diesel systems OPERATION AND INSTRUCTION MANUAL MODEL DM PUMP DIESEL SYSTEMS GROUP - STANADYNE, INC. P.O. BOX 1440, HARTFORD, CONNECTICUT 06102, U.S.A. PHONE: 203/525-0821 TELEX: 99218CONTENTS oeneeat Pace oben wwe sysrext SECTION 1 CONSTRUCTION AND OPERATION © TRANSFER PUMP. 3 RETURN ONLCIRCUIT 18 Hi AUTOMATICADVANCE 1 SECTION 2 section 3 a PARTS INSPECTION 2B. Detatub insPecriOn a SECTION 5 REASSEMBLY st SECTION 6 ACCESSORIES rs ELECTRICAL SHUT.OFF be Disassenbuy ao REASSEMBLY AND ADJUSTMENT et ToRUE CONTROL to SECTION 8 [BENCH TEST PROCEDURES 80 SPECIAL TEST BENCH REQUIREMENTS 40 (GENERAL TEST PROCEDURE a SECTION 9 INSTALLATION a section 10 FUEL PIPING AND FILTRATION no secon 11 {Tongue VALUES ha MWGeneral A PURPOSE OF THE MANUAL Thteeal arate mene ronda act oanai ecaeeaccae hchaenadataon mere selerepeceeatie nee bu Fates Rapa eee a mot opieecion Stoney area met Atesnomnen tees iat Serer ences, ieap tu ante chong al ear se ape one pry le Boar steel pablo serra ee rides eulcaet teem ieee Foe ee rane ema Saar feet penn ins ‘Risen wea derision win Reritareae resin erage Ieee Roane Sones tee! imate pa pc ete 8. MODEL NUMBER SYSTEM tis neceseary to understand the model number system fn rafoence tothe proper sections ofthis taal cov ting operation and maintenance of the pump. a bed « EXAMPLE: Model Number DAT & 39 TH TBR «DM 1 °D" series pump, >, 2— Number of Plungers (2 or 4 plunger versions) iablein 2,3, 4,6 & 8 0" (6-35mm) 0” (8.80mm) 35— 390" (34mm) 38 350° (Samm) m0 (237mm) 32 = 310” (640mm) at= S10” (stm) 59 — 390° (991mm) IN Arcomony Code (See SB #60) code pertains to combinations of special acces- sare fac slr hu orate ‘arable speed droop adjustment ete Soe the propor ervice bulletin or mantal section for operation gd {onstruction of these acessories Include iis any Selerence to the pump, 1. 2580 ~ Specification Number. Determines selection af parts and adjustments within aiven accesory code Must be included in {ny relerence tothe puny. NOTE: Pump rotation nd method of mounting are Provided under special notes on individual Paap Shecifations ©. GENERAL INFORMATION Ina diesel engine, iris drawn into the cylinder throu the intake valved compressed. A metered quantity of fuelis then injected into the cylinder, producings core msi mature. This mixture igsites fom est of ‘omprosson, and the expending gases fore the Paton Sowhward ‘The function ofa diesel fel injection pump isto aceue rately meter and deliver fel tom norrie men eying nd to inject it af high premure nto the combustion ‘Shamber at precselytimed intervals The extreme prec a on necessary can well be apprecinted since this cycle must he repeated thousand of times per minute wih etualy no variation in timing or amount of fuel in Jested Teinjection pump truly the heart of the i= elengine loosa Master Model DM Pump ‘he models DME and DM ae deed at opsoed BME corporates ssiale pumping chamber whereas the DMG hes 2 pumping chambers Simpl ihe Prime advantage 0 aster design, conte {ollower initial cost, greater reliabty, nae of service and ower maintenance cst, ‘The necesity for cost redaction ie more apparent in the small diesel engine where the injection equipment rep. resent a greater percentage ofthe cost, Since the basic ‘model has but 100 odd parte, and only four main rotat ‘ng members there iene chance! pat fale: Ropalts are generally very inexpensive, Today's small high out Peenin ve rated» nid for pre, eon Eon injection equipment capable speed oper: ation, quieter renning and ower exhaust emissions, Pri datriution betwen indo nbn in the Dump design, and the abity to preset fuel Row emt: Fates lengthy periods on the test stand, The pum is fell lubricated’ with the excention of the drive shaft ball eating), contains essentially the same number of paris reganilow ofthe numberof cylinder served an Speratesin any postion: New Design Features “This aiition to the Roose Master line of fuel injection fauipment incorperates many design improverments: and as been durability tested for more than 200,006 fous prior to release for production, ‘New Design Features include: 1. Housing and Drive ‘A. Housing strengthened inthe mack area, 1B Rgged mounting flange C. Drive shaft supported by a heavy duty ball bearing D, ncreaced diameter drive shaft with la tang drive. The drive shaft retained in he army. , Drive shaft rll pin for gear bub alignment. F. Springloaded, steel-backed i ive Springloaded, ste ip type a 2. Head and Rotor AA Integral, angled discharge fittings. 1B. Thrended transfer pump eap, . Shear groove in the rotor, 3. Governor ‘A. Weight retainer hub prss fitted othe rotor B. Cushioned woight retainer with ruber com: ression members fully enclosed within the SSoembly . Low maas governor weights D. Larger diameter metering valve 4. Transfer Pump A Larger aren inlet screen 5. Automatic Advance [AW Advance circuit dnect from transfer pump. B, Reed check valveSection 1—Construction and Operation ren A. COMPONENTS AND FUNCTIONS lis necosary to become familar with the function of the mate components ta understand the basic opers ting principles of the Roosa Master DM pump: Seo cutaway ew (Pig- 1.1) for construction details ‘MAIN COMPONENTS Drive Shatt Distributor Rotor ‘Transfer Purp Blades Pumping Planers Internal Cam fing Hydraule Head Preasure Regulator Assembly Governor ‘Automatic Advance Housing 11 Metering Valve “The main rotating components are the drive shat (1), Aistethutor rotor (2), transfer pump blades (3), gov srnor (8) reference to Fig. 11, the drive shalt engages the Aistribator rotor in the hydraulic head. The deve end ‘of the TIME rotor incorporates two. pumping plungert And the DM incorporates four "The plungers ate actuated toward each other simlts- ‘teouly by an internal camming through roles and ‘hoes which are carried in sols at the dre end of the rotor. The number of cam lobes normally equals the ‘numberof engine evlindrs. ee ‘Tho transfor pump at th rar ofthe rotor is ofthe pos tive displacement vane type and is enclosed da Uhe end cap, The end cap also houses the fuel nit strainer and transfer pump pressure regulator. The face ofthe Fgu- tar assembly is compressed against the distributor rotor and forms an end seal for the transfer pum, ‘The distributor rotor incorporates two charging ports and a single axial bore with one discharge port to rerve head outlets to the injection lines, Te weight Fe {ainer hub isa shrink Bt tothe de end ofthe rao. "The hydraulic head contains the bore in which the rotor revolves, the metering valve bore: the charging ports Sand the head discharge tinge ‘The high pressure tn fection lines to the nozzles are fatened to these dis Sarge stings ‘The DM pump contains its own mechanical governor, Capable of elon sped regulation. The centrifugal force ofthe weight the aio anand Uo ‘age to the metering valve, ‘The metering valve can bo osed to shut-of fuel through «solid linkage by an i Alependently operated shut-f lever ‘The automatic advanceisa hydraulic mechanism which advances or retards th beginning of fuel delivery from the pum.Section 1—Construction and Operation B. FUEL FLOW “The operating principles athe pump ean be understood more eadiyby following the fue creuit during» com Pete pump evel (Fig, 1-2)"The fuel How forthe DME {Fig ty basicaly the same as that ofthe DM (Fi Ls} with the exception of the charging of two add al plungers Fuel le drawn from the supply tank through nites into the purmp through the inlet filter scron (), the vane pe fue erence pump (2). Sine ele hyspased through the presse regulate sssemhly (3) tothe suction sie, Pel unser transfer pump pressure flows past the rotor fetainees (0 intoanannuhson the rotor. Tt then Bowes through a conaesting passage (5) i the