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'cav Dpa Pump Rebuild Manual'




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Section OF THE FUEL INJECTION PUMP
The injection pump is a pump fitted
with a mechanical governor and a operated automatic advance mechanism The
pump is on the rear of the engine plate and is driven by the timing chain A
splined quill shaft having a master spline at each end
Fig Cal
Main fuel filter air bleed points
1 Fuel cutoff tap 2 Blanking plug 3 Union screw
Taxi Issue 2 55430
THE FUEL SYSTEM Injection Pump Ca
close fit in the stationary hydraulic head The pumping
section of the rotor has a transverse bore containing
twin opposed pumping plungers These plungers are
operated by means of a cam ring carried in the pump
housing through rollers and shoes which slide in the
rotor The cam ring has four internal lobes operating
in diagonally opposite pairs The opposed plungers have
no return springs but are moved outwards by fuel under
pressure from the transfer pump the flow of fuel and
outward displacement of the plungers being determined
by the setting of the metering valve and the speed at
which the pump is rotating As a result the rollers which
operate the plungers do not follow the contour of the
internal cam ring entirely but will contact the cam lobes
Fig Ca2
at points which will vary according to the amount of
Fuel injection pump air bleed points plunger 1 Union nut 2 Air bleed screw 3 Air bleed screw
The automatic light load advance mechanism operates
by rotating the cam ring within the pump body A ball
ended lever screwed into the cam ring is operated by
to ensure correct location transmits the drive from the a piston one side of which is sliding in a
chain wheel to the injection pump drive hub cylinder The other side of the piston is subjected to fuel
A central rotating member forms the pumping and at transfer or drain pressure according to engine rotor and this is driven by the drive
hub which is admitted to the cylinder through the a splined drive shaft on which is mounted the locating bolt and a port in the
cylinder wall The flyweight assembly of fuel is controlled by the rotary and endwise movement
Mounted on the outer end of the pumping and of the metering rotor is a transfer pump Machined in the surface of the metering
valve is a
This pump raises the fuel pressure to an intermediate helical groove A vertical flat extends upwards from the
level and as its capacity is many times the maximum helical groove and protrudes beyond the hydraulic of the injection pump a regulating
valve
housed in the pump end plate allows excess fuel to be
bypassed back to the suction side of the transfer pump
A B
The pressure regulating valve in addition to pressure of the fuel from the transfer pump also
provides a means of bypassing the transfer pump when
priming the injection pump Referring to Fig Ca3 it
will be seen that the valve is cylindrical and contains
a small free piston the travel of which is limited by
two light springs When priming the injection pump fuel
at lift pump pressure enters the central port in sleeve and moves the free piston against
the pressure of the piston retaining spring to uncover the
priming port in the lower end of the valve sleeve The
priming port is connected by a passage in the end plate
to the delivery side of the transfer pump thus enabling
the fuel to bypass the stationary transfer pump and
prime the injection pump
When the injection pump is in operation fuel at enters the lower end of the valve sleeve forcing
the free piston upwards against the regulating spring
As the engine speed increases the transfer pressure rises Fig Ca3
moving the piston against the pressure of the regulating Section through the end plate and regulating valve
spring to progressively uncover the regulating port in A Priming 7 Regulating piston
the valve sleeve and allow a metered flow of fuel to by B
Regulating 8 Piston retaining spring
pass back to the inlet side of the transfer pump 1 Inlet connection 9 Fuel passage to transfer
The transfer pressure therefore is controlled by a 2 Sleeve retaining spring pump between the regulating spring pressure and the
3 Nylon filter 10 Regulating port
4 Sleeve guide plug 11 Fuel passage to of the injection pump at any moment 5 Regulating spring pump outlet
The pumping and distributing rotor revolves and is a 6 Regulating sleeve
Taxi Issue2 3125 Ca5
Ca THE FUEL SYSTEM Injection Pump
Fig Ca4
Section through the fuel injection pump
1 Backleakage connection 5 Transfer pump 9 Pumping plunger
2 Governor spring 6 Hydraulic head 10 Drive plate
3 Metering valve 7 Cam ring 11 Governor weight assembly
4 End plate and regulating valve 8 Automatic advance device 12 Quill flat is open to fuel at drain pressure in the governor
The under side of the metering valve is subject to fuel
housing at transfer pressure which tends to force the valve
In the surface at the lower end of the metering valve is upwards This upward movement of the valve is con
machined a flat the upper edge of which is of the same trolled by an adjustable stop screw which sets the
pitch as the helical groove This flat is open to fuel at relative positions of the helical groove the flat on the
transfer pressure lower end of the valve and the timing port so that light
The width of the land between the helical groove and load advance is obtained at the required engine speed
the flat at the lower end of the metering valve is slightly Machined on each lobe of the cam ring than the diameter of the timing port in
the metering after the peak of the cam is a retraction curve Under
valve chamber in the hydraulic head The timing port running conditions when the injection cycle is is situated opposite the metering port
is connected the distributing port in the rotor and the outlet port on
by a passage in the hydraulic head and the hollow the hydraulic head are still in partial alignment with
locating bolt to the port in the advance cylinder each other As the plunger rollers move off the peaks of
When the metering valve is in the fullload position the cams the retraction curves allow the plungers to
the helical groove in the valve is aligned with the timing move slightly outwards This movement of the plungers
port in the hydraulic head and fuel at drain pressure is effects a sudden reduction of pressure in the to the advance piston As the drain
pressure is line so preventing secondary injection and allowing to overcome the piston spring pressure the injector nozzle needle
valve to snap onto its seating to
cam ring is held in the fully retarded position terminate the spray of fuel into the combustion chamber
Under lightload conditions the metering valve is without dribble When starting the engine the to the low fuelling position aligning the
flat at valve is in the fullload position and the advance piston
the lower end of the metering valve with the timing port is subject to fuel at drain pressure As drain pressure is
The advance piston is now subject to fuel at transfer not sufficient to overcome the pressure of the and the piston and cam ring move to
the fully piston return spring the piston and the cam ring position in the fully retarded
Taxi Issue 2 3125
THE FUEL SYSTEM Injection Pump Ca
The distributor part of the rotor has a central axial
passage which connects the pumping space between the
plungers with the four inlet ports and single drilled radially in the rotor The radial hole at the
outer end of the rotor is the distributing port and as
the rotor turns this port is aligned successively with
the outlet ports in the hydraulic head from which the
injectors are fed via external highpressure pipes The
inlet or charging ports are equally spaced around the
rotor at an intermediate position and as the rotor turns
these are aligned successively with the inlet or metering
port in the hydraulic head This port admits fuel to the
rotor under control of the metering valve which governed
The mechanical governor is of the flyweight type the
weights being held in a retainer which is the injection pump drive hub and the drive
shaft and rotates with these components as a single unit
The weights are a sliding fit in the retainer pockets and
are so shaped that when under the influence of centri
fugal force they pivot about one edge A thrust sleeve
which is a sliding fit on the injection pump drive shaft Fig Ca6
is moved axially by the flyweights Movement of the Mechanical sleeve is transmitted by means of the governor
1 Governor weight 9 Metering port
arm and the springloaded hook link to rotate the 2 Governor arm 10 Metering valve The governor arm pivots about a fulcrum
3 Shutoff bar 11 Timing port
on the control bracket and is held in contact with the 4 12 Control sleeve by spring tension Connection between the 5
Idling spring 13 Drive shaft
6 Governor spring 14 Thrust arm and the throttle arm and shaft assembly is 7 Throttle shaft 15 Weight through the
governor spring and the idling spring 8 Linkage hook
and its guide
A shutoff bar operated by an external lever rotates
the metering valve to close the metering port
The metering valve is provided with a vertical slot
