Page 115 - CTS - Mechanic Diesel - TP

MECHANIC DIESEL - CITS

Inspection

• Inspect the plunger and barrel element for wear, and replace, if abnormal wear is found.
• Clean the plunger with test oil. Withdraw the plunger about 1/4 of its length vertically upward from the element
barrel. It must slide back slowly by its own weight into the element barrel.

• Inspect the delivery valves for wear on the relief piston, wear on the delivery valve pin and body seat, wear
on the seating surface. Replace the delivery valve if it has any of the above defects. These should not be
reconditioned
• Inspect the roller tappets for wear and damage. If excessive wear is found, replace. Inspect the camshaft for
wear damage.

• Inspect the taper roller bearings for pitting/worn out races.
• Inspect the control rack for smooth slide in the pump housing. If it sticks, polish it with fine 00 emery-paper.
• Replace the control rack if the teeth are found to be worn out. Replace the worn out guide bushes.
• Inspect the plunger spring for corrosion, cracks and edge replace it, if necessary.
Assembling

• Mount the pump housing on the swivelling vice Fit the gallery plug.
• Rinse the elements in clean test oil and insert so that thee groove of the barrel engages the locating pins.
• Insert the delivery valve and washer. Fit the delivery spong and delivery valve holder. Tighten the every valve
holder at the recommended torque with as not to spoil the thread after cleaning the threads.

Barrel seal tightening test
• Remove the FLP from the swivel vice.
• Connect the compressed air connection to the fuel inlet, se the outlets. Dip the pump in the test oil tank
and at 0.5 to 1.0 (kgf/cm ). If an air bubble appearly once in a while from the barrel seating, then the auto is
2
considered tight.
• Fit FI.P. on the swivel vice. Remove the plunger assembly.
• Fix the control rack and screw in the control rack locating
• Insert the control sleeve in the quadrant in such a way mat the clamping jaws of the quadrant with the control
Jack in the centre position point accurately forward
• Fit the upper spring plate plunger spring. Insert the plunger element in the lower spring plate. The plunger must
tum smoothly with the control rack movement
• Insert the roller tappet and align the tappet pins into the grooves in the pump housing. Push the roller tappets
and insert the tappet holders.
• Press the oil seals and the outer bearing races into the and plate. Insert the camshaft coating journals and
cams with light oil.
• Force the intermediate bearing into the pump housing by taping the camshaft with a rubber mallet.
• Remove the tappet holders by rotating the camshaft. Check the plunger element has a clearance of atleast 0.2
mm at the TDC position of the cam and then lock the tappet screws.
• Fit the bearing end plate and tighten the screws. Fit the governor housing with gasket.
• Insert the woodruff key into the camshaft and fix the fly weight assembly. Sequence of governor assembly
• Fix the guide sleeve and actuating T between the flywheels and connect sleeve to the guide lever.
• Connect the guide lever and fulcrum lever on their respective fulcrum pins and locate the bottom of the fulcrum
lever into the slot or governor cover.
• Connect the control rod rack to the fulcrum lever through the shackle. (Link fork)
• Hook the starter spring ends to their respective fulcrum points.
• Attach the tension lever on the same pivot point of the guide lever.

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CITS : Automotive - Mechanic Diesel - Exercise 5.6