DPA Manual

WORKSHOP MANUAL DPA FUEL INJECTION PUMP

DDNX116A(EN)

2007

(D)

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

(E)

Mantenga las manos y el cuerpo lejos del rociado del líquido, especialmente inyectores, tuberías y juntas de alta presión con fugas. La inyección de alta presión puede perforar la piel humana y producir una lesión fatal. En caso de que la inyección atraviese la piel, consiga atención médica inmediatamente. Vea la hoja de Datos de Sanidad y Seguridad.

(EN)

Do not put your skin into the fuel jets under pressure, especially those due to pressure pipe or seal leaks. High pressure liquids can cause deadly injuries. In case of an injection under the skin, contact a doctor immediately. Please refer to the health and security fuel documents.

(F)

Ne pas approcher les mains ni le corps des jets de liquides, particulièrement ceux provenant des fuites de tuyaux et des joint soumis a la haute pression. Le liquide sous haute pression injecté sous la peau peut causer des blessures mortelles. En cas d’injection sous la peau, consulter immédiatement un médecin. Se reporter a la fiche de santé et de sécurité du gazole.

(IT)

Non esporre le mani o altre parti del corpo a getti di gasolio ad alta pressione, specialmente a quelli provenienti da tubi o paraolii. I getti di liquidi ad alta pressione possono causare ferite anche mortali. In caso di iniezione sotto pelle contattare immediatamente un medico. Fare riferimento alle schede di sicurezza del gasolio.

(NL)

Zorg dat uw handen of andere lichaamsdelen niet in contact komen met vloeistofstralen onder hoge druk, met name bij een lek aan een leiding of dichting. Als de vloeistof onder hoge druk onder de huid terechtkomt, kan dit zelfs tot dodelijke verwondingen leiden. Als de vloeistof onder de huid terechtkomt, onmiddellijk een arts raadplegen. Lees de gezondheids- en veiligheidsfiche met betrekking tot de brandstof.

(P)

Não exponha a pele a jactos de combustível sob pressão, especialmente os devidos a fugas de tubos de pressão ou vedantes. Líquidos a alta pressão podem causar ferimentos mortais. No caso de injecção subcutânea, consulte imediatamente um médico. Consulte por favor a documentação respeitante a saúde e segurança de combustíveis.

(D)

Schutzbrille/Gesichtsschutz tragen.

(E)

Úsese protección para los ojos/la cara.

(EN)

Wear eye/face protection.

(F)

Porter un appareil de protection des yeux / du visage.

(IT)

Proteggersi gli occhi/la faccia.

(NL)

Veiligheidsbril/-masker gebruiken.

(P)

Use protecção da face/olhos.

(D)

Von Zündquellen fernhalten - Nicht rauchen.

(E)

Conservar alejado de toda llama o fuente de chispas -No fumar.

(EN)

Keep away from sources of ignition - No smoking.

(F)

Conserver à l'écart de toute flamme ou source d'étincelles - Ne pas fumer.

(IT)

Conservare lontano da fiamme e scintille - Non fumare.

(NL)

Ver van open vuur en ontstekingsbronnen houden – Niet roken.

(P)

Mantenha afastado de fontes de ignição – Proibido fumar.

(D)

Geeignete Schutzhandschuhe tragen.

(E)

Usen guantes adecuados.

(EN)

Wear suitable gloves.

(F)

Porter des gants appropriés.

(IT)

Usare guanti adatti.

(NL)

Aangepaste veiligheidshandschoenen dragen.

(P)

Use luvas apropriadas.

TABLE OF CONTENTS

INTRODUCTION

I

II

PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-REASSEMBLY

III

PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING

IV

PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY

V

© Delphi

PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-DISMANTLING

DDNX116A(EN) - Issue 1 of 07/2007

i

TABLE OF CONTENTS

TESTING & STORAGE

VI

APPENDIX

VII

Produced and published by:

Tel: (+44) (0) 01926 472 900 Fax: (+44) (0) 01926 472 901

ii

© Delphi

Delphi Diesel Systems Ltd. Spartan Close Warwick CV34 6AG England


INTRODUCTION I TABLE OF CONTENTS 1. 1.1 1.2

1.3

© Delphi

1.4 1.5 1.6

INTRODUCTION The Pump.......................................................................................................................................................................1-1 Description And Operation...........................................................................................................................................1-1 1.2.1 General..........................................................................................................................................................1-1 1.2.2 Working principles.......................................................................................................................................1-1 Overhaul.........................................................................................................................................................................1-3 1.3.1 Service problems.........................................................................................................................................1-3 1.3.2 General..........................................................................................................................................................1-3 Pump Name Plate..........................................................................................................................................................1-5 Overhaul Procedure......................................................................................................................................................1-6 Component Inspection..................................................................................................................................................1-6


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II PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-DISMANTLING TABLE OF CONTENTS

2.4

2.5 2.6

2.7

2.8

2.9

2.10 2.11 2.12

2.13 2.14

2.15

PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-DISMANTLING Preparation....................................................................................................................................................................2-9 Mounting The Pump.....................................................................................................................................................2-9 Removing The Control Levers......................................................................................................................................2-9 2.3.1 Standard control levers...............................................................................................................................2-9 2.3.2 Spring-returned throttle lever.....................................................................................................................2-9 2.3.3 Spring-returned shut-off lever..................................................................................................................2-10 2.3.4 ‘Break-back’ throttle lever..........................................................................................................................2-10 Governor Control Cover.............................................................................................................................................2-11 2.4.1 Removing the cover...................................................................................................................................2-11 2.4.2 Angled light-load advance adjusting screw.............................................................................................2-11 Dismantling The Throttle Link....................................................................................................................................2-12 Removing And Dismantling The Governor Linkage Assembly...............................................................................2-12 2.6.1 Removing the assembly............................................................................................................................2-12 2.6.2 Dismantling the assembly.........................................................................................................................2-13 Removing And Dismantling The Advance Device....................................................................................................2-14 2.7.1 Head locating fittings.................................................................................................................................2-14 2.7.2 Single-stage advance device.....................................................................................................................2-15 2.7.3 Light-load advance device.........................................................................................................................2-15 Releasing The Cam Screw Or Cam Advance Screw And Removing The High Pressure Outlet Connections....2-16 2.8.1 Cam screw..................................................................................................................................................2-16 2.8.2 Cam advance screw...................................................................................................................................2-16 2.8.3 High-pressure outlets.................................................................................................................................2-16 Removing And Dismantling The End Plate And Transfer Pump.............................................................................2-17 2.9.1 All end plates..............................................................................................................................................2-17 2.9.2 End plate with ‘loose’ sandwich plate......................................................................................................2-18 Loosening The Transfer Pump Rotor And Removing The Hydraulic Head............................................................2-18 Removing The Drive Plate Screws, Top Adjusting Plate, And Rollers And Shoes................................................2-19 Removal Of The Bottom Adjusting Plate, Cam Ring And Circlip............................................................................2-19 2.12.1 Bottom adjusting plate..............................................................................................................................2-19 2.12.2 Cam ring and circlip...................................................................................................................................2-20 Releasing The Drive Shaft Assembly........................................................................................................................2-20 Removing The Drive Shaft Assembly........................................................................................................................2-21 2.14.1 Cush-drive weight cage assembly............................................................................................................2-21 2.14.2 Non-cush-drive weight cage assembly....................................................................................................2-21 Removing The Drive Hub Seal...................................................................................................................................2-22

© Delphi

2. 2.1 2.2 2.3

iv


PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-REASSEMBLY III TABLE OF CONTENTS 3. 3.1

3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9

3.10 3.11

3.12 3.13 3.14

3.15 3.16

3.17

3.18 3.19

3.20 3.21

© Delphi

3.22

PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-REASSEMBLY Fitting The Drive Hub Seal, Drive Hub And Drive Shaft Assembly.........................................................................3-23 3.1.1 Fitting the drive hub seal and drive hub..................................................................................................3-23 3.1.2 Assembling the cush-drive weight cage..................................................................................................3-23 3.1.3 Assembling the governor weight cage components..............................................................................3-24 3.1.4 Fitting the drive shaft and tightening the drive shaft screw...................................................................3-24 Checking Drive Shaft End Float..................................................................................................................................3-25 Fitting The Timing Circlip And The Cam Ring..........................................................................................................3-26 The Hydraulic Head Rotor Screw...............................................................................................................................3-27 Roller And Shoe Assemblies......................................................................................................................................3-27 Fitting And Aligning The Top Adjusting Plate And The Drive Plate.......................................................................3-28 Setting The Roller-To-Roller Dimension (Two-Plunger Pumps).............................................................................3-28 Tightening The Drive Plate Screws............................................................................................................................3-29 Automatic Advance Device........................................................................................................................................3-30 3.9.1 Single-stage................................................................................................................................................3-30 3.9.2 Light-load....................................................................................................................................................3-30 Inserting And Securing The Hydraulic Head.............................................................................................................3-31 Tightening The Transfer Pump Rotor And Fitting The Transfer Pump Components............................................3-32 3.11.1 Tightening the rotor...................................................................................................................................3-32 3.11.2 Fitting the transfer pump components.....................................................................................................3-32 Assembling The End Plate..........................................................................................................................................3-33 Fitting The End Plate Assembly.................................................................................................................................3-33 Assembling The Governor Control Linkage..............................................................................................................3-34 3.14.1 Single-spring linkage.................................................................................................................................3-34 3.14.2 Two-spring linkage.....................................................................................................................................3-34 3.14.3 Three-spring linkage..................................................................................................................................3-35 Fitting The Governor Control Linkage To The Pump...............................................................................................3-35 Setting The Governor Link Length.............................................................................................................................3-36 3.16.1 Standard metering valves.........................................................................................................................3-36 3.16.2 ‘Roller pin’ metering valves.......................................................................................................................3-36 Throttle Link.................................................................................................................................................................3-37 3.17.1 Assembly....................................................................................................................................................3-37 3.17.2 Application of the Setting Code................................................................................................................3-37 Governor Control Cover.............................................................................................................................................3-37 3.18.1 Fitting the control shafts to the cover and fitting the cover to the pump..............................................3-37 Fitting The Control Levers..........................................................................................................................................3-38 3.19.1 Spring-returned throttle lever...................................................................................................................3-38 3.19.2 Spring-returned shut-off lever..................................................................................................................3-38 3.19.3 Standard throttle and shut-off levers.......................................................................................................3-39 3.19.4 ‘Break-back’ throttle lever..........................................................................................................................3-39 3.19.5 Angled light-load advance adjusting screw.............................................................................................3-40 Backleak Connection, Housing Vent Screw And Inspection Cover Plate...............................................................3-40 High Pressure Outlet Connections.............................................................................................................................3-40 3.21.1 Plain radial type..........................................................................................................................................3-40 3.21.2 ‘Plain’ banjo-type outlets...........................................................................................................................3-41 3.21.3 Banjos with delivery valves.......................................................................................................................3-41 Security........................................................................................................................................................................3-41


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IV PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING TABLE OF CONTENTS

4.3 4.4

4.5

4.6 4.7

4.8

4.9 4.10 4.11

4.12

4.13

4.14

PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING Mounting The Pump...................................................................................................................................................4-43 Removing The Shaft Locking Screw, The Governor Control Cover Fittings, And The Cover..............................4-43 4.2.1 Removing the anti-stall screw...................................................................................................................4-43 4.2.2 Shaft-locking screw....................................................................................................................................4-43 4.2.3 Torque adjustment screw..........................................................................................................................4-44 4.2.4 Spring-returned shut-off lever..................................................................................................................4-44 4.2.5 ‘Standard’ shut-off lever............................................................................................................................4-44 4.2.6 ‘Standard’ throttle lever.............................................................................................................................4-45 4.2.7 ‘Heavy duty’ throttle lever.........................................................................................................................4-45 4.2.8 ‘Break-back’ throttle lever..........................................................................................................................4-45 4.2.9 Exhaust brake lever....................................................................................................................................4-46 4.2.10 Removing the governor control cover.....................................................................................................4-46 4.2.11 Exhaust brake shaft....................................................................................................................................4-46 4.2.12 Shut-off shaft..............................................................................................................................................4-46 Dismantling The Throttle Link....................................................................................................................................4-46 Removing And Dismantling The Governor Linkage Assembly...............................................................................4-47 4.4.1 Single-spring linkage.................................................................................................................................4-47 4.4.2 Two-spring linkage.....................................................................................................................................4-47 4.4.3 Three-spring linkage..................................................................................................................................4-48 Removing And Dismantling The Advance Device....................................................................................................4-48 4.5.1 Head locating fitting...................................................................................................................................4-48 4.5.2 Advance device..........................................................................................................................................4-49 Slackening The Cam Advance Screw........................................................................................................................4-50 Removing The Clamping Plate, Support Plate, And The High Pressure Outlet Connections...............................4-50 4.7.1 High pressure outlet clamping plate........................................................................................................4-50 4.7.2 High pressure outlets.................................................................................................................................4-51 Removing The Support Bracket, End Plate, Sandwich Plate, And 'ESOS'.............................................................4-52 4.8.1 Rear support bracket..................................................................................................................................4-52 4.8.2 Removing and dismantling the ‘standard’ end plate..............................................................................4-52 4.8.3 Removing and dismantling the ‘viscosity compensating’ end plate assembly....................................4-53 4.8.4 Loose end plate sandwich plate................................................................................................................4-53 4.8.5 Electric shut-off solenoid (‘ESOS’)............................................................................................................4-54 Removing The Transfer Pump Components............................................................................................................4-54 Loosening The Transfer Pump Rotor And Removing The Hydraulic Head............................................................4-55 Dismantling The Hydraulic Head Assembly And Removing The Cam Ring..........................................................4-55 4.11.1 Loosening the drive plate screws.............................................................................................................4-55 4.11.2 Dismantling the hydraulic head................................................................................................................4-56 4.11.3 Four-plunger head and rotor.....................................................................................................................4-56 4.11.4 Removing the cam ring and circlip...........................................................................................................4-56 Removing The Drive Hub...........................................................................................................................................4-57 4.12.1 Loosening the drive shaft nut...................................................................................................................4-57 4.12.2 Withdrawing the ‘splined’ hub..................................................................................................................4-57 Removing And Dismantling The Drive Shaft............................................................................................................4-58 4.13.1 ‘Single-piece’ drive shaft...........................................................................................................................4-58 4.13.2 ‘Uprated’ single-piece drive shaft.............................................................................................................4-58 Removing The Drive Shaft Seals...............................................................................................................................4-59 © Delphi

4. 4.1 4.2

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PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY V TABLE OF CONTENTS 5. 5.1

5.2

5.3

5.4 5.5 5.6 5.7

5.8

5.9

5.10 5.11 5.12 5.13

5.14

5.15

5.16 5.17

5.18

© Delphi

5.19

PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY Preparation..................................................................................................................................................................5-61 5.1.1 Fitting the drive shaft seals.......................................................................................................................5-61 5.1.2 ‘Locked-shaft’ timing screw.......................................................................................................................5-61 Assembling The Governor Components...................................................................................................................5-62 5.2.1 ‘Single-piece’ drive shaft...........................................................................................................................5-62 5.2.2 Heavy duty and heavy duty (uprated) drive shafts.................................................................................5-62 Fitting The Drive Shaft Assembly..............................................................................................................................5-63 5.3.1 All shafts.....................................................................................................................................................5-63 5.3.2 Drive shaft end-float...................................................................................................................................5-63 Tightening The Drive Shaft Nut (Uprated Shafts)....................................................................................................5-64 Fitting The Timing Circlip, the Cam Ring, And The Advance Screw......................................................................5-65 The Hydraulic Head Rotor Screw...............................................................................................................................5-66 Fitting The Roller And Shoe Assemblies And Adjusting Plates..............................................................................5-66 5.7.1 Two-plunger head and rotor.....................................................................................................................5-66 5.7.2 Four-plunger head and rotor.....................................................................................................................5-67 Setting The Roller-To-Roller Dimension (Two-Plunger Pumps) And Tightening The Drive Plate Screws..........5-68 5.8.1 Setting the roller-to-roller dimension.......................................................................................................5-68 5.8.2 Tightening the drive plate screws.............................................................................................................5-68 Advance Device...........................................................................................................................................................5-69 5.9.1 Single-stage................................................................................................................................................5-69 5.9.2 Two-stage, start retard...............................................................................................................................5-70 Inserting The Hydraulic Head And Fitting The Head Locking Screws....................................................................5-70 Fitting And Securing The Hydraulic Head And Tightening The Transfer Pump Rotor.........................................5-71 Fitting The Transfer Pump Components...................................................................................................................5-71 Assembling The End Plate..........................................................................................................................................5-72 5.13.1 ‘Standard’ end plate...................................................................................................................................5-72 5.13.2 ‘Viscosity-compensating’ end plate..........................................................................................................5-72 5.13.3 ‘Loose’ end plate sandwich plate (if specified)........................................................................................5-73 Fitting The Support Bracket, The End Plate Assembly, And The ESOS.................................................................5-73 5.14.1 Rear support bracket..................................................................................................................................5-73 5.14.2 End plate.....................................................................................................................................................5-73 5.14.3 Electric shut-off solenoid (‘ESOS’), or ‘blanking’ plug............................................................................5-74 Assembling The Governor Linkage...........................................................................................................................5-74 5.15.1 Single-spring linkage.................................................................................................................................5-74 5.15.2 Two-spring linkage.....................................................................................................................................5-75 5.15.3 Three-spring linkage..................................................................................................................................5-75 Fitting The Governor Linkage Assembly...................................................................................................................5-76 Setting The Governor Link Length.............................................................................................................................5-76 5.17.1 Standard metering valves.........................................................................................................................5-76 5.17.2 ‘Roller pin’ metering valves.......................................................................................................................5-77 Throttle Link.................................................................................................................................................................5-77 5.18.1 Assembly....................................................................................................................................................5-77 5.18.2 Setting code................................................................................................................................................5-78 Fitting The Control Shafts To The Governor Control Cover And Fitting The Cover To The Pump......................5-78 5.19.1 ‘Standard’ cover.........................................................................................................................................5-78 5.19.2 ‘Exhaust brake’ cover.................................................................................................................................5-79


vii

V PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY TABLE OF CONTENTS

5.21

5.22

5.19.3 ‘Break-back’ throttle lever..........................................................................................................................5-79 Fitting The Governor Control External Components...............................................................................................5-80 5.20.1 ‘Heavy duty’ throttle lever.........................................................................................................................5-80 5.20.2 ‘Exhaust brake’ lever..................................................................................................................................5-80 5.20.3 Standard throttle and shut-off levers.......................................................................................................5-81 5.20.4 Spring-returned shut-off lever..................................................................................................................5-81 5.20.5 Torque adjustment screw..........................................................................................................................5-81 5.20.6 Other governor control cover fittings.......................................................................................................5-82 Fitting The High Pressure Outlet Connections And Other Components To The Pump........................................5-82 5.21.1 Backleak connection and inspection cover..............................................................................................5-82 5.21.2 High pressure outlets.................................................................................................................................5-83 Security........................................................................................................................................................................5-84

© Delphi

5.20

viii


TESTING & STORAGE VI TABLE OF CONTENTS 6. 6.1

6.2

6.3 6.4 6.5

6.6 6.7

6.8 6.9

6.10

© Delphi

6.11 6.12

TESTING & STORAGE Pre-Test Procedure......................................................................................................................................................6-85 6.1.1 Leakage testing...........................................................................................................................................6-85 6.1.2 Shaft seal testing........................................................................................................................................6-85 Test Preparation..........................................................................................................................................................6-85 6.2.1 Test machine..............................................................................................................................................6-85 6.2.2 Test machine drive.....................................................................................................................................6-85 6.2.3 Test conditions...........................................................................................................................................6-86 6.2.4 Fuel pipes....................................................................................................................................................6-86 Test Procedure.............................................................................................................................................................6-87 Measuring Pump Output............................................................................................................................................6-87 Transfer Pump Checking And Pressure Setting.......................................................................................................6-88 6.5.1 Transfer pump vacuum and pressure measurement..............................................................................6-88 6.5.2 Transfer pressure adjustment...................................................................................................................6-88 Pressurised Cam Boxes..............................................................................................................................................6-88 Testing Of Advance Devices.......................................................................................................................................6-89 6.7.1 Preparation.................................................................................................................................................6-89 6.7.2 Speed Advance Device..............................................................................................................................6-90 6.7.3 Light Load Advance...................................................................................................................................6-90 Maximum Fuel Setting...............................................................................................................................................6-90 Governor Setting And Testing...................................................................................................................................6-91 6.9.1 Maximum speed.........................................................................................................................................6-91 6.9.2 Torque screw setting.................................................................................................................................6-91 6.9.3 Idling setting...............................................................................................................................................6-91 6.9.4 Shut-off control..........................................................................................................................................6-91 Timing..........................................................................................................................................................................6-91 6.10.1 Introduction................................................................................................................................................6-91 6.10.2 Circlip timing..............................................................................................................................................6-92 6.10.3 Flange timing..............................................................................................................................................6-92 6.10.4 Locked-shaft timing....................................................................................................................................6-92 Sealing Of Pumps........................................................................................................................................................6-93 Storage Of Pumps.......................................................................................................................................................6-93 6.12.1 New pumps.................................................................................................................................................6-93 6.12.2 Overhauled pumps.....................................................................................................................................6-93 6.12.3 Storage conditions.....................................................................................................................................6-93


ix

VII APPENDIX TABLE OF CONTENTS

7.2 7.3 7.4

APPENDIX Torques Values............................................................................................................................................................7-95 7.1.1 End plate, brackets, hydraulic head and rotor.........................................................................................7-95 7.1.2 Governor and housing assemblies...........................................................................................................7-96 7.1.3 Auto advance arrangement.......................................................................................................................7-97 7.1.4 Pump body and drive shaft.......................................................................................................................7-97 Special Tools For Repair.............................................................................................................................................7-98 Special Tools For Testing...........................................................................................................................................7-99 Abbreviations Used In This Manual........................................................................................................................7-100

© Delphi

7. 7.1

x


INTRODUCTION I INTRODUCTION 1.1

The Pump

The DPA distributor-type fuel injection pump, incorporating a sensitive all-speed governor, is a compact, self-contained unit for high speed multi-cylinder diesel engines of up to 2 litres (122 in3) capacity per cylinder. It is a relatively simple design, and incorporates no ball or roller bearings, gears, or highly-stressed springs. The number of working parts does not increase significantly with an increase in the number of engine cylinders which the pump is required to serve.

