Professional Documents
Culture Documents
2008
DDNX121A(EN)
(D)
Kommen Sie nicht mit dem Hochdruckstrahl in Verbindung! Besonders nicht, wenn
Druckrohrleitung oder Dichtung geprft werden! Hochdruckflssigkeiten knnen tdliche
Verletzungen verursachen! Im Falle einer Berhrung mit der Haut, kontaktieren Sie
sofort einen Arzt. Bitte beachten Sie die Gesundheits-/und Sicherheitsunterlagen.
(E)
Mantenga las manos y el cuerpo lejos del rociado del lquido, especialmente inyectores,
tuberas y juntas de alta presin con fugas. La inyeccin de alta presin puede perforar
la piel humana y producir una lesin fatal. En caso de que la inyeccin atraviese la piel,
consiga atencin mdica inmediatamente. Vea la hoja de Datos de Sanidad y
Seguridad.
(EN)
Do not put your skin into the fuel jets under pressure, especially those due to pressure
pipe or seal leaks. High pressure liquids can cause deadly injuries. In case of an
injection under the skin, contact a doctor immediately. Please refer to the health and
security fuel documents.
(F)
Ne pas approcher les mains ni le corps des jets de liquides, particulirement ceux
provenant des fuites de tuyaux et des joint soumis a la haute pression. Le liquide sous
haute pression inject sous la peau peut causer des blessures mortelles. En cas
dinjection sous la peau, consulter immdiatement un mdecin. Se reporter a la fiche de
sant et de scurit du gazole.
(IT)
Non esporre le mani o altre parti del corpo a getti di gasolio ad alta pressione,
specialmente a quelli provenienti da tubi o paraolii. I getti di liquidi ad alta pressione
possono causare ferite anche mortali. In caso di iniezione sotto pelle contattare
immediatamente un medico. Fare riferimento alle schede di sicurezza del gasolio.
(NL)
Zorg dat uw handen of andere lichaamsdelen niet in contact komen met vloeistofstralen
onder hoge druk, met name bij een lek aan een leiding of dichting. Als de vloeistof onder
hoge druk onder de huid terechtkomt, kan dit zelfs tot dodelijke verwondingen leiden. Als
de vloeistof onder de huid terechtkomt, onmiddellijk een arts raadplegen. Lees de
gezondheids- en veiligheidsfiche met betrekking tot de brandstof.
(P)
No exponha a pele a jactos de combustvel sob presso, especialmente os devidos a
fugas de tubos de presso ou vedantes. Lquidos a alta presso podem causar
ferimentos mortais. No caso de injeco subcutnea, consulte imediatamente um
mdico. Consulte por favor a documentao respeitante a sade e segurana de
combustveis.
TABLE OF CONTENTS
INTRODUCTION
DISMANTLING
II
III
REASSEMBLY
IV
Delphi
TEST PROCEDURE
TABLE OF CONTENTS
VI
APPENDIX
VII
ii
Delphi
INTRODUCTION I
TABLE OF CONTENTS
INTRODUCTION
The Pump.......................................................................................................................................................................1-1
General...........................................................................................................................................................................1-1
This Manual...................................................................................................................................................................1-2
Equipment......................................................................................................................................................................1-2
Replacement Of Parts...................................................................................................................................................1-2
Pump Name Plate..........................................................................................................................................................1-3
Delphi
1.
1.1
1.2
1.3
1.4
1.5
1.6
iii
II DISMANTLING
TABLE OF CONTENTS
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
DISMANTLING
Preparation....................................................................................................................................................................2-5
2.1.1
Cleaning and draining..................................................................................................................................2-5
2.1.2
Mounting the pump.....................................................................................................................................2-5
2.1.3
Removing sealing caps and locking wire...................................................................................................2-5
2.1.4
Removing the drive hub (if fitted)...............................................................................................................2-6
2.1.5
Measuring drive shaft end float..................................................................................................................2-6
2.1.6
Measuring drive shaft radial play...............................................................................................................2-7
Governor Cover, Control Levers & Link Assembly.....................................................................................................2-7
2.2.1
Removing the fuel return connections.......................................................................................................2-7
2.2.2
Removing the throttle lever stop screws, maximum fuel screw, and torque control screw.................2-8
2.2.3
Removing the throttle lever.........................................................................................................................2-8
2.2.4
Removing the exhaust brake lever.............................................................................................................2-9
2.2.5
Removing the electronic actuator throttle lever (rigid type)....................................................................2-9
2.2.6
Removing the governor cover assembly.................................................................................................2-10
Dismantling The All-Speed Govenor.........................................................................................................................2-16
Removing The Control Bracket And Arm Assembly................................................................................................2-17
2.4.1
Removing the scroll link plate return spring............................................................................................2-17
2.4.2
Removing the governor control bracket assembly.................................................................................2-17
2.4.3
Dismantling the governor control arm assembly....................................................................................2-18
2.4.4
Dismantling the governor control plate assembly for torque trimmer variant....................................2-18
High Pressure Outlets Assembly, Electric Shut-off Solenoid (ESOS) & Transfer Pump.......................................2-19
2.5.1
High pressure outlets.................................................................................................................................2-19
2.5.2
Endplate assembly.....................................................................................................................................2-19
Electric Shut-off Solenoid (ESOS)..............................................................................................................................2-21
Transfer Pump.............................................................................................................................................................2-21
2.7.1
Removing the transfer pump components..............................................................................................2-21
2.7.2
Slackening the transfer pump rotor..........................................................................................................2-21
Advance Device...........................................................................................................................................................2-22
2.8.1
Single piston design with 2 bolt cold advance (CA)................................................................................2-22
2.8.2
Servo piston design with 2 bolt Cold Advance........................................................................................2-23
2.8.3
Servo piston design with 4 bolt cold advance.........................................................................................2-26
2.8.4
Single piston design without cold advance.............................................................................................2-27
Removing The Head Locking Screws And Releasing The Hydraulic Head............................................................2-28
2.9.1
Head locking screws..................................................................................................................................2-28
2.9.2
Removing and dismantling the LLA.........................................................................................................2-28
2.9.3
Removing and dismantling the latch valve..............................................................................................2-29
2.9.4
Removing the hydraulic head...................................................................................................................2-29
Drive Shaft...................................................................................................................................................................2-30
2.10.1
Dismantling the Zero Backlash Drive assembly......................................................................................2-30
2.10.2
Dismantling the splined drive assembly..................................................................................................2-32
Dismantling The Hydraulic Head - Check And Cheek Plate Designs......................................................................2-33
2.11.1
Releasing the drive plate screws..............................................................................................................2-33
2.11.2
Dismantling the rotor components...........................................................................................................2-33
2.11.3
Removing the lower check or cheek plate...............................................................................................2-33
2.11.4
Reverse thrust weight assembly...............................................................................................................2-34
2.11.5
Lock-shaft timing........................................................................................................................................2-34
Delphi
2.
2.1
iv
DISMANTLING II
TABLE OF CONTENTS
Removing the drive shaft seal/s................................................................................................................2-35
Delphi
2.11.6
3.3
Delphi
3.
3.1
3.2
vi
REASSEMBLY IV
TABLE OF CONTENTS
4.
