Parsun F15bm F9 9bm F15w F9 9w Outboard Engine Motor Workshop Service Repair Manual Download

NES

CAV

UK 2 81 -

New Equipment Service A rd

EXPOR1 2-8i

DPA PUMPS

DATE APRIL 1981

COMMERCIALLY CONFIDENTIAL TO LUCAS GROUP COMPANIES

AND AUTHORISED DISTRIBUTORS

DPA FUEL PUMPS VARIOUS APPLICATIONS DESPATCH NO

CUSTOMER

ENGINE

APPLICATION

3241F730

PERKINS

4.236

INDUSTRIAL

3342F920

DAVID BROWN

4.55

l)(59

3342F930

BL CARS

1.5 LITRE

INDUSTRIAL

3362F850

FIAT

8065-24-300

1280 TRACTOR

CASE IND.

An individual parts list and EVD are enclosed for the FIAT application 3362F850; full details in respect of the other pumps already appear on fiche except for the specific alterations given below.

Test plans however, are included for all four pumps.

PRODUCT INFORMATION

3241F730

-

Similar to 3241F340 but fitted with an SAE olive-type inlet connection 7133 37 in place of 7123-554 and set at a different rating. To date 358 pumps have been produced.

-

3342F920

-

3342F930

-

Similar to 3342F540 but fitted with a remote control manual lock device 7139-2C in place of the normal manual lock 7123-768. To date 1883 pumps have been produced.

Similar to 3243F970 but fitted with governor weights 7123-914E Relevant engine speeds and hook-ups are in place of 7123-659. as follows: 1500 rpm Hook-Up 8 1800 rpm Hook-Up 6 2000 rpm Hook-Up 5 2250 rpm Hook-Up 2

To date 361 pumps have been produced.

CAV Parts and Service Lucas CAV Limited PO Box 36 Warple Way London W3 75S Telephone 01-7433111

Telex 934986

©Copyright 1980

2

3362F850 -

Supplied to FIAT for their turbocharged 1280 Tractor this pump is fitted with the electric shut-off solenoid 7167-620A and a two-stage auto advance device. An initial batch of 400 pumps has been supplied.

IMPORTANT NOTE Information given with this note is correct at the time of issue and you may, therefore, safely order your requirements based on the enclosed publications If, however, additional relevant data is received in the shape of Service Instruction Notes or Fiche etc., please check them to see if any changes have been made before you order.

ofirG

,

G M DAWSON SERVICE CONTROLLER SERVICE TECHNICAL DEPARTMENT

MSW/GMD/MJG April 1981

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DPA 3247F371 AUSTIN/MORRIS

DATE DECEMBER 19

COMMERCIALLY CONFIDENTIAL TO LUCAS GROUP COMPANIES AND AUTHORISED DISTRIBUTORS

DPA FUEL INJECTION PUMP 3247F371

AUSTIN/MORRIS TAXI APPLICATION

The above DPA fuel injection pump is being manufactured for use with Austin/ Morris 1.5 litre engines for Taxi application.

Initially these vehicles will be seen in two main areas, Portugal and Singapore It is anticipated that by the end of this year around one thousand units will have been built with the despatch number 3247F370 and this could be the pump with which you may be faced for repair.

It should be noted however that the copy of the parts list enclosed relates to the DPA 3247F371.

The two pumps are identical and are used for similar applications, the exceptions being a change of the end plate studs plus the despatch number raised by one digit.

STUD (4 off) replaces 5335-738 (4 off)

5335-738D

This modification has been introduced to overcome the possibility of the clamp plate fouling the end plate boss on Austin/Morris 1.5 litre engines.

In addition we enclose a copy of the test plan for workshop use.

IMPORTANT NOTE Information given in this note is correct when issued and you may safely order from the enclosed publications. If, however, subsequent additional relevant information is received, i.e Service Instruction Notes, Fiche etc, reference should be made to the latest information to hand, before ordering parts or testing units.

