OPERATION MANUAL AND SCHEDULE OF SPARE PARTS FOR

THE INJECTION SYSTEM DSFP 1 FW

consisting of
Injection Pump
Injection Delivery Line
Injection Valve
Pressure Generator for the Testing of the Injection Valve

VEB EINSPRITZGERATEWERK AKEN

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Operation Manual an Schedule of Spare Parts

for the Injection System DSFP 1PW

consisting of
I Injection Pump
II Injection Delivery Line
III Injection Valve
IV Pressure Generator for the
Testing of the Injection Valve

VBB Schwermaschinenbau.
Karl Liebknecht" Magdeburg
Kombinat für Dieselmotoren
und Industrieanlagen
Enterprise: VEB Einspritzgeratewerk
Aken
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I Injection Pump
 3
Preface:
It cannot be the task of the operation manual to show each possible case of the working
practice and to give detailed theoretical explanations on the operating mode of the injection
pumps. Therefore it is not possible to claim damages to us with the hint that explanations in the
operation manual are missing that could have prevented the defect if they had existed.

If nevertheless there would be difficulties and problems during the service time of our injection
pumps the specialists of our customers* service department will be available readily at your
command to advise you.
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Index

0. Technical data
1. Design and operating mode
2. Mounting and dismounting of the injection pump at
the engine
2.1. Mounting
2.2. Dismounting
2.3. Adjusting of the control linkage
3. Fuel diagram
4. Maintenance
5. Information on operation
5.1. Planned putting out of operation of the injection pump
5.2. Putting out of operation at average situations
6. Conservation and storage
7. Defects at the injection pump and their removal
7.1. Breakdowns at the injection pump
7.2. Repair of the injection pump
7.2.1. General hints
7.2.2. Repair
7.2.3. Operating mode of the pressure generator
8. Schedule of spare parts
0. Technical Data 5

Type: DSFP 1FW

Construction: Single mounting pump; single-

chamber system, single flow
Number of delivery units: 1
Stroke of the piston: 40 mm
Prom it initial stroke: 10±1 mm
Pump-piston diameter: 40 mm
Controlling: chamfer (inclination 70 mm)
Pressure valve: constant-volume relief; relief
volume 0 mm 3
Drive dog: maximum 73 mm
Maximum driving speed: 300 r.p.m.
Maximum pressure in the pump: 123 MPa
Delivery amount: depending on the pump diameter
and on the dirve dog
Recommended pressure pipeline: pipe 15x5 with connection M3Ox1.5
with internal taper 9o
Suitable fuel: Diesel fuel, heavy oil up to
3500 sec. red./100°
Pressure oil stop: connection M12x1.5 for finestly
filtered engine oil (filter fine-
ness = 4/um)
Fuel intake pressure before 1. Diesel fuel 0.08 ... 0.35 MPa
the pump: 2. Heavy oil (preheating temperature =
100°C)0.08 ... 0.35 MPa
3. Heavy oil (preheating tempera-
ture >100°C) 0.25 ... 0.35 MPa
Distance between cam base
circle and locating surface: 195mm
Roll diameter: 125 mm
Bearing width of the roll: 50 mm
Pressure-feed oil lubrication: 0.2 ... 0.5 MPa
Weight of the pump: 122.5 kg
Moved weight: 24 kg
Overload safeguard of the
injection pump: at ca. 125 % engine power
Operating viscosity of the 16.7 mm /sec short-time maximum
fuel: 20 mm^/sec.
Operating temperature of the
injection pump: maximum 150°C
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1. Design and Operating Mode
The injection pump DSFP 1 FW is an individual pump designed as an individual unit in
accordance with international trends. All component parts essential for operation are
housed in the pump casing.
The construction can be seen from images 1 + 2 . The high-pressure section of the injection
pump is designed as a unit consisting of various elements, i.e. pumping element (1), pressure
valve (2) and valve support form a unit connected by 8 filister-head screws (3). Due to the
design of the high-pressure section, high peak pressures can be developed in the injection
pump. The unit is connected to the pump casing (4) over a pressure flange (5) with the heolp of
four expasion bolts (6). The pressure control valve (2) arranged in the unit is designed as a
pressure valve with constant-volume relief or with constant-pressure relief, depending on the
concrete operating conditions of the injection pump. The pumping element (1) is provided with a
triple-operating catch for leakage fuel which prevents leakage fuel from getting into the lower
part of the injection pump or into the camshaft space. Part of the leakage fuel is returned
through the upper leakage fuel bore hole (1.2.1) in the pump cylinder (1.2) to the low-pressure
space (4.1.) of the injection pump which is designed as a single-chamber system. Pressure oil
is applied to the lower bore hole (1.2.3) in the pump cylinder (1.2). This pressure oil forms a film
around the lower part of the pump piston (1.1) thus preventing draining of the residual leakage
into the lower part of the injection pump. This residual leakage is discharged together with part
of the pressure oil through the central leakage fuel bore hole (1.2.2) to the outside. The pump
piston (1.1) is provided with two diametrically arranged control helixes (1.1.1) which interact with
adequate control bore holes (1.2.4) in the pump cylinder. Due to the symmetrical arrangement
of the control grooves (1.1.1) and the control bore holes (1.2.4) contact between the pump
piston (1.1) and the pump cylinder (1.2) is prevented. Thus wear of the pump element (1) is
reduced. In order to prevent damages at the pump element (1) due to cavitation, baffle screws
(8) are inserted in the pump casing which throttle in connection with the control bore holes the
discharged fuel flow. The delivery amount is controlled by rotating the pump piston (1.1), to the
pump cylinder (1.2).
 7
The rotation of the pump piston is initiated by moving the control shaft of the engine with control
rack (9) and the con-' trol sleeve functioning as transfer elements. The control rack (9) of the
injection pump is designed as flexible safety control rack. A spring-loaded linkage (9.2) within
the control rack (9) takes over its function, when a fixed adjusting power of tha control rack is
exceeded (e.g. jammed control rack at the seizing of the pump piston). Thus the engine
will,further be controllable over the whole load region.
A full-load stop (12) is mounted on the injection pump in order to protect the pump from
overload (The stop operates at an engine performance of ca. 125 %; it is sealed by the injection
pump manufacturer.).
With the help of 2 screws the tappet body (13) with roil (14) and roller bolt (15) is solidly
connected to the pressure piece (17) in which the pump piston (1.1) is arranged rotatably and
which serves for the transmission of the viscosity pressure powers.
By this design damages at the camshaft are prevented when a seizing of the pump piston
takes place, since the whole roller follower will be stopped in the top dead centre of the injection
pump. An eccentric cam (13) is arranged in the pump casing (4) which will mate- into an
adequate window (13.0.1) of the ram body (13) when the pressure bolt (10.3) is operated and
which after a rotation of the eccentric cam (13) by 180° will put the injection pump out of
operation.

