Delphi DP200 User Manual

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WORKSHOP MANUAL

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DP200 SERIES FUEL INJECTION PUMP

2008

DDNX121A(EN)DDNX121A(EN

(

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 inyectores, 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 provenant 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, specialmente 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 vloeistofstralen 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.

(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.

INTRODUCTION I

DISMANTLING II

COMPONENT INSPECTION AND RENEWAL III

REASSEMBLY IV

TEST PROCEDURE V

DDNX121A(EN) - Issue 1 of 08/2008

TABLE OF CONTENTS

TOOLING, TORQUES & EVDS VI

APPENDIX VII

Produced and published by:

Delphi Diesel Systems Ltd. Spartan Close Warwick CV34 6AG Tel: +44 (0) 1926 472 900 England Fax: +44 (0) 1926 472 901

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INTRODUCTION I

TABLE OF CONTENTS

INTRODUCTION

1.1 The Pump.......................................................................................................................................................................1-1

1.2 General...........................................................................................................................................................................1-1

1.3 This Manual...................................................................................................................................................................1-2

1.4 Equipment......................................................................................................................................................................1-2

1.5 Replacement Of Parts...................................................................................................................................................1-2

1.6 Pump Name Plate..........................................................................................................................................................1-3

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II DISMANTLING

TABLE OF CONTENTS

DISMANTLING

2.1 Preparation....................................................................................................................................................................2-5

2.1.1 Cleaning and draining..................................................................................................................................2-5

2.1.2 Mounting the pump.....................................................................................................................................2-5

2.1.3 Removing sealing caps and locking wire...................................................................................................2-5

2.1.4 Removing the drive hub (if fitted)...............................................................................................................2-6

2.1.5 Measuring drive shaft end float..................................................................................................................2-6

2.1.6 Measuring drive shaft radial play...............................................................................................................2-7

2.2 Governor Cover, Control Levers & Link Assembly.....................................................................................................2-7

2.2.1 Removing the fuel return connections.......................................................................................................2-7

2.2.2 Removing the throttle lever stop screws, maximum fuel screw, and torque control screw.................2-8

2.2.3 Removing the throttle lever.........................................................................................................................2-8

2.2.4 Removing the exhaust brake lever.............................................................................................................2-9

2.2.5 Removing the electronic actuator throttle lever (rigid type)....................................................................2-9

2.2.6 Removing the governor cover assembly.................................................................................................2-10

2.3 Dismantling The All-Speed Govenor.........................................................................................................................2-16

2.4 Removing The Control Bracket And Arm Assembly................................................................................................2-17

2.4.1 Removing the scroll link plate return spring............................................................................................2-17

2.4.2 Removing the governor control bracket assembly.................................................................................2-17

2.4.3 Dismantling the governor control arm assembly....................................................................................2-18

2.4.4 Dismantling the governor control plate assembly for torque trimmer variant....................................2-18

2.5 High Pressure Outlets Assembly, Electric Shut-off Solenoid (ESOS) & Transfer Pump.......................................2-19

2.5.1 High pressure outlets.................................................................................................................................2-19

2.5.2 Endplate assembly.....................................................................................................................................2-19

2.6 Electric Shut-off Solenoid (ESOS)..............................................................................................................................2-21

2.7 Transfer Pump.............................................................................................................................................................2-21

2.7.1 Removing the transfer pump components..............................................................................................2-21

2.7.2 Slackening the transfer pump rotor..........................................................................................................2-21

2.8 Advance Device...........................................................................................................................................................2-22

2.8.1 Single piston design with 2 bolt cold advance (CA)................................................................................2-22

2.8.2 Servo piston design with 2 bolt Cold Advance........................................................................................2-23

2.8.3 Servo piston design with 4 bolt cold advance.........................................................................................2-26

2.8.4 Single piston design without cold advance.............................................................................................2-27

2.9 Removing The Head Locking Screws And Releasing The Hydraulic Head............................................................2-28

2.9.1 Head locking screws..................................................................................................................................2-28

2.9.2 Removing and dismantling the LLA.........................................................................................................2-28

2.9.3 Removing and dismantling the latch valve..............................................................................................2-29

2.9.4 Removing the hydraulic head...................................................................................................................2-29

2.10 Drive Shaft...................................................................................................................................................................2-30

2.10.1 Dismantling the Zero Backlash Drive assembly......................................................................................2-30

2.10.2 Dismantling the splined drive assembly..................................................................................................2-32

2.11 Dismantling The Hydraulic Head - Check And Cheek Plate Designs......................................................................2-33

2.11.1 Releasing the drive plate screws..............................................................................................................2-33

2.11.2 Dismantling the rotor components...........................................................................................................2-33

2.11.3 Removing the lower check or cheek plate...............................................................................................2-33

2.11.4 Reverse thrust weight assembly...............................................................................................................2-34

2.11.5 Lock-shaft timing........................................................................................................................................2-34

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DISMANTLING II

TABLE OF CONTENTS

2.11.6 Removing the drive shaft seal/s................................................................................................................2-35

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III COMPONENT INSPECTION AND RENEWAL

TABLE OF CONTENTS

COMPONENT INSPECTION AND RENEWAL

3.1 Cleaning.......................................................................................................................................................................3-37

3.2 GeneraL........................................................................................................................................................................3-37

3.2.1 Mated and matched assemblies...............................................................................................................3-37

3.2.2 Examination and replacement..................................................................................................................3-37

3.2.3 Seals............................................................................................................................................................3-38

3.3 Details...........................................................................................................................................................................3-38

3.3.1 Hydraulic head rotor..................................................................................................................................3-38

3.3.2 Hydraulic head plungers............................................................................................................................3-38

3.3.3 Cam ring and scroll plates.........................................................................................................................3-38

3.3.4 Rollers and shoes.......................................................................................................................................3-38

3.3.5 Transfer pump............................................................................................................................................3-38

3.3.6 Endplate......................................................................................................................................................3-39

3.3.7 Control valves.............................................................................................................................................3-39

3.3.8 Delivery valves and cambox pressurising valves....................................................................................3-39

3.3.9 High pressure outlet pressurising valves.................................................................................................3-39

3.3.10 Springs........................................................................................................................................................3-39

3.3.11 Fittings and threads...................................................................................................................................3-39

3.3.12 Linkages......................................................................................................................................................3-39

3.3.13 Control shafts.............................................................................................................................................3-39

3.3.14 Drive shafts and associated components................................................................................................3-39

3.3.15 Advance device..........................................................................................................................................3-40

3.3.16 Levers and external controls.....................................................................................................................3-40

3.3.17 Pump housing............................................................................................................................................3-40

3.3.18 Governor control cover..............................................................................................................................3-40

3.3.19 Orifices........................................................................................................................................................3-40

3.3.20 Electric shut-off solenoid...........................................................................................................................3-40

3.3.21 Wax motor..................................................................................................................................................3-40

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REASSEMBLY IV

TABLE OF CONTENTS

REASSEMBLY

4.1 Preparation..................................................................................................................................................................4-43

4.2 Assembling The Hydraulic Head................................................................................................................................4-43

4.2.1 Rotor plug...................................................................................................................................................4-43

4.2.2 Drive plate, rollers, shoes and retaining plates.......................................................................................4-44

4.3 Drive Shaft...................................................................................................................................................................4-47

4.3.1 Zero backlash and splined drive with cheek plates.................................................................................4-47

4.3.2 Spline drive with check plate head and rotor..........................................................................................4-50

4.4 Securing The Hydraulic Head And Checking Drive Shaft End Float And Radial Play...........................................4-51

4.4.1 Replacing the drive shaft seal/s................................................................................................................4-51

4.4.2 Securing the drive shaft.............................................................................................................................4-52

4.4.3 Aligning the hydraulic head......................................................................................................................4-52

4.4.4 Checking drive shaft end float...................................................................................................................4-52

4.4.5 Checking drive shaft radial play................................................................................................................4-53

4.4.6 Cam advance screw...................................................................................................................................4-53

4.4.7 Fitting the head locking screws, light load advance valve and latch valves.........................................4-54

4.5 Advance Device...........................................................................................................................................................4-55

4.5.1 Single piston design..................................................................................................................................4-56

4.5.2 Servo piston designs.................................................................................................................................4-58

4.5.3 2 Bolt Cold Advance fitted to single piston design.................................................................................4-62

4.5.4 4 Bolt Cold Advance fitted to servo piston design..................................................................................4-64

4.6 Transfer Pump And Endplate Assembly...................................................................................................................4-64

4.6.1 Transfer pump............................................................................................................................................4-64

4.6.2 Endplate assembly.....................................................................................................................................4-65

4.7 ESOS And High Pressure Outlets..............................................................................................................................4-68

4.7.1 ESOS or blanking plug...............................................................................................................................4-68

4.7.2 High pressure outlets and clamp plate.....................................................................................................4-68

4.8 Governor Linkage, Control Bracket And Cover.........................................................................................................4-69

4.8.1 Governor linkage........................................................................................................................................4-69

4.8.2 Fitting the governor assembly to the pump............................................................................................4-70

4.8.3 Fitting the scroll link plate return spring..................................................................................................4-70

4.8.4 Setting the governor link length...............................................................................................................4-71

4.8.5 Fitting the governor assembly for torque trimmer variant.....................................................................4-71

4.9 Assembling The Governor Cover..............................................................................................................................4-74

4.9.1 Governor cover only..................................................................................................................................4-74

4.9.2 Governor cover fitted with hydraulic excess fuel....................................................................................4-75

4.9.3 Governor cover fitted with boost control only........................................................................................4-77

4.9.4 Governor covers fitted with torque control and torque control plus boost control.............................4-81

4.9.5 Governor covers fitted with electronic actuator......................................................................................4-86

4.10 Governor Cover External Components.....................................................................................................................4-89

4.10.1 Fitting backleak connections.....................................................................................................................4-89

4.10.2 Fitting and aligning external levers..........................................................................................................4-89

4.10.3 Control stop screws and plugs..................................................................................................................4-90

4.11 Shaft Locking Screw Cover And Cam Ring Access Plug.........................................................................................4-92

4.11.1 Shaft locking screw....................................................................................................................................4-92

4.11.2 Drain plug...................................................................................................................................................4-92

4.11.3 Cover...........................................................................................................................................................4-92

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TABLE OF CONTENTS

4.11.4 Cam ring access plug.................................................................................................................................4-92

4.12 Drive Hub.....................................................................................................................................................................4-93

4.13 Leak Testing.................................................................................................................................................................4-93

4.14 Storage.........................................................................................................................................................................4-93

4.14.1 New pumps.................................................................................................................................................4-93

4.14.2 Overhauled pumps.....................................................................................................................................4-93

4.14.3 Storage conditions.....................................................................................................................................4-93

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TEST PROCEDURE V

TABLE OF CONTENTS

TEST PROCEDURE

5.1 Preparation..................................................................................................................................................................5-95

5.1.1 Leak testing.................................................................................................................................................5-95

5.1.2 Test machine..............................................................................................................................................5-95

5.1.3 Test machine drive.....................................................................................................................................5-95

5.1.4 Test conditions...........................................................................................................................................5-96

5.1.5 Connecting fuel lines.................................................................................................................................5-97

5.1.6 Machine test procedure.............................................................................................................................5-97

5.1.7 Transfer pressure measurement and initial setting................................................................................5-98

5.1.8 Cambox pressure measurement...............................................................................................................5-99

5.1.9 Adjustments to be pre-set.........................................................................................................................5-99

5.2 Test Procedure...........................................................................................................................................................5-101

5.2.1 Priming......................................................................................................................................................5-101

5.2.2 Checking and setting transfer pressure..................................................................................................5-102

5.2.3 Cambox pressure and backleakage checks............................................................................................5-103

5.2.4 Speed advance setting.............................................................................................................................5-103

5.2.5 Cold advance............................................................................................................................................5-104

5.2.6 Light-load advance valve setting............................................................................................................5-104

5.2.7 Boost control with torque trimmer.........................................................................................................5-105

5.2.8 Maximum fuel delivery setting...............................................................................................................5-106

5.2.9 Latch valve................................................................................................................................................5-107

5.2.10 Governor setting and testing..................................................................................................................5-107

5.2.11 Torque screw setting...............................................................................................................................5-108

5.2.12 Idle setting................................................................................................................................................5-108

5.2.13 Shut-off control check..............................................................................................................................5-109

5.3 Timing........................................................................................................................................................................5-109

5.3.1 General......................................................................................................................................................5-109

5.3.2 Keyed drive shafts....................................................................................................................................5-110

5.3.3 Keyless drive shafts.................................................................................................................................5-111

5.4 Leakage Testing.........................................................................................................................................................5-114

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VI TOOLING, TORQUES & EVDS

TABLE OF CONTENTS

TOOLING, TORQUES & EVDS

6.1 Tooling.......................................................................................................................................................................6-115

6.2 Torque Values............................................................................................................................................................6-118

6.3 Exploded View Diagram...........................................................................................................................................6-125

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APPENDIX VII

TABLE OF CONTENTS

APPENDIX

7.1 Abbreviations Used In This Manual........................................................................................................................7-137

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VII APPENDIX

TABLE OF CONTENTS

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1.1 The Pump

INTRODUCTION I

INTRODUCTION

DP200 PUMP

The DP200 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 two, three, four or six cylinders. It is primarily intended for the industrial and agricultural markets.

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 automatic air venting, compensation for variations in fuel viscosity. It can be fitted with a range of options to produce performances to match a wide variety of engine requirements, including

boost-pressure control of fuel delivery level for turbocharged engines, and load or speed dependent timing control. 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 Delphi Authorised Distributors.

It has been developed from the well-known range of DPA and DPS 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.

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

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I INTRODUCTION

INTRODUCTION

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); anticlockwise pumps will have items such as the maximum fuel screw, and the boost control fitted on the side opposite to that shown. In addition, the advance device will operate in the opposite mode.

Instructions for both full and partial dismantling of the pump are included e.g. total dismantling and examination of all components other than those that are factory-sealed units and removal of the hydraulic head and rotor only.

All the necessary tools are listed in Section 6. Special tools are identified by part number and standard tools by type and size.

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 components such as Part No. 60620197.

4. All the necessary tools as 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.

1-2

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INTRODUCTION I

INTRODUCTION

Only service parts supplied by Delphi Diesel Systems 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. 1.

C 89 2 0 A 06 0 L

Marketing Code: C = Spain No letter = UK

Suffix letter - Denotes the type of

ESOS fitted. See SIN DT294

Product Type (DP200)

Change to the individual

Design Source: 0 = USA 1 = Korea

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

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

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.