head tothe sd ‘ance (S) and also tothe charging creuit (7). ‘The fuel Rowsaround the anaulus (8) throueh a connecting pas {age to the metering salve (0) The radial postion of fhe metering valve, controled by the gover, ree Intex he How of feito the charging annuls (10) sthich incorporates the charging ports fe 12 ‘As the rotor revolves, the two inlet passages (11) regs- ter ith the cherging porta in the hydraulic head alow: ing fel to fow ito the pumping chamber, With farthor {elation the inlet pamager ove out of egbtry and the ‘Bechara oor of the rotor eerstero with neo he fea tatiete Whi the discharge port is opened, the rollers (13) "contact the cam obes forcing’ the plunger to {cther Fuel trapped between the plunges then pes ‘tele snd delivered by the nore to the combustion hare. ‘With the exceotion of the drive shaft Dearing, sell Init the pm fam iret feature he FRoona Master design As flat transfer pump presse Feachos the charging port, lots oo the Foor shank a= few fel and any entrapped ato Bow ato the psp {Im addition, an air vent passage (13) i the hydraulic head connects the outlet side of the transl pump with the pump housing. ‘This allow ar and some fue to be bled beck to the fet tank vin the retin tne. The fel {hs span file sing ad eat then nal componentDM4 ena aoe pupae a Kom soe A a= 4 mes Fe 4 ©. TRANSFER PUMP “The positive displacement vane type fuel transfer pump, onctts of stationary liner and spring Yoaded Blades ‘which are carrie tn slots the rotor Since the inside Viameter of te hiner isecrentre tothe rotor ae Tota: {Hom eauses the Blades to move in the rotor slots This blade movement changes the volume between the blade “ram rpm at rn nu speed iereases. Since dioplacement ofthe ans ferro xe ic ‘elements some ofthe intor the net sid of the transter pumps tes the pumping principle. Blade ince avlume peredoe ihe quadiant bee tteeon blade and’? (Fig 15) -At this tin the quad. ‘an pty wth ide shaped a portion of the reglator sembly. the increasing vol muy stot arse NER W/2 { ee wer lume causes fuel to be pulled through the inlet fitting dad filter screen into the transfer mp finer, Volume ibtween the two blades conte: incase unl inde 2 pac out of oy wa the regular not. At dhe int the rotor hes reached & position where movement Erbe Land 2 noglbe and volume f not chan ing (Fig. 1 5b). The fuel between the Blades fs being ‘ree a the hottom ofthe transfer pam liner. ‘As blade 1 passes the edge ofthe kidney shaped groove {fr the lower portion of the regulator assembly (Pig ss te gre sme Parmer scent fo rotor pcs blades and 2 i's direction opposite {otheir previous movement (Tig 1a). Thevoure bee {tween the blades reduced nl presarized fuel is de. Iivered through the groove of the rogulator asomby, he rotopretainer ante an aa he hot | TRANSFER PUMP PRESSURE 1sSection 1—Construction and Operation mer TRANSFER PUMP PRessuRE Fi 18 Ped eespetol te for pi Se ae at ae seat renee tae ae Soe me Sioa ele tarseatae Hemiese eee ee ‘ips rt i ‘SREP pert al tne prseurereglatag oo to prev Secruamcermopmnvanare VISCOSITY COMPENSATION ‘The DM tants pup was equally wll with ier. ‘en grads of diesel fae and varying temperatures, both of cd alet al waco Kure nd img ene {tre of the regulating system offsets preneure cena: ‘tna by vacityditsence: Located inthe spring ade justing plugs a thin plate incorporating a shar trie Poe alos el ekage pate san to ‘oturn (othe inlet side of the pump. Flow through a $hort orice virtually unaffected by vigoaty changes, ‘The biasing premure eacried againgt the back side of the piston f determined by the leakage pest designed Clearance of the pasa in the regulatar bore and the reste oy hrm the shaped ice With ci risus fuels, ory iti leskage occure past the, ton, The additional force onthe back side of the piston 1“ ens: alan ince Bow throu cic emain tenesthlgo:vacae a he a pressure est the tegulating sping a ‘moves the piston, reducing opened regulating slot aren, ‘This variation in piston positon componcatas tho leuk age which would peur with thin fuels and design pres ‘ree ae maintained over a brosd range of tacos changes D. CHARGING AND DISCHARGING CHARGING CYCLE ‘As the rota revolves, (Fig. 1.7) the two inlet ip therofr renter th arts of he baring st {y"the opening of the meterine rave, ows into the pumping chamber forcing the plunger apart. ‘Theplungersmove outward distance proportionate to {he tonto ue requied for jects the fll few stroke It only small quantity offal admitted {nto the pumping chamber, az at idling, the plunger ‘owe oul cor tance Mariam anger tered ‘nd comequey, aut Wel toy white Gye sprng (DMB) or eel spn (DME) Sai cetacP hole otto it ser Gall hen {he engine ts operating fll ond wil the plongers ‘ove to themow outard position Note (Pig) that thle the angie inlet passages in the rotor ae in {ey withthe port the charging emus the oor i ‘fare port notin egntry wits head outlet. Note ‘Bhat the relergre af the am lobes, Compare het teative postions (Fig. and 13)soe ans / sang spose vam) Fea DISCHARGE CYCLE seth tp sein (18, eit Hower eter rea Ft Bei ae erect ar ae ng ti Bectiaies ey gee ai SETAC use flab ae ieoraeiriecen me des ire Hert na eannea eee ee Set ies bean oeratan et Beecage neteapeeteior eee Ue nero Fig 18 E, DELIVERY VALVE FUNCTION ‘The delivery valve. (Fig. 1.98 and 1.96). rapidly dee ‘reases injection line pressure aller injection to & pre: ‘determined value lower than that ofthe nozle closing preseure ‘This reduction in pressure causes the nozzle {abet tum api sat achieve dar ai fry cut-oll and preventing improperly atomized fuel from entering the combustion chamber “The delivery valvegperates in horein the centr ofthe theta vol ot att Fe ree ow nly a stop to limit travel. Sesbing i= accompli the clone clerance betneen valve and bore into which i Fits Since the same delivery valve performs the onetion of retraction for each iyecton line, the reeule Smooth running engine at al loads and sped ‘When injection stats, fuel prestre moves the delivery valve slightly out of bore and aide the volume of fe Solent section AT danas vale sine send ute the tat tla ser de jacernent volume are delivered under high presure 0 the orale ers eds wen the pn on he phingersideof the delivery valves quichy redueerddue ‘the cam rollers passing the highest point om the am be which allows Che plunger ta move outward Following tis, the rotor port closes completely and ‘esidual injection tine pressure s maintained. Note th thetdivey valve nly ere a cl while the dx line prteuos are maintained bythe seal athe close Atti heal and rotor fig 18Section 1—Construction and Operation Me F. RETURN OIL CIRCUIT Fuel une transfer pump pressure edlacharged into @ som esa inthe hydric head 10). Hw throu the pamae i restice hy wie to prevent ‘howl etdrm afd undue press ae “Tha wont passage i located behind the metering valve Inte an cnete witha shor wera pasage eterng Ihe poverce compartment Shula; eter the ranaer pump, immediatly G. MECHANICAL GOVERNOR ‘The governor serves the purpose of maintaining the de- within Bhe operating Tange under Ip the mechanical gover 1.11 the movement af che weights acting mguint governor thrust levee ‘the metering valve by means ofthe governor arm linkage hooks Th lation var the repr of metering valve opening tothe passage, fom the {tanater pump, theres controlling the guamtity of fuel Lo'the plunger. The governor derives fx energy from ‘weights pivoting in the weight retainer. Centfugal ea war, evi ie governor gt he poverior arin which proc on tes Enifeedae ofthe pivot shaft and through & me, pot Live linkage hook. rotates the metering alee. The force ‘ne governor rm nued by the weights balanced ty the governor spring force, which ie