1.2

Description And Operation

1.2.1 General The pump is flange-mounted to the engine. It is oil-tight and, during operation, all moving parts are lubricated by fuel oil under pressure, so that no additional lubrication system is required. Pressure maintained within the pump housing prevents the ingress of dust, water, and other foreign matter. Fuel injection is effected by a single pumping ‘element’ having two, or four, opposed plungers located within a transverse bore, or bores, in a central rotating member (or ‘distributor rotor’). The rotor revolves in a stationary member known as the hydraulic head. The pumping plungers are actuated by internal lobes on a ‘cam ring’. Fuel is metered to the plungers during their outward, or ‘filling’ strokes, and the high pressure charges are distributed to the engine cylinders through ports in the rotor and the hydraulic head. The integral governor is of the mechanical, ‘fly-weight’, type, and gives accurate control of engine speed under all load conditions. Most versions of the pump also have an automatic advance device which varies commencement of injection, depending upon engine speed and load, to achieve optimum injection timing. The single pumping element ensures uniform delivery of fuel to each engine cylinder and thus eliminates the need to balance the deliveries from each of the high-pressure outlets (as is the case with ‘inline’ injection pumps).

© Delphi

1.2.2 Working principles The cam ring, mounted in the pump housing, normally has as many internal lobes as there are engine cylinders and operates the pumping plungers through rollers carried in shoes which slide radially in the rotor head. For four and six-cylinder pumps, the rotor has as many rotor ‘filling’ ports as there are engine cylinders, and one distributor port which, as the rotor turns, becomes aligned with each high pressure outlet port. For three-cylinder pumps a six-cylinder design is used, but the hydraulic head has only three equally-spaced high pressure outlet ports and the rotor has only three filling ports. The plungers are driven inwards six times per revolution, but for every other pumping stroke the distributor port in the rotor is connected to a ‘dead’ volume. This volume is either within the hydraulic head or in special hollow plugs fitted to the unused high pressure outlet ports. Although no filling takes place during the ‘unwanted’ plunger strokes, a small increase of pressure within the rotor does occur as the plungers are forced inwards; that pressure is kept to a minimum and is contained within the dead volumes. The four-plunger head and rotor has its plungers spaced at 90° for four-cylinder engines, and alternately spaced at 120 ° and 60 ° for six-cylinder engines. The plungers on the four-plunger head have approximately the same total pumping area as the largest plungers on the two-plunger head design. This reduces the stress on each plunger, so with the use of smaller rollers and a higher pumping rate cam profile, higher pumping pressures can be achieved for improved atomisation of the fuel at the injector, thus reducing harmful exhaust emissions. The plungers are forced inwards simultaneously as the rollers contact the diametrically-opposed cam lobes. This is the ‘injection’ stroke. The plungers are returned by the pressure of the in-flowing fuel during the ‘charging’ stroke. The pump rotor is driven by the engine through a splined ‘quill’ shaft, a ‘solid’ (single piece) shaft, or other drive, to suit the engine manufacturer’s requirements. The pump may be mounted on the engine horizontally, vertically, or at any other angle as required by the engine manufacturer. The accurate spacing of cam lobes and delivery ports ensures the exact equality of the timing interval between injections, and components which affect timing are designed with one assembly position only.


1-1

I INTRODUCTION INTRODUCTION

© Delphi

Fuel entering the pump through the main inlet connection is pressurised by a sliding-vane ‘transfer pump’ carried on the rotor inside the hydraulic head. The pressure will rise with an increase in engine speed and is controlled by a ‘regulating valve’ assembly located in the pump end plate. The fuel flows from the transfer pump through passageways in the hydraulic head via the electric shut-off solenoid (ESOS) (if fitted) and the metering valve to the pumping element. The outward travel of the opposed pumping plungers, under any conditions other than full-load, is determined by the quantity of fuel metered, which varies in accordance with the setting of the metering valve. In consequence, the rollers which operate the plungers do not follow the entire contour of the internal cam ring, but come into contact with the cam lobes at positions which vary according to the degree of plunger displacement during the charging cycle. The maximum amount of fuel delivered under full-load is regulated by physically limiting the outward travel of the plungers during the ‘charging cycle’. As the rotor turns, the inlet port is cut off and the single distributor port in the rotor registers with an outlet port in the hydraulic head. At the same time, the plungers are forced inwards by the rollers in contact with the cam lobes; fuel under injection pressure passes along the central bore of the rotor and through the aligned ports to one of the injectors. The rotor has as many inlet ports as the engine has cylinders. Normally, for low-output pumps, only one port at a time will be used for filling or ‘charging’ the rotor, but high-output pumps may utilise two or more filling ports simultaneously, to ensure adequate filling. The cam lobes are contoured to allow the plungers to travel outwards for a short distance immediately after pumping ceases, to give a rapid reduction of pressure, and thus a sharp ‘cut-off’ of fuel to prevent ‘dribble’ at the nozzles. If not prevented, fuel which entered the combustion chamber too late to burn correctly would give rise to excessive exhaust emissions. A control (or ‘throttle’) lever mounted on a shaft in the governor control cover is connected internally to one end of a spring, the other end of which is connected to the governor control arm. As the control lever is moved towards a position which corresponds to an increase in the speed or load demand on the engine, the load on the spring is increased. That load is transmitted to the governor arm and thence to the governor weights via a thrust sleeve. The weights are then forced inwards. The governor control arm also carries a spring-loaded link which transmits movement of the weights to the metering valve. As engine speed increases in response to the increase in pump output, so the weights move outwards until a new equilibrium is attained between control spring load and the centrifugal force generated by the weights. The governor flyweight assembly is mounted on the drive shaft and the control linkage assembly is mounted on the pump housing, therefore all of the mechanism is contained entirely within the pump housing. There are two types of drive which may be specified for the DPA pump. They are: A. ‘Two-piece’ ‘shaft-and-hub’ drive At its drive end, the shaft is fitted into a drive hub which is carried in a plain bearing in the front of the pump housing. The hub is fixed to the shaft by a central screw, This type of shaft arrangement may be driven by the engine in one of two ways: i. Quill-shaft-driven A short, external, ‘quill-shaft’, which has splines at each end, connects the drive hub to the engine pump drive gear. The drive gear is carried in bearings within the engine timing cover. ii. Gear-driven In this type of drive, the hub is designed to carry a gear which, when the pump is fitted to the engine, meshes directly with the other timing gears. This eliminates the ‘backlash’ due to the clearances between the splines which exist in the quill-shaft design.

1-2


INTRODUCTION I INTRODUCTION B. ‘Single-piece’ drive i. ‘Splined’ shaft The single-piece shaft has a spline at its drive end which fits into the engine drive arrangement. ii. ‘Tapered’ single-piece shaft The uprated single-piece shaft has a standard taper at its drive end, to which is fitted a pump drive component. The two-piece shaft may be specified with either a ‘rigid’ or a ‘cush-drive’ governor weight cage, dependent on plunger size. As plunger diameter is increased to provide a higher delivery level, so the torsional oscillation of the drive due to reaction to high pressure pumping loads increases. This has a detrimental effect on the quality of governing. In the ‘cush-drive’ weight cage, the effect of torsional oscillation on the governor mechanism is greatly reduced. Dependent upon the pump specification, the governor weight cage may be either removable or may be fixed permanently to the shaft. In the latter case, the assembly cannot be dismantled and, if necessary, the drive shaft and weight cage must be replaced as a unit. All single-piece drive shafts are fitted with cush-drive weight cages.

1.3

Overhaul

1.3.1 Service problems In all communications with a Delphi Distributor, quote the Despatch Number of the item of equipment. Every Distributor has full information on current Service Modifications, and will advise on genuine spare parts for pumps and equipment serviced by an operator.

© Delphi

1.3.2 General Any tools both standard and special, used for the servicing and 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. This Manual covers the dismantling and reassembly of the two main groups of DPA pumps. However, the features described for each group are not necessarily exclusive to that group. If any feature which is not described is encountered, carefully note the position of each component as it is removed from the pump. Except in the case of a complete overhaul, full dismantling is not always necessary. When a pump requires attention, the recommended practice is to set it up on a test machine and check to locate specific faults or maladjustments. Repairs or adjustments can then be undertaken on the basis of the test results. Dismantling, assembly, testing and adjustment of the DPA pump must be carried out by trained personnel, using specialised tools and test apparatus. The service tools listed in this publication must be used to obtain the closest possible match to factory standards. Conditions of scrupulous cleanliness must be observed in workshops where pump overhaul is carried out. The minimum facilities required are: 1. A bench, covered with non-rusting sheet metal or industrial-grade linoleum and fitted with an Engineer’s vice with a jaw size of 100 mm (4 in), The vice jaws must be faced with either soft metal or fibre pads. The bench must be kept scrupulously clean and used for fuel injection equipment only. 2. A suitable pump-mounting plate for fitment into the vice or a universal positioning device such as the ‘Hydraclamp’. 3. Easily-cleaned compartmented trays for separate storage of dismantled components (Such as Part No. 99-708). 4. All tools as listed in section 7.2 and section 7.3.


1-3

I INTRODUCTION INTRODUCTION

6. 7. 8. 9.

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’. 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. A supply of clean, lint-free (non-’fluffy’) cloths for cleaning and drying components. Cotton waste must never be used. A pump test machine which conforms to ISO 4008. 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.

© Delphi

5.

1-4


INTRODUCTION I INTRODUCTION 1.4

Pump Name Plate

The number stamped on the name plate attached to the pump housing identifies the type and model of the pump. Pumps which are of identical build, but with modified settings for different applications, are further identified by the Setting Code stamped beneath the Despatch Number. Should the name plate be obscured by paint, care must be taken to ensure that the type details are not defaced when removing the paint. A typical Despatch Number could be as shown below:

R 3 2 4 8 F 39 0 Y This character indicates whether or not an ESOS is fitted to the pump and, if so, its type. (For more details, see SIN DT294). Prior to Design Change Letter ‘D’, i.e. design changes ‘A’, ‘B’, and ‘C’, the design change letter was placed at the

Marketing Code: (See Note) R = France C = Spain G = India M = Mefin, Romania P = WSK Poznan, Poland V = Brazil U = Greenville, USA J = Kk, Japan No prefix letter = UK

end of the Despatch Number. Changes to the individual specification affecting parts interchangeability, but not fit or function of the pump.

Note: This letter will not be used in future Service documentation.

Individual features number. Product type (DPA)

Design Source Code 0 = USA 1 = Korea 4 = France 5 = Spain 7 = India 8 = Poland

Design changes from ‘D’ onwards shown here. 2 & 3 = UK 6 = Brazil 9 = Japan

Type of governor and advance type 0 & 1 = Mechanical governor without advance 2 & 3 = Mechanical governor with auto advance 4 & 5 = Hydraulic governor without auto advance 6 & 7 = Hydraulic governor with auto advance 8 & 9 = Mechanical governor with auto advance

Number of delivery ports

© Delphi

Note: Pumps with Marketing Code ‘M’ or ‘P’ and Design Source code 8 are no longer serviced by Delphi, all enquiries for part and test data should be referred to the engine or vehicle manufacturer / importer.


1-5

I INTRODUCTION INTRODUCTION 1.5

Overhaul Procedure

When fitting new component parts or assemblies, always ensure that the part number is correct for the pump type. Part numbers can be checked in the relevant pump Parts List on CD-ROM. If any part in a mated assembly is damaged or worn, the complete assembly must be rejected. Any component showing signs of fretting, wear, damage, corrosion, cracks, or distortion, must be discarded. All O-rings, gaskets, tab washers, and locking and sealing devices must be discarded and new ones fitted. Gasket kits, as designated in the Parts List, contain all necessary seals, gaskets and washers for most types of pump. In a few cases, additional separate items are also required. Drive shaft seals are used in various combinations according to pump type and application. They may be used singly or in pairs. The lips of the seals may face inwards or outwards, and in twin-seal applications they may face towards or away from each other. It is essential, therefore, that when the seal (or seals) is (are) removed, note is taken of the quantity and how they were fitted, so that replacement seals will be correctly fitted during reassembly. When investigating damage for which there is no obvious explanation, check that all related components are genuine approved parts of the correct part number. Only service parts supplied by Delphi Diesel Systems 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. For convenience, Dismantling and Reassembly of pumps fitted with the two classes of drive shaft are listed separately.

1.6

Component Inspection

Note the location of, and inspect, individual parts during dismantling, so that replacements can be obtained with the minimum of delay. Always ensure that the components removed from any particular pump are correct according to the relevant Parts List. The following information lists possible defects, and indicates the main items that may require replacement. The inspection requirements listed are the minimum advisable: • Check for damage to internal and external threads, especially on the transfer and distributor rotor, hydraulic head, studs, inlet and outlet connections, and connections and screws liable to be removed or torque-loaded while the pump is on the engine. • Look for distorted or fractured springs. Check that all springs quoted in the Parts List for the particular pump are present. If there is evidence that a spring has been bearing against surrounding components, ensure that the correct spring is fitted. • Check for any scoring, wear, corrosion, or any other damage to machined surfaces, including the pump body, hydraulic head bore, cam ring, end plate, advance device and end plate mounting faces. • When fitting new O-rings and oil seals care must be taken to use the specified protection caps etc. to avoid damage. Inspection of seals after assembly is recommended. Internal seals should be dipped in clean test oil prior to being assembled; external seals should be lightly coated with grease. • Inspect for wear and damage to drive shafts, key-ways, splines and associated parts; this is especially important on drive plates and quill shafts. Check the drive shaft end float if the ‘thrust face’ of the housing is worn. • Check the drive shaft hub screw support washer for cracks. • On up-rated pumps, the complete drive shaft assembly must be discarded if any part is defective. The assembly consists of drive shaft, governor weight cage, cush drive and mated drive plate. Note: On many types of pump the drive shaft and drive plate are matched during manufacture to give a free fit, with a controlled backlash. These parts should be kept together and, in the event of wear, the complete assembly must be renewed. Inspect for wear and scoring of all mechanical governor linkages, shafts, pivot points, arms and the governor weight cage and weights. Ensure that the correct number and type of governor weights are fitted. © Delphi

•

1-6


INTRODUCTION I INTRODUCTION •

Inspect the pumping plungers for nicks, scratches, wear, corrosion, or other damage, and their respective bores within the distributor rotor. Note: Great care must be taken with pumping plungers and bores. Plungers must only be removed from the bore if there is a need to inspect them, and then only for the short time required for inspection. Ensure that each plunger is correctly replaced in the end of the bore from which it came, and the same way round. Plungers and bores must be cleaned with clean test oil and reassembled wet. The plungers should be retained in the bore of the rotor by plunger-retaining clips, or corks.

•

• •

The rotor must be assembled to the hydraulic head, and the complete assembly immersed in a covered bath of clean test oil, until required for assembly. Examine the transfer pump for chipped, broken, or worn transfer pump blades. Blades may be either carbon, resinbonded material, or steel. They are identified by the fact that resin-bonded blades have a groove in the base of the central slot; carbon blades have no groove. The blades are not interchangeable, and replacement blades MUST be of the same type. Inspect the rollers and shoes for damage. Examine roller surfaces and check for their free rotation in their shoes. Roller and shoe assemblies must be kept together. Check for valve wear or scoring. Pay special attention to the metering valve and its bore. Examine the metering valve lever for looseness of its pin, which may be caused by severe operating conditions. Check the regulating valve and pressurising valves. Note: A few DPA pumps are fitted with hydraulic heads having an oversize metering valve bore and an oversize metering valve to suit. Pumps fitted with an oversize metering valve have the number 6,375 etched on the hydraulic head between the outlet connections adjacent to the metering valve bore. The Parts List will give the metering valve part number for each individual pump.

• •

Check for defects in the cambox outlet pressurising valve. Shake the assembly and listen for movement of the ball or the valve; that will denote a collapsed spring. Inspect for wear in the throttle and shut-off shafts and levers, and in the advance device components.

© Delphi

Note: Some governor covers are fitted with bushes in the throttle and shut-off shaft bores. If the bushes are worn, the complete governor cover must be replaced.


1-7

I INTRODUCTION

© Delphi

INTRODUCTION

1-8


PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-DISMANTLING II PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-DISMANTLING 2.1

Preparation

If the pump is the subject of a warranty claim, carefully check that all ‘anti-tamper’ seals specified in the Test Plan are intact. If any seal shows that it has been disturbed, or is missing, it is probable that any claim may be rendered invalid. Turn the pump on its side, with the inspection cover plate upwards. Remove and discard any sealing wire and seal from the cover plate securing screws. Unscrew and remove the securing screws and shake proof washers. Detach the cover plate and discard the gasket. Drain any remaining fuel from the pump into a suitable, clean container, fitted with a suitable lid. Retain the fuel for subsequent examination if there is found to be corrosion or other contamination within the pump, especially if the pump may be the subject of a warranty claim. Examine the components as the pump is dismantled. Refer to section 1.6 (Component Inspection) for guidance.

2.2

Mounting The Pump

Fit the pump to the fixture with the governor control cover (1) uppermost (see graphic below).

2.3

Removing The Control Levers

2.3.1 Standard control levers Unscrew and remove the throttle lever and shut-off lever securing nuts and washers (6) and (4). Detach the throttle lever (5), shut-off lever (2), and the dust caps (7) and (3).

2.3.2 Spring-returned throttle lever

© Delphi

Slacken and remove the self-locking nut (1), and washer (2). Lift the lever (3) and release the tension of the spring (5). Remove the lever, large washer (4), spring (5) and spring retainer (6). Carefully note how the spring is fitted, to aid reassembly.


2-9

II PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-DISMANTLING PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-DISMANTLING 2.3.3 Spring-returned shut-off lever Slacken and remove the self-locking nut (1), and washer (2). Lift the lever (3) and release the tension of the spring (4). Remove the lever, spring and dust cover (5). Carefully note how the spring is fitted, to aid reassembly.

2.3.4 ‘Break-back’ throttle lever Slacken and remove the lock-nut (1); remove the washer (2) and the throttle lever guide (3). Carefully lift off the throttle lever (4). CAUTION Release the spring-load on the lever slowly.

© Delphi

Remove the ‘break-back’ lever (5), spring (6), washer (7), and the spring retainer (8). Carefully note how the spring is fitted, to aid reassembly.

2-10



Governor Control Cover

2.4.1 Removing the cover If the pump is to be completely dismantled, slacken and remove the backleak connection (1) and the bleed screw assembly (3). Discard the sealing washers. Slacken the control lever stop screw locknuts and. Remove the lead seal (2) and locking wire from the cover stud nuts. Unscrew and remove the nuts and washers. Fit the relevant protection cap to the throttle shaft. Lift off the governor cover and at the same time lightly press down on the top of the protection cap. Press the throttle shaft through the cover so that it remains with the pump, connected to the governor spring. Fit the protection cap to the shut-off shaft and press the shaft out of the cover. Remove and discard all shaft O-rings and the cover gasket.

2.4.2 Angled light-load advance adjusting screw

© Delphi

Remove and discard the lead seal and locking wire (5), and anti-tamper cap (1) from the adjusting screw (2). Slacken the lock-nut (3) and remove the screw. Discard the sealing washer (4).


