), delivery vale spring. peg (2) and delivery valve ang 175, Connect short length of pipe, swan neck in shape, fo the delivery” valve holder, with the outlet end prove the observation of the fuel cutoff INLINE FUEL PUMP -. 9 176. The point of injection must now be found and the complete phasing operation carried out as follows: 177. Ensure that No, 1 camis a top dead centre. 178. Connect the pump fue! inlet to the fue} supply of the ‘test bench and loosen one of the air vent plugs. Allow fuel to flow until it is free of air bubbles then tighten the air vent plug. 179. Rotate the camshaft until No. 1. plunger is at bottom dead centie, fuel will now flow from the fuel chamber into No. I'element and out through the swan neck pipe. Fuel cannot pass through the remaining, clements since their delivery vaives are in position. 180. Turn the camshaft in the direction of rotation unti No. t plunger starts to tft. 181. As the plunger gradually closes the barrel por, the flow of fue tron he owes nec ie wll Ai Continue to rotate the camshatt yery slowly until the exact point at which the flow ceases is established. This is the point of port closure. 182. Take care thatthe plunger is rising in its stroke ora false reading will be obtained. 183. Set the graduated disc to zero, taking care not to distanb the camshaft, 184, Check that the camshaft has not tumed by repeating the operation in sequences 180, 181, and 182, Turn off the fue. 185. Remove the swan neck pipe, wash No. delivery valve (4), delivery valve spring (3) and spring peg (2) in clean test oll, and assemble to the pump. Tighten the Aclivery valve holder to a torque of 54 Nim (5.5 kel or 401/ft). 186, The camsheft is now set on No. 1 element at the point to which the adjustment of the remaining elements Js correlated and they must now be set t0 inject at their correct intervals. 187 In the following instruction the pomp is assumed {0 be a six oylinder type with an injection sequence of 153-624. 188. Remove the detivery valve holder (1), detivery valve spring peg (2), delivery valve spring (3), and delivery valve (4), but not the delivery valve seat and joinbwvasher {$) a ey slement: Replace te dry a Rede 1) and fit the swan neck pipe. Turn on the test oil, ‘which wall now flow from the pipe outlet. 189. Tum the camshaft and check the point of port closure for this element, JANUARY 1974INLINE FUEL PUMP -- 10 190. 1 should be within a few minutes of 60 degrees, but if the difference is in excess of 40.5 degrees for a4 stroke engine or 4 1 degree for a 2 stioke engine, adjustments must be made to the lower spring plate by. adjusting the lappet screw as described in paragraph 167. 191. Adjustment is made by slackening the tappet Jocknut and turning the lower spring plate which hes small notches to take the tappet adjusting spanner, tool past number 7044914 the phasing 192. Check the port ciosed position against the disc, Jf the point of port-osure is found to be early, the ower spring plate (11) must be lowered; if the point of port closure is late, the lower spring plate (11) must be ised. Lock the tappet nut (13) after adjustment 193, Turn off the test oil 194; Remove the swan neck pipe and holder and delivery valve seat (5). Check that the head clearance is 05 £0.15 mm. with the plunges head clearance exuge tool part number 7044-838 as described in paragraph 167, tnless otherwise detailed in the Test Data sheet. NOTE: When adjusting No, 1 element, the head clearance is determined first, and then the point of port closure. When succeeding elements sre adjusted, the correct port closing point is set first and the head clearance checked afterwards 195. If the head clearance of any clement is not within ‘the Fequired limats after phasing, the desrance on No. element must be increased of decieased within the tolerance of £015 mm. and the pump must be completely rephasad. . 196, Remove the gauge, and assemble the delivery valve seat and joint washer (5), delivery valve (4), delivery valve spring (3), delivery valve spring. pee’ (2) and Aetivery valve holder (1). 197, Tighten the delivery valve holder to a torque of 54 Num (5.5 Kglm or 40D Jit). 498. Phase and check ‘the head clearance of the remaining elements in the correct firing order. 399. Finally recheck the setting of No. J element in relation to the dise marking. If any discrepancy is found, the complete phasing operation must be repeated. 200, Assemble the feed pump to the injection pump. Calibrating the Injection Pump 201. When the phasing tests have been completed the next operation is co ensure that all the elements wall supply equal amousts of fuel. ‘Calibration’ is the term applied t0 the process of obtaining this balanced output, A test machine i essential for this process and x typical test machine is lustrated, JANUARY 1974 202 before a pump lenes she factory it is scustly adjusted and. the final sctting is indicated by a line scitbed on each control quadrant and control sleeve. 203, Slight alterations to the origina) setting may be needed after extended running, due to wear om the dlement, quadrant and delivery valve. The adjustment will be small and the new setting lines should be scribed after the calibration of fuel delivers. 204, The quantity of fuel delivered by each clement, and the point at which these quantities are balanced and checked will depend on the pump specification detailed in the test plan fora given application. 