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WORKSHOP MANUALDP200 SERIES FUEL INJECTION PUMP DDNX121(EN)
2006
(D) Kommen Sie nicht mit dem Hochdruckstrahl in Verbindung! Besonders nicht, wennDruckrohrleitung oder Dichtung geprft werden! Hochdruckflssigkeiten knnen tdlicheVerletzungen verursachen! Im Falle einer Berhrung mit der Haut, kontaktieren Siesofort 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 perforarla 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 ySeguridad.
(EN) Do not put your skin into the fuel jets under pressure, especially those due to pressurepipe or seal leaks. High pressure liquids can cause deadly injuries. In case of aninjection under the skin, contact a doctor immediately. Please refer to the health andsecurity fuel documents.
(F) Ne pas approcher les mains ni le corps des jets de liquides, particulirement ceuxprovenant des fuites de tuyaux et des joint soumis a la haute pression. Le liquide soushaute pression inject sous la peau peut causer des blessures mortelles. En casdinjection sous la peau, consulter immdiatement un mdecin. Se reporter a la fiche desant 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 pressionepossono causare ferite anche mortali. In caso di iniezione sotto pelle contattareimmediatamente un medico. Fare riferimento alle schede di sicurezza del gasolio.
(NL) Zorg dat uw handen of andere lichaamsdelen niet in contact komen met vloeistofstralenonder hoge druk, met name bij een lek aan een leiding of dichting. Als de vloeistof onderhoge druk onder de huid terechtkomt, kan dit zelfs tot dodelijke verwondingen leiden. Alsde vloeistof onder de huid terechtkomt, onmiddellijk een arts raadplegen. Lees degezondheids- en veiligheidsfiche met betrekking tot de brandstof.
(P) No exponha a pele a jactos de combustvel sob presso, especialmente os devidos afugas de tubos de presso ou vedantes. Lquidos a alta presso podem causarferimentos mortais. No caso de injeco subcutnea, consulte imediatamente ummdico. Consulte por favor a documentao respeitante a sade e segurana decombustveis.
(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.
CONTENTS
Delphi Diesel Systems Ltd
Publication N: DDNX121(EN) Issue 2 of 09/2006 i
INTRODUCTION 1
DISMANTLING 2
COMPONENT INSPECTION AND RENEWAL 3
REASSEMBLY 4
TEST PROCEDURE 5
TOOLING, TORQUES & EVDS 6
BC - Boost Control
CA - Cold Advance
CP - Zero Backlash Drive
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
NOTATIONAL CONVENTIONS AND ABBREVIATIONS
ii
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
Delphi Diesel Systems Ltd
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
CONTENTS
iii
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
CONTENTS
iv
CONTENTS
v
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
CONTENTS
vi
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
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.
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.
DP200 PUMP
INTRODUCTION
1 - 8
1.3 THIS MANUAL
The Dismantling, Reassembly and Testing Sectionsare laid out on a step-by-step basis, with eachaction accompanied by an illustration showing thecomponent(s) involved and, where applicable,its/their positions on the pump. The Manual is notbased on any one specification, but covers pumpfeatures which have been included up to the time ofpublication. For the purposes of illustration, morethan one pump specification has been used.
The pumps illustrated are for clockwise rotation(when viewed from the drive end); anticlockwisepumps will have items such as the maximum fuelscrew, and the boost control fitted on the sideopposite to that shown. In addition, the advancedevice will operate in the opposite mode.
Instructions for both full and partial dismantling ofthe pump are included e.g. total dismantling andexamination of all components other than those thatare factory-sealed units and removal of the hydraulichead and rotor only.
All the necessary tools are listed in Section 6.Special tools are identified by part number andstandard tools by type and size.
1.4 EQUIPMENT
Any tools, both standard and special-purpose, usedfor the servicing or repair of fuel injection equipment(FIE) must be reserved solely for use on FIE. Worn ordamaged tools can cause damage to criticalcomponents, as well as being a safety hazard.
The working area must be scrupulously clean andshould be in a room separated from any otheractivity; the ingress of dust and dirt, airborne orotherwise, 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 vicewith a jaw size of 100 mm (4 in). The vice jaws mustbe faced with either soft metal or fibre pads.
2. An adjustable pump-mounting device such as theHydraclamp, fitted with an appropriate adaptorplate.
3. Easily cleaned compartmented trays for separatestorage of dismantled components such as Part No.60620197.
4. All the necessary tools as listed in Section 6 of thisManual.
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 separatedfrom the clean area.
6. A tank large enough to accommodate a completepump and filled with clean test oil, near to a sourceof clean, dry, variable pressure compressed air forcarrying out leakage tests.
