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DP200
User Manual
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Delphi DP200 User Manual

WORKSHOP MANUAL
)
DP200 SERIES FUEL INJECTION PUMP
2008
DDNX121A(EN)DDNX121A(EN
(
(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.

TABLE OF CONTENTS

INTRODUCTION I
DISMANTLING II
COMPONENT INSPECTION AND RENEWAL III
REASSEMBLY IV
TEST PROCEDURE V
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008
i
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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© Delphi
DDNX121A(EN) - Issue 1 of 08/2008
INTRODUCTION I
TABLE OF CONTENTS
1.
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
2.
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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© Delphi
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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
3.
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
4.
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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IV REASSEMBLY
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
5.
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
6.
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
7.
APPENDIX
7.1 Abbreviations Used In This Manual........................................................................................................................7-137
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VII APPENDIX
TABLE OF CONTENTS
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© Delphi
DDNX121A(EN) - Issue 1 of 08/2008

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.
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008
1-1
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.
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© Delphi
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).
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008
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I INTRODUCTION
INTRODUCTION
1-4
© Delphi
DDNX121A(EN) - Issue 1 of 08/2008

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
1
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.
1
2.1.3 Removing sealing caps and locking wire
Remove any shrink sleeving, tamperproof caps or locking wire from adjustment screws.
2
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
2
1
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.
1
4
2
3
A952
2-6
© Delphi
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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).
3
2
1
7
6
4
5
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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DDNX121A(EN) - Issue 1 of 08/2008
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).
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A954 A1256
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II DISMANTLING
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
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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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DISMANTLING
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
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1
3
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).
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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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II DISMANTLING
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
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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
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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
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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.
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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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© Delphi
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
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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).
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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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© Delphi
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