Delphi DDNX184, DDNX184 EN WORKSHOP MANUAL

WORKSHOP MANUAL

DP210 FUEL INJECTION PUMP DDNX184(EN)

2003

(D) Schutzbrille/Gesichtsschutz tragen. (E) Úsese protección para los ojos/la cara. (EN) Wear eye/face protection

(F) Porter un appareil de protection des yeux / du visage. (IT) Proteggersi gli occhi/la faccia. (NL) Veiligheidsbril/-masker gebruiken. (P) Use protecção da face/olhos.

(D) Von Zündquellen fernhalten - Nicht rauchen. (E) Conservar alejado de toda llama o fuente de chispas -No fumar. (EN) Keep away from sources of ignition - No smoking. (F) Conserver à l'écart de toute flamme ou source d'étincelles - Ne pas fumer. (IT) Conservare lontano da fiamme e scintille - Non fumare. (NL) Ver van open vuur en ontstekingsbronnen houden – Niet roken. (P) Mantenha afastado de fontes de ignição – Proibido fumar.

(D) Geeignete Schutzhandschuhe tragen. (E) Usen guantes adecuados. (EN) Wear suitable gloves. (F) Porter des gants appropriés. (IT) Usare guanti adatti. (NL) Aangepaste veiligheidshandschoenen dragen. (P) Use luvas apropriadas.

(D) Kommen Sie nicht mit dem Hochdruckstrahl in Verbindung! Besonders nicht, wenn

Druckrohrleitung oder Dichtung geprüft werden! Hochdruckflüssigkeiten können tödliche Verletzungen verursachen! Im Falle einer Berührung mit der Haut, kontaktieren Sie sofort einen Arzt. Bitte beachten Sie die Gesundheits-/und Sicherheitsunterlagen.

(E) Mantenga las manos y el cuerpo lejos del rociado del líquido, especialmente inyecto-

res, tuberías y juntas de alta presión con fugas. La inyección de alta presión puede perforar la piel humana y producir una lesión fatal. En caso de que la inyección atraviese la piel, consiga atención médica inmediatamente. Vea la hoja de Datos de Sanidad y Seguridad.

(EN) Do not put your skin into the fuel jets under pressure, especially those due to pressure

pipe or seal leaks. High pressure liquids can cause deadly injuries. In case of an injection under the skin, contact a doctor immediately. Please refer to the health and security fuel documents.

(F) Ne pas approcher les mains ni le corps des jets de liquides, particulièrement ceux pro-

venant des fuites de tuyaux et des joint soumis a la haute pression. Le liquide sous haute pression injecté sous la peau peut causer des blessures mortelles. En cas d’injection sous la peau, consulter immédiatement un médecin. Se reporter a la fiche de santé et de sécurité du gazole.

(IT) Non esporre le mani o altre parti del corpo a getti di gasolio ad alta pressione, spe-

cialmente a quelli provenienti da tubi o paraolii. I getti di liquidi ad alta pressione possono causare ferite anche mortali. In caso di iniezione sotto pelle contattare immediatamente un medico. Fare riferimento alle schede di sicurezza del gasolio.

(NL) Zorg dat uw handen of andere lichaamsdelen niet in contact komen met vloeistofstra-

len onder hoge druk, met name bij een lek aan een leiding of dichting. Als de vloeistof onder hoge druk onder de huid terechtkomt, kan dit zelfs tot dodelijke verwondingen leiden. Als de vloeistof onder de huid terechtkomt, onmiddellijk een arts raadplegen. Lees de gezondheids- en veiligheidsfiche met betrekking tot de brandstof.

(P) Não exponha a pele a jactos de combustível sob pressão, especialmente os devidos a

fugas de tubos de pressão ou vedantes. Líquidos a alta pressão podem causar ferimentos mortais. No caso de injecção subcutânea, consulte imediatamente um médico. Consulte por favor a documentação respeitante a saúde e segurança de combustíveis.

CONTENTS

Publication N°: DDNX184(EN) 2K/03.03/FOLIUM

INTRODUCTION 1

DISMANTLING 2

COMPONENT INSPECTION AND RENEWAL 3

REASSEMBLY 4

TEST PROCEDURE 5

TOOLING, TORQUES & EVDS 6

BC - Boost Control CA - Cold Advance CP - Zero Backlash Drive CPS - Carriage Position Sensor DCU - Diesel Control Unit ESOS - Electric Shut-Off Solenoid EVD - Exploded View Diagram FIE - Fuel injection Equipment HP - High Pressure LLA - Light Load Advance OEM - Original Equipment Manufacturer SIN - Service Instruction Note TP - Transfer Pressure

NOTATIONAL CONVENTIONS AND ABBREVIATIONS

Produced by:

Delphi Diesel Aftermarket Operations Stratford Road Shirley, Solihull Tel.: (44) (0)121 746 6000 B90 4DT, UK Fax: (44) (0)121 746 6001

