Bosch K.K.PUMPGENERALAPRIL 2005S.I. 4331 / 21Sales Automotive Aftermarket DivisionPrinted in JapanPE PUMP REPAIR STANDARDSThis service information bulletin describes the replacement standards for PE pump components. APRIL 2005S.I. 4332 / 21 PUMP BODY (PEA / AD / ZW / P)Part name Inspection location Inspection Replacement standardsPlungers 1. Tilt the plunger block to approx.60,pulltheplungerup10~ 15 mm and then check that the plungerslidessmoothlyinto theplungerbarrelunderits ownweight.Turntheplunger in the barrel and check plunger movementi nthesameway several times.Replacetheplungerassembly iftheplungerslidesintothe barreltooquickly,ordoesnot slide smoothly.2.Checktheendoftheplunger andtheleadforanydamage using your ngernail.0.02 mm3. Check the sliding surface of the plunger visually and using your ngernailforanylengthwise scratches.0.02 mm4.Measur eanywear ont he plunger ange's contact surface using vernier calipers.Replacetheplungerassembly if the wear exceeds 5.0 mm.5. Checkvi sual l y( usi nga magnifyingglass)whetherany erosion on the plunger's sliding surface reaches the lead.Replacetheplungerassembly if the erosion reaches the lead.Delivery valves1.Whennot equi ppedwi t h variable retraction piston: cover theseatholewithyournger. Pullthevalveupandrelease i t.Checkwhethertheval ve returnstoapositionnearits original position.Replacethevalveifitdoes not return to a position near its original position.2.Checktheslidingsectionand thepistonfordamagevisually and using your ngernail.0.02 mm3.Checkt heval veseat sfor unevenwear usi ngyour ngernail.0.02 mmCPV 1.Checkforwearattheseats v i s ual l y andus i ngyour ngernail.Replaceifthevalveseatsare worn.2.Refertotherelevantservice manualtocheckCPVopening pressure and oil tightness.60FlangeErosionSeatsSeatAPRIL 2005S.I. 4333 / 21 PUMP BODY (PEA / AD / ZW / P)Part name Inspection location Inspection Replacement standardsDelivery valve holders1.Shakethedeliveryvalveholder (when equipped with a damping valve)andcheckwhetherit 'clicks.'Repl acethedel i ver yval ve holder if it 'clicks.'2.Checkvisuallyfordamageor erosionatthebottomend' s edge seal.Repl acethedel i ver yval ve holder if there is any erosion or damage.Springs 1.Checkvisuallyforwearand damageont hei nsi deand outside of the spring.Replace the spring if damaged or if wear exceeds 1/2 of wire diameter. 2.Checkwhethertheendsofthe spring are broken.Replace if either of the ends are broken.3.Checkwhetherthepl unger spring is inclined.Replaceiftheinclineexceeds 2 mm.4.Checkwhetherthedelivery valve spring is inclined.Replaceiftheinclineexceeds 1 mm.Control pinions1.Checkvi sual l yandusi ng your ngernailformissingor rounded teeth.Replace if the teeth are missing or rounded.2.Checkvi sual l ywhetherthe pi ni oncl ampscrewi sbent (preventi ngreti ghteni ng)or missing.Replace if bent or missing.Control sleeves1.Checkforplaybetweenthe controlsleeveandtheplunger ange.Replace if play is excessive.2 . C h e c k f o r d a ma g e o rdeformationatthebottomof the control sleeve.Re p l a c e i f d a ma g e d o rdeformed.3.Checkwhet hert hecont rolsleeve ball section is bent.Replace if bent.Control rack 1.Checkvisuallyandusingyour ngernail for missing or worn teeth.Replace the control rack if there are any broken or worn teeth.2. Check using a magnifying glass whetherthecontrolrackslots are damaged or cracked.Replace if the control rack slots are damaged or cracked.3.Measuretheplaybetweenthe controlrackandthecontrol pinion.Replacethecontrolrackifthe play exceeds 0.2 mm.4.Measuretheplaybetweenthe controlrackandthecontrol sleeve ball.Replacethecontrolrackifthe play exceeds 0.2 mm5.Layt hecont r ol rackona sur f acepl at eandcheck whether it is bent or twisted.If bent, measure the bend.Replacethecontrolrackifthe