Cva DPC Fuel pump workshop manual


Cav DPC fuel pumps Service and Repair
Service Book 1257 (English)
Covering

Reassembling the hydraulic head 1 to 3
4.1.1 Hydraulic head 1 to 3
4.1.2 Transfer pump 3 to 4
4.1.3 Transfer pressure regulating valve
4.1.4 High pressure outlets
4.1.5 Adjusting the roller-to-roller dimension
4 to 5
4.2 Reassembling the drive shaft assembly
and the pump housing 6 to 9
4.2.1 Assembling the shaft and
governor weight cage assembly 6
4.2.2 Fitting the drive shaft assembly
into the pump housing 6 to 7
4.2.3 Assembling the floating hub-type drive 8
4.2.4 Fitting the drive shaft assembly
into the pump housing 8 to 9
4.3 Fitting the cam ring 9
4.4 Fitting the hydraulic head 9 to 10
4.5 Assembling the advance system 10 to 13
4.5.1 Speed advance 10
4.5.2 Speed advance and manual advance override 11
4.5.3 Speed advance and [LA
or hydraulic advance override 12
4.5.4 Speed advance and LLA
with automatic advance override 12
4.5.5 Speed advance and [LA
with solenoid-operated advance override 13
4.6 Fitting the valve bodies 13 to 15
4.6.1 Advance "lock-off" head locating fitting 13
4.6.2 Excess fuel differential valve 14
4.6.3 Combined valve 14
4.6.4 Low-load advance valve 14
4.6.5 Solenoid-operated low-load advance 15
4.6.6 Boost controller (serviceable type) 15
4.6.7 Boost controller (non-serviceable type) 15
4.7 Securing the hydraulic head 16 to 17
4.7.1 Pumps for naturally-aspirated engines 16
4.7.2 Pumps with LLA
for use on naturally-aspirated engines 16
4.7.3 Pumps for turbocharged engines 16 to 17

Assembling the governor linkage
and control cover assembly 17 to 21
4.8.1 Bracket, arm and linkage assembly
4.8.2 Adjusting the linkage
4.8.3 Two-speed governor
4.8.4 Fitting the cover and the levers
4.8.5 All-speed governor
4.8.6 Fitting the cable support
bracket/rear support bracket
4.8.7 Fast idle system
Fitting external accessories
4.9.1 Switch (solenoid advance override)
4.9.2 Post-heating microswitch
4.9.3 Potentiometer (EGR system)
4.9.4 Thottle lever damper

Description of Lucas Hartridge test benches 1
6.1.2 Pump output measurement 1
6.1.3 Number of injection shots 1
6.1.4 Calibration fluid 1
6.1.5 Drive system 2
6.1.6 Injector Holder 2
6.1.7 Injector nozzles 2
6.1.8 Injector pipes 2
6.1.9 Measuring the pressures 3
6.1.10 Measuring the advance 3
6.2 Test conditions 4
6.3 Testing and adjusting 4
6.3.1 General 4
6.4 Test Plan 4
6.5 Test procedure 4 to 11
6.6 Timing 12
6.6.1 Internal timing 13 to 14

1.1 General 1
1.2 Characteristics & description 1
1.3 Despatch number significance 1
IT PRINCIPLES OF OPERATION
2.1 Transfer pump 3
2.2 Transfer pressure regulating valve 3
2.3 Metering, pumping and distribution 5
2.3.1 Hydraulic head 5
2.3.2 Cam ring 5
2.3.3 High pressure delivery valves 5
2.4 Excess fuel delivery 7
2.4.1 Principle and description 7
2.4.2 Excess fuel differential valve 7
2.5 Governor 9
2.5.1 Two-speed mechanical governor 9
2.6 Adjustment of commencement of injection 11
2.6.1 Principle and description 11
2.7 Drive 13
2.7.1 Principle and description 13
2.8 Shut-off device 15
2.8.1 Solenoid shut-off 15
2.9 Low-load advance (LLA) 17
2.9.1 Mechanically operated 17
2.9.2 Solenoid-operated 17
2.10 Boost controller 19
2.10.1 Principle and description 19
2.11 Advance override 21
2.11.1 Manual 21
2.11.2 Automatic 21
2.11.3 Hydraulic 23
2.11.4 Solenoid-operated 23
2.12 All-speed governor 25
2.12.1 Principle and description 25
2.13 Floating-hub drive 27
2.13.1 Description 27
2.14 Post-heating microswitch 29
2.14.1 Principle and description 29
2.15 Throttle lever damper 31
2.15.1 Principle and description 31