2-11

II PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-DISMANTLING PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-DISMANTLING 2.5

Dismantling The Throttle Link

Unhook and remove the governor spring (2) from the idling spring guide (not visible in the illustration) and the throttle shaft link (3). Remove the idling spring and guide. Remove the shut-off bar (1). Press down the tabs on the tab washers under the cover studs (6) and (7) and the control bracket screw (4). Remove the cover studs, tab washers, keep plate (5), and the bracket screw and washer. Discard the tab washers.

2.6

Removing And Dismantling The Governor Linkage Assembly

2.6.1 Removing the assembly

© Delphi

Lift off the control bracket assembly (1), complete with the governor arm (2), the metering valve (3), and the linkage hook assembly.

2-12


PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-DISMANTLING II PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-DISMANTLING 2.6.2 Dismantling the assembly Note: It is not essential to dismantle the linkage as, if any component is worn or damaged, the assembly must be replaced completely. A) ‘Single-spring’ linkage Remove the spring linkage components from the linkage hook (5) in the following sequence: selflocking nut (2), nut (1), pivot ball washer (3), and pivot ball (4); remove the hook from the governor arm and then remove the spring support washer (9), long spring (7) and spring retainer (6). Remove the hook from the metering valve (12). Separate the governor arm (10) and the control bracket (8) by removing the tension spring (11). Immerse the metering valve in clean test oil.

B) ‘Two-spring’ linkage

© Delphi

Remove the spring linkage components from the linkage hook (5) in the following sequence: selflocking nut (2), nut (1), pivot ball washer (3), pivot ball (4); remove the hook from the governor arm (11) and then remove the spring support washer (12), long spring (14), spring retainer (9), short spring (8) and small spring retainer (7). Remove the hook from the metering valve (6). Separate the governor arm and the control bracket (10) by removing the tension spring (13). Immerse the metering valve in clean test oil.


2-13

II PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-DISMANTLING PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-DISMANTLING C) ‘Three-spring’ linkage Lift off the governor assembly as described above. Remove the spring linkage components from the linkage hook (12) in the following sequence: selflocking nut (1) and nut (2). Remove the pivot ball washer (3) and pivot ball (15). Remove the hook from the offset hole in the governor arm (4). Remove the washer (5), small spring (6), spacer (14), spring support washer (7), long spring (13), spring guide (8), short spring (9), and small spring retainer (11), from the hook. Note: If the two short springs are not the same, record the position in which each was fitted. Remove the metering valve (10) from the hook and immerse it in clean test oil. Separate the governor arm and the control bracket by removing the tension spring. Note: Later pumps may be specified with two self-locking nuts, instead of one plain nut and one self-locking nut, on the linkage hook.

2.7

Removing And Dismantling The Advance Device

Note: If no automatic advance device is fitted, a head locating screw will be specified. It serves to locate the hydraulic head within the pump housing and is one of three screws which retain the hydraulic head. Invert the pump. Slacken and remove the head locating screw and washer. Discard the washer.

2.7.1 Head locating fittings There are several different types of head locating fitting, the use of which depends upon the specification of the advance device (if fitted). They are: 1. Standard 2. Damper-type 3. Automatic start-retard control 4. Manual start-retard (lever-type) 5. Manual start-retard (screw-type) The manual-retard type may be dismantled for cleaning and seal replacement only, but cannot be repaired. The damper-type cannot be dismantled or repaired.

© Delphi

Note: Care must be taken, as the head locating fitting is removed from the pump, that the small steel ‘lock-off’ ball is not mislaid.

2-14


PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-DISMANTLING II PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-DISMANTLING 2.7.2 Single-stage advance device Remove the pressure end plug (13) and discard the O-ring (12). Remove the plug (4) from the spring cap (6) and discard the sealing washer (5). Remove the spring cap, and discard the O-ring (8). Remove the shims (7), and spring (9). Loosen and remove the head locating fitting (3), discard the seal(s) (2) and remove the washer (1). Note: It is possible that the washer (1) may be left in the pump housing as the head locating fitting is removed. Later versions of the fitting are designed so that the washer is an integral part of the fitting. Loosen and remove the cap nut (16) and discard the ‘Dowty’ (or copper) washer (15). Gently ease the advance housing (14), with its piston (11), from the pump housing. If the advance housing is stuck to the gasket it may be necessary to tap the housing lightly with a hide or rubber mallet to release it. Remove and discard the gasket (10). Remove the advance piston for inspection. If its condition is satisfactory, re-fit the piston to the advance housing. and place the advance assembly in a container of clean test oil.

2.7.3 Light-load advance device Remove the plug (11) from the spring cap (9) and discard the sealing washer (10). Remove the spring cap and remove the spring seat (shim) (7). Discard the O-ring (8). Remove the spring (6) and the spring stop (maximum advance stop) (5). Remove the pressure end plug (1) and discard the O-ring (2). Loosen and remove the head locating fitting, discard the seals and remove the washer. Loosen and remove the stud cap nut and discard the ‘Dowty’ (or copper) washer. Gently ease the advance housing with its piston (3) from the pump housing. If the advance housing is stuck to the gasket (12) it may be necessary to tap the housing lightly with a hide or rubber mallet to release it. Remove the slide washer (4). Remove the piston for inspection; replace it and store the housing and piston assembly in a container of clean test oil.

© Delphi

Note: The piston and advance housing are a matched assembly. If either the piston or the housing is damaged, the complete assembly must be replaced.


2-15


Releasing The Cam Screw Or Cam Advance Screw And Removing The High Pressure Outlet Connections

2.8.1 Cam screw If no automatic advance device is specified, the cam ring will be retained in the pump housing by a single screw. Slacken and partially remove the cam screw. If necessary, lightly tap the screw with a hide mallet to release the cam ring. Remove the screw and washer. Discard the washer.

2.8.2 Cam advance screw Using the relevant special tool, or a suitable hexagon socket, slacken the cam advance screw (1). If necessary, lightly tap the cam advance screw with a hide mallet to release the cam ring (2). Remove the screw.

2.8.3 High-pressure outlets Note the position and type of each high pressure outlet connection (note the letter identification against each outlet hole). Remove the outlet connection banjo bolts (3) and banjos (5), and discard the two sealing washers (4) on each banjo bolt. There may be three types of connections fitted to the radial outlets in the hydraulic head:

A) ‘Plain’ radial. These are designed with a coned end for direct connection to the high pressure pipes. Remove each connection and discard the sealing washer. Note the position in which each banjo is fitted, remove the banjo bolt and discard the sealing washers.

2-16


© Delphi

B) Banjo bolts, with ‘plain’ banjos.

PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-DISMANTLING II PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-DISMANTLING C) Banjo bolts, and banjos fitted with delivery valves. Remove the banjo bolts (2) and discard the sealing washers (1). Place each banjo assembly (3) in a soft-jawed vice, clamping it at the banjo bolt end, but not across the sealing faces. Slacken and remove the delivery valve holder (10). Remove the peg (9), spring (8), upper sealing washer (6), delivery valve (7) and delivery valve body (5), and lower sealing washer (4). Discard both sealing washers. After examination, replace each delivery valve into its original delivery valve body and then keep them as a matched pair, immersed in clean test oil.

2.9

Removing And Dismantling The End Plate And Transfer Pump

2.9.1 All end plates Various combinations of end plate components may be specified. Carefully note the position of each component as it is removed. Loosen the inlet connection (1). Remove the securing screws (13) and washers (12) (if fitted) and remove the end plate and high pressure outlet support plate(s), if specified (not shown in the illustration), from the hydraulic head. Remove the inlet connection and discard the sealing washer (2). Remove the regulating sleeve retaining spring (4), filter (3) and either spring cap (5) or the transfer pressure adjuster assembly (14). Remove either the spring peg and regulating spring (15) and (16) or the regulating spring (6) (occasionally two (7)). Remove the regulating sleeve(9) with the piston (8) and piston retaining (or ‘priming’) spring (11). Remove and discard the washer (10) from the regulating sleeve. Keep the piston in the sleeve. Note: The spring (16) and peg (15) may be permanently attached to each other.

© Delphi

Remove the seal (19), the transfer pump blades (17), and the transfer pump liner (18) from the hydraulic head.


2-17

II PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-DISMANTLING PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-DISMANTLING 2.9.2 End plate with ‘loose’ sandwich plate Remove the sandwich plate (2) from the end plate (1).

2.10

Loosening The Transfer Pump Rotor And Removing The Hydraulic Head

If an ‘arrow’ is marked on the face of the rotor, it will indicate the direction in which the transfer pump rotor must be slackened. If there is no mark on the rotor, it must be slackened in the direction of pump rotation as indicated on the pump name plate, or as given in the Test Data for the pump. Hold the drive hub with a suitable spanner (1) and slacken the transfer pump rotor with the special tool (4) and a suitable wrench. Remove the tools and leave the transfer pump rotor finger-tight. Note the location and types of the remaining two head locking screws (2) and (3). They may be a plain screw and/or a damper assembly and/or a vent screw assembly. Unscrew and remove the screws and discard their washers. Withdraw the head and rotor assembly (5 from the pump housing, with a slight twisting motion in each direction. Remove and discard the large O-ring on the hydraulic head.

© Delphi

Note: Damper assemblies cannot be repaired.

2-18



Removing The Drive Plate Screws, Top Adjusting Plate, And Rollers And Shoes

Place the head and rotor assembly on the bench. Hold the drive plate (2) with the special tool (1) and loosen the drive plate screws (3) with the special tool (4). Unscrew and remove the transfer pump rotor. Place the hydraulic head on the bench with the drive plate uppermost. Remove the drive plate screws, drive plate, top adjusting plate, rollers and shoes, keeping the pairs of rollers and shoes together. Immerse the rollers and shoes in clean test oil.

2.12

Removal Of The Bottom Adjusting Plate, Cam Ring And Circlip

2.12.1 Bottom adjusting plate

© Delphi

Fit corks (1) or a plunger retaining clip into the transverse slots in the distributor rotor to retain the plungers. Remove the rotor from the hydraulic head and remove the bottom adjusting plate from the rotor. Take great care to avoid scratching the surface of the rotor. Examine the rotor for signs of excessive wear or damage. Moisten the rotor with clean test oil and carefully re-insert it into the hydraulic head to ensure protection of the bearing surfaces. Refit the transfer pump rotor to the distributor rotor, leaving it fingertight. If it is suitable for further service, place the hydraulic head assembly in a container of clean test oil.


2-19

II PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-DISMANTLING PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-DISMANTLING 2.12.2 Cam ring and circlip Note the direction of the arrow on the cam ring (1) then remove the cam ring. Note the positions of the ‘ears’ on the circlip (2) relative to the pump housing inspection window, and extract the circlip.

2.13

Releasing The Drive Shaft Assembly

© Delphi

Hold the drive hub (1) with the special tool (3) and, using the special tool (2), loosen the drive shaft screw by two turns. Gently tap the end of the tool holding the screw (as shown) then remove the screw and spring washer. Remove the support washer from the hub for examination.

2-20



Removing The Drive Shaft Assembly

2.14.1 Cush-drive weight cage assembly Remove the drive shaft and governor weight assembly from the pump housing. Stand the drive shaft vertically with the drive end uppermost. Remove the drive shaft seal from the annular groove in the shaft. Lift the weight assembly until the cush-drive back plate (1) is level with the annular groove. Hold the back plate and turn it until the three rivet heads in the weight cage (4) are aligned with the three notches in the back plate, which can then be removed from the weight cage. Turn the back plate until the internal ‘lip’ (5) is in line with the gap in the shaft splines, and lift it off. Remove the weight cage, governor weights, thrust washer and thrust sleeve. Remove the splined hub (2) from the cush-drive retainer. Remove the rubber inserts (3).

2.14.2 Non-cush-drive weight cage assembly

© Delphi

Withdraw the drive shaft and governor weight assembly. Stand the shaft vertically, with the drive shaft seal uppermost. Remove the seal (3) from the annular groove. Lift the weight cage assembly (2) and remove it from the drive shaft. Remove the governor weights (1), thrust washer (4) and thrust sleeve (5).


2-21


Removing The Drive Hub Seal

© Delphi

Withdraw the drive hub from the housing. Remove the pump from the fixture. Extract and discard the drive hub seal (1), using the special tool (2).

2-22


PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-REASSEMBLY III PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-REASSEMBLY 3.1

Fitting The Drive Hub Seal, Drive Hub And Drive Shaft Assembly

3.1.1 Fitting the drive hub seal and drive hub Immerse a new drive hub seal in clean test oil. The seal must be inserted into the pump housing with its ‘lip’ facing inwards. Fit the seal using the special tool (1) and a hide mallet (2). Fit the pump housing to the assembly plate, with the machined face for the governor control cover upwards. Moisten the drive hub seal with clean test oil then insert the drive hub through the plate into the pump housing.

3.1.2 Assembling the cush-drive weight cage

© Delphi

Fit the hub (2) into the weight cage (6) and align the two holes in the hub with the ‘cut-outs’ (4) and (5) in the cage. Fit the rubber inserts (3) between the hub and the weight cage. Place the back plate (1) so that the three notches slide over the heads of the three rivets in the weight cage, then rotate the plate until the ‘double’ (or ‘master’) spline (7) aligns with the double spline in the cush-drive hub.


3-23

III PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-REASSEMBLY PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-REASSEMBLY 3.1.3 Assembling the governor weight cage components Place the drive shaft (1) into the special fixture tool, with the seal groove uppermost. Fit the thrust sleeve (5), with its stepped end facing downwards, then the thrust washer (3). Fit a governor weight (4) and adjust the height of the fixture until the lip of the governor weight sits on the thrust washer. Place the remaining governor weights in a similar position around the drive shaft. (For governor specifications using less than six weights, see the table opposite for disposition of the weights.) Align the drive shaft splines with the splines in the weight cage hub and slide the weight cage (2) onto the weights. Fit a new drive shaft seal, ensuring that the correct size is selected, using the relevant protection cap. Take off the protection cap and remove the complete assembly from the fixture. Number of weights

Position of weights in carrier (using the clock face as guide)

6

Full

4

12, 2, 6, & 8 o’clock

3

12, 4, & 8 o’clock

2

12 & 6 o’clock

3.1.4 Fitting the drive shaft and tightening the drive shaft screw

© Delphi

Insert the drive shaft and weight assembly into the hub, weight cage end first. Secure the assembly in place with the support washer, spring washer and drive shaft screw. Tighten the screw to the specified torque value using the special tool (2), while holding the drive hub with the special tool (1).

3-24



Checking Drive Shaft End Float

© Delphi

Measure the gap between the rear face of the hub (1) and the pump housing mounting spigot (2), using two sets of ‘feeler’ gauges 180° apart in the gap. If dimension A exceeds 0.25mm (0.010 in), the weight cage and/or the pump housing must be renewed, and the end float rechecked.


3-25

III PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-REASSEMBLY PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-REASSEMBLY 3.3

Fitting The Timing Circlip And The Cam Ring

Fit the circlip (1) against the shoulder in the pump housing bore, placing the square ‘ear’ of the circlip centrally in the housing inspection aperture as shown. Insert the cam ring (2) against the circlip with its arrow facing the same direction as the arrow on the pump name plate. Note: The type of circlip specified will determine whether the ‘ears’ of the circlip must be visible in the inspection window for timing, or not. There are three alternatives: i. ‘Early’ version (for pumps of pre-1960 specifications). This circlip has two ‘rounded’ ears, one of which has a line stamped across its face. ii. ‘Current’ version. This has one ‘rounded’ ear and one ‘flat’ ear. This type is to be fitted with the gap between the ears placed centrally in the inspection window. Note: (1) For these two types, the position of the circlip will be adjusted after testing is completed to align either the line or the flat edge with a letter on the drive plate as designated in the Test Plan. Note: (2) The circlip must also be positioned according to the direction of rotation of the pump, and the side of the pump in which the window is placed. If the pump rotates clockwise and the window is on the right-hand side when viewed from the drive end, the flat ear (or the ear with the stamped line) must be at the bottom of the window (as shown in the illustration). For other arrangements, the circlip must be placed so that the drive plate approaches the timing position across the gap between the ears. This is important, to ensure accurate setting of timing. iii.

Alternative ‘current’ version. The two circlip ears are of similar shape and must be fitted approximately 180° away from the window.

© Delphi

Invert the fixture in the vice. If no automatic advance device is specified, secure the cam ring by inserting the cam ring screw, fitted with a new ‘Dowty’ washer, through the pump housing and into the cam. Tighten the screw to the specified torque. If an automatic advance device is specified, screw the cam advance screw into the cam ring. Tighten it to the specified torque using the special tool or a suitable hexagon socket, depending upon the type of cam advance screw. Remove the tool; if the cam ring will not move in the pump housing, lightly tap the advance screw with a hide mallet to release the cam ring.

3-26



The Hydraulic Head Rotor Screw

If the hydraulic head rotor screw has been removed, or is loose, a new screw and washer must be fitted. Unscrew and remove the transfer pump rotor. Remove the distributor rotor from the hydraulic head. Screw the drive plate screws fully home into the distributor rotor, leaving them finger-tight. Mount the rotor vertically so that the heads of the screws only are gripped lightly in a vice fitted with soft jaws. Thoroughly degrease the internal thread of the rotor and the thread of the screw. Lightly smear the thread of the screw with ‘Araldite’. Fit the screw to the rotor and tighten it to the specified torque, using the special tool (1). Carefully refit the rotor to the hydraulic head and then allow the ‘Araldite’ to ‘cure’ for at least six hours at room temperature before putting the pump into service. CAUTION Do not use any form of heat to reduce the curing time of the Araldite.

3.5

Roller And Shoe Assemblies

© Delphi

If fitted, remove the transfer pump rotor. Place the hydraulic head (1) on the bench, with the drive end uppermost. Remove the distributor rotor (2) and place the bottom adjusting plate (3) on the hydraulic head with the chamfered edges of the roller shoe ear scrolls uppermost. Insert the rotor into the hydraulic head and line up the guide slots on the bottom adjusting plate with the tapered end cut-outs on the rotor head, as shown. Remove the corks or clip retaining the pumping plungers in the distributor rotor. Insert the roller and shoe assemblies (4), with their ‘ears’ inwards, into the roller shoe guides as shown. The projecting ears on the shoes must be placed in the slots of the bottom adjusting plate so that the contours of the ears match the contours of the slots.


3-27


Fitting And Aligning The Top Adjusting Plate And The Drive Plate

Fit the top adjusting plate (1), with the chamfered edges of the roller shoe ear scrolls facing downwards, and engage the legs of the plate with the guide slots (7) and (8) of the bottom adjusting plate. Locate the two plates so that the fuel adjusting slot (4) in the top plate coincides with the scribed line (2) on the distributor rotor head. Fit the drive plate (5), with the machined recess facing downwards, and align the ‘cutaway’, which is between letters ‘A’ and ‘H’, with the fuel adjustment slot as shown. Fit the drive plate screws (3) and (6) and leave them finger-tight. (Note that the holes in the drive plate are offset so that the plate can only be fitted in one position). Lift the head and rotor assembly and fit the transfer pump rotor into the distributor rotor, leaving it finger-tight.

3.7

Setting The Roller-To-Roller Dimension (Two-Plunger Pumps)

Fit the Stirrup Pipe (1) in the special tool set to two diametrically-opposite high pressure outlet ports on the hydraulic head as shown and connect it to a Nozzle Testing Outfit (NTO). Operate the NTO to raise the pressure to the figure specified in the Test Data sheet (generally 30 atm). Turn the pump rotor until the pumping plungers and rollers are forced outwards to the maximum fuel position. Carefully measure the overall roller-to-roller dimension with a micrometer as shown. The dimension must be set to the correct test specification figure by movement of the adjusting plates. Note: Relief Valve (2) (part of the special tool set) must be fitted in the fuel line to ensure that the test pressure of 30 atm. is not exceeded. When other test pressures are stated on Test Plans this relief valve may be adjusted as required. If it is not fitted to the tool, care must be taken not to exceed the specified pressure. Excess pressure can cause damage to the shoe assemblies and adjusting plates.

© Delphi

Note: Four-plunger pumps do not require accurate setting at this stage.

3-28



Tightening The Drive Plate Screws

Hold the drive plate with the special tool (4) and tighten the drive plate screws (1) evenly to the specified torque, using the special ‘offset’ tool (2) and (3) (see section 7.1 and Note (2) below). Note: (1) As the hydraulic head is not yet fitted to the pump, the screws may be tightened by the use of a standard socket; however, a different torque to that specified for the ‘offset’ tool must be used (see section 7.1). Now slacken these screws and re-tighten them to the same torque value. It is important that this sequence of tightening, slackening, and re-tightening is followed. Tighten the screws evenly, to avoid rotor distortion which could cause the plungers to stick. Note: (2) In use, the torque wrench handle and spanner must form a straight line, with the handle extending away from the spanner. The distance between the centre of the adaptor and the centre of the ring spanner is 127 mm (5,0 in). With the superseded special tool the distance is 66 mm (2,6 in). See the list of Torque Values in section 7.1. Certain designs of torque wrench are not suitable for this operation. If the tools are not kept in a straight line, the applied torque will be incorrect.