205, Accurate measirement and adjustment of output ‘an be made only by trained and skilled personnel using 4 suitable power driven calibrating machine, and itis strong recommended that the work is cared out by 8 CAV. agent 206, The test machine must be capable of driving the pump at the speeds given in the test plan and should be able to maintain any selected speed within close limits. {It must supply filtered test oil to the injection pump by ‘gavity or pressure foed, and the filter must be of & quality which will give complete protection to the pump. 207. Each pump has « specific output according to its Application and care must be taken to ensure that the correct test plan isto hand before calibrating. 208. A study of the test plan will show the different ‘outputs which must be obtained at different control rod setlings for given speeds. 209."The output ftom each pumping element during calibration is messured over 100 pumping strokes, unless otherwise specified in the test plan.240, The test machine is fitted with an sutomatic tip mechanism which diverts the fuel away from the measuring glasses when the required muniber of strokes are completed. 211, Mount tess nozale BDN 12SD 128 set at 175 atmospheres on the test machine. NOTE: ‘The following sets of test injectors are available fon the unit exchange system direct from Leslie Hartridge Limited, Buckingham, Englond, Set of 6 Set of8 Pact Number 7244-106 Part Number 7244-108 232. The connstion bewson the fs nue a be hiek pressure outlet of the pump is made Dy a pipe mmo ode Srameter 32 tetrad mete 20 ms. long ovat specified in he test pa 213, Before slung he contol tod opening poston, as Specified in the fest plo, the vets postion of He ntl ro indenter mist he checked 214 Before eration the pump, ljectors and injector pes mist be throughly wented an operotion normally Eatted oot withthe pormp diven xt 200 rp 31S alter tenting, set the coatiol rod 10 the fist pasion gen fn te Tost plan and fock 1 wath the Eontrl raf bxdlator locking sci The ts pla shows the fuel pats thot must bo obtined ate different ontcol settings for specific speed Bie. The pump is now driven athe prescribed speed and he da Set ouput beck ne 100 roping stokes or 36 specif i the test plan. When fecording the level of he fel in de measuring ges, take cave 10 read he Feel at the lowest point of the YT —~ 220008216 217, Mipor adjustments to individua) elements must be Tollowed bya complete check at the same contro rod ‘opening spr and ever #00 strokes 218. Calibration js now cziied ut at the other contec} {od openings specified in tho test plan, and adjustments made st necessary 219. Individual element output is adested by slackening the quadrant screw and moving the quadrant sleeve so that it aliers the position of the plunger contra helix in relation to the fel port. The quadsant clamping screw ‘ust be tightened after the adjustment hes heen made 220. When carving out adjustments it should be noted hat to increase fuel dsivey the control deeve is rotated towards the governor. Only a small movement of the control sleeve is necessary Lo alter the fuel supply INLINE FUEL PUMP ~ 11 221, When the adjustments have been carried out and the tests completed, new setting fines should be drawn ‘on the control sleeve and quadrant. Camera black can be used to remove the old seting line on the control sleeve. 222. Refit excess fuel device if specified. 223. Maximum fuel output must aow be set_in accordance with the test plan and pump application, The ‘method varies with the type of governor. CAN, Mechanical Governor 224, The speed of a diesel engine is determined by the jad and Smount of fuel delivered, ‘The governor is ranged to control the latter, ieseesng or decreasing it to compensate for any changes in load which tend 10 cause vayition I speed. The CAN, unit isa Convendonalcentrifugally operated spring. opposed Avaveai type Asaable kage doers the dang positon of the weights 10 a longiadinal movement Operating the sol coating the fuel output of the Injection pump. The position of the throttle lever also alects the fuel output of the fuel injection pump, the ‘wo eontrols boing siferconnected with a series of links and moving pivots, to understand this we must consider a series of sketches (2.2000A-225, 2.2000A-226 and 2.2000A-228), 225, The important feature whieh must be clearly grape Hf be povemor operation to be andere That ever (1) oats on two pivots (2) and (4) and ean be moved by thrust at cither point. Ics the combination of these two ~ from the governor (vis 4) and from the ‘control lever (via 2) ~ operating on the fuel contyol rod G), which enables the speed to be held at any desired point anywhere within the range. The. following ‘examples show how this 1s effected JANUARY 1974INLINE FUEL PUMP ~ 12 2.20008.228 226, In Figure 2.20008.22 assume that the engine hes settled down 16 run steadily at approximately halt Speed. Any variation im speed will result ins change of Dosition of the By-weights (6) which will shift point (4) fo the lel if speed decreases or to the night if speed increases. This will swing lever (1) on pivot (2) and so move the fuel control rod (3) io alter the quantity oF fuck injeted. It should be clear from the sketch that an increase of speed will esoxe rad (3) to move to the le, {o reduce fuel supply to check the speed and vice versa if speed owas Under thse conditions therefor, the {governor acts a6 o normal fixed speed Hartnell type. His ow desired 0 increse speed and control lever (8) is awed tothe right to the three-quarter position 2.20008.226 227. The results of this are (a) Pivot (2) is thrust 0 the right, causing lever (1) 60 swing on pivot (4) and push control rod (3) t0 the right, increasing the fuel supply. Owing to the relative iengths ‘of