FUEL

INJECTION
PUMP
Before Dismantling:
• Prepare all
necessary tools
for dismantling
process
• Stop the diesel
generator by putting or
setting the governor
lever to stop position.

• Put lock and tag out to

the diesel generator to
be overhauled to prevent
accidental starting of it.
• Turn off the main • Close all necessary valves
such as:
valve of the air
1.)Inlet and outlet valve of
tank.
water cooling system
• Make sure that all 2.)Inlet and outlet valve of
auxiliary pumps are fuel oil system
isolated, not running 3.)Inlet and outlet
and/or in manual valve of lubrication
mode system
 • CAUTION: Make sure that
diesel generator is
already cooled down to
• Drain the cooling prevent injuries like
water from the burns. Just after the
diesel generator
diesel generator stops,parts particularly
the exhaust pipe, cylinder
head, and parts around
them are hot.
• Pull out the fuel injection pump
from the diesel generator.
 Dismantling
Procedure:

• Attach the fuel

oil injection
pump on vise
with the tappet
upward
• Use a gear puller or the
like to keep on pushing
the tappet assembly and
to remove the holding
pin.
• Remove the components
of the tappet assembly
in the following order:
plate, spring seat
(lower), spring, plunger,
and spring seat(upper)
• Remove the
control sleeve
and control rack.
• Release the injection
pump from the vise.
Turn the pump upside
down and fasten it
with the vise.
• Remove the
mounting bolts.
Remove the delivery
valve assembly.
• Remove the
positioning
screw
• Turn the injection pump
upside down again. Keep
holding the plunger
barrel by hand, and
remove it from the main
body.
• If the plunger barrel does
not come out, place a piece
of wood on the opposite
side of the plunger barrel.
Tap the piece of wood with
a hammer to push out the
plunger barrel.
• Remove the
deflector
 INSPECTION
AND
MAINTENANCE
:
• Clean the removed
parts with clean
wash oil, and blow air
over them.

• Inspect the plunger,

plunger barrel, and
deflector to see if any
corrosion is found.
Replace the component
with a new one if it is
corroded too much
• Measure the inner diameter of the
tappet, and calculate the tappet
clearance
• Fit a dial gauge onto
the tappet roller
surface, and measure
the bearing clearance
while moving the
roller up and down
Reassembly:
• Reassemble the fuel
oil injection pump in
procedure for
reverse order from
its disassembly.
• Hold the pump body
with its delivery valve
side upwards. Fasten
the pump body with a
vise.
• Apply some grease
on the new O-ring
and new backup ring.
attach them on the
barrel.
• Mount the
barrel
positioning
bolt.
• Align barrel
positioning bolt hole
on the pump body with
the hole on the barrel.
Insert the barrel in the
pump body.
• Align the dowel
of the delivery
valve assembly
in place. Mount
the assembly on
the pump body.
• Apply anti-abrasion
agent (Molykote U
Paste) on the thread
and seating surface of
each the bolts. Tighten
the bolts evenly in the
diagonal order with
the prescribed torque.
• Release the pump body
from the vise. Turn the
pump body upside
down and fasten it with
the vise again.

• Apply the grease to the

teeth on the gear of the
control rack and the
inner surface of the
control sleeve.
• Align the
beginnings of the
teeth on the rack
and sleeve(in the
direction of 0 mm
on the rack) and
assemble them.
• Mount or attach the
spring seat(upper),
plunger, spring, spring
seat(lower), plate ang
tappet assembly in this
order.

To mount the plunger, “Z”

mark in the lower part
must be in the opposite
direction to the rack.
• Use a gear puller
or the like to keep
pushing the tappet
and to mount the
holding pin.
• Mount the
deflector
• When completing the
reassembly, comfirm that the
rack moved smoothly and that
the point of “0” is correct.
 END!
Prepared by:
E/C RAPAL, JOHN LOUISE
E/C SIBAL, STEVEN JOHN
E/C VITERBO, ARGEL