contrlled by the ‘manly portioned thot lever and veh Enkage {or the des In the event of speed increase due to a load reduction, the resultant neraane in conefaga fore of the wel fee emcee alec reduce he mits the speed increase (wrth the operating range) ton vale determined by poverorspeing estan mt {ine ofthe trate Mee th nd the nh rine, ed Mb lcs ce er es etna eae Dee emer ae cae ea epee eeeres eee es Beatece et eterA light idle spring is provided for, more sensitive Feaulation when meth energy flow inthe low end of te speed range. The init Of throtle travel are st adjusting screws for proper low idle and high idle pesldons A light tension spring takes. up any slack inthe linkage joints and al allows the shut mechanam to toes {hermetering waive without having to overcame the mor spring force: Only very light freee ruled to Fotte the metering valve to the closed poston H. AUTOMATIC ADVANCE (SPEED RESPONSIVE) ‘The Roos Master design pets the we a sip, Feet acting hydraulic mechanism, powered by fl pres= Sure from the transfer pup, to rotate the eam and vaey Aelivery timing” The auvance meekaniam advances or ‘etadc tar of fuel delivery in response ta engine speed ‘hanges: tn most injection system, the setual begin: ‘ing of livery of fuel st the nozoe wil tart late Gon ‘nine degrees of rotation) asthe speed increase. Compensating this inherent “ineveasing injection l sul’ move the hgh epontpatormance of the Soene Staring delvry of Tl tthe nore erie ‘when the engine is operating at higher tpeed insures Thatcombunton tae place when the piston iti its most effective prsition th produce optimtm power with Ininimum specific fuel eonsuraption sad minima ke ‘The advance piston, located ina bore in the housing, en- fates the cat through the advance pin and moves the am (when fuel pressure moves the piston) opposite to tfeaiecton oor ation (Fig) ie eB) Fie under teaser pum pressure i fed through Aled passage im the hydesule bead which registers ‘wth the bore of the head locating serew, Fuel then AinetelUorough a groove inthe head locating serew ‘atannatuin the paton ole lu. Feta prs n the poston hole plug fading to the reed check valve. Tn {easing transfer pump. presure forces fuel Valve tothe advance piston. Fuel presse Dston must overcome the opposing spring force plus the ca onset crusty ‘dynamic injection lnding on the cam inorder och the a tn, The rd check valve pete thn during injection by apie the fein the pan ‘chamber’ When engine speed decreases tho hydaulie pressure i redusod and the spring returns te eam (0 retarded position in proportion tothe reduction of fpeedThe fuel in thepitton chamber iallowed to bleed ‘through a contol Grifce in te piston hole plug. ‘At low speeds, because transter pump pressure is com ey tote ca rman, te ead os tion When engine speed incense, mp res ste ise, which moves the pasion tan advanced Fea, Advance gion moenent tod a al movement of the cam i ni Paton length. ‘A “trimmer screw’ is provided to adjust advance pring preload which contrly start of cam movement. 1 can Br incorporated at either ide of the advance mca nism and mabe ated on the engine while ming SPEED ADVANCE OPERATION 72 “§ | Ew ae af = é alge -! “| = ct BS et : . : 3 eee gear err sen see rm SF iSection 2 — Removal From Engine "This procedure for removal of the pump from the engine Sthoukl be followed in. etal to assure ease’ of reinstallation |A._ Clean and wash down the pump, fttings and all Connections. cov eliminate. the possibility of Contamination entering. the system when Hines are ‘disconnected, CAUTION: Do not steam clean or wash Aiown while the engine is operating, Severe damage to {he pump may oocur Hf Its" amperature is chenged radially while eunning. 'B._ Shut off the fuel supply and disconnect inlet and ‘evar line fom thle fitungs. Loosen injection tubing thus at the nozeles and pump. CAUTION: In removing the injection tubing. nut rom the pump, hold. the Giccherge fitting with a wrench to prevent loosening from the hydraulic head. Immediataly after the nes are moved, ll purmp, nozzles and line openings should be pped oF plugged. ©. Chock the engine manual for proper timing position of crenkehaft. Bar the engine. in correct BXretion of tation until the engine timing mark i Indexed and the No, 1 cylinder is at the end of the Compression seek. Remove the timing line cover from the outboard side of the Pump. Timing line on the governor weight. retainer hub. should. be. dtectly ‘posite the line on the cam. 20 D. Disconnect throttle and shutoff Unkage and tlectrical conection if used E,_ In most cases it will be necessary to remove the pump drive gear from the hub or drive shaft. Refer to fhe engine manual FF. Support the pump with one hand and remove the mounting stud nuts and washers on Use pulp flange Remove the pump from the engineSection 3—Disassembly ‘Study the Manual first. Before commencing the Akash ofthe pump cove net nd outlet Hoe femove. all external Sine with fel ol and blow pressed ai Te'mut be constantly Kept ‘ive dust, and foreign matter ae the greatest enemies tf the fuel injection pump. Avan added precaution to prevent diet from entering. the Tuel system while Ecrvcing the pump, it i eseental that a dean Work ‘hace, clean tools, and elean hands be used NOTE: All seals and gaskets should be discarded ‘luring disassembly. A clean pan should be available in which the parts shape placed upon disassembly, and a pan of Eesn Tiel olf taust be avasable in which the parte may be Fhushed. Tt is recommended Ut these be deep das franc with rounded cormers to lessen the chances of fir pockets STEP 1. Remove the pump flange seal from the Fusing (Fig 2). STEP 2 Mount the pump in holding Fixture No. {ihis, Never clamp the pump in a vse always use fixture. Remove al lead plumb seal wize. Unscrew the three cover hold-down screws (Fig 3.28), Remove the xovernor control cover snd cover gasket (Fig. 220) u Shutoff lever tothe fullrun (W.0.T.) postion, tool No. 2902: with ta beneath the shorter the phic” ca ont tha shaft ahd ry sendy am aff the shaft assembly 5) Biseard the shut of cam, my ie STEP, Remo the shaft cm by rotating the leg of % ‘Section 3— Disassembly STEP 4 Remove the throttle shaft retainer clip by fe thotie lover to the fall rum (W-O) oh, “ala Sh ff th shat ard the retainer ci. ERS, iene ge a ee rena eta 7 i) eae ear etinat iipaeafmia na ene STEP 7. While depressing the metering valve Sipply raise the governor ak hy, Bath lnc Beok back yey eit Ene Premorarm and pace over the of the rage hook asrembl strat Mntncne? the likags speng (Pi STEP 6 Loosen the, wide stud (Fig. 64), Hold fhe governor spring and sprig retainer fernly between the thn and overt the governor spring ‘components and guide stad (ig. 3.60)fr, ihe Loosen and remove the rnaler pump end Sip leet spe plate std washer orn teyabane ich ig 3.3). 70 Tastal end ap plug No. 0579 Tato the a ‘ap and loosen and remove the transfer pump end cap assembly, using the appropriate end eap wrench. (Fig. 3.10a and 3.105) Disassemble the transfer pump regulator components (ig, $402), Remove the init Ate screen sal Ree rove the eid plate adjusting plug asembly with a 5720" hex hey ‘wrench (No. 14338) Shake the ree" lating pinged ton out of the late sembly. Using Toot No. 13001 remove the regulating Diston seal from the regulator. * lc Remove the transfer pump blades and liner (Fig s.i0a).Section 3—Disassembly STEP 11 Loosen the head locking screws and re- STEP 412 _ Loosen and semove the advance screw holo move one serew (Fig. 5-118), plug using Tool No. 14490 (Fig, 3128 & 3.120). is Insert Extractor No. 19201 into the hole in the ad- vance pin and extract the pin (Fig. 9120).