© Delphi

Check that the roller-to-roller dimension has not been altered during tightening of the screws. Disconnect the nozzle testing outfit and remove the stirrup pipe from the high pressure outlets on the hydraulic head.


3-29


Automatic Advance Device

3.9.1 Single-stage Place a new advance housing gasket (8) on the pump housing. Check that the flat end of the advance piston (9) is towards the oil feed drilling (pressure) end of the advance housing (12). Fit the advance housing and piston assembly to the pump housing, ensuring that the cam advance screw engages in the piston, and lightly secure the assembly in place with the cap nut (1) and a new ‘Dowty’ washer (13). Fit a new O-ring (10) to the pressure end plug (11) and screw the plug into the advance housing. Fit the advance spring(s) (7). Fit a new O-ring (6) to the spring cap (4). Insert the shim washers (5) into the recess in the cap and screw the cap into the advance housing. Leave the cap and plug finger-tight. Note: Refer to the relevant Test Plan for the correct shim thickness. Fit a new sealing washer (3) to the plug (2) and fit the plug to the spring cap, leaving it finger-tight.

3.9.2 Light-load

© Delphi

Fit a new gasket (12) to the pump housing and place the advance housing onto the pump and over the housing stud. Place a new ‘Dowty’ (or copper) washer onto the stud and hold the advance device in place with the cap nut, finger-tight. Fit the slide washer (4) (with its concave face towards the cam advance screw) and the piston (3) to the pressure end of the advance housing (the fuel supply port will be visible in the correct end of the housing). Using the relevant seal protection cap, fit a new Oring (2) to the pressure end plug (1) and fit the plug to the advance housing. To the opposite end of the advance housing, fit the spring guide (maximum advance stop) (5), and the spring (6). Using the relevant seal protection cap, fit a new Oring (8) to the spring end cap (9). Fit the specified thickness of shim (spring seat) (7) to the cap and fit the cap to the advance housing, leaving it fingertight. Fit a new sealing washer (10) to the plug (11) and fit the plug to the spring cap, leaving it fingertight.

3-30



Inserting And Securing The Hydraulic Head

Invert the pump assembly and fixture in the vice so that the governor housing face is uppermost. Confirm that the new large O-ring for the hydraulic head (1) is of the correct thickness (2 mm or 3 mm), dependent upon the width of the groove (7). Fit the new O-ring to the hydraulic head. Lubricate the portion of the head which fits into the pump housing, and the housing, with clean test oil. Carefully insert the head into the housing, with a rotating motion, so that the splines on the inner end of the drive shaft engage with the splines in the drive plate. Rotating the head on entry prevents ‘jamming’ of the hydraulic head in the housing and consequent damage to the pump housing. Align the metering valve bore with the contour (4) in the machined face of the housing and, when the head is in position, secure it with the head locking screw (6) and a new washer (5), and the vent screw assembly (2) and a new washer (3), leaving both screws finger-tight. (Ensure that the head vent screw assembly and head locking screw are in the same positions as noted when dismantling). If no automatic advance device is specified, secure the hydraulic head by inserting the head locating screw, fitted with a new ‘Dowty’ washer, through the pump housing and into the hydraulic head. Tighten the head locating screw to the specified torque. If an automatic advance device is specified, fit new O-rings to the head locating fitting. Fit the steel washer (if specified) and insert the head locating fitting into the advance housing so that the ball seat (not specified if the pump is fitted with a light-load advance device), is just showing. Fit the steel ‘lock-off’ ball and screw the head locating fitting into the hydraulic head. Progressively and evenly tighten the advance device cap nut, the head locating fitting, the head vent screw assembly and the head locking screw to their specified torque values.

© Delphi

Note: The pump may be fitted with a number of alternative head locking screws; plain, vent, or damper-type. In the latter case a special tool must be used in conjunction with the torque wrench to gain access to the hexagon under the head of the damper for tightening. Also, a variety of head locating fittings may be specified; plain (where no advance assembly is fitted), with a lock-off ball, without a lock-off ball, with manual retard devices (‘toggle’ or ‘screw-in’), or with a damper.


3-31


Tightening The Transfer Pump Rotor And Fitting The Transfer Pump Components

3.11.1 Tightening the rotor Hold the drive hub with the special tool (1) and tighten the transfer pump rotor with the special tool (2) to the specified torque value. Note that the transfer pump rotor must be tightened in the opposite direction to pump rotation.

3.11.2 Fitting the transfer pump components Insert the transfer pump liner (2) into the pump housing with the slot in the rim of the liner in the same position which it occupied prior to dismantling. See the table below: If the liner has a recess in one face, that recess must be placed at the ‘6 o’clock’ position. Fit the liner seal (3). Insert the transfer pump blades (1) into the rotor. Take care to avoid damaging the edges of the blades on the edges of the liner. Check the freedom of movement of the transfer pump blades by rotating the pump by hand. When lubricated, the grip of the liner seal should prevent the liner from rotating as the blades turn.

Liner groove position (viewed from the rotor end)

Clockwise

3 o’clock

Anti-Clockwise

9 o’clock

© Delphi

Pump rotation (viewed from the drive end)

3-32



Assembling The End Plate

Place the piston retaining (priming) spring (12) into the end plate (16). Fit a new seal (11) onto the piston and sleeve assembly (10). Fit into the sleeve, from the top, the regulating spring (6) [occasionally two (7), or spring peg and regulating spring (9)], the sleeve plug (5) (or the transfer pressure adjuster assembly (8)). Fit the assembly into the end plate. Fit the filter (3) and the sleeve retaining spring (4). Fit a new sealing ring (2) to the fuel inlet connection (1) and fit the connection to the end plate, leaving it finger-tight.

3.13

Fitting The End Plate Assembly

Fit the sandwich plate (2) (if the end plate is a ‘loose sandwich plate’ version) to the end plate (1), ensuring that the dowel pin in the end plate is fitted into the groove (3) in the sandwich plate. Note: Some sandwich plates are bonded to the end plate. Place the end plate, with the inlet connection uppermost, against the hydraulic head, ensuring that the end plate dowel engages with the slot in the rim of the transfer pump liner. (The letter ‘C’ (4) on the end plate signifies the position in which the dowel is fitted for clockwise rotation of the pump). Secure the end plate with the four screws and washers (items (14) and (13) in section 3.12). Tighten these screws, and then the inlet connection, to their specified torque values.

© Delphi

Note: Some pump specifications may incorporate a high-pressure pipe support plate or plates (item (15) in section 3.12) held in position by the end plate securing screws. If so, fit the plate(s) in position as noted during dismantling.


3-33


Assembling The Governor Control Linkage

3.14.1 Single-spring linkage Fit the governor control bracket (8) into the governor arm (10) and fit the linking spring (11) to the governor arm. Fit the spring retainer (6) (large end first), spring (7), and spring support washer (9) to the hook (5). Pass the hook through the offset hole in the governor arm and then fit the pivot ball (4), pivot ball washer (3), nut (1) and self-locking nut (2). Fit the metering valve (12) to the hook as shown.

3.14.2 Two-spring linkage

© Delphi

Fit the governor control bracket (10) into the governor arm (11) as shown, and fit the linking spring (13) to the governor arm. Fit the small spring retainer (7) (large end first) to the linkage hook (5), then the short spring (8), and large spring retainer (9), (large end first). Fit the long spring (14), and the spring support washer (12). Pass the hook through the offset hole in the governor arm and then fit the pivot ball (4), pivot ball washer (3), nut (1), and the self-locking nut (2). Fit the metering valve (6) to the hook as shown.

3-34


PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-REASSEMBLY III PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-REASSEMBLY 3.14.3 Three-spring linkage Fit the governor control bracket into the governor arm and attach the linking spring as described in sections a) and b) above. Fit the metering valve (10) to the hook. Ensure that the ‘open’ side of the hook is facing in the correct direction, as shown. Fit the small spring retainer (11) (large end first), short spring (9), spring guide (8) (large end first), long spring (12), washer (7), spacer (13) (large end first), short spring (6), and spring support washer (5) to the linkage hook. Pass the hook through the offset hole in the governor arm (4) and fit the pivot ball (14), pivot ball washer (3), nut (2), and the self-locking nut (1). Note: (1) The two short springs may differ; if so, fit them in their positions as noted during Dismantling. Note: (2) In later pumps, two self-locking nuts may be used to retain the linkage components instead of a plain nut and a self-locking nut.

3.15

Fitting The Governor Control Linkage To The Pump

© Delphi

Fit the governor control linkage assembly into the pump housing by placing the ‘toes’ on the lower end of the governor arm onto the ‘step’ of the thrust sleeve, and at the same time insert the metering valve into the metering valve bore in the hydraulic head. Place the keep plate (1) on the control bracket (3) so that the slotted end faces away from the linkage hook assembly (4). Place two new tab washers (2) and (9) on the keep plate, with their ‘lips’ placed nearest to the metering valve and engaging the long edge of the keep plate. Screw in the two governor control cover studs (7) and (8) and leave them finger-tight. Place a new control bracket screw tab washer (6) on the control bracket in the correct position as shown, with the ‘tail’ bent down over that edge of the control bracket lying under the linkage hook assembly. Insert a new bracket screw (5) and tighten the screw and control cover studs to their specified torque values. Lock all tabs.


3-35


Setting The Governor Link Length

3.16.1 Standard metering valves Set the link length with a vernier caliper as shown, so that the specified internal dimension (as stated in the relevant Test Plan) is obtained between the larger diameter of the governor control cover stud (4) and the metering valve lever pin (5). Adjustment is made by slackening the linkage locking nut (1) and tightening or loosening the linkage nut (2). When setting, apply light pressure to the governor control arm (3) to hold the metering valve in the fully open position. Ensure that the vernier caliper is held parallel to the axis of the pump and that the ‘leg’ of the caliper has not entered the groove in the metering valve pin. After setting, tighten the linkage lock-nut and re-check the link length to ensure that it has not changed.

3.16.2 ‘Roller pin’ metering valves

© Delphi

Set the link length so that the specified internal dimension (as specified on the relevant Test Plan as ‘Method B’ ) is obtained between the smaller diameter of the governor control cover stud (1) and the metering valve pin (2).

3-36



Throttle Link

3.17.1 Assembly Place a new housing gasket onto the governor housing face, with the gasket ‘tongues’ placed in the slots (7) of the control bracket. Slide the shut-off bar (2) into the aperture (6) in the control bracket and under the ‘lip’ (1) of the tab washer. Fit the relevant protection cap to the end of the throttle shaft (5) and fit new O-rings to the groove(s) in the shaft. Place the idling spring onto the idling spring guide (not visible in the illustration – see item ‘A’ in section 3.17.2). Insert the guide into the hole in the governor arm specified in the Setting Code in the Test Plan and attach the governor spring (3) to the guide. Insert the other end of the spring into the hole in the throttle shaft link (4) also as specified in the Test Plan. Interpretation of the Setting Code details is given in the diagram in section 3.17.2).

3.17.2 Application of the Setting Code Locate the code number in the table. The vertical and horizontal lines from this number to the pump components give the correct numbered hole in the throttle shaft link and the governor arm for assembling the governor spring, e.g. for code No. 8 fit the governor spring (B) to the No. 2 hole in the throttle shaft link (C) and the idling spring guide (A) into the No. 3 hole in the governor arm (D). Fit the free end of the governor spring to the idling spring guide.

3.18

Governor Control Cover

© Delphi

3.18.1 Fitting the control shafts to the cover and fitting the cover to the pump Fit the relevant protection cap onto the shut-off shaft and place new shaft O-rings in the grooves. Insert the shaft into the governor control cover then remove the protection cap. Place the peg on the lower face of the shaft towards the edge of the cover. Insert the throttle shaft into the governor control cover and, at the same time, fit the governor control cover onto the two studs. Whilst lowering the governor control cover into position on the pump housing, engage the shutoff shaft peg with the hook of the shut-off bar. Remove the protection cap. Fit the cover stud washers and nuts and tighten them to the specified torque. Fit a new sealing washer to the cover vent screw assembly, fit the vent to the cover and tighten it to the specified torque.


3-37


Fitting The Control Levers

3.19.1 Spring-returned throttle lever Fit the spring retainer (4), spring (3) and the large washer (5), over the shaft. Place the lever (2) over the shaft and, at the same time, place one end of the spring against the lever and the other end against the idling screw support, or otherwise, as noted during dismantling. Locate the lever onto the ‘flats’ on the throttle shaft; fit the washer (6) and the selflocking nut (1). Tighten the nut to the specified torque. Check that the lever moves easily through its full working range.

3.19.2 Spring-returned shut-off lever

© Delphi

Fit the spring retainer (5) and the spring (4) over the shaft. Place the lever (3) over the shaft, locating it correctly onto the ‘flats’ on the shaft, and hook the spring into the small hole in the lever, with its other end around the pillar on the governor cover, as noted during dismantling. Fit the washer (2) and the self-locking nut (1). Finally, tighten the nut to the correct torque value. Check that the lever moves easily through its full working range.

3-38


PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-REASSEMBLY III PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-REASSEMBLY 3.19.3 Standard throttle and shut-off levers Fit the shut-off dust cover (1), shut-off lever (2), shutoff lever washer and nut (3). Fit the throttle shaft dust cover (6), throttle lever (4), washer and nut (5). Tighten both nuts to their specified torque. Check that the levers move easily through their full working ranges.

3.19.4 ‘Break-back’ throttle lever

© Delphi

Fit the spring retainer (8), washer (7), and spring (6) (with the ‘legs’ of the spring facing upwards) over the throttle shaft. Fit the break-back lever (5) and then the throttle lever (4), so that the spring legs engage the ‘outer’ edges of the two lugs (9) & (10) and (11) & (12) on each lever (or as noted during dismantling). Also, ensure that the ‘flats’ in the break-back lever hole engage with the ‘flats’ on the shaft. Fit the throttle lever guide (3), washer (2), and self-locking nut (1). Tighten the nut to the specified torque. Check that the throttle lever operates correctly and that, when further rotation of the break-back lever is prevented by contact with the max. speed stop, the throttle lever is able to rotate further, against the spring.


3-39

III PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-REASSEMBLY PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-REASSEMBLY 3.19.5 Angled light-load advance adjusting screw Fit the nut (2) to the adjusting screw (1), and a new washer (3). Fit the screw to the governor control cover and turn the screw in to the Initial Setting, as specified in the Test Plan.

3.20

Backleak Connection, Housing Vent Screw And Inspection Cover Plate

Fit a new washer (2) to the backleak connection (1), screw the connection into the pump housing and tighten it to the specified torque. Fit the inspection cover plate (3) and a new gasket (4) to the pump housing and secure the cover plate with the screws and washers (5) and (6), lightly tightened (the cover may need to be re-opened during testing to adjust the fuel delivery).

3.21

High Pressure Outlet Connections

3.21.1 Plain radial type

© Delphi

Fit a new sealing washer to each outlet connection, screw the connection into the hydraulic head and tighten it to the specified torque.

3-40


PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-REASSEMBLY III PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-REASSEMBLY 3.21.2 ‘Plain’ banjo-type outlets For pumps to which more than one type of banjo connection may be fitted, refer to the relevant Parts List to identify which type of connection is to be placed in each outlet port in the hydraulic head. Fit the banjo bolts (7) to the banjos (1) to (6), with a new washer either side of each banjo. Fit the banjo bolts to the hydraulic head and tighten them to the specified torque.

3.21.3 Banjos with delivery valves Fit a new lower seal (4) into the banjo connection (3). Place the delivery valve body (5) into the banjo, followed by the delivery valve (7), upper seal (6), spring (8), and spring peg (9). Screw the delivery valve holder (10) into the banjo, leaving it finger tight. Place the banjo in a soft-jawed vice (not across the sealing surfaces, and taking care to use the minimum necessary force). Tighten the holder to the specified torque. CAUTION Do not tighten the holders when they have been fitted to the pump. Fit the banjo bolt (2), with new washers (1), to the assembled outlet and fit each assembly to the hydraulic head. Tighten the banjo bolts to their specified torque.

3.22

Security

© Delphi

Where possible, check that all components have been tightened to their specified torque values. Fit sealing wire and seals loosely to the cover stud nuts as specified in the Test Plan. Attach locking sleeves and suitable lengths of locking wire with new seals loosely to the pump for sealing the light load advance adjusting screw (after Testing) and for the throttle adjusting screw (after final setting on the engine). Do not ‘emboss’ the seals.


3-41

III PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-REASSEMBLY

© Delphi

PUMPS WITH TWO-PIECE ('HUB') DRIVE SHAFTS-REASSEMBLY

3-42


PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING IV PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING 4.1

Mounting The Pump

Secure the pump to the fixture, with the governor control cover uppermost. Remove and discard any sealing wire and seal from the cover plate securing screws (4) and (6). Unscrew and remove the screws and their shake proof washers. Detach the cover plate (5) and discard the gasket. Drain any remaining fuel into suitable, clean, covered container. The fuel should be retained for possible subsequent examination if corrosion or other contamination is found during dismantling, especially if the pump is the subject of a Warranty claim. Examine the components as the pump is dismantled (refer to section 1.6 Component Inspection for guidance).

4.2

Removing The Shaft Locking Screw, The Governor Control Cover Fittings, And The Cover

Slacken the throttle lever stop screws (2) and (3).

4.2.1 Removing the anti-stall screw Unscrew the lock-nut (1) and remove the anti-stall screw. Discard the sealing washer.

4.2.2 Shaft-locking screw

© Delphi

If ‘locked-shaft timing’ is specified for the pump, slacken and remove the locking screw (1) and special washer (3). Discard the O-ring (2).


4-43

IV PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING 4.2.3 Torque adjustment screw Remove and discard the lead seal and wire (5), and ‘anti-tamper’ cap (4) from the torque adjustment screw (3). Unscrew the lock-nut (2) and remove the screw. Discard the sealing washer (1).

4.2.4 Spring-returned shut-off lever Slacken and remove the self-locking nut (1), and washer (2). Lift the lever (3) and release the tension of the spring (4). Remove the lever, spring and dust cover (5), noting how the spring is attached to the lever and abuts the governor cover.

4.2.5 ‘Standard’ shut-off lever

© Delphi

Unscrew and remove the self-locking nut (3) and washer; remove the lever (2), and dust cover (1).

4-44


PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING IV PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING 4.2.6 ‘Standard’ throttle lever Unscrew and remove the throttle lever securing nut (5) and washer. Remove the throttle lever (4) and the dust cap (6).

4.2.7 ‘Heavy duty’ throttle lever Slacken the nut on the pinch bolt (2). Insert a large screwdriver blade into the slit (3) in the throttle lever. Gently ease the gap open and remove the lever from the throttle shaft (1). Remove the shaft key and the throttle shaft circlip (not visible in the illustration), and the dust cover and pad (4).

4.2.8 ‘Break-back’ throttle lever Slacken and remove the lock-nut (1); remove the washer (2) and the throttle lever guide (3). Note how the spring is fitted against the ‘ears’ (9), (10), (11), and (12) of the two levers and then carefully lift off the throttle lever (4). CAUTION Release the spring-load on the lever slowly.

© Delphi

Remove the break-back lever (5), spring (6), washer (7), and the spring retainer (8). Fit the appropriate protection cap to the throttle shaft and push the shaft down through the governor cover.


4-45

IV PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING 4.2.9 Exhaust brake lever Note how the spring is fitted against the governor cover at (7). Slacken and remove the screw (1), shake proof 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).

4.2.10 Removing the governor control cover Unscrew and remove the governor cover vent screw assembly and discard the washer. Remove the backleak connection, which may be in the governor cover or the pump housing. Remove and discard the lead seal and locking wire from the governor cover stud nuts. Unscrew and remove the nuts and washers. Fit the appropriate protection cap to the throttle shaft. Lift off the governor control cover and at the same time press down the throttle shaft. The shaft must be pressed fully through the cover, to remain with the pump and connected to the governor spring.

4.2.11 Exhaust brake shaft If fitted, push the exhaust brake shaft down through the cover. Remove the shaft and discard its O-rings.

4.2.12 Shut-off shaft Fit the appropriate protection cap to the shut-off shaft and push it out of the cover. Discard the O-ring(s).