R C GEORGE NES CONTROLLER SERVICE TECHNICAL DEPARTMENT MSW/RCG/ LJ DECEMBER 1980 CAV Parts and Service Lucas CAV Limited PO Box 36 Warple Way London W3 7SS Telephone 01•743 3111

Telex 934986

©Copyright 1980

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CAV Rationalisation and Type Conversion Data

Fuel Injection Equipment No2- DPA Pump for Ford 3 cylinder engines

CAV Parts and Service

CAV PARTS AND SERVICE RATIONALISATION OF CAV DPA FUEL INJECTION PUMPS

No. 2 - DPA PUMPS - MECHANICALLY GOVERNED MADE FOR FORD 3 CYLINDER ENGINES

SECTION No.

PAGE No.

1

Introduction

1

2

How to use this publication

1

3

List of DPA pump types

2

4

General information

3

5

Stock holding recommendation

4

6

Conversion details

5

SECTION 2

SECTION 1 INTRODUCTION

HOW TO USE THIS PUBLICATION RECOMMENDED PROCEDURE First check that the required type of DPA pump is included in Section 3 of this publication, 'List of DPA pump types'. If the required type is listed it will be shown as a retained, non-retained or superseded type.

This publication is the second of a new series of DPA pump rationalisation booklets. It refers only to DPA pumps made for the range of Ford 3 cylinder engines.

After we have completed a contract for the supply of fuel injection pumps, as original equipment, to an engine manufacturer we continue to produce these pumps to meet the service requirements of our agents and customers.

If a retained type it can be ordered in the usual way or another type of pump can be converted to the type required. Usually conversion to a retained type is carried out only when a suitable pump in the agent's stock has not moved for some time.

Information regarding a suitable type and the parts required will be found in Section 6, 'Conversion Details'.

In time the quantities ordered fall to a very low level, when it becomes uneconomical for our factory to maintain production of these pumps although service parts will still be available to order.

If the pump required is a non-retained type a pump of another type must be converted to the required type. In some instances the difference is merely the fuel setting. Section 6, 'Conversion Details', shows the actions necessary to convert a pump of a retained type to the required type.

We have decided, therefore, to discontinue the manufacture of these 'low call' pump types and this also means that our factory will be able to increase the output of current and new types of pump. Up-to-date information on obsolescent pumps will be circulated in the usual way.

The latest issue of the Service Parts List fiche must be consulted when starting a conversion, because the fiche will be more up-to-date regarding supersessions of part numbers, etc.

Also the notes section contains essential information on matters affecting conversions e.g. the position of high pressure outlet connectors when fitted to the hydraulic head. It also supplements the information in the parts list.

This publication has been issued to enable agents to continue to provide service to customers who require pumps that have been deleted from our manufacturing schedules. These pumps are known as non-retained types.

NON-RETAINED TYPES OF PUMP LISTED IN THIS BOOKLET CAN BE OBTAINED FROM THE CONVERSION OF OTHER TYPES OF PUMP, IN PRODUCTION AT THE TIME OF WRITING.

ALL PUMPS SUPPLIED TO A CUSTOMER MUST BE SET TO THE CORRECT FUEL SETTING FOR THE ENGINE AND APPLICATION TO WHICH IT IS TO BE FITTED.

ONE OF ONLY FIVE TYPES OF PUMP, RETAINED TYPES, CAN BE CONVERTED TO ONE OF THE 22 TYPES LISTED ON A LATER PAGE. ALL OF THESE RETAINED TYPES OF PUMP ARE CURRENTLY BEING PRODUCED IN QUANTITY, WHICH MEANS THAT THERE SHOULD BE A STEADY DEMAND FOR THEM,

SECTION 4, 'GENERAL INFORMATION' SHOULD BE READ THROUGH EACH TIME THAT THIS BOOKLET IS REFERRED TO, AS IT REMINDS THE READER OF FACTORS WHICH MAY BE IMPORTANT FOR THE CONVERSION THEY PROPOSE.