Fig. 1 Explanation of Despatch Number

Note: 1 The pumps shown in the illustrations do not necessarily represent any one specification, but are used to show particular

features.

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

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).

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INTRODUCTION

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DISMANTLING

2.1 Preparation

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

2.1.1 Cleaning and draining

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

If the pump is to have a possible defect rectified, 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 advance device (see Section 2.8) and closely examine the components for signs of corrosion or metal particles. If there is no contamination, refit the advance device, using a new gasket, O-rings on the head locating fitting, and a new sealing washer under the dome nut. Tighten the head locating fitting and the dome nut to their respective torques and proceed with the test.

DISMANTLING II

A980

2.1.2 Mounting the pump

Mount the pump on a Hydraclamp using a Hartridge mounting plate (1) with a suitable adaptor ring (2).

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

2.1.3 Removing sealing caps and locking wire

Remove any shrink sleeving, tamperproof caps or locking wire from adjustment screws.

A950

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II DISMANTLING

2.1.4 Removing the drive hub (if fitted)

Restrain the drive hub (1) with the special tool (2). 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.

2.1.5 Measuring drive shaft end float

DISMANTLING

A986

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 (4) to the drive shaft thread. Screw in the dial gauge holder (3), and fit the gauge (2). Adjust the gauge pin to contact the mounting plate adaptor ring at (1). Push the drive shaft inwards and set the dial gauge to zero. Pull the drive shaft outwards and note the maximum gauge reading.

End-float should be 0.05 mm to 0.2 mm. 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.

A952

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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 (4) 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 (2) and (3). Do not rotate the drive shaft. Reject the housing if the maximum play or the difference between the measurements exceed the figures below.

DISMANTLING II

DISMANTLING

A1005

Drive type Max. play Max. Difference

Belt 0.22 mm 0.1 mm

Gear or hub 0.27 mm 0.2 mm

2.2 Governor Cover, Control Levers & Link Assembly

2.2.1 Removing the fuel return connections

Note:

Fuel return arrangements will vary, dependent upon the pump specification.

Unscrew and remove the connections (1) and (2) fitted to the cover. If there is a bleed screw fitted at position (3), unscrew and remove it. Discard the sealing washers.

If a boost control device is fitted, unscrew the tube nut (6) and remove the drain pipe (7); discard the rubber olive (5) and the two sealing washers (4).

A1261

A953

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II DISMANTLING

DISMANTLING

2.2.2 Removing the throttle lever stop screws, maximum fuel screw, and torque control screw

Loosen the lock nuts on the idling stop screw (1), maximum speed stop screw (2), and torque screw (5), and remove the screws and washers. Discard any rubber sealing washers. Slacken and remove the blanking plug (4) on the side of the governor cover opposite to the maximum fuel stop (or boost control device). Discard any sealing washer.

Note:

For pumps fitted with boost control, maximum fuel adjustment is incorporated within the boost control device (6).

If the pump is not fitted with a boost-control, remove the maximum fuel stop screw (3); discard the rubber sealing washer.

2.2.3 Removing the throttle lever

A) Rigid type

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

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B) Break-back type

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

2.2.4 Removing the exhaust brake lever

DISMANTLING II

DISMANTLING

87654321

A1007

Slacken and remove the screw (1), shakeproof washer (2) and flat washer (3). Lift the lever (4) and release the tension of the spring (5). Remove the lever, spring and dust cover (6).

2.2.5 Removing the electronic actuator throttle lever (rigid type)

Slacken and remove the bolt (558) and washers (559 and (560).

2 3

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2.2.6 Removing the governor cover assembly

A) Governor cover only

Push the exhaust brake shaft (2) and the throttle shaft (3) down into the cover. Remove the four Torx screws at (1), (4), (5), and (6).

Lift off the cover and pull the throttle shaft (3) out of its bore. Remove and discard the "trapped" O-ring (1) from the sealing face of the cover. Remove the exhaust brake shaft (2) and discard its O-ring.

B) Governor covers fitted with hydraulic excess fuel

Using suitable circlip pliers, remove the internal circlip (810) from the governor cover. Lever out the closing plug (811) and remove and discard the O- ring (812).

Note:

At the later stage (depending on which other features are fitted) when removing the governor cover, the hydraulic excess fuel device has to be disengaged.

DISMANTLING

EVD15

Grip the governor cover firmly and hold the excess fuel piston (813) with the thumb so as to disengage the fork in the control bracket from the excess fuel pin (819). Lift the governor sufficiently to release the excess fuel pin from the fork and then release the excess fuel piston.

Remove the hydraulic excess fuel piston. From inside the governor cover, use the excess fuel

piston to push out the excess fuel assembly. Separate the sleeve (814) and discard the O-ring

(815). Remove the external 'e-clip' (816), spring (817) and pin guide (818) from the excess fuel pin (819).

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C) Governors covers fitted with boost control only

a) Removing the cover

Slacken and remove the cover plug (4); remove and discard the plug O-ring.

Note:

Take care when releasing the plug as it will be under pressure from the pre-load spring (if fitted).

DISMANTLING II

Remove the shim(s) from the plug and the preload spring from within the cover (2), if fitted.

Remove the two securing screws (1) and (3) and remove the cover.

Note:

Securing screws (1) and (3) and plug (4) may be of the temper resistant design. To remove these, a special tamper resist Torx bit will be required. See Section 6.

b) Removing the diaphragm

Remove the diaphragm assembly (1); lift out the spring plate (2), control springs (3), shim (4) and fuel control rod (5).

A955

1 5432

A788

c) Removing the fuel adjustment screw

Note:

Other than for removal of the adjusting screw, do not dismantle the diaphragm assembly; if the diaphragm requires replacement, the whole assembly must be replaced.

Hold the nut (2) with a spanner; use an Allen key to remove the fuel adjustment screw (1) from the adjustment screw body. Carefully lever out and discard the O-ring (3) from its recess in the rear of the diaphragm assembly.

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d) Removing the diaphragm stroke adjustment screw.

Unscrew and remove the diaphragm stroke adjustment screw (1) from the screw body (2).

Remove and discard the O-ring from the adjustment screw.

e) Removing the boost control housing

Use the special tool to unscrew and remove the stroke adjustment screw body (1).

DISMANTLING

A568

Note:

As the adjustment screw body is unscrewed, check that the "Eslok" patch on the thread still creates a tight fit in the governor cover thread. If it is not, the body must be discarded.

Remove the shim(s) (2). Detach the housing (3); carefully remove and discard the O-ring (5). Check the spring pin (4) for damage; if necessary, replace it.

f) Removing the cover

Hold the governor control cover as shown; very carefully lift it just enough to expose the locating dowel pin (1) (if fitted).

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DISMANTLING

D) Governor cover fitted with Torque Control and Torque Control plus Boost Control

Remove pressure end plug circlip (1).

DISMANTLING II

A1465

a) Spring end components

If fitted, remove the plastic sealing plug in the preload plug (1) with a pointed tool. Unscrew and remove the plug, using the appropriate size of Allen key, and discard the O-ring (3). Remove the large spring (4), the spring plate (5) (if fitted), and the small spring (6) (if fitted). Remove shim (2) from inside preload plug.

Note: 1 The preload plug fitted to later pumps may be

chamfered at its outer end, to prevent unauthorised tampering.

Note: 2 It may be necessary to re-position the pump on

the Hydraclamp mounting plate to gain access to the preload plug.

b) Removal of the governor control cover

If no boost control is fitted, the cam follower will be pivoted on a spindle, which is formed as a part of a pivot plug screwed into the governor control cover (1). A plastic tamper proof plug will be fitted into the hexagon hole in the plug and must be removed for fitment of the appropriate Allen key. 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).

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c) Removal of the boost control cover and diaphragm

Remove any tamperproof seal(s) from the boost control cover fixing screws (3) and (6), and the

preload spring plug (4). Slacken and remove the plug; discard the O-ring (7). Remove the preload spring (9) and remove the shim (8) from the plug.

Note the position of the air inlet connection (2) on the boost control cover relative to the fuel backleak return connection (1). Slacken and remove the two cover fixing screws and their flat washers.

DISMANTLING

8 9

A1475

WARNING

The cover (5) 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. If any

part of it is worn or damaged, the whole assembly must be replaced.

Note: 2 The spring (2), spring seat (3), and spindle (4),

cannot be lifted out at this stage, as they are retained by the cam follower and a circlip within the governor cover.

d) Removing the governor cover

Push the exhaust brake shaft (2) and the throttle shaft (3) down into the cover. Remove the four Torx screws at (1), (4), (5), and (6).

Lift and rotate the cover off towards the torque trimmer side, and pull the throttle shaft (3) out of its bore. Remove and discard the "trapped" O-ring (7) from the sealing face of the cover. Remove the exhaust brake shaft (2) and discard its O-ring.

A1456

A1477A1476

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.

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DISMANTLING

e) Removing the governor main spring

Slide the cover away (in the direction of the torque trimmer) until the angle plate (1) is no longer in the recess (2). Remove the governor main spring (3) from the throttle shaft link, noting the hole into which it is fitted. Lift off the control cover and discard the trapped O-ring (4). Discard the small transfer gallery O-ring that is in the housing recess below the small hole (5).

DISMANTLING II

f) Removing the piston and the pressure end plug

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

g) Removing the cam follower and its pivot

Remove the small circlip (2) and the cam follower (6) from the spindle (5). Remove the washer (4) (not visible) from the spindle.

If no boost control is fitted to the governor cover and the cam follower is carried on a "pivot plug", remove the small circlip (2) and the cam follower. Unscrew and remove the pivot plug (1); remove and discard the O-ring (3).

A1470

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II DISMANTLING

E) Governor cover fitted with Electronic Actuator

a. Removing the governor cover

Remove the four fixing screws from the governor cover and gently lift the cover away from the housing.

Disengage the governor spring, taking note of the throttle link hole number.

Remove the lever (565) and discard the O-ring (564).

Remove and discard the circlip (569) from the end of the actuator shaft. (Later designs use a 'Nyloc' nut.) Remove the lever (568) and washers (566).

b. Removing the Actuator

To remove the actuator (553) from the control cover it is necessary to use a pair of "mole- grips", as the screws (551) securing the unit are fitted with tamperproof steel balls (552) and tamper-evident washers (550).

Grip the washer (550) and rotate it in an anticlockwise direction; this will loosen the washer and at the same time slacken the screw.

Discard the screw, the ball and the tamperevident washer.

Carefully remove the actuator from the control cover and then remove and discard the O-rings (557).

DISMANTLING

DT237/2 fig 1

2.3 Dismantling The All-Speed Govenor

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

Remove and discard the two O-rings (7) and (8) from the throttle shaft.

Note:

Early pumps had a 3 hole link plate. A note must be made of which hole is used to locate the spring. The appropriate Service Test Plan will confirm the correct hole to use.

10987654321

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2.4 Removing The Control Bracket And Arm Assembly

2.4.1 Removing the scroll link plate return spring

Push the scroll link plate (3), to compress the spring and expose the end (5) of the spring pin; 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 (4).

WARNING

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

DISMANTLING II

Note:

If it is difficult to grip the pin, carefully slacken the spring stop screw (1) and allow the stop to swing away from the pin, again taking care to avoid rapid ejection of the pin.

2.4.2 Removing the governor control bracket assembly

Straighten the "ears" of the two tab washers (2) and (9). Slacken and remove the control plate screws (3), (4), (6), and (8). Lift out the bracket (7), together with the control arm assembly (1) and the metering valve (5), from the pump housing.

Discard the tab washers.

Note:

Screws 3 & 8 are of different lengths.

A950

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DISMANTLING

2.4.3 Dismantling the governor control arm assembly

Unscrew and remove the linkage lock nut (1) and adjusting nut (2). Remove the pivot ball washer (3). Withdraw the linkage hook (9), with the fibre washer (4) and spring (6) from the governor control arm (5); remove the spring retainer (7), and metering valve assembly (8) from the linkage hook.

2.4.4 Dismantling the governor control plate assembly for torque trimmer variant

A961

A) Removing the delivery adjusting screw

To remove the adjustment screw (1) from the scroll link carriage assembly, use either the special adjustment tool or an Allen screw with a suitably sized hexagon socket. Rotate the screw anti- clockwise to disengage it from the scroll link (4). Discard the retaining clip (2).

Lift the screw to disengage the retaining clip from the angle plate (3).

B) Removing the angle plate

To remove the angle plate (1), rotate it anti- clockwise until it can be lifted up between the arms (2) and (3) of the scroll link plate as shown.

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DISMANTLING

2.5 High Pressure Outlets Assembly, Electric Shut-off Solenoid (ESOS) & Transfer Pump

2.5.1 High pressure outlets

Remove all the nuts (1), (2), (4), and (5) securing the clamping plate (3) to the outlet connections, and remove the plate.

If fitted, remove the four support plate screws at position (6) and (8) and the pump-to-engine support bracket (7).

Unscrew and remove each high pressure outlet, using a long-reach socket. Remove and discard the seating washer from the bottom of each outlet bore.

The high pressure outlets may be pressurising valves which are factory-sealed units and cannot be serviced. Alternatively the outlets may contain delivery valves which must be retained in their matched seat / valve pairs.

Remove the delivery valves, delivery valve springs and pegs.

Delivery valve holders

must be discarded.

A962

DISMANTLING II

A985b

2.5.2 Endplate assembly

A) Removing the endplate assembly

If fitted, unscrew and remove the accumulator (7); discard the O-rings (5) and (6).

Slacken, but do not remove, the fuel inlet connection (1). Slacken and remove the four endplate screws (2), and (4) and remove the endplate assembly (3) complete.

EVD017

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II DISMANTLING

B) Dismantling the end plate assembly

a) Viscosity compensating design

Remove the fuel inlet connection (1) and discard the O-ring (2). Tip out the filter (3). Remove and discard the adjuster (4) and the O-ring (on current designs).

Screw the extractor (13) into the regulating sleeve (6) and pull the sleeve out of the end plate.

Remove the piston retainer (10), the piston (8), and the regulating spring (5); remove and discard the O- ring (9) from the groove (7). Tip out the sleeve retaining spring (11) and the spring seat washer (12).

Note:

The piston, sleeve and adjuster are matched and are not interchangeable.

Remove the sandwich plate (14).