bendortwistingexceeds0.05 mm6.Checkwhethertheendsofthe rackguidegrooveontheback ofthecontrolrackaremarked excessivelyfromstrikingthe back bolts.Replace if marked excessively.Damping valveThreadSeatAPRIL 2005S.I. 4334 / 21 PUMP BODY (PEA / AD / ZW / P)Part name Inspection location Inspection Replacement standardsLower spring seatsCheckthesurfacesthatcontact the plunger spring for wear.Replace if worn.Tappet assemblies1. Check for any play between the roller, the bushing and the pin.Replaceifplayexceeds0.3 mm.2. Check the surface of the tappet rollervisuallyandusingyour ngernailforpeeling,localized wear and lengthwise scratches.Replaceifpeeling,wornor scratched.3.Checkthetappetbodyvisually andusingyourngernailfor lengthwise scratches.0.6 mmCamshaft 1.Checkvisuallyandusingyour ngernailforpeelingonthe camsurfaceandtaper,andfor localized wear and scratches.Replaceifpeeling,wornor scratched.2.Suppor t t heendsof t he camshaf t i nVbl ocksand measur ede ect i oni nt he center using a dial gauge.Replaceifde ectionexceeds 0.15 mm.3.Checkvisuallyandusingyour ngernailforwearattheoil seallipcontactsurfacesofthe camshaft.Replaceifwearexceeds0.06 mm.4.Checkvisuallyandusingyour ngernai l forpeel i ngatthe centerbearingcontactsurface, for l ocal i zedwear andforlengthwise scratches.Replaceifpeeling,wornor scratched.5.Checkwhetherthekeygroove haswidenedorthethreadson theendsofthecamshaftare damaged.Repl acei f t hegroovehas wi denedorthethreadsare damaged.Center bearings and bearings1.Checkvisuallyandusingyour ngernailwhetherthesurfaces thatcontactthecamshaftare peeling,onlypartiallycontact the camshaft, or are damaged.Replace if peeling, only partially contactingthecamshaft,or damaged.0.06 mm.2.Assembletheinnerandouter racesandcheckwhetherthey st i ckormakeanyunusualnoise when rotated.Replacebearingsiftheystick or make any unusual noise.3.Checkvisuallyandusingyour ngernailwhetherthebearing rol l eront heout erracei s peeling or damaged.Replacebearingifpeelingor damaged.0.02 mm.APRIL 2005S.I. 4335 / 21 PUMP BODY (PEA / AD / ZW / P)Part name Inspection location Inspection Replacement standardsPump housing1.Checkvisuallyandusingyour ngernailfordamage,cracks andsteppedwearwherethe pumphousingisattachedto the engine.Replacethepumphousingifit is cracked, worn or damaged.2.Checkvisuallywhetherthefuel chamber and the cam chamber are cracked or damaged.Replacethepumphousingif cracked or damaged.3.Assemblethetappets.Ifthere i sanypl ay, measur et he tappets'outerdiametersand t hedi amet ersof t hepump housing holes.Replaceifplayexceeds0.1 mm.4.Checkvisuallyandusingyour ngernailforwearordamage wheretheplungerblocksare installed.Replacethepumphousingif worn or damaged.5.Checkvisuallywhetheranyof the threads or the adapters are worn or damaged.Replacethepumphousingif worn or damaged.6.Assembl etheupperspri ng seats.Checkvisuallywhether theupperspringseats'contact surfaces are worn excessively.Replace the pump housing and spring seats if worn excessively.Deectors PE-Ztypepumps:Checkfor anyerosionattheendofthe deectors.Replacethede ectorsifthere is any erosion.Drive gear Checkwhetheranyofthedrive gearteetharemissing,damaged or worn excessively.Replacethedrivegearifthe drivegearteetharemissing, damaged or worn excessivelyAPRIL 2005S.I. 4336 / 21 PUMP BODY (TICS)Part name Inspection location Inspection Replacement standardsPlungers 1.Assemblethetimingsleeveon theplungerblockandtiltthe plungerblocktoapprox.60. Then,pulltheplungerout10 ~15mmandcheckthatthe plungerslidessmoothlyinto the barrel under its own weight.Turntheplungerinthebarrel andcheckplungermovement in this way several times.Replacetheplungerassembly iftheplungerslidesintothe barreltooquickly,ordoesnot slide smoothly.2.Whenchecki ngt het i mi ng sl eeveonl y, assembl