ALL CONVERSIONS ARE ECONOMICAL IN BOTH PARTS AND LABOUR REQUIREMENTS, AS FEW MAJOR COMPONENTS ARE NEEDED. SOME CONVERSIONS REQUIRE ONLY A CHANGE OF FUEL SETTINGS.

Agents and distributors should stock a selection of retained type DPA pumps and the parts needed for conversion. Section 5, 'Stock holding recommendations' lists the pumps and components which are expected to be the fastest moving types used on this range of engines.

1

SECTION 3

LIST OF DPA PUMP TYPES

TYPE 3232848 3232858 3232868 3232958 3232968 3232978 3233020 3233030 3233F151 3233F161 3233F171 3233F211 3233F290 3233F300 3233F320 3233F380 3233F390 3233F440 3233F631 3233F641 3233F651 3233F661

CATEGORY Superseded Superseded Superseded Superseded Superseded Superseded Superseded Superseded Retained Non-retained Non-retained Non-retained Retained Superseded Superseded Non-retained Retained Non-retained Retained Retained Retained Retained

SUPERSEDED BY

FORD ENGINE

3233F151 3233F161 3233F171 3233F151 3233F161 3233F171 3233F151 3233F171 â&#x20AC;&#x201D;

158 cu in 175 cu in 201 cu in 158 cu in 175 cu in 201 cu in 158 cu in 201 cu in 158 cu in 175 cu in 201 cu in 201 cu in 201 cu in 201 cu in 175 cu in 175 cu in 201 cu in 183 cu in 175 cu in 183 cu in 201 cu in 158 cu in

3233F390 3233F380

SECTION 4

GENERAL INFORMATION

ALL THE PUMP TYPES LISTED HERE ARE FITTED WITH THE SAME HOUSING AND HYDRAULIC HEAD AND ROTOR ASSEMBLY. MANY OTHER PARTS ARE ALSO A STANDARD FITTING THROUGHOUT THE RANGE, WHICH MEANS THAT ANY PUMP TYPE LISTED CAN BE CONVERTED TO ANY OTHER PUMP TYPE LISTED, AT A LOW TO MODERATE COST. THE CONVERSIONS PRINTED IN SECTION 6 COST THE MINIMUM FOR PARTS AND LABOUR AND USE PUMPS MOST LIKELY TO BE IN DEMAND.

HIGH PRESSURE OUTLET CONNECTORS To ensure correct assembly each outlet port in the pump hydraulic head is identified by a letter rolled on it during manufacture.

The part numbers of the high pressure outlet connectors, shown in the Conversion Details section, are followed by a letter enclosed in brackets, viz (W). This denotes the position where this connector is fitted to the hydraulic head.

DESIGN CHANGES

HEAD LOCATING FITTING ASSEMBLY The assembled head locating fitting also incorporates a retard device. Some of these retard devices are manually operated and others function automatically, depending on the pump design.

The pumps referred to in these pages are 'F' design change types, except for the earlier and superseded types. When earlier design change pumps are converted, as explained in Section 6, they should be updated to F design change type as well.

TEST PLANS

Information regarding design change modification is issued to our Agents when the latest design change is introduced.

Service test plans are now issued on fiche and our Agents should have a test plan for each of the pump types referred to in these pages.

SERVICE PARTS KITS

SOME PUMPS IN THIS FORD RANGE ARE IDENTICAL BUT ARE SET TO A DIFFERENT FUELLING SPECIFICATION AND ARE GIVEN A DIFFERENT DESPATCH NUMBER.

Stocks of gasket kits 7135-70 and other parts and sub assemblies appropriate to this range of pumps should be maintained specifically for rationalisation purposes. Some parts which are included in these kits and sub assemblies are available separately. Stock holding recommendations can be found in Section 5.