‘Loosen and remove the advance plug and power piston plug (Fg. 81124, 3.120, 3.12" & 8.195) NOTE: The sides of the housing just above the ad- vance beara "C or “CC” marking to denote pomp Totation, The power side of the piston is Tocsted 6m the “C™ cide of a clockwise rotating pump and vice inasorbe the, auto advance component (Fi 5:12h)- Holding the advance adjusting screw sssombh ta 1/9" hee hey rent CX Toosgn and ea p ja ‘acon, rove, teed ve fre the pston ole ig use 8/64” hex key wrench (No. 13510), loosen an Femuve the two rel valve screws: The reed valve " 1aved, Remove the poton ring and sal from Q ston Repo he advancing ‘ing, using Waldes ‘Truare Plets No, 32 16549) and disassemble the washer, spring and advance adjusting screw.Section 3— Disassembly STEP 19 _Retum te pump and holding ature as « ‘i toe intial potion Ia the vie with the rea of there head led shy’ dor the eomaining head locking sere, fader tian ands {alight rotary motion CPi NOTE: Use caution s0 a8 not to drop the governor ‘weights STEP 15 Loosen and remove one pivot shaft re {ner aut and seal (Fig, 3150). 14. To dlisesemnble the governor, invert the Ter the weights, gowenor thrust nto our hd (F314. of Pivare No, ‘al Place head and rotor assembly on to 19085, = ‘he gree ar vot safe, a amd kage Book assembly may now be removed (Fis. 3. "te cq: nn 2 nt se cours a teen ae oy atone aneer STEP 16, Install Po! No, 19928 on the gear bub Kbosen and remove the hub retaining hut and washe? (Pig: 3.100) Install Gear Hub Puller Tool No, 19024 (Fig. 3.166) ‘and remove the gear hub. smowe the retaining rig using Waldes Traare Pliers Novo (ho 20008) le 3160. af ah Section 3—Disassembly NOTE: Step 17 i aly necrary if damage has oe ‘curred tothe drive sha, rll pin or ball Bearing. STEP 17. Remove the bearing shoulder ring using Waldes UPruare Pliers Nov 1510 (No, 30044) (Fis 8.17a), It may be nocessary to pros off the ball bear: ‘ng assembly slghlly in order to do thi, Remove the driveshaft rll pin using diagonal pliers (Big 317). To remove the roll pin if ie broken tue", 5/64" easy out extractor of'& 3/32" carbide tipped dil STEP 18 Remove the seal retaining ving from the Frousing' (Figs 3.180), eens Place the inor portion of tool No, 18978 onto tool No 20268 and press (Prom the front ofthe housing} the two rive shaft seas from the housing using an arbor press (Pig. 8.186). (Barly models may contain three seals NOTE: Discard these sess, as they should not be feused. ace with, Tool No. ‘SSppert. the beri OY 2 damege (Fig. $70). ‘Wig2 to prevent bearingSTEP 19 Lift the liner locating ring 50). (Theeary design tans pump fe ah STEP 20. Remove the ror retainets (Fig. 120) STEP 21 _Lift the head ftom the rotor (Fig. 8.210), TE the cam ring em the rotor (Fig. 3.21b) oh deri, heal partie esr. ie Fae TREE Ate tae tart ah saat ites cates eas Sue Fea ee al Se dee ee eee ae Sri bate hee fee O.tahaty oy aehie Oe fi aSection 3— Disassembly STEP 22 Remove the rotaining rings and cushion ‘elainers from the governor weight retainer aseembly Fir 3220). NOTE: Discard the retaining rings since they should ee Nessie ara rie to emg every wale . {Blimp Neccstis listed nthe appropriate pec ‘Sion fo determine "Tove that ae Zot" wll beso denignated, Loocen and remove del. ay valve stop serew ung a 333" hex key wrench “3506 oF 13898) or 16” hex Mey wrench Co 2) for a'260° delivery valve: The delvery valve ‘and spring may now be removed: Ifthe delivery ies nt slide freely from is bore, use Bxtraclor Now"s3385" Cg" 3.2te), Discard the delivery vale sop GBs, ‘Remove weight retainer and rubber cushions from the hub (Fig 3220), valve fom the asm STEP, 20 Remove the metering vale fom te a ‘Seembiy with ‘Walder "vuare T3G84) (Eg. 3.23). Fe, nieSection 4 — Parts Inspection A. GENERAL, INSPECTION Dirt isthe greatest enemy ofthe fuel injection pump. Keep the work area clean Pacts must be washed in a suitable solvent and then placed ine clean pan containing fresh fuel or eallbrating ot Examine all parte carefully in accordance with Instructions wileh follow Discard al “O" rings, seals, gaskets, weight retalner cushions” and weight retaining rings. Replace. with propriate Roosa Master gasket hits, Examine all Springs for froting, wear, distortion or breakage. Clean eatefully check al bores, grooves and seal seats for damage or wear of any kind Replace damaged oF worn parts as necessary, B. DETAILED INSPECTION SPECIFICALLY SPECT: oe yx ee wie gt? Sor loose OF FE Rt x * SEER GaaraSection 4 — Parts Inspection ©. SUPPLEMENTARY INSPECTION 1. Drive Shoft- Measure th distanes across the fats ofthe drive tang which must not bollss than 480". The Shaft diameter in the drive shat eal area must be free fof nicks and seratches forthe seals to fonction propery. ‘trom the seal ips ls normal (Fig bleed passage for freedom of movement. If the wire is free, flush the head and blow fut all passages with clea, dry alr I vent wire fs toc cemove and replace it after a thorough cleaning, tthe passage Refer Yo ne proper specifications fe the cormact vent wire, CAUTION Do not immerse this head in solvent for extended periods a sealant damage wvill result (Fig. 2), {i Distributor Rotor- Examine the radi contactad by the leaf spring(s} and the tang slot for excessive wear Check all slots, charging and discharge ports for thipping of edges or dit, and the rotor shank for major Scrntches. Slight erosion on the edge of the discharge pott is considered normal f damage or excessive west apparent, the head and rotor must be replaced 95.8 ‘atehed unit. Final check for excessive wear’ of the ‘olor should be performed on the test stand by checking for minimom cranking delivery 4. Dalivery Valve - Inspect delivery valve retraction cuff for chipping or erosion of edger (Fig. 3h b ‘5. Plungers - While holding the rotor under clean ol, wert the plungers into their bore. Insert only” the Tonger plungers ifthe DM pump ls belng examined With thumb and forefinger over tho shoe slots. tilt from de to side several times to determine “complete frendom of movement, Inerchanging or reversing theit Inltial positions may be necessary, as these are matehed parts. Repeat with the short set"without removing first set om the DM pump. Ifthe plungers fre sticking, but not visibly damaged, clean both Dlungers and bore witha soft brush anda solvent sach 4s lacquer thinner of acetone. (Do not force plunger’ ‘their hore and do not handle rotor shank) (Pigs a @ 4b), oma CY cor a My, Fe Bi{6 Com Rollers & Shoes - Check each roller i its shoe for freedom of rotation. Inspect the top edge of each shoe, where retained by the leaf spring, for Chipping or fxeeisive wear. Improved roller surfaces wil result from jong, normal operation i clas fuel a (Pigs 450 web OM2 OM4 on a) 2. Leaf Springs) & Sereu(s)- Check for excessive ‘wear at points where the springls contacts the radon ‘he rotor and along the steps that retain the roller shoes: Chock the adjusting screws] for tightness in the rotor (Pigs. Ain & 48), DMZ 8 Cam Since only the working portions ofthe lobes fon the inside diametor are ground, any tool marks between lobes should not be considered as demage, ‘hel ate apprerance of the cts rom eat treatment rather than fem operation. Carefully inspect the car lobes und edges of ll Mat surfaces, f there vidence of spalling o Making out replace with & new far. Improved cam lobe finish will result from lng, formal operation in clean ful il (Fig: 4.7) 6 8. Governor Weights - Check pivot points (heel and toe) ofall weights for excessive wear (Fig. 48) Ls 10. Transfer Pump Blades Inspect with the utmost re. Check fr cippingon any ofthe edges including spring bore edges, pitting, imbedded foreign particles Sr scoring on the rounded ends, Determine blade wea bby measuring the length (0538" minimom). Inepect