2. Mounting and Dismountins of the Injection Pump on the Engine

2.1. Mounting
The mounting of the injection pump is carried out with relaxed lifting eccentric cam. Here the
roller follower of the injection pump is situated ca. 2 mm below the top dead centre. By turning
the injection cam belonging to the adequate cylinder station is to be turned into the bottom
dead centre position. The engine manufacturer delivers shims for each cylinder station. With
the help of these shims tolerances of the measure cam basic circle -engine block can be
levelled. When the injection pump are changed this shim remains on the engine block.
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The tolerance levvelling within the injection pump is done with the manufacturer's of the
injection pumps. When the injection pumps are delivered the manufacturer of the injection
pumps guaratees that the prestroke tolerance of the single injectiqn pumps one to the other
is 0,2 mm.
The prestroke of the injection pumps is 10 - 0,1 mm at nominal size of cam basx circle -
engine block of 185 mm. This little tolerance spares a new regulation of the concerned
cylinder station of the engine when a change of the injection pump is necessary.
The fixing of the position of the injection pump on the engine block is performed by 2
cylindrical pins. In the engine block there are 4 screws for injection pumps (studs). The
injection pump is fastened by 4 hexagonal-head nuts. Here at tightening the given in the
engine documentation turning moment is to be observed After this the fuel pipeline, the
lubricating oil pipelines and the leakage-fuel pipelines as well as the injection pressure
pipeline are to be installed.

Attention;
Because of the narrow space at the engine it is possible that by striking against the pressure
bolt the automatic of the eccentric cam can be triggered by the mounting process. An
engaging ist impossible since the cam of the injection pump is in top dead centre during the
mounting process. By striking of the pressure bolt the spring in the automatic of the eccentric
cam is loaded. During the turning then the eccentric cam engages near the top dead centre.
It is possible to turn the camshaft further with engaged lifting accentric cams, too. Before
putting into operation of the engine it is to be controlled whether all eccentric cams of the
automatic are in engaged condition. Engaged eccentric cams are to be disengaged with the
help of the clamping device, contained in the mounting gang tool. The disengaging can only
take place quite near to the top dead centre or in the top dead centre.
 9
For this purpose, if necessary, the cam shaft ist to be turneduntil the adequate injection cam ist
standing in top dead centre.The markings at the linfting eccentric cams must show into the
direction of the engine block.
2.2. Dismounting

The dismounting is to be done in reverse order. The shim remains on the engine block,

2.3. Adjusting to the control Linkage

Since the injection pumps are set to the test stand by the manufacturer the control linkage of
the engine must only be adjusted according to one injection pump. The slip gauge for the injection
pump DSFP 1FW is 91 mm (image 3). With the help of the fork gauge this measure is adjusted
at the injection pump. The blocking of the control rack is done with the help of a screw at the
full-load stop after removing the there situated screw plug. The connection between the
adjusting shaft of the engine and the control rack of the injection, pump is carried out by a splice piece
belonging to the control linkage of the engine. For this purpose the snap ring is reaoved from
the linkage, the sleeve is pulled over the splice piece, and the pin is lifted thus that the splice piece
can engage into the space of the linkage of the control rack. Then the pin is pulled through the
bore hole of the splice piece, and the sleeve is pulled over the pin and is then secured by the
snap ring. After this the locking screw at the full-load stop is removed and the screw plug is
arranged again. At the other injection pumps this process is reduced to the adjusting of the linkage of
the control rack to the splice piece of the control linkage of the engine.

3. Fuel DiagramThe injection pump DSFP 1FW is always to be operated with fuel feed pumps
for ensuring the required fuel feed pressure of 0,08 to 0,35 MPa with Diesel fuel and 0,08 to 0,35
MPa with heavy oil at a preheating temperature =< 100 °C and 0,25 to 0,35 MPa at a pre-heating
temperature > 100 °C before the pump.
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This fuel feed pressure is necessary for proper filling of the injection pump during the suction process and
for fuel passage for flushing and cooling of the injection pump. The design of the fuel feed pump can be
chosen by the engine manufacturer. However, agreement with the injection pump manufacturer is
required.

4, Maintenance
The injection pump DSFP 1FW needs no maintenance with the exception of checking and replacing of
component parts after specified periods of operation. The component parts mentioned below should be
checked after the following periods of operation;
Element: smooth running, wear of control helixes,
flushing 6000 h
Pressure valve: tightness 6000 h
Baffle screws: flushing in baffle area 3000 h
Tappet body: working faces 6000 h

5. Information on In.iection Pump Operation

5.1. Planned Putting out of Operation of the Injection Pump

When a planned putting out of operation of the injection pump is necessary (-e.g. measurement of the
compression pressure) the control rack is to be drav/n to "stop" with the help of pulling hooks and in this
position it is to be blocked with the help of the pin (image 4), When the injection pump is put into
operation again, the blocking must be taken away and the control rack must slowly glide to the given
drive dog.

5.2. Putting out of Operation at Average Situations For a fast putting out of operation the injection
pump is equipped with an automatic of the eccentric cam. This automaticis principally to be actuated
only at average situations. A frequent actuating of the automatic causes damages at the roller follower.
To put the injection pump out of operation press shortly and strongly on the pressure bolt and then turn
immediately and fast
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the eccentric cam by 180° with the help of a 12 point opening socket wrench thus that the
marking of the eccentric cam is at the top.
When the injection pump is put into operation again turn the eccentric cam back and draw it out
with the help of the clamping device. It is forbidden to use the eccentric cam for pre-pumping or
for pressure tests.