WHEN CHANGING A PUMP FUELLING TO A DIFFERENT TEST PLAN IT IS ESSENTIAL TO OBSERVE ALL THE REQUIREMENTS OF THAT TEST PLAN, SUCH AS ROLLER TO ROLLER DIMENSIONS AND GOVERNOR SPRING HOOK UP POSITIONS. THIS IS BECAUSE THESE SPECIFICATIONS VARY WITH PUMPS THAT OTHERWISE ARE IDENTICAL.

Conversion information should always be checked against the latest issue of the Service Parts fiche as any change of part number, etc., is shown on the next issue.

3

SECTION 5

STOCK HOLDING RECOMMENDATIONS

The following components should also be stocked:-

The 22 DPA pump types listed in these pages have been divided into three groups, as follows:-

Cam Ring 7139-552C, 7139-940Q and 7167-400D

Superseded - 10 pump types Non-retained in production - 5 pump types Retained in production - 7 pump types

AA Housing and Piston 7123-819BJ, 7123-819H and 7123-819AW

Retained pump types are the units which can be converted to non-retained types and other retained types.

Piston Hole Plug 7123-473 and 7123-473B

OF THE 7 RETAINED TYPES ONLY 3 OF THESE ARE REQUIRED FOR CONVERSION TO A NON-RETAINED TYPE. THESE ARE 3233F151, 3233F290 AND 3233F390.

Head Loc. fitting and Retard Device 7123-261N and 7167-359

As only 4 of the retained types will be sufficient to cater for most of the orders received by our Agents and Distributors we recommend that the following pumps be stocked.

3233F151

3233F290

3233F390 3233F651

4

Connector 7139-322

Nameplate 7123-976K

Cover Plate 7139-478A

Rivet NR21-4

SECTION 6

CONVERSION DETAILS - DPA FUEL PUMPS

CONVERT FROM No. TO

ACTION

1 3233F151 3233F390 Change listed parts, reset the fuelling etc and change pump label

REMOVE

7135-74C 7139-841C 7123-294B 7123-293C 7123-819AW 7123-473B 7123-499 5936-332

FIT

7135-74D 7139-552C 7123-294 7123-293B 7123-819BJ 7123-473

1 1 1 1 1 1 1 1 1

Sleeve & Piston Cam Ring Spring, outer Spring, inner AA Hsg & Piston Plug, piston hole Banjo Washer Connector (W)

1 1 2 2

Coverplate & Valve Gasket Screw Locking Washer

1 1 1 1

Banjo Pressurising Valve Washer Connector (W)

7123-819H 7123-261N 7123-473 NC 7-8 7139-748A

1 1 1 1 1 1 2

AA Hsg & Piston Head Locating Fitting Plug, piston hole Steel Ball Cover Plate Spring, inner Sealing Ring

7123-819AW 7167-359 7123-473B

1 1 1 1 1 1 2

AA Hsg & Piston Head locating fitting Plug, piston hole Steel Ball Cover Plate Spring, inner Sealing Ring

7139-322 7167-312A 9045-137 5334-274A NP1-5

2

3233F161 3233F151 Change listed parts, reset the fuelling etc and change pump label

3

3233F171 3233F151 Reset the fuelling etc and change pump label

4

3233F211 3233F290 Remove banjo and pressurising valve and fit connector, reset the fuelling etc and change pump label

7123-499 7139-752 5936-332

3233F290 3233F390 Change listed parts, reset the fuelling etc and change pump label

7123-819AW 7167-359 7123-473B

5

6

3233F380 3233F390 Reset the fuelling etc and change pump label

7

3233F390 3233F290 Change listed parts, reset the fuelling etc and change pump label

8

3233F440 3233F390 Reset the fuelling etc and change pump label

9

3233F631 3233F651 Reset the fuelling etc and change pump label

7139-350 7123-515A 5334-274

7139-322

7167-312A 7123-293C 7139-821

7123-819H 7123-261N 7123-473 NC7-8 7139-748A

5

QTY DESCRIPTION

7167-312A 7123-293C 7139-821

SECTION 6

CONVERSION DETAILS - DPA FUEL PUMPS

No.