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
Delphi
4.11
REASSEMBLY
Preparation..................................................................................................................................................................4-43
Assembling The Hydraulic Head................................................................................................................................4-43
4.2.1
Rotor plug...................................................................................................................................................4-43
4.2.2
Drive plate, rollers, shoes and retaining plates.......................................................................................4-44
Drive Shaft...................................................................................................................................................................4-47
4.3.1
Zero backlash and splined drive with cheek plates.................................................................................4-47
4.3.2
Spline drive with check plate head and rotor..........................................................................................4-50
Securing The Hydraulic Head And Checking Drive Shaft End Float And Radial Play...........................................4-51
4.4.1
Replacing the drive shaft seal/s................................................................................................................4-51
4.4.2
Securing the drive shaft.............................................................................................................................4-52
4.4.3
Aligning the hydraulic head......................................................................................................................4-52
4.4.4
Checking drive shaft end float...................................................................................................................4-52
4.4.5
Checking drive shaft radial play................................................................................................................4-53
4.4.6
Cam advance screw...................................................................................................................................4-53
4.4.7
Fitting the head locking screws, light load advance valve and latch valves.........................................4-54
Advance Device...........................................................................................................................................................4-55
4.5.1
Single piston design..................................................................................................................................4-56
4.5.2
Servo piston designs.................................................................................................................................4-58
4.5.3
2 Bolt Cold Advance fitted to single piston design.................................................................................4-62
4.5.4
4 Bolt Cold Advance fitted to servo piston design..................................................................................4-64
Transfer Pump And Endplate Assembly...................................................................................................................4-64
4.6.1
Transfer pump............................................................................................................................................4-64
4.6.2
Endplate assembly.....................................................................................................................................4-65
ESOS And High Pressure Outlets..............................................................................................................................4-68
4.7.1
ESOS or blanking plug...............................................................................................................................4-68
4.7.2
High pressure outlets and clamp plate.....................................................................................................4-68
Governor Linkage, Control Bracket And Cover.........................................................................................................4-69
4.8.1
Governor linkage........................................................................................................................................4-69
4.8.2
Fitting the governor assembly to the pump............................................................................................4-70
4.8.3
Fitting the scroll link plate return spring..................................................................................................4-70
4.8.4
Setting the governor link length...............................................................................................................4-71
4.8.5
Fitting the governor assembly for torque trimmer variant.....................................................................4-71
Assembling The Governor Cover..............................................................................................................................4-74
4.9.1
Governor cover only..................................................................................................................................4-74
4.9.2
Governor cover fitted with hydraulic excess fuel....................................................................................4-75
4.9.3
Governor cover fitted with boost control only........................................................................................4-77
4.9.4
Governor covers fitted with torque control and torque control plus boost control.............................4-81
4.9.5
Governor covers fitted with electronic actuator......................................................................................4-86
Governor Cover External Components.....................................................................................................................4-89
4.10.1
Fitting backleak connections.....................................................................................................................4-89
4.10.2
Fitting and aligning external levers..........................................................................................................4-89
4.10.3
Control stop screws and plugs..................................................................................................................4-90
Shaft Locking Screw Cover And Cam Ring Access Plug.........................................................................................4-92
4.11.1
Shaft locking screw....................................................................................................................................4-92
4.11.2
Drain plug...................................................................................................................................................4-92
4.11.3
Cover...........................................................................................................................................................4-92
vii
IV REASSEMBLY
TABLE OF CONTENTS
4.11.4
Cam ring access plug.................................................................................................................................4-92
Drive Hub.....................................................................................................................................................................4-93
Leak Testing.................................................................................................................................................................4-93
Storage.........................................................................................................................................................................4-93
4.14.1
New pumps.................................................................................................................................................4-93
4.14.2
Overhauled pumps.....................................................................................................................................4-93
4.14.3
Storage conditions.....................................................................................................................................4-93
Delphi
4.12
4.13
4.14
viii
TEST PROCEDURE V
TABLE OF CONTENTS
5.
5.1
5.2
5.3
Delphi
5.4
TEST PROCEDURE
Preparation..................................................................................................................................................................5-95
5.1.1
Leak testing.................................................................................................................................................5-95
5.1.2
Test machine..............................................................................................................................................5-95
5.1.3
Test machine drive.....................................................................................................................................5-95
5.1.4
Test conditions...........................................................................................................................................5-96
5.1.5
Connecting fuel lines.................................................................................................................................5-97
5.1.6
Machine test procedure.............................................................................................................................5-97
5.1.7
Transfer pressure measurement and initial setting................................................................................5-98
5.1.8
Cambox pressure measurement...............................................................................................................5-99
5.1.9
Adjustments to be pre-set.........................................................................................................................5-99
Test Procedure...........................................................................................................................................................5-101
5.2.1
Priming......................................................................................................................................................5-101
5.2.2
Checking and setting transfer pressure..................................................................................................5-102
5.2.3
Cambox pressure and backleakage checks............................................................................................5-103
5.2.4
Speed advance setting.............................................................................................................................5-103
5.2.5
Cold advance............................................................................................................................................5-104
5.2.6
Light-load advance valve setting............................................................................................................5-104
5.2.7
Boost control with torque trimmer.........................................................................................................5-105
5.2.8
Maximum fuel delivery setting...............................................................................................................5-106
5.2.9
Latch valve................................................................................................................................................5-107
5.2.10
Governor setting and testing..................................................................................................................5-107
5.2.11
Torque screw setting...............................................................................................................................5-108
5.2.12
Idle setting................................................................................................................................................5-108
5.2.13
Shut-off control check..............................................................................................................................5-109
Timing........................................................................................................................................................................5-109
5.3.1
General......................................................................................................................................................5-109
5.3.2
Keyed drive shafts....................................................................................................................................5-110
5.3.3
Keyless drive shafts.................................................................................................................................5-111
Leakage Testing.........................................................................................................................................................5-114
ix
Delphi
6.
6.1
6.2
6.3
APPENDIX VII
TABLE OF CONTENTS
APPENDIX
Abbreviations Used In This Manual........................................................................................................................7-137
Delphi
7.
7.1
xi
VII APPENDIX
Delphi
TABLE OF CONTENTS
xii
INTRODUCTION I
INTRODUCTION
1.1
The Pump
DP200 PUMP
The DP200 distributor-type fuel injection pump is a compact, self-contained unit that is suitable for direct injection engines
of up to 33 BHP per cylinder and with two, three, four or six cylinders. It is primarily intended for the industrial and
agricultural markets.
All internal working parts are lubricated by fuel oil and the pump housing is maintained at an internal pressure that
prevents the ingress of external dirt or other foreign matter.
Standard features include automatic air venting, compensation for variations in fuel viscosity.
It can be fitted with a range of options to produce performances to match a wide variety of engine requirements, including
boost-pressure control of fuel delivery level for turbocharged engines, and load or speed dependent timing control.
Due to the complexity of this product, the need for highly-trained personnel, and a high level of investment in equipment
and workshop resources, together with the need for up-to-date Technical Information, it can only be tested or serviced
by Delphi Authorised Distributors.
It has been developed from the well-known range of DPA and DPS injection pumps and is the result of the Delphi policy
of continued improvement of products to meet the demands of new legislation and operational requirements.
Delphi
1.2
General
Fuel pumps may require off-engine workshop attention for two main reasons:
a.
Investigation of a specific fault in engine performance, which may only require partial dismantling.
b.
A complete overhaul e.g. at the same time as a major engine overhaul.
A full performance test is recommended, both before and after any level of attention, as many aspects of pump
performance are interrelated.
1-1
I INTRODUCTION
INTRODUCTION
1.3
This Manual
The Dismantling, Reassembly and Testing Sections are laid out on a "step-by-step" basis, with each action accompanied
by an illustration showing the component(s) involved and, where applicable, its/their positions on the pump. The Manual
is not based on any one specification, but covers pump features which have been included up to the time of publication.
For the purposes of illustration, more than one pump specification has been used.
The pumps illustrated are for clockwise rotation (when viewed from the drive end); anticlockwise pumps will have items
such as the maximum fuel screw, and the boost control fitted on the side opposite to that shown. In addition, the advance
device will operate in the opposite mode.
Instructions for both full and partial dismantling of the pump are included e.g. total dismantling and examination of all
components other than those that are factory-sealed units and removal of the hydraulic head and rotor only.
All the necessary tools are listed in Section 6. Special tools are identified by part number and standard tools by type and
size.
1.4
Equipment
Any tools, both standard and special-purpose, used for the servicing or repair of fuel injection equipment (FIE) must be
reserved solely for use on FIE. Worn or damaged tools can cause damage to critical components, as well as being a
safety hazard.
The working area must be scrupulously clean and should be in a room separated from any other activity; the ingress of
dust and dirt, airborne or otherwise, must be prevented.
The minimum facilities required are:
1.
A bench covered in non-rusting metal or industrialgrade linoleum and fitted with an engineer's vice with a jaw size
of 100 mm (4 in). The vice jaws must be faced with either soft metal or fibre pads.
2.
An adjustable pump-mounting device such as the "Hydraclamp", fitted with an appropriate adaptor plate.
3.
Easily cleaned compartmented trays for separate storage of dismantled components such as Part No. 60620197.
4.
All the necessary tools as listed in Section 6 of this Manual.
5.
A low-pressure washing facility using a suitable, approved, cleaning fluid (not water or water-based) to clean pumps
externally prior to dismantling.
Cleaning must be carried out in a place separated from the "clean area".
6.
A tank large enough to accommodate a complete pump and filled with clean test oil, near to a source of clean, dry,
variable pressure compressed air for carrying out leakage tests.
7.
Supplies of clean, lint-free (non-fluffy) cloths for cleaning and drying components. Cotton waste must never be
used.
8.
A pump test machine that conforms to ISO 4008.
9.
Adequate storage facilities for pumps, tools and test equipment, with separate areas for pumps before and after
repair.
Note:
All cleaning tanks, workshop and test facilities and fluids must conform to any Fire Prevention or Health and Safety
Regulations in force at the time of use.
1.5
Replacement Of Parts
Delphi
All gaskets and seals must be replaced during reassembly. However, in the event of partial dismantling, only those seals
that have been disturbed need replacement, unless leaks from elsewhere are detected during testing prior to dismantling.