along which fuel passes at transfer pressure into the
metering port The valve is situated in a chamber in the
hydraulic head into which the diagonally drilled metering
port opens and rotation of the valve varies the effective
area of the metering port to regulate the flow of fuel to
the pumping and distributing rotor
When the throttle arm is moved to give increased
speed the light idling spring is compressed as the guide
is drawn through the governor arm and the governor
spring is tensioned Tension of the governor spring acting
upon the governor arm and thrust sleeve resists move
ment of the governor flyweights As the engine speed
increases the increasing centrifugal force moves the
flyweights outwards overcoming the governor spring
tension to move the governor arm and the metering
valve towards the closed position When the selected
speed has been attained it will be maintained by governor
action Should the engine speed fall the flyweights will
move inwards causing an increase of fuelling which
restores the selected engine speed
When the throttle arm is in the idling position the
Fig Ca5 governor spring is untensioned and governing action is
Lightload advance device controlled by the light idling spring
A Full load 1 Transfer pressure In operation fuel at lift pump pressure enters the pump
B Low load 2 To pumping element through the connection on the pump end plate and passes
Taxi Issue2 81968 Ca7
Ca THE FUEL SYSTEM Injection Pump
through a fine nylon gauze filter to the inlet side of the 1
transfer pump
From the transfer pump the fuel passes through a
passage in the hydraulic head to an annular the rotor and thence to the metering valve
The position of the metering valve depends upon the
setting of the throttle arm which varies the pressure on the governor arm Any variation in
pump speed is accompanied by an increase or decrease
in transfer pressure which assists in regularing the flow
of fuel into the pumping section of the rotor The
volume of fuel passing into the pumping element is by the transfer pressure the position of the
metering valve and the time during which an inlet port
in the rotor is aligned with the metering port in the
hydraulic head B
When one of the rotor inlet ports is aligned with the
metering port in the hydraulic head fuel at flows into the rotor and forces the apart the amount of plunger governed by the quantity of fuel which
can flow Fig Ca8
into the rotor while the ports are aligned As the rotor The injection cycle
turns the inlet port is cut off and the pump to be forced inwards by their rollers bearing on a A Inlet stroke 2 Pumping and
distributing rotor
B Injection stroke 3 Pumping of cam lobes This causes an immediate rise in 1 Fuel inlet 4 Fuel to as the single
distributor port in the rotor
comes into register with an outlet port in the hydraulic engage eccentric slots in the top and bottom the plungers force the fuel up the central
bore of plates Two lugs on the top adjusting plate engage slots
the rotor and out to the respective injector in the bottom adjusting plate to locate the plates one to
The maximum amount of fuel delivered at one charge the other
is controlled by limiting the maximum outward move The top adjusting plate isclamped to the rotor by
ment of the plungers In Fig Ca7 is shown an endon the drive plate the adjusting plate being cut away in
view of the rotor and it will be seen that the cam rollers the areas of the drive plate securing screws to permit
are carried in shoes which bear against the ends of the adjustment of the plates by rotation The maximum The roller shoes which slide in slots
in the ward travel of the pump plungers is limited by the ears
rotor have specially shaped projecting ears which of the roller shoes coming into contact with the curved
slot sides in the adjusting plates As the slots are eccentric
rotation of the adjusting plates relative to the rotor
provides a means of adjusting the maximum plunger
stroke
Section Ca7
REMOVING AND REPLACING THE FUEL
INJECTION PUMP
Thoroughly clean the outside of the injector pump
body and then disconnect the throttle stop and kick
down if fitted controls Disconnect the fuel feed and
return pipes from the pump
Disconnect the high pressure pipes from the pump and
the injectors remove the clamp and damper bushes and
detach the pipes individually from the engine Seal the
pump outlet unions with sealing caps 18G 216 to prevent
the ingress of foreign matter
Fig Ca7 Unscrew the three nuts with plain washers securing the
Maximum fuel adjustment injection pump flange to the rear of the engine front plate
1 Top adjusting plate 4 Pumping end of rotor and draw the pump rearwards to disengage it from the
2 Roller shoe ear 5 Pumping plunger engine Withdraw the quill shaft from inside the injection
3 Roller pump chain wheel hub
Ca8 Taxi Issue 3 94241
THE FUEL SYSTEM Injection Pump
Before replacing the fuel injection pump it is necessary Place a new joint washer in position on the engine front
to set the static injection timing plate and offer up the injection pump to the engine
To ensure correct timing relationship between the Engage the pump drive hub with the quill shaft and
injection pump and the engine the injection pump driving retain the pump in position by fitting the securing nuts
hub the quill shaft and the driving flange of the injection and washers finger tight Rotate the injection pump to
pump chain wheel are provided with master splines also align the timing mark on the pump mounting flange
a timing mark is scribed on the fuel injection pump with the timing pointer Tighten the three nuts to flange and an adjustable timing
pointer is the injection pump in this to the flange of the chain wheel hub Refit the highpressure pipes and the
fuel feed and
Before fitting the injection pump to the engine the drain pipes Connect the throttle and shutoff of the timing pointer on the flange of the
chain and ensure that both controls have their full range of
wheel hub should be checked using timing gauge movement
18G 698 and reset if necessary Bleed the fuel system as described in Section Ca5
A degree plate fitted to the crankshaft pulley with pointer on the timing case is provided to Maximum and idling speed ease of timing
After fitting either a new or overhauled injection pump
Initial adjustment of the injection timing is provided for the engine maximum light running speed and the idling
in the injection pump driving flange the holes for the speed must be checked and adjusted if necessary Before
bolts which secure it to the chain wheel being elongated making either of these adjustments it is imperative that
Crank the engine until the appropriate timing mark the engine air cleaner is correctly serviced and with the timing groove on the
crankshaft Run the engine until it has attained its normal Ensure that No 1 piston is on its compression most important
Ensure that the shut
stroke off control is in the fully open position and remove the
Remove the injection pump chain wheel coverplate locking sleeve from the maximum speed adjusting screw
From the front of the timing chain case and note the Using a tachometer to check the engine speed adjust
position of the master spline in the pump driving flange the maximum speed stop screw to give a maximum light
which should now be in the seven oclock position as running speed of 3700 rpm thus giving a maximum
seenfrom the front of the engine road governed speed of 3500 rpm Tighten the locknut
Insert injection timing gauge 18G 698 through the Fit the locking sleeve and seal it with wire and a lead
chain wheel hub engaging the splined end of the gauge seal using sealing pliers 18G 541
with the internal splines of the pump driving flange The Adjust the idling stop screw to give an idling speed of
master spline will allow the gauge to engage the driving 600 rpm and tighten the locknut
flange in one position only Turn the gauge by hand
undue force is not necessary in a clockwise direction
as seen from the rear of the engine to take up any
backlash in the injection pump drive mechanism Hold Section Ca8
the gauge in this position slacken the two securing
DISMANTLING AND REASSEMBLING THE
screws and move the timing pointer to align it with the
FUEL INJECTION PUMP
slot on the edge of the gauge Should the movement
required to line up the timing pointer be appreciable Dismantling and servicing of the fuel injection pump
then initial adjustment should be made by altering the should only be carried out by specially trained of the injection pump driving flange
relative to
the chain wheel This adjustment is made by four bolts securing the driving flange to the chain
wheel and carefully turning the driving flange the
required amount by means of the timing gauge Tighten
the driving flange securing screws and carry out of the timing pointer as described then remove the timing gauge
NOTEAfter every occasion of injection pump re
moval or attention to the crankshaft camshaft and timing
gear the position of the timing pointer should be checked
and reset if necessary as described above
Fit the injection pump quill shaft into the Rotate the injection pump drive hub and position the