fiat surfaces vioualy for deep scores, If any discrepancies are noted, replace Both blade sets and Springs (Fig. &9),Section 4 — Parts Inspection 11, Metering Volue & Arm - Check the metering valve body for excessive wear. Be sure the metering ‘valve arm is well seatod ond that there is no redial ‘mavemant ofthe am onthe valve- Chock the metering Valve spring for distortion and the metering valve sett pin for wear oF loooeness (Pig. 4.10) “ i afSection 5 — Reassembly STEP, 1 To intl the die shat sal, place the pms lght costo cium bac grease fo tho owt tal ore an the O10. tthe see re {suemly: Places new sea, wih the seal ip facing the tool, on the short end of Tool No. 20268 (Fig S51A}. Press the seal into the housing until the tol bottoms against the housing (Fig, 5.1B). Note: This seal must not protrude into the housing cavity Invert the pump housing (Nange end. up) on the bor peas Pace a now tea rth sal ip facing the ‘apres the va ino the Reng ed of the Rousse tine the too bottoms (igs 1) me "IF the housing seal bore is scored due to sel romoval, apply a light coating of Gasoila sealing compound to the seal bore instead of grease. saFis, 53 Section 5 — Reassembly STEP 2 Install the boating shoulder ring in, the [Ronee on the drive shall using Waldes Truste Picts oP iBAo' (Ne, 2008s) thie 5). Place the drive sha into the bearing on an atbor press wwth:thvcoded ene owe, Support ibe bearing fener Face with Ton) Ro, eas ese he: she ea te trig uni te hearing shoulder rng ic Mah eth the faring (ia, 32) Press the drive shaft roll pin into the drive shaft pla hile unl pin bottoms (Fig 8.20), = 25! iG STEP 3 Mount the pump housing in holding Hatre No, 1965, Never clap the ping Hoang ‘Grease theO,D.of the dive seat henring snd the drive shafe-assembly" into the hotsing '53A}, Do not force bearing into Use howsing Is. Isa Place the drive shalt spring washer against the bearing (Fig, 5b) . “ 52Assemble the retaining ring to the housing so that the open ends are against the depretaed area of the Spying washer, using, Waldes ‘Pruare Pliers No. 2500 (Ror boota) (Fig. 830), CAUTION: ‘This retaining ring will take considerable compression fotce to inert in the howeng” Use the Fecommencled: Waldes “Fruare. Plies ‘No, 2500" (No, 40043) and he extremely careful not to let the retain: Ing ring slip off the plies when installing STEP 4 Assemble the goor hub to the drive shat, ‘eth the notched portion of the gear hab inline with The driveshaft rll pin (Pig. 84a). Install Tool No. 19928 on the gear hub, Place the hab Fetaining washer and nut on the driveshaft and torque (ig .40 bibl Reter to Tongue Vale Chast for proper torque NOTE: The corrct torque on this nut is extremely important. Extensive damage to the pump and engine ray eal the nut ie not Properly Secured [REFERENCE TORQUE VALUE CHARTSection 5 — Reassembly STEP 5 Place tho rubber cushions on the governor SNeight retainer pins and assemble the ul tothe ‘Nolght retainer (Fig. 55a) fg Place the cushion retsinerson the weight retainer pins (Fg: 5b) Assemble the retaining rings into the weight retainer jn" slots with Waldes “Trunre “Applicator No. 18-0210-098 (No. 20045) (Fig. 5.5) GAUTION: Do, not dit, th etaing ek for proper assem ng to to fetaining rng® with a smal badd screw ‘Biny sid hot move under ght presnure se k STEP 6 Rinse the rotor thoroughly in lean fuel oi fr calibrating al, Place the rotor on top of holding Fiature ‘No.19965. Install the delivery valve to ite bore using Hctractor Tool No. 19589, Make sure that operates freely in its bore. NOTE: Do not mistake slight interference of the ctor collet inthe bore for delivery eave sticking. Ti the valve is not socured straight and tghe in the etre colle the cles diameter Can dag tn the Fotor bore Install delivery valve spring and a new delivery valve slope the stor bore Hnaaition of sed sto can fesult in leakage and low outpt at cranking speeds, Start the delivery valve retaining serew into Une pore {Using the fer end of the delivery valve Exteactor Tool No, 18389 or use a''16” hex key wrench (No, 12322) for a 280" delivery valve. Tighten the serew £0 the spectid torque (Fig 5.8) CAUTION: Exess tightening of tie screw may ie cause seizure ofthe hydraulic head snd rotor asembh Insuficent Torque mey eause leaking and hard sart= ne ie Delivery Valve Replacement Delivery valves of various retraction for diferent Sppication Corect part nae OV" etehed on the Head ofthe rotor indicate 8-001" oversize dalvery valve bore. A rotor so marked must tise 001" overeve delivery valve, Pare numbers for ‘both standard and oversize valves are listed on inh ‘ual pump specications. The oversize valve is leo ‘dentited bs" Hackening’ on both ends and in the ioe on the delivery valve shankSTEP 7 Remove the rotor from the helding fixture and submerge it sn clean fel oil or calibrating ol Install the pumping plungars and” check. them for {reedom of movement. Assemble the leaf springs) leat Spring adjusting screw (s) and shims (if twed) tthe NOTE: DMs roller hos vary in size for diferent ap Dieations and ate market with a mumber‘on the end, Eg, rom "20 to P10" in increments of "9" All out ‘astm ear the same mark The che sie for a fiven application is determined by part momber only. ‘Asser the cam rollers to the shoes by inserting om {he end of the shoe. Never attempt to press toler ing its shoe from the outer edges as the groove width at this point ls than the foller outate diameter Sand shoe breakage may reault Assemble the elles nd hogs to hoe ts In the rotor head (Fi. ba & Plunger Replacement: ‘Since the plungers are positioned centrally inthe bore during operation ond the rave carnal stort icear of plungers i virtualy nonexistent. Replecement heuer maybe’ made im Instances ohere bust or dlomage’ in handling hos occurred. Plungers of any seen namin ear re ard In fol ft Sizes: A." C and D. The rotor i etthed with the letter indicating bore size. This mark is found on the head of the rotor. 4 lunge rentcement is reece th ie do lgnation on the rotor and use the plunger of cor. ondinert number as dest on edu rs an art Naw Flea the sade ae rough", ‘bear part Nos ough 1108 respectively. The Teplacementplungers for a 30° diameter plunger pump ith. & rotor marked °C", ttould be part No, 11040. Always refer to current tn ‘dividual specications for part hum, NOTE: A limited number of pumps. will have a "ctched on the rotor folling the letter grading code. This mark indicates @ 00%" oversice plunger bare. Replacement plingers should be ordered acco Ing Yo the oversize plunger group shown on indieidual Speciiations bua. Trvtall Fixture No, 19969 in a vse (clamping on the fat) so that the sir inlet hole fe not covered bythe vie, Ascomble @ /4"-18 N'P-T. fiting to the ai inlet ofthe Agture. "his atting should be ‘adapted to 8 Supply of clean, filtered compres air, rerulated (0 slprestre between 40 and 100, ately, holding the rollers and shoes In th tal the rotor Senembly seth fate on the ae ile Gide. Rotate the rotor unt the rollers are puted to {hr extreme outward poston shoe fttoed on the ‘shring) by. the ait_preeure. Using Mlcrometer, measure. the rollertovlle dimension (Fig) antanceetwown hoe races ofthe ‘am rollers) and compare thie with the spe- testo “ose he flr tl desing The mp specification, turn the leaf spring adjusting [crew inward (clockwise) to merease and ota (Gounter-clockise) to reduce the roller-to-oler di mension. NOTE: ‘The rolle-toroller setting provides a com- Dletely acetrate maximum fuel adjosment and Enould mot difler from that shown t the appl specicationSection 5—Reassembly om nwt Fixture No, 19969 in a vise (clamping on the fiat) so that the sir inlet hole i not covered by. the ‘ise, Assemble 9 4°“18 