If any part of a "mated" assembly is worn or damaged, the whole assembly must be replaced. Any component showing
signs of corrosion or water ingress, cracks or distortion must be replaced.
1-2
INTRODUCTION I
INTRODUCTION
Only service parts supplied by Delphi Diesel Systems Aftermarket Operations may be used as replacements. Parts
supplied from alternative sources may appear to be externally similar and may carry the same part numbers as the
genuine item but may be inferior in material specification or finish and lead to malfunction or premature failure.
1.6
The number stamped on the type-plate attached to the pump housing identifies the type and model of the pump. Pumps
with identical build but with different settings, dependent upon engine application, are further identified by the setting
code stamped beneath the serial number.
A typical Despatch Number could be as shown in Fig. 1.
C 89 2 0 A 06 0 L
Suffix letter Denotes the type of
ESOS fitted.
See SIN DT294
Marketing Code:
C = Spain
No letter = UK
Design Source:
0 = USA
1 = Korea
2&3 = UK 4 = France
5 = Spain 6 = Brazil
7 = India
8 = Poland
9 = Japan
Individual features
number.
No. of delivery
outlets:
0, 3 & 5 = 4 cyl.
1 & 4 = 6 cyl.
2 = 3 cyl.
6 - 9 to be allocated
If the name plate has been painted over, special care is needed when removing the paint to avoid erasure of the
information. Use a small quantity of proprietary paint-stripper, carefully observing the manufacturers instructions.
Delphi
Note:
2 As components are removed, inspect them and put those considered unfit for further service to one side for
replacement; place those which are fit for further service into a clean compartmented tray. (Trays available through
Delphi Diesel Systems Aftermarket Operations, Service Operations Department.) A guide to areas of possible wear or
damage appears in Section 3 (Component Inspection & Renewal).
1-3
I INTRODUCTION
Delphi
INTRODUCTION
1-4
DISMANTLING II
DISMANTLING
2.1
Preparation
A list of all tools required to dismantle and reassemble the pump is in Section 6.
A980
Delphi
Remove any shrink sleeving, tamperproof caps or locking wire from adjustment screws.
2-5
A950
II DISMANTLING
DISMANTLING
2.1.4 Removing the drive hub (if fitted)
Restrain the drive hub (1) with the special tool (2).
Slacken the drive hub nut and spring washer just
sufficiently to allow release of the hub.
Use a suitable extractor to release the hub from the
drive shaft taper.
A986
A952
Delphi
2-6
DISMANTLING II
DISMANTLING
2.1.6 Measuring drive shaft radial play
Note:
In order to assess the condition of the bearing and
drive shaft, radial play must be measured prior to
dismantling.
With the pump and gauge (1) mounted rigidly
relative to each other, adjust the gauge pin to bear
(at right angles) against the parallel section (4) of
the drive shaft. Note that this section is very short,
therefore a fine tip will be required on the gauge pin.
Push the shaft radially towards the gauge and set
the gauge to zero.
Pull the shaft radially to the opposite extreme and
record the gauge movement. Repeat the readings
with the gauge repositioned as shown at (2) and (3).
Do not rotate the drive shaft. Reject the housing if
the maximum play or the difference between the
measurements exceed the figures below.
2.2
A1005
Drive type
Max. play
Max. Difference
Belt
0.22 mm
0.1 mm
Gear or hub
0.27 mm
0.2 mm
3
7
5
6
A1261
Delphi
A953
2-7
II DISMANTLING
DISMANTLING
2.2.2 Removing the throttle lever stop screws, maximum fuel screw, and torque control screw
Loosen the lock nuts on the idling stop screw (1),
maximum speed stop screw (2), and torque screw
(5), and remove the screws and washers. Discard
any rubber sealing washers. Slacken and remove
the blanking plug (4) on the side of the governor
cover opposite to the maximum fuel stop (or boost
control device). Discard any sealing washer.
A978
Note:
For pumps fitted with boost control, maximum fuel
adjustment is incorporated within the boost control
device (6).
4
A953
A1002
1
2
3
4
5
6
7
8
A1003
Delphi
A1006
2-8
DISMANTLING II
DISMANTLING
B) Break-back type
Slacken, remove and discard the self-locking nut (1);
remove washer (2), upper spring retainer (3), spring
(4), lower spring retainer (5), throttle lever (6), breakback lever (7), and dust cover (8).
A1007
1
2
3
4
5
6
A954
Delphi
Slacken and remove the bolt (558) and washers (559 and (560).
2-9
A1256
II DISMANTLING
DISMANTLING
2.2.6 Removing the governor cover assembly
A) Governor cover only
Push the exhaust brake shaft (2) and the throttle
shaft (3) down into the cover. Remove the four Torx
screws at (1), (4), (5), and (6).
Lift off the cover and pull the throttle shaft (3) out of
its bore. Remove and discard the "trapped" O-ring
(1) from the sealing face of the cover. Remove the
exhaust brake shaft (2) and discard its O-ring.
EVD15
4
5
Note:
At the later stage (depending on which other
features are fitted) when removing the governor
cover, the hydraulic excess fuel device has to be
disengaged.
A485a
A562a
Delphi
A1048
2-10
DISMANTLING II
DISMANTLING
C) Governors covers fitted with boost control only
a) Removing the cover
Slacken and remove the cover plug (4); remove and
discard the plug O-ring.
Note:
Take care when releasing the plug as it will be under
pressure from the pre-load spring (if fitted).
A955
Note:
Securing screws (1) and (3) and plug (4) may be of
the temper resistant design. To remove these, a
special tamper resist Torx bit will be required. See
Section 6.
b) Removing the diaphragm
Remove the diaphragm assembly (1); lift out the
spring plate (2), control springs (3), shim (4) and fuel
control rod (5).
A788
Delphi
2-11
A787
II DISMANTLING
DISMANTLING
d)
Removing
the
diaphragm
stroke
adjustment screw.
Unscrew and remove the diaphragm stroke
adjustment screw (1) from the screw body (2).
Remove and discard the O-ring from the adjustment
screw.
A568
4
3
2
A1257
Delphi
A1469
2-12
DISMANTLING II
DISMANTLING
D) Governor cover fitted with Torque Control and Torque Control plus Boost Control
Remove pressure end plug circlip (1).
1
A1465
A1467
A1466
Note:
2 It may be necessary to re-position the pump on
the Hydraclamp mounting plate to gain access to
the preload plug.
b) Removal of the governor control cover
If no boost control is fitted, the cam follower will be
pivoted on a spindle, which is formed as a part of a
pivot plug screwed into the governor control cover
(1). A plastic tamper proof plug will be fitted into the
hexagon hole in the plug and must be removed for
fitment of the appropriate Allen key. If the pivotplug is to be removed, slacken it by no more than
one turn before removal of the governor control
cover (to avoid the risk of damage to internal
components).
Delphi
A1473
2-13
II DISMANTLING
DISMANTLING
c) Removal of the boost control cover and
diaphragm
Remove any tamperproof seal(s) from the boost
control cover fixing screws (3) and (6), and the
preload spring plug (4). Slacken and remove the
plug; discard the O-ring (7). Remove the preload
spring (9) and remove the shim (8) from the plug.
Note the position of the air inlet connection (2) on
the boost control cover relative to the fuel backleak
return connection (1). Slacken and remove the two
cover fixing screws and their flat washers.
4
7
8
9
5
2
A1475
1
A1456
WARNING
The cover (5) will be lifted up under the action of the
diaphragm return spring as the screws are
loosened.
Note:
1 Do not dismantle the diaphragm assembly. If any
part of it is worn or damaged, the whole assembly
must be replaced.
Note:
2 The spring (2), spring seat (3), and spindle (4),
cannot be lifted out at this stage, as they are
retained by the cam follower and a circlip within the
governor cover.
d) Removing the governor cover
Push the exhaust brake shaft (2) and the throttle
shaft (3) down into the cover. Remove the four Torx
screws at (1), (4), (5), and (6).
Lift and rotate the cover off towards the torque
trimmer side, and pull the throttle shaft (3) out of its
bore. Remove and discard the "trapped" O-ring (7)
from the sealing face of the cover. Remove the
exhaust brake shaft (2) and discard its O-ring.
A1477
2
3
A1048
A1260
Delphi
Note:
If the control cover is lifted too far, the carriage
angle plate may become distorted; if resistance is
felt, lower it and move it further away, then lift it
again.
A1476
2-14
DISMANTLING II
DISMANTLING
e) Removing the governor main spring
Slide the cover away (in the direction of the torque
trimmer) until the angle plate (1) is no longer in the
recess (2). Remove the governor main spring (3)
from the throttle shaft link, noting the hole into
which it is fitted. Lift off the control cover and
discard the trapped O-ring (4). Discard the small
transfer gallery O-ring that is in the housing recess
below the small hole (5).