6. Conservation and Storage

The interior parts of the injection pumps delivered by the producer are protected against
corrosion by the preserving agent S 100 D. The exterior unfinished surfaces of the injection
pump are greased byacidless vaseline. The conservation will be effective for tv/o years. The
injection pumps must be stored in original packing in dry rooms and must be secured against
corrosion. In regualr intervals of ca. 3 months the control rack is to be moved in order to avoid a
sticking of the pump piston.

7. Defects at the Injection Pump and their Removal

Defects can be caused at the engine itself or by the injection
equipment.
In the following, only the defects in the injection system will
be considered.

7.1. Breakdowns in the Injection Pump

a) The temperature of the exhausting gas is not in the required tolerance band. The rate of
delivery is not correct.
- Pump piston seized (1.1)
- Pressure valve (2.1) seized or broken resp.
- High-pressure areas leaking
- Pressure valve spring (20) broken
- Pump spring (21) broken
- Connection between control rack and control linkage
defective
- Pressure pipe is cracked
- Di efective roller (14)
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b) Ignition pressure is not within the required tolerance band.
The rate of delivery is not correct.
- Unsuitable or no s h i m (22) resp. between the injec
tion pump and the engine block
- Defective roller (14)
c) Excessive leaking fuel discharge through the connection for
leakage fuel (23)
- O-ring is defective
The injection pump can be further operated until the next cutdown of the engine. It must be ensured
that no leakage fuel gets into the camshaft space.
d) Excessive pressure oil discharge through the connection for leakage fuel (23)
- O-ring (25) is defective
Pressure oil connection (27) for this injection pump must be blocked.
The injection pump can be further operated until the next cutdown of the engine. It must be ensured
that no leakage fuel gets into the camshaft space.
e) Excessive pressure oil consumption and no discharge through the connection for leakage fuel (23)
- O-ring defective
The injection pump must be put out of operation immediately in order to prevent dilution of lubricating
oil.

7.2. Repair of the Injection Pump

Only experienced and trained workers must be allowed to carry out maintenance and repair works.
When the injection pump is dismounted pay attention to tidiness. It must be ensured that the working place is
free form swarf and other dirt. It is recommended to wash component parts in petrol or diesel fuel.
7.2.1. General Hints
The following directions should be noted:
- Do not mix up component parts of the pump element nor of the pressure control valve.
 13
- Component parts of the pump element and of the pressure control valve put down
always on a soft base (cloth).
- High pressure areas should be protected against damaging and should be cleaned with the
help of clean diesel fuel and by a non-fraying cloth or paper resp. when being remounted.
- O-ring should be rubbed with lip seal paste before being assembled.
- Expansion bolts should be rubbed at the working sureface and at the thread with graphite
paste.
- Expansion bolts must be tightened or loosened cross- and stepwise.

7.2.2. Repair
a) Replacing of pressure control valve
- Clamp injection pump on assembly angle 223.124706-22.
- Loosen filister-head screw (3)
- Remove valve support (28)
- Remove"stroke limiter (29) and pressure control valve spring (20)
- Change the pressure control valve Reassemble in
reverse order.
b) Replacing of the pump element
Dismounting
- Press roller tappet (13) in with mounting appliance 222. 330406-43 (ca. 5 mm)
- Pull out snap ring (30) and sliding block (36) with the help of screw M8
- Dismount mounting appliance
- Loosen hexagonal socket-head bolts (16, 31)
- Remove roller (14) and roller tappet (15)
- Pull out tappet body (13) with the help of the hexagonal socket-head bolts (31)
- Take out distance disk (32)
- Pull out pump piston (1.1) with pressure piece (17) of the pump casing until it is possible
to unhook the pressure piece
- Pull out the pump piston (1.1) completely
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- Pull out pump spring (21), control sleeve (10) and upper spring
plate (33)
- Undo baffle screw (8) and locking screws (34)
- Loosen filister-head screws (3), remove valve support (28),
- stroke limiter (29)» pressure control valve spring (20) and
- pressure control valve (2). Loosen hexagonal screws 20x1.5 (35),remove pressure flange (5)
- Press out pump cylinder (1.2) with the help of dismounting
appliance 222.330206-22 (image 5).

Mountin
- Insert rubber 0-rings (24, 25, 26) at the pump cylinder.
- Press in pump cylinder (1.2) with the help of the mounting appliance 222.330406-43
(image6).
The groove (1.2.5) of the pump cylinder (1.2) is to be adjusted to the socket of the locking
screw (34).
Little correction of the position of the pump cylinder can be done in pressed-in situation putting
in a brass or aluminium plug through the control holes (1.2) and carefully turning the pump
Cylinder to the adequate direction.
- Screw in guide screw (34)
- Insert pressure flange (5) and tighten the 4 hexagonal nuts M20x1.5(35)
- Install pressure control valve (2) as described under a)
- Turn the injection pump
- Insert the control sleeve (10). Attention! Marking (10.1) of the control sleeve (10) and
marking (9.0.1) of the control rack must correspond (image 7)
- Insert the upper spring plate (33).Before the further assembly of the injection pump the
be ginning of delivery is to be readjusted, since it can have been deferred by tolerances in
manufacturing at the pump element. For this purpose use the adjusting device 222.330106-13
(image 8). The further assembly is accomplished without pump spring. Pump piston (1.1) with
hooked-in pressure piece (17) is to be introduced and is to be put carefully on the holding
bolt
 15
The adjusting of the beginning of delivery is accomplished without spacing disk (32). Then
the tappet body (13) is to be introduced, the roller (14) with the roller bolt (15) is to be put on
and to be screwed together with the hexagonal socket-head screws (16, 31). The
hexagonal socket-head screws (16, 31) only need little greese. The difference value
between the measured measure and the required measure 10-+0,1 shows the hickness of
the spacing disk to be put in at mounting. As shown in image 8 the adjusting appliance is to
be used without s h i m (22).
- Insert pump piston (1.1)
- Mount pump spring (21)
- Hook in pressure piece (17)
- Put on the measured space disk (32)
- Insert tappet body (13), put on roller bolt (15) with roller (14) and screw with the help of
hexagonal socket-head screws (16,31)
- Mount securing wires
- With the help of the mounting appliance 22.330406-43 press in roller follower (13) thus that
the sliding block (36) can be introduced.
- Secure sliding block (3D) with the help of the snap ring (30)
- Dismount counting appliance
- Mount eccentric cam (13)
- Insert baffle screws (8)
c) Seizure of pump piston
- Secure roller tappet (13) standing under pre-stress of the pump spring with the help of the
dismounting locking 222.330306-32 (image 9). Screw in hexagonal-head screw M12x80 up
to dog.
- Remove sliding block (36)
- Loosen hexagonal socket-head screw (16, 31)
- Remove roller (14) and roller bolt (15)
- Loosen hexagonal socket-head screws (17.1)
- Relax pump spring by turning out the hexagonal-head screw M12x80
- Pull roller tappet, pressure piece, pump spring, spring plate and control sleeve
 16
- Continue as described in b)
d) Change of defect O-rings of the element assembly
- V/hen the O-rings (24, 25, 26) of the element assembly are
changed operate according to b), but with the difference that
the filister-head screws (3) are not loosened (The element
assembly will not be dismounted,)
- When mounting the item "Adjustement of the beginning of
delivery" is not applicable,