N-P-P iting Yo thea inlet of tie ature. "This ting should te adap to 8 Supply of clean, filtered, comprensed al, regulaed toa pressure between 40 and 100 pst, Handle. the rotor {arefuly, holding the rollers and shoes in thelr slots Install the rotor assembly to the fixture on the a inlet side~ Loosen the dial indicator retsning screw and slide the indicator to itg outer limit. Rotate the ‘otor ntl the roller are pushed to thei extreme out ‘ward position (shoes bottgimed on the leaf spring) by the si pressure: Using a 1" to 2 micrometer measure {he tier orlerdipensons (F372) (stance fetween te outer erfaces of the posed am roles id compare this with the spocitcation. To set the follertovaller dimension tothe pump specinestion, set the lle, adjusting each leaf spring alternately: Turn the leat spring adjusting screws inward (clockiise) £0 Inerate end outward. (counterclockwise) to reduce the rolerto-oller dimensions. Singe each roller shoe for 4 given cylinder = contolled by a separate lel pring, it may be necessary to invertor interchange ‘at springs ta obtain correct dimensions on both sets Gf rollers: Holler settings of both evlinders unt be ‘vithin Oia" of each other while mafntaining the aver tage rolierstovroller setting within the spectiation Check centrality of the rollers (to assure that each fone starts ts pumping stroke at the same time) as {elt 8, Rotate the rotor until one roller is aligned with {he i inaeator plunger Slide the Tock inicator retaining screw. "Zero" in tn Afar on gk pnt of ery voting kid », Rotate rotor (ether direction) until the next Tie ores ia dicaton Bryer: Aloe SIny correction, cheek and ieeord centrality of all four rollers 6. Toller centrality is beyond specified tolerance, ler lo shoes can nerchanged Receck ‘centrality alter each change. Be sure to Tochec rolle-tocoler dimension. NOTE: ‘The rollertosllr setting provides « com Pltey’ accor asinumy feel aifsument and tou not ier from that shown tm the apliable specification, STEP 8 When the rolersowller adjustment ia Sorneted, remove the rotor assembly fom the Sxture, ski Cth er ps are oat Tsladged from ther slots "Thoraughly rinse the rotor {in dean fuel oi or eabrating oi and place the rotor Shank end up on top of Fstare Nor 19068, Place the arsine topo the rls with dete so Sicating the apposite nection of pump rotation (Fi. 28a) Tee ncenary since pump rotation aways ‘xpteued au viewed fromthe deve end.‘Te pump Tot deliver proper fuel Hf the cam ring is incorrectly ‘Soombled a if oe te = 4REASSEMBLY OF TRANSFER PUMP. SPRING WASHER DESIGN, STEP 9. Insert the two rotor retainers between the tor and head. Position the retainers 0 the cutout portion is over ihe hole which the regulator assembly oll pin enters (Fig 5.9). STEP 10_ The inside diameter ofthe transfer pump Tiner locating ting has dimples to keep the rotor fe. ‘einen at The dimples reno centered on ally" Place the liner locating Suh the dimples foward the rear of th pump. No dimples should eoincide with the points at mich the ‘brovretainers join, Do not seat the liner loeating sing at this time (Fig 6.100). ning over the meaner ‘The liner lating ring should be seted in place with the transfor pump end cap used as a instalation Yok Insta the end cap and tread into the hydraulic head by applying slight presrure on tof the end. ca, Roiate the cap counterclockwise untl'a sight “chk shar. hele tee alg thames ih the threads in the head, thas minimusing the posibiity of cose threading. umn the cap. deckwise by hand Unt tight, Continue tightening with wrench unt the {nd cap is bottomed inthe head (Fig, S40). Hemove te end cop, the liner locating rng should ow bo Al Install the transfer head (Fg, 9.100). the bottom of tts groove to avoid int fend cap threads a it installed cap seal othe hydraulic pe weal must be pushed down t5 france with the 23 a Insert the transfer pump liner so thatthe slat sn ine ih the hole whi the regulator asscably soll pt enter (Pig 30) vee Assemble sprinus to, transfer pump blade halves and inet the Blades in thelr slots nthe rotor (Fig 310. ‘The lade springs must be fully compresas! a they are pie and car shoal bake ot ca a he lades during instalation, asthe sharp edge ofthe Liner fan score the Bade ends *Fe 5a REASSEMBLY OF TRANSFER PUMP PRESSURE PLATE DESIGN A second style of transfer pump components is ‘currently inuse Steps 9.1 and 0.1 give instructions for reassembly of the new pressure plate” desig Deuals for reassembly of the earlier type “sprig “washer” design are contained in Stepe tand 10-08 Pages 5.7 and 5° Many of the component parts for these wo designs ‘renot interchangeable, and care shoul be exercised fo use only the correct parts with each design, Upgrading of an carly madel DMZ or DMA to the now “pressure plate’ design should be performed nly if kit form, and further Information on this Subject is contained in Service Bulletin 4 STEP 9.1 Assemble the rotor retainers to the head. and rotor withthe cutout portions meeting over tht Tollpin hole inthe hydreulle head (Pig. 8.91), Rotor Ftsners for th late desig are identified bya radial notch on the outside STEP 10.1 Place the liner locating ring over the [elt ain ae oli i agai heeds Ts mr locating rng fr the presse plate : split rng. Postion the spit in the rag 80" from the ‘pli in the vetainers: (Fig. 8.10.14} Install the gx in transfer pump seal into the hydra ttn the rancor snp Sel between the fingers wil enty this sea fom the Found cross seton snl ued withthe eal design amponents. The eorret seal must be used or eagh ‘sig In order to obtain the correct teeter pump pressure. The two types of transfer pump seals are not interchangeable Fig. 5.10.18) the transfer Tine withthe hole wl pln wil enter (Fig. 3 a ne 2 that the lot i i ‘regulator assembly 70 Toe), ‘Assemble springs to transfer pump blade halves and install the blades In thet slots tn the rotor (Fi Bu0.1D) ‘The "blade springs “must “be fally Compressed a8 they ore insealled snd care should be taken not to cock the blades during installation, as the sharp edge af the ner eam score the blade eds snSection 5—Reassembly SPRING WASHER DESIGN Assemble the transfer pump regulator components (Eig 5-t0) lastall the inlet filter sereen seal on the Iegulator, Using Tool No. 13301, place the remalatin pista seal in the groove of the fepalator, Do not ol ‘her the seal when susembling Install Ue piston to the {cgulator with the piston hore facing the inlet end of the reuulater. The’ pstor should wot ind or stick inithin the regulator bore, Install the regulating spring. Install the nd plate adjusting plug with 9 532" het Liytwremch (Nar i290) unt iis hs with the inlet side othe eegulator. CAUTION: Do not tighten the yy Hurther at {hs tiny a hie can resale i when the ‘hap Ts completely aserbled and operated Assemble the trnler pomp sring washer and ltr ‘een retaining washer tothe reguldtor ane (Fi 50h}, lace the inet fer sereen un the renulator assembly (Fig. 8:10) mucr iter sence Avccmble the relator assembly to. the liner (i Sighs The focating pins he nthe contre ‘i the weaulatr for the proper pump rotation. On the ince a the rexlator assembly “Co “CC> we tarnped {or docknie or counterclockwise pump rotation, Fetal tale pur end cp ad thread into he OF the eng eap, Rotate the cap counterclockwise une slight “cick te hear now tam the cap dockwie Manel uni ight (Fig. 8:10)Section 5 — Reassembly PRESSURE PLATE DESIGN ‘Assemble the transfer ator components GFie'S.1G IE, Install Ge ret ter seroon sel on theringaltr: Uaioe No. Sab place ‘he ‘BiSnotrel Duce theseal whew assembling, Intl he pte th rato ith he ton be facing {Inlet ond ofthe regulator. The piston should not Bind ck iti Te sty br eal he log witha 952" herkey