1
4
A1470
A1471
1
2
Delphi
2-15
A1472
II DISMANTLING
DISMANTLING
E) Governor cover fitted with Electronic Actuator
a.
b.
2.3
DT237/2 fig 1
1 2 3 4
7 8
9 10
Note:
Early pumps had a 3 hole link plate. A note must be made
of which hole is used to locate the spring. The
appropriate Service Test Plan will confirm the correct
hole to use.
Delphi
A958
2-16
DISMANTLING II
DISMANTLING
2.4
WARNING
Cover the pin and spring with a non-fluffy cloth in
case it is released prematurely, allowing it to be
ejected at speed.
2
A950
Note:
If it is difficult to grip the pin, carefully slacken the
spring stop screw (1) and allow the stop to swing
away from the pin, again taking care to avoid rapid
ejection of the pin.
Note:
Screws 3 & 8 are of different lengths.
9
5
7
Delphi
A1049
2-17
II DISMANTLING
DISMANTLING
2.4.3 Dismantling the governor control arm assembly
Unscrew and remove the linkage lock nut (1) and
adjusting nut (2). Remove the pivot ball washer (3).
Withdraw the linkage hook (9), with the fibre washer
(4) and spring (6) from the governor control arm (5);
remove the spring retainer (7), and metering valve
assembly (8) from the linkage hook.
A961
2.4.4 Dismantling the governor control plate assembly for torque trimmer variant
A) Removing the delivery adjusting screw
To remove the adjustment screw (1) from the scroll
link carriage assembly, use either the special
adjustment tool or an Allen screw with a suitably
sized hexagon socket. Rotate the screw anticlockwise to disengage it from the scroll link (4).
Discard the retaining clip (2).
Lift the screw to disengage the retaining clip from
the angle plate (3).
2
3
1
A1492
2
1
A493a
Delphi
2-18
DISMANTLING II
DISMANTLING
2.5
High Pressure Outlets Assembly, Electric Shut-off Solenoid (ESOS) & Transfer Pump
2
5
4
A962
7
8
A985b
1
7
EVD017
3
Delphi
2-19
A963
II DISMANTLING
DISMANTLING
B) Dismantling the end plate assembly
a) Viscosity compensating design
Remove the fuel inlet connection (1) and discard the
O-ring (2). Tip out the filter (3). Remove and discard
the adjuster (4) and the O-ring (on current designs).
Screw the extractor (13) into the regulating sleeve
(6) and pull the sleeve out of the end plate.
Remove the piston retainer (10), the piston (8), and
the regulating spring (5); remove and discard the Oring (9) from the groove (7). Tip out the sleeve
retaining spring (11) and the spring seat washer
(12).
Note:
The piston, sleeve and adjuster are matched and are
not interchangeable.
13
1
2
3
5
6
A1302
14
9
7
8
10
A1008
11
12
A1018
Delphi
A493
2-20
DISMANTLING II
DISMANTLING
2.6
3
4
A1258
2.7
A1284
JPT
Transfer Pump
A964
A965
Note:
Care must be taken to avoid damage to the blade
rubbing faces during storage or assembly.
Delphi
2-21
II DISMANTLING
DISMANTLING
2.8
Advance Device
DP200 utilises a number of different advance devices. They fall into two main categories;
a.
Single piston design.
Direct actuation of the cam-ring by an advance piston operated by transfer pressure and controlled by a
combination of spring and cambox pressure.
b.
Servo piston design.
Indirect actuation of the cam-ring by an advance piston via a servo valve operated by transfer pressure and
controlled by a combination of spring and cambox pressure.
Each of these two types may be fitted with cold start timing retard with or without a wax motor mechanism.
A1485
The ball valve seat is a press-fit in the CA housing. Do not attempt to remove the ball valve seat, ball, or spring.
If there is a problem with the assembly, it must be replaced.
Slacken and remove the two Allen screws (1) and (2).
B) Removing the CA assembly
Remove the CA body (1); discard the O-ring (2).
Remove the start-retard spring from the advance
housing, if fitted (not shown).
Delphi
A1486
2-22
DISMANTLING II
DISMANTLING
C) Dismantling of the CA piston assembly
Remove the piston assembly from within the CA
housing (1). Grip the piston (2) lightly in a vice fitted
with soft jaws. With a suitable screwdriver, slacken
and remove the screw (9) and remove the phase
plate (8), stop plug (7), stop tube (6), outer spring
(5), inner spring (4), and shims (3). Remove the
piston from the vice.
7
6
5
4
3
2
WARNING
Caution: The screw will be under considerable
tension from the springs.
A1487
Note:
Early pumps may be fitted with pistons that have
small "flats" to assist with clamping in the jaws of a
vice.
A1485
Delphi
The ball valve seat is a press-fit in the CA housing. Do not attempt to remove the ball valve seat, ball, or spring.
If there is a problem with the assembly, it must be replaced.
Slacken and remove the Allen screws (1) and (2).
2-23
II DISMANTLING
DISMANTLING
B) Removing the CA assembly
Remove the CA body (302); discard the O-ring (308).
C) Removing the advance device
DT167 fig 1
Delphi
2-24
DISMANTLING II
DISMANTLING
D) Dismantling the Servo Valve Assembly
Delphi
2-25
EVD010
II DISMANTLING
DISMANTLING
2.8.3 Servo piston design with 4 bolt cold advance
A) Removing the wax motor
Align the pump to place its axis horizontal with the
advance device uppermost. As the CA device may
be fitted to the auto advance housing with the wax
motor facing in one of two positions, note the
direction in which it is fitted.
Slacken and remove any cable retaining nuts and
washers.
Slacken and remove the wax motor (307); discard
the O-ring (306).
Remove the cam (410), spring (409) and spring seat
(408) from within the CA housing (302).
Slacken and remove the four Allen screws (301).
DT157 fig 1
Delphi
2-26
DISMANTLING II
DISMANTLING
2.8.4 Single piston design without cold advance
A) Removing the spring cap
Remove the spring cap advance gauge access
screw (1) and discard the sealing washer (2).
Unscrew the advance piston spring cap (3); remove
and discard O-ring (4). Remove the main advance
springs (6) and (7), and shim(s) (5). Unscrew the
piston plug (12); remove and discard the O-ring (11).
Remove the spring plate (8), circlip (9), and the
retard spring (10) (if fitted).
10
11
A1250
7
12
Note:
The start retard spring (10) and the end plate
regulating sleeve retaining spring have similar
dimensions, but their ratings are different. As this
may cause confusion during reassembly, the
springs must be separately identified.
1 2
A1009
1
2
10
3
4
9
8
5
6
A1294
Delphi
A967
2-27
II DISMANTLING
DISMANTLING
2.9
Removing The Head Locking Screws And Releasing The Hydraulic Head
A1251
8
7
4
3
1
A1011b
Delphi
DT228 fig 4
2-28
DISMANTLING II
DISMANTLING
2.9.3 Removing and dismantling the latch valve
a) Lock nut adjuster type
Slacken, but do not remove, the lock-nut (2);
slacken, but do not remove the sleeve (4). Slacken
the valve body (8) and remove the valve assembly.
Note:
The inner O-ring (10) may remain within the pump
housing
Remove and discard the O-rings (9) and (10).
Discard the washer (11) and filter in the end of the
valve body (if fitted).
Remove the adjuster (1) from the sleeve (4) and
discard the seal (3). Remove the sleeve from the
body (8) and tip out the spring (6) and valve (7).
b) Cap type
Remove the cap (a) and discard the seal (b).
Remove the sleeve from the body (8) and tip out the
spring (6) and valve (7).
Remove and discard the O-rings (9) and (10).
Discard the washer (11) and filter in the end of the
valve body (if fitted).
10
11
A1518
11
10
b
6
DT228 fig 3
Delphi
A1495
2-29
II DISMANTLING
DISMANTLING
B) Removing the hydraulic head
Realign the pump with its axis vertical, as shown,
and lift the head out of the pump housing; carefully
hold the plungers within the rotor and invert the
hydraulic head.
Note:
The rear scroll plate may adhere to the face of the
hydraulic head, if it does, remove it.
2
1
2.10
A1496
Drive Shaft
A970
Delphi
A1497
2-30
DISMANTLING II
DISMANTLING
B) Removing the rollers and shoes
Remove the rollers and shoes, keeping them in their
matched pairs.
Note:
1 The roller shoe (1) in the rotor tang drive slot (2)
is longer than the others.
Note:
2 On some later designs, all 4 shoes are the same
length.
