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WORKSHOP MANUAL DP200 SERIES FUEL INJECTION PUMP DDNX121(EN) 2006

Bomba injetor Série - Dp200 Delphi

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  • 1. WORKSHOP MANUAL DP200 SERIES FUEL INJECTION PUMP DDNX121(EN) 2006
  • 2. (D) Kommen Sie nicht mit dem Hochdruckstrahl in Verbindung! Besonders nicht, wenn Druckrohrleitung oder Dichtung geprft werden! Hochdruckflssigkeiten knnen tdliche Verletzungen verursachen! Im Falle einer Berhrung 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 lquido, especialmente inyectores, tuberas y juntas de alta presin con fugas. La inyeccin de alta presin puede perforar la piel humana y producir una lesin fatal. En caso de que la inyeccin atraviese la piel, consiga atencin mdica 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, particulirement ceux provenant des fuites de tuyaux et des joint soumis a la haute pression. Le liquide sous haute pression inject sous la peau peut causer des blessures mortelles. En cas dinjection sous la peau, consulter immdiatement un mdecin. Se reporter a la fiche de sant et de scurit 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) No exponha a pele a jactos de combustvel sob presso, especialmente os devidos a fugas de tubos de presso ou vedantes. Lquidos a alta presso podem causar ferimentos mortais. No caso de injeco subcutnea, consulte imediatamente um mdico. Consulte por favor a documentao respeitante a sade e segurana de combustveis. (D) Schutzbrille/Gesichtsschutz tragen. (E) sese proteccin 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 proteco da face/olhos. (D) Von Zndquellen 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 l'cart de toute flamme ou source d'tincelles - 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 ignio Proibido fumar. (D) Geeignete Schutzhandschuhe tragen. (E) Usen guantes adecuados. (EN) Wear suitable gloves. (F) Porter des gants appropris. (IT) Usare guanti adatti. (NL) Aangepaste veiligheidshandschoenen dragen. (P) Use luvas apropriadas.
  • 3. CONTENTS INTRODUCTION 1 DISMANTLING 2 COMPONENT INSPECTION AND RENEWAL 3 REASSEMBLY 4 TEST PROCEDURE 5 TOOLING, TORQUES & EVDS 6 Delphi Diesel Systems Ltd Publication N: DDNX121(EN) Issue 2 of 09/2006 i
  • 4. NOTATIONAL CONVENTIONS AND ABBREVIATIONS BC - Boost Control CA - Cold Advance CP - Zero Backlash Drive DCU - Diesel Control Unit ESOS - Electric Shut-Off Solenoid EVD - Exploded View Diagram FIE - Fuel injection Equipment HP - High Pressure LLA - Light Load Advance PECSA - Pressure End Cold Servo Advance SECSA - Spring End Cold Servo Advance SIN - Service Instruction Note TP - Transfer Pressure Produced by: Delphi Diesel Systems Ltd. Diesel Aftermarket Spartan Close Warwick CV34 6AG Tel.: (44) (0)1926 472 900 UK Fax: (44) (0)1926 472 901 ii Delphi Diesel Systems Ltd
  • 5. CONTENTS 1 INTRODUCTION 1.1 The Pump ........................................................................................................................................................................7 1.2 General ............................................................................................................................................................................7 1.3 This Manual .....................................................................................................................................................................8 1.4 Equipment .......................................................................................................................................................................8 1.5 Replacement of Parts .....................................................................................................................................................8 1.6 Pump Name Plate ......................................................................................................................................................8 - 9 2 DISMANTLING 2.1 Preparation ....................................................................................................................................................................11 2.1.1 Cleaning and draining .......................................................................................................................................11 2.1.2 Mounting the pump ..........................................................................................................................................11 2.1.3 Removing sealing caps and locking wire ........................................................................................................11 2.1.4 Removing the drive hub (if fitted) ....................................................................................................................12 2.1.5 Measuring drive shaft end float .......................................................................................................................12 2.1.6 Measuring drive shaft radial play ....................................................................................................................12 2.2 Governor Cover, Control Levers & Link Assembly ....................................................................................................13 2.2.1 Removing the fuel return connections ............................................................................................................13 2.2.2 Removing the throttle lever stop screws, maximum fuel screw and torque control screw ......................13 2.2.3 Removing the throttle lever ..............................................................................................................................13 2.2.4 Removing the exhaust brake lever ..................................................................................................................14 2.2.5 Removing the electronic actuator throttle lever (rigid type) .........................................................................14 2.2.6 Removing the governor cover assembly .................................................................................................14 - 19 2.3 Dismantling the All-Speed Governor ..........................................................................................................................19 2.4 Removing the Control Bracket and Arm Assembly ...................................................................................................19 2.4.1 Removing the scroll link plate return spring ..................................................................................................19 2.4.2 Removing the governor control bracket assembly ........................................................................................20 2.4.3 Dismantling the governor control arm assembly ..........................................................................................20 2.4.4 Dismantling the governor control plate assembly for torque trimmer variant ..........................................20 2.5 High Pressure Outlets, End Plate Assembly, Electric Shut-off Solenoid (ESOS) & Transfer Pump ......................21 2.5.1 High pressure outlets ........................................................................................................................................21 2.5.2 Endplate assembly .....................................................................................................................................21 - 22 2.6 Electric Shut-off Solenoid (ESOS) ...............................................................................................................................22 