master spline in the drive hub at seven oclock when
Fig Ca9
looking on the drive end of the pump This will engagement of the quill shaft splines with the drive Checking the position o f the injection
pump timing
hub pointer using timing gauge 18G 698
Taxi Issue 6 83137 Ca9
Ca THE FUEL SYSTEM Injection Pump
and the Service tools and special test equipment referred slide washer and piston from inside the advance device
to in the following instructions should be available The housing Remove and discard the O seals from the
workshop in which these operations are carried out spring cap and end plug
should be absolutely clean and the atmosphere free from Slacken the fuel inlet connection and then remove the
dust or dirt It is also recommended that components screws and studs securing the end plate to the hydraulic
are immersed in clean Shell Calibration Fluid C head Carefully remove the carbon vanes from their after they are dismantled from the main
in the transfer pump rotor and withdraw the to protect them from possible damage and pump and to prevent the ingress of foreign
matter Unscrew the fuel inlet connection and carefully with
Abrasives should never be used for cleaning as the draw the components of the regulating valve from the
resulting damage would seriously impair both the end plate in the following order sleeve retaining and the working life of the pump The
com nylon filter regulating plug reguIating spring valve
ponents should be washed in clean Shell Calibration sleeve with piston and joint washer and lastly the piston
Fluid C but they must not be wiped with cotton waste retaining spring
rags or cloth wipers of any kind
Hold the drive hub with drive shaft screw assembly
Cut the sealing wire remove the coverplate and joint tool 18G 659 and using box spanner 18G 634 in from the side of the pump housing and drain the
tion with a standard ratchet wrench slacken the transfer
fuel oil from the pump pump rotor The word OFF and an arrow etched on
Withdraw the quill shaft from the drive hub and the exposed face of the rotor indicate the direction in
mount the pump on assembly base 18G 633 A secured which the rotor is unscrewed
in a vice Unscrew and remove the two hydraulic head locking
Remove the banjo pipes from the hydraulic head screws one of which carries an air vent valve and care
Unscrew the selflocking nuts with plain washers and fully withdraw the hydraulic head and distributing rotor
reniove the shutoff lever and throttle arm from their assembly from the pump housing Remove the Remove the dust cover from each shaft Cut the
from the groove in the periphery of the hydraulic head
locking wire unscrew the two control cover securing Unscrew the transfer pump rotor taking care not to
nuts and remove the two flat washers Press the throttle allow the pumping and distributing rotor assembly to fall
shaft downwards and withdraw the control cover com out from the hydraulic head
plete with shutoff shaft and adjusting screws Remove
Stand the hydraulic head assembly on the bench with
and discard the control cover to pump housing gaskets
the drive plate uppermost Hold the drive plate with
Press back the locking tabs and unscrew the two assembly spanner 18G641 and unscrew the two drive
control cover studs and the small set screw securing the plate securing screws Remove the drive plate lift off
control bracket to the pump housing Remove the keep the top adjusting plate and withdraw the rollers and
plate and tab washers then lift the complete control roller shoes from the pumping and distributing assembly together with the metering valve
Withdraw the rotor from the hydraulic head and re
shutoff bar from the pump housing Remove the shutoff
move the bottom adjusting plate Refit the rotor to the
bar from the control bracket Disconnect the metering
hydraulic head and to protect the working from the linkage hook and protect its precision
immerse the assembly in a bath of clean Shell surface by immersing it in a bath of Shell Calibra
Fluid C
tion Fluid C Unscrew the selflocking nut and remove
the nylon pivot washer to release the linkage hook from Withdraw the cam ring from the pump housing
the governor arm Disconnect the throttle shaft link from noting the arrow etched on the visible face of the cam
the governor spring and remove and discard the two O ring The arrow is to assist when reassembling and ifs
seals from the throttle shaft Disconnect the governor direction corresponds with the direction of pump rota
spring from the idling spring guide and withdraw the tion as shown on the pump and spring from the governor arm Remove the
Compress the cam ring locating circlip using arm spring to release the governor arm from pliers 18G 1004 and withdraw the circlip from inside
the control bracket pump housing
Turn the pump upsidedown and slacken both the Hold the drive hub with drive shaft screw cap and the end plug in the advance device
tool 18G 659 and using torque adaptor 18G 664 and a
housing until the pressure of the maximum advance stop standard socket wrench unscrew the drive shaft screw
spring inside the advance device housing is relieved from inside the drive hub reversing the procedure the cap nut and the head locating bolt
both in Fig Ca12 The splined drive shaft complete with
of which have aluminium and rubber sealing washers governor weights assembly may now be withdrawn from
and remove the advance device housing Unscrew and inside the pump the advance screw from the cam ring Remove Remove and
discard the 0seal from the drive shaft
and discard the advance device housing gasket and remove the weight retainer weights thrust washer
Unscrew the end plug and the spring cap noting the and sleeve from the drive shim inside the cap Withdraw the spring stop Withdraw the
drive hub from inside the pump housing
ca10 Taxi Issue 6 83137
THE FUEL SYSTEM Injection Pump Ca
and remove the spring washer and support washer from
their location inside the drive hub The washers are
removed by turning them end on inside the drive hub them along the master spline Two flats are
machined on the outside diameter of the support washer
to facilitate this operation
Remove the drive hub oil seal from the pump oil seal extractor tool 18G 658
Wash all components thoroughly in clean Shell Cali
bration Fluid C Cotton waste rags or cloth wipers
must not be used to wipe the components If the plug with sealing washer using rotor plug
spanner 18G 652 and blow out the internal passages in
the pumping and distributing rotor with compressed air
Coat the threads of the plug with Araldite and refit and
tighten the plug to 28 Ib in 32 kg m
Push out the pumping plungers one at a time noting that the end of the plunger which has
been in contact with the roller shoe is polished and
should be replaced in this position Examine the working
Fig Call
surface of the plungers and the plunger bore in the pump
ing and distributing rotor for wear and abrasions The Removing the drive hub oil seal using oil seal of the hydraulic head and its mating
surface in the 18G 658
rotor should also be examined for wear and any of these parts be worn the pumping rotor and hydraulic head which are mated guides in the
pumping and distributing rotor for must be renewed as a unit action and freedom of movement
Some injection pumps are fitted with hydraulic heads Check the drive shaft splines for wear assemble the
having an oversize metering valve bore and an oversize drive shaft to the drive plate and ensure that there is no
metering valve to suit Oversize metering valves which excessive radial movement between the drive shaft and
are identified by a machined groove are available but plate
only hydraulic heads having a standardsize metering valve Test the fit of the vanes in their slots in the transfer
bore are supplied as replacements Injection pumps fitted pump rotor The vanes should be a sliding fit when
with oversize metering valves are identified by the number lubricated with fuel oil
6375 etched upon the hydraulic head between the outlet Inspect the bore of the regulating valve sleeve for adjacent to the metering valve
bore and ensure that the valve piston can move freely along
Inspect the plunger rollers for flats and the cam ring the whole length of the sleeve bore
lobes for signs of wear Test the roller shoes in their Inspect all springs for fractures and check them against
new counterparts for length Weak or fractured springs
should be renewed Check the governor weight retainer
thrust washer and thrust sleeve against new counterparts
for signs of wear
When reassembling thoroughly rinse all components
in freshly filtered clean Shell Calibration Fluid C and
assemble all parts wet
Fit a new drive hub oil seal to the pump housing
driving it onto its seat with oil seal guide 18G 663 Insert
oil seal inspection plug 18G 660 into the oil seal A
correctly fitted oil seal will show a continuous black line
when viewed through the flange end of the oil seal
inspection plug
Fit the support washer and spring washer into the
drive hub Remove the oil seal inspection plug and pass
A51471
the drive hub through the seal seating the drive hub
flange against the pump housing
Fig Ca10 Place the governor weight retainer on plate 18G662