CONVERT FROM TO

ACTION

10

3233F641 3233F651 Reset the fuelling etc and change pump label

11

3233F651 3233F631 Reset the fuelling etc and change pump label

12

3233F661 3233F651 Change listed parts, reset the fuelling etc and change pump label

REMOVE

7139-9400 7123-473E

6

FIT

QTY DESCRIPTION

7167-400D 7123-473L

1 1

Cam Ring Plug, piston hole

CAV

DP15 To DPA Conversion Kit 7135 - 89

APPLICATION:

VAUXHALL YMT COACH

This conversion should be undertaken either when the DP1 5 fuel injection pump is beyond economical repair or a replacement pump is not available.

The purpose of this leaflet is to assist the agent/dealer or operator to convert the more popular type of vehicle. There may, however, be some minor variation in fittings on body types not covered by this leaflet. Any difficulties encountered in this respect can be readily overcome by a competent mechanic.

The principal changes required for the conversion are given under the following headings: -

The Purrtp (S ee F ig. 1) Disconnect all attachments to DP15 fuel pump, i.e. high pressure pipes, throttle and stop controls, fuel feed and backleak pipes.

Remove DP1 5 fuel pump. F it DPA3362F120 fuel pump which is a direct replacement and bolts onto pump carrier in place of DP15. When fitting pump, ensure that master spline on pump drive aligns with timing pin in engine drive coupling. To ensure correct pump timing, scribed line on pump mounting flange must align with line on pump carrier. Fit new ball stud !6) supplied with throttle rod assembly (8) to throttle arm on pump.

High Pressure Pipes Release H.P. pipes from their clamps and clips. Remove and discard all H.P. pipes but retain clamps, clips and rubber grommets. F it new H.P. pipes together with rubber grommets ensuring that grommets are centrally located in their clamps. Pipes must be finger tight onto fuel pump and injectors prior to finally tightening clamps. Tighten H.P. pipes at fuel pump end only.

Fuel Fecd and Bcck leak Pipes Remove fuel feed and backleak pipes from fuel filter, remove 3 union nuts and discard pipes. Fit union nuts and sleeves (olives) to new pipes and fit pipes to filter and fuel pump.

., ,tletNo. FL95 =JBLISHED BY SERVICE PUBLICATIONS DEPARTMENT C. V ?ARTS and SERVICE, WARPLE WAY, LONDON W3 7SS " 19RO LucasCAV LIMITED ALL RIGHTS RESESVED

F195

Key to Numbers:1.

2.

3.

4.

5.

Return spring bracket Emergency stop cable Hole pump carrier Securing clip Anchor post -

6 7.

8.

9.

10.

Ball stud Cable nipples Throttle rod assembly Throttle rod Relay bracket

Fig. 1. View of pump and throttle controls

Throttle Controls (See Fig. 1) Remove and discard throttle return spring and spring bracket. Remove throttle rod(8)from relay bracket (10) and discard complete throttle rod. Disconnect throttle rod (9)from relay bracket (10) and remove and discard relay bracket. Fit new relay bracket and fit new throttle rod assembly (8) and throttle rod(9) to relay 10)as illustrated in Fig. 1 . F it throttle rod (8)to fuel pump throttle arm. Adjust rod length so that, when throttle pedal is fully depressed, over-ride spring on throttle rod is compressed by approximately 1Omm(0,4in). To achieve adjustment, reposition adjusting block on throttle rod. Fit new throttle return spring, anchoring spring in hole (3) provided in pump carrier.

Stop Controls (See Fig. 1) Remove and discard stop return spring and spring bracket. F it new stop return spring bracket (1) which must be fitted beneath two bolts securing pump carrier to compressor. Fit new stop return spring. Using existing cable nipples (7) and anchor post(5)fit stop cables to pump stop lever. The normal method of anchorage is illustrated and a suitable securing clip (4)for emergency stop cable(2) is included to achieve this. In some cases, however, it may be necessary to reposition emergency stop cable to achieve correct lever operation.