2
A1498
3
2
1
5
Delphi
A1499
2-31
II DISMANTLING
DISMANTLING
E) Removing the support blocks
Note:
There is no support block in the groove into which
the hydraulic head rotor tang fits.
Invert the drive shaft and grip it very lightly, across
two diametrically opposite roller shoe gaps, in a
vice fitted with soft jaws. Use an extended Torx
screw adaptor to slacken the three screws (1), (2),
and (3). Remove the screws, their flat washers, and
the support blocks.
A1500
A1004
1
2
3
4
A972
Delphi
5
6
7
8
2-32
DISMANTLING II
DISMANTLING
2.11
2
1
3
4
A1290
5
2
4
6
A975a
A1304
Delphi
A1254
2-33
II DISMANTLING
DISMANTLING
Remove the rear scroll plate (4) (still within the
housing), cam ring (3), front scroll plate (2), inner
bearing (1), and the governor weight cage assembly
(not shown) complete with the weights, thrust
sleeve and thrust washer.
Note:
1 Some basic designs of pump will not be fitted with
a bearing or scroll plates.
After removal of the cam ring, remove the circlip
fitted in the pump housing before removal of the
weight cage.
A1501b
Note:
2 Some pumps are fitted with reverse thrust split
and return rings.
EVD01
2
3
Delphi
A977
2-34
DISMANTLING II
DISMANTLING
2.11.6 Removing the drive shaft seal/s
Delphi
Remove the pump housing from the Hydraclamp and place it on the workbench with the drive shaft seals
uppermost.
Using the special seal removal tool, carefully lever out the seal (1) noting the way round the seal is fitted into the
housing.
If two seals are fitted, remove the circlip spacer and using the special seal removal tool, carefully lever out the
seal noting the way round the seal is fitted into the housing.
2-35
II DISMANTLING
Delphi
DISMANTLING
2-36
Cleaning
If water contamination is suspected, carry out an initial examination of all internal components before attempting any
further cleaning. Clean out all passageways in the head and rotor by flushing out with clean test oil.
Also inspect for unusual marking, deposits, odour, seal swelling in the housing, in which case degraded RME fuels may
be a factor.
3.2
GeneraL
Delphi
All components must be checked for corrosion, wear, or damage. Under service workshop conditions it is not
feasible to test individual parts or sub-assemblies to determine their suitability for further service. Close
examination of the areas vulnerable to damage, and interpretation of the results of tests prior to dismantling,
should indicate the condition of parts.
a.
Corrosion
Check for signs of corrosion or water ingress (rust or staining) damage to machined surfaces. These include
the pump housing, drive shaft, hydraulic head bore, metering valve and bore cam ring, scroll plates, cheek
plates end plate and auto-advance device mounting face.
b.
Wear
Inspect drive shaft splines and associated parts for wear or damage. If excessive end-float or radial play was
detected prior to pump strip-down, examine the drive shaft thrust washer and housing bearing thrust face,
governor backplate and thrust face of drive shaft, and governor drive splines, for wear.
c.
Damage
Inspect all parts for damage or bending due to abuse, especially external levers and controls.
3-37
3.3
Details
3-38
Delphi
3.3.10 Springs
Look for distorted or fractured springs. Very carefully examine the areas of contact with adjoining components
(spring pegs, throttle shaft links etc). Check that all springs specified in the Parts List for the pump are present.
3.3.12 Linkages
Inspect all mechanical governor linkages, shafts, pivot pins and arms for wear, cracks or scoring of their mating
surfaces.
Delphi
3-39
3.3.19 Orifices
Examine all orifices for blockage and carefully clear any obstruction with dry compressed air.
Note:
Early pumps may be fitted with pistons that have small flats to assist with clamping in the jaws of a vice.
3-40
Delphi
If a pre-dismantling test of the injection pump indicates that the CA device is not operating correctly, carry out
the following test on the wax motor, out of the CA housing (no test is necessary if operation is according to the
Test Plan).
The motor may be tested for correct function by connecting it either to a fully charged 12 V battery, or to a stabilised
DC power supply set to 12.0 V and capable of supplying at least 3 A for at least 5 minutes. The test data refers to
12 V operation only - currents and times are significantly different for operation at 24 V. The motor is not polarity
sensitive.
Before testing, place the motor on a flat surface, with the spindle downwards, and press lightly on the motor for
about 15 seconds to ensure that the spindle is in its fully retracted position.
Clamp the motor, with its spindle facing upwards lightly in a vice fitted with soft jaws.
A1488
Delphi
WARNING
When the motor is switched off after testing, and it is not installed in the CA device (with spring pressure bearing
upon the plunger), a light pressure, no more than 20 N (4.5 lbf, 2kgf), must be maintained on the plunger to ensure
that it returns fully to its rest position, until it has cooled down to ambient temperature (usually after about 3
minutes). Failure to follow this instruction could lead to the ingress of air into the motor, with subsequent failure
to operate correctly.
3-41
Delphi
3-42
REASSEMBLY IV
REASSEMBLY
4.1
Preparation
Before using thread-locking compound, if specified, ensure that the mating surfaces are completely oil-free and dry.
When reassembling pumps, it is important to use the correct overhaul kit. The relevant kit numbers can be found in the
Service Parts List.
Lightly lubricate all flexible seals and O-rings with clean test oil before fitment to their respective components. Always
use the correct protection cap when fitting new O-rings. Apply the specified grease to the drive shaft seal and the throttle
and exhaust brake shafts before assembly in their respective positions. Dip all internal components in clean test oil before
assembly.
Refer to the relevant Test Plan for details of special build items and any initial setting instructions.
Refer to Section 6 for all special tools and torque values.
The direction of rotation of the pump, as shown on the nameplate, is as viewed from the drive end.
4.2
Note:
1 Check the direction of the arrow on the distributor rotor head agrees with that of the arrow on the pump nameplate.
Note:
2 The plungers in four-plunger rotors must be fitted with the longer plungers opposite to each other and in line with the
distributor port in the rotor.
1
2
3
4
A979
Thoroughly degrease both the plug and rotor threads and smear the plug thread with a small amount of 'Loctite'
638. Refit the plug, using a new sealing washer, and tighten it to the specified torque.
Lubricate the rotor with clean test oil (but do not allow any oil in the vicinity of the plug) and refit the rotor to the
hydraulic head. Place the hydraulic head assembly in a clean environment until the recommended 'Locktite' curing
time has elapsed (typically, 6 hours at room temperature).
Delphi
Note:
Do not attempt to accelerate the curing process by heating the hydraulic head assembly.
4-43
IV REASSEMBLY
REASSEMBLY
When the curing time has passed, store the head in a covered container filled with clean test oil until it is required
for reassembly.
A975
WARNING
If the rotor tends to jam as it enters the hydraulic head bore, lift it out and try again. Do not use even light force
to fit the rotor.
Refit the transfer pump rotor but do not tighten.
Place the head on the bench and remove the plunger-retaining clips. Place the two dowel pins (2) and (4) through
their holes in the rotor head and into the lower cheek plate. Fit the upper cheek plate (3), aligning the slots and
dowel pin holes with those in the rotor head; push the cheek plate fully onto the dowel pins.
As the plungers are no longer retained by the clips, either proceed immediately to next section, or insert cork or
rubber plugs to prevent loss of the plungers.
b) Drive plate
Place the drive plate onto the rotor head, slotted
face downwards. Align the two screw holes.
1
3
2
WARNING
The two holes are not diametrically opposite to each
other; there is a very small angular difference
between them, as shown at (1) in the incorrectlyassembled example.
5
6
A989
A1291
Delphi
Fit the two screws (3) and (5) and fit the specified
tool (2) into the drive plate (6). Use a bi-hexagon
socket (4) and torque wrench to tighten the screws
progressively and evenly up to the specified torque.
4-44
REASSEMBLY IV
REASSEMBLY
c) Fitting the roller and shoes
Fit the shoes (1) and rollers (2) to the slots in the
rotor head and cheek plates.
Note:
The rollers and shoes in a pump are a matched set
and must be kept together. However, any roller/
shoe combination may be fitted into any rotor slot.
A1252
Note:
In addition to matching the scrolls, correct
assembly of the bottom adjusting plate may be
confirmed by observing that the chamfered edges
(2) of the scrolls should face the top adjusting plate.
A1512a
1
8
5
4
Delphi
A1512b
4-45
IV REASSEMBLY
REASSEMBLY
d) Alignment of the drive plate
In order to ensure correct alignment of the rotor
delivery port with the drive shaft keyway, the two
holes for the drive plate screws in the drive plate
and in the rotor are not on the same transverse
centreline. If necessary, turn the drive plate until the
holes are aligned.
To illustrate the difference, the drive plate is shown
deliberately incorrectly assembled.