et he timingsleevetotheplunger upside-down,thenrepeatthe above test.Replacetheplungerassembly iftheplungerslidesintothe timingsleevetooquicklyor does not slide smoothly.3.Theremainingtestsarethe sameasthoseforA/AD-P typepumps.Refertopage 2/17.Timing rod, pins and sleeves1.Checkvi sual l ywhetherthe timingrodpinsaredamaged, cracked or worn excessively.Replace if damaged or cracked or if any wear exceeds 0.3 mm.2.Checkvisuallyandusingyour ngernailwhetherthetiming sl eevegroovei sdamaged, cracked or worn excessively.Replace the sleeve if damaged or crackedor i f anywearexceeds 0.3 mm.3. Repl ac et het i mi ngr od assembl yandt hepl unger assemblyifthereisanyplay between the pin and the timing sl eevegroove,ori fthepi n doesnotmovesmoothlyinthe groove.Play must not exceed 0.3 mm.4. Check for wear of the pin at the support end of the timing rod.Replaceifwearexceeds0.3 mm.5.Checkwhetherthetimingrod ball bearing is worn excessively andwhetherthereisanyplay.Also check whether the bearing turns smoothly.Replacetheballbearingifitis wornexcessivelyordoesnot turn smoothly.6.Checkvi sual l ywhetherthe insideofthebushingatthe governorendofthetimingrod is worn.Replace if worn.6010 ~ 15 mmUpper faceLower face10 ~ 15 mm60APRIL 2005S.I. 4337 / 21 PUMP BODY (TICS)Part name Inspection location Inspection Replacement standardsPump housing1.Checkvisuallyandusingyour ngernailfordamage,cracks andsteppedwearwherethe pumphousingisattachedto the engine.Replacethepumphousingifit is cracked, worn or damaged.2.Checkvisuallywhetherthefuel chamber and the cam chamber are cracked or damaged.Replacethepumphousingif cracked or damaged.3.Assemblethetappets.Ifthere i sanypl ay, measur et he tappets'outerdiametersand t hedi amet ersof t hepump housing holes.Replaceifplayexceeds0.1 mm.4.Checkvisuallyandusingyour ngernailforwearordamage wherethepl ungerbl ocki s installed.Replacethepumphousingif worn or damaged.5.Checkwhetherthesurfacethat contacts the pre-stroke actuator is damaged, worn or could leak.Replace the pump housing if the surfaceisdamaged,wornor could leak.6.Checkvisuallywhetheranyof the threads or the adapters are worn or damaged.Replacethepumphousingif worn or damaged.Pre-stroke actuator shaft1.Checkwhetherthedriveshaft ball is worn.Replaceifwearexceeds0.3 mm.2.Checkwhethertheshafti s rusted.Also,turntheshaft byhandandcheckwhetherit turns smoothly.Replace the pre-stroke actuator if the shaft is rusted or does not turn smoothly.U-shaped linkCheckwhethertheareawhere thepre-strokeactuatorshaftball contactstheU-shapedl i nki s worn.(Estimatetheamountof wearbymeasuringthediameter of the depression.)Exceeds 0.3 mmDiameterofdepression2.5 mmAPRIL 2005S.I. 4338 / 21 PUMP BODY (TICS)Part name Inspection location Inspection Replacement standardsElectrical pre-stroke actuator components:cables, connectors and terminals1.Checktheresistancesbetween theterminalsusingacircuit tester.Replace the pre-stroke actuator iftheresistancesarenotas specied.2 . Ch e c k t h e r e s i s t a n c e sb e t we e n t h e p r e - s t r o keact uat ort er mi nal sandt he correspondingcableterminals.Check while moving the cable.Replace the pre-stroke actuator iftheresistancesarenotas specied.3.Usinganinsulationresistance tester,checkthei nsul ati on resistance not only between the terminals, but also between the housing and the body.Replace the pre-stroke actuator iftheresistancesarenotas specied.4.Movethesensorcoreandthe temperaturecompensationcoil by hand to check whether there is any play.Replace the pre-stroke actuator if there is any play.5. Check the operating voltage. Replace the pre-stroke actuator if the voltage is not 2.8V.6.MovetheU-shapedcoreby hand to check whether there is any play.Replace the pre-stroke actuator if there is any