Injection System

16. Injection System V3

This chapter deals with the high pressure side of the fuel

The injection pumps are one-cylinder pumps with built-in roller tap‐
pets. The element, of mono element type, is pressure lubricated and
the drain fuel is led to a pipe system with atmospheric pressure out‐
side the pump, or back to the low pressure cycle of the injection pump.
Each injection pump is equipped with an emergency stop cylinder
coupled to an electro-pneumatic overspeed protecting system.
The injection line consists of an injection pipe and a connection piece,

16.1. Injection pump

16.1.1. Removal of injection pump V3

It is recommended that the engine runs 5 min. with light fuel before it
is stopped for overhaul of the injection pump.
1 Shut off fuel supply to the engine and stop the prelubricating pump.
2 Unscrew and remove the fuel feed pipes and the pneumatic air pipe.
Loosen the oil pipes to the pump.
3 Remove the pneumatic shut-down cylinder.
4 Remove the injection line. Immediately cover all openings with tape
or plugs to prevent dirt from entering the system.
5 Turn the crankshaft so that the injection pump tappet is in the bottom
position, the roller resting on the base circle of the cam.
6 Loosen the flange nuts and lift off the pump.
7 Cover the bore in the engine block.

16.1.2. Mounting of injection pump V3

1 Clean the contact surfaces of the pump. Also clean the plane and the
bore of the engine block.

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2 Check the O-ring of the insert part and lubricate with grease or engine
oil. Check that the fuel cam is not in the lifting position.
3 Fit the pump. Slide the fuel rack connection into place during this op‐
eration.
4 Check with a feeler gauge that the pump housing is aligned with the
camshaft, i.e. measures B1 = B2 according to Fig 16-1.
5 Tighten the flange nuts to torque, remove protecting tapes and/or
plugs and connect the oil pipes.
6 Rotate the control shaft and check that all pumps follow the shaft
movement. Check the fuel rack positions of all pumps, see section
22.1.
7 Remove the protecting tapes or plugs and connect the fuel feed pipes
and the injection line. Tighten the nuts to torque.
8 Open fuel supply to the engine and vent the fuel system according
to the instructions in chapter 17. The injection pump is provided with
a venting plug (42).
9 with a new steel sealing ring and tighten to the torque stated in section
07.1.

Note!
Never use copper seal rings on the injection pumps. A deformed seal
ring may cause hazardous fuel spray and/or fire.

16.1.3. Control of fuel delivery commencement V3

The beginning of the effective pump stroke is determined by an indi‐

rect method, i. e. by watching when the passage between the low
pressure side and the high pressure side of the injection pump is shut
by the edge of the element plunger, A in Fig 16-1, the so-called "flow‐
ing position".
One method is described below but it is recommended to use the
pneumatic test equipment (848 044) for more accurate control and
when calibrating an injection pump.
Control of fuel delivery commencement is necessary only if major
components have been changed, e. g. injection pump, injection pump
element or camshaft piece.
1 Shut off fuel supply to the engine.
2 Remove the injection pipe.
3 Open the screws (39) crosswise in steps of 30°, remove the head
piece (35) and the fuel delivery valve cone and spring (33).

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4 Replace the head piece (35) and tighten the screws (39) to torque.
5 Connect the funnel 3V86C29 to the injection pump to obtain fuel
supply.
6 Set the injection pump rack at its maximum end position.
7 Turn the crankshaft to a position 22° before TDC at ignition.
8 Fill the funnel with distillate fuel. Fuel is now flowing out from the head
piece (35).

Injection pump

33 35

3V86C29

A
0 5

43
14

16

17
42
21 44
32
18 39
28

B1 B2

11

11. Fuel rack 14. Control sleeve 16. Spring disc 17. Spring 18. Spring disc 21.
Fixing screw 28. Calibrating disc 32. Screw 33. Spring 35. Head piece 39. Screw
42. Vent screw 43. Seal ring 44. Erosion plug

Fig 16-1 V1

9 Keep the level in the funnel constant by refilling and turn the crank‐
shaft slowly in the engine rotating direction. Watch when fuel stops
emerging. Read the position of the crankshaft.
10 Repeat steps 7, 8 and 9 for all the cylinders to be checked.
11 Compare the crankshaft positions with the correct values, see test
records. The deviation between the different cylinders in one engine
should not exceed 0.5° crank angle. If larger deviations are noted, the