Note:
The inner face of the driveplate has a machined
groove (see illus. A1512c item (3) over page) to
ensure that the "ears" of the roller shoes are not
trapped when the drive plate screws are tightened.
e) Fitting the drive plate
Fit the drive plate, aligning the screw holes correctly
with those in the rotor head.
Fit the drive plate screws, leaving them finger-tight.
Set the adjusting plates so that the slot (1) in the top
plate is approximately in the centre of the gap (2) in
the drive plate. The final position of the adjusting
plates will be set during testing.
A989
Delphi
A1512c
4-46
REASSEMBLY IV
REASSEMBLY
4.3
Drive Shaft
Note:
1 Only use the minimum necessary clamping force.
DO NOT clamp on the polished inner bearing
surface (4).
A1500
Note:
2 Later designs incorporate the lubrication groves in the drive shaft.
It is imperative that combinations of early and late designs do not result in a build where there is no
lubrication groove present.
A groove in both the shoe and drive shaft is permissible.
B) Fitting the shoe plate and roller catch plate
Remove the shaft from the vice and invert it. Fit a
small "tommy" bar (6) through the transverse hole
in the shaft; mount the shaft again in the vice fitted
with soft jaws, in such a position that the bar will
prevent rotation of the shaft as the catch plate
screws are tightened. Do not clamp the shaft on the
polished inner bearing surface (5), but clamp it
across the smaller diameter, very lightly.
Fit the shoe plate (1) and the roller catch plate (3)
and secure them with the four Torx screws (2) and
(4), tightened to the specified torque.
Delphi
Note:
No washers are fitted under the screw heads.
4-47
3
2
4
5
1
6
A1499
IV REASSEMBLY
REASSEMBLY
C) Fitting the rollers and shoes
Fit the rollers and shoes to the drive shaft; the
longest shoe (1) is fitted to the slot (2) which does
not have a support block. Ensure that the lubrication
groove (3) in one end of the long shoe faces towards
the drive end of the shaft.
2
1
Note:
Changes in the design of the shoe and drive shaft
have resulted in the lubrication groove being
removed from the shoe. It is now in the drive shaft.
Mixing of old and new designed is allowed. Having
a groove in both parts is permissible, but having no
grooves will result in premature failure.
A1498
A1503
EVD01
A1502
Delphi
A1504
4-48
REASSEMBLY IV
REASSEMBLY
F) Fitting the O-ring and rear scroll plate
Place the Hydraclamp plate so that it is horizontal.
Place the assembled hydraulic head on the plate,
with the high pressure outlets facing downwards.
Dip a new O-ring in clean test oil and fit it into the
groove (3) in the hydraulic head.
Place one of the scroll plates (1) in the recess in the
hydraulic head (the "rear" scroll plate position.
Ensure that its arrow is facing in the correct
direction of rotation (as indicated on the pump
nameplate) and the slot (2) is centralised in the gap
in the hydraulic head, as shown.
A1505
G) Fitting the cam ring, front scroll plate and inner bearing
Place the cam ring (1) on the hydraulic head, with
its arrow facing in the direction of pump rotation,
and with the cam advance screw hole (2) aligned
with the head locating fitting hole (3).
Place the other scroll plate on the cam (in the "front"
position), also with its arrow pointing in the
direction of rotation, and with the slot (4) aligned
with the metering valve bore (9). Place the inner
bearing (5) over the front scroll plate, with its
shallow recess facing downwards and the wide slot
(6) centralised in line with the metering valve bore.
Ensure that both scroll plate slots (4) and (8) are
aligned with each other and with the metering valve
bore.
1
4
7
8
9
A1506
A1507
Delphi
Note:
The small blind hole (7) accommodates the extended shank of one of the governor plate securing screws to prevent
rotation of the inner bearing.
4-49
IV REASSEMBLY
REASSEMBLY
H) Fitting the drive shaft assembly
Hold the drive shaft assembly together and place it
into the assembled components on the hydraulic
head, rotating the shaft as necessary to align the
slot with the hydraulic head rotor "tang".
Rotate the shaft so that a gap (1) between any two
adjacent weight "pockets" is aligned with the
metering valve bore (2) to ensure that the head of
the advance housing stud will pass between the two
opposite pockets when the pump housing is fitted.
Note:
With some pump specifications, the assembled
drive shaft may not pass easily through the inner
bearing without the risk of damage to the bearing
surface. In those cases assemble the inner bearing
to the drive shaft from the drive end before fitting
the governor weight cage assembly.
A1508
A1509
2
3
Delphi
A1515
4-50
REASSEMBLY IV
REASSEMBLY
B) Assembling the weight cage components
Place the governor thrust washer (4) on to the "toes" (2) of the weights, followed by the thrust sleeve (1).
C) Fitting the drive shaft assembly
Place the specified seal protection cap over the drive shaft thread.
Lower the drive shaft assembly into the pump housing and carefully push it fully downwards.
D) Fitting the timing circlip (if specified)
Fit the circlip into the pump housing making sure it
locates against the shoulder in the housing with the
ears placed centrally in the housing inspection
cover aperture.
Note:
One ear of the circlip is flat, the other rounded. The
flat ear is to be positioned so that when the pump
drive shaft rotates, the drive plate timing letters turn
'towards' the flat ear and not away from it.
A1781
A1495
4.4
Securing The Hydraulic Head And Checking Drive Shaft End Float And Radial Play
Delphi
4-51
IV REASSEMBLY
REASSEMBLY
If a second drive shaft seal is required fit the circlip, if specified, into the groove in the pump housing seal recess.
The circlip must be so positioned within the groove so as not to impede fuel flow through the tell tale hole, if a
seal fails.
Repeat the process for fitting the first seal.
A970
A952
Delphi
4-52
REASSEMBLY IV
REASSEMBLY
4.4.5 Checking drive shaft radial play
Note:
If the original housing and shaft are to be used and
radial play at the bearing was found to be within the
limits stated below, it should not be necessary to
measure radial play at this stage. If either item has
been replaced, radial play must be measured.
With the pump and dial gauge (1) mounted rigidly
relative to each other (e.g. on a plate fitted to the
Hydraclamp), adjust the gauge pin to bear against
the parallel section (4) of the drive shaft. Push the
shaft radially towards the gauge and set the gauge
to zero. Pull the shaft radially to the opposite
extreme and record the gauge movement.
Repeat the readings with the gauge repositioned as
shown at (2) and (3). Do not rotate the drive shaft.
Reject the housing if either the maximum play or
the difference between the measurements exceed
the figures below.
120
4
3
Drive type
Max. play
Max. Difference
Belt
0.22 mm
0.1 mm
Gear or hub
0.27 mm
0.2 mm
A1259
Note:
During this operation, the cam ring usually
becomes jammed in the housing. Using a rubber or
hide mallet, lightly tap the cam screw axially to free
the cam ring.
Delphi
A997
4-53
IV REASSEMBLY
REASSEMBLY
4.4.7 Fitting the head locking screws, light load advance valve and latch valves
A) Head locking screws
Fit a new filter, if specified, into the open end of the
screw. Dip a new O-ring in clean test oil and using
the appropriate seal protection sleeve, slide the Oring into the groove of the screw body.
Fit the locking screw into the hydraulic headlocating hole as noted during dismantling.
Do not tighten until all three head bolts are in
position.
EVD09
3
1
A1011b
b) Cap type
DT228 fig 4
Delphi
Fit the ball (220) and spring (221) into the valve body
(219).
Using the appropriate seal protection sleeve, fit a
new O-ring (277) to the adjusting screw (222).
Screw the adjuster into the valve body (219).
Fit the assembly into the hydraulic head-locating
hole as noted during dismantling.
Using the appropriate seal protection sleeve, fit new
O rings (217) and (218)
Do not tighten until all three head bolts are in
position.
The sealing cap (278) is not to be fitted until the
pump has been set on the test bench.
4-54
REASSEMBLY IV
REASSEMBLY
C) Latch valve
a) Lock nut adjuster type
Fit new O-rings (9) and (10) to the valve body (8),
and fit a new O-ring (5) to the adjuster body (4),
using the appropriate seal protection sleeves. Fit
the valve (7) into the body, followed by the spring
(6); fit the adjuster (4) into the body.
Fit the adjusting screw (1) into the adjuster (4),
screwing it in by approximately four turns. Fit a new
seal (3) to the screw, followed by the lock-nut (2).
Fit a new seal (11) to the latch valve assembly; fit
the assembly through the pump housing and into
the hydraulic head.
The positions of the adjusting screw and adjuster
will be set during testing.
b) Cap type
Using the appropriate seal protection sleeve, fit new
O-rings to the valve body.
Fit the valve (1) into the body followed by the spring
(2).
Fit a new O-ring (3) using the appropriate seal
protection sleeve onto the cap (4) and screw it into
the valve body.