7. Supplies of clean, lint-free (non-fluffy) cloths forcleaning and drying components. Cotton wastemust never be used.
8. A pump test machine that conforms to ISO 4008.
9. Adequate storage facilities for pumps, tools and testequipment, with separate areas for pumps beforeand 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.
INTRODUCTION
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).
C 89 2 0 A 06 0 L
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.
Marketing Code:
C = Spain
No letter = UK
Product Type (DP200)
Suffix letter -
Denotes the type of
ESOS fitted.
See SIN DT294
Change to the individual
specification affecting parts
interchangeability, but not fit or
function of pump.
Individual features
number.
Design change letter -
Has no significance at the
time of publication of this
manual
No. of delivery outlets:
0, 3 & 5 = 4 cyl.
1 & 4 = 6 cyl.
2 = 3 cyl.
6 - 9 to be allocated
Design Source:
0 = USA 1 = Korea
2&3 = UK 4 = France
5 = Spain 6 = Brazil
7 = India 8 = Poland
9 = Japan
Fig. 1 Explanation of Despatch Number
INTRODUCTION
1 - 10
DISMANTLING
2 - 11
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
DISMANTLING
2 - 12
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 subjectedto end-thrust, end-float must be measured priorto dismantling. The pump and gauge must beclamped to an assembly plate mounted in a viceor on a Hydraclamp.
Fit the appropriate adaptor (4) to the drive shaftthread. Screw in the dial gauge holder (3), and fit thegauge (2). Adjust the gauge pin to contact themounting plate adaptor ring at (1). Push the driveshaft inwards and set the dial gauge to zero. Pull thedrive shaft outwards and note the maximum gaugereading.
End-float should be 0.05 mm to 0.2 mm. If themaximum is exceeded, examine the housing thrust-faces during dismantling. If no significant wear ordamage is apparent, requiring replacement of thepump housing, correct the end-float by the use ofalternative shims during reassembly.
2.1.6 Measuring drive shaft radial play
Note: In order to assess the condition of the bearing anddrive shaft, radial play must be measured prior todismantling.
With the pump and gauge (1) mounted rigidlyrelative to each other, adjust the gauge pin to bear (atright angles) against the parallel section (4) of thedrive 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 thegauge to zero.
Pull the shaft radially to the opposite extreme andrecord the gauge movement. Repeat the readingswith the gauge repositioned as shown at (2) and (3).Do not rotate the drive shaft. Reject the housing ifthe maximum play or the difference between themeasurements 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
34
1
23
4
A986
2
1
DISMANTLING
2 - 13
A953
A953
A1006
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
1 2 3 4 5 6 7 82.2.3.2 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).
A1002
4
6
DISMANTLING
2 - 14
A954
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
1 2 34
5
6
EVD15
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
2d) 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.
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 23
45
6
DISMANTLING
2 - 17
A1473
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 theaction of the diaphragm return spring as thescrews are loosened.
Remove the cover and the diaphragm assembly(1).
If fitted, remove the shim from within the cupin the lower face of the diaphragm assembly.
Note 1: Do not dismantle the diaphragmassembly. If any part of it is worn or damaged,the whole assembly must be replaced.
Note 2: The spring (2), spring seat (3), andspindle (4), cannot be lifted out at this stage, asthey are retained by the cam follower and acirclip within the governor cover.
d) Removing the governor cover
Push the exhaust brake shaft (2) and the throttleshaft (3) down into the cover. Remove the fourTorx screws at (1), (4), (5), and (6).
Lift and rotate the cover off towards the torquetrimmer side, and pull the throttle shaft (3) out ofits bore. Remove and discard the trapped O-ring (7) from the sealing face of the cover.Remove the exhaust brake shaft (2) and discardits O-ring.
Note: If the control cover is lifted too far, thecarriage angle plate may become distorted; ifresistance is felt, lower it and move it furtheraway, then lift it again.
A1476
A1456
A1475
4
7
8
9
3
2
4
6
5
1
3
2 4
1
A1048 A1260
32 4
1
3
2
5
6
7
1
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
23
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
23
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).
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 controlcover it is necessary to use a pair of mole-grips, as the screws (551) securing the unit arefitted with tamperproof steel balls (552) andtamper-evident washers (550).
Grip the washer (550) and rotate it in an anti-clockwise direction; this will loosen the washerand at the same time slacken the screw.
Discard the screw, the ball and the tamper-evident washer.
Carefully remove the actuator from the controlcover 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 ANDARM 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 23
45
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
56789
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 assemblyfor 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
32
1
4
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.