DISMANTLING

A1302

A1018A1008

Note:

If damaged carefully remove the sandwich plate locating pin from the end plate using a long nose pair of pliers. Note the particular hole in the endplate too which it is fitted. Incorrect fitting will effect transfer pump operation.

Non-viscosity compensating design

Remove the fuel inlet connection (240) and discard the O-ring (241). Tip out the retaining spring (284), filter (242), adjuster assembly (285), regulating spring and peg (286) and piston (287). Invert the end plate and lightly tap it on a flat surface, taking care not to damage the aluminium face of the end plate and remove the regulating sleeve (245), sealing washer (248) and priming spring (288).

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DISMANTLING

2.6 Electric Shut-off Solenoid (ESOS)

Remove any detachable electrical connection screw(s) or nut (6), washer (7) and connection (5), depending upon the type of ESOS fitted; slacken and remove the ESOS body (1). Remove the armature (or plunger) (4) and spring (3). Remove and discard the O-ring (2).

If no ESOS is fitted, a solid plug will take its place if so, remove the plug and discard its O-ring.

Note:

On later solenoids, the spring is attached to the plunger and is retained within the body.

DISMANTLING II

2 3

JPTA1258 A1284

2.7 Transfer Pump

2.7.1 Removing the transfer pump components

Note:

Make a note of the orientation of the transfer pump liner (2) before dismantling, particularly the position of the recess (4) in one face, to aid correct reassembly.

Remove the transfer pump sealing ring (1). Carefully lift out the liner together with the two pairs of transfer pump blades (3) and their separating springs (not visible).

WARNING

Internal recirculation. If fitted, remove the spring and poppet valve, which are retained within the barrel by the liner.

The springs are very small and could be easily mislaid.

Note:

Care must be taken to avoid damage to the blade rubbing faces during storage or assembly.

A965A964

2.7.2 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 (1). Hold the transfer pump rotor with the special tool (2). Slacken but do not remove the rotor; the direction in which it is to be slackened can be determined by examination of the end face of the rotor.

Rotors marked with an arrow indicate the direction in which to turn the rotor to remove it. Remove the tools; drive hub and key, leaving the rotor just finger-tight.

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DISMANTLING

2.8 Advance Device

DP200 utilises a number of different advance devices. They fall into two main categories; a.

Single piston design.

Direct actuation of the cam-ring by an advance piston operated by transfer pressure and controlled by a combination of spring and cambox pressure.

Servo piston design.

Indirect actuation of the cam-ring by an advance piston via a servo valve operated by transfer pressure and controlled by a combination of spring and cambox pressure.

Each of these two types may be fitted with cold start timing retard with or without a wax motor mechanism.

2.8.1 Single piston design with 2 bolt cold advance (CA)

A) Removing the wax motor

Align the pump to place its axis horizontal with the advance device uppermost. As the CA device may be fitted to the auto advance housing with the wax motor facing in one of two positions, note the direction in which it is fitted.

Slacken and remove any cable retaining nuts and washers.

Slacken and remove the wax motor (4); discard the O-ring (3).

WARNING

Do not attempt to remove the plunger from the body of the wax motor. If the plunger is partially or fully removed from the body, operation of the motor will be severely impaired by the ingress of air into the body of the motor.

The ball valve seat is a press-fit in the CA housing. Do not attempt to remove the ball valve seat, ball, or spring. If there is a problem with the assembly, it must be replaced.

Slacken and remove the two Allen screws (1) and (2).

B) Removing the CA assembly

Remove the CA body (1); discard the O-ring (2). Remove the start-retard spring from the advance

housing, if fitted (not shown).

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DISMANTLING

C) Dismantling of the CA piston assembly

Remove the piston assembly from within the CA housing (1). Grip the piston (2) lightly in a vice fitted with soft jaws. With a suitable screwdriver, slacken and remove the screw (9) and remove the phase plate (8), stop plug (7), stop tube (6), outer spring (5), inner spring (4), and shims (3). Remove the piston from the vice.

WARNING

Caution: The screw will be under considerable tension from the springs.

DISMANTLING II

Note:

Early pumps may be fitted with pistons that have small "flats" to assist with clamping in the jaws of a vice.

2.8.2 Servo piston design with 2 bolt Cold Advance

A) Removal of the wax motor

Slacken and remove any cable retaining nuts and washers.

Slacken and remove the wax motor (4); discard the O-ring (3).

WARNING

Caution: Do not attempt to remove the plunger from the body of the wax motor. If the plunger is partially or fully removed from the body, operation of the motor will be severely impaired by the ingress of air into the body of the motor.

A1485

A1487

The ball valve seat is a press-fit in the CA housing. Do not attempt to remove the ball valve seat, ball, or spring. If there is a problem with the assembly, it must be replaced.

Slacken and remove the Allen screws (1) and (2).

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B) Removing the CA assembly

Remove the CA body (302); discard the O-ring (308).

C) Removing the advance device

Slacken and remove the pressure end cap (325) and O-ring (324).

An auxiliary spring may be fitted. (337) Remove the advance housing cap-nut (417);

remove and discard the sealing washer (416). Slacken the head locating fitting (420), or transfer

pressure damper (if fitted), no more than three turns. Tap the advance housing (323) with a softfaced mallet to free it from the gasket (415). Remove the head locating fitting and then the advance housing, complete with the piston. Discard the gasket (415).

If fitted, carefully remove the spring ring (421) retaining the lock-off ball (422) in the head locating fitting and remove the ball. Discard the spring ring.

Remove and discard the split nylon ring (418), if fitted, and the O-rings (419) from the head locating fitting.

The piston sleeve (310) and piston (326) may still be retained within the housing (302). Remove the piston and one of the O-rings (309), then lightly grip the housing in a vice fitted with soft jaws and with a suitable flat bladed screwdriver lever out the sleeve using the O-ring groove. Discard the remaining O-ring (309).

DISMANTLING

DT167 fig 1

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DISMANTLING

D) Dismantling the Servo Valve Assembly

The housing and piston assembly (323) contains a servo valve within the advance piston. Removal of the piston from the housing will enable the servo valve assembly to be dismantled.

This device consists of a number of springs and shim washers that are under compression. Care must be exercised when dismantling the unit.

Remove the retaining circlip (312), using a suitable pair of circlip pliers.

Clamp the piston in a vice fitted with soft jaws with the spring assembly uppermost. A suitable large flat steel washer having an internal hole diameter of between 7 and 8 millimetres can be used to compress the springs and shims to enable the retaining e-clip (313) to be removed.

Carefully release the spring pressure and remove the shim (314), plate (315), spring (316), stop plate (317), spacer (318), shim (319) and spring (320). The servo valve retaining circlip (321) and washer (322) can be removed to release the valve from the piston.

Some pumps may have an additional spring fitted in the piston bore beneath the servo valve.

DISMANTLING II

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DISMANTLING

2.8.3 Servo piston design with 4 bolt cold advance

A) Removing the wax motor

Slacken and remove any cable retaining nuts and washers.

Slacken and remove the wax motor (307); discard the O-ring (306).

Remove the cam (410), spring (409) and spring seat (408) from within the CA housing (302).

Slacken and remove the four Allen screws (301).

DT157 fig 1

B) Removing the CA assembly

Remove the CA body (302); discard the O-ring (308) and retard pin (406).

C) Removing the advance device

Slacken and remove the spring end cap (413) and O-ring (324). An auxiliary spring may be fitted (not shown). Remove the advance housing cap-nut (417); remove and discard the sealing washer (416). Slacken the head locating fitting (420), or transfer pressure damper (if fitted), no more than three turns. Tap the

advance housing (323) with a softfaced mallet to free it from the gasket (415). Remove the head locating fitting and then the advance housing, complete with the piston. Discard the gasket

(415). If fitted, carefully remove the spring ring (421) retaining the lock-off ball (422) in the head locating fitting and

remove the ball. Discard the spring ring. Remove and discard the split nylon ring (418), if fitted, and the O-rings (419) from the head locating fitting.

D) Dismantling the piston and servo valve

Remove the servo valve from within the advance piston. Carefully remove the circlip (403), washer (404). If the servo valve is removed from the advance piston for future inspection, note the way round it is fitted into the

piston.

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2.8.4 Single piston design without cold advance

A) Removing the spring cap

Remove the spring cap advance gauge access screw (1) and discard the sealing washer (2).

Unscrew the advance piston spring cap (3); remove and discard O-ring (4). Remove the main advance springs (6) and (7), and shim(s) (5). Unscrew the piston plug (12); remove and discard the O-ring (11).

Remove the spring plate (8), circlip (9), and the retard spring (10) (if fitted).

Note:

The start retard spring (10) and the end plate regulating sleeve retaining spring have similar dimensions, but their ratings are different. As this may cause confusion during reassembly, the springs must be separately identified.

DISMANTLING

A1250

DISMANTLING II

A1009

B) Removing the advance device

Remove the advance housing cap-nut (8); remove and discard the sealing washer (9).

Slacken the head locating fitting (5), or transfer pressure damper (if fitted), no more than three turns. Tap the advance housing (2) with a softfaced mallet to free it from the gasket (1). Remove the head locating fitting and then the advance housing, complete with the piston (10). Discard the gasket (1).

If fitted, carefully remove the spring ring (6) retaining the lock-off ball (7) in the head locating fitting and remove the ball. Discard the spring ring.

Remove and discard the split nylon ring (3), if fitted, and the O-rings (4) from the head locating fitting.

C) Removing the cam screw

Fit the special adaptor (1) to the cam advance screw (2). Using a suitable socket and wrench, slacken the cam screw. The cam ring will almost certainly become stuck in the pump housing.

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

9 8

5 6

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DISMANTLING

2.9 Removing The Head Locking Screws And Releasing The Hydraulic Head

2.9.1 Head locking screws

Slacken and remove the two head locking screws (1) and (4); remove and discard the O-rings (2) and (3) and the filters (not shown) in the inner ends of the screws.

A1251

2.9.2 Removing and dismantling the LLA

a) Lock nut adjuster type

A differential valve for controlling light-load advance may be fitted in place of one of the head locking screws.

Slacken the locking nut (8) before removing the valve body (3) from the pump. Remove the locking nut and discard the seal (7). Remove the adjusting screw (6) and spring (5). Tip out the ball (4). Remove and discard the O-rings (1) and (2). Remove and discard the filter if fitted.

b) Plug adjuster type

With a suitable pointed implement, prize out the seal plug (278). Unscrew and remove the valve body (219) from the pump and remove and discard the O- rings (217 & 218). If fitted, remove and discard the filter.

Unscrew and remove the adjuster (222) and discard the O-ring (277). Tip out the spring (221) and ball (220).

A1011b

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DT228 fig 4

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2.9.3 Removing and dismantling the latch valve

a) Lock nut adjuster type

Slacken, but do not remove, the lock-nut (2); slacken, but do not remove the sleeve (4). Slacken the valve body (8) and remove the valve assembly.

Note:

The inner O-ring (10) may remain within the pump housing

DISMANTLING II

DISMANTLING

Remove and discard the O-rings (9) and (10). Discard the washer (11) and filter in the end of the valve body (if fitted).

Remove the adjuster (1) from the sleeve (4) and discard the seal (3). Remove the sleeve from the body (8) and tip out the spring (6) and valve (7).

b) Cap type

Remove the cap (a) and discard the seal (b). Remove the sleeve from the body (8) and tip out the

spring (6) and valve (7). Remove and discard the O-rings (9) and (10).

Discard the washer (11) and filter in the end of the valve body (if fitted).

2.9.4 Removing the hydraulic head

987654321

A1518

11 109

876

DT228 fig 3

A) Releasing the hydraulic head

Twist and pull the hydraulic head until the large O- ring (1) is just exposed.

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A1495

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II DISMANTLING

B) Removing the hydraulic head

Realign the pump with its axis vertical, as shown, and lift the head out of the pump housing; carefully hold the plungers within the rotor and invert the hydraulic head.

Note:

The rear scroll plate may adhere to the face of the hydraulic head, if it does, remove it.

Place a plunger retaining cap (1) over the rotor; remove and discard the large O-ring (2).

Keep the hydraulic head either in a bath of clean test oil, ensuring that the exposed part of the rotor is covered or in a clean plastic bag until it is required for reassembly.

DISMANTLING

A1496

2.10 Drive Shaft

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

2.10.1 Dismantling the Zero Backlash Drive assembly

A) Removing the drive shaft

Push the drive shaft (1) carefully up through the front bearing and remove it from the pump, holding the rollers and shoes in position as the shaft is lifted above the cam ring.

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DISMANTLING

B) Removing the rollers and shoes

Remove the rollers and shoes, keeping them in their matched pairs.

Note: 1 The roller shoe (1) in the rotor tang drive slot (2)

is longer than the others.

Note: 2 On some later designs, all 4 shoes are the same

length.

C) Dismantling the drive shaft assembly

DISMANTLING II

A1498

Note:

If the drive shaft is to be replaced, the components fitted to the shaft may be transferred if they are suitable for further service.

D) Removing the catch plate and the support plate

If the roller cage and support blocks are to be removed, place a suitable "tommy bar" (5) through the transverse hole in the drive shaft; grip the drive shaft lightly in a vice fitted with soft jaws, using the tommy bar to resist the slackening torque. Use a Torx screw bit and adaptor to remove the four catch plate screws (2) and (4). Remove the catch plate (3) and shoe plate (1).

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II DISMANTLING

E) Removing the support blocks

Note:

There is no support block in the groove into which the hydraulic head rotor tang fits.

Invert the drive shaft and grip it very lightly, across two diametrically opposite roller shoe gaps, in a vice fitted with soft jaws. Use an extended Torx screw adaptor to slacken the three screws (1), (2), and (3). Remove the screws, their flat washers, and the support blocks.

2.10.2 Dismantling the splined drive assembly

DISMANTLING

A1500

A) Removing the pump housing

Remove the pump from the Hydraclamp, carefully holding it together, and place it on the bench with the drive shaft uppermost.

Align a gap (1) in the weight cage with the centre line of the pump so that the gap that will be diametrically opposite will allow the weight cage to pass the head of the advance device stud as the pump housing is withdrawn.

Lift the housing off the drive shaft assembly.

B) Dismantling the drive shaft assembly

Lift the drive shaft (1), governor weight cage (2), weights (3), and thrust sleeve (4) together from the spacer (5), scroll plate (6), cam ring (7), and scroll plate (8).

A1004

2 3

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DISMANTLING

2.11 Dismantling The Hydraulic Head - Check And Cheek Plate Designs

2.11.1 Releasing the drive plate screws

Use the special tool (1) to hold the drive plate (3); use a bi-hexagon socket to slacken and remove the drive plate screws (2) and (4). Remove the drive plate.