play.7.Checkwhet her t hecabl e coatingisdamaged,brokenor deformed.Re p l a c e t h e p r e - s t r o keactuator if damaged, broken or deformed.8. Use a magnifying glass to check for any cracks in the pre-stroke actuator.Replace the pre-stroke actuator if there are any cracks.Move the cable up and down and side to side.APRIL 2005S.I. 4339 / 21 GOVERNORS (GENERAL)Part name Inspection location Inspection Replacement standardsGovernor cover, governor housing and closing cover1.Checkt hegover norcover,housi ngandcl osi ngcover v i s u a l l y f o r c r a c k s a n ddamaged threads.Replaceifcrackedorthreads damaged.2.Checkvisuallyandusingyour ngernail whether the governor cover,housi ngandcl osi ng covermat i ngsurfacesare damaged.Replace if damaged.3.Checkvisuallyandusingyour ngernailwhethereachlever shaftbushingisdamagedor worn excessively.Replaceifdamagedorworn excessively.Flyweight 1.Checkthattheyweightmoves smoothly.Checkwhetherthe roller (slider) and pins are loose or sticking.Replaceifplayexceeds0.1 mm.2.Checktherol l er(sl i der)for steppedwearandeccentric wear.Replaceifwearexceeds0.06 mm.3. Check the threads for damage. Replacethe yweightifthe threads are damaged.Springs 1. Check the start spring hooks for excessive wear.Replaceifwearexceeds0.1 mm.2.Checkthegover norspri ng hooks for excessive wear.Replaceifwearexceeds0.5 mm.3.Checkthereturnspringhooks for excessive wear.Replaceifwearexceeds0.1 mm.4. Check v i s ual l y whet hert hespr i ngsareof f cent er,permanently set or rusted.Re p l a c e i f o f f c e n t e r ,permanently set or rusted.Exterior levers and stopper boltsCheck whether the lever - stopper boltcontactsurfacesareworn excessively.Replaceifwearexceeds0.5 mm.Diaphragm 1.Checkwhetherthediaphragm istorn,creasedorhasanypin holes.

Replacethediaphragmifitis torn,creasedorhasanypin holes.2.Checkwhetherthecaulkingis loose.Replace if loose.APRIL 2005S.I. 43310 / 21 GOVERNORS (RFD AND RSV)Part name Inspection location Inspection Replacement standardsEccentric shaftCheckwhet her t heshaf t i s scratchedorwornexcessively.Checkwhet her t her ei sany playbetweentheshaftandthe bushing.Checkvisuallyforany oil leaks.Replaceifplayexceeds0.1 mm,orifwornorscratched excessively.Supporting leverCheckwhetherthesupporting lever and shaft are too tight or too loose.Replaceifplayexceeds0.1 mm.Tension lever 1. Check whether there is any play betweenthesupportinglever and the tension lever pin.Replaceifplayexceeds0.1 mm.2.Checkwhetherthetensi on l everpi nsuppor t sandt he shaftaretootightortooloose (non-presstted type).Replaceifplayexceeds0.1 mm.3. Check whether the tension lever shaftholeiswornexcessively.Checkwhetherthereisany playbetweenthetensionlever and the shaft.Repl acei f wor nor i f pl ay exceeds 0.2 mm.4.Checkwhetherthereisany st eppedwear wher et he t ensi onl evercont act st he strokeadjustingscrewandthe shafts.Replaceifwearexceeds0.5 mm.5. Check whether the tension lever chrome plating is peeling.Replacethetensionleverif peeling.6.Checkwhetherthegovernor spr i nghookhol ei swor n excessively.Replace the tension lever if the hole is worn excessively.7.Press tted bushing type:Checkwhetherthegovernor spr i nghookhol ei swor n excessivelyandcheckwhether thehook'stensionleversideis cracked.Replacethetensionleverif the hole is worn excessively or the hook's tension lever side is cracked.Shifter 1. Check whether the tension lever andshi ftercontacti swor n excessively.Replaceifwearexceeds0.5 mm.2.Checkwhethertheshifter' s chrome plating is peeling.Repl acet heshi f t er i f t he chrome plating is peeling.Thrust damperRepl acetherubberdampers regardless of their condition.Sleeve Checkwhetherthesleeveand yweight(roller)contactisworn excessively.Replaceifwearexceeds0.06 mm.Bearing Turnthebearingbyhandand