TO DISMANTLE, INSPECT, ASSEMBLE A DPA PUMP

TOOLS AND EQUIPMENTS

 DPA injection pump.

 Test balance
 Special service tools
 Cleaning material

Procedure

 Clean the exterior parts of the pump thoroughly.

 Mount the pump on the holding bracket.
 Loosen top cover, un house governor spring from throttle lever.
 Remove governor spring by un-housing the spring main from the link.
 Remove shut off bar.
 Loosen and remove the three screws holding the brackets to the pump housing.
 Remove bracket straight up with linkage governor arm and metering valve.
 Remove metering valve from linkage.
 Loosen the end plate screws and inlet connection.
 Invert the pump. Remove the pulsation at damper end if used.
 Remove advance piston plugs.
 Remove inlet connection from end plate.
 Loosen the rotor nut.
 Remove heed locking screw and carefully withdraw the hydraulic heed from the housing.

PRECAUTIONS OBSERVED WHEN TESTING DPA PUMP

 Ensure that the pump driven test bench is set to run in the direction of rotation of the
injection pump, as indicated by the arrow on the pump name plate.
 Ensure that the fuel flow to the pump inlet IS not less than 100cc/min. A maximum feed
pressure of 15kg/cm² is permissible.
 Do not run the pump for long periods at high speed with low fuel output.
 Do not run the pump for long periods with the shut off control in the closed position.

MERITS OF DPA

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  Lighter and more compact in construction owing to concentric arrangement of all
working parts.
 Less costly in manufacturing due to its simpler construction.
 Does not require calibration and phasing.
 An automatic injection timing control can be readily in corporate.
 More convenient to install since it can be mounted at any desired angle.

DEMERITS

 Not capable of generating very high injection pressures demanded by large diesel
engines with direct injection.
 It’s difficult to incorporate for turbo charged engines.
 Has only one pumping element hence in case of any fault, there will be a breakdown.

 Read and make notes on testing adjusting of DPA pumps

REMOVAL OF TURBOCHARGER

 Remove exhaust connector.

 Remove connector hose.
 Shift hose to air connector side.
 Disconnect turbo charger supply tube and remove turbocharger drain tube.
 Remove turbo charger assembly.

INSTALLATION OF TURBOCHARGER.

 Install gasket and turbocharger.

 Install gasket and turbocharger drain tube.
 Install O-ring and connect turbocharger supply tube.
 Shift hose to turbocharger side.
 Install connector hose.
 Install seal ring, gasket and exhaust connector.

OVERHAULING A TURBOCHARGER

TOOLS, EQUIPMNETS AND MATERIALS

Scribing tool, non caustic cleaning solvent, and engine with turbocharger.
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PROCEDURE

 Clean the exterior of the turbocharger with a non caustic cleaning solvent.
 Mount the unit on the vice.
 Before removing the housing, use a scribing tool to mark the location of compressor and
the turbine housing to the bearing housing.
 Remove the clamp on bolts securing the compressor housing and lift of the housing.
 Remove the turbine housing clamp or bolt and lift the bearing housing clear of the
turbine housing.
 Mount the bearing housing in the upright position in a special fixture on soft screwed
vice. Make sure that the vice jaws grip the turbine wheel extension nut only and not the
turbine fins.
 Unscrew the lock nut retaining the compressor wheel and lift the wheel off the turbine
shaft.
 Remove the turbine shaft from the turbine and off the bearing housing.
 Remove the circlip or cap screws.
 With a piece of wood slowly inverted into the centre hole on the thrust assembly lift the
assembly out of bearing housing.
 Remove the remainder of the thrust assembly and the two main turbine shaft supports
bearing the circlips.

ASSIGNMENT

1. Describe the construction and operation of sleeve metering pump. (15 marks)

2. By use of a neat diagram explain the operation of an automatic timer. (15 marks)