DISMANTLING II

A1290

2.11.2 Dismantling the rotor components

Remove the rollers and shoes (1), (3), (5) and (7). Remove the dowel pins (2) and (4) fitted to the cheek plate design and the upper cheek or check plate (6).

2.11.3 Removing the lower check or cheek plate

Retain the plungers in their respective bores with the specified plastic clips (1), short lengths of nitrile rubber tube, or small corks.

Unscrew and remove the transfer pump rotor, lift out the hydraulic head rotor and remove the lower check or cheek plate (2). Refit the rotor to the hydraulic head, and then refit the transfer pump rotor finger tight.

Store the head in a covered container filled with clean test oil.

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II DISMANTLING

DISMANTLING

Remove the rear scroll plate (4) (still within the housing), cam ring (3), front scroll plate (2), inner bearing (1), and the governor weight cage assembly (not shown) complete with the weights, thrust sleeve and thrust washer.

Note: 1 Some basic designs of pump will not be fitted with

a bearing or scroll plates. After removal of the cam ring, remove the circlip

fitted in the pump housing before removal of the weight cage.

Note: 2 Some pumps are fitted with reverse thrust split

and return rings.

2.11.4 Reverse thrust weight assembly

Reverse thrust split and return rings. Some pumps will have a two piece thrust ring, a

retaining ring sandwiched between the thrust sleeve washer and governor weight cage.

Carefully remove the retaining ring (2) and remove the two halves of the thrust ring (1) noting the 'stepped edge' for locating into the weight cage.

A1501b

2.11.5 Lock-shaft timing

If the pump is specified with locked-shaft timing, the screw (3) will be fitted through a two-diameter spacer (2); if locked-shaft timing is not specified, a plain spacer will be fitted. Remove the screw and discard the O-ring.

EVD01

A977

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DISMANTLING

2.11.6 Removing the drive shaft seal/s

Remove the pump housing from the Hydraclamp and place it on the workbench with the drive shaft seals uppermost.

Using the special seal removal tool, carefully lever out the seal (1) noting the way round the seal is fitted into the housing.

If two seals are fitted, remove the circlip spacer and using the special seal removal tool, carefully lever out the seal noting the way round the seal is fitted into the housing.

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COMPONENT INSPECTION AND RENEWAL

3.1 Cleaning

If water contamination is suspected, carry out an initial examination of all internal components before attempting any further cleaning. Clean out all passageways in the head and rotor by flushing out with clean test oil.

Also inspect for unusual marking, deposits, odour, seal swelling in the housing, in which case degraded RME fuels may be a factor.

3.2 GeneraL

3.2.1 Mated and matched assemblies

The hydraulic head and rotor should be separated and examined; they should be re-mated immediately after examination and immersed in a covered bath of clean test oil until required for reassembly into the pump.

Note:

If light load advance is specified, the metering valve will be matched to the hydraulic head.

The following groups are matched and must be kept assembled in their sets:

Rollers and shoes Advance housing and piston Cam ring and scroll plates Stop solenoid plunger and body Regulating sleeve, piston and adjusting screw Governor cover and torque control piston

If any part of a matched set is considered to be unfit for further service, the whole set must be replaced.

Note:

The pump housing drive shaft bush is not a service repair item; if the bearing is worn, the housing must be replaced.

3.2.2 Examination and replacement

All components must be checked for corrosion, wear, or damage. Under service workshop conditions it is not feasible to test individual parts or sub-assemblies to determine their suitability for further service. Close examination of the areas vulnerable to damage, and interpretation of the results of tests prior to dismantling, should indicate the condition of parts.

Corrosion

Check for signs of corrosion or water ingress (rust or staining) damage to machined surfaces. These include the pump housing, drive shaft, hydraulic head bore, metering valve and bore cam ring, scroll plates, cheek plates end plate and auto-advance device mounting face.

Wear

Inspect drive shaft splines and associated parts for wear or damage. If excessive end-float or radial play was detected prior to pump strip-down, examine the drive shaft thrust washer and housing bearing thrust face, governor backplate and thrust face of drive shaft, and governor drive splines, for wear.

Damage

Inspect all parts for damage or bending due to abuse, especially external levers and controls.

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COMPONENT INSPECTION AND RENEWAL

3.2.3 Seals

Replace the advance device gasket and all O-ring seals, including the "trapped" O-ring in the governor cover face. Note that overhaul kit does not include drive shaft seals, which are stocked as separate items.

When fitting new O-rings and oil seals, care must be taken to use protection caps to avoid damage to the seals. O-rings must be dipped in clean test oil prior to being assembled. External seals must be lightly coated with the specified grease. Where possible, inspect seals for small cuts after assembly.

3.3 Details

3.3.1 Hydraulic head rotor

Withdraw the rotor from the hydraulic head. Examine the running surface very closely for signs of erosion, particularly the area around the delivery port. If

significant erosion is evident, the head and rotor assembly must be replaced. Also check the condition of the drive tang on CP drive pumps.

3.3.2 Hydraulic head plungers

If damage to the plungers is suspected, carefully separate them from the rotor, one at a time, and inspect them for scoring or other damage. Replace the hydraulic head if the plungers show severe scratching. Clean each plunger with test oil and immediately replace it very carefully in its original bore, the same way round.

The recommended plastic retainer, or short lengths of clean nitrile rubber tubing, should be used to retain the plungers in their bores.

Note: 1 The two pairs of plungers are of different lengths; the two longer plungers are fitted in line with the axis of the

rotor delivery port.

Note: 2 DP200 pumps specified with light-load advance will be fitted with "graded" metering valves. Refer to the

appropriate parts list for details.

3.3.3 Cam ring and scroll plates

Inspect the running surface of the cam ring and scroll plates for signs of breakdown of the leading face or apex of the profile. If there are significant signs of pitting or "smearing" they must be replaced as a set. Smearing is the result of failure of the surface due to abrasion or overloading, which may be due to excessive hydraulic pressure (possibly caused by nozzle blockage).

3.3.4 Rollers and shoes

Inspect rollers and shoes for damage. Pay particular attention to the condition of the contact surfaces and check that the rollers rotate freely in their shoes. If the cam ring has failed, the rollers and shoes may also have been severely damaged. If satisfactory, rollers must be replaced in their original shoes.

3.3.5 Transfer pump

Check the blades for chips, scores or breakages. Examine the blade springs for distortion Blades must be replaced in sets and must be of the same type as the

originals. Examine the rotor for wear or damage. Examine the liner for corrosion or scoring and replace it if there are any signs of damage.

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3.3.6 Endplate

Examine the inner face of the endplate for wear. Replace it if there is any significant scoring. If the sandwich plate is scored or worn, it must be replaced and not reversed. The transfer pressure accumulator retainer must not be protruding. Replace if faulty.

3.3.7 Control valves

Check all control valves for wear or scoring. Examine the metering valve for "stepping" of the control slot edges and at the point where it enters the bore in

the hydraulic head. Check that the valve and the governor link pin are securely fixed in the bar and that the roller is free to rotate on the pin and is not worn. Check the regulating sleeve and piston and differential valve for damage, corrosion or blockage of orifices.

3.3.8 Delivery valves and cambox pressurising valves

Check for erosion or other damage to delivery valve assemblies. Replace them (as matched pairs) if necessary. If movement of the cambox pressurising valve can be detected when shaken the spring may have collapsed, in

which case the whole assembly must be replaced, as it is factory-sealed.

3.3.9 High pressure outlet pressurising valves

Only the "ball" type of pressurising valve is used and, in the 7185-022 series, the balls should be either flush with the outer face of the valve body or protrude by no more than 0,5 mm (see SIN DT312 for full details of both types of valve).

3.3.10 Springs

Look for distorted or fractured springs. Very carefully examine the areas of contact with adjoining components (spring pegs, throttle shaft links etc). Check that all springs specified in the Parts List for the pump are present.

3.3.11 Fittings and threads

Check all screws and nuts for damage. Check the cam advance screw flats, which may have been damaged by careless application of the high tightening torque.

Check all threads for damage, especially on the transfer and distributor rotors, hydraulic head, cam advance screw hole, studs, fuel inlet and return and high pressure outlet connections.

3.3.12 Linkages

Inspect all mechanical governor linkages, shafts, pivot pins and arms for wear, cracks or scoring of their mating surfaces.

3.3.13 Control shafts

Examine control shafts and their associated bores in the governor cover for distortion, wear, looseness of joints or elongation of spring anchor holes.

3.3.14 Drive shafts and associated components

Inspect the shaft for wear or damage, especially where the oil seal contacts the shaft. Check splines and keyways for cracks or chipping. Check the tang slot on CP drive pumps.

Examine the thrust surfaces on the inner face of the pump housing and the weight cage for damage or scoring. Examine the governor weight cage and weights for wear, cracks or damage. Ensure that the correct number and

type of governor weights are fitted.

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COMPONENT INSPECTION AND RENEWAL

3.3.15 Advance device

Examine the components for corrosion. If water has been present in the fuel it will tend to settle in the advance housing. Check that the piston moves freely.

3.3.16 Levers and external controls

Examine all levers for cracks and for excessive wear at contact points.

3.3.17 Pump housing

Examine the housing for damage, especially to sealing surfaces. If the bearing is unfit for further service, the housing must be replaced. If the small dowel pin, which locates the governor control cover, is damaged, it must be replaced. If the advance device stud is damaged and requires replacement, remove it by using two suitable nuts locked together. Fit a new stud using the same technique.

3.3.18 Governor control cover

Check the control shaft bores, stop screw threads, and adjusting screw seal spotfaces (anti-stall, maximum fuel stop, and boost control). Check the boost control locating dowel pin. Check the torque trimmer piston bore.

3.3.19 Orifices

Examine all orifices for blockage and carefully clear any obstruction with dry compressed air.

3.3.20 Electric shut-off solenoid

Ensure that all the solenoid electrical parts are clean, especially the connection(s), and that the plunger is free in its bore. Check that the flexible valve seat is in good condition, with no pitting or other damage, and that the spring is not distorted. Check the coil for electrical continuity by measuring its resistance. Ensure that the solenoid is completely dry and check insulation resistance between each terminal and the solenoid body (insulated return solenoids only).

Note: 1 A few solenoids are specified to be operated only when there is a requirement to stop the engine.

Note: 2 If any fault is apparent in the stop solenoid assembly, the whole unit must be replaced.

3.3.21 Wax motor

If a pre-dismantling test of the injection pump indicates that the CA device is not operating correctly, carry out the following test on the wax motor, out of the CA housing (no test is necessary if operation is according to the Test Plan).

The motor may be tested for correct function by connecting it either to a fully charged 12 V battery, or to a stabilised DC power supply set to 12.0 V and capable of supplying at least 3 A for at least 5 minutes. The test data refers to 12 V operation only - currents and times are significantly different for operation at 24 V. The motor is not polarity sensitive.

Before testing, place the motor on a flat surface, with the spindle downwards, and press lightly on the motor for about 15 seconds to ensure that the spindle is in its fully retracted position.

Clamp the motor, with its spindle facing upwards lightly in a vice fitted with soft jaws.

Note:

Early pumps may be fitted with pistons that have small flats to assist with clamping in the jaws of a vice.

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COMPONENT INSPECTION AND RENEWAL

As the motor is of earth-return design, connect the body of the motor to one pole of the power supply and connect the insulated terminal through a switch and a fuse, to the other pole of the power supply. The wires, switch and fuse must be capable of carrying a current of 3 A without the overall voltdrop in the circuit exceeding 0.5 V.

With the power supply switched off and the motor cold, the protrusion of the new motor spindle from the front face of the motor (dimension "X") should be 4.5 +/- 0.2 mm (unless stated otherwise in the Test Plan).

Switch on the power supply and allow at least one minute for the motor to reach its operating temperature, during which time the spindle will be extended from the motor housing. The protrusion of the spindle must then be a maximum of 7.2 mm greater than when the motor was at ambient temperature.

A1488

WARNING

When the motor is switched off after testing, and it is not installed in the CA device (with spring pressure bearing upon the plunger), a light pressure, no more than 20 N (4.5 lbf, 2kgf), must be maintained on the plunger to ensure that it returns fully to its rest position, until it has cooled down to ambient temperature (usually after about 3 minutes). Failure to follow this instruction could lead to the ingress of air into the motor, with subsequent failure to operate correctly.

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REASSEMBLY IV

REASSEMBLY

4.1 Preparation

Before using thread-locking compound, if specified, ensure that the mating surfaces are completely oil-free and dry. When reassembling pumps, it is important to use the correct overhaul kit. The relevant kit numbers can be found in the

Service Parts List. Lightly lubricate all flexible seals and O-rings with clean test oil before fitment to their respective components. Always

use the correct protection cap when fitting new O-rings. Apply the specified grease to the drive shaft seal and the throttle and exhaust brake shafts before assembly in their respective positions. Dip all internal components in clean test oil before assembly.

Refer to the relevant Test Plan for details of special build items and any initial setting instructions. Refer to Section 6 for all special tools and torque values. The direction of rotation of the pump, as shown on the nameplate, is as viewed from the drive end.

4.2 Assembling The Hydraulic Head

Note: 1 Check the direction of the arrow on the distributor rotor head agrees with that of the arrow on the pump nameplate.

Note: 2 The plungers in four-plunger rotors must be fitted with the longer plungers opposite to each other and in line with the

distributor port in the rotor.

4.2.1 Rotor plug

If the rotor plug is loose or a leak along the thread is suspected as a result of the pre-dismantling test, the plug must be removed, replaced if necessary, and re-sealed, using the following procedure:

Temporarily fit the two drive plate clamping screws (4) and (5) into their holes in the rotor head, leaving them finger tight. Leave the plunger clips (3) in position, remove the transfer pump rotor and carefully remove the distributor rotor from the hydraulic head body, avoiding any contact with the running surface of the rotor. Invert the rotor and lightly clamp the screw heads in a vice fitted with soft jaws.

Remove the plug screw, using the specified tool (1), fitted with a straight Allen key (2) or relevant socket. If the plug thread is damaged, replace the plug.

A979

Thoroughly degrease both the plug and rotor threads and smear the plug thread with a small amount of 'Loctite'

638. Refit the plug, using a new sealing washer, and tighten it to the specified torque. Lubricate the rotor with clean test oil (but do not allow any oil in the vicinity of the plug) and refit the rotor to the

hydraulic head. Place the hydraulic head assembly in a clean environment until the recommended 'Locktite' curing time has elapsed (typically, 6 hours at room temperature).