listenforanyabnormalnoise.Checkwhetherthebearingis worn.Replacethebearingifthereis anyabnormalnoiseorifitis worn.WearCracks(presstted bushing type)APRIL 2005S.I. 43311 / 21 GOVERNORS (RFD AND RSV)Part name Inspection location Inspection Replacement standardsSwivel lever and speed setting lever shaft1.Checkwhetherthebushi ng cont act surfacesarewor n excessively.Replaceifwearexceeds0.1 mm.2.Checkwhethertheinsidesof thebushingsarescratchedor worn excessively.Repl acet hebushi ngsi fscratched or worn excessively.3. Check for any oil leaks.Guide lever(RFD-K)1.Checkwhethertheguidelever andi ncreasel evercont actsurface is worn excessively.0.06 mm2. Check whether the cancel spring iscrackedorpermanentlyset.Checkwhetherthesetforceis as specied.Replacethecancelspringif crackedorpermanentlyset, ori fthesetforcei snotas specied.3.Checkwhethertheincrease lever and tension lever side pin D is worn excessively.0.1 mm4. Check whether the tension lever and bracket holder is loose.Replaceifplayexceeds0.1 mm.5.Checkwhetherthereisany playatthesupportingleverpin bracket contact.Replaceifplayexceeds0.1 mm.6.Checkwhet hert heendoftheshifter(thatcontactsthe tensionlever)isworn.Check whetherthechromeplatingis peeling.Replace the shifter if worn or if the coating is peeling.7.Checkwhetherthereisany playbetweentheblockatthe bottomoftheguideleverand the supporting lever.Replacetheguideleverand thesupportingleverifthereis any play.Flyweight(with radial rubber dampers)1.Replacetherubberdampers regardless of their condition.2.Checkwhetherthe yweight ortheplateteeth(contacting therubberdampers)areworn excessively.Replace if worn excessively.APRIL 2005S.I. 43312 / 21 GOVERNORS (RFD AND RSV)Part name Inspection location Inspection Replacement standardsTension lever 1. Check whether the tension lever assembly'sslidingpartsare worn excessively or do not move smoothly.Repl acet het ensi onl ever assemblyiftheslidingparts arewornexcessivelyordonot move smoothly.2.Checkwhetherthetorquecam rodisbentorthethreadsare damaged.Replacethetorquecamrod i f bent or t het hr eadsar e damaged.3. Check whether the tension lever pin is worn excessively or does not move smoothly.Repl ac et hepi ni f wor n excessively or it does not move smoothly.4.Checkwhethertheguidelever balljointisscratchedorworn excessively.Replacetheguideleverifthe balljointisscratchedorworn excessively.5.Checkwhetherthegovernor springseatandthepinare worn excessively or do not move smoothly.Replaceifwornexcessivelyor not moving smoothly.APRIL 2005S.I. 43313 / 21 GOVERNORS (RLD)Part name Inspection location Inspection Replacement standardsFloating lever 1. Check whether the oating lever groovefacesarescratchedor worn excessively.Replacethe oatingleverif scratched or worn excessively.2.Checkwhetherthereisany playbetweentheoatinglever grooveandtheguideleverball joint.Replacethe oatingleverif there is excessive play.Rack connecting link and supporting lever1.Checkwhet her t her ack connectinglink'sballjointis damaged or worn excessively.Replaceifdamagedorworn excessively.2.Checkwhetherthelink'sstart spring hole is worn.Replace if the hole is worn.3.Checkwhetherthereisany playbetweentheoatinglever groove and the rack connecting link's ball joint.Replace if there is any play.Supporting lever and oating lever1. Check whether the oating lever andL-shapedl evercontact surface is worn excessively.Replace if worn excessively.2.Checkwhet her t heNo.2 supportingleverpinandthe guideplatecontactsurfaceare worn excessively.Replace if worn excessively.Lever shafts 1. Check whether the lever shaft's oilsealcontactsurfacesare worn excessively.Replace if worn excessively.2.Checkwhetherthelevershaft andeachsuppor t i ngl ever sl i di ngsur f acear ewor n excessively.Replace if worn