NOTE: Ensure that all nuts, bolts, clamps, controls and pipes are secure, except for H P. pipe nuts at injectors.

2

FL96

Venting and Starting Slacken vent screw on fuel pump body and operate fuel feed pump priming lever until air-free fuel flows. Continue operating priming lever while tightening vent screws.

Crank engine until fuel oil flows from high pressure pipes at injector end, then tighten connections.

Start engine and allow to warm. Loosen locknut of idling adjustment screw and set idling speed.

Tighten locknut.

Loosen locknut on maximum speed stop screw and set maximum speed. Tighten locknut, fit sleeve over stop screw, lock with wire and seal.

Finally check that stop and emergency stop controls are independently effective.

Parts included in Conversion Kit

Quantity

CAV Part No.

Description

3362F120

Fuel Pump

1

11060811

Nut for ball stud

1

9968238

No. 1 Injector pipe

1

9968239

No. 2 Injector pipe

1

9968240

No. 3 Injector pipe

1

9968241

No. 4 Injector pipe

1

9968242

No. 5 Injector pipe

1

9968243

No. 6 Injector pipe

1

91022802

Hose

-

back leak

1

91022798

Hose

-

fuel feed

1

91048210

Relay bracket assy.

1

11011046

Washer

1

137150

Split pin 7/8"

91052526

Vauxhall Part No.

x

1

1/6"

Throttle control rod assy.

1

91005913

Bracket

1

6368175

Spring

-

stop return

1

7209323

Spring

-

throttle return

1

9961 137

Clip

7094460

Sleeve (5/16" olive)

-

-

stop return spring

emergency stop cable

1 3

3

FL96 Exhaust Brakes (See figs. 2 and 3) On vehicles equipped with exhaust brakes, the following components are required in addition to the Conversion Kit 7135-89 :-

Vauxhall Part No.

Description

191081

Elbow - air pipe to cylinder

1

91041919

Bracket - air cylinder support

1

123316

Bolt - air cylinder securing

1

91041917

Rod - stop control

1

Quantity

These additional parts are obtainable from Vauxhall/Bedford authorised distributors.

This further modification is necessary to change the direction of operation of the stop control rod by reversing the direction of rotation of the cross shaft.

Key to Numbers:-

1.

Stop control rod

2.

Union - air pipe to cylinder

3.

Bracket - air cylinder support

4.

Securing bolt - air cylinder

Fig. 2.

Exploded view of linkage to DPi 5 pump with parts to be discarded shown annotated.

4

FL95

-

1 KJ

1

2

_

Key to Numbers:-

1

3. Bracket - air cylinder support

Stop control rod

4. Securing bolt - air cylinder

2. Elbow - air pipe to cylinder

Fig. 3. Exploded view of linkage on DPA pump with replacement parts shown annotated.

Procedure

Ensure that all air in the system has been drained.

Disconnect air cylinder return spring from anchor bracket. Slacken control rod operating lever on cross shaft. Remove and discard rod(1 )Fig. 2 and fit new control rod (1 )Fig. 3.

Remove union (2) Fig. 2 from end of stop control air cylinder and replace with elbow(2)Fig. 3.

Remove air cylinder from support bracket(3)Fig. 2 and remove and discard bracket. Fit new bracket(3) Fig. 3 and refit air cylinder replacing long air cylinder securing bolt (4)Fig. 2 with shorter one (4)Fig. 3 (Part No. 123316). To achieve ref itment of air cylinder it will be necessary to rotate cross shaft through approximately 900 in a clockwise direction, looking at shaft from servo cylinder side.

With cylinder rod fully into cylinder and pump stop lever in the run position, secure control rod operating lever onto shaft.

Refit air cylinder return spring, anchoring it to hole provided in bracket.

5