2.7 Transfer Pump ...............................................................................................................................................................23 2.7.1 Removing the transfer pump components .....................................................................................................23 2.7.2 Slackening the transfer pump rotor .................................................................................................................23 2.8 Advance Device .....................................................................................................................................................23 - 24 2.8.1 Single piston design with 2 bolt cold advance ...............................................................................................24 2.8.2 Servo piston design with 2 bolt cold advance ........................................................................................25 - 26 2.8.3 Servo piston design with 4 bolt cold advance ........................................................................................26 - 27 2.8.4 Single piston design without cold advance ............................................................................................27 - 28 2.9 Removing the Head Locking Screws and Releasing the Hydraulic Head ...............................................................28 2.9.1 Head locking screws .........................................................................................................................................28 2.9.2 Removing and dismantling the LLA ................................................................................................................28 2.9.3 Removing and dismantling the latch valve ....................................................................................................29 2.9.4 Removing the hydraulic head ..........................................................................................................................29 2.10 Drive Shaft .....................................................................................................................................................................30 2.10.1 Dismantling the zero backlash drive assembly .......................................................................................30 - 31 2.10.2 Dismantling the splined drive assembly .........................................................................................................31 iii
  • 6. CONTENTS 2.11 Dismantling the Hydraulic Head - Check and Cheek Plate Designs .........................................................................31 2.11.1 Releasing the drive plate screws .....................................................................................................................31 2.11.2 Dismantling the rotor components ..................................................................................................................32 2.11.3 Removing the lower check or cheek plate ......................................................................................................32 2.11.4 Reverse thrust weight assembly ......................................................................................................................32 2.11.5 Lock-shaft timing ...............................................................................................................................................33 2.11.6 Removing the drive shaft seal/s .......................................................................................................................33 3 COMPONENT INSPECTION AND RENEWAL 3.1 Cleaning .........................................................................................................................................................................35 3.2 General ..........................................................................................................................................................................35 3.2.1 Mated and matched assemblies ......................................................................................................................35 3.2.2 Examination and replacement .........................................................................................................................35 3.2.3 Seals ...................................................................................................................................................................35 3.3 Details ............................................................................................................................................................................35 3.3.1 Hydraulic head rotor .........................................................................................................................................35 3.3.2 Hydraulic head plungers ...................................................................................................................................35 3.3.3 Cam ring and scroll plates ................................................................................................................................35 3.3.4 Rollers and shoes ..............................................................................................................................................35 3.3.5 Transfer pump ............................................................................................................................................35 - 36 3.3.6 Endplate .............................................................................................................................................................36 3.3.7 Control valves ....................................................................................................................................................36 3.3.8 Delivery valves and cambox pressurising valves ..........................................................................................36 3.3.9 High pressure outlet pressurising valves ........................................................................................................36 3.3.10 Springs ...............................................................................................................................................................36 3.3.11 Fittings and threads ...........................................................................................................................................36 3.3.12 Linkages .............................................................................................................................................................36 3.3.13 Control shafts .....................................................................................................................................................36 3.3.14 Drive shafts and associated components .......................................................................................................36 3.3.15 Advance device ..................................................................................................................................................36 3.3.16 Levers and external controls ............................................................................................................................36 3.3.17 Pump housing ....................................................................................................................................................36 3.3.18 Governor control cover .....................................................................................................................................36 