Holding the drive plate with spanner 18G 641 when and pass locating pin 18G 661 through the weight
unscrewing the drive plate securing screws retainer to locate in the plate so that the weight Issue3 6394
Ca11
Ca THE FUEL SYSTEM Injection Pump
is trapped between the plate and the shoulder of the
locating pin Place the weights equally spaced in
position on the weight retainer
The slot in each weight should be uppermost and
nearest the locating pin Fig Ca 13 Each weight should
be aligned with a pocket in the weight retainer and with
its inner end against the locating pin Place the thrust
washer and thrust sleeve on the locating pin and resting
on the governor weights The thrust sleeve must be fitted
with the flange having the projection uppermost Exert
downward pressure on the thrust sleeve and the assembly
will enter the weight retainer Withdraw the locating pin
and remove the assembly from the plate Slide the assem
bly onto the drive shaft Fit protection cap 18G 657 over
the drive shaft splines and fit a new 0 seal in the
machined groove on the shaft Insert the drive shaft and
weight assembly into the pump housing and engage the
drive shaft splines with the splines in the drive hub Fit
the drive shaft screw and holding the drive hub with Fig Ca13
drive shaft screw assembly tool 18G659 tighten the
Assembling the governor weights thrust washer and
drive shaft screw to the figure given in GENERAL
thrust sleeve into the weight retainer using Service
DATA using torque adaptor 18G664 and torque
tools 18G 661 and 18G 662
wrench 18G 537 Fig Ca12
Compress the cam ring locating circlip using circlip
stamped on the periphery of the pumping end of the rotor
pliers 18G 1004 and seat it against the shoulder in the
corresponds with the pump rotation as indicated on the
boreof the pump housing Place the cam ring in position
pump nameplate
against the circlip The direction of the arrow on the
Withdraw the pumping and distributing rotor complete
visible face of the cam ring must conform with the
with plungers from the hydraulic head Place the top
direction of pump rotation as marked on the pump
adjusting plate in its correct position on the rotorthat
nameplate Fit the cam advance screw finger tight to
is with the slot in the periphery of the adjusting plate
locate the cam ring and check the ring for freedom of
aligned with the scribed mark on the periphery of the
movement in the pump housing
pumping end of the rotor Fig Ca14
If the hydraulic head and pumping and distributing Fit the drive plate to the rotor with its relieved face
rotor are renewed ensure that the direction of the arrow next to the top adjusting plate The slot in the periphery
of the drive plate must be in line with the scribe mark
on the periphery of the rotor Fig Ca14 Tighten the
drive plate securing screws lightly to hold the top
adjusting plate in position on the rotor Invert this
assembly so that the distributing end of the rotor is upper
most Slide the rollers into their shoes and insert the
roller and shoe assemblies into their guides in the rotor
ensuring that the contour of the roller shoe ears conforms
with the contour of eccentric slots in the top adjusting
plate Assemble the bottom adjusting plate to the rotor
with the contour of the eccentric slots in the adjusting
plate conforming to the contour of the roller shoe ears
and the slots in the periphery of the bottom adjusting
plate engaging the lugs on the top adjusting plate Fit
the assembly of the pumping and to the
hydraulic head and fit and lightly tighten the transfer
pump rotor Stand the assembly of the hydraulic head
and the pumping and distributing rotor on the bench with
SA the pumping end of the rotor uppermost
Fit relief valve timing adaptor 18G 653 A preset at 15
Fig Ca12
atmospheres to highpressure outlet V on the hydraulic
Holding the drive hub with drive shaft screw assembly head and connect up the whole assembly to injector
tool 18G 659 while tightening the drive shaft screw nozzle testing machine 18G 109 A Fig Ca15
with torque adaptor 18G664 and torque wrench Operate the handle of the test machine and turn the
18G 537 pumping and distributing rotor in the normal direction of
Ca12 Taxi Issue3 6394
THE FUEL SYSTEM Injection Pump Ca
rotation until the pumping plungers are forced outwards
to the maximum fuel position Set the dimension using a micrometer to the dimension given
in GENERAL DATA Move the adjusting plates
clockwise to increase and to decrease the
dimension with maximum fuel adjusting probe 18G 656
Tighten the drive plate securing screws to the figure given
in GENERAL DATA using torque wrench 18G 537
This setting is approximate final adjustment being made
with the pump mounted on a powerdriven test machine
see Section Ca9 The drive plate is held when tighten
ing the with assembly drive plate spanner
18G 641 Disconnect the test machine and the hydraulic
adaptor from the hydraulic head
Fit a new oil seal into its groove in the machined
periphery of the hydraulic head
Turn the pump drive shaft in the pump housing and
position the master spline at 12 oclock Align the master
spline in the drive plate with the metering valve bore in
the hydraulic head Lubricate the periphery of the
hydraulic head and the bore of the pump housing Fig with clean Shell Calibration Fluid C Hold the
hydraulic head assembly square with the axis of the pump Setting the dimension using a and with the metering valve bore at 12 oclock
meter and Service tools 18G 109 A and 18G 653 A
push the hydraulic head into the pump housing Rotate
the drive shaft slightly to assist the engagement of the
shaft with the drive plate to the end of the regulating valve sleeve
Insert the two hydraulic head locking screws leaving and insert the valve piston into the sleeve Insert the
them finger tight and ensuring that the screw with the regulating spring into the end of the valve
vent valve is fitted immediately above the pump name sleeve Place the regulating plug on the top of the sleeve
plate with its spigoted end engaging the sleeve bore Fit the
Mount drive shaft screw assembly tool 18G 659 in the sleeve retaining spring onto the guide Pass the nylon
splined drive hub and using torque wrench 18G 536 and filter end leading over the spring and
assembly box spanner 18G 634 tighten the transfer pump regulating plug onto the shoulder of the valve sleeve
rotor to the figure given in GENERAL DATA Insert this assembly valve sleeve first into the bore of
Fit the transfer pump liner and insert the carbon vanes the end plate and secure it in position with the fuel inlet
into the slots in the transfer pump rotor connection and washer
Ensure that the transfer pump liner locating peg is in Position a new oil seal in its recess in the upper face of
position C in the pump end plate the hydraulic head and fit the assembled end plate to the
Insert the piston retaining spring into the regulating head engaging the locating peg on the inner face of the
valve bore in the end plate ensuring that it is in the bottom of the bore Fit a new seal washer
Fig Ca14
Assembly the top adjusting plate and the drive plate Fig Ca16
with the slots in their peripheries aligned with the Tightening the transfer pump rotor using torque
scribed mark on the pumping end of the rotor wrench 18G536 and Service tools 18G 659 and 18G634
Taxi Issue 4 88664 Ca13
Ca THE FUEL SYSTEM Injection Pump
end plate with the slot in the periphery of the transfer
pump liner The end plate securing screw holes are
unequally spaced to ensure correct assembly of the end
plate to the hydraulic head Tighten the set screws and
studs to the torque figure given in GENERAL DATA
using torque wrench 18G 536 Tighten the fuel inlet con
nection to the torque figure in GENERAL DATA
using torque wrench 18G 537
Tighten the cam ring advance screw to the figure given
in GENERAL DATA using torque wrench 18G 372
Check the cam ring for freedom of movement
Place a new advance device housing gasket in position
on the pump housing with the flat of the at the drive hub end of the pump To ensure sealing this gasket should be assembled dry
Assemble the advance device housing to the pump Fig using new rubber and aluminium sealing
Setting the internal dimension between the for the head locating bolt and cap nut Using valve lever pin and the control cover stud with the
torque wrench 18G 537 tighten the head locating bolt vernier heldparallel to the axis of the pump
the cap nut and the two head locking screws to the
figures given in GENERAL DATA Check the cam lever pin and its nearest control cover stud to the length
ring for freedom of movement given in GENERAL DATA using a vernier gauge as
Fit new 0seals to the lightload advance piston plug shown in Fig Ca17 Adjustment is made by the spring cap using protection cap 18G 640 to pass
or tightening the hook linkage nut During this operation
the seals over the threads light pressure should be applied to the governor arm
Insert the slide washer and piston in that order into in the direction of the metering valve and the vernier
the advance device housing on the side where the fuel gauge should be held parallel to the pump axis