Note:

Do not attempt to accelerate the curing process by heating the hydraulic head assembly.

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IV REASSEMBLY

REASSEMBLY

When the curing time has passed, store the head in a covered container filled with clean test oil until it is required for reassembly.

4.2.2 Drive plate, rollers, shoes and retaining plates

A) Cheek plates and dowel pin design

a) Ensure that the plastic plunger retaining clips are firmly in position,

Remove the transfer pump rotor and lift out the distributor rotor. Place one of the cheek plates (1) over the rotor, ensuring it is the right way round i.e. that the slots and holes in it will align with those in the rotor head, and taking great care to avoid scratching the running surface of the rotor. Hold the cheek plate in position and dip the rotor in clean test oil; carefully refit it to the hydraulic head.

A975

WARNING

If the rotor tends to jam as it enters the hydraulic head bore, lift it out and try again. Do not use even light force to fit the rotor.

Refit the transfer pump rotor but do not tighten. Place the head on the bench and remove the plunger-retaining clips. Place the two dowel pins (2) and (4) through

their holes in the rotor head and into the lower cheek plate. Fit the upper cheek plate (3), aligning the slots and dowel pin holes with those in the rotor head; push the cheek plate fully onto the dowel pins.

As the plungers are no longer retained by the clips, either proceed immediately to next section, or insert cork or rubber plugs to prevent loss of the plungers.

b) Drive plate

Place the drive plate onto the rotor head, slotted face downwards. Align the two screw holes.

WARNING

The two holes are not diametrically opposite to each other; there is a very small angular difference between them, as shown at (1) in the incorrectly- assembled example.

Fit the two screws (3) and (5) and fit the specified tool (2) into the drive plate (6). Use a bi-hexagon socket (4) and torque wrench to tighten the screws progressively and evenly up to the specified torque.

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REASSEMBLY

c) Fitting the roller and shoes

Fit the shoes (1) and rollers (2) to the slots in the rotor head and cheek plates.

Note:

The rollers and shoes in a pump are a matched set and must be kept together. However, any roller/ shoe combination may be fitted into any rotor slot.

B) Check plate design

a) Remove the transfer rotor from the distributor rotor and remove the distributor rotor from the head.

b) Fitting the bottom adjusting plate

Compare the bottom adjusting plate (1) with the top adjusting plate to determine which way round the plate should be fitted - the scrolls on the plates must match each other. Very carefully place the bottom plate over the rotor (3), taking great care to avoid scratching of the rotor surface.

1 32

A1252

Note:

In addition to matching the scrolls, correct assembly of the bottom adjusting plate may be confirmed by observing that the chamfered edges (2) of the scrolls should face the top adjusting plate.

Dip the distributor rotor in clean test oil and refit it to the head; refit the transfer rotor, leaving it finger tight.

Remove the plunger retaining clips.

c) Fitting the top adjusting plate

Fit the shoes (3) and rollers (4) to the distributor rotor head ensuring that the "ears" (5) of the shoes match the scrolls of the bottom adjusting plate. Fit the top adjusting plate (1) to the rotor, ensuring that the "legs" of the plate fit into the slots (7) and (8) in the bottom plate and that the slot (2) is aligned with the identification data (6) on the head of the rotor.

A1512a

A1512b

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IV REASSEMBLY

d) Alignment of the drive plate

In order to ensure correct alignment of the rotor delivery port with the drive shaft keyway, the two holes for the drive plate screws in the drive plate and in the rotor are not on the same transverse centreline. If necessary, turn the drive plate until the holes are aligned.

To illustrate the difference, the drive plate is shown deliberately incorrectly assembled.

Note:

The inner face of the driveplate has a machined groove (see illus. A1512c item (3) over page) to ensure that the "ears" of the roller shoes are not trapped when the drive plate screws are tightened.

e) Fitting the drive plate

Fit the drive plate, aligning the screw holes correctly with those in the rotor head.

Fit the drive plate screws, leaving them finger-tight. Set the adjusting plates so that the slot (1) in the top

plate is approximately in the centre of the gap (2) in the drive plate. The final position of the adjusting plates will be set during testing.

REASSEMBLY

A989

A1512c

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REASSEMBLY

4.3 Drive Shaft

4.3.1 Zero backlash and splined drive with cheek plates.

A) Fitting the support blocks

If the drive shaft has been dismantled to its component parts fit the support blocks to the relevant slots, with their concave ends facing radially outwards and their flat faces towards the drive shaft. Secure them with the Torx screws (1), (2), and (3) and flat washers.

Place the drive shaft in a vice fitted with soft jaws, gripping it lightly across two diametrically opposite slots. Tighten the screws to the specified torque using an extended Torx bit (see Section 6).

Note: 1 Only use the minimum necessary clamping force.

DO NOT clamp on the polished inner bearing surface (4).

REASSEMBLY IV

A1500

Note: 2 Later designs incorporate the lubrication groves in the drive shaft.

It is imperative that combinations of early and late designs do not result in a build where there is no lubrication groove present.

A groove in both the shoe and drive shaft is permissible.

B) Fitting the shoe plate and roller catch plate

Remove the shaft from the vice and invert it. Fit a small "tommy" bar (6) through the transverse hole in the shaft; mount the shaft again in the vice fitted with soft jaws, in such a position that the bar will prevent rotation of the shaft as the catch plate screws are tightened. Do not clamp the shaft on the polished inner bearing surface (5), but clamp it across the smaller diameter, very lightly.

Fit the shoe plate (1) and the roller catch plate (3) and secure them with the four Torx screws (2) and (4), tightened to the specified torque.

Note:

No washers are fitted under the screw heads.

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IV REASSEMBLY

C) Fitting the rollers and shoes

Fit the rollers and shoes to the drive shaft; the longest shoe (1) is fitted to the slot (2) which does not have a support block. Ensure that the lubrication groove (3) in one end of the long shoe faces towards the drive end of the shaft.

Note:

Changes in the design of the shoe and drive shaft have resulted in the lubrication groove being removed from the shoe. It is now in the drive shaft. Mixing of old and new designed is allowed. Having a groove in both parts is permissible, but having no grooves will result in premature failure.

D) Assembling the governor weight cage

Reverse thrust split and return ring. Fit the two halves of the split thrust washer to the

weight cage and retain it with the spring ring. The 'stepped' side should face in towards the cage.

Fit the governor weights to the weight cage (1). Arrange them so that, if there are less than six weights (i.e. 4 or 3) they are to be symmetrically positioned. If there are only three, place one in every alternate pocket; if there are four, place them as shown in the illustration.

Place the governor thrust washer (2) on the "toes" (4) of the weights, followed by the thrust sleeve (3).

REASSEMBLY

A1503

A1498

A1502EVD01

E) Fitting the governor weight assembly to the drive shaft

Hold the weight cage and the governor thrust sleeve assembly and invert it. Place the assembly over the drive shaft and lower it, rotating it a little if necessary to engage the splines on the drive shaft. When the assembly is correctly located on the splines release the thrust sleeve and allow it to rest on the support block screws.

A1504

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REASSEMBLY

F) Fitting the O-ring and rear scroll plate

Place the Hydraclamp plate so that it is horizontal. Place the assembled hydraulic head on the plate,

with the high pressure outlets facing downwards. Dip a new O-ring in clean test oil and fit it into the groove (3) in the hydraulic head.

Place one of the scroll plates (1) in the recess in the hydraulic head (the "rear" scroll plate position. Ensure that its arrow is facing in the correct direction of rotation (as indicated on the pump nameplate) and the slot (2) is centralised in the gap in the hydraulic head, as shown.

G) Fitting the cam ring, front scroll plate and inner bearing

Place the cam ring (1) on the hydraulic head, with its arrow facing in the direction of pump rotation, and with the cam advance screw hole (2) aligned with the head locating fitting hole (3).

Place the other scroll plate on the cam (in the "front" position), also with its arrow pointing in the direction of rotation, and with the slot (4) aligned with the metering valve bore (9). Place the inner bearing (5) over the front scroll plate, with its shallow recess facing downwards and the wide slot (6) centralised in line with the metering valve bore.

Ensure that both scroll plate slots (4) and (8) are aligned with each other and with the metering valve bore.

REASSEMBLY IV

2 3

A1507A1506

A1505

6 7

8 9

Note:

The small blind hole (7) accommodates the extended shank of one of the governor plate securing screws to prevent rotation of the inner bearing.

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IV REASSEMBLY

H) Fitting the drive shaft assembly

Hold the drive shaft assembly together and place it into the assembled components on the hydraulic head, rotating the shaft as necessary to align the slot with the hydraulic head rotor "tang".

Rotate the shaft so that a gap (1) between any two adjacent weight "pockets" is aligned with the metering valve bore (2) to ensure that the head of the advance housing stud will pass between the two opposite pockets when the pump housing is fitted.

Note:

With some pump specifications, the assembled drive shaft may not pass easily through the inner bearing without the risk of damage to the bearing surface. In those cases assemble the inner bearing to the drive shaft from the drive end before fitting the governor weight cage assembly.

REASSEMBLY

A1508

I) Fitting the pump housing

Fit the appropriate seal protection cap (1) over the drive shaft thread and taper.

Align the head locating fitting hole (2) in the pump housing with the matching hole (3) in the hydraulic head and lower the housing onto the inner components until it just touches the hydraulic head O-ring (4).

4.3.2 Spline drive with check plate head and rotor

A) Fitting the weight cage to the drive shaft

Fit the pump to the Hydraclamp with its axis vertical and it's mounting face downward.

Hold the drive shaft with its axis vertical, and the drive end facing downwards. Place the governor weight cage (3) over the shaft and align the splines in the cage and on the shaft. Place the weights in to the weight "pockets".

A1509

Note:

If less than six weights (i.e. 4, 3, or 2) are to be fitted, they must be spaced symmetrically within the cage.

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B) Assembling the weight cage components

Place the governor thrust washer (4) on to the "toes" (2) of the weights, followed by the thrust sleeve (1).

C) Fitting the drive shaft assembly

Place the specified seal protection cap over the drive shaft thread. Lower the drive shaft assembly into the pump housing and carefully push it fully downwards.

D) Fitting the timing circlip (if specified)

Fit the circlip into the pump housing making sure it locates against the shoulder in the housing with the ears placed centrally in the housing inspection cover aperture.

Note:

One ear of the circlip is flat, the other rounded. The flat ear is to be positioned so that when the pump drive shaft rotates, the drive plate timing letters turn 'towards' the flat ear and not away from it.

A1781

E) Fitting the cam ring

Fit the cam ring to the housing, with its arrow facing in the direction indicated on the pump nameplate and with the cam advance screw hole visible through the advance device mounting face "window".

F) Fitting the hydraulic head

Realign the Hydraclamp to place the pump axis horizontal.

Fit the hydraulic head to the housing, align the drive shaft and drive plate "master" splines and, using a twisting action, push the hydraulic head fully into the housing. Align the head locking screw hole (2) in the hydraulic head with the hole (1) in the pump housing.

A1495

4.4 Securing The Hydraulic Head And Checking Drive Shaft End Float And Radial Play

4.4.1 Replacing the drive shaft seal/s

Fit the protection sleeve over the tapered end of the drive shaft. The sleeve must cover the circlip groove in the drive shaft. Failure to do so will cause the lip of the seal to be cut and create a fuel oil leak.

Moisten a new seal with clean test oil and fit into the pump housing. Ensure that the seal is the correct way round as noted during dismantling. Use the punch and a soft-headed mallet to drive the seal fully into the recess in the pump housing.

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If a second drive shaft seal is required fit the circlip, if specified, into the groove in the pump housing seal recess. The circlip must be so positioned within the groove so as not to impede fuel flow through the tell tale hole, if a seal fails.

Repeat the process for fitting the first seal.

4.4.2 Securing the drive shaft

Dip the thrust washer (1) in clean test oil, fit it over the drive shaft and fit the circlip (2) correctly into the shaft groove.

A970

4.4.3 Aligning the hydraulic head

Re-align the Hydraclamp to place the plate vertically and the pump with its axis aligned horizontally. Grip the hydraulic head and, using a twisting and pushing action, slide the head fully into the pump housing.

Check that the holes in the housing and the hydraulic head are aligned with each other.

4.4.4 Checking drive shaft end float

Note:

If this dimension was found to be correct when measured prior to dismantling, and no components which could affect end-float have been replaced, it should not be necessary to repeat this measurement.

Fit the appropriate adaptor (4) to the drive shaft thread. Screw in the dial gauge holder (3), and fit the dial gauge (2). Adjust the gauge pin to contact the mounting plate adaptor ring (1).

Push the drive shaft inwards and set the dial gauge to zero. Pull the drive shaft outwards and note the maximum gauge reading. End-float should be between 0,05mm and 0,2mm. If it is outside that tolerance, correct it by the use of an alternative thrust washer (5).

A952

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4.4.5 Checking drive shaft radial play

Note:

If the original housing and shaft are to be used and radial play at the bearing was found to be within the limits stated below, it should not be necessary to measure radial play at this stage. If either item has been replaced, radial play must be measured.

With the pump and dial gauge (1) mounted rigidly relative to each other (e.g. on a plate fitted to the Hydraclamp), adjust the gauge pin to bear against the parallel section (4) of the drive shaft. 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 (2) and (3). Do not rotate the drive shaft.

Reject the housing if either the maximum play or the difference between the measurements exceed the figures below.

REASSEMBLY

REASSEMBLY IV

120°

A1259

Drive type Max. play Max. Difference

Belt 0.22 mm 0.1 mm

Gear or hub 0.27 mm 0.2 mm

4.4.6 Cam advance screw

Align the Hydraclamp plate to place the pump with its axis vertical. Fit the cam advance screw (2) to the cam ring and, using the special adaptor (1) in a suitable socket fitted to a torque wrench, tighten the screw to the specified torque.

Note:

During this operation, the cam ring usually becomes jammed in the housing. Using a rubber or hide mallet, lightly tap the cam screw axially to free the cam ring.

A997

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4.4.7 Fitting the head locking screws, light load advance valve and latch valves

A) Head locking screws

Fit a new filter, if specified, into the open end of the screw. Dip a new O-ring in clean test oil and using the appropriate seal protection sleeve, slide the O- ring into the groove of the screw body.

Fit the locking screw into the hydraulic head- locating hole as noted during dismantling.