3.3.19 Orifices ...............................................................................................................................................................36 3.3.20 Electric shut-off solenoid ..................................................................................................................................36 3.3.21 Wax motor ..........................................................................................................................................................37 4 REASSEMBLY 4.1 Preparation ....................................................................................................................................................................39 4.2 Assembling the Hydraulic Head ..................................................................................................................................39 4.2.1 Rotor plug ...................................................................................................................................................39 - 40 4.2.2 Drive plate, rollers, shoes and retaining plates .......................................................................................40 - 42 4.3 Drive Shaft .....................................................................................................................................................................42 4.3.1 Zero backlash and splined drive with cheek plates ................................................................................42 - 45 4.3.2 Spline drive with check plate head and rotor .........................................................................................45 - 46 iv
  • 7. CONTENTS 4.4 Securing the Hydraulic Head and Checking Drive Shaft End Float and Radial Play ..............................................46 4.4.1 Replacing the drive shaft seal/s .......................................................................................................................46 4.4.2 Securing the drive shaft ....................................................................................................................................46 4.4.3 Aligning the hydraulic head .............................................................................................................................47 4.4.4 Checking drive shaft end float ..........................................................................................................................47 4.4.5 Checking drive shaft radial play .......................................................................................................................47 4.4.6 Cam advance screw ..........................................................................................................................................48 4.4.7 Fitting the head locking screws, light load advance valve and latch valves ........................................48 - 49 4.5 Advance Device .............................................................................................................................................................49 4.5.1 Single piston design ..................................................................................................................................50 - 51 4.5.2 Servo piston designs .................................................................................................................................52 - 55 4.5.3 2 Bolt cold advance fitted to single piston design ..................................................................................55 - 56 4.5.4 2 bolt cold advance fited to servo piston design ...........................................................................................56 4.5.5 4 bolt cold advance fitted to servo piston design ..........................................................................................57 4.6 Transfer Pump and End Plate Assembly ...........................................................................................................................57 4.6.1 Transfer pump ...................................................................................................................................................57 - 58 4.6.2 Endplate assembly ...........................................................................................................................................58 - 60 4.7 ESOS and High Pressure Outlets .......................................................................................................................................61 4.7.1 ESOS or blanking plug ............................................................................................................................................61 4.7.2 High pressure outlets and clamp plate ..........................................................................................................61 - 62 4.8 Governor Linkage, Control Bracket and Cover .................................................................................................................62 4.8.1 Governor linkage ......................................................................................................................................................62 4.8.2 Fitting the governor assembly to the pump .........................................................................................................62 4.8.3 Fitting the scroll link plate return spring ...............................................................................................................63 4.8.4 Setting the governor link length ............................................................................................................................63 4.8.5 Fitting the governor assembly for torue trimmer variant ........................................................................63 - 65 4.9 Assembling the Governor Cover .......................................................................................................................................65 4.9.1 Governor cover only ........................................................................................................................................65 - 66 4.9.2 Governor cover fitted with hydraulic excess fuel .........................................................................................66 - 67 4.9.3 Governor cover fitted with boost control only ..............................................................................................68 - 70 4.9.4 Governor cover fitted with torque control and torque control plus boost control ..................................71 - 75 4.9.5 Governor cover fitted with electronic actuator .............................................................................................75 - 77 4.10 Governor Cover External Components .............................................................................................................................77 4.10.1 Fitting backleak components ..................................................................................................................................77 4.10.2 Fitting and aligning external levers .......................................................................................................................78 4.10.3 Control stop screws and plugs ...............................................................................................................................79 4.11 Shaft Locking Screw, Drain Plug and Cam Ring Access Plug ........................................................................................80 