oil drilling enters the piston bore Screw in the piston Locate the idling spring on the idling spring guide
plug Insert the maximum advance stop and spring in Insert the guide into hole No 2 in the governor arm
that order into the remaining open end of the advance Fig Ca6 and connect the governor spring to the idling
unit housing and screw in the cap Tighten the piston spring guide
plug and spring cap to the torque figures given in Insert the plain end of the shutoff bar into the slot
GENERAL DATA using torque wrench 18G 537 in the control bracket and position the shutoff bar under
Insert the metering valve into the metering valve bore
the tab of the control cover stud locking washer
in the hydraulic head
Engage the governor arm with the control bracket Using protection cap 18G 564 fit the lower Oseal to
and connect the governor arm spring to both components the shutoff shaft Fit the upper 0 seal using protection
Fit the assembly governor arm and control bracket to cap 18G 665 Pack the groove between the 0seals with
the pump housing The lower end of the governor arm Shell Alvania No 2 grease Press the shutoff shaft into
should engage the outside face of the thrust sleeve flange its bore in the control cover The peg which engages the
Place the keep plate in position with its open end towards shutoff bar should be close to the inside edge of the
the shutoff bar Fit new tab washers with their pointed control cover and should be left projecting slightly above
tabs towards the governor arm Secure the keep plate in the control cover with the two governor control cover studs Fit Place a new
control cover gasket in position on the
the small screw and tab washer at the metering valve end pump housing ensuring that the locating tabs of the
of the control bracket Tighten the control cover studs to gasket engage the slots under the keep plate To ensure
the torque figure given in GENERAL DATA using satisfactory sealing this gasket should be soaked in Shell
torque wrench 18G 536 Lock the studs in position by Calibration Fluid C before assembly
bending up the pointed tabs Tighten the small screw to Fit new lower and upper 0seals to the throttle shaft
the torque figure given in GENERAL DATA and lock using protection caps 18G 654 and 18G 665 Pack the
it with the tab washer groove between the 0seals with Shell Alvania No 2
Assemble the spring retainer spring and fibre washer grease Connect the free end of the governor spring to
onto the governor linkage hook in that order Pass the hole No 2 22litre engine or hole No 1 end of the linkage hook through the governor
engine in the throttle shaft link Fig Ca6
arm Fit the pivot ball washer onto the linkage hook Press the throttle shaft into its bore in the control
and screw on the linkage nut about three turns Press cover Place the control cover in position on the control
back the spring retainer and attach the linkage hook to cover studs Ensure that the shutoff shaft peg engages
the metering valve The hook end should turn towards the shutoff bar and pull the shutoff shaft fully home
the metering valve as the control cover is lowered onto the gasket Fit new
Set the internal dimension between the metering valve sealing washers on the control cover studs and fit and
Cu14 Taxi Issue 4 88664
THE FUEL SYSTEM Injection Pump Ca
tighten the stud nuts to the torque figures given in
GENERAL DATA using torque wrench 18G 536 Place
the dust caps on the throttle and shutoff shafts Fit the
throttle arm and the shutoff lever to their and secure them in place with their nuts Ca9
TESTING AND ADJUSTING THE FUEL
INJECTION PUMP
After overhaul the fuel injection pump must be and the maximum fuel output adjusted if
necessary These tests and adjustments are carried out on
a powerdriven test bench embodying the and pressure gauges and equipment to test the
fuel transfer pump and a graduated glass to measure the Fig pump backleakage In addition the tools
Checking the automatic advance device in the following paragraphs are also required advance gauge 18G 638 B
NOTEThe following precautions must be observed Remove the small set screw from the centre of the
when testing the pump advance unit housing spring cap and assemble automatic
1 Ensure that the powerdriven test bench is set to run advance gauge 18G 638 B to the spring cap with the
in the direction of rotation of the injection pump as degree scale and pointer uppermost and the scale set to
indicated by the arrow on the pump nameplate zero
Serious damage may be caused to the pump if it is Throughout the following operations and tests the pump
run in the reverse direction throttle and shutoff levers must be in the fully open
2 Ensure that the fuel flow at the pump inlet is not position except where stated otherwise
less than 1000 ccmin If this flow cannot be The pump and the feed pipe must now be filled and
obtained a maximum feed pressure of 2 lbsq in primed as follows
15 kgcm2 is permissible 1 Connect the fuel feed pipe to the drain connection
3 Do not run the pump for long periods at high speed on the pump housing
with low fuel output 2 Open both of the vent screws on the injection
4 Do not run the pump for long periods with the shut pump
off control in the closed position 3 Turn on the gravity feed When test oil free from
air bubbles flows from the vent screw on the
After checking the direction of rotation mount the
hydraulic head close this vent screw Wait till the
pump on the test bench and connect up the drive Fit
test oil flowing from the vent screw in the connections to the hydraulic head in place of the
control housing is free from air bubbles then close
banjo pipes Using highpressure pipes 6 mm x 2 mm x
this vent screw also
865 mm 34 in long connect the radial connections to
4 Rotate the pump drive through 180 and repeat
a matched set of test nozzles The test nozzles should be
operations 2 and 3
Type BDN12SD12 mounted in nozzle holders Type
5 Fit the feed and return pipes to their formerly and set to
at 175 atmospheres
6 Slacken the highpressure pipe unions at the
Ensure that the pump throttle arm has the full range
injector end
of movement by unscrewing fully the idling and maximum
7 Start the test machine and run at 100 rpm until
speed stop screws
oil free from air bubbles issues from the injector
Remove the hydraulic head locking screw not the one
pipe the vent valve and connect the pressure
8 Tighten the injector pipe connection while the test
gauge by means of a flexible pipe to transfer pressure
machine is 18G 636 which is screwed into the head locking
The following tests are designed to check in turn each
screw hole
of the separate functions of the injection pump Before
Connect the feed pipe preferably of the transparent
however making these individual tests a general check
type to the fuel inlet connection on the injection pump
should be carried out to ensure oiltightness of all joint
end plate The vacuum gauge should be fitted by means
washers oil seals and pipe connections while the pump
of a T coupling to the feed pipe
is running and when stationary
Connect the inlet connection on the the drain connection on the pump housing and the 1 Transfer pump vacuum test
drain cock on the to the return pipe on I Start the test machine and run the pump at
the test bench by means of flexible pipes 100 rpm
Taxi Issue 4 6394 Ca15
Ca THE FUEL SYSTEM Injection Pump
6 Fuel delivery check
Without altering any of the adjustments check
that the fuel delivery at 800 rpm is 36 to 44 CC
per 200 shots Remove the shutoff lever adjust
ment tool
7 Advance check
Run the fuel pump at 800 rpm Move the shut
off lever to the fully closed position and check
that the advance reading is 312 to 4 12 Fit and seal
the metering valve adjustment screw sealing cap
with wire and a lead seal using sealing pliers
18G 541
NOTEIf for any reason it is found necessary
to tighten or slacken the governor control cover cap
A9255 nuts the settings made at 4 and 5 will be dis
turbed and operations 4 5 6 and 7 should
Fig Ca19 be repeated
Adjusting the maximum fuel setting using Service 8 Backleakage
tool 18G 656 Set the shutoff lever fully open and the throttle
arm fully closed Run the pump at 1000 rpm
Turn the test oil feed cock to the off position
and measure the backleakage through the gradu
and note the depression registered on the vacuum
ated The backleakage should be
gauge This should build up to 1 6 in 406mm Hg
5 to 50 CC per 100shot cycle
within 60 seconds maximum Check the fuel feed
pipe unions for air leaks indicated by the presence 9 Maximum fuel setting
of air bubbles in the pipe line If necessary this test the advance gauge
tighten the feed pipe unions and carry out a further must show a zero reading
test Run the pump at 1000 rpm with both controls
NOTEDo not run the pump for periods ex in their fully open position when the average
ceeding 60 seconds with the test oil supply turned off delivery for 200 shots from all four test injectors
After the vacuum test is completed turn on the should be 6 9
1 CC In arriving at this figure
test oil supply and with the pump running at compare the delivery from all injectors to ensure