1 INTRODUCTION

1.1 The Pump .........................................................................................................................................................................7

1.2 General ........................................................................................................................................................................7 - 8

1.3 This Manual......................................................................................................................................................................8

1.4 Equipment ........................................................................................................................................................................8

1.5 Replacement of Parts.......................................................................................................................................................8

1.6 Pump Name Plate.......................................................................................................................................................8 - 9

2 DISMANTLING

2.1 Preparation .....................................................................................................................................................................11

2.1.1 Cleaning and draining ........................................................................................................................................11

2.1.2 Mounting the pump ...........................................................................................................................................11

2.1.3 Sealing caps and drive shaft lock bolt..............................................................................................................11

2.1.4 Drive hub (if fitted) .............................................................................................................................................12

2.1.5 Measuring drive shaft end float ........................................................................................................................12

2.1.6 Measuring drive shaft radial play .....................................................................................................................12

2.2 Drive Shaft......................................................................................................................................................................13

2.3 High Pressure Outlets and End Plate Assembly .........................................................................................................13

2.3.1 High pressure outlets ........................................................................................................................................13

2.3.2 Endplate assembly .....................................................................................................................................13 - 14

2.4 Electric Shut-off Solenoid (ESOS) ................................................................................................................................14

2.5 Transfer Pump ................................................................................................................................................................14

2.6 Governor Cover External Components .......................................................................................................................15

2.6.1 Fuel return connections ....................................................................................................................................15

2.6.2 Throttle lever stop screws, maximum fuel adjuster blanking plug and torque control screw ..................15

2.6.3 Throttle lever ......................................................................................................................................................16

2.7 Governor Cover .............................................................................................................................................................16

2.7.1 Governor cover with torque control only ................................................................................................16 - 17

2.7.2 Governor cover fitted with boost control ................................................................................................17 - 19

2.8 All Speed Governor ......................................................................................................................................................19

2.9 Governor Control Bracket and Arm Assembly ..........................................................................................................19

2.9.1 Scroll link plate return spring ...................................................................................................................19 - 20

2.9.2 Governor control bracket assembly ................................................................................................................20

2.9.3 Governor control arm assembly ......................................................................................................................20

2.10 Slackening the Transfer Pump Rotor ..........................................................................................................................20

2.11 Advance Device .....................................................................................................................................................20 - 21

2.11.1 Cam screw...........................................................................................................................................................22

2.12. Head Locating Fittings and Hydraulic Head ................................................................................................................22

2.12.1 Head locking screws...........................................................................................................................................22

2.12.2 Light load advance (LLA) ...................................................................................................................................22

2.12.3 Latch valve ..........................................................................................................................................................22

2.12.4 Releasing the hydraulic head ............................................................................................................................23

2.12.5 Drive assembly ...........................................................................................................................................23 - 24

2.13 Drive Shaft Seal(s) ........................................................................................................................................................24

3 COMPONENT INSPECTION AND RENEWAL

3.1 Cleaning ..........................................................................................................................................................................25

3.2 General............................................................................................................................................................................25

3.2.1 Mated and matched assemblies .......................................................................................................................25

3.2.2 Examination and replacement ..........................................................................................................................25

CONTENTS

iii

3.2.3 Seals ....................................................................................................................................................................25

3.3 Details .............................................................................................................................................................................25

3.3.1 Hydraulic head rotor ..........................................................................................................................................25

3.3.2 Hydraulic head plungers ....................................................................................................................................25

3.3.3 Cam ring and scroll plates .................................................................................................................................25

3.3.4 Rollers and shoes ...............................................................................................................................................25

3.3.5 Transfer pump .............................................................................................................................................25 - 26

3.3.6 Endplate...............................................................................................................................................................26

3.3.7 Control valves .....................................................................................................................................................26

3.3.8 Delivery valves and cambox pressurising valves ...........................................................................................26

3.3.9 Springs ................................................................................................................................................................26

3.3.10 Fittings and threads............................................................................................................................................26

3.3.11 Linkages...............................................................................................................................................................26

3.3.12 Throttle shaft .......................................................................................................................................................26

3.3.13 Drive shafts and associated components ........................................................................................................26

3.3.14 Advance device...................................................................................................................................................26

3.3.15 External controls .................................................................................................................................................26

3.3.16 Pump housing .....................................................................................................................................................26

3.3.17 Governor control cover ......................................................................................................................................26

3.3.18 Orifices.................................................................................................................................................................26

3.3.19 Electric shut-off solenoid ...................................................................................................................................26

3.4 Storage ..........................................................................................................................................................................26

3.4.1 New pumps ........................................................................................................................................................26

3.4.2 Overhaul pumps ................................................................................................................................................26

3.4.3 Storage conditions ............................................................................................................................................27

4 REASSEMBLY

4.1 Preparation .....................................................................................................................................................................29

4.1.1 Hydraulic head ....................................................................................................................................................29