Lucas
PubN.. 2157 (En)
El DISMANTLING
3.1 Dismantling of assemblies 1 to 9
3.1.1 Levers, control cover, bracket 1 to 2
3.1.2 Two-speed governor 3
3.1.3 All-speed governor 3
3.1.4 Hydraulic head 4 to 5
3.2 Advance systems 6 to 8
3.2.1 Speed advance 6
3.2.2 Speed, LLA or hydraulic advance override 6
3.2.3 Speed, LLA, automatic advance override 7
3.2.4 Speed, LLA, solenoid-operated advance override 7
3.2.5 Speed and manual advance override 8
3.3 Cam ring 8
3.4 Drive system 9
3.4.1 "Toothed belt" -type drive 9
3.4.2 "Floating hub" -type drive 9
3.5 Dismantling the sub-assemblies 10 to 17
3.5.1 Control cover 10
3.5.2 Cable support bracket 11
3.5.3 Governor assembly 11
3.5.4 Hydraulic head 11 to 13
3.5.5 Transfer pressure regulating valve 14
3.5.6 Advance "lock-off" head locating fitting 14
3.5.7 Excess fuel valve 14
3.5.8 Combined valve 14
3.5.9 Low-load valve body assembly 15
3.5.10 Solenoid-operated low-load advance 15
3.5.11 Boost controller 15
3.5.12 Low-load advance (LLA) 15
3.5.13 Manual advance override 16
3.5.14 Automatic advance override 16
3.5.15 Post-heating microswitch 16
3.5.16 Potentiometer 16
3.5.17 Drive shaft "Toothed belt" - type drive 17
3.5.18 Drive shaft "Floating hub" - type drive 17


Pub 2157 (En) 111
REASSEMBLY
4.1 Reassembling the hydraulic head 1 to 3
4.1.1 Hydraulic head 1 to 3
4.1.2 Transfer pump 3 to 4
4.1.3 Transfer pressure regulating valve 4 to 5
4.1.4 High pressure outlets 5
4.1.5 Adjusting the roller-to-roller dimension 5
4.2 Reassembling the drive shaft assembly
and the pump housing 6 to 9
4.2.1 Assembling the shaft and
governor weight cage assembly 6
4.2.2 Fitting the drive shaft assembly
into the pump housing 6 to 7
4.2.3 Assembling the floating hub-type drive 8
4.2.4 Fitting the drive shaft assembly
into the pump housing 8 to 9
4.3 Fitting the cam ring 9
4.4 Fitting the hydraulic head 9 to 10
4.5 Assembling the advance system 10 to 13
4.5.1 Speed advance 10
4.5.2 Speed advance and manual advance override 11
4.5.3 Speed advance and LLA
or hydraulic advance override 12
4.5.4 Speed advance and LLA
with automatic advance override 12
4.5.5 Speed advance and LLA
with solenoid-operated advance override 13
4.6 Fitting the valve bodies 13 to 15
4.6.1 Advance "lock-off" head locating fitting 13
4.6.2 Excess fuel differential valve 14
4.6.3 Combined valve 14
4.6.4 Low-load advance valve 14
4.6.5 Solenoid-operated low-load advance 15
4.6.6 Boost controller 15
4.7 Securing the hydraulic head 16 to 17
4.7.1 Pumps for naturally-aspirated engines 16
4.7.2 Pumps with LLA
for use on naturally-aspirated engines 16
4.7.3 Pumps for turbocharged engines 16 to 17

Pub N. 2157 (En)
4.8 Assembling the governor linkage
and control cover assembly 17 to 21
4.8.1 Bracket, arm and linkage assembly
4.8.2 Adjusting the linkage
4.8.3 Two-speed governor
4.8.4 Fitting the cover and the levers
4.8.5 All-speed governor
4.8.6 Fitting the cable support
bracket/rear support bracket
4.8.7 Fast idle system
Fitting external accessories
4.9.1 Switch (solenoid advance override)
4.9.2 Post-heating microswitch
4.9.3 Potentiometer (EGR system)
4.9.4 Thottle lever damper

Test equipment
5 TORQUE
6 TESTING
6.1.1 Description of Lucas Hartridge test benches 1
6.1.2 Pump output measurement 1
6.1.3 Number of injection shots 1
6.1.4 Calibration fluid 1
6.1.5 Drive system 2
6.1.6 Injector Holder 2
6.1.7 Injector nozzles 2
6.1.8 Injector pipes 2
6.1.9 Measuring the pressures 3
6.1.10 Measuring the advance 3
6.2 Test conditions 4
6.3 Testing and adjusting 4
6.3.1 General 4
6.4 Test Plan 4
6.5 Test procedure 4 to 11
6.6 Timing 12
6.6.1 Internal timing 13 to 14
6.6.2 External timing 15
6.7 Checking the pump for leaks 15 to 16
6.8 Sealing 17
6.9 Storage 18

Lucas Automotive supplies systems
and components to every major
automotive company in the world.
Lucas is recognised as the leading
name in its specialist technologies
— Electrics and Electronics,
Braking and Diesel Systems.

180 page manual covering all aspects of Service
For Cav Pumps an esential part of Cav service

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