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injection pumps must be changed and/or overhauled and checked. It

is recommended to check/re-calibrate whenever the pump element
or tappet is changed on an injection pump. The tolerance for the cal‐
ibrating disc (28) when calibrating a pump is +0.00 ... +0.05 mm which
corresponds to 1/5° crank angle.
Note! For accurate calibrating, the pneumatic test equipment
(848 044) for injection pump should be used.
12 Reassemble the fuel delivery valve, pressure relief valve and the
head piece. Tighten the screws (39) to torque given in section 07.1.

16.1.4. Injection pump overhaul V3

It is presupposed that the injection pump is removed from the engine

and the outside of the pump carefully cleaned.

Note!
The element cylinder, plunger and delivery valve are matched and
they must be kept together during the overhaul.

1 It is recommendable to put the pump in a screw vice, in positions

convenient for the different operations.
2 Support the roller tappet and open the fixing screw (21).
3 The roller tappet and the element plunger can now be taken out. Take
care when handling the plunger because it may come loose from the
tappet.
4 Remove the spring and the control sleeve.
5 Turn the pump into vertical position.
6 Open the screws (39) crosswise in steps of 30°, remove the head
piece and remove the fuel discharge valve with spring and pressure
relief valve with spring.
7 Open the screws (32) of the element in steps of 30°.
8 Take out the element cylinder by using a soft tool. Always use clean
latex gloves when handling injection equipment.
9 Wash the element plunger and the cylinder in clean fuel or special
oil and always keep them together, the plunger being inserted in the
cylinder. Pay special attention to the grooves and bores for leak fuel
and lubrication oil.
10 Normally, further dismantling is not necessary. It is recommendable
to keep the components of different pumps apart from each other, or
to mark the details so they can be fitted into the same pump. The

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details must be protected against rust and especially the running sur‐
face of the element plunger should not be unnecessarily handled with
bare fingers.
11 Wash the parts in absolutely clean diesel oil and lubricate with engine
oil.
12 Renew the seal rings and supporting rings in the pump house and
on the element cylinder and lubricate the rings with vaseline or lubri‐
cating oil.
13 Re-install the element cylinder into the position where the fixing
groove corresponds to the guiding pin.
14 Tighten the screws (32) crosswise in steps according to section
07.10.1 to ensure equal tightening of every screw.
15 Reinstall the main delivery valve with spring and the pressure relief
valve with its spring.
16 Mount the head piece (35) and tighten the screws (39) crosswise in
steps, according to section 07.10.1, to ensure equal tightening of ev‐
ery screw.

Caution!
Incorrect mounting may cause the engine to overspeed!

17 Turn the pump and fit the control sleeve (14). Move the fuel rack (11)
to a position where two marks can be seen. One of the control sleeve
teeth is chamfered, and this tooth must slide into the tooth space be‐
tween the marks of the rack.
18 Re-install the spring disc (16) and spring (17).
19 Remove the seal ring (43) and mount a new one using the tool
846195.
20 Assemble the element plunger and tappet with the spring disc (18)
and calibrating disc (28).
21 Note the mark on one of the plunger vanes. The marked plunger vane
must slide into the fuel rack side of the control sleeve, i.e. correspond
to the marks on the fuel rack and the chamfered tooth of the control
sleeve. The guiding groove of the tappet must correspond to the fixing
screw, i.e. be turned to the slide opposite the marked plunger vane.
22 Re-install the plunger tappet assembly.
23 Screw in and tighten the fixing screw (21).
24 Check that the fuel rack (11) can be easily moved.
25 Unless the pump is immediately mounted on the engine, it must be
well oiled and protected by a plastic cover or similar. The fuel ports
and injection line connection must always be protected by plugs or
tape.

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16.1.5. Changing of erosion plugs V1

1 Remove the locking wire or plate and the erosion plugs (44), see Fig
16-1.
2 Mount new erosion plugs and tighten to correct torque, see section
07.1.
3 Lock the erosion plugs with the locking plates or with wires to the
fastening screws.

Note!
To prevent the risk of a high pressure fuel leakage, the erosion plugs
must be locked.

16.2. Injection line V3

16.3. Injection valve V3

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