4.2 Drive Shaft......................................................................................................................................................................29

4.2.1 Catch and support plates ...................................................................................................................................29

4.2.2 Rollers and shoes ...............................................................................................................................................29

4.2.3 Governor weight cage ......................................................................................................................................30

4.2.4 Fitting the governor weight assembly to the drive shaft ..............................................................................30

4.2.5 O-ring and rear scroll plate ..............................................................................................................................30

4.2.6 Cam ring, front scroll plate and inner bearing ........................................................................................30 - 31

4.2.7 Drive shaft assembly .........................................................................................................................................31

4.2.8 Fitting the pump housing .................................................................................................................................31

4.3 Drive Shaft Seals, End Float and Radial Play .............................................................................................................31

4.3.1 Drive shaft seals ................................................................................................................................................32

4.3.2 Securing the drive shaft ....................................................................................................................................32

4.3.3 Measuring drive shaft end float ........................................................................................................................32

4.3.4 Measuring drive shaft radial play .....................................................................................................................33

4.4 Hydraulic Head, Cam Screw and Head Locating Fittings ..........................................................................................33

4.4.1 Aligning the hydraulic head ..............................................................................................................................33

4.4.2 Cam advance screw ...........................................................................................................................................33

4.4.3 Head locating fittings .........................................................................................................................................34

4.5 Advance Device ......................................................................................................................................................34 - 35

CONTENTS

4.5.1 Fitting the advance device assembly to the pump housing...........................................................................35

4.5.2 Tightening the head fittings and advance end plates .....................................................................................36

4.6 Governor Control Bracket and Arm Assembly..................................................................................................................36

4.6.1 Governor control arm assembly .............................................................................................................................36

4.6.2 Fitting the governor control bracket assembly......................................................................................................37

4.6.3 Scroll link plate return spring ..................................................................................................................................37

4.6.4 Setting the governor link length..............................................................................................................................37

4.7 Governor Cover ..............................................................................................................................................................38

4.7.1 Governor covers fitted with boost control .....................................................................................................38 - 39

4.7.2 Governor cover fitted with torque control only.....................................................................................................39

4.7.3 Assembling the torque trimmer ......................................................................................................................39 - 40

4.7.4 Throttle shaft and governor main spring ..............................................................................................................40

4.7.5 Fitting the governor cover .......................................................................................................................................40

4.8 Governor Cover External Components ..............................................................................................................................41

4.8.1 Throttle levers............................................................................................................................................................41

4.8.2 Throttle lever stop screws, maximum fuel screw and torque control screw.............................................41 - 42

4.8.3 Fuel return connections............................................................................................................................................42

4.9 Drive Hub, Transfer Pump and Endplate Assembly ........................................................................................................42

4.9.1 Drive hub ...................................................................................................................................................................42

4.9.2 Transfer pump rotor .................................................................................................................................................42

4.9.3 Internal recirculation (if fitted) ................................................................................................................................43

4.9.4 Assembling the transfer pump ...............................................................................................................................43

4.9.5 Endplate assembly ...........................................................................................................................................43 - 44

4.10 ESOS and High Pressure Outlets ........................................................................................................................................44

4.10.1 ESOS ..................................................................................................................................................................44 - 45

4.10.2 High pressure outlets and clamp plate ..................................................................................................................45

4.11 Drive Shaft Lock Bolt, Drain Plug and Cam Advance Screw ...........................................................................................45

4.11.1 Drive shaft lock bolt .................................................................................................................................................45

4.11.2 Drain plug ..................................................................................................................................................................46

4.11.3 Cam advance reading screw ...................................................................................................................................46

4.12 Leak Testing ...........................................................................................................................................................................46

5 TEST PROCEDURE

5.1 Pump Specification........................................................................................................................................................47

5.1.1 Rotation ...............................................................................................................................................................47

5.1.2 Gov. link length...................................................................................................................................................47

5.1.3 Plunger diameter ................................................................................................................................................47

5.1.4 Drive type ............................................................................................................................................................47

5.1.5 Pump features .....................................................................................................................................................47

5.1.6 OEM code ............................................................................................................................................................47

5.2 Test Conditions...............................................................................................................................................................48

5.2.1 Test fluid ..............................................................................................................................................................48

5.2.2 Inlet feed pressure ..............................................................................................................................................48

5.2.3 Nozzles.................................................................................................................................................................48

5.2.4 Nozzle opening pressure ...................................................................................................................................48

5.2.5 Nozzle holder ......................................................................................................................................................48

5.2.6 H.P. pipes .............................................................................................................................................................48

5.3 Pre-Test Notes ................................................................................................................................................................49

5.3.1 Introduction .........................................................................................................................................................49

5.3.2 Leak testing .........................................................................................................................................................49

CONTENTS

5.3.3 Test machine drive .............................................................................................................................................49

5.3.4 Pre set notes ................................................................................................................................................49 - 50