100 rpm airvent the pump by means of the vent that the difference in output from any two does
valve on the hydraulic head locking screw not exceed 6 CC Before taking a reading the test
oil in the should be allowed to
2 Transfer pump pressure settle for 15 seconds and the With the pump running at 100 rpm note the
should be allowed to drain for 30 seconds before
pressure registered on the pressure gauge which a fresh test is made
should read 12 lbsq in 8 kgcm2 To adjust the pump output stop the test bench
3 Transfer pump pressure and turn the test oil feed cock to the off position
Increase the pump speed to 800 rpm when a Remove the coverplate from the side of the pump
pressure of 32 to 44 lbsq in 23 to 31kgcm2
should be registered on the pressure gauge
4 Fuel delivery setting
Run the pump at 800 rpm and after slackening
the locknut alter the metering valve adjustment
screw till a zero reading is obtained on the auto
matic advance gauge Tighten the locknut and re
check the advance reading Fit the shutoff lever
adjustment tool 18G697 to the fuel pump and
adjust the shutoff lever to obtain an average fuel
delivery of 36 to 44 CC per 200 shots Ensure that
the advance gauge still shows a zero reading
5 Advance setting
Run the pump at 800 rpm Slacken the metering
valve adjustment screw locknut and alter the
adjustment screw to obtain an advance reading of Fig Ca20
134 to 214Tighten the locknut and recheck the
The shutoff lever adjuster 18G697 mounted on the
advance reading fuel injection pump and test bench
Ca16 Taxi Issue4 6394
THE FUEL SYSTEM Injection Pump Ca
11 Cutoff test
With the shutoff lever held in the fully closed
position run the pump at 200 rpm The average
delivery for 200 shots with the throttle arm in
the fully open position should not exceed 10 CC
12 Throttle operation
Run the fuel pump at 200 rpm with the throttle
arm in the fully closed position The average
delivery with the shutoff lever fully open should
not exceed 10 CC per 200 shots
13 Fuel delivery check
With both controls fully open run the fuel pump
at 1650 rpm and record the average delivery
per 200 shots
Fig Ca21 14 Governor setting
Tightening the drive plate screws using torque wrench Increase the pump speed to 1850 rpm and set
18G 537 and torque adaptor 18G 655A the throttle arm by means of the maximum speed
adjustment screw to give a maximum average
delivery of 10 CC per 200 shots No line should
exceed 18 CC Tighten the adjustment screw
locknut
15 Fuel delivery check
Reduce the pump speed to 1650 rpm and re
housing to provide access to the interior of the check the fuel delivery The average delivery now
pump Slacken the two drive plate securing screws should not be less than that recorded in operation
sufficiently to permit movement of the adjusting 13 minus 4 CC per 200 shots
plates Turn the pump drive until the slots in the
peripheries of the drive plate and the top adjusting 16 Timing setting
plate are visible through the aperture in the pump This setting is made after all the foregoing tests
housing Engage the end of the maximum fuel have been completed with the pump removed
adjusting probe 18G 656 in the slot in the top from the powerdriven test bench
adjusting plate and tap the tool with a light It should be noted that unlike the inline fuel
hammer to move the plate in the required direction injection pump which has a static commencement
The adjusting plate is turned in the same direction of injection point the point at which commence
as the normal direction of the pump rotation to ment of injection occurs in the increase the maximum output Movement of the
fuel injection pump varies according to the fuel
adjusting plate in the opposite direction will requirements of the engine The timing of the
decrease the maximum output This operation pump is carried out with the
must be carried out very carefully as the amount pumping plungers set to delivery maximum fuel on
of movement required will be very small Tighten No 1 injection line and with the plunger rollers
the drive plate securing screws to the torque figure in contact with the cam lobes therefore after all
given in using tools 18G 537 occasions of pump overhaul or adjustment to the
and 18G 655A While tightening the screws the pump output it is imperative that the pump timing
torque wrench must be in line with the spanner is checked and the timing mark on the pump
Fig Ca21 After making this adjustment replace flange remarked if necessary
the coverplate and carry out the complete filling Remove the coverplate from the side of the
and priming operation Recheck the fuel delivery pump housing and the four redial connections
and if necessary readjust the pump output from the hydraulic head Connect injector nozzle
testing machine 18G 109 A to outlet V on the
10 Fuel delivery hydraulic head to means of relief valve timing
Decrease the pump speed to 100 rpm and check adaptor 18G 653 A The relief valve must be set to
the output The average delivery for 200 shots operate at 30 atmospheres
under these conditions should not be less than Turn the pump drive hub in the normal direction
that obtained when setting the pump maximum of rotation until the timing mark E on the drive
fuel output minus 15 CC When carrying out this plate becomes visible through the aperture in the
test use 30 seconds draining time side of the pump housing Operate the handle of
and allow the test oil to settle for 15 seconds the test machine to apply a pressure of 30 atmo
before taking a reading spheres to the pump This will force the pumping
Taxi Issue 7 83137 Ca17
Ca THE FUEL SYSTEM Injection Pump
plungers outwards to the limit of their travel as
the drive hub is turned Continue turning the drive
hub in the normal direction of rotation until
resistance is encountered With the pump held in
this position mount flangemarking gauge 18G 648A
preset to 86 on the pump quill shaft Check that
the timing mark on the pump flange lies along the
scribing guide on the flange marking gauge If
necessary delete the old timing mark and scribe a
new mark by drawing a scribing tool along the
guide on the flange marking gauge
Disconnect the pump from the test machine
and fit the banjo pipes to the hydraulic head Refit
the coverplate to the side of the fuel pump A57660
housing and seal the securing screws with wire and Fig Ca22
a lead seal using sealing pliers 18G 541 Scribing the timing mark on the fuel injection pump
mounting flange using Service tool 18G 648 A
Maximum and idling speed adjustments
These adjustments are carried out after the pump has
been installed on the engine and are detailed in Section When testing the injectors for spray and
the injectors for service the nozzle opening pres
sure should be set to 130 atmospheres for 22litre
engines and 135 atmospheres for 252litre Ca10 The needle lift should be 029 to 035 in 75
90 mm for 22litre engines and 4 to 75 mm for
ALTITUDE SETTINGS 252litre engines
Each vehicle leaves the Factory with its maximum fuel
setting adjusted for sealevel conditions If the vehicle is
to be operated continuously above sealevel adjustment
of the injection pump is necessary to set the maximum Section Ca12
fuel delivery to conform with the figures given in the
following table LIFT PUMP
Follow the instructions given in Section Cl but after
replacing the lift pump bleed the fuel system as described
Moximum fuel output for 200 in Section Ca5
Altitude
0 to 2000 ft 68 to 70 CC
0 to 600 m
Section Ca13
1 2000 t o 4000 ft
600 t o 1200 m
64 to 66 CC 83 to 85 cc
MODIFIED INJECTION PUMP
4000 to 6000 ft 60 t o 62 CC 77 t o 79 CC Type 1200 to 1800 m
This pump is as described in Section Ca6 but with
6000 t o 8000 ft 56 to 58 CC 72 to 74 cc
various detail modifications to improve engine governing
1800 to 2400 m
and the addition of an antistall device The 8000 to 10000 ft 51 to 53 CC 66 to 68 cc
2400 to 3000 m
include a governor spring idling spring and maximum
advance stop spring of new load rates Other modifica
10000 to 12000 ft 47 to 49 cc 61 to 63 CC
tions incorporated in this pump are to the metering valve
3000 to 3600 m
quill shaft and banjo pipes
The antistall device consists of an adjusting screw
which protrudes from the drive end of the control cover
and a locknut In operation the inner end of the adjusting
screw contacts the governor arm to act as a stop The
Section Ca11 effect of this is to prevent the governor from reducing
the metering area below the position permitted by the
FUEL INJECTORS antistall screw Therefore adjustment of the antistall
Follow the instructions given in Section C6 noting screw should only be carried out as described in Section
the following points Ca13 under Maximum and idling speed
Taxi Issue 7 83137
THE FUEL SYSTEM Injection and replacing of air bubbles in the pipe line If necessary tighten
Follow the instructions in Section Ca7 noting that the the feed pipe unions and carry out a further test
correct injection timing for this pump is 26 BTDC NOTE Do not run the pump for periods ex
ceeding 60 seconds with the test oil supply turned off
Maximum and idling speed adjustments After the vacuum test is completed turn on the
After fitting either a new or overhauled injection pump test oil supply and with the pump running at