4.3

Dismantling The Throttle Link

© Delphi

Unhook and remove the governor spring (5) from the idling spring guide (not visible in the illustration) and throttle shaft link (6). Remove the idling spring and guide. Remove the shut-off bar (4). Remove and discard the governor control cover gasket (9). Press down the tabs on the control cover stud and bracket screw tab washers. Remove the control cover studs (1) and (2) and discard their tab washers, the ‘keep’ plate (3), and the bracket screw (7) and its tab washer (8). Remove and discard the two throttle shaft O-rings.

4-46



Removing And Dismantling The Governor Linkage Assembly

4.4.1 Single-spring linkage Lift off, as an assembly, the control bracket (8), complete with the governor arm (10), metering valve (12), and the linkage hook assembly. Remove the self-locking nut (2), nut (1), pivot ball washer (3), pivot ball (4), and remove the hook from the offset hole in the governor arm. Remove the spring support washer (9), spring (7), and spring retainer (6) from the hook (5). Remove the metering valve from the hook and immerse it in clean test oil. Separate the governor arm and control bracket by disconnecting the spring (11).

4.4.2 Two-spring linkage

© Delphi

Lift off, as an assembly, the control bracket (10), complete with the governor arm (11), metering valve (6), and the linkage hook assembly. Remove the self-locking nut (2), nut (1), pivot ball washer (3), pivot ball (4), and remove the hook from the offset hole in the governor arm. Remove the spring support washer (12), long spring (14), spring retainer (9), short spring (8) and small spring retainer (7) from the hook (5). Remove the metering valve from the hook and immerse it in clean test oil. Separate the governor arm and control bracket by disconnecting the spring (13).


4-47

IV PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING 4.4.3 Three-spring linkage Lift off the governor assembly as described in a) and b) above. Remove the self-locking nut (1) and nut (2). Remove the pivot ball washer (3) and pivot ball (15). Remove the hook (12) from the offset hole in the governor arm (4). Remove the washer (5), small spring (6), spacer (14), spring support washer (7), long spring (13), spring guide (8), short spring (9), and small spring retainer (11), from the hook. Note: If the two short springs are not the same, record the position in which each was fitted. Remove the metering valve (10) from the hook and immerse it in clean test oil. Separate the governor arm and control bracket by disconnecting the spring. Note: Later pumps may have two self-locking nuts on the linkage hook instead of one plain nut and one selflocking nut.

4.5

Removing And Dismantling The Advance Device

4.5.1 Head locating fitting There are several different types of head locating fitting, the use of which depends upon the specification of the advance device (if fitted). They are: 1. Standard 2. Damper-type 3. Automatic start-retard control 4. Manual start-retard (lever-type) 5. Manual start-retard (screw-type)

© Delphi

The manual-retard type may be dismantled for cleaning and seal replacement only. The dampertype cannot be dismantled or repaired.

4-48


PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING IV PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING 4.5.2 Advance device Note: The piston and advance housing are a matched assembly. If the piston or the housing are damaged or worn, the complete assembly must be replaced. A) Two-stage, start-retard Invert the pump. Remove the pressure end plug (21) from the advance housing (1) and discard the O-ring (20). Remove the plug (13) from the spring cap (15) and discard the sealing washer (14). Remove the spring cap and discard the O-ring (16). Remove the shim washers (17), outer spring (12), inner spring (11), spring plate (10), short (‘retard’) spring (9) and housing circlip (8). Loosen and remove the damper assembly (7) (or head locating fitting) complete with the steel ball (6). Remove and discard the O-rings (5), and remove the washer (4) (see the note below). Remove the cap nut (3) and discard the ‘Dowty’ (or copper) washer (2). Gently ease the advance housing, with the advance piston (19), from the pump housing. Remove the piston for inspection. If its condition is satisfactory, re-fit the piston to the auto-advance housing. Immerse the advance assembly in clean test oil. Remove and discard the advance housing gasket (18). B) Single-stage Remove the pressure end plug (13) and discard the O-ring (12). Remove the plug (4) from the spring cap (6) and discard the sealing washer (5). Remove the spring cap, and discard the O-ring (8). Remove the shims (7), and spring (9). Loosen and remove the head locating fitting (3), with its lock-off ball, discard the seals (2) and remove the washer (1) (see the note below). Note: It is possible that the washer may be left in the pump housing as the head locating fitting is removed. Later versions of the fitting are designed so that the washer is an integral part of the fitting.

© Delphi

Loosen and remove the cap nut (16) and discard the ‘Dowty’ (or copper) washer (15). Gently ease the advance housing (14), with its piston (11), from the pump housing. Remove the piston for inspection. If its condition is satisfactory, re-fit the piston to the advance housing. Remove and discard the gasket (10) and place the advance assembly in a container of clean test oil.


4-49

IV PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING 4.6

Slackening The Cam Advance Screw

Use the special tool (1) to slacken the cam advance screw (2). If the cam ring has become locked in the pump housing, lightly tap the screw with a hide mallet to release the cam ring (3).

4.7

Removing The Clamping Plate, Support Plate, And The High Pressure Outlet Connections

4.7.1 High pressure outlet clamping plate

© Delphi

If a clamping plate is fitted, note the way in which it is fitted. Remove all of the nuts (1) securing the plate (2) to the outlet connections, and remove the plate.

4-50


PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING IV PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING 4.7.2 High pressure outlets A) Hydraulic head radial outlet assemblies There may be four types of connections fitted to the radial outlets in the hydraulic head: i. ‘Plain’ radial, which are designed with a coned end for direct connection to the high pressure pipes. Remove each connection from the hydraulic head and discard the sealing washer. ii. Banjo bolts, with ‘plain’ banjos. Note the position in which each banjo is fitted, remove the banjo bolt and discard the sealing washers. iii. The radial connection or banjo bolt with either a ‘ball’- or ‘piston’-type pressurising valve. Neither of these is repairable. iv. Banjos fitted with delivery valves. Remove the banjo bolts (2) and discard the sealing washers (1). Place each banjo assembly (3) in a soft-jawed vice, clamping it at the banjo bolt end, but not across the sealing faces. Slacken and remove the delivery valve holder (10). Remove the peg (9), spring (8), upper sealing washer (6), delivery valve (7) and delivery valve body (5) and lower sealing washer (4). Discard both sealing washers. Place each delivery valve into its original delivery valve body and keep them as a matched pair. B) Hydraulic head axial outlet assemblies i.

ii.

Axial outlet pressurising valves Slacken and remove each pressurising valve (6). Remove and discard the seating washer (1) from the bottom of each outlet bore. The pressurising valves are sealed units, and cannot be serviced. Axial outlet delivery valves Slacken and remove each delivery valve holder (5), spring peg (4), spring (3), delivery valve assembly (2), and discard the seating washer (1) from the bottom of each outlet bore.

Note: (1) The delivery valve holder has a sealing face designed with a conical (‘knife-edge’) shape that does not require a sealing washer between itself and the delivery valve body. If, for any reason, it is removed from the hydraulic head, it must be replaced with a new holder.

© Delphi

Note: (2) Each delivery valve and delivery valve body are a matched pair and must be kept together. Place the delivery valve assemblies in clean test oil after examination


4-51


Removing The Support Bracket, End Plate, Sandwich Plate, And 'ESOS'

4.8.1 Rear support bracket Note: It will be necessary to remove some types of rear support bracket after the end plate has been removed. The example illustrated is one of that type. Note the position of the bracket before removing it. Depending on the design of the bracket (2), slacken and remove the two or four fixing bolts (1), and remove the bracket.

4.8.2 Removing and dismantling the ‘standard’ end plate

© Delphi

Loosen the fuel inlet connection (1). Remove the end plate securing screws (14), washers (13), and high pressure outlet support plate(s) (15) (if fitted). Remove the end plate (16) from the pump. Remove the fuel inlet connection and discard the sealing washer or O-ring (2). Remove from the end plate the sleeve retaining spring (4) and the filter (3). Remove either the transfer pressure adjuster assembly (8) and the spring peg and spring (9) (if fitted), or the spring peg (5) and regulating spring (s) (6) and (7). Remove the regulating sleeve (10) with its piston, and the piston retaining (or ‘priming’) spring (12). Remove and discard the washer (11) from the regulating sleeve.

4-52


PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING IV PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING 4.8.3 Removing and dismantling the ‘viscosity compensating’ end plate assembly Slacken the fuel inlet connection. (1) Remove the end plate assembly (12) from the pump. Remove the inlet connection and discard the O-ring (2). Remove the filter (3). Remove and discard the adjuster (4). Screw the extractor (13) into the regulating sleeve (6) and pull the sleeve out of the end plate. Remove and discard the O-ring (8) from the groove in the sleeve. Remove the piston retainer (11) (if fitted), the piston (7), and the regulating spring (5). Tip out the sleeve-retaining spring (9) and the spring seat (10). Note: The piston and sleeve are matched and, if faulty, must be replaced as an assembly. Place them in clean test oil.

4.8.4 Loose end plate sandwich plate

© Delphi

Remove the sandwich plate (2) from the end plate (1).


4-53

IV PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING 4.8.5 Electric shut-off solenoid (‘ESOS’) If fitted, remove any detachable electrical connections from the ESOS; cable (7), complete with its protective cover (8), screw (9) and washer (10), or ‘Lucar’ connection (5) and nut (6). Slacken and remove the ESOS body (4) from the hydraulic head. Remove the armature (or ‘plunger’) (1) and spring (2). Remove and discard the O-ring (3). Note: (1) Some later pumps may be fitted with an ESOS in which the spring will be held captive on the armature. Unless the spring requires replacing, it is not necessary to separate the two components. Note: (2) Some hydraulic heads may be fitted with a blanking plug instead of an ESOS. Remove the plug and discard its O-ring.

4.9

Removing The Transfer Pump Components

© Delphi

Remove and discard the sealing ring (7). Remove the transfer pump blades (1) from the rotor (5). If split steel blades (2) and (4) are fitted, be careful not to mislay the small separating springs (3) from between the blades. Remove the transfer pump liner (6). Leave the rotor (5) in position in the hydraulic head rotor.

4-54



Loosening The Transfer Pump Rotor And Removing The Hydraulic Head

If an ‘arrow’ is marked on the face of the rotor, it will indicate the direction in which the transfer pump rotor must be slackened. If there is no mark on the rotor, it must be slackened in the direction of pump rotation as indicated on the pump name plate, or as given in the Test Plan for the pump. Hold the drive hub with a suitable spanner (1) and slacken the transfer pump rotor with the special tool (4). Remove the tools and leave the transfer pump rotor finger-tight. The hydraulic head may be secured by various types of head locking screw in positions (2) and (3), one of which may incorporate a damper. Note the locations of the head locking screws, then unscrew and remove them and discard their washers. Withdraw the head and rotor assembly (5), with a slight twisting motion in each direction, from the pump housing. Remove and discard the hydraulic head large O-ring (not visible in the illustration). Note: Head locking screws which incorporate a damper assembly are not repairable.

4.11

Dismantling The Hydraulic Head Assembly And Removing The Cam Ring

4.11.1 Loosening the drive plate screws

© Delphi

Place the head and rotor assembly on the bench with the drive plate (2) uppermost. Hold the drive plate with the special tool (1) and loosen the screws (3) with special tool (4). Remove the screws and the drive plate.


4-55

IV PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING 4.11.2 Dismantling the hydraulic head Remove the top adjusting plate (not shown), and the roller and shoe assemblies (4). If they are suitable for further service, immerse the assemblies in clean test oil. Fit corks, or a plunger retaining clip, into the rotor slots to retain the plungers. Unscrew and remove the transfer pump rotor. Remove the distributor rotor (2) from the hydraulic head (1) and detach the bottom adjusting plate (3). Moisten the distributor rotor with clean test oil and very carefully re-insert it into the hydraulic head to ensure protection of the bearing surfaces. Secure the rotor in position with the transfer pump rotor, leaving it finger-tight. Immerse the hydraulic head in clean test oil.

4.11.3 Four-plunger head and rotor The dismantling procedure for this type of hydraulic head is the same as that for the two-plunger version (described in (b) above), except that, instead of ‘legs’ which extend from the top adjusting plate (4) to link with the bottom plate (1), two dowel pins (2) and (5) are fitted through the ‘head’ (3) of the distributor rotor to link the adjusting plates. Remove the pins.

4.11.4 Removing the cam ring and circlip Remove the cam advance screw. Note the direction of the arrow on the cam ring (2) then withdraw it. Note the positions of the ‘ears’ on the timing circlip (1) (if fitted) and extract the circlip using circlip pliers.

© Delphi

Note: If a circlip is fitted which has neither straightedged ears nor a timing line, it will be fitted so that the ears are not visible through the inspection window.

4-56



Removing The Drive Hub

4.12.1 Loosening the drive shaft nut Hold the drive shaft with a suitable spanner (1) and unscrew and remove the drive shaft nut and spring washer.

4.12.2 Withdrawing the ‘splined’ hub

© Delphi

With special tool (4), withdraw the splined hub (2) from the drive shaft (1) and remove the drive shaft key. Detach the drive shaft circlip (not visible in the illustration) and thrust washer (3).


4-57


Removing And Dismantling The Drive Shaft

4.13.1 ‘Single-piece’ drive shaft Remove the drive shaft and governor weight cage assembly from the pump housing. Remove the circlip (4) and withdraw the drive shaft from the weight cage assembly. Remove the thrust sleeve (7), thrust washer (6), and weights (1). Turn the cush drive back plate (3) until it can be removed from the weight cage, then remove the rubbers (2) and the hub (5).

4.13.2 ‘Uprated’ single-piece drive shaft

© Delphi

Remove the drive shaft and governor weight assembly from the pump housing. Remove the spring ring (not visible in the illustration). Remove the thrust sleeve (4), and the thrust washer (3). Remove the weights (1) from the weight cage (2).

4-58



Removing The Drive Shaft Seals

© Delphi

Remove the pump housing from the fixture. Carefully note the way in which the drive shaft seals are inserted. Extract and discard the outer seal (1), using the special tool (2). Remove the housing circlip with circlip pliers. Extract and discard the inner seal, again using the special tool as shown. Ensure that the tool does not damage the bore of the housing.


4-59

IV PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING

© Delphi

PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-DISMANTLING

4-60


PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY V PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY 5.1

Preparation

5.1.1 Fitting the drive shaft seals Moisten two new seals with clean test oil. These seals must be inserted in the same positions as noted prior to dismantling. Using the appropriate tool (1), carefully drive in the inner seal, using a ‘hide’ or rubber mallet (2). Next, fit the housing circlip with its open end adjacent to the ‘tell-tale’ holes (where provided) and then fit the outer seal, again using the appropriate tool.

5.1.2 ‘Locked-shaft’ timing screw

© Delphi

Fit a new O-ring (2) to the screw (1). Fit the speciallyshaped washer (3) and screw to the pump housing, ensuring that the narrow portion of the washer is placed beneath the locking screw head, so that the screw is prevented from being in contact with the drive shaft. Tighten the screw to its ‘running’ torque (see section 7.1.4).


5-61

V PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY 5.2

Assembling The Governor Components

5.2.1 ‘Single-piece’ drive shaft Place the drive shaft centrally in the special assembly tool, with its drive end uppermost. Place the governor thrust sleeve (7) (with its ‘stepped’ end downwards) and thrust washer (6) onto the shaft. Place the specified number of governor weights (1) into the tool, in their positions as indicated in the table opposite. The upper ‘lip’ of each weight must rest on the thrust washer. Slide the weight cage onto the shaft and over the weights. Fit the cush drive hub (5) to the shaft so that its master spline is aligned with that of the shaft, and its ‘ears’ are at 90° to those in the weight cage. Fit the rubber segments (2) between the pairs of ears and fit the back plate (3). Rotate the back plate so that it is retained by the heads of the three rivets in the weight cage. Number of weights

Position of weights in carrier (using the clock face as guide)

6

Full

4

12, 2, 6, & 8 o’clock

3

12, 4, & 8 o’clock

2

12 & 6 o’clock

5.2.2 Heavy duty and heavy duty (uprated) drive shafts

© Delphi

Support the shaft on the bench in an upright position, with the open ends of the governor weight cage uppermost. Place the specified number of governor weights (1) into the weight cage (2) as shown, with their ‘lips’ resting against the shaft, in their positions as indicated in the table. Fit the thrust washer (3) and thrust sleeve (4) (with its ‘stepped’ end facing upwards) onto the drive shaft; press down the thrust sleeve and fit the shaft retainer (not shown).

5-62



Fitting The Drive Shaft Assembly

5.3.1 All shafts Fit the pump housing to the assembly plate, with the machined governor mounting face upwards. Fit the appropriate seal protection cap (1) over the end of the drive shaft (2). Dip the protection cap in clean test oil and insert the drive shaft, with a rotating action, through the drive shaft seals as shown. When the shaft is securely in position, detach the protection cap. Fit the thrust washer and circlip, Fit the key, splined hub, spring washer, and drive shaft nut to the drive shaft (if specified).

5.3.2 Drive shaft end-float A) Uprated shaft

© Delphi

When the drive shaft assembly has been fitted to the pump, check drive shaft end-float by pulling the end of the shaft and measuring the clearance between the thrust washer and the pump housing spigot, using two feeler gauges 180° apart. The clearance must be between 0,05 and 0,19 mm (0,002 to 0,0075 in). Thrust washers of different thickness are available to allow adjustment of the end float.


5-63

V PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY B) Standard shaft Check the drive shaft end-float. This should not exceed 0,25 mm (0,010 in). If this figure is exceeded, the governor weight retainer and/or pump body must be renewed and the end-float re-checked.

5.4

Tightening The Drive Shaft Nut (Uprated Shafts)

© Delphi

Tighten the nut to the specified torque, whilst preventing the drive shaft from turning by means of a suitable spanner (1).

5-64



Fitting The Timing Circlip, the Cam Ring, And The Advance Screw

Fit the circlip (1) against the shoulder in the pump housing bore, placing the square ‘ear’ of the circlip centrally in the housing inspection aperture as shown. Insert the cam ring (2) against the circlip with its arrow facing the same direction as the arrow on the pump name plate.

Note: The type of circlip specified will determine whether the ‘ears’ of the circlip must be visible in the inspection window for timing, or not. There are two alternatives: i. This version has one ‘rounded’ ear and one ‘flat’ ear (as shown in the illustration above). This type is to be fitted with the gap between the ears placed centrally in the inspection window. Note: (1) For this type, the position of the circlip will be adjusted after testing is completed, to align either a line stamped across the ear, or the flat edge, with a letter on the drive plate as designated in the Test Plan. Note: (2) The circlip must also be positioned according to the direction of rotation of the pump, and the side of the pump in which the window is placed. If the pump rotates clockwise and the window is on the right-hand side when viewed from the drive end, the flat ear (or the ear with the stamped line) must be at the bottom of the window (as shown in the illustration above).

© Delphi

ii.

For other arrangements, the circlip must be placed so that the drive plate approaches the timing position across the gap between the ears. This is important, to ensure accurate setting of timing. In this version, the circlip is not used for timing the pump; the two circlip ears are of similar shape and must be fitted approximately 180° away from the window. Invert the pump and screw the cam advance screw into the cam ring. Tighten the screw to the specified torque using the special tool. Remove the tool and, if the cam does not move freely in the pump housing, lightly tap it with a hide mallet to release it.


5-65


The Hydraulic Head Rotor Screw

If the rotor screw has been removed, or is loose, a new screw and washer are required. Unscrew and remove the transfer pump rotor. Detach the distributor rotor from the hydraulic head. Screw the two drive plate screws fully into the distributor rotor, leaving them finger-tight. Place the rotor in a vice, fitted with soft jaws, so that the heads of the screws only are gripped lightly. Thoroughly degrease the threads of the rotor and the screw, then lightly smear the thread of the screw with ‘Araldite’. Insert the screw and, using the special tool (1), tighten it to the specified torque. Remove the drive plate screws, and carefully refit the rotor to the hydraulic head. Allow the ‘Araldite’ to cure for at least 6 hours at room temperature before putting the pump into service. Do not use heat to accelerate the curing process.

5.7

Fitting The Roller And Shoe Assemblies And Adjusting Plates

If fitted, remove the transfer pump rotor.

5.7.1 Two-plunger head and rotor A) Fitting the bottom adjusting plate Place the hydraulic head (1) on the bench, with the drive end uppermost. Remove the distributor rotor (2) from the head and place the bottom adjusting plate (3) on the head, with the chamfered edges of the roller shoe ‘ear’ scrolls uppermost. Moisten the distributor rotor with clean test oil, carefully reinsert the rotor into the hydraulic head and line up the guide slots on the bottom adjusting plate with the tapered-end ‘cut-outs’ on the rotor head, as shown. Screw the transfer pump rotor into the distributor rotor, leaving it finger-tight.

B) Fitting the rollers and shoes

© Delphi

Remove the corks (or clip) retaining the plungers. Insert the roller and shoe assemblies (4), with the ‘ears’ of the rollers inwards, into the roller shoe guides as shown. The projecting ears on the shoes must be placed in the slots of the bottom adjusting plate so that the contours of the ears match the contours of the adjusting plate slots.