A985b4
3
2
1
5
6
7
8
1
2
3
4
2.5 HIGH PRESSURE OUTLETS, END PLATEASSEMBLY, ELECTRIC SHUT-OFFSOLENOID (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
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
56
7
1
2
3A493A
DISMANTLING
2 - 22
2.5.2.2 Dismantling the end plate assembly
a) Viscosity compensating design
Remove the fuel inlet connection (1) and discard
the O-ring (2). Tip out the filter (3). Remove and
discard the adjuster (4) and the O-ring (on current
designs).
Screw the extractor (13) into the regulating
sleeve (6) and pull the sleeve out of the end plate.
Remove the piston retainer (10), the piston (8),
and the regulating spring (5); remove and discard
the O-ring (9) from the groove (7). Tip out the
sleeve retaining spring (11) and the spring seat
washer (12).
Note: The piston, sleeve and adjuster are
matched and are not interchangeable.
Remove the sandwich plate (14).
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.
A1284A1258
1
2
3
4
5 6
7
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.
JPT
A1018
A493
A1302
A1008
13
14
1
2
3
5
6
7
8
9
11
12
4
240241
284
285
242
287
288
245
248
286
10
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 pumpliner (2) before dismantling, particularly theposition of the recess (4) in one face, to aidcorrect reassembly.
Remove the transfer pump sealing ring (1). Carefullylift out the liner together with the two pairs oftransfer pump blades (3) and their separatingsprings (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 easilymislaid.
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 andpush the hub fully onto the shaft taper; hold the hubwith the special tool (1). Hold the transfer pumprotor with the special tool (2). Slacken but do notremove the rotor; the direction in which it is to beslackened can be determined by examination of theend face of the rotor.
Rotors marked with an arrow indicate the directionin which to turn the rotor to remove it.
Remove the tools; drive hub and key, leaving therotor just finger-tight.
2.8 ADVANCE DEVICE
DP200 utilises a number of different advancedevices. They fall into two main categories;
a) Single piston design.
Direct actuation of the cam-ring by an advancepiston operated by transfer pressure and controlledby a combination of spring and cambox pressure.
b) Servo piston design.
Indirect actuation of the cam-ring by an advancepiston via a servo valve operated by transferpressure and controlled by a combination of springand cambox pressure.
Each of these two types may be fitted with cold starttiming retard with or without a wax motormechanism.
A965
11
2
3
4
21
DISMANTLING
2 - 24
2.8.1 Single piston design with 2 bolt cold advance (CA)
2.8.1.1 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 (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
67
89
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 transferpressure damper (if fitted), no more than threeturns. Tap the advance housing (323) with a soft-faced mallet to free it from the gasket (415).Remove the head locating fitting and then theadvance 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 headlocating fitting and remove the ball. Discard thespring ring.
Remove and discard the split nylon ring (418), iffitted, and the O-rings (419) from the headlocating fitting.
The piston sleeve (310) and piston (326) may stillbe retained within the housing (302). Remove thepiston and one of the O-rings (309), then lightlygrip the housing in a vice fitted with soft jaws andwith a suitable flat bladed screwdriver lever outthe sleeve using the O-ring groove. Discard theremaining O-ring (309).
A1485 1 2 3 4
DT167 fig 1
DISMANTLING
2 - 26
2.8.2.4 Dismantling the Servo Valve Assembly
The housing and piston assembly (323) containsa servo valve within the advance piston. Removalof the piston from the housing will enable theservo valve assembly to be dismantled.
This device consists of a number of springs andshim washers that are under compression. Caremust be exercised when dismantling the unit.
Remove the retaining circlip (312), using asuitable pair of circlip pliers.
Clamp the piston in a vice fitted with soft jawswith the spring assembly uppermost. A suitablelarge flat steel washer having an internal holediameter of between 7 and 8 millimetres can beused to compress the springs and shims toenable the retaining e-clip (313) to be removed.
Carefully release the spring pressure and removethe shim (314), plate (315), spring (316), stopplate (317), spacer (318), shim (319) and spring(320). The servo valve retaining circlip (321) andwasher (322) can be removed to release the valvefrom the piston.
Some pumps may have an additional springfitted 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
DT157 fig 1
EVD010
DISMANTLING
2 - 27
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.
2.8.3.4 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
12
34
5
6
78
9
1112
10
10
9
8
7
6
5
4
3
2
1
DISMANTLING
2 - 28
2.8.4.3 Removing the cam screw
Fit the special adaptor (1) to the cam advance
screw (2). Using a suitable socket and wrench,
slacken the cam screw. The cam ring will almost
certainly become stuck in the pump housing.