7.2.3. Operating Llode of the Pressure Generator (image 10)

The tightness of the pressure control valve is to be tested as follows:
The device for the tightness control of the pressure control valve is to be mounted on the pump
to be tested. The pressure connection of the injection pump is to be screwed with the pressure
pipeline of the test device. The connecting branch with manometer is to be inserted between
the pressure connection of the pressure generator and the pressure pipeline.
The control rack of the pump to be tested is to be put in zero-admission position.
With the help of the pump lever of the pressure generator a pressure of ca. 10 MPa is to be
generated. The pressure drop from 5 MPa to 3 MPa is not allowed to be exceeded v/ithin 30 sec.
When the pressure drop takes place in a shorter time the pressure control valve is untight and
mu3t be changed.
 17

8. Schedule of Spare Parts

Each of the mentioned details can be bought as a purchase part.

Ser.No. Term Order No. Wear part

Injection pump DSPP 1FW 224.309506-70
1 Pumping element 222.343106-23 X

2 Pressure control valve, without balancing .222.343506-63 X

3 Filister-head screw Ml6x100 TGL 0-912-10.9

4 Pump casing, one-piece 221.307106-50
5 Pressure flange 221.300106-03
6 Expansion bolt 221.307206-64
7 Guide screw 221.301106-24
8 Baffle screw 221.301206-33 X
8.1. Packing ring A24x29 TGL O-7603-Cu
9 Elastic control rack, complete, consisting of: 222.313006-73
9.1. Control rack 221.313106-13
9.2. Linkage 221.313206-23
9.3. Spring plate 221.313306-34
9.4. Spacer 221.313406-44
9.5. Dog 221.313506-54
9.6. Sleeve 221.313706-74
9.7. Bolt 221.313806-34
9.8. Pressure spring C1,8x24x17.5 TGL 18395
9.9. Snap ring 18x1.2 TGL 31665
9.10. Snap ring 30x1.6 TGL 31666
9.11. Snap ring 12 TGL 0-471
9.12. Gauge disk 14 x 0.1 TGL 10404 - St
9.13. Gauge disk 14 x 0.2 TGL 10404 - St
9.14. Gauge disk 14 x 0.5 TGL 10404 - St
9.15. Gauge disk 14 x 0.8 TGL 10404 - St
9.16. Gauge disk 12 x 0.1 TGL 10404 - St
9.17. Gauge disk 12 x 0.2 TGL 10404 - St
9.18. Gauge disk 12 x 0.5 TGL 10404 - St
9.19. Gauge disk 12 x 1 TGL 10404 - St
10 Control sleeve 221.300206-13
11 Adjusting mark 221.101806-24
 18
Ser. No. Term Order No. Wear part
11.1. Gauge disk 6x0.1 TGL 10404 - St
11.2. Gauge disk 6x0.2 TGL 10404 - St
11.3. Gauge disk 6x0.5 TGL 10404 - St
11.4. Gauge disk 6x1 TGL 10404 - St
11.5. Lens screw BM5x12 TGL 0-85-5.8
12 Pull-load dog 221.300606-54
13 Tappet-body 221.311106-62 x
13.1. Cylindrical pin 10 M6x20 TGL 0-7
14 Roll, complete 222.321606-44 x
15 Roller bolt 221.311306-73 x
16 Holding screw, long 221.304806-64
17 Pressure piece, complete 222.307506-73
Filister-head screw for grooving cutter
17.1. 221.307806-34
block
17.2.. Pressure piece 221.307606-13
17.3. Grooving cutter block 221.307706-24
17.4. Distance plate 221.308306-04
18 Eccentric cam, complete 222.309006-63
18.1. Flange bearing f. eccentric cam 221.309106-03
18.2. Eccentric cam 221.309206-13
18.3. Pressure bolt 221.309306-24
18.4. Dog 221.309406-34
13.5. Helical compression spring C2x34x7.5 TGL 18395
13.6. dto. C1x11x7.5 TGL 18395
18.7. Cylindrical pin Sm6 x 18 TGL 0-7
18.8. Ball 8 m II TGL 15515
18.9. Snap ring 25 TGL 0-471
18.10. 0-ring 28 x 3 TGL 6365-WS 2.055
18.11. 0-ring. 45 x 5 TGL 6365-WS 2.055
19 Hexagonal-head screw M8 x 25 TGL 0-933-8.8
20 Helical compression spring 221.112506-54
21 Pump spring 221.000706-04
22 Inset 221.304506-34
23 Screwed-in nozzle 8 x 32 M TGL 0-3901 St
23.1. Packing ring A 14 x 18 TGL 0-7603-A1.
 19
Ser. No. Term Order No. Wear part
24 0-ring 80 x 5 TGL 6365 - WS 12.097
25 0-ring 80 x 5 TGL 6365 - WS 12.097
26 0-ring 80 x 5 TGL 6365 - WS 12.097
27 Screwed-in nozzle 8-32 M TGL 0-3901 St
28 Valve support 221.310106-43
29 Stroke limiter 221.318706-84
30 Snap ring 20 TGL 0-472
31 Holding screw, short 221.311306-84
32.1. Distance disk 221.301406-54
32.2. Distance disk 221.301506-64
32.3. Distance disk 221.301606-74
32.4. Distance disk 221.301706-84
32.5. Distance disk 221.301806-04
32.6. Distance disk 221.301906-14
33 Upper spring plate 221.300306-24
34 Locating screw 221.301006-14
35 Hexagonal nut M 20x1.5 TGL 0-934-8
36 Sliding block 221.300506-44 x
37 Packing 221.305206-24
38 Screwed-in nozzle 12-32 M TGL 0-3901 St
38.1. Packing ring Al6x2O TGL 0-7603-A1
39 Packing 221.304706-54
40 Filister-head screw M 8 x 30 TGL 0-912-10.9
41 Tappet screw 221.301306-44
41.1. Packing ring A6 x 10 TGL 0-7603-A1
42 Control rack flange 221.300706-64
43 Driving flange 221.300906-34
44 Filister-head screw for full-load dog 221.304906-74
45 Spacing pipe 221.311706-34
46 Bridge 221.310406-74
47 Hexagonal-head screw M8 x 50 TGL 0-933-8.8
48 Packing ring A 26 x 34 TGL 0-7603 Cu
49 Identification plate 499.010-0:34(3)
50 Half-round notch pin 2x6 TGL 0-1476
51 Metal seal TGL 9-16437
 20
Ser.No. Designation Order No.
1 Gang tool for mounting 225.306006-37
2 Pressure generator 224.122006-70
3 Pressure generator 223.117806-04