5.4 Test Procedure................................................................................................................................................................50

5.4.1 Introduction .........................................................................................................................................................50

5.4.2 Warm-up and stabilisation.................................................................................................................................50

5.4.3 Initial settings .....................................................................................................................................................51

5.4.4 Transfer pressure ........................................................................................................................................51 - 52

5.4.5 Cambox pressure ...............................................................................................................................................52

5.4.6 Speed advance ............................................................................................................................................53 - 54

5.4.7 Cold advance ..............................................................................................................................................54 - 55

5.4.8 Light load advance ......................................................................................................................................55 - 56

5.4.9 Maximum fuel .....................................................................................................................................................56

5.4.10 Torque trimmer ...........................................................................................................................................57 - 58

5.4.11 Boost control .......................................................................................................................................................59

5.4.12 Latch Valve ..........................................................................................................................................................60

5.4.13 Maximum fuel adjustment ................................................................................................................................61

5.4.14 Torque screw ...............................................................................................................................................61 - 62

5.4.15 Governor ......................................................................................................................................................62 - 63

5.4.16 Light Load Valve .................................................................................................................................................63

5.4.17 Idle setting ...........................................................................................................................................................64

5.4.18 ESOS ....................................................................................................................................................................65

5.4.19 Timing..................................................................................................................................................................65

5.5 Overcheck Procedure ....................................................................................................................................................66

5.5.1 Introduction .........................................................................................................................................................66

5.5.2 Pump preparation ...............................................................................................................................................66

5.5.3 Test machine drive .............................................................................................................................................66

5.5.4 Overcheck pre-set notes .............................................................................................................................66 - 67

5.5.5 Overcheck test procedure ..................................................................................................................................67

6 TOOLING, TORQUES & EVD’s

6.1 Tooling..........................................................................................................................................................69 - 70

6.2 Torque values......................................................................................................................................................71

6.3 EVD ..............................................................................................................................................................72 - 76

INTRODUCTION

1 - 7

1.1 THE PUMP

The DP210 distributor-type fuel injection pump is a compact, self-contained unit that is suitable for direct injection engines of up to 33 BHP per cylinder and with three, four or six cylinders with either clockwise or anticlockwise gear drives. It is primarily intended for diesel engines which have to meet the Tier 2 off-highway exhaust emissions legislation for the industrial and agricultural markets in Europe and USA.

All internal working parts are lubricated by fuel oil and the pump housing is maintained at an internal pressure that prevents the ingress of external dirt or other foreign matter.

Standard features include improved shaft locked orientation timing, servo controlled light load advance and speed advance with solenoid switched cold advance, torque trimmer control of maximum fuel delivery including excess fuel for starting, transfer pressure curve slope adjustment with viscosity compensation.

It can also be fitted with a range of options to suit particular customer and engine rating requirements, including boost-pressure control for

turbocharged engines, high strength camrings, quick fit low pressure connections and throttle levers with combined break-back and throttle return spring features.

Due to the complexity of this product, the need for highly trained personnel, and a high level of investment in equipment and workshop resources, together with the need for up-to-date Technical Information, it can only be tested or serviced by a Delphi authorised distributor.

It has been developed from the well-known range of DPA, DPS and DP200 injection pumps and is the result of the Delphi policy of continued improvement of products to meet the demands of new legislation and operational requirements.

1.2 GENERAL

Fuel pumps may require off-engine workshop attention for two main reasons:

(a) Investigation of a specific fault in engine

performance, which may only require partial dismantling.

(b) A complete overhaul e.g. at the same time as a

major engine overhaul.

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INTRODUCTION

1 - 8

A full performance test is recommended, both before and after any level of attention, as many aspects of pump performance are interrelated.

1.3 THIS MANUAL

The Dismantling, Reassembly and Testing Sections are laid out on a “step-by-step” basis, with each action accompanied by an illustration showing the component(s) involved and where applicable, its/their positions on the pump. The Manual is not based on any one specification, but covers pump features which have been included up to the time of publication. For the purposes of illustration, more than one pump specification has been used.

The pumps illustrated are for clockwise rotation (when viewed from the drive end). Any component used for anticlockwise pumps that is different, is individually described.

1.4 EQUIPMENT

Any tools, both standard and special-purpose, used for the servicing or repair of fuel injection equipment (FIE) must be reserved solely for use on FIE. Worn or damaged tools can cause damage to critical components, as well as being a safety hazard.

The working area must be scrupulously clean and should be in a room separated from any other activity; the ingress of dust and dirt, airborne or otherwise, must be prevented.

The minimum facilities required are:

1. A bench covered in non-rusting metal or industrialgrade linoleum and fitted with an engineer’s vice with a jaw size of 100 mm (4 in). The vice jaws must be faced with either soft metal or fibre pads.

2. An adjustable pump-mounting device such as the “Hydraclamp”, fitted with an appropriate adaptor plate.

3. Easily cleaned compartmented trays for separate storage of dismantled pumps are available from Delphi Aftermarket Operations, Service Operations Department.