excessively.Sensor lever and torque cam1. Check whether the sensor lever tipandthetorquecamcontact surface are worn excessively.Replacethesensorleverifthe tip is worn.Replace the torque cam if worn.2.Checkwhet hert hesensor levercollariswornexcessively andwhetherthereisanyplay between the collar and the pin.Repl acethesensorl everi f wornexcessivelyorifthereis any play.3. Check whether the sensor lever pi votssmoothl yaroundthe U-shapedl everpi n.Check whether the U-shaped lever pin hole is worn excessively.Repl acet hesensor l everand/ortheU-shapedleverif the sensor lever does not pivot smoothlyorifthepinisworn excessivelyGuide plate Ch e ck wh e t h e r t h e No. 2supportinglever'spinandguide pl atecontactsurfacei sworn excessively.Replaceifwearexceeds0.5 mm.APRIL 2005S.I. 43314 / 21 GOVERNORS (RLD)Part name Inspection location Inspection Replacement standardsGovernor shaft1.Checkthatthespringseats move smoothly on the governor shaft.Repairorreplacethegovernor shaftorspri ngseatsi fthe spring does not move smoothly on the shaft.2.Checkwhetherthegovernor shaftisdamaged,bentorhas damaged threads.Repairorreplacethegovernor shaft if damaged, bent, or if the threads are damaged.APRIL 2005S.I. 43315 / 21 GOVERNORS (RED)Part name Inspection location Inspection Replacement standardsLinks and connectors1.Checkwhetherthelink'supper balljointisdamagedorworn excessively.Replacethegovernoractuator andt hecopper pl at eand connectoriftheballjointis damaged or worn excessively.2.Assembletheconnectortothe link'sballjoint.HoldtheDC motor's movable coil to prevent itfrommovingandmovethe connect or backwar dsand forwards to check for any play.Replacethegovernoractuator andt hecopper pl at eand connectorifplayexceeds0.5 mm.3.HoldtheDCmotor'smovable coiltopreventitfrommoving andmovethelinkbackwards andforwardstocheckforany playbetweentheballjointand the DC motor's guide groove.Replacethegovernoractuator andt hecopper pl at eand connectorifplayexceeds0.5 mm.Linear DC motor1.Sl owl ymovethel i nearDC motor'smovablecoilassembly upanddownandcheckthatit moves smoothly.Replacethegovernoractuator assemblyifitdoesnotmove smoothly.2.Ti l t t hegover nor act uat orassembl ytoapproxi matel y 30.Movethemovablecoil assembl yt oi t supper mostposition and check that it slides down smoothly under its weight.Replacethegovernoractuator assemblyifitdoesnotmove smoothly.Connector sub-assemblyUseamagnifyingglasstocheck whetherthecopperplateorthe connectorisdamagedorbent excessively.Replacethecopperplateand connect orasanassembl y ifthecopperplateisbentor damaged.Speed sensorCheck the clearance between the speedsensorandthesensing gear cogs.Replace the governor assembly i f t hecl earancei snot as specied:0.8 ~ 1.0 mm.Spring seats Checkwhet her t her ei sany stepped wear at the rack opening.Also check the rack for excessive wear.Replace if worn.Approx. 30APRIL 2005S.I. 43316 / 21 GOVERNORS (RED)Part name Inspection location Inspection Replacement standardsGovernor actuator1. Measur et her esi st ance betweeneachterminalusinga circuit tester (REDIII type).Replacethegovernoractuator iftheresistancesarenotas specied.2. Use a magnifying glass to check thesolderingateachcable- terminal connection for cracks.Replacethegovernoractuator if cracked.Cables and harnesses1.Checkthecontinuitybetween e a c h t e r mi n a l a n d t h econnector using a circuit tester. Atthistime,movethecableto check whether any wires inside the cable are broken.Replacethegovernoractuator if there is no continuity.2.Checkwhet her t hecabl e coatingisdamaged,brokenor deformed.Replacethegovernoractuator if the cable coating is damaged, broken or deformed.3.Usinganinsulationresistance tester,checkthei nsul ati on resistance not only between the terminals, but also between