Fit the assembly into the hydraulic head-locating
hole as noted during dismantling.
Do not tighten until all three head bolts are in
position.
4.5
10
11
A1518
DT228 fig 3
Advance Device
Delphi
DP200 uses a number of different advance devices. They will fall into two main categories:
a.
Single piston design
Direct actuation of the cam-ring by an advance piston operated by transfer pressure and controlled by a
combination of spring and cambox pressure.
b.
Servo piston design
Indirect actuation of the cam-ring by an advance piston via a servo valve operated by transfer pressure and
controlled by a combination of spring and cambox pressure.
Each of these two types may be fitted with cold start timing retard with or without a wax motor mechanism.
4-55
IV REASSEMBLY
REASSEMBLY
4.5.1 Single piston design
A) Fit the circlip (1) into the groove in the advance housing bore.
If not already in position, fit the advance piston (2)
into the advance housing (5) with the flat end of the
piston towards the transfer pressure port in the
housing (visible just at the inner end of the internal
thread). Align the transverse hole in the piston with
the opening in the advance housing.
Fit the lock-off ball (8), if specified, into the deeper
of the two recesses in the head fitting (6) or the
damper, whichever is specified. Fit the spring clip
(7), if specified, over the ball, with its bent end in the
orifice countersink. Do not yet fit new O-rings or the
split backing ring.
Push the head locating fitting up through the larger
of the two holes in the advance housing. Place a
new gasket (3) onto the advance housing, with the
straight edge (4) adjacent to the pump housing stud
hole. Ensure that the shoulder of the head locating
fitting will not cut the gasket when the fitting is
tightened.
4
3
2
1
10
9
7
8
A1013
Place the advance housing over the stud and the cam advance screw, and onto the pump housing, ensuring that
the gasket is correctly located over the housing stud shoulder.
Engage the fitting with the thread in the hydraulic head and screw it fully in. If necessary adjust the position of
the hydraulic head.
Centralisation of the hydraulic head is necessary to avoid damage to the O-rings as the head fixings are screwed
in.
Fit a new sealing washer (10) to the stud, followed by the dome nut (9).
B) Tightening the head fittings
When the head is centralised, remove the head
locating fitting (5) or damper. Dip new O-ring (4) in
clean test oil; use the appropriate seal protection
sleeve and fit one O-ring to the groove (6) and the
other to groove (7). If present, fit the split nylon
backing ring (3) above the O-ring in groove (6).
Progressively tighten in the following order, light
load advance valve (2), head locating fitting (8),
head locking bolt or latch valve (1), to their specified
torques. When all screws are tightened, check that
the advance piston moves freely within the advance
housing.
3
2
4
5
6
7
8
A1295
Delphi
A1014
4-56
REASSEMBLY IV
REASSEMBLY
C) Fitting the Pressure end cap
Using the appropriate seal protection cap, dip a new
O-ring (1) in clean test oil and fit it to the end plug
(2), fit the plug to the end of the advance housing at
which the transfer pressure port is visible and
tighten it to the specified torque.
2
1
A1015
9
8
7
Note:
1 The spring plate must be fitted even if no start
retard spring is specified.
6
5
Note:
2 It is possible to confuse the start retard spring with
the spring which holds the transfer pressure
regulating sleeve in position in the end plate.
Carefully check the springs before fitment, having
identified them during dismantling, as advised.
Delphi
Using the appropriate seal protection cap fit the Oring (4) to the spring cap (3). Place the specified
number of shims (5) in the cap, followed by the
advance spring(s) (6) and (7). Screw the cap
assembly into the advance housing and tighten it to
the specified torque. Fit the cap plug (1) with a new
washer (2) and assemble it to the cap, tighten the
plug to the specified torque.
4-57
4
3
2
1
A1016
IV REASSEMBLY
REASSEMBLY
4.5.2 Servo piston designs
A) Fitted with cold advance at the spring end
a) Assembling the Servo Valve
Carefully clamp the advance piston in a vice fitted
with soft jaws. Never clamp tight enough to cause
distortion or surface damage.
Fit the servo valve (5) followed by the retard spring
(2), if fitted, ensuring that it fits over the spigot on
the servo piston (6). Insert the piston rod (3) into the
advance piston (1). Fit the washer (7) and a new
retaining circlip (4).
2
3
5
6
4
7
EVD011
EVD010
Thickness
7185-436A
0.76 mm
7185-436B
1.52 mm
7185-436C
2.28 mm
7185-436D
3.04 mm
Delphi
4-58
REASSEMBLY IV
REASSEMBLY
c) Fitting the advance device assembly to the
pump housing
Fit the lock-off ball, if specified, into the deeper of
the two recesses in the head fitting (4). Do not yet
fit new O-rings.
Push the head locating fitting up through the larger
of the two holes in the advance housing. Place a
new gasket (1) onto the advance housing, with the
straight edge (2) adjacent to the pump housing stud
hole. Ensure that the shoulder of the head locating
fitting will not cut the gasket when the fitting is
tightened.
Place the advance housing over the stud and the
cam advance screw, and onto the pump housing,
ensuring that the gasket is correctly located over the
housing stud shoulder.
4
3
2
1
10
9
7
8
A1013
Engage the fitting with the thread in the hydraulic head and screw it fully in. If necessary adjust the position of
the hydraulic head.
Centralisation of the hydraulic head is necessary to avoid damage to the O-rings as the head fixings are screwed
in.
Fit a new sealing washer (6) to the stud, followed by the dome nut (5).
d) Tightening the head fixings
When the head is centralised, remove the head
locating fitting (5) or damper. Dip new O-ring (4) in
clean test oil; use the appropriate seal protection
sleeve and fit one O-ring to the groove (6) and the
other to groove (7). Fit the split nylon backing ring
(3) above the O-ring in groove (6).
Progressively tighten in the following order, LLA
valve (2), head locating fitting (3), head locking bolt
or latch valve (1) to their specified torques. When all
screws are tightened, check that the advance piston
moves freely within the advance housing.
3
2
4
5
6
7
8
A1014
A1295
Delphi
4-59
IV REASSEMBLY
REASSEMBLY
b) Assembling the advance device
Secure the advance housing assembly in a manner
that prevents the piston bore from being distorted
and the open ends accessible for component
assembly.
Assemble the servo advance piston, advance spring
(328), shim (327) and spring cap (413) into the
advance housing. The spring cap is not to be torque
tightened as it will be subsequently removed.
The CA control pin (406) must be omitted at this
stage.
The advance piston must be orientated in the
advance housing with the cam ball screw hole
adjacent to the window. This will ensure the slot is
on the head locating fitting side. The advance piston
must be free to move within the housing by pushing
it from the open end and allowing the spring to
return it.
c) Fit the advance reference stop (405) over the
advance piston plug.
Fit a new O-ring (308) to the wax motor housing
(402) and position it, correctly orientated, over the
advance reference stop.
Care is to be taken to avoid altering the advance
piston orientation within the advance housing.
Tighten the four bolts (301) in a diagonal sequence,
progressively in 20 lbf.in. steps until the final torque
is obtained.
Check for free movement of the advance piston.
EVD02
Delphi
d) Remove the spring cap, shim, advance spring and withdraw the advance piston assembly.
Fit the CA control pin (406).
Replace the advance piston assembly, correctly orientated. Fit the advance spring, shim, and spring cap fitted
with a new O-ring (324). Tighten the spring cap to the correct torque value.
4-60
REASSEMBLY IV
REASSEMBLY
e) Fitting the advance device assembly to the
pump housing
Fit the lock-off ball, if specified, into the deeper of
the two recesses in the head fitting (4) or the
damper, whichever is specified. Do not yet fit new
O-rings.
Push the head locating fitting up through the larger
of the two holes in the advance housing. Place a
new gasket (1) onto the advance housing, with the
straight edge (2) adjacent to the pump housing stud
hole. Ensure that the shoulder of the head locating
fitting will not cut the gasket when the fitting is
tightened.
Place the advance housing over the stud and the
cam advance screw, and onto the pump housing,
ensuring that the gasket is correctly located over the
housing stud shoulder.
4
3
2
1
10
9
7
8
A1013
Engage the fitting with the thread in the hydraulic head and screw it fully in. If necessary adjust the position of
the hydraulic head.
Centralisation of the hydraulic head is necessary to avoid damage to the O-rings as the head fixings are screwed
in.
Fit a new sealing washer (6) to the stud, followed by the dome nut (5).