4.11.1 Shaft locking screw ..................................................................................................................................................80 4.11.2 Drain plug ..................................................................................................................................................................80 4.11.3 Cover ..........................................................................................................................................................................80 4.11.4 Cam ring access plug ..............................................................................................................................................80 4.12 Drive Hub ..............................................................................................................................................................................80 4.13 Leak Testing ..........................................................................................................................................................................80 4.14 Storage ..................................................................................................................................................................................81 4.14.1 New pumps ...............................................................................................................................................................81 4.14.2 Overhauled pumps ..................................................................................................................................................81 4.14.3 Storage conditions ...................................................................................................................................................81 v
  • 8. CONTENTS 5 TEST PROCEDURE 5.1 Preparation ....................................................................................................................................................................83 5.1.1 Leak testing ........................................................................................................................................................83 5.1.2 Test machine ......................................................................................................................................................83 5.1.3 Test machine drive ............................................................................................................................................83 5.1.4 Test conditions ...........................................................................................................................................83 - 84 5.1.5 Connecting fuel lines ........................................................................................................................................84 5.1.6 Machine test procedure .............................................................................................................................84 - 85 5.1.7 Transfer pressure measurement and initial setting .......................................................................................85 5.1.8 Cambox pressure measurement ......................................................................................................................85 5.1.9 Adjustments to be pre-set .........................................................................................................................86 - 87 5.2 Test Procedure ...............................................................................................................................................................87 5.2.1 Priming ...............................................................................................................................................................87 5.2.2 Checking and setting transfer pressure ...........................................................................................................88 5.2.3 Cambox pressure and backleakage checks .............................................................................................88 - 89 5.2.4 Speed advance setting ......................................................................................................................................89 5.2.5 Cold advance ..............................................................................................................................................89 - 90 5.2.6 Light load advance valve setting .....................................................................................................................90 5.2.7 Boost control with torque trimmer ..................................................................................................................91 5.2.8 Maximum fuel delivery setting .................................................................................................................91 - 92 5.2.9 Latch valve .........................................................................................................................................................93 5.2.10 Governor setting and testing ...........................................................................................................................93 5.2.11 Torque screw setting .........................................................................................................................................93 5.2.12 Idle setting ..........................................................................................................................................................94 5.2.13 Shut-off control check .......................................................................................................................................94 5.3 Timing ............................................................................................................................................................................94 5.3.1 General ........................................................................................................................................................94 - 95 5.3.2 Keyed drive shafts .....................................................................................................................................95 - 96 5.3.3 Keyless drive shafts ...................................................................................................................................96 - 99 5.4 Leakage Testing .............................................................................................................................................................99 6 TOOLING, TORQUES & EVDS 6.1 Tooling ................................................................................................................................................................101 - 103 6.2 Torque values .....................................................................................................................................................104 - 108 6.3 Exploded view diagram ....................................................................................................................................109 - 119 vi
  • 9. INTRODUCTION 1 - 7 1.1 THE 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. DP200 PUMP 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.
  • 10. INTRODUCTION 1 - 8 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 industrial-grade linoleum and fitted with an engineers 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. 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.