adjust the engine maximum light running speed as 100 rpm air vent the pump by means of the in Section Ca7 Then proceed as follows
to valve on the hydraulic head locking screw
adjust the idling speed and antistall device
1 With the engine stopped unscrew the antistall 2 Transfer pump pressure
screw until it is out of contact with the governor With the pump running at 100 rpm note the
arm pressure registered on the pressure gauge which
should read 11 lbsq in 8 kgcm2
2 Start the engine ensure that it is at its normal
running temperature and adjust the idling stop
3 Transferpump pressure
screw to set the engine speed at between 450 and
Increase the pump speed to 1300 rpm when a
500 rpm
pressure of 43 to 54 lbsq in 29 to 38 kgcm2
3 Screw in the antistall screw carefully until a slight should be registered on the pressure gauge
speed increase is noticed then unscrew one third
of a turn and lock in position with the locknut 4 Fuel delivery setting
4 Readjust the idling stop screw to set the idling Run the pump at 1300rpm and after slackening
speed at 500 rpm and tighten the idling stop screw the locknut alter the metering valve adjustment
locknut screw till a zero reading is obtained on the auto
5 Test the antistall screw setting by running the matic advance gauge Tighten the locknut and
engine at about 3000 rpm and then releasing recheck the advance reading Fit shutoff lever
the throttle adjustment tool 18G 697 to the fuel pump and
a If the engine stalls the pump is underdamped adjust the shutoff lever to obtain an average fuel
and the antistall screw should be screwed in delivery of 62 to 70 CC per 200 shots
slightly relocked and the setting retested Ensure that the advance gauge still shows a zero
b If the engine deceleration is slow or sluggish reading
the pump is overdamped and the antistall
screw should be screwed out slightly relocked 5 Advance setting
and the setting retested Run the pump at 1300rpm Slacken the meter
6 Check that the engine stops when the shutoff lever ing valve adjustment screw locknut and alter the
is operated adjustment screw to obtain an advance reading of
134 to 214 Tighten the locknut and recheck the
NOTEAfter every adjustment of the antistall screw advance that the engine idling speed is controlled by the
idling stop screw and not by the antistall screw 6 Fuel delivery check
Without altering any of the adjustments and reassembling that the fuel delivery at 1300 rpm is 62 to 70
Follow the instructions in Section Ca8 noting that this CC per 200 shots Remove the shutoff lever
pump is fitted with four governor weights adjustment and adjusting 7 Advance check
Mount the pump on a test bench and fill and prime Run the fuel pump at 1300 rpm Move the
the pump as described in Section Ca9 Check the oil shutoff lever to the fully closed position and of all joint washers oil seals and
pipe connec that the advance reading is 33 to 43 Fit and seal
tions with the pump running and when stationary Then the metering valve adjustment screw sealing cap
proceed with the following tests noting that the pump with wire and a lead seal using sealing arm and shutoff lever must be in the fully
open 18G 541
position except where stated otherwise NOTEIf for any reason it is found necessary
1 Transfer pump vacuum test to tighten or slacken the governor control cover cap
Start the test machine and run the pump at 100 nut the settings made at 4 and 5 will be dis
rpm turbed and 5 6 and 7 should
Turn the test oil feed cock to the off position be repeated
and note the depression registered on the vacuum
gauge This should build up to 16in 406 mm Hg 8 Backleakage
within 60 seconds maximum Check the fuel feed Set the shutoff lever fully open and the throttle
pipe unions for air leaks indicated by the presence arm fully closed Run the pump at 1000 rpm
Taxi Issue 5 6394 Ca19
THE FUEL SYSTEM Injection Pump
and measure the backleakage through the gradu 11 Cutoff test
ated The backleakage should be With the shutoff lever held in the fully closed
5 to 50 CC per 100 shot time cycle position run the pump at 200 rpm The average
delivery for 200 shots with the throttle arm in the
fully open position should not exceed 8 CC
Maximum fuel setting
12 Throttle operation
With the throttle arm in the fully closed position
this test the advance gauge
must show a zero reading unscrew the antistall screw until it is out of contact
with the governor arm and tighten the locknut
Run the pump at 1000 rpm with both controls Run the pump at 200 rpm with the throttle arm
in their fully open position when the average still fully closed The average delivery with the
delivery for 200 shots from all four test injectors shutoff lever fully open should not exceed 10 CC
should be 691 CC In arriving at this figure per 200 shots
compare the delivery from all injectors to ensure
that the difference in output from any two does 13 Fuel delivery check
not exceed 6 CC Before taking a reading the test With both controls fully open run the fuel pump
oil in the should be allowed to at 1630 rpm and record the average delivery per
settle for 15 seconds and the 200 shots
should be allowed to drain for 30 seconds before a 14 Governor setting
fresh test is made Increase the pump speed to 1850 rpm and set
To adjust the pump output stop the test bench the throttle arm by means of the maximum speed
and turn the test oil feed cock to the off position adjustment screw to give a maximum average
Remove the coverplate from the side of the pump delivery of 10 CC per 200 shots No line should
housingto provide accessto the interior of the pump exceed 18 CC Tighten the adjustment screw
Slacken the two drive plate securing screws suffi locknut
ciently to permit movement of the adjusting plates
Turn the pump drive until the slots in the peri 15 Fuel delivery check
pheries of the drive plate and the top adjusting Reduce the pump speed to 1630 rpm and re
plate are visible through the aperture in the pump check the fuel delivery The average delivery now
housing Engage the end of the maximum fuel should not be less than that recorded in operation
adjusting probe 18G656 in the slot in the top 13 minus 4 CC per 200 shots
adjusting plate and tap the tool with a light
hammer to move the plate in the required direction 16 Timing setting
The adjusting plate is turned in the same direction This setting is made after all the foregoing tests
as normal pump rotation to increase the maximum have been completed with the pump removed from
output Movement of the adjusting plate in the the powerdriven test bench
opposite direction will decrease the maximum It should be noted that unlike the inline fuel
output This operation must be carried out very injection pump which has a static commencement
carefully as the amount of movement required will of injection point the point at which commence
be very small Tighten the drive plate securing ment of injection occurs in the screws to the torque figure given in GENERAL
fuel injection pump varies according to the fuel
DATA using tools 18G 537 and 18G 655A requirements of the engine The timing of the dis
While tightening the screws the torque wrench tributor type pump is carried out with the pumping
must be in line with the spanner Fig Ca21 plungers set to deliver maximum fuel on No 1
After making this adjustment replace the cover injection line and with the plunger rollers in
plate and carry out the complete filling and priming contact with the cam lobes therefore after all
operation Recheck the fuel delivery and if neces occasions of pump overhaul or adjustment to the
sary readjust the pump output pump output it is imperative that the pump timing
is checked and the timing mark on the pump
flange remarked if necessary
Remove the cover plate from the side of the
Fuel delivery pump housing and the four radial connections
Decrease the pump speed to 100 rpm and check from the hydraulic head Connect injector nozzle
the output The average delivery for 200 shots testing machine 18G 109 A to outlet Von the
should now be not less than that obtained when hydraulic head by means of relief valve timing
setting the pump maximum fuel output minus 15 adaptor 18G 653 A The relief valve should be set
CC When carrying out this test use 30 seconds to operate at 30 atmospheres
draining time and allow the test Turn the pump drive hub in the normal direction
oil to settle for 15seconds before taking a reading of rotation until the timing mark E on the drive
Ca20 T axi Issue 5 6394
THE FUEL SYSTEM Injection Pump Ca
plate becomes visible through the aperture in the 5 Lift off the air cleaner body and intake hose as an
side of the pump housing Operate the handle of assembly Note the rubber air seal between the
the test machine to apply a pressure of 30 atmo cleaner body and the intake manifold on the
spheres to the pump This will force the pumping engine
plungers outwards to the limit of their travel as
the drive hub is turned Continue turning the drive Refitting
hub in the normal direction of rotation until 6 Reverse the procedure in 1 to 5
resistance is encountered With the pump held in
this position mount flangemarking gauge 18G648A
preset to 86 on the pump quill shaft Check that
