Section 24 Page 14 1098 Service Training 2.4.1.9 INJECTION PUMP 24. 1 REMOVALANDINSTALLATION OF THEINJECTION PUMP, VERSION WITH SETSCREW ‘TIMING Two different types of series DP 200 fuel injection pumps are installed in engines types 903.27 and 903.27 HR. One type is provided with setscrew timing, the other with pin timing. The following assembly instructions take this fact into consideration. REMOVAL OF THE INJECTION PUMP - Set the crankshaft to the TOC of cylinder 1 (valves closed), and use the blocking drift (1) Part No. 000 008 61 00 to secure it against twisting. - Loosen grub screw (1) of the injection pump by approx. ¥turn. ~ Slide the locking plate (2) so thatit contacts the larger recess on the screw head. - Tighten the grub screw. This will block the injection pump shaft. - Dismount all fuel lines on the pump. - Pull off the electrical connecting cables from the shut-off valve and cold start injection advance. - Separate the speed control linkage. - Remove the cover for the drive wheel of the injection pump at the timing case cover. - Unscrew the driveshaft nutof the injection pump and remove the snap ring. - Unscrew the hexagon nuts ofthe pump flangeand the rear pump bracket on the engine cylinder block. - Loosen the injection pump from the pump shaft with extractor WM 146. - Remove the pump and make sure that the wedge (4) does not slip off the shaft.Service Training Section 21 15/22 10.98 Page 15 INSTALLATION OF THE INJECTION PUMP - Set the crankshaft to the TDC of cylinder 1 and secure it against twisting with the blocking drift - Eveninits as-supplied condition, the injection pump is blocked in start of delivery cylinder 4 status. - Insert the injection pump into the engine cylinder block - Look out for the wedge (4) and the O-ring (3). - Mount the snap ring and the hexagon nut on to the drive shaft. Tighten the nut with 80 Nm. - Tum the pump in direction of the engine cylinder block in order to eliminate the side play. The three retaining nuts must be tightened in this position. - Check the tightening torque of the drive shaft nuts again and mount the end cover. - Mount the rear pump bracket. - Loosen the pump block and the locking plate back into position. The loosened drive shaft corresponds to the smaller elongated hole in the locking plate. - Remove the blocking drift of the crankshaft. - Mount the fuel lines. ~ Attach the throttle linkage. - Connect the electrical connecting cables. NOTE: Ifthe setscrew was loosened inadvert- ently after the removal of the pump or a new pump was delivered without the pump shaft fixed in place, adjust the fixing angle as described below.Section 24 Page 16 1088 Service Training CHECKING THE FIXING ANGLE FOR THE INJECTION PUMP SETTING Required special tools: Universal adjusting device MS.67B Intermediate gear PD.67-3 CAUTION: Thefollowinginstructions shouldbe followed closely if: - the engine performance is poor, ~ the setscrew forthe injection pump shaftwas loosened afterremoval of the fuel injection pump from the engine. NOTE: —Thecodeletters for fuel injectionpumps used on 900 series engines are AN or BN. - Remove the fuel injection pump. CAUTION: Ifthe pump is clamped in a vice, do not exert any pressure on the alu- minium parts. - Securely clamp the pumpin a vice. Install the interme- diate gear PD.67-3 (1) for the universal adjusting device MS.6713 (5) on the injection pump shaft. Fasten the intermediate gear with the nut for the injection pump gear; tighten the nut with the fingers only. - Loosen the setscrew (2) on the universal adjusting device andset the adjusting device for pumps with the code letters AN to 89°, for pumps with the code letters BN to 88°. Retighten the setscrew on the universal adjusting device. These angles are called the fixing angles. - Install the adjusting device and spacer (4) on the intermediate gear located on theinjection pump shaft.Section 24 Service Training oe owe - Loosen the setscrew (6) on the adjusting device and move the pointer (3) forward until its front edge is located over the centre of the injection pump flange; then retighten the setscrew. Check that the adjust- ment mark on the flange is in the centre of the notch on the pointer. - Ifthe adjustment mark position isnot correct, remove the adjusting device and the intermediate gear. Take the pump to your nearest Perkins dealer and have it checked. Ifthe adjustment mark isin the centre of the notch on the pointer, remove theadjusting device and the intermediate gear from the pump. ~ Install the fuel injection pump. 2.1.1.9.2 FUELINJECTION PUMPS WITH PIN TIMING Fuel injection pumps with a timing pin (1) meet the emission control requirements and are provided with untamperable adjusting screws. This pump type has a drilled hole in the injection pump flange through which a timing pin (1) is inserted to hold (4) the injection pump shaftin adefined position