4 Nozzle-holder collet, compl. 223.122106-11

5 Rotary-plate collet, compl. 223.123806-11

6 Assembly angle 223.124706-22
7 Collet, nozzle-holder 222.335006-13
8 Meter device 222.330106-13
9 Dismounting device 222.330206-22
10 Dismounting safeguard 222.330306-32
11 Mounting device 222.330406-43
12 Chucking device 222.113506-54
13 Screw detail 221.104706-74
14 Pork gauge 221.330006-24
15 Turning nut for nozzle-holder 221.107806-54

16 Filister-head screw M8x40 TGL 0-912-10.9 40200217

17 Hexagon-head screw M6x4O TGL 0-933.8.8 40230604

Pos. 3 can be used with for pos. 6 asa clampf device

nozzle- holder.

Pos. 20 can be used as an VD adapter for nozzle-holder

26/20.
18 Hexagon-head nut . M6 TGL 0-934-6.6 41040032
19 Stop device 223.334006-63

20 Adapter 222.106906-24

21
II. Operation Manual Injection Pressure Line

22
In.iection Pressure Line
The injection pressure line is a double-walled construction. A protecting jacket made of
metal ballows is pushed over the injection pressure pipe 1 5 x 5 .

The outside protecting jacket serves for the safe drain of fuel which may flow over out of
the injection pressure pipe when perhaps a circuit-break will take place.
The drain of this fuel is performed by a connecting piece at the lower end of the pipeline.
Between the pressure pipe and' the protecting jacket there is a profile rubber, wound screw-
shaped as a distance holder round the pressure pipe.
The sealing of the protecting jacket is performed by O-rings, inserted into two connecting pieces.
Before assembling a new injection pressure line the outside protecting jacket must be turn
off. The adjusting screw will get accessible when the ballows are Pressed together in
longitudinal direction.
The matching arbors are to be screwed on the pressure connections of the injection pump and
the injection valve. By careful additional bending the pressure pipe is to be matched for as long
as it can be pushed without stress to the stop over the pivots. At this the distance has to be
observed and the angular position has to be tested by aligning as well.
Before the final assembly the protective tube has to be pushed. over again.
After romoving teh matching arbors the pressure line has to be mounted onto the packing
tapers and has to be tightened by means of the adjusting screw.
The stress-free seating of the pipelines is to be checked at each assembly of the pump
and of the valve.
 23
Schedule of Details and Spare Parts
Term Order No.
Injection pressure lineused for
224.319606-31
engine
6 VDS 48/42 Al-2Ne = 600
h.p./cyl.
1. Capsule 223.319806-74
2. Pressure, pipe, complete 222.319706-82
3. Lock plate 222.109306-24
4. Screwed-in nozzle 221.108406-34
5. Packing ring Al6x20 TGL 0-7603-Cu
6. Hexagonal-head screw M8x12 TGL 0-933.8.8
7. Spring ring A 8 TGL 7403
M20x1.5 M 24x1.5 TGL 49-
8. Protective jacket
14470
9. 0-ring 40x5 TGL 6365 WS 12.097
 24

III. Operation Manual Injection Valve 48/42

 25
Index
1. Technical data
2. Description
2.1. Nozzle support
2.2. Injection-nozzle
3. Function and operating mode
4. Storage and conservation
5. Putting into operation
5.1. Test of functionality
5.2. Mounting
6. Maintenance
7. Hints for mounting
7.1. General hints
7.2. Dismounting and mounting of the injection-nozzle 7.3. Dismounting and
mounting of the nozzle holder
 26
1. Technical Data
Type: 48/42 for engine VD 48/42
Construction: flange-mounted with pressure Spring lying below
Valve stem diameter: 65 mm
Opening pressure of the
Valve : 25 MPa - 2 MPa t

Maximum allowed pressure: 100 MPa

Injection valve: WAF 1070-140-V 45
Weight: 22.5 kg
Maximum spray-hole cross
section: 3.32.mm2
Cooling: by choice with or without
Coolant throughput: 80 cm /sec at a test pressure
of 1 kp/cm and a viscosity of
of the testing medium of 5 cSt.
Turning moment of the nozzle nut 450 - 50 Nm
2.Description
The injection malve 48/42 is a valve of size W (valve stem diameter 65 ram), suitable for cylinder
outputs up to 1000 h.p. The injection valve is fixed to the cylinder head by 3 pins. The sealing to
the cylinder is granted by a copper sealing. As usual, the injection valve consists of the nozzle-
support and the injection valve.
2.1. Nozzle-Support
An elbow and a connecting thread for the nozzle cooling and the leakage fuel connection are
arranged at the top of the holder body. Besides tliis, the passage holes for the fastening screws
are provided in the top. At the lower end. of the stem the injection nozzle is fixed with the help of
the sleeve nut. Between support and nozzle there is a hardened intermediate plate, which
limits on one side the stroke of the nozzle-needle and on the other side serves for the
connection of the fuel bore holes and the cooling bore holes between support and nozzle. Two
plain pins prevent the torsion
 27
of the intermediate plate and the nozzle. The fuel and cooling bote hole is sealed by lapped
surfaces.
The pressure spring, pre-stressed with the adjusting spindle to generate the opening pressure
of the injection valve lies between two spring plates inside of the support. The lower spring plate
is supported on the gudgeon of the nozzle-needle. The upper spring plate is situated on the
adjusting spindle, adjustable by a thread in the support body. The blocking of the adjustable
spindle after adjusting of the opening pressure is performed by a hexagonal-head nut,
arranged in the head of the support body. Sealing this room is accomplished by the screw plug
and a copper sealing. The screw plug is provided with a thread for the leakage oil drain or the
lifting device of the valve.
2.2. Injection Nozzle
The injection nozzle consists of the nozzle-body and the nozzle-needle. The nozzle-body and
the nozzle-needle form a unit and can be replaced only as a unit. The cooling-room is provided
in the nozzle-body.