the timing mark on the pump flange lies along the Section Ca16
scribing guide on the flange marking gauge If
necessary delete the old timing mark and scribe a INJECTION PUMP 252litre diesel engine
new mark by drawing a scribing tool along the The pump is as described in Sections Ca6 and Ca13
guide on the flange marking gauge but with a type number DPA 3249F520 and the setting
Disconnect the pump from the test machine and code stamped on the pump nameplate
fit the banjo pipes to the hydraulic head Refit the Later engines are fitted with a modified pump This
coverplate to the side of the fuel pump housing pump is as described above but with a type number
and seal the securing screws with wire and lead DPA 3342F110 and having two springs fitted to the
seal using sealing pliers 18G 541 linkage hook instead of a single spring
Removing and settings Follow the instructions in Section Ca7 noting that the
Follow the instructions in Section Ca10 correct injection timing for this pump is 23 BTDC
Maximum and idling speed adjustments
Follow the instructions given in Section Ca13
Dismantling and Ca14 Refer to the instructions given in Section Ca13 and
Section Ca8
AIR CLEANER Oil Bath Type
Testing and Conditionsfor test
1 Release the clips and detach the air inlet tube and
1 The test equipment must be set to drive the pump
the breather hose from the air cleaner body
2 Remove the screws retaining the air cleaner in the direction of rotation indicated on the pump
assembly to the lefthand valance nameplate
3 Lift out the air cleaner assembly 2 Fuel available at the injection pump inlet must be
1000 ccmin flow minimum or 2 lbsq in
Refitting 15 maximum
4 Reverse the procedure in I to 3 3 Test injectors must be a matched set with type
BDN12SD12 nozzles operating at 175 atmo
spheres
4 Injector pipes should be 6 mm x 2 mm x 34 in
Section Ca15 865 mm long
5 The injection pump throttle and shutoff levers
AIR CLEANER Dry Type must be in the fully open position except
otherwise stated
1 Remove the drive screw retaining the air intake 6 All fuel delivery figures are for 200 shots
hose clip to the radiator frame 7 Allow 30 seconds glass draining time and 15
2 Release the clip and detach the breather hose from seconds settling time when taking fuel delivery
the air cleaner intake readings
3 Remove the central wing nut detach the air cleaner 8 The maximum fuel delivery given in the test plan is
top cover and remove the element for sealevel conditions For continuous use above
4 Release the air cleaner body from its support sealevel see Section Ca10 for maximum fuel
bracket Issue 7 94241
Ca21
Ca THE FUEL SYSTEM Injection Pump
Test plan for pumps DPA 3249F520 and DPA 3342F110 Setting code Test No 1 Description RPM Requirements
Remarks
Transfer pump vacuum 100 16 in 406 mm Hg Fuel supply turned off After test
within 60 seconds airvent from hydraulic vent screw
at 100 rpm
2 Transfer pressure 100 1 1 lbsq in8 kgcm2
minimum
Transfer pressure 1200 58 to 78 lbsq in
41to 55 kgcm2
I Advance position
Advance position
1200
1800
to 2
Use metering valve adjustment
screw to obtain this reading
Metering valve adjustment as in
test 4 Shutoff lever fully closed
Lock valve adjustment screw and
seal it using tool 18G 541
6 I Backleakage 1200 3 to 50 CC for 1
time cycle
00 stroke Throttle lever fully closed
7 Maximum fuel delivery 1200 90 CC average Adjust output by moving adjusting
Spread between lines not plate relative to drive plate with
to exceed 10 CC tool 18 G 656 Tighten drive plate
screws to correct torque with tool
18 G 655 A
8 Fuel delivery check Average as test 7 minus This is a minimum delivery figure
32 CC
9 1 Cutoff operation
I Average delivery 08
maximum
CC Shutoff lever fully closed
I1 Throttle operation
Fuel delivery check 1650
I1 Average delivery 10 CC
maximum
Record delivery
Throttle lever fully closed and anti
stall screw unscrewed and locked
12 Governor setting 1850 Average delivery 18 CC Set throttle lever with maximum
maximum No line to speed adjustment screw
exceed 25 CC Lock stop screw
13 Fuel delivery check 1650 Average delivery as in This is a minimum figure Throttle
test 1 1 minus 04 CC set as in test 12
14 Governor setting 1850 Average delivery of 18 CC Set throttle with maximum speed
adjustment screw Lock stop screw
Adaptor 18G653 A set at 30
atmospheres connecting 1 8G 109A
to outlet V Apply fuel pressure
18G648A
set at 86 and mark pump flange
with Taxi Issue 7 94241
KEY TO THE FUEL INJECTION PUMP Description No Description No Description
1 End plate 44 Thrust sleeve 86 Throttle shaft
2 Locating pin 45 Thrust washer 87 Seal for throttle shaft
3 Screw for end plate 46 Drive shaft 88 Dust cap for shaft
4 Stud for end plate 47 Drive shaft seal 89 Nut for shaft
5 Nut for stud 48 Drive shaft screw 90 Throttle arm
6 Piston retaining spring 49 Spring washer for screw 91 Governor spring
7 Regulating piston 50 Support washer 92 Guide for idling spring
8 Regulating sleeve 51 Drive hub 93 Control cover
9 Washer for sleeve 52 Drive hub seal 94 Adjusting screw
10 Filter 53 Quill shaft 95 Washer for adjusting screw
11 Regulating plug 54 Pump housing 96 Locknut for screw
12 Regulating spring 55 Gasket for control cover 97 Locking sleeve
13 Sleeve retaining spring 56 Coverplate 98 Adaptor for sleeve
14 Inlet connection 57 Gasket for coverplate 99 Vent screw
15 Washer for inlet connection 58 Screw for coverplate 100 Vent screw body
16 Transfer pump rotor 59 Washer for screw shakeproof 101 Washer for vent screw body
17 Transfer pump blade 60 Drain connection 102 Adjustment screw for metering valve
18 Transfer pump liner 61 Washer for connection 103 Washer for nut
19 Transfer pump seal 62 Governor arm 104 Locknut
20 Hydraulic head and rotor assembly 63 Spring for governor arm 105 Sealing cap
21 Rotor plug 64 Keep plate 106 Automatic advance device housing and piston
22 Washer for plug 65 Tab washer 107 Gasket for housing
23 Hydraulic head seal 66 Control bracket 108 Stud for housing
24 Banjo pipe 67 Screw for bracket 109 Cap nut for stud
25 Bolt for banjo pipe 68 Tab washer for screw 110 Washer for cap nut
26 Washer for bolt 69 Stud for control cover 111 Cam advance screw
27 Fuel feed pipe connection 70 Nut for stud 112 Piston plug
28 Olive for fuel feed pipe 71 Washer for stud 113 Seal for plug
29 Hydraulic head locking screw 72 Linkage nut 114 Piston spring cap
30 Washer for screw 73 Pivot ball washer 115 Seal for cap
31 Hydraulic head vent screw assembly 74 Linkage washer 116 Screw for cap
32 Vented locking screw for hydraulic head 75 Linkage hook 117 Washer for screw
33 Vent screw 76 Linkage spring 118 Head locating bolt
34 Adjusting plate bottom 77 Spring retainer 119 Slide washer
35 Roller shoe 78 Metering valve 120 Maximum advance stop
36 Roller 79 Shutoff bar 121 Spring for stop
37 Adjusting plate top 80 Shutoff Shaft 122 Shim washer for spring
38 Drive plate 81 Seal for shutoff shaft 123 Washer for head locating bolt
39 Drive plate screw 82 Shutoff lever 124 Joint washer for pump mounting flange
40 Cam ring 83 Dust cap for shaft 125 Washer for nut
41 Locating circlip for cam ring 84 Washer for shaft 126 Nut for injection pump mounting bolt
42 Governor weight 85 Nut for shaft 127 Idling spring
43 Retainer for governor weights

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Disclaimer:
The information on this web site has not been checked for accuracy. It is for entertainment purposes only and should be independently verified before using for any other reason. There are five sources. 1) Documents and manuals from a variety of sources. These have not been checked for accuracy and in many cases have not even been read by anyone associated with L-36.com. I have no idea of they are useful or accurate, I leave that to the reader. 2) Articles others have written and submitted. If you have questions on these, please contact the author. 3) Articles that represent my personal opinions. These are intended to promote thought and for entertainment. These are not intended to be fact, they are my opinions. 4) Small programs that generate result presented on a web page. Like any computer program, these may and in some cases do have errors. Almost all of these also make simplifying assumptions so they are not totally accurate even if there are no errors. Please verify all results. 5) Weather information is from numerious of sources and is presented automatically. It is not checked for accuracy either by anyone at L-36.com or by the source which is typically the US Government. See the NOAA web site for their disclaimer. Finally, tide and current data on this site is from 2007 and 2008 data bases, which may contain even older data. Changes in harbors due to building or dredging change tides and currents and for that reason many of the locations presented are no longer supported by newer data bases. For example, there is very little tidal current data in newer data bases so current data is likely wrong to some extent. This data is NOT FOR NAVIGATION. See the XTide disclaimer for details. In addition, tide and current are influenced by storms, river flow, and other factors beyond the ability of any predictive program.