relative to thepumphousing. On this pumptypethe injection pump shaftisalsofixed with a setscrew (4). Itisimportantthat the setscrew is loosened and the pump shaft can turn when the pumpisinstalled in the engine. An electrically operated cold startinjection advance (3), which retards the start of injection for normal operation, and a cut-off magnet (2) are installed in the pump. The pumpisself- priming.Section 24 Page 8 1098 Service Training REMOVING THE FUEL INJECTION PUMP Required special tools Timing pin for pump 276 10.033 Blocking drift for crankshaft 000 008 61 00 Torx bit 276 10 122 ~ Bring the crankshaft to TDC of the number 1 cylinder (valves closed) and prevent it from turning with a blocking drift (1), Part No. 000 008 6100. ~ Remove all fuel lines at the pump. - Disconnect the electriccablesat the shutoff valve and cald start injection advance. - Detach the throttle linkage. - Remove the injection pump gear cover. CAUTION: Insert a lint-free cloth between the front side of the injection pump gear and timing case to ensure that the screws (5)used for fastening the gear tothe pumphub cannotdropintothe timing case. If this happens, the tim- ing case must be removed. ~ Slide the timing pin (7) through the injection pump gear and pump hub into the cutout in the pump housing. This is done to check that the piston of the number 1 cylinder is at TDC of the compression stroke. - Remove the four screws (5) and take the injection pump gear off the pump hub. - Unscrew the nuts (4) securing the injection pump flange and withdraw the pump andtiming pin from the injection pump gear.Service Training Section 24 10.98 Page 92219 INSTALLING THE FUEL INJECTION PUMP. CAUTION: Before the installation of the injection pump inthe engine, set the piston of the number 1 cylinder to TDC of the compression stroke. Ifthe crankshaft must be rotated, the pump must be installed temporarily, otherwise the loose injection pump gear could dam- age the timing case. The pump shaft may not be turned without the spacer (1) being installed under the setscrew (2). Turning the pump shaftwith the setscrewtighton the shaft will damage the shaft. The spacer (1) must be installed un- derneath the setscrew (2) before the installation of the injection pump so that the pump shaft can rotate. - Check the O-ring (5) on the pump flange and, if required, renewit. Apply a thin film of clean engine oil to the O-ring ~ Insert the 8 mm timing pin (4) through the drilled hole in the pump hub into the recess in the pump housing. = Place the pump on the three timing case studs and make sure that the timing pin is inserted in the slot in the injection pump gear. Press the pump fully against the timing case. Screw the injection pump flange nuts (3) completely against the rear of the timing case. ~ Install the screw and nut for the mounting bracket. Ensure that the mounting bracket does not exert any force on the pump during the installation. - Tighten the injection pump flange nuts (3) to a torque of 22 Nm (2.2 kgf m). CAUTION: Do not remove the nut (7) on the injection pump shaft. The injection pump hub is mounted on the injec- tion pump shaft inthe factory sothat the pumpcan beadjusted correctlyin relation to the engine. If the hul removed, it must be reinstalled by a Perkins dealer who has the special equipment required for this work.Section 24 Pege 20 10.98 Service Training ~ Position the injection pump gearso thatitcontacts the pump hub. Screw the screws (6) through the slots in the injection pump gear into the pump hub, - Exert pressure on the injection pump gear in a anti- clockwise direction to take up any backlash. Fully tighten the screws to 28 Nm (2.9 kgf m). With- draw the timing pin (4) and refit the injection pump gear cover on the timing case cover. ~ Pull the blocking drift out of the flywheel. 2.1.1.10 EXPLANATION OF COLD START ADVANCE (CSA) The Lucas injection pump possesses a starting aid device (CSA) which advances the fuel injection timing inorder to prevent the formation of white smoke, and to enable a better starting procedure. This device is electrically activated and works with a wax-flled ex- pansion element With a cold engine and a cooling water temperature of less than 50 °C, the fuel injection timing is 11° BTDC. As soon as the engine reaches its normal operating temperature, a sensor in the cooling water circulation of the cylinder head releases a voltage of 12 V. This causes awax-filled element to be heated, and theearly setting from 11° to 4° is cancelled again 2.1.4.11 FUEL SUPPLY PUMP REMOVAL ~ Disconnect the fuel lines at the fuel supply pump. - Loosen the four fastening screws (3), and remove the fuel supply pump with both retaining plates. In some cases, removing the fuel supply pump is problematic. In such cases, tum the crankshatt until the camshaft eccentric cam releases the drive lever of the supply pump