wrench (No. 19398) uate ‘Huth with the inlet side of the regulator. CAUTION: Do not tighten the plug any farther at tas time, as this ean result in severe damage when the pump 1 completly assembled and operated Sos ble the regulator assembly to the line (Fi “thea mabe nthe ret Ble tthe regulator forthe proper pump rotation, On the fice of the regulator assembly Cor SCC" is Stamped for ‘clockwise or coutteriocwise pump tocar Assemble the flier sersen to the pressure plate and install the sereen retaining ring. (Pig. §.10.1G) OG Coat the beveled surface of the pressure plate and the threads on the outside diameter of the end ap ‘with Lubriplats #030AA oF equivalent Install the assembled pressure plate an scrn onto the transfer pomp regulator assembly (Fig. 5.10.18 Insal the transfer pump end cap and three into the raul head ‘alle pressure onto cam cap Rasa the ep couterSosoee une stslightcick"is heard now tarn the cap Clockwise yan unt tight (Pig. 810-1) \ Sy eeeSTEP 11. Place the governor asm in position in the Rousing with the fork'for the govemnor linkage hook ‘sembly facing the rea of the Purp Insert the pivot aft (Knife edge facing the reat of the pump), in the im slot (Fig. 1a). ot shaft sea] and nut, and tighten Ascomble the wssively fo the spected tongue (Fig. both cap nuts oa STEP 12 Remove the head and rotor assembly fom the fxcure. Postion the governor Weights into the re {iner sockets (Fig. 5.120. Inn the governor trae water and hrs seve Into the lower slot ofthe governor weights by iting the weights outward sighs. The two deep gooves al ihe Jit lew hou face para we ned Pi S:10b), Sih scons the tops ‘They should sal be level a Art seve ‘the assembled weights ‘and ‘ollspeed against the STEP 13, "The hydraulic head and rotor assembly, hiding the tater pump acy an ig a {betel fatal elo the hae ead ser fest greasing ft si eh fim of around th iste edge of the housing ad tly downward at the rear o sd am ring so that the unthreaded Wil sure proper portion of the tiny fing. Porn the eight retaler until the del point on the end of the fotor registers with the drill paint‘on the drive shaft {Grasp the hydraulic head frmfy in both hands and insert It into the housing ore witha alight rotary motion (Fig. 18a & 5.136) Do not force. It the as. fembly should’ jam during insertion, withdraw ond Sart over, Make sure the azembly ig y7ung nt ep ep zt heheh ol Eure ie ‘ull tase damage to the sea, resulting in lo Stn force ay ceived to overcone the de Shaft spring washer fore Fe, si soSection 5 — Reassembly t sh STEP 16 Depress the metering valve assembly and the guide stad and washer nto the housing and tighten (Pig. 516). fe STEP 14 Rotate the head assembly until the head ate Tocking strew holes line up with tht, corresponding holes he housing. Inert the two head locking screws finger tight (Pig 14). Do not tighten witha erench ‘in Step 28. ‘re she STEP 47 Pall back the governor linkage book, Stetching the spring Just enough to assemble the hook ‘orrecty othe fork on the governor arm” Position the poste end ofthe on ve th pon the metering {or foedonn of movement fsevemor aris STEP 15 Assemble the metering valve, spring and fr, Mm tolthe sem sscrbly (Pig 8650). sh sh Place the metering valve assembly into its bore (Fig 5.186), Depress and rotate the valve several times Insure freedom of movement. If valve sticks, rinse of silent odor erating: Neve any abrasive, or the special surlace treatment provided wi removed. S10oh STEP 18 _Ascomble the governor spring, gpring re- Ine, esr and dle Spring glue on the Hanh. ‘py aR ito pene tof pats in ores to ih iemn place whe assembling install the epeing ‘omponents onto the guide stud az shown (Fig. 8.18) STEP 20 Invert the the vice. Coat the seal of clean ease, Insert-and tighten the heed locating Screw to specified torque (Fig. 5.20a & 5200). and holding fxtre in Pitethend ovating srrew with i TEP 21 Azsemble the auto advance components STEP 19 Apply ali Hier Zia) Pace the reed vals Int the piston bole vt shotolf shal seals Assemble the throtle plug snd inset and tighten two reed valve screws, femoly partial through ts bore nthe housing Slide Urn’ 5/64" hex hey wrench to the specied torave the thatte shat lever over he throtle shaft so the projection inte throttle sha lever bore eng {he fese ey tay on the shaft. Postion the forked end ofthe thrftie lever so that iesteaddles the guide stad ostmile the shutoff lever amet with shighe Fo {ses motion, so ts not a damage the sea. I the throttle shat lever fs comecty installed, rotating the throttle ‘Shaft assembly tothe tear will ese compression of the iovernor spring (Fig 5.19) Trtal the piston ring seal and ringin the groove of the ‘advance pitt, Assemble the spring and washer onto the ndvehce adjesting rerew and place the assembly Into the hore ofthe advance piston (piston rng sie) (Compress the washer and spring and install the advance ring retaining Ying using WaldesTruare Piers No. E00 (No, WH4i9) insert the advance adjusting screw scembly ato the piston hole plug and tighten using HPs ey wrench (No) sm ate coe ‘lockwise Use care not to damage the piston ring when Installing the assembly to the piston hole plag. The tvivance adjusting stew length should be preadjusted {efore bench testing, a indicated on the pump spect tation, Install the adjusting serew nat and new Seal f SS sitSection 5 — Reassembly Install the advance plug and power piston plug as- emily in the pump housing (ig. 62D) NOTE: The sides of the housing near the advance boss bege a "Cor “CC marking to denote pump fabion: ‘The power side ofthe piston is located on the de manked °C fora clockwee rotating Pump etd Align the advance pin hoe in advance piston withthe Unreal ole nthe cam ving. Inset vance pin lit the cant ring Dalkend Ses (Fig. Ble). fe may Herne 9 ve th pin Back and forth lightly to islitace installing. Install the advance sew hele plug and new sel i IN hoosng ond hen wing Toot No Ts80 CE. Siar ‘Tighten, the advance plugs to the specified torque (ile Sate @'s2ih ™ STEP 22 lov he nop and Daren te vs. for to mea sting 7 RET Uvetliciovet in wide open poston and rats Uhedsiveshaft inthe propor direction of rotation un- UPN Bt a thon of the overnot arm engoge lots ithe thrust {beque screw Uf uscd] should bo backed out. throttle lever eld in wide open postion, use link {gauge No” 1804 to check the cnarance between t feats shalt and che verte ab on the in ‘(Refer to" pump ‘spectcations ont cea Aaa ofthe artes ‘ade by using linkage Wrench No, 13979 to change Teta engine the inkage hook Loosen the ‘Agjuting screw and nid linkage to maximum open Tngth: Taser nkage Gauge: No. 160 tert tab ond sl sate and side nase Socket ro then apt fice of ab as int, en adjusting. se, adjustment end reset required (Pig. 8.2). 