4. All the necessary tools are listed in Section 6 of this manual.

5. A low-pressure washing facility using a suitable, approved, cleaning fluid (not water or water-based) to clean pumps externally prior to dismantling. Cleaning must be carried out in a place separated from the “clean area”.

6. A tank large enough to accommodate a complete pump and filled with clean test oil, near to a source of clean, dry, variable pressure compressed air for carrying out leakage tests.

7. Supplies of clean, lint-free (non-fluffy) cloths for cleaning and drying components. Cotton waste must never be used.

8. A pump test machine that conforms to ISO 4008.

9. Adequate storage facilities for pumps, tools and test equipment, with separate areas for pumps before and after repair.

Note: All cleaning tanks, workshop and test facilities

and fluids must conform to any Fire Prevention or Health and Safety Regulations in force at the time of use.

1.5 REPLACEMENT OF PARTS

All gaskets and seals must be replaced during reassembly. However, in the event of partial dismantling, only those seals that have been disturbed need replacement, unless leaks from elsewhere are detected during testing prior to dismantling.

If any part of a “mated” assembly is worn or damaged, the whole assembly must be replaced. Any component showing signs of corrosion or water ingress, cracks or distortion must be replaced.

Only service parts supplied by Delphi Aftermarket Operations may be used as replacements. Parts supplied from alternative sources may appear to be externally similar and may carry the same part numbers as the genuine item but may be inferior in material specification or finish and lead to malfunction or premature failure.

1.6 PUMP NAME PLATE

The number stamped on the type-plate attached to the pump housing identifies the type and model of the pump. Pumps with identical build but with different settings, dependent upon engine application, are further identified by the setting code stamped beneath the serial number.

A typical Despatch Number could be as shown in Fig.

Note 1: The pumps shown in the illustrations do not

necessarily represent any one specification, but are used to show particular features.

Note 2: As components are removed, inspect them and

put those considered unfit for further service to one side for replacement; place those which are fit for further service into a clean compartmented tray. (Trays available through Delphi Diesel Systems Aftermarket Operations, Service Operations Department.) A guide to areas of possible wear or damage appears in Section 3 (Component Inspection & Renewal).

INTRODUCTION

1 - 9

C9320A000L

If the name plate has been painted over, special care is needed when removing the paint to avoid erasure of the information. Use a small quantity of proprietary paint-stripper, carefully observing the manufacturer’s instructions.

Marketing Code: C = Spain No letter = UK

Product Type (DP210)

Suffix letter -

Denotes the type of ESOS fitted.

See SIN DT294

Change to the individual specification affecting parts interchangeability, but not fit or function of pump.

Individual features number.

Design change letter -

Has no significance at the time of publication of this manual

No. of delivery outlets: 0, 3 & 5 = 4 cyl. 1 & 4 = 6 cyl. 2 = 3 cyl. 6 - 9 to be allocated

Design Source: 0 = USA 1 = Korea

2 & 3 = UK 4 = France 5 = Spain 6 = Brazil 7 = India 8 = Poland 9 = Japan

Fig. 1 Explanation of Despatch Number

INTRODUCTION

1 - 10

DISMANTLING

2 - 11

2.1 PREPRATION

A list of all tools required to dismantle the pump is given in Section 6.

2.1.1 Cleaning and draining

Externally clean the pump. Remove the drain plug (1) and drain any fuel oil remaining in the housing.

If the pump is suspected to be faulty, or is subject to a warranty assessment, a preliminary test on the test machine may be required. In this case, externally clean the pump as above but drain the fuel oil into a clean container for possible subsequent analysis.

If the pump has not seized and it is to be tested prior to dismantling, examination will first be necessary to determine if dirt or water ingress has occurred, so as to avoid contamination of the test fuel and possible damage to the test equipment.

If it is not possible to see through the drain plug hole, remove the spring end cover plate of the advance device (see Section 2.11) and closely examine the components for signs of corrosion or metal particles.

Note: Do NOT remove the advance device as removal

of the HLF will destroy the knife edge sealing of the plug.

If there is no contamination, refit the end cover plate, using a new O-ring. Tighten the two screws to the respective torque and proceed with the test.

2.1.2 Mounting the pump

Mount the pump on a Hydraclamp using a mounting plate (1) with a suitable adaptor ring.

Align the pump with its axis horizontal and the governor cover uppermost.

2.1.3 Sealing caps and drive shaft lock bolt

Remove any shrink sleeving or tamperproof caps from adjustment screws. Remove the drive shaft lock screw and washer (1) and discard the O-ring. Remove the plug that enables accsess to the cam ring for the advance readings (not shown).

3433

3449

3450

DISMANTLING

2 - 12

2.1.4 Drive hub (if fitted)

Restrain the drive hub with the special tool. Slacken the drive hub nut and spring washer just sufficiently to allow release of the hub.