3. Function and Operating Mode

The necessary fuel amount for the combustion in the cylinder is sprayed into the cylinder
through the injection valve. By choice of number, arrangement and design of the spray-
holes the engine producer fits the fineness of the spraying of the fuel and the length of the
fuel rays to the specific conditions. Between the single injections the nozzle is shut. By the
pressure, generated at the delivery of the injection pump, the nozzle-needle is opened
against the spring power, and the fuel gets into the cylinder. After ending the delivery of
the injection pump the pressure falls, and the nozzle-needle shuts again.

4. Storage and Conservation

Injection valves are to be stored in original packing in dry rooms at normal temperature, which
are free of aggressive mediums and of dust. A damage of the sensitive injection valve by
impact or shock is to be prevented.
 28
The injection nozzle should not be stored longer than 6 months in mounted conditions. When it
must be stored for a longer time the injection nozzle is to be dismounted out of the injection
valve, it must be represerved with the help of non-aging, resin-free and acidless protective oil,
e.g. silicone-oil M 50 or test oil S 100 of "Gesellschaft für Rohstoffgewinnung und Verfahrens-
technik Cottbus", and it is to be stored apart from the nozzle holder. The storage is to be
carried out in suitable packing, if possible in original packing, thus, that all damaging influences,
as oxygen, dissolvent, heat, humidity and ultraviolet rays are excluded. After a storage period
of one year a re-conservation is necessary. For this purpose all details must be set free from
protection against corrosion with the help of etherial degreasants and after drying they must be
moistened with a non-aging, resin-free and acidless protective oil (see above). When
dismounting and mounting the injection valve consider item 7. When the injection nozzles are
delivered in tropical regions they are durably protected against corrosion by melting dip-mass.
In this case a re-conservation is not necessary.

5. Putting into Operation

5.1. Before mounting the injection valve into the engine it should be tested for its functionality to
avoid break-downs of the engine.
For this purpose it is necessary to deconservate valves, having been stored for more than 6
months, with the help of etherical degreasants and to install the seal rings again (see here also
item 7.). For the testing of the. injection valve item 7.4. should be taken into consideration.
5.2. Mounting
When mounting the injection valve attention is to be paid to an undamaged sealing between
the injection valve and the cylinder head. For the connection of the fuel pressure line the hints
agent supply and drain line and the fuel leakage line the hints contained in the operation
manuals for the engine are to be considered.
 29
6. Maintenance
With the exception of controls of component parts the injection valve needs no maintenance.
Since the power-stressed components (e.g. adjusting spindle, spring plate and pressure spring)
will settle after some working time a drop of the opening pressure is inevitable. Too low
opening pressures of the nozzle can be notice-able in increasing exhaust-gas temperatures
and increasing exhaust-gas opaqeness. For this purpose, especially within the first 100
working hours,after new installation or mounting at injection valves resp« the engine
parameters are to be considered. When there are deviations from the usual working
parameters the opening pressure of the injection valve, the tightness of the 'injection nozzle and
the spraying are to be controlled.
When the engine is operated in partial-load work during a longer time a cleaning of the injection
nozzles is necessary inshort in-tervals if the engine's parameter deviate. The middle operation
time until the wear dimensional limit of the injection nozzle is reached for diesel fuel LCD? at
6000 working hours and for heavy oil at 4000 working hours. These data of working life require an-
inspection of the injection valves of 1500 worling hours.

7. Hints for Mounting

7.1. General Hints
At dismounting and mounting of the injection nozzle accurate cleanness and care must be
observed. Work bench and tools must be free of dirt. Cleaning rags containing fibres or dust are
not permitted to be used. The lapped cleaning surfaces must be pro-tected against damages
by all means, since an additional lapp-ing of damaged surfaces generally will not be successful.
Before mounting the elements, especially the lapped surfaces, are to be cleaned with diesel fuel
or other washing fluids.
Needle guides are only to be changed completely together with the needle since they are
fitted together.
A grinding of the desity seating is not to be recommended, since by this the packing surface is
widened and the functionality is questionable.
 30
The following tools are necessary for the complete dismounting: Special wrench for nozzle nut
SW 60 Open-end wrench SW 19 and SW 32
Point opening socket-wrench or socket wrench SW 24 Screw driver B 2x300 TGL
48-73*503 with non-skid device Round punch G 2.5 TGL 48-71221
7.2. Dismounting and Assembly of the Injection Nozzle
Loosen lock nut 13 and hexagon nut 11 and relax pressure spring by turning of the adjusting
spindle 9. Nozzle nut 2 is to be loosened (Forcible loosening must be avoided, since this could
lead to seizures pf the thread.). Heating up of the nozzle nut in hot oil will facilitatete the
loosening. Take off the injection nozzle 1 (At his is to consider that the nozzle needle does not
fall out of the nozzle body.). The assembly takes place in reverse order.). At this consider the
following:
Before the assembly the elements are to be cleaned (see section 7.1.). It is useful to perform a
glide test of the nozzle needle (The before this cleaned and moistened with test agent nozzle
needle which is put in the nozzle body is torn out of the nozzle body by ca. 1/3 of its sliding
surface. When it is situated in nearly vertical position it must slide on to the packing seating by
its dead weight.). The lapped high-pressure sureface must be dried. This can be done e.g. by
repeated laying up of newsprint. The nozzle nut is to be tightened with special wrench (The
thread is to be greased.)- The nozzle nut is to be tightened with a turning moment of 45-5 kpm.
7.3. Disassembly and Assembly of the Nozzle Holder
Take out the injection nozzle (see section 7.2.).
Take off stop plate 5.
Take-out the lower spring plate 6, the pressure spring 7 and
the upper spring plate 3. ' .
The adjusting spindle 9 is to be taken out after removing the
hexagon nut 11 in the direction of the holder foot. The assembly
will be performed in reverse sequence.
 31
7.4. Adjusting and Testing of the Injection Valve
For the adjusting and testing of the injection valve a pressure jig with a die diameter of
minimum 22 mm is necessary in order to control the unobjectionable function of the valve. The
pressure jig according to drawing Wo. 224.122006-70 is recommended. As a test agent pure
'diesel fuel or S 100 isto be used. When heavy oil is used a function test is only to be performed
after cleaning by means of diesel fuel.