lever (1) above an! Below pivot (2) 2 small movement of the control lever (8) wil couse 2 relatively large movement of rod (3) and the engine will accelerate rapidly. (h) The relatively Tange movement of the top end lever (1) may force rod (3) to the maxitiim fuel stop (14) at the Simit of its travel before the desized amount of movement of the control lever (8) has boen effected. ‘The remaining raovement of lever (8) could then only be ‘obtained by moving pivots (4) tothe right, which would mean forcing the flyweights apart against ‘heir spring presure, This would apply heavy loading on the linkage JANUARY 1974 and is obviously undesirable. Spring loading (9) of the canirot lever (8) is therefore provided to absorb this excess movement until the Mly-weights move outwards normally with increasing speed, 228, As the engine accelerates, the ly-weights will move outwards to @ position corresponding to the desired higher speed range, and the results of this (2.200.228) will ber (@) Pivot (4) and pivot (2) will move to the sight, thereby allowing spiing (9) to regain its equilibrium and take up its normal position (b) The flyweights (6) now turning through a greater radivs and acting on pivot (4) will move lever (1) about the new centre of pivot (2) causing fuel contvol rod (3) to shift (o the lelt, decreasing the fuel supply as the speed ries. (©) The governor is now operating at the selected higher speed range. The positions of pivot (2) and pivot (4) Which are naw to the right of the helf-speed position will be retained by spring (9) and any movernent of the Ay-weights (6) due to speed variation willbe transmitted hugh pts (4) and (2) ad lever (1) 1 he contd 229, When it is desired to run the engine ata lower speed, the control lever (8) i8 moved to the left, The ssovernor weights and linkage will move to the positions required, following a reverse sequence of events, and give sabisfectory control over the selected jower speed range, 230, The numbers in brackets in the following peges ‘efer to ilustcetion 2.2000A-230.INLINE FUEL PUMP — 13 231, ‘The main essential to guarantee satsfeciory Operation of the C.A.V. mechanical goversoy is hat all roving pattsacetrce fiom any binding within the fons 232. The liskage which transmits the movement from the weights tothe conteol-ro4 shoul be thee, si advised 10 visually check sl pivots ang bearings for wear. 233. Check the bashes fited to the bellerank. levers (225) and (2%) also the element support sleeve (231) Should those bushes (925) and (226) requite replacement remove existing Bushes (rom the casting and press new ones into place, ream tothe correct Sie Using Feamer CA.V. tool suitber 70461 4 234. Check the bores say which the pivot pins (234) iucate in the weights (217) should these show any wear the weights shoul be replaced. these are not serviced singulstly, aly in matched poles 238, Remove ftom the gavemor all extersal connections ko the oi ler plug (144) andthe oi ewe plog (11) 1136, Drain all the oil om the govemor 2337, Two hexagon nals (91) wil be aoted seated with dite, ths ware should be removed and the nus removed. this will allow the timing lever and fork falccum pin (190) 40 be withaawn 238, Remove he two nuts (159) which soome the onizol lever (200) and flange assembly (193) the entre Jssembly can be withdrawn feor the en coves (251. 239. Remove the eight sorews which seoure the end over ane remove end cover (154) tis wil expose the ‘petting components of the governor 240. The control tod linkage (77) can now be unscrewed from the onteal tod and the assemably Wwithdravin by. swaping. dwn though 90" and uuohitching the forked lever. 24), Examination of the governor weights will show two Screws (229) which ste located parallel to the pump ccamshafi, These screws should be removed. in order that the plate (228) which they secured can be withdrawn towards the governor linkage hence exposing a pin (227) which the plate secured 242. Tura the pump camshaft until sch time as the pin (227) is in a position opposite to the extension of the ‘housing, the pir ean then be pressed upwards and finally removed using only flogers, This will enable the governor linkage to be withdrawa from the governor weights. 243, Remove the brass element guide bush (222) from the end of the cemshaft, at this point of the dismantling procedure the bash should not be attached in any way and can be lifted out, exposing the governor weight assembly securing mut (160). 244, Romove the aut (166) which secures the governor weight assembly to camshalt using tool (CAV. Too} number 7044-1128) and withdraw the governo! weights ‘ssembiy using extractor (C.A.V. Too) mumber 70448) The lange portion of the extractor is screwed inte the goveInor Weight assembly ss far us possible. the hexagon sorew is then tightened against the camshaft which will feselt In the weight assemély being drawn from the camshaft, During this operation care must be tkes that the weights are in Tact being removed and not the rnreads fling, 249. Remove the Key (150) from the Keyway in the camshatt 246. Remove linkage fom contol rod. this. achieved by removieg tho tock tab and one Screw. DAT. Remove How the rear cover housing (151). the susiliary idling stop (205). Should this require further be JANUARY 1974INLINE FUEL PUMP. 14 uasembly, ap the unit n aw and remove the pig (212) which will expose the spring (209) end the plunger G07). 248. in order to disassemble the weights further for sibie overhaul, proceed as fallows:- fa) Place weights in a vice (with Jows protected) and

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