the housing and the body.Replacethegovernoractuator iftheresistancesarenotas specied.Connectors and terminals1. Check whether the connector is damaged.Repl acet heconnect or i fdamaged.2.Checkwhethertheterminals are rusted, bent or broken.Replacethegovernoractuator if the terminals are rusted, bent or broken.3.Checkwhetherthesolderingis cracked or damaged.Replacethegovernoractuator ifthesolderingiscrackedor damaged.Move the cable.1234567APRIL 2005S.I. 43317 / 21 FEED PUMPSPart name Inspection location Inspection Replacement standardsCheck valves Checkwhetherthecheckvalves arewornexcessively.Checkthe seats for scratches and excessive wear.Replacethecheckvalvesif worn excessively or if the seats are scratched or worn.Pistons Checkt hepi st onsf or r ust ,damage and excessive wear.Replacethepistonsifrusted, damaged or worn excessively.Springs Checkwhetherthespringsare rusted or broken.Replace the springs if rusted or broken.Tappet assemblies1.Checkt heout si desof t he t a p p e t s f o r d a ma g e o rexcessive wear.Replace the tappets if damaged or worn excessively.2.Checktherollersandpinsfor excessive wear.Replacetherollersandpinsif worn excessively.Housing and pushrods1.Checkt heout si deof t he housing for damage.Check the threads for damage.Re p l a c e t h e h o u s i n g i fdamaged.2.Checkthecheckvalveseat surfaces for excessive damage.Repl acethehousi ngi fthe check valve seats are damaged excessively.3.Checkt heout si deof t he pushr odf or damageand excessive wear.Re p l a c e t h e p u s h r o d i fdamaged or worn excessively.4.Checkthatthepushrodmoves smoothly in the housing.Repl acet hepushr odand housing if the pushrod does not move smoothly in the housing.APRIL 2005S.I. 43318 / 21 TIMERS (STANDARD TYPES)Part name Inspection location Inspection Replacement standardsSprings, spring seats, rollers and bushings1.Checkwhetherthespringsare rusted, bent or damaged.Replace the entire set if rusted, bent or damaged.2.Checkwhet hert hespr i ng seats,rollersandbushingsare damaged or worn excessively.Replaceifdamagedorworn excessively.Flyweight holder1.Checkthe ywei ghthol der taper, key groove and yweight pin for excessive wear.Replace if worn excessively.2.Checkwhetherthetimer ange pins are cracked or the threads are damaged.Replace if cracked or damaged.Flyweights Check the yweight pin holes and the curved surfaces for excessive wear.Replacethe yweightsifworn excessively.Flanges 1.Checkwhetherthe angepins are worn or cracked.Replacethe angesifthepins are worn or cracked.2.Checkwhetherthetapersand keygroovesaredamagedor worn excessively.Replaceifdamagedorworn excessively.3.Checkwhet her t he ange rollers and curved surfaces are damaged or worn excessively.Replaceifdamagedorworn excessively.Timer case Checkwhet her t heout si de of t het i mercasei sdent ed.Checkwhetherthethreadsare damaged.Repl acei fdentedori fthe threads are damaged.APRIL 2005S.I. 43319 / 21 TIMERS (ECCENTRIC TYPES)Part name Inspection location Inspection Replacement standardsTimer housing and disks1.Checkwhethertheclearance between the pins and the small camholesisexcessivedueto wear.Replace the housing and cams if worn excessively.2.Checkwhethertheoi l sealsurfaces are damaged or worn.Replace the oil seal if damaged or worn.3. Check whether the inside of the timerhousingisdamagedor worn excessively.Re p l a c e t h e h o u s i n g i fdamaged or worn excessively.4.Checkwhetherthesurfaces cont act i ngt heoi l seal are damaged or worn.Replaceifdamagedorworn excessively.Flanges 1.Checkwhetherthekeygroove and taper are damaged or worn excessively.Replacethe angeifdamaged or worn excessively.2.Checkwhethertheclearances betweenthe angeandthe large cam are excessive due to wear.Replace the ange and cams if worn excessively.3. Check