A t t e n t i o n !
The fuel jets are not permitted to be touched since they penetrate the skin tissue and cause
painful inflammations (blood poisoning!).
During the cleansing of the injection valve and for a longer period after this no naked flame is
allowed to burn in the area of the working place since the fine sprayed fuel is easily in-
flammable.
If possible the fuel vapour should be exhausted at once and should be led into open air.
1. Adjusting
Repeatedly the pressure spring is to be pumped thoroughly in the injection valve without being
tensioned to cleanse out dirt, perhaps being present. By turning of the adjusting spindle 9 the
pressure spring is tensioned while permanently is pumped until the injection pressure of the
injection valve is obtained.
Tighten (counter) the hexagon nut 11.
Control the injection pressure and the function again.
Mount the lock nut 13 with the packing ring.
2. Testing
The injection pressure must be situated'within the stated values. The (injection valve must
unobjectionably spray at a pumping sequence of 2 strokes/sec. By this the fuel must be
sprayed. An equal formation of all the jets must be provided. The injection valve is not allowed
to redrop.
»
 32
Schedule of Details and Spare Parts
Term Order No.
Injection valve 6 VDS 48/42 48/42
Ne- = 600 h.p./cyl. Al-2 used for engine
233.048107-1316
VD 48/42 Ne= 600 h.p./cyl.Nozzle WAF
1070-140-15
-

1. Injection nozzle WAP 243.017000-24

2. Nozzle nut 241.464200-03
3. Packing ring 241.463401-74
4. Cylindrical pin 6m6x36 TGL 0-7
5. Tappet plate 241.454900-34
6. Spring plate, below 241.455000-54
7. Pressure spring \ 241.464300-14
8. Spring plate, at the top 241.455300-84
9. Adjusting spindle 241.455401-74
10. Holding body 241.456900-72
11 Hexagonal nut M 16 TGL 0-934
12 Packing ring A3Ox38 TGL 0-7603
13 Indicator nut 241.455600-24
14 Disk 241.464000-44
15 Elbow 241.464500-33
16 Pin, AM12x120 TGL 0-934
17 Hexagonal nut M12 TGL 0-934
18 Disk Ml 2 TGL 0-934
 33

IV. Operation Manual for Pressure Generator

for the Testing of the Injection Valve
 34
1. General Requirements
1.1. This pressure generator is a testing device for the injection valves for engine VD 48/42
as well as engine VD 26/20
2. Application
2.1. The pressure generator is suitable for the work with diesel fuel or with S 100 D and
serves for the testing of the spray figure at the valves.
3. Design Description
3.1. The pressure generator - drawing No. 224.122006-70
consists of: drive part, compl. 223.118006-82 Pos. 1
Upper part of the pump 223.110541-07 Pos. 2
complete
eccentric shaft, compl. 223.118806-73 Pos. 3
hand lever 222.119306-63 Pos. 4
fuel tank 222.119706-12 Pos. 5
pressure line, complete 222.121606-64 Pos. 8
test manometer 222.125706-64 Pos. 40
in the assembly (nozzle holder
tool gang (collet, complete 223.122106-11 Pos. 3
225.306006-37 (rotary plate
there are con- (collet, complete 223.123806-11 Pos. 4
tained: (T-nozzle holder
(collet 223.333406-83 Pos. 6
The pressure generator is screwed in at a holder welded to the bord wall of the ship in a room
provided for this purpose in vertical position with the help of 4 hexagonal-head screws. Quite
near there is the rotary plate collet, complete, 223.123806-11 to be completed with the nozzle
holder .collet, complete 223.122106-11 and is to be fixed at a provided for this aim collet with
the help of 4 hexagonal-head screws M 16. The test nanometer 222.125706-64 and the
pressure line 222.121606-64 with the injection valve are to be screwed on the upper part of the
pump 223.110541-07, the injection valve being clamped to the nozzle holder. . • ,
 35
4. Description of the functionality
4.1. By actuating the hand lever 222.119306-63 the injection valve is admitted with fuel under
high pressure with the help of the customary injection pump 223.110541-07 adjusting on a
constant delivery amount over the injection pressure line. By this the spraying figure and the
opening pressure of the nozzle can be controlled.

5. Technical Data
5.1. Main measures
Length . 360 ram
Width 220 mm
Height 340 mm
Weight 25.7 kp
Fuel Diesel fuel; S 100 D
Spraying pressure 25 MPa-2 MPa at engine VD 48/42
35 MPa-1 MPa at engine VD 26/20
Pump piston 21 mm
Stroke 12 mm

Attention!
The fuel jets are not permitted to be touched since they penetrate the skin tissue and cause
painful inflammations (blood poisoning!). During the spraying of the injection valves and for a
longer period after this no naked flame is allowed to burn in the area of the working place since
the fine sprayed fuel is easily inflammable.
If possible the fuel vapour should be exhausted at once and should be led into open air.
IV/1/19 3165 3000 90
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17

8. Schedule of Spare Parts

Each of the mentioned details can be bought as a purchase part.