5-66


PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY V PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY C) Fitting the top adjusting plate and drive plate Fit the top adjusting plate (1) to the rotor head, with the chamfered edges of the roller shoe ‘ear’ scrolls facing downwards, and engage the legs of the plate in the guide slots (7) and (8) of the bottom adjusting plate. Place the two plates so that the fuel adjusting slot (4) in the top plate coincides with the scribed line (2) on the rotor head. Fit the drive plate (5), with its machined recess facing the rotor, and align the slot which is between letters ‘A’ and ‘H’ with the top adjusting plate slot. Fit the drive plate screws (3) and (6) and leave them finger-tight. Note: The drive plate bolt holes in the rotor are not diametrically opposite each other, consequently the drive plate can only be fitted to the rotor in one position.

5.7.2 Four-plunger head and rotor A) Top adjusting plate Remove the plunger retaining corks (or clip) from the rotor. Fit the top adjusting plate (4) to the rotor, followed by the drive plate (not shown), with its machined recess facing the rotor, ensuring that the fuel adjustment slot (5) lies within the drive plate slot. Insert the drive plate screws through the drive plate and top adjusting plate into the rotor head (6), and leave them finger-tight. Note: The drive plate bolt holes in the rotor are not diametrically opposite each other, consequently the drive plate can only be fitted to the rotor in one position.

B) The dowel pins, rollers and shoes, and the bottom adjusting plate Remove the rotor from the hydraulic head and invert it. Insert the dowel pins (2) and (7), with their ‘radiused’ ends uppermost, i.e. facing away from the drive plate. and insert the roller and shoe assemblies (3) into their slots in the rotor head, ensuring that the scroll contours of their ‘ears’ correspond to those on the adjusting plates. Fit the bottom adjusting plate (1) into position over the radiused ends of the dowels and over the ears on the shoes. The adjusting slot (9) in the bottom adjusting plate must be aligned with the matching slot in the top plate. Note: In four-plunger rotors the plunger pairs have different lengths and are matched as pairs to the bores. The longest plungers must be fitted into the plunger bore which is in-line with the distributor rotor outlet port (8). Moisten the rotor with clean test oil and carefully re-fit it into the hydraulic head. Lift the assembly and fit the transfer pump rotor, leaving it finger tight. © Delphi

Note: The design of the adjusting plates used in later pumps will be slightly different to those shown.


5-67


Setting The Roller-To-Roller Dimension (Two-Plunger Pumps) And Tightening The Drive Plate Screws

5.8.1 Setting the roller-to-roller dimension A) Radial outlet hydraulic heads Fit the ‘Stirrup Pipe’ (1) in the special tool set to two diametrically-opposite high pressure outlet ports on the hydraulic head and connect it to a Nozzle Testing Outfit (NTO). Operate the NTO to raise the pressure to the figure specified in the Test Plan (generally 30 atm).

B) Axial outlet hydraulic heads Fit the Universal Timing Kit to the high pressure outlets. Turn the pump rotor until the pumping plungers and rollers are forced outwards to the maximum fuel position. Measure the overall roller-to-roller dimension with a micrometer. The roller-to-roller dimension must be set, to the figure specified in the Test Plan, by movement of the adjusting plates. Note: (1) The Relief Valve (2) (part of the special tool set) must be fitted in the fuel line to ensure that the test pressure of 30 atm. is not exceeded. When other test pressures are stated on Test Plans this relief valve can be omitted, but care must be taken not to exceed the specified pressure. Excess pressure can cause damage to shoe assemblies and adjusting plates. Note: (2) Four-plunger pumps do not require accurate setting at this stage.

5.8.2 Tightening the drive plate screws

© Delphi

Note: As the hydraulic head is not yet fitted to the pump, the screws may be tightened by the use of a standard socket; however, a different torque to that specified for the ‘offset’ tool must be used (see section 7.1).

5-68


PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY V PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY Hold the drive plate with the special tool (4) and tighten the drive plate screws (1) evenly to the specified torque, using the special ‘offset’ tool (2) and (3) (see section 7.1.1 and Note below). Now slacken the screws and re-tighten them to the same torque value. It is important that this sequence of tightening, slackening, and retightening is followed. Tighten the screws evenly, to avoid rotor distortion which could cause the plungers to stick.

Note: In use, the torque wrench handle and spanner must form a straight line, with the handle extending away from the spanner. The distance between the centre of the adaptor and the centre of the ring spanner is 127 mm (5,0 in). With the superseded special tool the distance is 66 mm (2,6 in). See the list of Torque Values in section 7.1. Certain designs of torque wrench are not suitable for this operation. If the tools are not kept in a straight line, the applied torque will be incorrect. Check that the roller-to-roller dimension has not been altered during tightening of the screws. Disconnect the NTO and remove the stirrup pipe from the high pressure outlets on the hydraulic head.

5.9

Advance Device

5.9.1 Single-stage Place a new advance housing gasket (8) on the pump housing. Check that the flat end of the advance piston (9) is towards the oil feed drilling (pressure) end of the advance housing (12). Fit the advance housing and piston assembly to the pump housing, ensuring that the cam advance screw engages in the piston, and lightly secure the assembly in place with the cap nut (1) and a new ‘Dowty’ washer (13). Fit a new O-ring (10) to the pressure end plug (11) and screw the plug into the advance housing. Fit the advance spring(s) (7). Fit a new O-ring (6) to the spring cap (4). Insert the shim washers (5) into the recess in the cap and screw the cap into the advance housing. Leave the cap and plug finger-tight. Note: Refer to the relevant Test Plan for the correct shim thickness.

© Delphi

Fit a new sealing washer (3) to the plug (2) and fit the plug to the spring cap, leaving it finger-tight.


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V PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY 5.9.2 Two-stage, start retard Place a new advance housing gasket (14) on the pump housing (13). Ensure that the blank end of the piston (15) is towards the oil feed drilling (pressure) end of the advance housing. Fit the advance assembly to the pump housing, ensuring that the cam advance screw engages with the piston, and lightly secure it in place with a new ‘Dowty’ (or copper) washer (1), and the cap nut (2) on the advance stud. Fit a new O-ring (16) to the pressure end plug (17) and screw the plug into the housing, leaving it finger-tight. Fit the housing circlip (3), short spring (4), spring plate (5), inner spring (6), and outer spring (7). Fit a new O-ring (11) to the spring cap (10), insert the shim washers (12) (as specified in the Test Plan) into the spring cap and screw the cap into the advance housing, leaving it finger-tight. Fit the plug (8) with a new washer (9) and fit it to the spring cap, leaving it finger-tight.

5.10

Inserting The Hydraulic Head And Fitting The Head Locking Screws

Invert the pump assembly so that the governor housing face is uppermost. Confirm that the new large O-ring to be fitted is of the correct thickness (2 or 3 mm) for the groove (7) in the hydraulic head. Fit the large O-ring to the hydraulic head. Lubricate the portion of the hydraulic head that fits into the pump housing, and the housing, with clean test oil. Fit the hydraulic head to the housing, with a rotating motion, so that the splines on the inner end of the drive shaft engage with the splines in the drive plate. Rotating the head on entry prevents ‘jamming’ of the hydraulic head, and damage to the pump housing. If necessary, rotate the transfer pump rotor to aid engagement of the splines. Align the metering valve bore with the contour (4) in the machined face of the housing.

© Delphi

Check that the head locking screw holes are also aligned correctly with their matching holes in the pump housing and secure the head with the two screws (2) and (6), each fitted with new sealing washers (3) and (5), leaving them fingertight. Ensure that the head vent screw assembly (or damper) and head locking screw are in the same location as noted when dismantling.

5-70



Fitting And Securing The Hydraulic Head And Tightening The Transfer Pump Rotor

Invert the pump; assemble the seals and steel ball to the auto advance device head locating fitting (5) (or damper, if specified). Screw in the fitting, thus securing the advance housing to the pump housing. Then, progressively and evenly, tighten the advance housing cap nut (6), head locating fitting, head vent screw assembly (2), and head locking screw (3) (or other hydraulic head fixings) to their specified torques. Remove the pressure end plug and ensure that the advance piston is free to move; refit the plug and tighten it and the spring cap to their respective torques. Note: The special offset tool will be required to tighten a damper-type head locating fitting.

Hold the drive shaft with the appropriate tool (1) and tighten the transfer pump rotor with the special tool (4) to the specified torque. The transfer pump rotor is tightened in the opposite direction to pump rotation (as shown on the pump name plate).

5.12

Fitting The Transfer Pump Components

Insert the transfer pump liner (6) into the pump housing with the slot (7) in the rim of the liner in the same position which it occupied prior to dismantling. See the table below: If the liner has a recess in one face, that recess must be placed at the ‘6 o’clock’ position. Fit the liner seal (8). Carefully insert the transfer pump blades (1) into the rotor (5). Take care to avoid damaging the edges of the blades on the edges of the liner. Check the freedom of movement of the transfer pump blades by rotating the pump by hand. When lubricated, the grip of the seal should prevent the liner from rotating as the blades turn. If split steel blades (2) and (4) are specified, fit the separating springs (3) to each pair of half-blades, and insert each pair as an assembly. Ensure that the blades are free to move within the rotor slots. Liner groove position (viewed from the rotor end)

Clockwise

3 o'clock

Anti-Clockwise

9 o'clock

© Delphi

Pump rotation (viewed from the drive end)


5-71


Assembling The End Plate

Note: The end plate components specified for any particular pump may vary from those shown. It is therefore essential that the components are noted during dismantling, and that the pump Parts List is consulted.

5.13.1 ‘Standard’ end plate Place the piston retaining (priming) spring (12) into the end plate (13). Fit a new seal (11) to the sleeve and piston assembly (10). Fit into the sleeve, from the top, the regulating spring(s) (6) and (7) (or spring peg and regulating spring (9)), the sleeve plug (5) or the transfer pressure adjuster assembly (8). Fit the assembly into the end plate. Fit the filter (3) and the sleeve retaining spring (4). Fit a new sealing ring (2) to the fuel inlet connection (1) and fit the connection to the end plate, leaving it finger-tight.

5.13.2 ‘Viscosity-compensating’ end plate Using the appropriate seal protection cap, fit a new O-ring (9) to the groove (7) in the regulating sleeve (6) Insert a new adjusting plug (4) into the threaded end of the sleeve using an Allen key. Refer to the Test Plan for the initial setting position of the adjusting plug. Invert the regulating sleeve and insert the spring (5), followed by the piston (8) into the opposite end. Fit the piston retainer (12) (if specified) over the lower end of the sleeve, ensuring that it is pushed fully into position. Note that the retainer may be formed with either a detent or a ‘sprag’ to ensure its retention on the sleeve.

Fit the spring seat (11), and the sleeve retaining spring (10) into the end plate (13). Moisten the sleeve O-ring with test oil and place the sleeve assembly, with the adjuster uppermost, into the end plate (use of the threaded extractor tool, screwed into the sleeve, may ease fitment of the sleeve to the end plate). Fit the filter (3). Using the appropriate protection sleeve, fit a new O-ring (2) to the fuel inlet connection (1) and screw the connection into the end plate, leaving it finger-tight.

© Delphi

Note: Various designs of fuel inlet connection may be specified with adapters; ‘olive’, ‘push-on’, or banjo connectors, for connection to the low-pressure fuel supply pipe. (It may be necessary to fit a special ‘female’ inlet connection solely for testing).

5-72


PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY V PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY 5.13.3 ‘Loose’ end plate sandwich plate (if specified) Fit the sandwich plate (2) into the recess in the end plate (1). If the sandwich plate is new, it does not matter which way round the plate is fitted. However, if the original plate is to be used again, it must be fitted with the same face towards the transfer pump rotor (shown by slight curved marks on the face of the plate). The dowel pin in the end plate will control the position of the slot (3) in the edge of the plate. (The letter ‘C’ (4) on the end plate signifies the position in which the dowel pin must be fitted to a clockwise rotation pump). Note: If the original sandwich plate shows any sign of scoring, do not reverse it as this will cause internal leaks and affect the efficiency of the transfer pump; it must be replaced.

5.14

Fitting The Support Bracket, The End Plate Assembly, And The ESOS

5.14.1 Rear support bracket If specified, the bracket should be fitted to the hydraulic head before fitment of the end plate. Its fixing screws are independent of those for fixing the end plate. Note that the end plate design will differ from that which does not use a support plate. Place the bracket (2) in the correct position, as noted during dismantling, against the end of the hydraulic head. Fit the fixing screws (1), and tighten them to the specified torque.

5.14.2 End plate

© Delphi

Place the end plate, with the inlet connection uppermost, onto the hydraulic head, ensuring that the dowel on the inner face of the end plate engages in the slot in the rim of the transfer pump liner. Secure the end plate and high pressure outlet clamping plate(s) (if specified) with the end plate screws. Tighten these screws and then the inlet connection to their specified torques.


5-73

V PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY 5.14.3 Electric shut-off solenoid (‘ESOS’), or ‘blanking’ plug If an ESOS is specified, assemble it as follows. If detachable electrical connections are specified, fit the terminal blade (5) to the solenoid, retained by the nut (6), or fit the cable (8), secured by the screw (9) and washer (10). Fit the protective sleeve (7) over the connection Fit a new O-ring (3) to the solenoid (4), using the appropriate seal protection sleeve. Place the plunger return spring (2) into the solenoid, followed by the plunger (1), with the flexible valve end outwards. Screw the assembly into the hydraulic head and leave it finger-tight. Note: Later solenoids may have plungers to which the spring is permanently fitted. If a blanking plug is specified, dip a new O-ring in clean test oil and fit it to the plug, using the appropriate seal protection sleeve. Screw the plug into the hydraulic head, leaving it finger-tight. Note: The solenoid (or plug) may be required to be removed for fitment of a pressure gauge during testing.

5.15

Assembling The Governor Linkage

5.15.1 Single-spring linkage

© Delphi

Fit the governor control bracket (8) into the governor arm (10) and fit the linking spring (11) to the governor arm. Fit the spring retainer (6) (large end first), spring (7), and spring support washer (9) to the hook (5). Pass the hook through the offset hole in the governor arm and then fit the pivot ball (4), pivot ball washer (3), nut (1) and self-locking nut (2). Fit the metering valve (12) to the hook as shown.

5-74


PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY V PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY 5.15.2 Two-spring linkage Fit the governor control bracket (10) into the governor arm (11), as shown, and fit the linking spring (13) to the governor arm. Fit the small spring retainer (7) (large end first) to the linkage hook (5), then the short spring (8), and large spring retainer (9), (large end first). Fit the long spring (14), and the spring support washer (12). Pass the hook through the offset hole in the governor arm and then fit the pivot ball (4), pivot ball washer (3), nut (1), and the self-locking nut (2). Fit the metering valve (6) to the hook as shown.

5.15.3 Three-spring linkage Fit the governor control bracket into the governor arm and attach the linking spring as described in section 5.15.1 and section 5.15.2. Fit the metering valve (10) to the hook. Fit the small spring retainer (11) (large end first), short spring (9), spring guide (8) (large end first), long spring (12), washer (7), spacer (13) (large end first), short spring (6), and spring support washer (5) to the linkage hook. Pass the hook through the offset hole in the governor arm (4) and fit the pivot ball (14), pivot ball washer (3), nut (2), and the self-locking nut (1).

© Delphi

Note: The two short springs may differ; if so, fit them. In later pumps, two self-locking nuts may be used to retain the linkage components instead of a plain nut and a self-locking nut.


5-75


Fitting The Governor Linkage Assembly

Dip the metering valve into clean test oil. Fit the governor control linkage assembly into the pump housing by placing the ‘toes’ on the lower end of the governor arm onto the ‘step’ of the thrust sleeve, and at the same time insert the metering valve into the metering valve bore in the hydraulic head. Place the keep plate (1) on the control bracket (3) so that the slotted end faces away from the linkage hook assembly. Place two new tab washers (2) and (7) on the keep plate, with their lips placed nearest to the metering valve and engaging the long edge of the keep plate. Screw in the two governor control cover studs (6) and (8) and leave them finger-tight. Place a new tab washer (5) on the control bracket in the correct position as shown, with the ‘tail’ bent down over that edge of the control bracket lying under the linkage hook assembly. Insert the bracket screw (4) and tighten the screw and control cover studs to their specified torque values. Lock all tabs.

5.17

Setting The Governor Link Length

5.17.1 Standard metering valves Set the link length with a vernier caliper as shown, so that the dimension specified in the Test Plan is obtained between the larger diameter of the governor control cover stud (4) and the metering valve lever pin (6). CAUTION Ensure that the ‘leg’ of the vernier caliper does not slip into the groove in the metering valve pin. It will be of assistance if the spring is held to expose a little of the hook (5).

© Delphi

Adjustment is made by slackening the lock-nut (1) and tightening or loosening the linkage nut (2). When setting, apply light pressure to the governor control arm (3) to hold the metering valve in the fully open position. Ensure that the vernier caliper is held parallel to the axis of the pump. After setting, tighten the lock-nut and re-check the link length to ensure that it has not changed.

5-76


PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY V PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY 5.17.2 ‘Roller pin’ metering valves Set the link length so that the specified internal dimension (as specified on the relevant Test Plan as ‘Method B’ ) is obtained between the smaller diameter of the governor control cover stud (1) and the metering valve pin (2).

5.18

Throttle Link

5.18.1 Assembly

© Delphi

Place a new cover gasket (1) on the governor housing face, with the gasket tongues placed in the slots (10) of the control bracket (2). Slide the shutoff bar (4) into the aperture (8) in the control bracket and under the ‘lip’ (9) of the tab washer. Fit the relevant protection cap to the end of the throttle shaft (7) (unless the Heavy Duty shaft is specified) and fit new shaft O-rings (6). Place the idling spring onto the idling spring guide (not visible in the illustration – see item ‘A’ in section 5.18.2). Insert the guide into the hole in the governor arm specified in the Setting Code in the Test Plan and attach the governor spring (3) to the guide. Insert the other end of the spring into the hole in the throttle shaft link (5) also as specified in the Test Plan. Interpretation of the Setting Code details is given in the diagram insection 5.18.2.


5-77

V PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY 5.18.2 Setting code Locate the code number in the table. The vertical and horizontal lines from this number to the pump components give the correct numbered hole in the throttle shaft link and the governor arm for assembling the governor spring, e.g. for code No. 8 fit the governor spring (B) to the No. 2 hole in the throttle shaft link (C) and the spring guide (A) into the No. 3 hole in the governor arm (D).

5.19

Fitting The Control Shafts To The Governor Control Cover And Fitting The Cover To The Pump

5.19.1 ‘Standard’ cover

© Delphi

Fit the relevant protection cap to each of the control shafts. Place new shaft O-rings (2) and (6) onto the shafts (if not already fitted). Fit the shut-off shaft (7) into the governor control cover. Rotate the shaft to place the peg (8) towards the adjacent edge of the cover, so that it can easily be engaged with the shutoff bar (9). Fit the throttle shaft (1) into the governor cover and, at the same time, fit the governor cover onto the two control cover studs (3). Whilst lowering the cover into position on the pump housing, fit the shut-off shaft ‘peg’ into the hook of the shut-off bar. Fit the cover stud washers (4) and nuts (5) and tighten the nuts to the specified torque. Remove the shaft protection caps.

5-78


PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY V PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY 5.19.2 ‘Exhaust brake’ cover Fill the grease groove (2) on the exhaust brake shaft with the specified grease. Using the appropriate seal protection cap, fit two new O-rings (1) to their grooves. Fit the shaft into its bore in the governor cover, ensuring that it is pushed fully into position. Rotate the shaft until the ‘flat’ face (3) on the lever is against the inside end face of the governor cover. Continue as in section 5.19.1.

5.19.3 ‘Break-back’ throttle lever Fit the spring retainer (8), washer (7), and spring (6) (with the ‘legs’ of the spring facing upwards) over the throttle shaft. Fit the break-back lever (5) and throttle lever (4), so that the spring legs engage either side of the two lugs (9) & (10) and (11) & (12) on each lever. Also, ensure that the ‘flats’ in the break-back lever hole engage with the ‘flats’ on the shaft. Fit the throttle lever guide (3), washer (2), and self-locking nut (1). Tighten the nut to the specified torque.

© Delphi

Rotate the throttle lever in either direction until the relevant ‘stop’ on the break-back lever rests against its throttle stop screw. The throttle shaft should also rotate. Continue to move the throttle lever, which should be capable of moving further against the spring, but the throttle shaft should rotate no further. Repeat this action in the opposite direction. Again, the throttle shaft should not rotate once the stop screw is reached. If the action is not as described, check that the flats in the break-back lever are correctly located with those of the throttle shaft.


