regeneracja pompy wtryskowej LUCAS pdf.pdf

4.1Test equipment......................................................................................................65

4.1.1ISO test conditions for testing DPC-type injection pumps........................65

4.1.2Test conditions for DPC pumps conforming to "EURO 96"

emissions legislation.................................................................................65

4.1.3Test conditions for testing DPCN-type injection pumps............................66

4.2Testing - General...................................................................................................67

4.2.1Fitting the pump to the test bench............................................................67

4.2.2Test plans..................................................................................................67

4.2.3Procedure for priming and venting the pump prior to test........................67

4.2.4Setting the advance to zero......................................................................68

4.3Checking and adjusting.........................................................................................68

4.3.1Pre-setting the transfer pressure..............................................................68

4.3.3Adjusting the advance...............................................................................69

4.3.4Checking cambox pressure......................................................................69

4.3.5Adjusting maximum fuel delivery..............................................................70

4.3.6Checking and adjusting the governor.......................................................71

4.3.7Checking the opening of the differential valve..........................................71

4.3.8Adjusting the boost controller and maximum fuel delivery.......................71

4.3.9Adjusting the low-load advance (LLA)......................................................72

4.3.10Checking the low-load advance (LLA) cut-out..........................................73

4.3.11Adjusting the progessive low-load advance (LLAP).................................73

4.3.12Checking the progressive low-load advance (LLAP)................................73

4.3.13Adjusting the automatic advance override................................................73

4.3.14Adjusting the hydraulic advance override.................................................74

4.3.15Adjusting the electrical microswitch(es)....................................................74

4.3.16Checking the electrical microswitch(es)...................................................74

4.3.17Adjusting the pneumatic "switch" (EGR system)......................................75

4.3.18Checking the pneumatic "switch"..............................................................75

4.3.19Adjusting the "diagnostic" screw...............................................................75

4.3.20Checking the "diagnostic" screw...............................................................75

.................................................76

4.3.22Adjusting the throttle lever damper ...........................................................76

4.3.23Adjusting the throttle lever dashpot..........................................................76

4.3.24Adjusting the pneumatic actuator.............................................................77

4.3.25Checking the pneumatic actuator.............................................................77

4.4Timing of the pump................................................................................................78

4.4.1General.....................................................................................................78

4.4.2Internal timing through the inspection aperture........................................78

4.4.3Internal timing through the governor cover...............................................80

4.4.4Internal timing by peg................................................................................82

4.4.5External timing..........................................................................................84

4.5Checking for leaks.................................................................................................85

4.5.1Checking the pump for leaks....................................................................85

4.5.2Checking the boost controller for leaks....................................................85

4.5.3Checking the pneumatic actuator for leaks..............................................86

4.5.4Checking the pneumatic "switch" for leaks...............................................86

4.6Sealing..................................................................................................................87

4.6.1General.....................................................................................................87

4.6.2DPC pumps built prior to modification "B"................................................87

4.6.3DPC pumps with modification "B".............................................................87

4.7.1New pumps...............................................................................................88

4.7.2Overhauled pumps....................................................................................88

4.7.3Storage conditions....................................................................................88

5.1Torque values................................................................................................89 -106

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an easily-cleaned compartmented tray in which

to place the parts,

When overhauling injection pumps, the use of accurate

technical literature can save a great deal of time.

consists of technical notes known as Service Instruction

Notes.

It is not always necessary to completely dismantle a

pump, except in the case of a complete overhaul.

Before carrying out any work, it is recommended that

the pump is checked on the test bench to determine the

cause of the defect. Repair or adjustment operations

can then be undertaken based on the results obtained.

- a vessel containing clean test fluid, with an

automatically-closed lid,

- a vessel containing grease (e.g. Shell Alvania R2)

and a vessel containing tallow,

- soft lint-free cloth or absorbent paper.

Defective parts are to be replaced by genuine

replacement parts only and replacement is to be limited

to that required by the rectification operation or as

described on the estimate.

Dismantling, checking, reassembling and adjusting the

pump must only be done by qualified personnel using

the correct special tools and a test bench of the specified

type.

Ensure that the injection pump overhaul shop is always

kept absolutely clean.

Make out a job sheet for each pump that is overhauled.

- a low-pressure washing facility, with an airline,

water or water-based), to clean pumps externally

prior to dismantling,

- a bench covered with non-rusting metal or

industrial-grade linoleum to be used only for work

on pumps,

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It is essential to:

- follow the methods described on the following

pages,

- use the specified tools,

- avoid extraction of the pins from the various

components,

- replace all seals, washers, sealing wires and lead

seals by new ones,

- replace the bearings with new ones each time

they are removed,

- replace any components that show signs of

damage, wear, gumming-up, corrosion, cracking

or distortion,

- use all the components in a kit even if only one of

the kit components is required.

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Clean the pump externally (using a suitable solvent).

Remove the inspection plug and drain the pump if

necessary. Extract the O-ring from the plug and discard

it.

Secure the pump, horizontally, on support plate

1804-411 using the appropriate adaptor ring.

Remove all seals (wires, lead seals, heat shrink sleeves,

dabs of paint) and any protective caps.

Disconnect the low-load advance, progressive

low-load advance or advance override linkages,

if fitted to the pump. Remove and discard the

self-locking nut

and the washer

from the

shaft of the throttle lever

. Remove the throttle

lever, the return spring

and the spring guide

On those applications where the arrangement

shown opposite is fitted, remove and discard the

self-locking nut

and the washer

from the

lever, the return spring

and the spring guide

. Remove the washer

, the spring guide

and the spring

that tensions the lever

If the pump is fitted with a Coded Anti-Start (CAS)

device, and protection brackets are secured by

shear screws, loosen the screws using a cold

chisel or a centre punch and remove them.

Remove the brackets and covers. Remove the

inlet banjo bolt and the stop solenoid.

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If the pump is equipped with two microswitches

on the throttle lever, carry out the operations for

removing a switch (see Section 2.2 Fig.4), then

remove the two support/switch assemblies from

the plate by removing the securing screw

and

the washer

If the pump is fitted with a pneumatic "switch",

remove the securing screw with the washers

and and the switch . Remove the two

screws , the washers and the switch

support bracket . Remove the screw

which secures the cam to the throttle lever and

the washer

. Remove and discard the self-

the washer

, the cam

, the spacer

, the

throttle lever

, the return spring

and the

spring guide

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