Do not tighten until all three head bolts are in position.

B) Light load advance valve

a) Lock-nut adjuster type

Place the ball (4) into the valve body (3), followed by the spring (5) and the adjusting screw (6). Fit the seal (7) and the lock-nut (8).

Fit new O-rings (1) and (2) to the valve body using a protection cap.

EVD09

b) Cap type

Fit the ball (220) and spring (221) into the valve body (219).

Using the appropriate seal protection sleeve, fit a new O-ring (277) to the adjusting screw (222).

Screw the adjuster into the valve body (219). Fit the assembly into the hydraulic head-locating

hole as noted during dismantling. Using the appropriate seal protection sleeve, fit new

O rings (217) and (218) Do not tighten until all three head bolts are in

position. The sealing cap (278) is not to be fitted until the

pump has been set on the test bench.

A1011b

DT228 fig 4

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C) Latch valve

a) Lock nut adjuster type

Fit new O-rings (9) and (10) to the valve body (8), and fit a new O-ring (5) to the adjuster body (4), using the appropriate seal protection sleeves. Fit the valve (7) into the body, followed by the spring (6); fit the adjuster (4) into the body.

Fit the adjusting screw (1) into the adjuster (4), screwing it in by approximately four turns. Fit a new seal (3) to the screw, followed by the lock-nut (2).

Fit a new seal (11) to the latch valve assembly; fit the assembly through the pump housing and into the hydraulic head.

The positions of the adjusting screw and adjuster will be set during testing.

b) Cap type

Using the appropriate seal protection sleeve, fit new O-rings to the valve body.

Fit the valve (1) into the body followed by the spring (2).

Fit a new O-ring (3) using the appropriate seal protection sleeve onto the cap (4) and screw it into the valve body.

Fit the assembly into the hydraulic head-locating hole as noted during dismantling.

Do not tighten until all three head bolts are in position.

REASSEMBLY IV

4 3 2 1

987654321

A1518

DT228 fig 3

4.5 Advance Device

DP200 uses a number of different advance devices. They will fall into two main categories: a.

Single piston design

Direct actuation of the cam-ring by an advance piston operated by transfer pressure and controlled by a combination of spring and cambox pressure.

Servo piston design

Indirect actuation of the cam-ring by an advance piston via a servo valve operated by transfer pressure and controlled by a combination of spring and cambox pressure.

Each of these two types may be fitted with cold start timing retard with or without a wax motor mechanism.

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4.5.1 Single piston design

A) Fit the circlip (1) into the groove in the advance housing bore.

If not already in position, fit the advance piston (2) into the advance housing (5) with the flat end of the piston towards the transfer pressure port in the housing (visible just at the inner end of the internal thread). Align the transverse hole in the piston with the opening in the advance housing.

Fit the lock-off ball (8), if specified, into the deeper of the two recesses in the head fitting (6) or the damper, whichever is specified. Fit the spring clip (7), if specified, over the ball, with its bent end in the orifice countersink. Do not yet fit new O-rings or the split backing ring.

Push the head locating fitting up through the larger of the two holes in the advance housing. Place a new gasket (3) onto the advance housing, with the straight edge (4) adjacent to the pump housing stud hole. Ensure that the shoulder of the head locating fitting will not cut the gasket when the fitting is tightened.

2 1

6 7

A1013

Place the advance housing over the stud and the cam advance screw, and onto the pump housing, ensuring that the gasket is correctly located over the housing stud shoulder.

Engage the fitting with the thread in the hydraulic head and screw it fully in. If necessary adjust the position of the hydraulic head.

Centralisation of the hydraulic head is necessary to avoid damage to the O-rings as the head fixings are screwed in.

Fit a new sealing washer (10) to the stud, followed by the dome nut (9).

B) Tightening the head fittings

When the head is centralised, remove the head locating fitting (5) or damper. Dip new O-ring (4) in clean test oil; use the appropriate seal protection sleeve and fit one O-ring to the groove (6) and the other to groove (7). If present, fit the split nylon

3 4

backing ring (3) above the O-ring in groove (6). Progressively tighten in the following order, light

load advance valve (2), head locating fitting (8), head locking bolt or latch valve (1), to their specified torques. When all screws are tightened, check that the advance piston moves freely within the advance

5 6 7

housing.

A1295A1014

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C) Fitting the Pressure end cap

Using the appropriate seal protection cap, dip a new O-ring (1) in clean test oil and fit it to the end plug (2), fit the plug to the end of the advance housing at which the transfer pressure port is visible and tighten it to the specified torque.

D) Fitting the Spring end cap

Fit the retard spring (9) (if specified), followed by the spring plate (8) with its spigot facing towards the advance piston.

Note: 1 The spring plate must be fitted even if no start

retard spring is specified.

Note: 2 It is possible to confuse the start retard spring with

the spring which holds the transfer pressure regulating sleeve in position in the end plate. Carefully check the springs before fitment, having identified them during dismantling, as advised.

REASSEMBLY IV

A1015

A1016

Using the appropriate seal protection cap fit the O- ring (4) to the spring cap (3). Place the specified number of shims (5) in the cap, followed by the advance spring(s) (6) and (7). Screw the cap assembly into the advance housing and tighten it to the specified torque. Fit the cap plug (1) with a new washer (2) and assemble it to the cap, tighten the plug to the specified torque.

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4.5.2 Servo piston designs

A) Fitted with cold advance at the spring end

a) Assembling the Servo Valve

Carefully clamp the advance piston in a vice fitted with soft jaws. Never clamp tight enough to cause distortion or surface damage.

Fit the servo valve (5) followed by the retard spring (2), if fitted, ensuring that it fits over the spigot on the servo piston (6). Insert the piston rod (3) into the advance piston (1). Fit the washer (7) and a new retaining circlip (4).

REASSEMBLY

EVD011

Fit the spring (320), shim (319), spacer (318), stop plate (317), spring (316), plate (315) and shim (314).

Using a large flat steel washer having an internal hole diameter of between 7 & 8 mm, compress the spring assembly sufficiently enough to fit a new retaining circlip (313) on to the end of the servo valve rod.

Check the servo valve for freedom of movement within the advance piston.

The shims (319) and (314) are of pre-set sizes and are dedicated for each application and under no circumstances can the shim sizes be changed.

For identification of the shim sizes, Table 'A' states the relative dimensions for each part number specified in the relevant parts list.

Table ' A '

Part No. Thickness

7185-436A 0.76 mm

7185-436B 1.52 mm

7185-436C 2.28 mm

EVD010

7185-436D 3.04 mm

b) Fit the advance piston assembly into the advance box with the flat on the piston towards the bottom of the advance box. Align the transverse hole in the piston

with the opening in the advance housing. Locate the advance reference stop plate (317) against the step in the bore and fit circlip (312).

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c) Fitting the advance device assembly to the pump housing

Fit the lock-off ball, if specified, into the deeper of

the two recesses in the head fitting (4). Do not yet fit new O-rings.

Push the head locating fitting up through the larger of the two holes in the advance housing. Place a new gasket (1) onto the advance housing, with the straight edge (2) adjacent to the pump housing stud hole. Ensure that the shoulder of the head locating fitting will not cut the gasket when the fitting is tightened.

2 1

Place the advance housing over the stud and the cam advance screw, and onto the pump housing, ensuring that the gasket is correctly located over the housing stud shoulder.

Engage the fitting with the thread in the hydraulic head and screw it fully in. If necessary adjust the position of the hydraulic head.

Centralisation of the hydraulic head is necessary to avoid damage to the O-rings as the head fixings are screwed in.

Fit a new sealing washer (6) to the stud, followed by the dome nut (5).

d) Tightening the head fixings

When the head is centralised, remove the head locating fitting (5) or damper. Dip new O-ring (4) in

clean test oil; use the appropriate seal protection sleeve and fit one O-ring to the groove (6) and the other to groove (7). Fit the split nylon backing ring (3) above the O-ring in groove (6).

Progressively tighten in the following order, LLA valve (2), head locating fitting (3), head locking bolt or latch valve (1) to their specified torques. When all screws are tightened, check that the advance piston moves freely within the advance housing.

6 7

A1013

3 4

5 6 7

A1295A1014

B) Fitted with cold advance at the pressure end

a) Assembling the Servo Valve

Fit the servo piston into the bore of the advance piston, followed by the spring piston. Both items are symmetrical, but can be identified from each other as the servo piston is the shorter of the two

items.

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b) Assembling the advance device

Secure the advance housing assembly in a manner that prevents the piston bore from being distorted and the open ends accessible for component assembly.

Assemble the servo advance piston, advance spring (328), shim (327) and spring cap (413) into the advance housing. The spring cap is not to be torque tightened as it will be subsequently removed.

The CA control pin (406) must be omitted at this stage.

The advance piston must be orientated in the advance housing with the cam ball screw hole adjacent to the window. This will ensure the slot is on the head locating fitting side. The advance piston must be free to move within the housing by pushing it from the open end and allowing the spring to return it.

c) Fit the advance reference stop (405) over the advance piston plug.

Fit a new O-ring (308) to the wax motor housing (402) and position it, correctly orientated, over the advance reference stop.

Care is to be taken to avoid altering the advance piston orientation within the advance housing.

Tighten the four bolts (301) in a diagonal sequence, progressively in 20 lbf.in. steps until the final torque is obtained.

Check for free movement of the advance piston.

REASSEMBLY

EVD02

d) Remove the spring cap, shim, advance spring and withdraw the advance piston assembly. Fit the CA control pin (406). Replace the advance piston assembly, correctly orientated. Fit the advance spring, shim, and spring cap fitted

with a new O-ring (324). Tighten the spring cap to the correct torque value.

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e) Fitting the advance device assembly to the pump housing

Fit the lock-off ball, if specified, into the deeper of

the two recesses in the head fitting (4) or the damper, whichever is specified. Do not yet fit new O-rings.

2 1

Place the advance housing over the stud and the cam advance screw, and onto the pump housing, ensuring that the gasket is correctly located over the housing stud shoulder.

Engage the fitting with the thread in the hydraulic head and screw it fully in. If necessary adjust the position of the hydraulic head.

Centralisation of the hydraulic head is necessary to avoid damage to the O-rings as the head fixings are screwed in.

Fit a new sealing washer (6) to the stud, followed by the dome nut (5).

f) Tightening the head fittings

When the head is centralised, remove the head locating fitting (5) or damper. Dip new O-ring (4) in

clean test oil; use the appropriate seal protection sleeve and fit one O-ring to the groove (6) and the other to groove (7). Fit the split nylon backing ring (3) above the O-ring in groove (6).

Progressively tighten in the following order, LLA valve (2), head locating fitting (8), head locking bolt or latch valve (1) to their specified torques. When all screws are tightened, check that the advance piston moves freely within the advance housing.

6 7

A1013

3 4

5 6 7

A1295A1014

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4.5.3 2 Bolt Cold Advance fitted to single piston design

A) Assembly of the CA piston

Place the CA piston (2), with its open end uppermost, in a vice fitted with soft jaws and grip the piston lightly. Put the shim(s) (3), and the inner and outer springs (4) and (5) into the piston, followed by the stop tube (6), with its larger bore facing upwards.

Note:

If either the CA housing or the advance housing has been replaced (or both have been replaced), a new stop plug (7) must be fitted.

Place the stop plug onto the piston with its shorter taper facing the piston. Place the screw (9) in the recessed end of the phase plate (8) and then put the screw down through the spacer. Push the screw down to compress the springs, fit it into the head of the piston and tighten the screw to the specified torque.

Place the piston assembly in the CA housing.

Note:

It is essential that only the specified torque is applied, and no more, to ensure that the screw remains tight in service, but is not overstressed.

B) Fitment of the CA housing to the AA device

Dip a new O-ring (1) in clean test oil and fit it to the groove in the CA housing (2). Fit the CA assembly to the AA device and secure it with the two screws (3) and (4) (without washers). Tighten the screws to their specified torque.

A1487

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A1485A1486

REASSEMBLY

C) Fitting the wax motor

If a new CA housing (1) has been fitted, realign the pump so that the wax motor aperture faces upwards. Place the spring (2) into the housing, followed by the ball valve (3). Place a new valve seat (4) over the ball.

Use a suitable, clean, piece of hard plastic rod with a flat and "square" end to centralise the seat over the ball. Press carefully down on the rod and tap it lightly to "start" the seat into the housing bore, ensuring that no plastic chippings are released into the device; do not press the seat fully down.

Remove the rod; dip a new O-ring (5) in clean test oil and fit it into the recess in the CA housing. Carefully screw the wax motor (6) into the housing, ensuring that the valve seat is not displaced. Screw the motor fully into position and tighten it to the specified torque. This action will automatically place the valve seat in the correct position.

A1489

REASSEMBLY IV

D) Fitting the pressure end plug

Using the appropriate seal protection sleeve, fit a new O-ring to the pressure end plug. Screw the plug in to the advance housing and tighten to the correct torque value.

E) 2 Bolt Cold Advance fitted to servo piston design

Fit the cold advance piston sleeve (310), fitted with two new O-rings (309), into the wax motor housing (302). Fit the piston (326) into the sleeve.

Fit a new O-ring (308) in the wax motor housing groove and secure the housing to the advance housing using the two securing screws (301). To prevent distortion, evenly tighten the screws to the specified torque value.

EVD03

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4.5.4 4 Bolt Cold Advance fitted to servo piston design.

Fit the spring seat (408) flat face first into the wax motor housing followed by the spring (409). Fit the cam (410) stepped end first into and on to the end of the spring ensuring that the groove along one side of the cam locates with the guide pin in the wax motor body.

Fit a new O-ring (306) into the recess in the CA housing and screw the wax motor (307) into the housing and tighten to the correct torque value.

4.6 Transfer Pump And Endplate Assembly

EVD04

4.6.1 Transfer pump

A) Tightening the transfer pump rotor

Fit a Woodruff key to the keyway in the drive shaft and fit a "slave" drive hub (if one is not specified for the pump). Fit the drive shaft nut and leave it just tight enough to hold the hub. Fit the specified tools (1) and (2) to the drive hub and transfer pump rotor respectively. Tighten the rotor against the normal direction of pump rotation, to the specified torque.

B) Internal recirculation

If fitted, fit the retaining spring (143) to the poppet valve (142). Fit this assembly into the recess in the hydraulic head barrel, curved surface face first. Compress the spring carefully with the transfer pump liner as it is fitted into the barrel of the hydraulic head.