5-79


Fitting The Governor Control External Components

5.20.1 ‘Heavy duty’ throttle lever Fit the pad and the dust cover (4) to the throttle shaft and secure them with the circlip. Insert the shaft key (not visible in the illustration) into the shaft. Open up the slit (3) in the lever, with a screwdriver blade, sufficiently to slide the lever onto the throttle shaft (1). Fit the throttle lever onto the shaft, fully engaging the key. Tighten the nut (2) to the specified torque.

5.20.2 ‘Exhaust brake’ lever

© Delphi

Fit the dust cover (8) over the shaft. Place the hooked end (6) of the spring (7) up through the central hole (4) in the lever (5), with the ‘turned-over’ part (‘lug’) (9) of the lever facing the spring. Whilst holding the lever and spring together, place the straight end of the spring against the throttle shaft ‘boss’ (10) on the governor control cover. Place the slotted hole in the lever over the exhaust brake shaft. Fit the screw (1) with the shake proof washer (2) under its head and a plain washer (3) against the lever. Tighten the screw to its specified torque.

5-80


PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY V PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY 5.20.3 Standard throttle and shut-off levers Fit the throttle shaft dust cover (6), throttle lever (4), washer, and nut (5). Fit the shut-off dust cover (1), shut-off lever (2), washer and nut (3). Tighten both nuts to their specified torque.

5.20.4 Spring-returned shut-off lever Fit the dust cover (5) and the spring (4) over the shaft. Place the lever (3) over the shaft and, at the same time, hook the spring onto the lever. Locate the lever onto the ‘flats’ on the shaft and fit the washer (2) and the self-locking nut (1). Tighten the nut to the specified torque.

5.20.5 Torque adjustment screw

© Delphi

Fit the lock-nut (2) and a new sealing washer (1) to the screw (3). Turn the screw into the cover by approximately three turns, or as specified in the Test Plan (this is to ensure that the screw will not affect the governor until it is set during the Test procedure). Tighten the lock-nut.


5-81

V PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY 5.20.6 Other governor control cover fittings If specified for fitment to the cover, fit the vent screw assembly with a new sealing washer, and fit it to the cover. If specified, place a new sealing washer on the backleak connection and fit the connection to the cover. Tighten all screws and nuts to their specified torques. If specified, fit the anti-stall screw into the cover and turn it by approximately four turns; secure it with the lock-nut, finger-tight. If not already fitted, fit the throttle idling and maximum speed stop screws and their lock-nuts and spring washers, so that the inner ends of the screws just protrude from their ‘pillars’ in the control cover (unless stated otherwise in the Test Plan).

5.21

Fitting The High Pressure Outlet Connections And Other Components To The Pump

5.21.1 Backleak connection and inspection cover

© Delphi

If specified for fitment to the pump housing, fit a new sealing washer (2) to the backleak connection (1), screw the connection into the pump housing and tighten it to the specified torque. Fit the inspection cover plate (3), with a new gasket (4), to the pump housing and secure it with the cover plate screws and washers (5) and (6). Tighten the screws and connection to their specified torques.

5-82


PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY V PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY 5.21.2 High pressure outlets A) Hydraulic head radial outlets i.

ii.

iii.

Radial connections (with or without pressurising valves) Fit a new sealing washer to each connection, fit the connections to the hydraulic head and tighten them to the specified torque. Banjos and banjo bolts (with or without pressurising valves) Fit the banjos to the banjo bolts or pressurising valves, with new sealing washers either side of each banjo. Fit the assemblies to the hydraulic head in their respective positions as noted during dismantling and leave each bolt finger-tight. Tighten all pressurising valves to the specified torque (a special tighten technique may also be specified). (If a banjo outlet clamping plate is specified, refer to section 5.21.2 C before tightening the bolts). Banjos fitted with delivery valves Fit a new lower seal (4) into the banjo connection (3). Place the delivery valve body (5) into the banjo, followed by the delivery valve (7), upper seal (6), spring (8), and spring peg (9). Screw the delivery valve holder (10) into the banjo, leaving it finger tight. Place the banjo in a soft-jawed vice (not across the sealing surfaces, and taking care to use the minimum necessary force). Tighten the holder to the specified torque.

Note: Do not tighten the holders after they have been fitted to the pump.

© Delphi

Fit each banjo bolt (2), with new sealing washers (1), either side of the banjo, and fit each assembly to the hydraulic head. If the banjos were in any position other than parallel to the axis of the pump prior to dismantling, ensure that they are re-fitted in the same positions. Tighten the banjo bolts to their specified torque.


5-83

V PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY PUMPS WITH SINGLE-PIECE DRIVE SHAFTS-REASSEMBLY B) Hydraulic head axial outlets i.

ii.

Pressurising valves Fit a new sealing washer (1) into each high pressure outlet, then fit the pressurising valve (6). Tighten each pressurising valve to the specified torque. Axial outlet delivery valves Fit a new sealing washer (1) into each high pressure outlet, followed by the delivery valve assembly (2). Fit the spring peg (4) and spring (3) to a new delivery valve holder (5), and fit the holder to the outlet.

Note: Delivery valve holders with conical (‘knife edge’) sealing faces must not be used again, once they have been removed from the hydraulic head). Tighten each delivery valve holder, using the specified procedure for achieving the correct torque. Note: There may be more than one type of high pressure outlet connection fitted to any particular pump. If this is so, refer to the relevant Parts List, which will indicate the type of connection to be fitted to each outlet. C) High pressure outlet clamping plate If a high-pressure outlet clamping plate (2) is specified with banjo connections and banjos, it must be fitted to all of the banjos before the banjo bolts are tightened. Fit a nut (1) to each banjo and lightly clamp the banjos in position. Do not yet tighten the nuts to their specified torque. The banjo bolts may then be tightened to their specified torque.

5.22

Security

© Delphi

Where possible, check that all other components have been tightened to their specified torque values as listed in section 7.1. Ensure that the appropriate locking sleeves and suitable lengths of locking wire with new seals (as specified in the Test Plan) are loosely attached to the pump for sealing the governor control cover stud nuts, torque adjustment screw, and the light-load adjusting screw (if fitted) after Testing, and for sealing the throttle lever maximum speed screw after final setting on the engine.

5-84


TESTING & STORAGE VI TESTING & STORAGE 6.1

Pre-Test Procedure

6.1.1 Leakage testing All pumps must undergo a pressure test before and after machine test, using the following method: 1. Drain all fuel from the pump and connect a supply of clean, dry, variable pressure air to the pump inlet connection. 2. Seal off the low-pressure outlet connections on the pump and completely immerse the pump in a bath of clean test oil. 3. Raise the air pressure in the pump to 1.4 kg cm2 (20 lb in2). Leave the pump immersed in oil for 10 minutes to allow any trapped air to escape. 4. If no leaks are detected, reduce the air pressure to 0.14 kg cm2 (2 lb in2) for 30 seconds; if there is still no leak, increase the pressure to 1.4 kg cm2 (20 lb in2), and if there are still no leaks after a further 30 seconds it can be passed as ‘leak-free’. 5. On pumps without a drive shaft oil seal it is necessary to stop the oil leaking past the drive shaft during pressure testing. A special tool is available, but it is necessary to blank-off the 12 x 1.5 mm threaded connection. 6. All leaks must be rectified before testing and setting the pump. If a leak is detected after performance testing, some (or all) of the Test Plan may have to be repeated.

6.1.2 Shaft seal testing Certain pumps have a single-piece drive shaft with two inward-facing ‘lipped’ oil seals. The gap in the circlip between the seals must be aligned with a ‘tell-tale’ hole in the pump body. The inner seal, nearest to the governor sleeve, is checked by the normal pressure test, leakage being indicated at the tell-tale hole. A special tool is used for testing the outer seal; this consists of a flanged cylinder with three fixing studs, an air pressure connection, and a sealing gasket. The tool is attached to the pump mounting flange, and a supply of filtered air applied to the connection. The DPA pump and the tool are immersed in a bath of clean test oil, and air pressure applied at 0.28 kg cm2 (4 lb in2) for 20 seconds. Bubbles at the tell-tale hole normally indicate an oil seal failure, but first ensure that these are not caused by a faulty gasket.

6.2

Test Preparation

6.2.1 Test machine 1.

2.

3.

Pump performance can be influenced by test machine design. To minimise variations in performance, Delphi requires that their pumps be tested on Hartridge test machines, which conform to the design requirements contained in the relevant International Standard on FIE testing (ISO 4008, Parts I and II.) Hartridge test machines (e.g. models HA400, HA700, HA875, HA1100MkII, HA1150, HA2500, HA3000, AVM, and PGM) have the ability to test the whole range of DPA pumps. If a Hartridge test machine is not available, the use of a Universal Calibrator is recommended, in conjunction with a test machine of at least 5 kW (7.5 hp) power output, and conforming to ISO 4008 (Part I – Drive Systems Requirements) The details of pump mounting will depend upon the type of test machine available.

6.2.2 Test machine drive

© Delphi

1.

The machine must incorporate the following features: a. An anti-backlash coupling of sufficient torsional stiffness for the particular pump. (See the ‘Explanatory Notes’ appended to the Test Plan). b. A drive unit, suitable for distributor pumps, which can accommodate pumps with ‘supported’ drive shafts. An ‘unsupported’ Test Machine drive is required for pumps with supported drive shafts, which are intended for direct gear drive.


6-85

VI TESTING & STORAGE TESTING & STORAGE ‘Unsupported’ drive shafts will require the test machine drive to be set to its ‘supported’ position. The relevant Test Plan will state which drive shaft type is fitted to the pump to be tested. CAUTION Before carrying out any activity on the test machine drive arrangement, ensure that the electrical power supply to the machine is switched off. 2. 3. 4. 5. 6.

Locate the relevant Test Plan, referring to the pump Despatch Number on the pump name plate. The Test Plan includes information necessary for the correct mounting of the pump on the test machine. Fit a suitable test drive adaptor to the pump drive shaft. Ensure that the adaptor is fully tightened. Fit the relevant adaptor ring to the pump mounting plate. Ensure that the test machine drive is set to be compatible with the pump drive, as described in section 6.2.2 1a above. (Refer to the test machine manufacturer’s instructions for setting the drive). Ensure that the direction of rotation of the test machine is selected according to the pump name plate. Note: Incorrect rotation will result in serious damage to the pump.

7.

Ensure that no end-loading is applied to the pump when it is fitted to the drive adaptor. Rotate the drive by hand in the direction of normal rotation to check that the pump is free to rotate. Before starting the machine, check the following: – that the pump is firmly secured to the mounting – that the mounting is secured to the machine bed – that the drive adaptor is securely clamped

6.2.3 Test conditions The ISO test conditions quoted in the Test Plan must be strictly adhered to, i.e.: 1. The test oil must conform to ISO 4113 and, for pump test purposes, must be maintained at 40° ± 2°C. This may require the use of heaters or coolers, depending upon ambient conditions. 2. Inlet feed pressure must be set to 0.1 bar, unless otherwise stated. The minimum flow rate available at the pump inlet should be 1000 cc per minute. 3. The test injector configuration must be as stated in the Test Plan (e.g. ISO 4010 nozzles); orifice plates must be fitted, if specified, and nozzle opening pressure must be set to the specified figure. 4. The high pressure (HP) pipes must be as specified.

6.2.4 Fuel pipes With the pump mounted on the test machine, connect the following: 1. HP pipes to the pump HP outlets and to the test injectors. (Shrouding of the pipes with close-fitting neoprene rubber tubing will reduce the noise generated by the pipes during testing). Note: It may be necessary to fit special outlets for test purposes only. Refer to the Test Plan. Check the pipe ends, for restriction of the bores, with wires of the same diameter as the bore. If any pipe has become restricted with use, it must be opened-out by the use of a reamer. The pipes must then be thoroughly cleaned to remove any swarf. Ensure that bends are of at least the minimum recommended radii, with at least 100 mm of straight pipe at each end.

4.

The fuel supply pipe to the pump inlet in the end plate. Backleakage from the outlet connection(s) as appropriate to the pump under test and the test machine being used. Transfer pressure gauge either in place of the ESOS, the blanking plug, or a head locking screw. (Refit the ESOS or blanking plug when instructed by the Test Plan). © Delphi

2. 3.

6-86


TESTING & STORAGE VI TESTING & STORAGE 5.

6.3 1.

2. 3.

Cam box pressure, from a modified inspection cover plate, or from the governor control cover vent screw hole.

Test Procedure General Explanatory Notes and an individual Test Plan, quoting the Despatch Numbers of the range of pumps to which it may be applied, are published for each different model of pump. The sequence of operations listed in the Test Plan gives the test performance requirements at various pump speeds, the timing procedure, and any special precautions necessary to safeguard the pump. Set the fuel feed pressure as instructed in the Test Plan. Energise the ESOS, if fitted, with the voltage specified in the Test Plan, or as indicated by the pump Despatch Number suffix letter (see SIN D054). Note: There is one version of the ESOS which operates on the ‘energise to stop’ principle. If specified for the pump under test, it must not be energised during testing, but only to check its effectiveness in stopping delivery, when specified in the Test Plan.

4.

Prime the pump thoroughly before testing and at other times during the test, as directed in the Test Plan. Any variations from the following procedure for certain pumps will be explained in the Test Plan. i. Slacken both the vent valve on the governor control cover and the head vent screw. ii. Turn on the oil supply to the specified feed pressure (0.14 kg cm2 (0.1 bar)) to fill the pump. Run the pump at 100 rpm. When test oil, free from bubbles, issues from the vents, re-tighten the vent valve and the vent on the head locking screw. iii. Slacken the connections at the injector end of the high pressure pipes or, if fitted on the test machine, open the ‘bleed’ valves at the injectors. iv. Run the pump at 100 rpm. When test oil, free from bubbles, issues from all high pressure pipes, re-tighten the connections, or close the bleed valves. v. Examine the pump after priming for oil leaks at all jointing faces, connections and oil seals. Pumps must be free from leaks, both when running and when stationary. Note: (1) If the pump is to undergo a test before dismantling, ensure that all diesel fuel is drained out before it is mounted on the test machine; leave the HP and backleak pipes loose and collect the discharged fuel until test oil starts to appear. Discard the oil and tighten the connections. Note: (2) Do not run the pump for long periods at high speed and at low or zero output. The Test Plan will give specific instructions for both of these activities.

6.4

Measuring Pump Output

© Delphi

Fuel delivery is checked at full throttle setting at one or more speeds by measuring the volume passing through each injector. All critical fuel delivery levels are quoted in the Test Plan in mm3/stroke and the ‘shot count’ used should be adjusted to give a minimum volume of 40 % with one operation of the ‘shot count’ mechanism, when using open-top glass ‘graduates’. All other fuel delivery checks are quoted over 200 shots. The Test Plan will quote the maximum fuel delivery, overall tolerance, and the maximum permissible delivery variation spread between injectors.


6-87

VI TESTING & STORAGE TESTING & STORAGE 6.5

Transfer Pump Checking And Pressure Setting

6.5.1 Transfer pump vacuum and pressure measurement Transfer pump vacuum is sometimes required to be checked while the pump is running at a low speed, with the vacuum gauge connected to the pump fuel inlet connection. A specified depression must be obtained in a specified time. Note: The pump may need re-priming after this test. Transfer pressure is checked at one or more specified speeds. Remove one head locating screw, or the ESOS (or blanking plug) and fit the appropriate adaptor tool into the hydraulic head. Fit a pipe between the pump and the pressure gauge of the test machine. Transfer pressure is read directly from the gauge.

6.5.2 Transfer pressure adjustment Transfer pressure is controlled by the regulating valve in the end plate. To adjust the transfer pressure the operation of the regulating valve is modified as follows: On certain pumps, transfer pressure can be adjusted within the limits of an individual specification in one or both of two ways: 1. By changing the end plate sleeve plug Several plugs with different step thickness are available; the stepped portion in contact with the regulating spring determines the spring compression. 2. By varying the pre-load on the regulating spring There is a transfer pressure adjuster which varies the pre-loading of the regulating spring. It has a spring peg fitted between the adjusting screw and regulating spring. This has the same effect as method (1) above, but allows more variation and gives easier adjustment. Additional information will be given in the individual Test Plan. Tools are available for setting the screwed adjuster in the end plate while the pump is running. After the transfer pressure has been set by the use of an adjuster, the tool must be pulled fully upwards to avoid restriction of fuel flow into the pump. If a change of end plate sleeve plug is necessary to comply with the Test Plan, the appropriate part numbers and the item designation are given in the Parts List.

6.6

Pressurised Cam Boxes

© Delphi

The test pressure gauge is connected to the governor control cover vent screw hole or to a modified inspection cover. On self-venting pumps this must allow the pressure to be read without restricting the permanent bleeding operation. This can be carried out by using the requisite tools from the special service kit. On some pumps the cam box is pressurised during running by a spring-loaded ball pressurising valve located in the backleak connection in the inspection cover. Pressure limits are given in the appropriate Test Plan. If pressure is incorrect, check that the pump is not leaking and there is no restriction in the backleak passageways. If the pressurising valve is faulty, a new inspection cover complete with valve must be fitted.

6-88



Testing Of Advance Devices

6.7.1 Preparation The Test Plan will specify the type of advance device fitted, and details the tests required. Advance devices may be tested using either of two special tools: A) The ‘early’ advance gauge (‘quadrant’ type) This tool consists of a gauge with a scale covering 0 to 18° and a ‘feeler’ pin. To fit this tool, proceed as follows: Remove the small screw from the piston spring cap on the advance device. Pass the threaded bush of the feeler pin assembly through the hole in the tool bracket. Insert the end of the plunger into the hole in the spring cap and screw the bush into the spring cap hole. This will clamp the bracket between the spring cap and the shoulder on the threaded bush. ‘Zero’ the gauge by moving the scale relative to the pointer.

B) The ‘Universal’ advance gauge (‘linear’ type) This gauge is based on a sealed transparent tube (3), within which is carried a scale (5) graduated on one side in degrees, and on the other in millimetres. The tube is clamped to the body of the gauge by a ‘tube-locking’ nut (2). The axial position of the scale within the tube is adjusted by rotation of the end plug (9). The scale is prevented from rotating by a small grub-screw (6). The central pin (8) has a groove (7), against which the scale is aligned. The other end of the pin protrudes from the open end of the gauge and is maintained in contact with the advance piston by a spring (4).

© Delphi

To fit the gauge to the advance device, remove the small plug from the spring cap (1) and fit the gauge body in its place. There is a small plug (10) from which any air may be bled before commencing testing. With the gauge fitted to the advance device, slacken the knurled tube-locking nut (2) and rotate the tube so that the required scale is uppermost. Lightly tighten the locking nut. Rotate the end-plug to align the scale zero with the groove in the rod. Run the pump at low speed and vent any trapped air by slackening the bleed screw.


6-89

VI TESTING & STORAGE TESTING & STORAGE 6.7.2 Speed Advance Device The tests outlined in the test data must be applied to ensure that the degree of advance obtained is within the stated limits at the speeds specified. The amount of advance may be adjusted either by altering transfer pressure, or by changing the thickness of the shims between the piston spring and the spring cap, see test data. When the test results are satisfactory, remove the special tool and prime the pump.

6.7.3 Light Load Advance As the light load advance is sensitive to load, it responds to changes of fuelling and therefore to changes in the position of the metering valve. The Test Plan lists the checks to be made at various speeds, with specified fuel deliveries at different shut-off lever settings. These are set with the throttle lever held against the maximum speed screw and the shut-off lever held in a position under the control of the special shut-off lever adjuster tool. At each setting, a specified advance should be obtained. Adjustment is made by moving the angular adjustment screw on the governor housing. When the test results are satisfactory, remove the special tool and re-prime the pump.

6.8

Maximum Fuel Setting

The maximum fuel delivery is checked at a specified speed, with the throttle and shut-off controls fully open. If output is not within the specified limits, stop the test machine and adjust the pump as follows: 1. Slacken the screws securing the inspection cover, and drain the pump. 2. Remove the inspection cover. 3. Slacken the two drive plate screws. 4. Engage the special tool with the slot in the periphery of the adjusting plate. 5. Adjust the plate by lightly tapping the knurled end of the tool. The direction in which the drive plate is turned to increase or to decrease fuelling depends on the type of adjusting plates fitted. 6. Tighten the drive plate screws evenly to the specified torque value, using the special adaptor tool, the special spanner tool, and a torque wrench. Note: (1) It will be necessary to prevent the drive from rotating by placing a suitable bar in the test bench drive. Ensure that the test bench is switched off before doing this. Note: (2) When the special adaptor tool is used with the spanner tool (now superseded) the centre of the spanner must be 66 mm (2,6 in) from the centre of the adaptor. When using the later, recommended, spanner tool the distance between the spanner and adaptor centres is 127 mm (5,0 in). The torque spanner and the ring spanner must form a straight line when tightening the screws and care must be taken to ensure that the spanner does not strike the side of the inspection aperture. Replace and secure the inspection cover, refill the pump, vent it as necessary and re-check the maximum fuel delivery. Repeat until the delivery volumes are within the specified limits.