Use a suitable extractor to release the hub from the drive shaft taper. Remove the woodruff key (if fitted).

2.1.5 Measuring drive shaft end float

Note: To assess the condition of components subjected

to end-thrust, end-float must be measured prior to dismantling. The pump and gauge must be clamped to an assembly plate mounted in a vice or on a Hydraclamp.

Fit the appropriate adaptor (3) to the drive shaft thread. Screw in the dial gauge holder (1), and fit the gauge (2). Adjust the gauge pin to contact the thrust washer (4). Push the drive shaft inwards and set the dial gauge to zero. Pull the drive shaft outwards and note the maximum gauge reading, ensuring the thrust washer (4) remains against the pump housing.

End-float should be 0.05mm to 0.2mm. If the maximum is exceeded, examine the housing thrustfaces during dismantling. If no significant wear or damage is apparent, requiring replacement of the pump housing, correct the end-float by the use of alternative shims during reassembly.

2.1.6 Measuring drive shaft radial play

Note: In order to assess the condition of the bearing and

drive shaft, radial play must be measured prior to dismantling.

With the pump and gauge (1) mounted rigidly relative to each other, adjust the gauge pin to bear (at right angles) against the parallel section (2) of the drive shaft.

Note that this section is very short, therefore a fine tip

will be required on the gauge pin. Push the shaft radially towards the gauge and set the gauge to zero.

Pull the shaft radially to the opposite extreme and record the gauge movement. Repeat the readings with the gauge repositioned as shown at (3) and (4). Do not rotate the drive shaft. Reject the housing if the maximum play is 0.27mm or the difference between the measurements exceeds 0.2mm.

1863

A1005

DISMANTLING

2 - 13

2.2 DRIVE SHAFT

Remove the circlip (2) and thrust washer (1).

2.3 HIGH PRESSURE OUTLETS AND END PLATE ASSEMBLY

2.3.1 High pressure outlets

Turn the pump vertical so that the endplate is uppermost.

Remove all the nuts (1) securing the clamping plate (2) to the outlet connections, and remove the plate.

If fitted, remove the four support plate screws and the pump-to-engine support bracket (not shown).

The outlets contain delivery valves that must be retained in their matched seat / valve pairs.

Unscrew and remove each high pressure outlet (1), using a long-reach socket, and then remove the delivery valves (2), delivery valve springs and pegs.

Delivery valve holders must

be discarded.

Remove and discard the seating washer from the bottom of each outlet bore.

2.3.2 Endplate assembly

2.3.2.1 Removing the endplate assembly

Slacken, but do not remove, the fuel inlet connection (1). Slacken and remove the four endplate screws (2) and remove the endplate assembly (3) complete.

1865

4000

4001

4002

2138

DISMANTLING

2 - 14

2.3.2.2 Internal components

Remove the fuel inlet connection (1) and discard the O-ring (2). Tip out the filter (3) together with the end plate sleeve assembly and remove the piston retainer (12), the piston (10) and the regulating springs with spring peg (8). From the opposite end of the regulating sleeve unscrew the double adjuster (4) using a 4.5mm hex key. Remove the O-ring (5) and discard. With a 2mm hex key remove, clockwise, the inner adjuster (6), remove the O-ring (7) and discard. From the regulating sleeve remove and discard the O-ring (11).

Note: The piston, sleeve and adjusters are matched and are not interchangeable.

Remove the sandwich plate (13).

Note: If damaged carefully remove the sandwich plate locating pin (14) from the end plate using a pair of long nose pliers. Note the particular hole in the endplate to which it is fitted. Incorrect fitting when reassembling will affect transfer pump operation.

2.4 ELECTRIC SHUT-OFF SOLENOID (ESOS)

Remove any detachable electrical connections, nut and washer, depending upon the type of ESOS fitted; slacken and remove the ESOS body. Remove and discard the O-ring.

2.5 TRANSFER PUMP

Note: Make a note of the orientation of the transfer pump

liner (2) before dismantling, particularly the position of the recess (1) in one face, to aid correct reassembly.

Remove the transfer pump sealing ring (3). Carefully lift out the liner together with the two pairs of transfer pump blades (4) and their separating springs (5).

CAUTION: The springs are very small and could be easily

mislaid.

Note: Care must be taken to avoid damage to the blade

faces during storage or assembly.

If internal recirculation is fitted, remove the spring and poppet valve assembly (1) which is retained within the barrel by the liner.

1889

E2322

5 6

10 11 12

1314

E2322

E251

DISMANTLING

2 - 15

2.6 GOVERNOR COVER EXTERNAL COMPONENTS

2.6.1 Fuel return connections

Note: Fuel return arrangements will vary, dependent

upon the pump specification.

Align the pump with its axis horizontal and the governor cover uppermost.

Unscrew the tube nut (1), the banjo bolt (2) and remove the drain pipe (3). Discard the two sealing washers from the banjo bolt.