A1038

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EVD05

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C) Assembling the transfer pump

Fit the transfer pump liner (1) into the head. The cut- out (6) in one end face of the liner must be positioned at the lowest point in the liner cavity i.e. approximately the 6 o'clock position.

The locating groove (2) in the liner must be positioned so that it wi ll align with the spring dowel pin in the face of the end plate. The position of that pin is determined by the direction of rotation of the pump.

Lubricate a new transfer pump sealing ring (4) with clean test oil and fit it into its groove in the head. Fit the split steel transfer pump blades (3) and the springs (5).

4.6.2 Endplate assembly

REASSEMBLY

REASSEMBLY IV

A964

A1017

A965

A) Viscosity compensating design

Confirm that the spring dowel pin (1) is inserted into the correct hole in the inner face of the end plate, for the direction of rotation of the pump. The letter "C" embossed on the outer face of the end plate shows the position of the pin for clockwise rotation (when viewed from the pump drive end).

Using the appropriate seal protection cap fit a new O-ring (5) to the groove (7) in the regulating sleeve. Insert a new adjusting plug (9) into the threaded end of the sleeve using an Allen key. Refer to the Test Plan for the initial setting position of the adjusting plug. Later designs have an O-ring fitted, instead of a 'Tufloc' patch.

A1018b

Invert the regulating sleeve and insert the regulating spring (8), followed by the regulating piston (6) into the opposite end. Fit the piston retainer (4) over the lower end of the sleeve, ensuring that it is pushed fully into position. Note that the retainer may be formed with either a detent or a "sprag" to ensure its retention on the sleeve.

Fit the spring seat washer (2) and the sleeve retaining spring (3) into the end plate. Ensure that the sleeve O-ring is moistened with test oil and place the sleeve assembly, with the adjuster uppermost, into the end plate, followed by the filter (10). Using the appropriate protection sleeve, fit a new O-ring (11) to the fuel inlet connection (12) and screw the connection into the end plate ensuring that the slot (13) is aligned over the tangs (14) on the sleeve, leaving it finger-tight.

Note:

The fuel inlet connection may be specified with male or female threads for connection to the fuel supply pipe.

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B) Non-viscosity compensating design

Insert the priming spring (288) into the bottom of the end plate housing (150) ensuring the spring remains correctly positioned and does not turn on to its side. Fit a new sealing washer (248) to the regulating sleeve (245) and insert the regulating piston (287) into the sleeve. Place the sleeve and piston into the end plate with the sleeve priming port at the bottom.

Place a new filter (242) with its flange uppermost, into the endplate and push it gently and firmly down until squarely seated on the top of the sleeve.

Fit the regulating spring and peg (286) into the sleeve, followed by the adjuster assembly (285) with the screw adjuster socket head upper most and the retaining spring (284). Fit a new O-ring (241) to the fuel inlet connection (240) and screw into the endplate assembly finger tight.

REASSEMBLY

A493b

C) Sandwich plate

Fit the sandwich plate (1) into the recess in the endplate (2), with either face outwards if new, but with the same face towards the transfer rotor if the original plate is to be used again. The spring dowel pin will control the position of the groove in the edge of the plate.

Note:

If the original sandwich plate shows any signs of scoring, do not reverse it as this will cause internal leaks and affect the efficiency of the transfer pump; it must be replaced.

D) Fitting the endplate assembly

Fit the endplate in position, matching the slot in the liner to the spring pin. Fasten the endplate with the four Allen screws (2) and (3) tightened progressively and diagonally to the specified torque.

Tighten the fuel inlet connection (1) to the specified torque.

Check that the drive shaft rotates freely.

A1020

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A1305a

REASSEMBLY

E) Transfer pressure accumulator

Dip new O-rings (1) and (2) in clean test oil and fit them to the accumulator, using the specified seal protection cap. Fit the accumulator to the endplate and tighten it to the specified torque.

REASSEMBLY IV

F) Fitting the support bracket to the hydraulic head

If specified, fit the pump-to-engine support bracket (1) in the position noted during dismantling and tighten the screws (3) and (4), progressively and diagonally, to their specified torque.

If the position of the plate was not noted during dismantling, its orientation may be determined by reference to the position of the engine manufacturer's adaptor plate for anchorage of control cables (if fitted). The adaptor plate will be retained by fixings through the holes (2). The cable holes should align with the free ends of the throttle lever and the exhaust brake lever (if specified).

A1490

A1021

Note:

On some applications, fitting of the support bracket may be deferred until after governor link length has been set. The vernier gauge used for the setting procedure will foul on the bracket.

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4.7 ESOS And High Pressure Outlets

4.7.1 ESOS or blanking plug

Note: 1 If the solenoid (1) is of the later type, the spring

(3) will be attached to the plunger (4) and is not replaceable.

Note: 2 It is essential that the specified solenoid is fitted,

as there are versions available which operate in the reverse sense to all others or require additional wiring and resistors. Refer to the Despatch Number and SIN DT294 for correct details.

REASSEMBLY

A1292

If detachable electrical connections are specified for the solenoid fit the terminal blade (5) to the solenoid, retained by the washer (7) and nut (6).

Fit a new O-ring (2) to the solenoid body (1), using the appropriate seal protection sleeve. Place the plunger return spring (3) into the solenoid, followed by the plunger (4), with the flexible seal end outwards. Later designs have captive plungers. Screw the assembly into the hydraulic head and leave it finger tight.

If a blanking plug is specified, dip a new O-ring in clean test oil and fit it to the plug, using the appropriate seal protection sleeve. Screw the plug into the hydraulic head, leaving it finger-tight.

The solenoid (or plug) will be removed for fitment of a pressure gauge during testing.

4.7.2 High pressure outlets and clamp plate

Reposition the Hydraclamp to place the pump axis vertically, with the end plate uppermost.

The outlet connections may be fitted either with pressurising valves (4) (which are factory-sealed units), or delivery valves (6).

A1022A1035

A1023

A) Pressurising valves

Into each high pressure outlet of the hydraulic head fit a new sealing washer (1) then fit the pressurising valve (4) leaving it finger-tight.

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B) Delivery valves

Into each high pressure outlet of the hydraulic head fit a new sealing washer (1), delivery valve body and valve (2). Fit the spring peg (5), and spring (3) to a new holder (6) and fit the holder to the outlet, leaving it finger-tight.

Note: 1 The delivery valve holders must not be lubricated

before fitment to the hydraulic head.

Note: 2 Delivery valve holders which have been fitted to

a pump and tightened to the correct torque must not be used again. They must be replaced.

When all of the delivery valve holders have been fitted, tighten them progressively to their initial specified torque then rotate each holder through the specified additional angle (see Section 6).

Fit the high pressure outlet clamp plate (7), followed by a nut (8) on each outlet; tighten the nuts progressively to their specified torque.

REASSEMBLY IV

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4.8 Governor Linkage, Control Bracket And Cover

4.8.1 Governor linkage

On to the linkage hook (10) place the spring retainer (11), long spring (7), and washer (4). Feed the linkage hook through the smaller (12) of the two holes in the upper part of the governor arm (5) and then fit the pivot ball washer (3) with its dome towards the governor arm, plain adjusting nut (2), and self-locking nut (1). Leave the nuts at the outer end of the thread. Their final position will be established when the link-length is set.

Engage the hook of the link with the roller (9) of the metering valve, with the open end of the linkage hook facing the metering valve lift stop (8).

Assemble the control arm to the support bracket (6) as shown.

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4.8.2 Fitting the governor assembly to the pump

REASSEMBLY

Realign the Hydraclamp to place the pump axis horizontal.

Align the governor thrust sleeve so that the "flats" are horizontal and visible through the access hole (1). Ensure that the locating hole in the spacer (6) is aligned with the governor control plate fixing screw hole at (2). Align the scroll plate slots (3) and (4) with the metering valve bore (5).

Insert the metering valve (3) into its bore. Fit the assembled control arm and control bracket (1) into the pump to rest the control arm forks on the flats on the thrust sleeve. Fit the arms of the scroll link plate (2) into the scroll plate slots.

Fit a new tab washer, so that its lip will face downwards, to the fixing screw with the longest shank, followed by the spring stop (6). Fit the screw at position (5), ensuring that it enters the hole in the internal spacer. Ensure that the detent (11) is located correctly in the corresponding hole in the governor control plate.

Fit a new tab washer to screw (10), with its lip positioned as shown at (9).

Fit screws (7) and (8). Check that the governor assembly is in the correct

position, and then tighten all control bracket screws to their specified torques and bend up the locking tabs.

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4.8.3 Fitting the scroll link plate return spring

Fit the spring (3) over the spring pin up to the pin shoulder (1). Fully compress the spring; carefully grip the pin and the spring and insert the exposed end of the pin into the hole in the scroll link plate (5).

Transfer grip to the exposed end (4) of the pin, push the scroll link plate towards the pump centreline and fit the spigot of the pin into the hole (2) in the spring stop.

CAUTION

There is a risk of the spring and pin being ejected at high speed if grip is relaxed before the pin is securely fitted into the spring stop.

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4.8.4 Setting the governor link length

Push the governor control arm (3) fully towards the hydraulic head and hold it in position. Using a vernier caliper, measure the distance between the circular upper part of the control bracket screw (4) and the lower part of the metering valve roller (6), below the link hook (5). Ensure that the caliper leg does not enter the hook locating groove in the metering valve roller.

Use the adjusting nut (2) to set the link length to the dimension quoted in the Test Plan then hold the adjusting nut with a spanner and tighten the selflocking nut (1).

Re-check the link length with the caliper and readjust it if necessary.

Note:

If fitting of the support bracket was earlier deferred, it should now be fitted.

REASSEMBLY IV

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4.8.5 Fitting the governor assembly for torque trimmer variant

A) Fitting the carriage angle plate

Place the angle plate (1) at about 45 degrees as shown, onto the scroll link carriage between the two arms (3) and (4). Rotate the angle plate clockwise to fit it under the two arms (2) and (3) which must fit into the gap (5).

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B) Fitting the carriage return spring stop, the control plate screws and the maximum fuel screw

Place the spring stop (5) onto the governor control plate (2) as shown and fit the small hexagon-headed screw (6), leaving it finger tight. Fit the dome- headed screw (4), also leaving it finger tight.

Note:

No washers are fitted to these screws.

Fit new tab washers to the two remaining screws (1) and (8) and fit the screws to the pump, ensuring that the tabs are located correctly over the edge of the control plate. Note that the screw (1) has a plain extension to its shank that passes down through the housing to locate the inner bearing.

Tighten all four screws to their specified torques and bent the tabs to lock screws (1) and (8).

Check that the scroll link carriage moves smoothly.

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Fit a new retaining clip (9) to the fuel adjustment screw (3) and place the retaining clip into the angle plate with its open side facing upwards as shown. Fit the threaded end of the screw to the scroll link plate at (7). Rotate the adjustment screw either just enough to ensure that the thread has been engaged correctly, or to any other position specified in the Test Plan.

Note:

If, during setting and testing, the position of the delivery screw has to be altered more than 10 times, the retaining clip must be replaced to ensure satisfactory performance throughout the product life.

C) Fitting the governor linkage components

Place the linkage hook (7) over the metering valve roller (8) with its open side positioned as shown. Fit the large spring seat (6) to the hook, followed by the spring (5) and the small spring seat (4). Fit the hook through the small hole in the governor plate (9). Fit the pivot ball washer (3) with its domed side towards the governor plate, adjusting nut (2) and self-locking nut (1) to the hook.

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D) Fitting the scroll link plate return spring

Grip the spring pin (1) lightly with thin-nosed pliers and place the spring (3) over the pin, holding the spring in position. Place the plain end of the pin in the relevant hole in the scroll link carriage (4) and the shouldered end in the hole (2) in the spring stop. Release the pin.

Check again that the scroll link carriage moves smoothly and is returned fully to its rest position by the spring.

REASSEMBLY IV

E) Setting the governor link-length

Set a vernier caliper to the link-length specified in the Test Pan. Push the scroll link carriage against the return spring to allow one leg of the gauge to be placed against the circular head of the control plate screw (5). Place the other leg against the metering valve roller (4). Ensure that the gauge leg does not slip into the groove in which the link hook (3) is located.

Note:

For some pump specifications it may be necessary to remove the support plate from the hydraulic head to allow correct use of the vernier caliper.

Adjust the nut (2) and lock nut (1) to obtain the required dimension. Tighten the lock nut and check that the setting has not been disturbed.

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4.9 Assembling The Governor Cover

4.9.1 Governor cover only

A) Exhaust brake/manual shut-off control shaft and "trapped" O-ring

Fill the grease groove (3) on the shaft with the specified grease. Using the appropriate seal protection cap fit two new O-rings (1) to the grooves (2) and (4). Fit the shaft into its bore in the governor cover, ensuring that it is pushed fully into position. Rotate the shaft until the "upturn" on the lever is against the flat inside face of the governor cover (6).

Fit a new large O-ring (5) to the groove in the governor cover.

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B) Throttle shaft and governor main spring

Fit the specified seal protection sleeve over the throttle shaft (9); slide two new O-rings into position at (7) and (8).

Fit the idling spring (2) and the pivot ball washer (3) (with its spherical face towards the governor arm (4)) to the spring guide (1). Fit the guide through the large hole in the governor arm.

Hook one end of the governor main spring (5) through the hole in the end of the guide and the other end through the hole in the throttle shaft link (6).

Note:

Early designs of throttle shafts had 3 holes. The hole to be used will be stated in the Test Plan.

Fill the throttle shaft grease groove (10) with the specified grease.

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C) Fitting the governor cover

Moisten the shaft with clean test oil and push it up through the hole (1) in the governor cover.

Press the shaft firmly into place. Place the cover assembly onto the pump, locating the dowel pin (3), if fitted, into the hole (2) in the cover, and secure the cover with the four Torx screws, tightened to their specified torque.

Note:

Some pumps use fitted Torx screws in place of the dowel pin. Fit the four Torx screws leaving them finger tight. Check that the throttle lever and exhaust brake lever (if fitted) operate smoothly over their full ranges before tightening the Torx screws to their specified torque.

REASSEMBLY IV

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4.9.2 Governor cover fitted with hydraulic excess fuel

A) Piston and sleeve assembly

Fit the excess fuel pin (819) into the guide (818), then the return spring (817). Retain the spring with the circlip (816) located in the pin groove.

Fit the pin assembly, guide first, into the excess fuel bore in the governor cover. Dip the piston sleeve (814) in clean test oil, fit a new O-ring (815) and press the sleeve firmly into the cover, O-ring end first.