512STEP 23. Install a new shutiof cam with the tight inner edge engaging the sit, The cam should Ssapint poston. ial ne theo sha fetainer iprath the stright mner edge engaging the ot The ‘tip Should snap ito pontion (Fig: 823) fe Sk STEP 24 ont! enver and natal caver oh pump, [Assemble a new easket «governor ‘up the fa STEP. 25incert end cap plug (No. 20849) in the end cap ‘nd tighten the end cap to the specified torgse, sing the appropriate end cap wrench CAUTION: ‘The transfer pump end cap inlet reauies Sapecal Reng wthan Oring scl 20 wre thread): Do not use a taper pipe treed type fting a8 {his cid bottom and rel in seizure ofthe bead nd fotor aatempbly and damage tthe end cap thread. ‘Assemble the end ap locking plate washer and stew, tothe hea and Uahten (Fi B50)” STEP 26. Tighten the two head locking serews to the spotfied torque (Fig. 5.20) STEP 27, Remove the pump ftom holding fixture Sint install the pump flan seat (Pig. 327). si ohSection 6— Accessories ELECTRICAL SHUT-OFF ‘The Electrical Shut-Off Device may be furnished for “onergived to run" or “entrplued to shutoff” operation. I is evalable for 12,24 and $2 volt systems. Since this Aovce is housed within the governor contro cover, the ‘external dimensions of the pump do not change. OPERATION ENERGIZED T0 SHUT-OFF (E780): Energizing the fall overcomes the fore of th shut-down eal spring. pulling the arm in and eausing the tab on its lower end o-contact the governor linkage hook. This moves the Tinkage hook sgainst. the governor linkage spring tension, rotating’ the metering position and eating of the ful (Fig. 6.1).NOTE: Most BASSO applications se « coll with a voltage rating ower than system voltage to provide ponitve shut-off faction, This is allowable since the colli usod under Ineermittent duty conditions ogee ENERGIZED TO RUN (BTR: Deenergizing the coi lows the shut-down col spring to release the shutoff finn. The lower end of the aria moves the governor Tinkage hook, rotating the metering valve tothe closed foe (Fig. 62). NOTE: * ‘applications of Modet device for emergency Gee if the cll Becomes inoper ‘dueto olecrial system failure, The override conssts of ‘trod and guide asembly atachod tothe control cover through « tapped hole at the rear of the cover in a location that. sligas the rod with tho solenoid arm ‘assembly. When the rod is pushed nto the cove to the Timit of its travel it contacts the solenoid arm fsvembly and locks i up agelnst tho solentd, allowing the linkage hook to operate. Shutoll of the pump ‘during an electrical failure is accomplished by pulling ‘out the override rod ff tb DISASSEMBLY Remove the cover screws, governor control cover and [fesuet from pomp, Remove the eover contact hls ‘Reshers and work the solenoid assembly cut of ‘cover, Remove Use shuteff spring and arm Some applications wil incorporate a grounding wire sscmbly secured atone end to a contact serew and at the other end to the rear conteal cover screw in order to. provides) grounded connection. On these ‘applications a'~hot” lead only Is required for the ‘ohposite terminal es MECHANICAL OVERRIDE 1. Remove the governor control cover 2, Pushin the control rod so thatthe snap rings away from the inside edge of the guide ascembly. 4, Remove the snap rng and pull the control zed out of the guide. 4, Loosen and remove the cover gue, the washer and the eal4 ~~ INSPECTION Examine the solenoid visually for cracks and swelling {nthe enespaslating material and Toowsnes ofthe contact screws. ‘Check the solenoid for a complete 'Sreuit with an ohmmeter. REASSEMBLY AND ADJUSTMENT Assemble the shutoff arm and spring to the col, Before installation of the solenoid assembly to the cover fs ‘made, adjustment ofthe arm travel and spring tension Should be carried out as Indicated (Figs 6.5 through ‘S}asing tools 14087 and 14726, Check the linkage hook adjustment with reference to Setin 5, Step 2, Tnstall, new insulating tes to both contact screws, Inset the assembly into the governor control cover a3" Unit. feplace the insulating washer and assemble the contact ‘nuts (10-15 inch pounds). Mount te cover assembly, ‘vith new cover seal, to Ube pup and tighten securely ENERGIZED TO RUN. ENERGIZED TO SHUT OFF ENERGIZED TO RUN ENERGIZED TO SHUT OFF ENERGIZED TO RUN ONLY ENERGIZED TO RUN ONLYFg a Section 6 — Accessories RBASSEMBLY- MECHANICAL OVERRIDE 1. Serew guide into the rear of the governor cover, securing te washer and’ seal 2 Push in the control rod and secur it from the fide with" che snap Ting 3, During normal run conditions when the electric shutoff Ts in operating positon, keep the. rod txtended to its fal outward moveinent TESTING With the pump mounted on the test bench, the lectrical Shutoff device’ must. be checked "with saad voliage rating inte on cover) and ‘wide open throttle at the following speedo fi iad speed C: High idle (hutott only) 1K use of automotivetype batteries is impractical, ond heavy duty battery charger ean be used fg lags une Ste and wa wth rpm dr (elt max doing apption Use of small, inexpensive trickle chargers is not recommended: since a voltage drop of 2 lls can ‘beexpected when current is plied to the coll Th an ful in luestionable operation and rejetion of {zondcols'under some cones tions, NOTE: Do not attempt to check solenoid operation SH. the cover removed trom “the pump. The ‘evernor bnkage Spring ids operation when The SPEED LIGHT LOAD ADVANCE ‘To obtain the desired. performance from some Chines, the characteristics of both speed and oad Sidvance are needed. (e rtarded injetion ming at Starting. advanced injection timing inthe full Toad Speed range and forther advanced Injection ming at ‘dueed hein nade) Model DM pump for sch plications are equipped with a speed ight ance which funetions during part load operating fonditions. See Fig. 69) 2 ‘The speed/light load advance mechaniem (Pig. 6.10) consns of usped advance ison and aiped en ron. The advance pntn, in aalielybye anaer rnd conneted 20 cam ring by thecam pin sensing piston fs hydralial a rang anus th the hydrpl ad he tanser LenS posse Aappied Lo the speed advance piston icreamee and ‘Reroasos with engine speed. Fel pressure from the Srging bnnul i gop wp The fond sensing piston and varies as the metering valve is opened Elo the governor in response changesm engine To In operation, the speedght load savance device ‘When the engine te started, injection siming io fetarded, See Fig. 6.11) As the engine. speed ie imereased, the transfer pump pressure moves the ffecanane pen ceusing ca ing a ita direction of rotor rotation to advance Injection timing’ When the engine reaches Nghidle ‘elaine there evry Te london the engine at highidle, the metering valve ie nearly closed nd Brestrein he caring annul Jom As the oad the engine i irene nd wngie sped governor ene the marin, aie, tbe nerebing hydraulic reeare inthe Share annua Tne Increased thargng pesire spring ease the lond sensing parton Dish the spect advance, in the same dirction a Foto rotailon to retard jection ming, ISee Fi. 6 13) When the engine is operating a fall load and Speed, the transfer pump pressure applied to the ‘abvance piston is balenged by charging” preeure Applied to the load sensing platon. hs pressure ‘balance ‘maimeans. the advance "piston "in the Bazin ful Toad advanes ‘paseo, “When the ‘Siler, raducing™ the ‘presrure in the charg Smulis. The reduced charging preseare the lood "sensing piston allows. transfer pum; pressure tomove the advance plston tothe light dvanced position. (See Fig. 69)Fhe epee ight lod advance mechanism shown in 6:0is typical of the present design. However, « emer ater and bie spring can be ade to che Ioad'sensing for taloring advance performance %0 pectic applications (See Fig. 618) All adjustments of the, specd/light load advance devi mont be ge -on the "tat "stand Readjustment of this device on the engine cout result ‘damage due to operating the ‘engine et excessive advanced Gining Removal of the load sensing piston from its plug wil ‘not be possible in early medels.As the load sensing som an fT" made ou "the near fotore to" parm disassembly. Presently, the piston and plug must be Serviced with the aasembly 80811, whee const of {elon Gensing piston plug, piston seals and snap rina ‘THE ROOSA MASTER ANEROID Apr sai etn coned Sear at Bi Se Seether ie es Sn eieyine ie eal During acelerton, whe the injecon_ pu aes ioe i tai foto es Unl al bo aed inet as suppl tothe tf to conmis Seager aan fant guancle eclas fhe ia ond fun quay dete "dr sctserain i etd W prea oveialt a Sxewolve sme Th ante Soe ce was : ope and raced "fal genni ne hae apn Titockange cones tp tapSSt eal tle tS Drove ehugh ao asc eoabaatons “