Ser.No. Term Order No. Wear part

Injection pump DSPP 1FW 224.309506-70
1 Pumping element 222.343106-23 X

2 Pressure control valve, without balancing .222.343506-63 X

3 Filister-head screw Ml6x100 TGL 0-912-10.9

4 Pump casing, one-piece 221.307106-50
5 Pressure flange 221.300106-03
6 Expansion bolt 221.307206-64
7 Guide screw 221.301106-24
8 Baffle screw 221.301206-33 X
8.1. Packing ring A24x29 TGL O-7603-Cu
9 Elastic control rack, complete, consisting of: 222.313006-73
9.1. Control rack 221.313106-13
9.2. Linkage 221.313206-23
9.3. Spring plate 221.313306-34
9.4. Spacer 221.313406-44
9.5. Dog 221.313506-54
9.6. Sleeve 221.313706-74
9.7. Bolt 221.313806-34
9.8. Pressure spring C1,8x24x17.5 TGL 18395
9.9. Snap ring 18x1.2 TGL 31665
9.10. Snap ring 30x1.6 TGL 31666
9.11. Snap ring 12 TGL 0-471
9.12. Gauge disk 14 x 0.1 TGL 10404 - St
9.13. Gauge disk 14 x 0.2 TGL 10404 - St
9.14. Gauge disk 14 x 0.5 TGL 10404 - St
9.15. Gauge disk 14 x 0.8 TGL 10404 - St
9.16. Gauge disk 12 x 0.1 TGL 10404 - St
9.17. Gauge disk 12 x 0.2 TGL 10404 - St
9.18. Gauge disk 12 x 0.5 TGL 10404 - St
9.19. Gauge disk 12 x 1 TGL 10404 - St
10 Control sleeve 221.300206-13
11 Adjusting mark 221.101806-24
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Ser. No. Term Order No. Wear part
11.1. Gauge disk 6x0.1 TGL 10404 - St
11.2. Gauge disk 6x0.2 TGL 10404 - St
11.3. Gauge disk 6x0.5 TGL 10404 - St
11.4. Gauge disk 6x1 TGL 10404 - St
11.5. Lens screw BM5x12 TGL 0-85-5.8
12 Pull-load dog 221.300606-54
13 Tappet-body 221.311106-62 x
13.1. Cylindrical pin 10 M6x20 TGL 0-7
14 Roll, complete 222.321606-44 x
15 Roller bolt 221.311306-73 x
16 Holding screw, long 221.304806-64
17 Pressure piece, complete 222.307506-73
Filister-head screw for grooving cutter
17.1. 221.307806-34
block
17.2.. Pressure piece 221.307606-13
17.3. Grooving cutter block 221.307706-24
17.4. Distance plate 221.308306-04
18 Eccentric cam, complete 222.309006-63
18.1. Flange bearing f. eccentric cam 221.309106-03
18.2. Eccentric cam 221.309206-13
18.3. Pressure bolt 221.309306-24
18.4. Dog 221.309406-34
13.5. Helical compression spring C2x34x7.5 TGL 18395
13.6. dto. C1x11x7.5 TGL 18395
18.7. Cylindrical pin Sm6 x 18 TGL 0-7
18.8. Ball 8 m II TGL 15515
18.9. Snap ring 25 TGL 0-471
18.10. 0-ring 28 x 3 TGL 6365-WS 2.055
18.11. 0-ring. 45 x 5 TGL 6365-WS 2.055
19 Hexagonal-head screw M8 x 25 TGL 0-933-8.8
20 Helical compression spring 221.112506-54
21 Pump spring 221.000706-04
22 Inset 221.304506-34
23 Screwed-in nozzle 8 x 32 M TGL 0-3901 St
23.1. Packing ring A 14 x 18 TGL 0-7603-A1.
0t0matik arama için kitap dışı
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Ser. No. Term Order No. Wear part
24 0-ring 80 x 5 TGL 6365 - WS 12.097
25 0-ring 80 x 5 TGL 6365 - WS 12.097
26 0-ring 80 x 5 TGL 6365 - WS 12.097
27 Screwed-in nozzle 8-32 M TGL 0-3901 St
28 Valve support 221.310106-43
29 Stroke limiter 221.318706-84
30 Snap ring 20 TGL 0-472
31 Holding screw, short 221.311306-84
32.1. Distance disk 221.301406-54
32.2. Distance disk 221.301506-64
32.3. Distance disk 221.301606-74
32.4. Distance disk 221.301706-84
32.5. Distance disk 221.301806-04
32.6. Distance disk 221.301906-14
33 Upper spring plate 221.300306-24
34 Locating screw 221.301006-14
35 Hexagonal nut M 20x1.5 TGL 0-934-8
36 Sliding block 221.300506-44 x
37 Packing 221.305206-24
38 Screwed-in nozzle 12-32 M TGL 0-3901 St
38.1. Packing ring Al6x2O TGL 0-7603-A1
39 Packing 221.304706-54
40 Filister-head screw M 8 x 30 TGL 0-912-10.9
41 Tappet screw 221.301306-44
41.1. Packing ring A6 x 10 TGL 0-7603-A1
42 Control rack flange 221.300706-64
43 Driving flange 221.300906-34
44 Filister-head screw for full-load dog 221.304906-74
45 Spacing pipe 221.311706-34
46 Bridge 221.310406-74
47 Hexagonal-head screw M8 x 50 TGL 0-933-8.8
48 Packing ring A 26 x 34 TGL 0-7603 Cu
49 Identification plate 499.010-0:34(3)
50 Half-round notch pin 2x6 TGL 0-1476
51 Metal seal TGL 9-16437

0t0matik arama için kitap dışı

0t0matik arama için kitap dışı
 32
Schedule of Details and Spare Parts
Term Order No.
Injection valve 6 VDS 48/42 48/42
Ne- = 600 h.p./cyl. Al-2 used for engine
233.048107-1316
VD 48/42 Ne= 600 h.p./cyl.Nozzle WAF
1070-140-15
-

1. Injection nozzle WAP 243.017000-24

2. Nozzle nut 241.464200-03
3. Packing ring 241.463401-74
4. Cylindrical pin 6m6x36 TGL 0-7
5. Tappet plate 241.454900-34
6. Spring plate, below 241.455000-54
7. Pressure spring \ 241.464300-14
8. Spring plate, at the top 241.455300-84
9. Adjusting spindle 241.455401-74
10. Holding body 241.456900-72
11 Hexagonal nut M 16 TGL 0-934
12 Packing ring A3Ox38 TGL 0-7603
13 Indicator nut 241.455600-24
14 Disk 241.464000-44
15 Elbow 241.464500-33
16 Pin, AM12x120 TGL 0-934
17 Hexagonal nut M12 TGL 0-934
18 Disk Ml 2 TGL 0-934