Fit the excess fuel piston (813), open end inwards, into the piston sleeve and over the return spring.

B) Transfer tube

Lubricate two new O-rings (214) to the transfer tube (275) fitted on the side of the pump body adjacent to the hydraulic excess fuel chamber in the governor cover.

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C) Governor cover

At the later stage of assembly (depending on which other features are fitted) when fitting the governor cover, the hydraulic excess fuel device has to be engaged with the scroll link assembly fork by compressing the piston assembly and afterwards checked for positive location.

Lower the governor cover onto the pump housing. Press the excess fuel piston (813) in and locate the head of the excess fuel pin (819) over the scroll link assembly fork.

Temporarily secure the governor housing with two diagonally opposite screws (508) finger tight. Insert a suitable probe into the maximum fuel stop screw hole to abut the scroll link plate assembly. Push the probe in gently, but firmly. If the scroll link plate assembly appears to be spring loaded, the excess fuel pin is NOT correctly located and the procedure for engaging the pin must be repeated.

REASSEMBLY

D) Excess fuel piston closing plug

Fit a new O-ring (812) to the excess fuel plug (811). Dip the plug in clean test oil and fit it in the excess fuel bore. Retain the plug with the circlip (810).

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4.9.3 Governor cover fitted with boost control only

BOOST CONTROL DEVICE

Note:

The diaphragm assembly is a factory-assembled item. If the boost control has been fully dismantled and removed from the governor control cover, carry out the following

reassembly and procedure.

A) Fitting the fuel adjustment screw

Use an Allen key (1) to screw the socket-headed fuel adjustment screw (2) into the hexagon side (3) of the diaphragm assembly, until the plain end protrudes approximately 2mm above the bottom of the spring cup (4) (not the bottom of the O-ring recess). Fit a new O-ring (5) fully into the recess. The adjustment screw will be finally set during testing.

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B) Fitting the boost control housing

The diaphragm stroke adjustment screw body (3) is supplied with a patch of "Eslok" thread sealing compound, therefore a new screw body must always be used when reassembling the boost control. Grip the screw body lightly in a vice fitted with soft jaws. Fit a new O-ring (2) to the stroke adjustment screw (1), dip the screw in clean test oil and screw it into the body until the O-ring is just concealed. Remove the screw body from the vice.

Fit the shim (4), to the stroke adjustment screw body; place the body into the bore in the housing (5).

Fit the housing to the governor control cover with a new O-ring (7). Ensure spring pin (6) in the governor cover locates in the cut-out in the boost housing.

Tighten the adjustment screw body to the specified torque using the special tool.

Insert the fuel control pin (5) into the bore of the stroke adjustment screw.

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C) Fitting the diaphragm

Fit the specified thickness of spring shim (4) into the boost control housing and over the stroke adjustment screw body, followed by the spring (3). Place the spring seat (2) into the spring cup of the diaphragm assembly (1) and place the diaphragm assembly over the spring, ensuring that the seat remains in the cup.

D) Fitting the cover

Fit the cover (1) to the housing and secure it with the two screws (2) and (3).

Note: 1 At this stage, the position of the boost pressure

inlet (1) is not important.

REASSEMBLY

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Note: 2 If the boost cover is a tamper resistant version,

then the use of an old cover allowing fitment of the setting gauge will be required until after the stroke and/or fuel settings have been made.

E) Setting the boost stroke

a) Fitting the gauge

Fit the special tool (3) and dial gauge (2) to the cover, locking the gauge in position with the grub screw (4). Set the gauge to zero then fully depress the gauge pin (1) against the diaphragm spring and note the reading. This "boost stroke" will be specified in the test plan.

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b) Adjusting the stroke

If adjustment is required, remove the cover and dial gauge and the inner components. Clockwise rotation of the stroke adjustment screw (1) will increase stroke. Replace the inner components, cover, gauge and tool to check the stroke.

When the stroke has been set, remove the gauge and tool from the cover and tighten the two housing cover screws to their specified torques.

Note:

If the boost cover is a tamper resistant version, then the use of an old cover allowing fitment of the setting gauge will be required until after the stroke and/or fuel settings have been made.

F) Fitting the cover plug (non-tamper resistant version) and backleak connection

Using the specified protection sleeve fit a new O- ring (2) to the closing plug (1). If specified, fit the pre-load spring (4) into the cover and fit the shim (3) to the plug. Fit the plug to the cover (5) and leave it finger tight.

If a backleak pipe (11) is specified, fit a new rubber olive (9) up to the swaged collar next to the tube nut (10) on the backleak connection. Fit the connection to the boost control body (8) and the governor control cover, using new sealing washers (7) either side of the banjo. Tighten the fuel return connection (6) to its specified torque.

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G) Exhaust brake/manual shut-off control shaft and "trapped" O-ring

cover, ensuring that it is pushed fully into position. Rotate the shaft until the "upturn" on the lever is against the flat inside face of the governor cover (6).

Fit a new large O-ring (5) to the groove in the governor cover.

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H) Throttle shaft and governor main spring

Fit the specified seal protection sleeve over the throttle shaft (9); slide two new O-rings into position at (7) and (8).

Fit the idling spring (2) and the pivot ball washer (3) (with its spherical face towards the governor arm (4)) to the spring guide (1). Fit the guide through the large hole in the governor arm. Hook one end of the governor main spring (5) through the hole in the end of the guide and the other end through the hole in the throttle shaft link (6).

Note:

Early designs of throttle shafts had 3 holes. The hole to be used will be stated in the Test Plan.

Fill the throttle shaft grease groove (10) with the specified grease.

REASSEMBLY

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I) Fitting the governor cover

Moisten the shaft with clean test oil and push it up through the hole (1) in the governor cover.

Note:

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4.9.4 Governor covers fitted with torque control and torque control plus boost control

A) Torque control only

Fitting the pivot-plug. If the cam follower and pivot-plug were removed

during Dismantling, dip a new O-ring (2) in clean test oil and fit it to the pivot-plug (1), using the appropriate seal protection cap. Fit the pivot-plug to the governor control cover and screw it in finger- tight. Fit washer (4) to the pivot plug spindle (5) then the cam follower (6) retained by a new circlip (3) as shown.

B) Boost control with torque control

Note:

The diaphragm assembly is a factory-assembled item.

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If the boost control has been fully dismantled and removed from the governor control cover, carry out the following reassembly and procedure.

Dip a new O-ring (5) in clean test oil and place it in the recess in the governor control cover. Locate the boost control housing (4) over the dowel pin (6) and secure it in position using a new adjustment screw body (3) (and shim (7) if fitted), if necessary. Use the special tool to tighten the body to the specified torque.

Dip a new O-ring (2) in clean test oil and fit it to the adjusting screw (1), using the specified seal protection cap. Fit the screw into the stroke adjustment screw body and screw it into the body until the O-ring is just concealed, or to a position specified in the relevant Test Plan.

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C) Fitting the spindle

Place the shim (4) into the recess in the boost control housing, followed by the spring (3). Fit the spring plate (2) to the spindle (1) and place the spindle assembly through the spring and the adjustment screw (5).

Do not yet fit the cam follower to the spindle.

D) Fitting the cover

Fit the diaphragm assembly to the boost control housing.

Fit the cover (1) to the housing and secure it with the two screws (2) and (3).

REASSEMBLY

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Note: 1 At this stage, the position of the boost pressure

inlet is not important.

Note: 2 If the boost cover is a tamper resistant version,

then the use of an old cover allowing fitment of the setting gauge will be required until after the stroke and/or fuel settings have been made.

E) Setting the boost stroke

a) Fitting the gauge

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b) Adjusting the stroke

When the stroke has been set, remove the gauge tool and temporarily remove the cover.

REASSEMBLY IV

F) Fitting the cam follower

Hold the diaphragm in position and invert the governor control cover. Place the washer (1) and the cam follower (4) over the spindle (2) and up to the shoulder on the spindle, with the "shaped" section of the follower facing into the "window" (5) in the torque control bore. Fit a new circlip (3) into the groove in the spindle.

G) Fitting the preload spring and cover plug

Invert the governor control cover again and place it on the bench. If specified, fit the shim to the "cup" in the lower face of the diaphragm assembly (1) and fit the assembly to the boost control housing.

Place the boost control cover over the diaphragm with the air inlet connection (2) facing in the correct direction as noted during dismantling and secure it in position with the two screws (4), tightened to the specified torque.

Fit the shim (5) and pre-load spring (6) (if specified) into the boost control cover (3). If fitted, fit a new O- ring to the cover plug, using the specified seal protection cap, and fit the plug to the cover, leaving it finger-tight. (Tighten the plug to the specified torque when the governor cover has been secured to the pump housing.)

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Note:

Later designs of cover may either be plain or have a small central plug bolt and sealing washer.

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H) Cover locating dowels (if fitted)

Examine the governor cover locating dowel pin (1) (if specified) and check that its protrusion above the flat surface of the pump housing is within the limits of dimension "Y" shown.

Note:

Later pumps may not be fitted with dowel pins, but may be specified with "fitted" governor cover fixing screws to ensure that the components in the governor cover and in the governor assembly remain in their correct relative positions.

REASSEMBLY

Section X - X

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Y = 4.25 ± 0.25 mm

I) Assembling the torque trimmer

Dip a new O-ring (9) in clean test oil and fit it to the plain plug (10), using the appropriate seal protection cap. Fit the plug into the plain bore in the governor control cover (7), pushing it in just far enough to reveal the circlip groove. Fit a new circlip (11) into the groove. From the opposite end of the torque trimmer bore, use a suitable bar to push the plug back against the circlip.

Fit the torque trimmer piston (8) into the open end of the torque trimmer bore, with the conical recess in the piston facing outwards (i.e. towards the "spring" end). Fit the torque trimmer cam (6), with the small conical end facing the piston. Fit the small spring (5) (if specified) into the hollow end of the cam, followed by the spring plate (4) (if specified) and the large spring (3).

Dip a new O-ring (2) into clean test oil and fit it to the threaded pre-load plug (1), using the appropriate seal protection cap. Fit the plug to the governor control cover and screw it in to the position specified in the relevant Test Plan. If no position is specified, leave the plug protruding from the cover by approximately 4 mm. The final position of the plug will be set during Testing.

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J) Exhaust brake/manual shut-off control shaft and "trapped" O-ring

Fit a new large O-ring (5) to the groove in the governor cover.

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K) Throttle shaft and governor main spring

Fit the specified seal protection sleeve over the throttle shaft (9); slide two new O-rings into position at (7) and (8).

Note:

Early designs of throttle shafts had 3 holes. The hole to be used will be stated in the Test Plan.

Fill the throttle shaft grease groove (10) with the specified grease.

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L) Fitting the governor cover

Moisten the shaft with clean test oil and push it up through the hole (1) in the governor cover. Press the shaft firmly into place. Place the cover assembly onto the pump, locating the dowel pin (3), if fitted, into the hole (2) in the cover, and secure the cover with the four Torx screws, tightened to their specified torque.

Note:

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4.9.5 Governor covers fitted with electronic actuator

The only items of the actuator that may be replaced are the electrical connector (2), the gasket (1) and the screws (3). The O-rings (557) must be replaced each time the actuator is removed from the governor cover.

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Delphi DP200 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

TABLE OF CONTENTS

1.1 The Pump

INTRODUCTION

1.2 General

1.3 This Manual

1.4 Equipment

1.5 Replacement Of Parts

1.6 Pump Name Plate

DISMANTLING

2.1 Preparation

2.1.1 Cleaning and draining

2.1.2 Mounting the pump

2.1.3 Removing sealing caps and locking wire

2.1.4 Removing the drive hub (if fitted)

2.1.5 Measuring drive shaft end float

2.1.6 Measuring drive shaft radial play

2.2 Governor Cover, Control Levers & Link Assembly

2.2.1 Removing the fuel return connections

2.2.2 Removing the throttle lever stop screws, maximum fuel screw, and torque control screw

2.2.3 Removing the throttle lever

2.2.4 Removing the exhaust brake lever

2.2.5 Removing the electronic actuator throttle lever (rigid type)

2.2.6 Removing the governor cover assembly

2.3 Dismantling The All-Speed Govenor

2.4 Removing The Control Bracket And Arm Assembly

2.4.1 Removing the scroll link plate return spring

2.4.2 Removing the governor control bracket assembly

2.4.3 Dismantling the governor control arm assembly

2.4.4 Dismantling the governor control plate assembly for torque trimmer variant

2.5 High Pressure Outlets Assembly, Electric Shut-off Solenoid (ESOS) & Transfer Pump

2.5.1 High pressure outlets

2.5.2 Endplate assembly

2.6 Electric Shut-off Solenoid (ESOS)

2.7 Transfer Pump

2.7.1 Removing the transfer pump components

2.7.2 Slackening the transfer pump rotor

2.8 Advance Device

2.8.1 Single piston design with 2 bolt cold advance (CA)

2.8.2 Servo piston design with 2 bolt Cold Advance

2.8.3 Servo piston design with 4 bolt cold advance

2.8.4 Single piston design without cold advance

2.9 Removing The Head Locking Screws And Releasing The Hydraulic Head

2.9.1 Head locking screws

2.9.2 Removing and dismantling the LLA

2.9.3 Removing and dismantling the latch valve

2.9.4 Removing the hydraulic head

2.10 Drive Shaft

2.10.1 Dismantling the Zero Backlash Drive assembly

2.10.2 Dismantling the splined drive assembly

2.11 Dismantling The Hydraulic Head - Check And Cheek Plate Designs

2.11.1 Releasing the drive plate screws

2.11.2 Dismantling the rotor components

2.11.3 Removing the lower check or cheek plate

2.11.4 Reverse thrust weight assembly

2.11.5 Lock-shaft timing

2.11.6 Removing the drive shaft seal/s

COMPONENT INSPECTION AND RENEWAL

3.1 Cleaning

3.2 GeneraL

3.2.1 Mated and matched assemblies

3.2.2 Examination and replacement

3.2.3 Seals

3.3 Details

3.3.1 Hydraulic head rotor

3.3.2 Hydraulic head plungers

3.3.3 Cam ring and scroll plates

3.3.4 Rollers and shoes

3.3.5 Transfer pump

3.3.6 Endplate

3.3.7 Control valves

3.3.8 Delivery valves and cambox pressurising valves

3.3.9 High pressure outlet pressurising valves

3.3.10 Springs

3.3.11 Fittings and threads

3.3.12 Linkages

3.3.13 Control shafts