If the cam ring has become stuck, remove the
wrench and socket from the adaptor; remove the
adaptor from the cam advance screw and tap the
adaptor sideways with a soft-faced mallet until
the cam has been released. Remove the cam
screw from the cam ring.
2.9 REMOVING THE HEAD LOCKING SCREWSAND 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
34
12
34
56
78
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 withinthe pump housing
Remove and discard the O-rings (9) and (10).Discard the washer (11) and filter in the end of thevalve body (if fitted).
Remove the adjuster (1) from the sleeve (4) anddiscard the seal (3). Remove the sleeve from thebody (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.
A1518
DT228 fig 3
A1495
A1496
1 2 3 4 5 6 7 8 9 10 11
1
2
1
11 9 10
6 7 8
a
b
DISMANTLING
2 - 30
2.10 DRIVE SHAFT
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
32
1
4
5
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.
DISMANTLING
2 - 32
2.11.2 Dismantling the rotor components
Remove the rollers and shoes (1), (3), (5) and (7).
Remove the dowel pins (2) and (4) fitted to the cheek
plate design and the upper cheek or check plate (6).
2.11.3 Removing the lower check or cheek plate
Retain the plungers in their respective bores with the
specified plastic clips (1), short lengths of nitrile
rubber tube, or small corks.
Unscrew and remove the transfer pump rotor, lift out
the hydraulic head rotor and remove the lower check
or cheek plate (2). Refit the rotor to the hydraulic
head, and then refit the transfer pump rotor finger
tight.
Store the head in a covered container filled with
clean test oil.
Remove the rear scroll plate (4) (still within the
housing), cam ring (3), front scroll plate (2), innerbearing (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.
A1304
A1254
EVD01
1
3 45
7
A975a6
1
2
1 2
A1501b
12 3 4
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.
DISMANTLING
2 - 34
COMPONENT INSPECTION AND RENEWAL
3 - 35
3.1 CLEANINGIf water contamination is suspected, carry out aninitial examination of all internal components beforeattempting any further cleaning. Clean out allpassageways in the head and rotor by flushing outwith clean test oil.
Also inspect for unusual marking, deposits, odour,seal swelling in the housing, in which case degradedRME fuels may be a factor.
3.2 GENERAL
3.2.1 Mated and matched assembliesThe hydraulic head and rotor should be separatedand examined; they should be re-matedimmediately after examination and immersed in acovered bath of clean test oil until required forreassembly into the pump.
Note: If light load advance is specified, the meteringvalve will be matched to the hydraulic head.
The following groups are matched and must be keptassembled in their sets:
Rollers and shoesAdvance housing and pistonCam ring and scroll platesStop solenoid plunger and bodyRegulating sleeve, piston and adjusting screwGovernor cover and torque control piston
If any part of a matched set is considered to be unfitfor further service, the whole set must be replaced.
Note: The pump housing drive shaft bush is not aservice repair item; if the bearing is worn, thehousing must be replaced.
3.2.2 Examination and replacementAll components must be checked for corrosion,wear, or damage. Under service workshopconditions it is not feasible to test individual parts orsub-assemblies to determine their suitability forfurther service. Close examination of the areasvulnerable to damage, and interpretation of theresults of tests prior to dismantling, should indicatethe condition of parts.
(a) CorrosionCheck for signs of corrosion or water ingress (rust orstaining) damage to machined surfaces. Theseinclude the pump housing, drive shaft, hydraulichead bore, metering valve and bore cam ring, scrollplates, cheek plates end plate and auto-advancedevice mounting face.
(b) WearInspect drive shaft splines and associated parts forwear or damage. If excessive end-float or radial playwas detected prior to pump strip-down, examine thedrive shaft thrust washer and housing bearing thrustface, governor backplate and thrust face of driveshaft, and governor drive splines, for wear.
(c) DamageInspect all parts for damage or bending due toabuse, especially external levers and controls.
3.2.3 SealsReplace the advance device gasket and all O-ringseals, including the trapped O-ring in thegovernor cover face. Note that overhaul kit does notinclude drive shaft seals, which are stocked asseparate items.
When fitting new O-rings and oil seals, care must betaken to use protection caps to avoid damage to theseals. O-rings must be dipped in clean test oil priorto being assembled. External seals must be lightlycoated with the specified grease. Where possible,inspect seals for small cuts after assembly.
3.3 DETAILS
3.3.1 Hydraulic head rotorWithdraw the rotor from the hydraulic head.Examine the running surface very closely for signsof erosion, particularly the area around the deliveryport. If significant erosion is evident, the head