  • 11. INTRODUCTION C 89 2 0 A 06 0 L Marketing Code: C = Spain No letter = UK Product Type (DP200) Design Source: 0 = USA 1 = Korea 2&3 = UK 4 = France 5 = Spain 6 = Brazil 7 = India 8 = Poland 9 = Japan 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 manufacturers instructions. 1 - 9 Note 1: The pumps shown in the illustrations do not necessarily represent any one specification, but are used to show particular features. Note 2: As components are removed, inspect them and put those considered unfit for further service to one side for replacement; place those which are fit for further service into a clean compartmented tray. (Trays available through Delphi Diesel Systems Aftermarket Operations, Service Operations Department.) A guide to areas of possible wear or damage appears in Section 3 (Component Inspection & Renewal). Suffix letter - Denotes the type of ESOS fitted. See SIN DT294 Change to the individual specification affecting parts interchangeability, but not fit or function of pump. Individual features number. Design change letter - Has no significance at the time of publication of this manual No. of delivery outlets: 0, 3 & 5 = 4 cyl. 1 & 4 = 6 cyl. 2 = 3 cyl. 6 - 9 to be allocated Fig. 1 Explanation of Despatch Number
  • 12. INTRODUCTION 1 - 10
  • 13. DISMANTLING 2 - 11 A980 A950 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. 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. 1 1 2
  • 14. DISMANTLING 2 - 12 A986 A952 A1005 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 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 thrust-faces during dismantling. If no significant wear or damage is apparent, requiring replacement of the pump housing, correct the end-float by the use of alternative shims during reassembly. 2.1.6 Measuring drive shaft radial play Note: In order to assess the condition of the bearing and drive shaft, radial play must be measured prior to dismantling. With the pump and gauge (1) mounted rigidly relative to each other, adjust the gauge pin to bear (at right angles) against the parallel section (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. Drive type Max. play Max. Difference Belt 0.22 mm 0.1 mm Gear or hub 0.27 mm 0.2 mm 1 2 3 4 1 2 3 4 2 1
  • 15. DISMANTLING 2 - 13 A953 A953 A1006 4 A1007 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). 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 2.2.3.1 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). A1261 A978 A1003 1 2 3 4 5 7 6 1 2 3 5 1 2 3 4 5 6 7 8 2.2.3.2 Break-back type 1 2 3 4 5 6 7 8 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). A1002 6
  • 16. DISMANTLING 2 - 14 A954 1 2 3 4 A1048 A485a 2.2.4 Removing the exhaust brake lever 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). A1256 1 2 3 4 5 6 2.2.5 Removing the electronic actuator throttle lever (rigid type) Slacken and remove the bolt (558) and washers (559 and (560). 2.2.6 Removing the governor cover assembly 2.2.6.1 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. 2.2.6.2 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. 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). 813 814 815 816 817 818 819 A562a 5 6 EVD15
  • 17. DISMANTLING 2 - 15 A955 A788 A787 A568 2.2.6.3 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). Remove the shim(s) from the plug and the pre-load 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). 1 2 3 4 1 2 3 4 5 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. 1 2 3 1 2 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.
  • 18. DISMANTLING 2 - 16 A1257 A1469 A1465 A1466 e) Removing the boost control housing Use the special tool to unscrew and remove the stroke adjustment screw body (1). 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. 2 1 3 4 5 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). 2.2.6.4 Governor cover fitted with Torque Control and Torque Control plus Boost Control Remove pressure end plug circlip (1). 1 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. A1467 1 1 1 2 3 4 5 6
  • 19. DISMANTLING 2 - 17 A1473 A1475 A1477 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). 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. Caution: 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. 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. A1476 A1456 4 7 8 9 3 2 4 5 6 1 3 1 2 4 1 2 3 4 1 5 2 3 6 7 A1048 A1260
  • 20. DISMANTLING 2 - 18 A1470 A1471 A1472 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). 1 2 3 4 5 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). 1 2 3 4 A1473 1 2 3 6 2 4 5 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).
  • 21. DISMANTLING 2 - 19 DT237/2 fig 1 A958 A959 2.2.6.5 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 anti-clockwise direction; this will loosen the washer and at the same time slacken the screw. Discard the screw, the ball and the tamper-evident washer. Carefully remove the actuator from the control cover and then remove and discard the O-rings (557). 2.3 DISMANTLING THE ALL-SPEED GOVERNOR 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. 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. 1 2 3 4 5 6 7 8 1 2 3 5 4
  • 22. DISMANTLING 2 - 20 A1049 A961 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. 1 2 3 4 5 9 8 7 6 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. 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 2.4.4.1 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). 1 2 3 4 5 6 7 8 9 A1492 3 2 1 4
  • 23. DISMANTLING 2 - 21 A962 A963 2.4.4.2 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. 3 2 1 4 A985b 5 6 7 8 1 2 3 4 2.5 HIGH PRESSURE OUTLETS, END PLATE 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. 2.5.2 Endplate assembly 2.5.2.1 Removing the endplate assembly 5 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 6 7 1 2 3 A493A