If any backleak connections are fitted unscrew and remove them. Discard any washers.

2.6.2 Throttle lever stop screws, maximum fuel adjuster blanking plug and torque control screw

Loosen the lock nuts on the idling stop screw (1), and torque screw (3), and remove the screws and washers. Using a pair of “molegrips” grip and undo the conical tamperproof nut of the maximum speed screw (2). Remove and discard the nut and screw. Discard any rubber sealing washers.

Using the special tool, slacken and remove the blanking plug (1) on the side of the governor cover. Discard any sealing washer.

3456

1901

2165

DISMANTLING

2 - 16

2.6.3 Throttle lever

2.6.3.1 Rigid type

Remove and discard the self-locking nut (1); remove washer (2), upper spring retainer (3), spring (4), spring retainer (6), spacer (5), throttle lever (7), and dust cap (8).

2.6.3.2 Break-back type

Remove and discard the self-locking nut (11); remove washer (10), upper spring retainer (9), spring (8), spacer (7), lower spring retainer (6) and washer (1). Remove break-back lever (2) and throttle lever (4) together with spring (3). Remove dust cover (5).

2.7 GOVERNOR COVER

2.7.1 Governor cover with Torque Control only

Remove the pressure end plug circlip (1).

2.7.1.1 Spring end components

Note: It may be necessary to re-position the pump on the Hydraclamp mounting plate to gain access to the preload plug.

Unscrew and remove the plug (1) and discard the O-ring.

E2631

1907

1916

1 2 3

4912

DISMANTLING

2 - 17

Remove the large spring (4), the spring plate (5) (if fitted), and the small spring (6) (if fitted).

Remove shim(s) (2) from inside preload plug (1); remove and discard the O-ring (3).

2.7.1.2 The pivot plug

If no boost control is fitted, the cam follower will be pivoted on a spindle, which is formed as part of a pivot plug (1) screwed into the governor control cover. If the pivot plug is to be removed, slacken it by no more than one turn before removal of the governor control cover (to avoid the risk of damage to internal components).

2.7.2 Governor cover fitted with Boost Control

Note the position of the air inlet connection (3) on the boost control cover.

2.7.2.1 Boost control cover and diaphragm

Slacken and remove the cover fixing screws (2).

Caution: The cover (1) will be lifted up under the action of the diaphragm return spring as the screws are loosened.

Remove the cover and the diaphragm assembly (1).

If fitted, remove the shim from within the “cup” in the lower face of the diaphragm assembly.

Note 1: Do not dismantle the diaphragm assembly as this is a factory-assembled item. If any part of it is worn or damaged, the whole assembly must be replaced.

E2711

2123

1922

E2712

1 2 3 4 5 6

DISMANTLING

2 - 18

Note 2: The spring, spring seat and spindle (3), cannot be lifted out at this stage, as they are retained by the cam follower and a circlip within the governor cover.

Push the throttle shaft (2) down into the cover. Remove the Torx screws (1) securing the governor cover.

2.7.2.2 Removing the governor cover

Lift and rotate the cover off towards the torque trimmer side, and push the throttle shaft (2) out of its bore. Remove and discard the “trapped” Oring (1) from the sealing face of the cover.

Remove the O-ring from the transfer port and discard.

Note: If the control cover is lifted too far, the carriage angle plate may become distorted; if resistance is felt, lower it and move it further away, then lift it again.

2.7.2.3 Removing the piston and the pressure end plug

Tip out the torque trimmer cam (1); remove and discard circlip (2) (if fitted). Tip out piston (3). Use a suitable piece of soft metal or plastic rod to push the plug (5) out of the cover; remove and discard the O-ring (4).

2.7.2.4 Removing the cam follower and its pivot

Remove the small circlip (3) and the cam follower (1) from the spindle (2). The washer behind the cam follower (not visible) may be difficult to extract and can be left until the spindle is removed.

2122

E2723

1924

1 2

4 5

2115

DISMANTLING

2 - 19

If no boost control is fitted to the governor cover remove the small circlip (4) and the cam follower (3). Unscrew and remove the pivot plug (1); at which point the washer (not visible) can be removed from the spindle. Remove and discard the O-ring (2).

2.7.2.5 Boost housing

Remove the spindle (1), spring seat washer (2), spring (3) and shim (4). Remove the stroke adjuster (6) from the body (7) and discard the Oring (5). Using the special tool slacken and remove the stroke adjustment screw body (7), the shim (8) and the housing (9). Remove the dowel pin (10) if damaged. Remove and discard O-ring (11).

2.8 ALL-SPEED GOVERNOR

Detach the governor main spring (5) from the idling spring peg (3). Remove the peg, idling spring (2) and pivot ball washer (1) from the governor arm (4). Remove the main spring from the throttle shaft link (6).

Remove and discard the O-rings from the throttle shaft (7).