© Delphi

7.

6-90



Governor Setting And Testing

6.9.1 Maximum speed Prior to setting the maximum speed adjustment screw, note the delivery reading at maximum full-load speed. With the test machine running at the required governor setting speed, turn the screw until the reduced setting specified in the Test Plan is achieved. Tighten the lock-nut. Subsequent checks should confirm that delivery at maximum full-load speed remains within the specified limits, and that the governor ‘run-out’ curve is to specification. If delivery is not within the specified limits, and readjustment of the maximum speed screw does not achieve the desired result, check that the governor main spring and that the governor link-length are correct to specification. Note: Final governor setting must be carried out with the pump fitted to the engine, and in accordance with the engine manufacturer’s instructions.

6.9.2 Torque screw setting Run the test machine at the specified speed and set the torque screw to give the specified delivery.

6.9.3 Idling setting The idling fuel delivery must be set to ensure that sufficient fuel is delivered, with the throttle closed, to sustain idling when the pump is initially fitted to the engine. (Some adjustment may be necessary to set the engine idling speed to the manufacturer’s specification). With the test machine running at the specified speed, adjust the idling screw to give the specified delivery.

6.9.4 Shut-off control Run the test machine at the specified speed, and hold the throttle lever fully open. In turn, operate the ‘exhaust brake’ lever (if fitted), disconnect the power supply to the ESOS (if fitted), and operate the shut-off lever. Delivery must not exceed the level specified in the Test Plan. If an ESOS is fitted, it will be necessary to stop the test machine to enable the solenoid to reopen the valve when re-energised.

6.10

Timing

On completion of all testing, the drive hub screw of a hub-drive pump must be slackened and re-tightened three times to the correct torque value.

6.10.1 Introduction All pumps require timing, to enable them to be fitted correctly to the engine. See the Test Plan for relevant details. After completion of tests remove the pump from the test machine and drain it by slackening the inspection cover screws. Remove the inspection cover.

© Delphi

A) Radial outlets Connect the stirrup pipe to the fuel outlet specified on the test plan and to the outlet diametrically opposite. Fit the relief valve to the stirrup pipe, and connect the complete tool through a high-pressure pipe to a Nozzle Testing Outfit (NTO). For 3-cylinder pumps, connect one branch of the stirrup pipe to the specified outlet; arrange the other branch to face away from the pump and seal it off with a blanking plug.


6-91

VI TESTING & STORAGE TESTING & STORAGE B) Axial outlets Use the Universal timing Tool, connected to all of the high-pressure outlets. Normally a pressure of 30 atm, with a relief valve fitted in the system, is specified in the test data but sometimes a higher pressure is quoted. To obtain the higher pressures, connect the stirrup pipe directly to the NTO, omitting the relief valve. Note: Do not exceed the specified pressure. Excess pressure can cause damage to the shoe assemblies and adjusting plates.

6.10.2 Circlip timing Pressurise the pump as described in 6.10.1a) or b) and turn the pump drive shaft in the direction indicated on the pump name plate until resistance to further movement is felt. This is the timing position. Access to the timing circlip may be obtained through the inspection cover aperture. One ‘ear’ of the timing circlip has a straight edge. Move the circlip until the edge is aligned with the mark on the drive plate as specified in the Test Plan. Older circlips had a line scribed across the relevant ‘ear’. (Circlips with two straight ears are only for spacing, and the circlip ends are placed remote from the inspection aperture.) After carrying out this operation refit the inspection cover and gasket and tighten the screws.

6.10.3 Flange timing The Test Plan gives specific information about the timing mark on the pump flange. A flange marking gauge tool is available; this consists of a cast aluminium body with a lock-screw, around which slides a ring carrying the scribing plate. The ring is held in position by a scale plate on which direct readings in degrees are taken from the edge of the scribing plate. Interchangeable spigot plates, one with a 46 mm bore and one with a 50 mm bore, are held in position by a caphead screw, and these accommodate the different pump spigots. Interchangeable inserts adapt the gauge to any type of pump drive. The inserts are held by two screws and are placed relative to the scale zero by a dowel pin. When using the insert, the gauge is fitted to the tapered shaft, located with the Woodruff key, and clamped in position by a 9/16 in UNF nut, fully tightened to ensure the correct location of the gauge on the drive shaft. A bar through the 1/4 in hole in the insert holds it when tightening or removing the nut. A special extractor, fitted into the thread of the insert, permits withdrawal of the gauge after use. The quill shafts and hubs normally used with the pumps must be used for flange-marking and timing. To mark the flange, first ensure that any previous mark has been removed by filing, ensuring that no swarf can enter the pump. Pressurise the pump as described in section 6.10.1 A) or B) and turn the drive shaft in the direction indicated on the pump name plate until resistance to further movement is felt. Hold the pump in the timed position and fit the marking gauge, with the appropriate insert and spigot plate and set to the indexing figure specified in the Test Plan, to the pump drive. Using the gauge as a template, scribe a line on the flange between the plates of the scribing gauge. Note: The quill drive, where normally fitted to the pump, must be used, to allow for possible wear and machining tolerances. In certain instances it may be only be necessary to check that the existing flange marking is accurate. If it is incorrect, the existing line must be erased and the flange re-marked.

Slide the shaft locking screw washer into the position which will allow the screw to contact the drive shaft and tighten the screw to the specified torque (do not exceed the specified torque) to avoid damage to the drive shaft. This screw will remain tightened until the pump is secured to its engine. Then the screw must be loosened and the two-position washer moved completely across, to allow the screw to be re-tightened without interfering with the drive shaft.

6-92


© Delphi

6.10.4 Locked-shaft timing


Sealing Of Pumps

After test, the inspection cover, with the exception of those pumps which are internally-timed, must be made tamperproof by passing sealing wire through the heads of the two securing screws and affixing a lead seal. The same must be applied to the governor cover dome nuts, and both seals must be embossed with an authorised stamp. A sleeve must be fitted over the torque screw on externally-adjusted pumps and secured with wire and lead seal, also embossed. Governor maximum speed screws cannot be sealed until the governor is set on the engine, so the cover, the wire and the lead seal should be loosely attached to the pump in order that the pump can be made tamper-proof after final adjustment.

6.12

Storage Of Pumps

6.12.1 New pumps New pumps must be stored in their ‘as received’ condition, with their original packing intact.

6.12.2 Overhauled pumps Run the pump at full load and half maximum speed for 5 minutes on ISO 4113 test oil. Drain the oil; fit the inspection cover and tighten the screws to the specified torque. Fit protection caps to the inlet and backleak connections, and seal the pump, together with some ‘rust-preventing’ material, in damp-proof packaging.

6.12.3 Storage conditions

© Delphi

Pumps must be stored in a dry, dust-free area, away from direct sunlight or contact with any artificial heat source. The temperature limits of the storage area must be between minus 30°C and plus 60°C. Humidity must be between 0 and 80 percent. Pumps must be stored with the axis horizontal; un-boxed pumps must never be stored one on top of another. A ‘stock-rotation’ system must be observed, to minimise storage time of any individual pump. If a pump has been stored for one year, it must be subjected to a full test according to the relevant Test Plan, and the storage procedure repeated.


6-93

VI TESTING & STORAGE

© Delphi

TESTING & STORAGE

6-94


APPENDIX VII APPENDIX 7.1

Torques Values

The torque values are correct at the time of printing. Any variations made necessary by modifications or changes in design will be published in the relevant Service Instruction Notes and the latest information must be followed.

7.1.1 End plate, brackets, hydraulic head and rotor Item

Remarks

Nm

kg m

ib in

End plate securing screws

5.1

0.52

45.0

HP outlet banjo bolt

31.0

3.10

270.0

HP outlet banjo bolt, 7139-177A and B

31.0

3.10

270.0

HP outlet banjo bolt, 7139-177 C, D, E, F and G

36.0

3.60

320.0

HP outlet banjo bolt, 7139-752

31.0

3.10

270.0

HP outlet banjo bolt, 7139-752A

36.0

3.60

320.0

Axial outlet pressurising valves

41.0

4.20

360.0

10.0 plus 65° ± 5°

3.10

91.0

Delivery valve holder

41.0

4.10

360.0

HP outlet support bracket clamping nuts

41.0

4.10

360.0

Rear support bracket screw

14.0

1.40

120.0

Fuel inlet connection

50.8

5.18

450.0

Head locating screw

19.1

1.95

170.0

Transfer pump rotor

7.3

0.75

65.0

Fuel inlet connection

13.5

1.38

120.0

On connection with olive

Distributor rotor plug screw

3.1

0.32

28.0

Secured with ‘Araldite’

Electric shut-off solenoid (ESOS)

15.0

1.53

130.0

Drive plate screw, direct torque

18.1

1.85

160.0

Plungers diameter up to and including 7.5 mm

Drive plate screw, direct torque

28.4

2.90

250.0

Plungers diameter 8.0 mm and above

Drive plate screw (A)

15.7

1.60

140.0


Drive plate screw (A)

24.3

2.48

215.0

Plungers diameter 8.0 mm and above and 4-plunger

Drive plate screw (B) & (C)

13.0

1.33

115.0


Drive plate screw (B) & (C)

20.6

2.10

180.0

Plungers diameter 8.0 mm and above and 4-plunger

Axial outlet delivery valves

© Delphi

Torque

With or without vent screw

(A) obtained with spanner 7144-511 and adaptor 7144-482 (66 mm centre distance) (B) obtained with spanner 7144-511A and adaptor 7144-482 (127 mm centre distance) (C) obtained with spanner 7244-404 and adaptor 7144-482 (127 mm centre distance)


7-95

VII APPENDIX APPENDIX Note: Drive plate screws are tightened using a special technique with either Spanner Tool Part No 7144-511A or 7244-404, and an adaptor fitted in a torque wrench. In use, the torque wrench handle and spanner must form a straight line with the handle extending away from the spanner. The distance between the centre of the adaptor and the centre of the ring spanner is 127 mm (5.0 in). If superseded Spanner Tool Part No 7144-511 is used, this distance is 66 mm (2.16 in). Certain designs of torque wrench are not suitable for this operation.

7.1.2 Governor and housing assemblies Item

Torque

Remarks

Nm

kg m

ib in

Banjo bolt, permanent vent orifice

27.1

2.76

240.0

Governor cover self-venting head

Banjo bolt, backleak connection

40.7

4.15

360.0

Self venting pump

Governor vent body, screw

7.3

0.75

65.0

Exhaust brake lever nut

2.3

0.24

20.0

Break back throttle lever nut

5.7

0.58

50.0

Locking screw

0.7

0.07

6.0

Governor link assembly

Lock nut

6.8

0.69

60.0

Low load setting screw (both)

Lock nut

6.8

0.69

60.0

Anti-stall screw, torque screw

Governor vent screw

4.5

0.46

40.0

Throttle shaft nut

3.4

0.35

30.0

Uprated throttle lever pinch bolt nut

4.5

0.45

40.0

Uprated shut-off lever pinch bolt nut

4.5

0.45

40.0

Control bracket screw

2.3

0.24

21.0

Shut-off shaft nut

3.4

0.35

30.0

Control cover cap nut

4.5

0.46

40.0

Control cover stud

6.8

0.69

60.0

Throttle stop screw nut

2.2

0.23

20.0

© Delphi

Governor cover with Permanite gasket

7-96


APPENDIX VII APPENDIX 7.1.3 Auto advance arrangement Torque

Item

Remarks

Nm

kg m

ib in

Spring cap

28.4

2.90

250.0

Screw, cam advance 7123-947 (hexagon)

33.8

3.45

300.0

Screw, cam advance 7123-975

50.6

5.18

450.0

Piston plug

28.4

2.90

250.0

Automatic advance device

Cam locating screw

29.9

3.05

265.0

Advance device not fitted

Spring cap screw

4.5

0.46

40.0


Cap nut

14.7

1.50

130.0

Advance device fitted

Head locating screw

32.4

3.30

285.0

Advance device not fitted

Head locating screw

39.5

4.03

350.0

Advance device fitted

Housing stud

6.8

0.69

60.0

Lubricate stud prior to insertion

Blanking plug, head locating fitting assembly

33.8

3.45

300.0

Self-venting pump


7.1.4 Pump body and drive shaft Item Drive shaft screw, 28.5 mm long

Torque Nm

kg m

ib in

32.3

3.30

285.0

Remarks Slacken and tighten to the correct torque value. Carry out this operation three times.

Drive shaft screw, 31.7 mm long

36.3

3.70

320.0

Slacken and tighten to the correct torque value. Carry out this operation three times. Heavy duty, up-rated drive.

81.4

8.30

720.0

Splined hub nut

81.4

8.30

720.0

Backleak connection

20.6

2.10

180.0

Drive shaft locking screw

6.8

0.69

60.0

In 'locked' position

Drive shaft locking screw

20.0

2.10

180.0

In 'running' position

© Delphi

Gear hub nut


7-97

NOTE Tighten using plain washer under nut. Remove plain washer, substitute spring washer and tighten.

VII APPENDIX APPENDIX 7.2

Special Tools For Repair Part No.

Dial gauge

1000-317

Seal assembly tool

1804-14

Solenoid socket

1804-15A

Drive shaft seal assembly tool

1804-526

Drive shaft seal protection tool

1804-528

TP rotor spanner

7044-889

Drive hub seal guide

7144-260A

Drive shaft screw adaptor

7144-261

Timing adaptor assembly

7144-262

Drive plate screw torque adaptor

7144-482

Drive plate screw spanner

7244-404

Drive plate spanner (slotted type)

7144-744

Drive shaft holding tool

7144-773

Single piece drive shaft assembly tool

7244-23A

Drive hub holding spanner

7244-24

Cam advance screw socket

7244-125B

Drive extractor

7244-231

Outer drive seal extractor

7244-334A

Throttle spring assembly tool

7244-405

Seal protection cap, drive shaft

7144-900

Seal protection cap, head locating and ESOS

7044-897

Seal protection cap, AA plugs

7044-898

Seal protection cap, end plate sleeve

7144-11

Seal protection cap, latch and switch valve

7144-18

Seal protection cap, throttle and shut-off shaft, latch valve sleeve nut and switch

7144-458C

Seal protection cap, quill type drive shaft

7244-184

Protection sleeve, shut-off shaft

7144-459A

Protection sleeve, shut-off shaft

7144-894

Superseded by: Clips (6-off)

1804-449

© Delphi

Description

7-98


APPENDIX VII APPENDIX 7.3

Special Tools For Testing Part No.

Transfer pressure gauge adaptor

DPA202A

Cambox pressure measuring kit

7244-275A

TP adjuster, M12

7244-410A

TP adjuster, M14

7244-571

TP adjuster, M14, long reach

7244-597

ESOS test plug

7244-417

Universal advance gauge

7244-590

Set of spare extension rods

7244-590/1

Spare AA gauge tube

7244-590/2

Basic flange marking gauge

7244-27

46 mm ring

7244-26D

50 mm ring

7244-26E

Insert for standard pumps

7244-28

Insert for uprated pumps, 20 mm tapered drive

7244-30

Insert for uprated drive, gear hub

7244-31

Insert for uprated drive, splined hub

7244-32

Long spigot pump spacer

7244-29

Max. fuel adjusting tool

7144-875

Shut-off lever adjustment tool (light load pumps)

7144-559A

Pressure testing tool for outer seal

7144-760

© Delphi

Description


7-99

VII APPENDIX APPENDIX Abbreviations Used In This Manual

°C AA atm ESOS FIE in ISO kg cm2 lb/in2 Max mm NTO SIN TP

degrees Celsius Automatic Advance Atmospheres Electric Shut-Off Solenoid Fuel Injection Equipment inches International Standards Organisation Kilograms Per Centimetre Pounds Per Square Inch Maximum Millimetres Nozzle Testing Outfit Service Information Notes Transfer Pressure

© Delphi

7.4

7-100


APPENDIX VII

© Delphi

NOTES


8-101

Whilst every care has been taken in compiling the information in this publication, Delphi Diesel Systems Ltd. cannot accept legal liability for any inaccuracies. Delphi Diesel Systems Ltd. has an intensive programme of design and development which may well alter product specification. Delphi Diesel Systems Ltd. reserve the right to alter specifications without notice and whenever necessary to ensure optimum performance from its product range. All Rights Reserved No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form, or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of Delphi Diesel Systems Ltd.

Il a été apporté une attention particulière pour garantir l'exactitude des renseignements contenus dans cette publication par Delphi Diesel Systems Ltd, mais la société décline toute responsabilité légale à cet égard. Delphi Diesel Systems Ltd poursuit un programme intensif de conception et de développement qui peut entraîner la modification des spécifications des produits. Delphi Diesel Systems Ltd se réserve le droit de modifier les spécifications, sans préavis et si cela est nécessaire, pour assurer les performances optimales de sa gamme de produits. Tous droits réservés Toute reproduction, mémorisation dans un système informatique ou transmission sous quelle que forme que ce soit, ou par tout moyen électronique, mécanique, par photocopie, enregistrement ou autre de cette publication est interdit sans l'autorisation préalable de Delphi Diesel Systems Ltd.

Bei der Zusammenstellung der in dieser Veröffentlichung enthaltenen Informationen wurde mit größtmöglicher Sorgfalt vorgegangen. Delphi Diesel Systems Ltd. kann jedoch rechtlich nicht für etwaige Ungenauigkeiten zur Verantwortung gezogen werden. Delphi Diesel Systems Ltd. führt ein fortlaufendes Designund Entwicklungsprogramm durch, weshalb es möglich ist, daß sich Produktdaten ändern. Delphi Diesel Systems Ltd. behält sich das Recht vor, ohne Vorankündigung Spezifikationen jederzeit zu ändern, um die optimale Leistung seiner Produkte sicherzustellen. Alle Rechte vorbehalten. Kein Teil dieser Veröffentlichung darf ohne vorherige Genehmigung durch Delphi Diesel Systems Ltd. abgedruckt, in einem Datenverarbeitungssystem gespeichert oder auf irgendeine Art und Weise, sei es auf elektronischem oder mechanischem Wege, durch Fotokopieren, Aufzeichnen oder auf sonstige Art, übertragen werden.

Anche se ogni cura è stata adottata nel compilare le informazioni di questa pubblicazione, Delphi Diesel Systems Ltd. Declina qualsiasi responsabilità per eventuali imprecisioni. Delphi Diesel Systems svolge un intenso programma di progettazione e sviluppo che potrebbe modificare le specifiche del prodotto. Delphi Diesel Systems si riserva il diritto di modificare le specifiche senza preavviso e ogniqualvolta lo ritenga necessario ai fini di assicurare le prestazioni ottimali dalla sua gamma di prodotti. Tutti i diritti riservati Nessuna parte di questa pubblicazione può essere riprodotta, memorizzata in un sistema elettronico o trasmessa in qualsiasi forma o con qualsiasi mezzo, elettronico, di fotocopiatura, di registrazione o altro, senza la preventiva autorizzazione di Delphi Diesel Sistems Ltd.

Aunque hemos tomado todas las precauciones necesarias al recopilar esta publicación, Delphi Diesel Systems Ltd no acepta ninguna responsabilidad legal por inexactitudes que puedan aparecer en la misma. En Delphi Diesel Systems Ltd se sigue un programa intensivo de diseño e investigación el cual podría en cualquier momento alterar la especificación de los productos. Delphi Diesel Systems Ltd se reserva el derecho de alterar las especificaciones sin notificación previa y siempre que esto sea necesario para asegurar el mejor funcionamiento posible de sus productos. Todos los Derechos Reservados No se permite copiar, almacenar en sistema recuperable ni transmitir esta publicación de ninguna forma o medio electrónico, mecánico, de fotocopia, grabación o cualquier otro, sin autorización previa de Delphi Diesel Systems Ltd.

Ainda que se tenha lido o máximo cuidado na compilação da informação contida nesta publicação, a Delphi Diesel Systems Ltd, não pode aceitar qualquer responsabilidade legal por inexactidões. A Delphi Diesel Systems Ltd. tem um programa intensivo de projecto e desenvolvimento que pode porventura alterar as especificações do produto. A Delphi Diesel Systems Ltd. reserva o direito de alterar especificações sem aviso e sempre que seja necessario para assegurar um desempenho óptimo da sua linha de produtos. Todos os direitos reservados. Nenhuma parte desta publicação pode ser reproduzida, armazenada num sistema de onde possa ser recuperada ou transmitida de alguma forma, ou por quaisquer meios, electrónico, mecânico, de fotocópia, gravação ou outros, sem autorização antecipada de Delphi Diesel Systems Ltd.

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