  • 24. DISMANTLING 2.5.2.2 Dismantling the end plate assembly 2 - 22 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). 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. A1302 A1008 1 2 3 4 5 6 7 A1258 A1284 b) 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). 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. A1018 JPT A493 13 14 1 2 3 5 6 7 8 9 11 12 4 240 241 284 285 242 287 288 245 248 286 10
  • 25. DISMANTLING 2 - 23 A964 A1038 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). CAUTION: 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. 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. 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. b) 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. A965 1 2 3 4 1 2
  • 26. DISMANTLING 2.8.1 Single piston design with 2 bolt cold advance (CA) 2.8.1.1 Removing the wax motor 2 - 24 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). 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. 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). 2.8.1.2 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). 2.8.1.3 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. Caution: The screw will be under considerable tension from the springs. Note: Early pumps may be fitted with pistons that have small flats to assist with clamping in the jaws of a vice. A1485 1 2 3 4 A1486 A1487 1 2 1 2 3 4 5 6 7 8 9
  • 27. DISMANTLING 2 - 25 2.8.2 Servo piston design with 2 bolt Cold Advance 2.8.2.1 Removal of 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). 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. 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). 2.8.2.2 Removing the CA assembly Remove the CA body (302); discard the O-ring (308). 2.8.2.3 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 soft-faced 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). A1485 1 2 3 4 DT167 fig 1
  • 28. DISMANTLING 2.8.2.4 Dismantling the Servo Valve Assembly 2 - 26 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. 2.8.3 Servo piston design with 4 bolt cold advance 2.8.3.1 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 (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). 2.8.3.2 Removing the CA assembly Remove the CA body (302); discard the O-ring (308) and retard pin (406). 2.8.3.3 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 soft-faced mallet to free it from the gasket (415). Remove the head locating fitting and then the EVD010 DT157 fig 1
  • 29. DISMANTLING 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. 2 - 27 2.8.3.4 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. 2.8.4 Single piston design without cold advance 2.8.4.1 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. 2.8.4.2 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 soft-faced 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. A1009 A1294 A1250 1 2 3 4 5 6 7 8 9 11 12 10 10 9 8 7 1 2 3 4 5 6
  • 30. DISMANTLING 2.8.4.3 Removing the cam screw 2 - 28 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. 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. 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). 277 219 218 217 278 222 221 220 A967 A1251 A1011b DT228 fig 4 1 2 1 2 4 3 1 2 3 4 5 6 7 8
  • 31. DISMANTLING 2 - 29 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 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 2.9.4.1 Releasing the hydraulic head Twist and pull the hydraulic head until the large O-ring (1) is just exposed. 2.9.4.2 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. 1 2 3 4 5 6 7 8 9 10 11 A1518 DT228 fig 3 A1495 A1496 1 2 1 11 9 10 6 7 8 a b
  • 32. DISMANTLING 2.10 DRIVE SHAFT 2 - 30 Remove the circlip (1) and thrust washer (2). 2.10.1 Dismantling the Zero Backlash Drive assembly 2.10.1.1 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. 2.10.1.2 Removing the rollers and shoes Remove the rollers and shoes, keeping them in their matched pairs. Note1: The roller shoe (1) in the rotor tang drive slot (2) is longer than the others. Note2: On some later designs, all 4 shoes are the same length. 2.10.1.3 Dismantling the drive shaft assembly 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. 2.10.1.4 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). A970 A1497 A1498 A1499 1 2 1 1 2 3 2 1 4 5
  • 33. DISMANTLING 2 - 31 A1500 A1004 A972 A1290 2.10.1.5 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. 3 2 1 1 1 2 3 4 5 6 7 8 1 2 3 4 2.10.2 Dismantling the splined drive assembly 2.10.2.1 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. 2.10.2.2 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). 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.
  • 34. DISMANTLING 2.11.2 Dismantling the rotor components 2 - 32 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. 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. Note1: 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. Note2: 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. 1 A1304 A1254 1 EVD01 3 4 5 7 A975a 6 1 2 1 2 A1501b 2 3 4
  • 35. DISMANTLING 2 - 33 A977 2 3 1 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. 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.
  • 36. DISMANTLING 2 - 34
  • 37. COMPONENT INSPECTION AND RENEWAL 3 - 35 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. (a) 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. (b) 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. (c) Damage Inspect all parts for damage or bending due to abuse, especially external levers and controls. 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.