2.9 GOVERNOR CONTROL BRACKET AND ARM ASSEMBLY

2.9.1 Scroll link plate return spring

Push the scroll link plate (3), to compress the spring and expose the end of the spring pin (1); grip the end of the pin, release the scroll link plate and pull the pin away from the spring stop (2). Tip the “shouldered” end of the pin upwards to clear the spring stop and carefully release and remove the pin and spring.

Warning

Cover the pin and spring with a non-fluffy cloth in case it is released prematurely, allowing it to be ejected at speed.

1937

2104

E2725

2115

A1473

10 11

DISMANTLING

2 - 20

2.9.2 Governor control bracket assembly

Straighten the “ears” of the two tab washers (3) and (5). Slacken and remove the control plate screws (2) and (6) and discard tab washers.

Note: Screws are of a different length and head shape

so a note must be made of their respective positions.

Lift out the bracket and anchor plate (7) together with the control arm assembly (4) and the metering valve (1), from the pump housing.

2.9.3 Governor control arm assembly

Unscrew and remove the linkage lock nut (7) and adjusting nut (6). Remove the pivot ball washer (5). Withdraw the linkage hook with the washer and spring (3) from the governor control arm (4); remove the spring retainer (2), and metering valve assembly (1) from the linkage hook.

2.10 SLACKENING THE TRANSFER PUMP ROTOR

Temporarily refit a drive hub and key to the shaft and push the hub fully onto the shaft taper; hold the hub with the special tool (2). Hold the transfer pump rotor with the special tool (1). Slacken but do not remove the TP rotor; the direction in which it is to be slackened can be determined by examination of the end face of the TP rotor.

TP rotors marked with an arrow indicate a clockwise (left handed thread) direction in which to turn the rotor to remove it.

Remove the tools; drive hub and key, leaving the TP rotor just finger-tight.

2.11 ADVANCE DEVICE

Align the pump vertically with the transfer pump uppermost.

Slacken but do not remove the cold start solenoid (1) and the four end plate bolts (2) and (5).

Slacken and remove the cap nut (3). Slacken and undo the head locating fitting (4) no more than two turns.

Push the advance assembly back onto the pump housing enabling the head locating fitting to be released and it to be fully removed. Remove the Orings and discard, noting their relevant positions.

1949

1954

1943

1948

1 2 3 4 5 6

DISMANTLING

2 - 21

Remove the HLF plug (2) in the end by inserting a suitable bar (1) in to the centre of the sleeve to allow it to be gripped, without collapsing, with a pair of side cutters to assist its removal. The sleeve will collapse if no bar is inserted.

Note: DO NOT push the sleeve any further in to the head

locating fitting otherwise it will be unable to be removed and a new head locating fitting will have to be used.

Remove the advance device. Remove and discard the advance housing gasket and the cap nut washer. Remove the solenoid and discard the O-ring.

Remove the two screws and plate from the spring end (1), opposite end to the cold start solenoid.

Remove the control spring and shim, remove and discard the O-ring.

From the pressure end remove the two screws and plate. Remove and discard the O-ring.

Slide out the advance piston and servo valve assembly.

Remove the servo valve assembly from the advance piston. Using suitable spanners grip and remove the light load screw (1) from the light load piston (2).

Lightly grip in a rubber jawed vice whilst pushing down on the light load piston (2), compress the spring (3) sufficiently to expose the retaining E-clip (1). Remove the E-clip from the servo shaft (6), gently release the spring pressure, lift off the light load piston with the spring and bottom spring plate (4). Only remove the bottom E-clip (5) if damaged.

1961

1968

1971

1 2

E46

DISMANTLING

2 - 22

2.11.1 Cam screw

Using a suitable socket and wrench, slacken but do not remove the cam screw.

If the cam ring has become stuck, remove the wrench and socket from the cam advance screw and tap the screw sideways with a soft-faced mallet until the cam has been released. Remove the cam screw from the cam ring.

2.12 HEAD LOCATING FITTINGS AND HYDRAULIC HEAD

2.12.1 Head locking screws

Align the pump horizontally with the top of the pump uppermost.

Note: Before removing the head locating fittings make

a note of their relative positions.

Slacken and remove the two head locking screws (1) and (2); remove and discard the O-rings and the filters (if fitted) in the inner ends of the screws.

2.12.2 Light Load Advance (LLA)

Remove the tamper resistant plug (5) from the valve body (2). Unscrew and remove the adjusting screw and tapered valve pin (4) from the body. Remove and discard the O-ring (3).

Note: It is advisable to retain the filter (1) within the

body of the valve and to clean and clear any foreign matter with the use of dry compressed air. The process of removing the filter will damage the valve body and will require a new LLA valve to be fitted.

2.12.3 Latch valve

Remove the tamper resistant plug (1). Unscrew and remove the adjuster (3) from the body (6) and tip out the spring (4) and piston (5). Remove and discard the O-rings (7) and (8).

E2123

1972

1979

E2121

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