whether the operating oil passagesareblockedwithoil, sludge or dirt.Clean.4.Checkvi sual l ywhetherthe angeoilsealcontactsurface is worn or damaged.Replacethe angeifdamaged or worn excessively.Flyweights 1.Checkwhethertheclearances betweenthepress ttedpins and the large cam pin holes are excessive due to wear.Repl acethe ywei ghtsand cams if worn excessively.2.Checkwhetherthepilotpin holes are worn excessively.Replace the yweight assembly if worn excessively.3. Check whether the spring seats are worn excessively.Replace the yweight assembly if worn excessively.Large and small camsCheckthatthesmallcamsmove smoothly in the large cams.Check whether there is excessive clearancebetweenthelargeand small cams.Replacethelargeandsmall camsasasetiftheclearance is excessive.APRIL 2005S.I. 43320 / 21 TIMERS (ECCENTRIC TYPES)Part name Inspection location Inspection Replacement standardsPlates 1.Checkwhethertheplatesare worn.Checkthatthecams movesmoothlyonthepins.Checkwhetherthepinsare damaged or worn excessively.Replacetheplatesifwornor damaged.Repairorreplace thecamsiftheydonotmove smoothly on the pins.2.Checkwhetherthepinsare loose.Replacetheplatesifthepins are loose.3.Checkthatthepistonsmove smoothl yonthepresstted pins.Checkwhetherthepinsandpistonholesaredamaged or worn excessively.Repair or replace if damaged.4. Check that the large cams move smoothl yonthepresstted pi ns.Checkwhet her t he pinsandlargecamholesare damaged or worn excessively.Repair or replace any damaged or worn parts.Cylinders and pistons1.Checkwhet her t heout ersurfacesofthepi stonsare damaged or worn excessively.Repair or replace any damaged or worn parts.2.Checkwhetherthecylinder andpistonslidingsurfacesare damaged or worn excessively.Repair or replace any damaged or worn parts.3.Checkthatthepistonsslide normallywhenassembledin the pistons.Repair or replace any damaged or worn parts.4.Checkwhetherthecylinder s p r i n g s e a t s a r e wo r nexcessively (stepped wear).Repair or replace any damaged or worn parts.5. Check whether the cylinder and ange sliding surfaces are worn excessively.Repair or replace any damaged or worn parts.Springs, spring seats and pilot pins1.Checkwhetherthespringsare permanently set or bent.Re p l a c e t h e s p r i n g s i fpermanently set or bent.2. Check whether the pilot pins are bent or worn excessively.Replacethespringsifbentor worn excessively.3.Checkwhetherthepilotpins slidesmoothlyinthespring seats.Replace the pilot pins if they do not move smoothly.4. Check whether the spring seats are worn excessively.Replace the spring seats if they are worn excessively.Cover Checkwhet hert heseal and cont act surfacesof t her i ng press ttedtothetimerhousing are damaged.Replace the cover if damaged.APRIL 2005S.I. 43321 / 21 TIMERS (ECCENTRIC TYPES)Part name Inspection location Inspection Replacement standardsTiming ring 1. Check whether the timing ring is damaged.Repl acet het i mi ngr i ngi fdamaged.2.Checkwhetherthethreaded holesandthepinholesare cracked.Replacethetimingringifthe threaded holes or pin holes are cracked.3.Checkwhetherthesealringis damaged.Replacethetimingringifthe seal ring is damaged.Bearing coverCheckwhet hert heoi l seal s pressttedtothebearingcover aredamaged.Checkthattheoil seals are properly presstted.Repl acethebeari ngcover assembly if the sealing surfaces aredamagedortheoilseals are not properly presstted.Viscous damper1. Check each thread for damage. Repl acei f t het hreadsare damaged.2.Checkwhet her t hecovercaulking is loose.Replace if the caulking is loose.3. Check whether the housing and cover are marked or dented.Replace if the housing or cover is marked or dented.4.Checkwhetheranyoilleaks from the cover or seal plugs. Replaceifanyoilleaksfrom the cover or seal plugs.