Delphi
4-61
3
2
4
5
6
7
8
A1014
A1295
IV REASSEMBLY
REASSEMBLY
4.5.3 2 Bolt Cold Advance fitted to single piston design
A) Assembly of the CA piston
Place the CA piston (2), with its open end
uppermost, in a vice fitted with soft jaws and grip
the piston lightly. Put the shim(s) (3), and the inner
and outer springs (4) and (5) into the piston,
followed by the stop tube (6), with its larger bore
facing upwards.
7
6
5
3
Note:
If either the CA housing or the advance housing has
been replaced (or both have been replaced), a new
stop plug (7) must be fitted.
2
1
A1487
Place the stop plug onto the piston with its shorter
taper facing the piston. Place the screw (9) in the
recessed end of the phase plate (8) and then put the
screw down through the spacer. Push the screw
down to compress the springs, fit it into the head of
the piston and tighten the screw to the specified
torque.
Place the piston assembly in the CA housing.
Note:
It is essential that only the specified torque is applied, and no more, to ensure that the screw remains tight in
service, but is not overstressed.
B) Fitment of the CA housing to the AA device
Dip a new O-ring (1) in clean test oil and fit it to the
groove in the CA housing (2). Fit the CA assembly
to the AA device and secure it with the two screws
(3) and (4) (without washers). Tighten the screws to
their specified torque.
A1485
Delphi
A1486
4-62
REASSEMBLY IV
REASSEMBLY
C) Fitting the wax motor
If a new CA housing (1) has been fitted, realign the
pump so that the wax motor aperture faces
upwards. Place the spring (2) into the housing,
followed by the ball valve (3). Place a new valve seat
(4) over the ball.
Use a suitable, clean, piece of hard plastic rod with
a flat and "square" end to centralise the seat over
the ball. Press carefully down on the rod and tap it
lightly to "start" the seat into the housing bore,
ensuring that no plastic chippings are released into
the device; do not press the seat fully down.
Remove the rod; dip a new O-ring (5) in clean test
oil and fit it into the recess in the CA housing.
Carefully screw the wax motor (6) into the housing,
ensuring that the valve seat is not displaced. Screw
the motor fully into position and tighten it to the
specified torque. This action will automatically
place the valve seat in the correct position.
1
2
3
5
6
A1489
Delphi
EVD03
4-63
IV REASSEMBLY
REASSEMBLY
4.5.4 4 Bolt Cold Advance fitted to servo piston design.
Fit the spring seat (408) flat face first into the wax
motor housing followed by the spring (409). Fit the
cam (410) stepped end first into and on to the end
of the spring ensuring that the groove along one
side of the cam locates with the guide pin in the wax
motor body.
Fit a new O-ring (306) into the recess in the CA
housing and screw the wax motor (307) into the
housing and tighten to the correct torque value.
EVD04
4.6
A1038
B) Internal recirculation
If fitted, fit the retaining spring (143) to the poppet
valve (142). Fit this assembly into the recess in the
hydraulic head barrel, curved surface face first.
Compress the spring carefully with the transfer
pump liner as it is fitted into the barrel of the
hydraulic head.
Delphi
EVD05
4-64
REASSEMBLY IV
REASSEMBLY
C) Assembling the transfer pump
Fit the transfer pump liner (1) into the head. The cutout (6) in one end face of the liner must be
positioned at the lowest point in the liner cavity i.e.
approximately the 6 o'clock position.
The locating groove (2) in the liner must be
positioned so that it will align with the spring dowel
pin in the face of the end plate. The position of that
pin is determined by the direction of rotation of the
pump.
Lubricate a new transfer pump sealing ring (4) with
clean test oil and fit it into its groove in the head. Fit
the split steel transfer pump blades (3) and the
springs (5).
A1017
2
3
4
A964
A965
12
1
11
10
9
8
A1018b
6
4 5
3
13
7
14
A1018b
Fit the spring seat washer (2) and the sleeve retaining spring (3) into the end plate. Ensure that the sleeve O-ring
is moistened with test oil and place the sleeve assembly, with the adjuster uppermost, into the end plate, followed
by the filter (10). Using the appropriate protection sleeve, fit a new O-ring (11) to the fuel inlet connection (12) and
screw the connection into the end plate ensuring that the slot (13) is aligned over the tangs (14) on the sleeve,
leaving it finger-tight.
Delphi
Note:
The fuel inlet connection may be specified with male or female threads for connection to the fuel supply pipe.
4-65
IV REASSEMBLY
REASSEMBLY
B) Non-viscosity compensating design
Insert the priming spring (288) into the bottom of
the end plate housing (150) ensuring the spring
remains correctly positioned and does not turn on
to its side. Fit a new sealing washer (248) to the
regulating sleeve (245) and insert the regulating
piston (287) into the sleeve. Place the sleeve and
piston into the end plate with the sleeve priming
port at the bottom.
Place a new filter (242) with its flange uppermost,
into the endplate and push it gently and firmly down
until squarely seated on the top of the sleeve.
Fit the regulating spring and peg (286) into the
sleeve, followed by the adjuster assembly (285)
with the screw adjuster socket head upper most and
the retaining spring (284). Fit a new O-ring (241) to
the fuel inlet connection (240) and screw into the
endplate assembly finger tight.
A493b
C) Sandwich plate
Fit the sandwich plate (1) into the recess in the
endplate (2), with either face outwards if new, but
with the same face towards the transfer rotor if the
original plate is to be used again. The spring dowel
pin will control the position of the groove in the
edge of the plate.
Note:
If the original sandwich plate shows any signs of
scoring, do not reverse it as this will cause internal
leaks and affect the efficiency of the transfer pump;
it must be replaced.
A1020
A1305a
Delphi
4-66
REASSEMBLY IV
REASSEMBLY
E) Transfer pressure accumulator
Dip new O-rings (1) and (2) in clean test oil and fit
them to the accumulator, using the specified seal
protection cap. Fit the accumulator to the endplate
and tighten it to the specified torque.
2
A1490
2
3
1
4
A1021
Delphi
Note:
On some applications, fitting of the support bracket may be deferred until after governor link length has been set.
The vernier gauge used for the setting procedure will foul on the bracket.
4-67
IV REASSEMBLY
REASSEMBLY
4.7
1
2
3
4
Note:
2 It is essential that the specified solenoid is fitted,
as there are versions available which operate in the
reverse sense to all others or require additional
wiring and resistors. Refer to the Despatch Number
and SIN DT294 for correct details.
A1035
A1292
6
A1022
Fit a new O-ring (2) to the solenoid body (1), using the appropriate seal protection sleeve. Place the plunger return
spring (3) into the solenoid, followed by the plunger (4), with the flexible seal end outwards. Later designs have
captive plungers. Screw the assembly into the hydraulic head and leave it finger tight.
If a blanking plug is specified, dip a new O-ring in clean test oil and fit it to the plug, using the appropriate seal
protection sleeve. Screw the plug into the hydraulic head, leaving it finger-tight.
The solenoid (or plug) will be removed for fitment of a pressure gauge during testing.
7
1
2
3
5
6
8
A1023
A) Pressurising valves
Delphi
Into each high pressure outlet of the hydraulic head fit a new sealing washer (1) then fit the pressurising valve (4)
leaving it finger-tight.
4-68
REASSEMBLY IV
REASSEMBLY
B) Delivery valves
Into each high pressure outlet of the hydraulic head
fit a new sealing washer (1), delivery valve body and
valve (2). Fit the spring peg (5), and spring (3) to a
new holder (6) and fit the holder to the outlet,
leaving it finger-tight.
Note:
1 The delivery valve holders must not be lubricated
before fitment to the hydraulic head.
Note:
2 Delivery valve holders which have been fitted to
a pump and tightened to the correct torque must
not be used again. They must be replaced.
2155
4.8
Delphi
4-69
9
10
11
12
A961
A1037
IV REASSEMBLY
REASSEMBLY
4.8.2 Fitting the governor assembly to the pump
Realign the Hydraclamp to place the pump axis
horizontal.
Align the governor thrust sleeve so that the "flats"
are horizontal and visible through the access hole
(1). Ensure that the locating hole in the spacer (6) is
aligned with the governor control plate fixing screw
hole at (2). Align the scroll plate slots (3) and (4) with
the metering valve bore (5).
Insert the metering valve (3) into its bore. Fit the
assembled control arm and control bracket (1) into
the pump to rest the control arm forks on the flats
on the thrust sleeve. Fit the arms of the scroll link
plate (2) into the scroll plate slots.
5
6
A1025b
4 5
A999
10
11
A998
A1049
A959
Delphi
CAUTION
There is a risk of the spring and pin being ejected at
high speed if grip is relaxed before the pin is
securely fitted into the spring stop.
4-70
REASSEMBLY IV
REASSEMBLY
4.8.4 Setting the governor link length
Push the governor control arm (3) fully towards the
hydraulic head and hold it in position. Using a
vernier caliper, measure the distance between the
circular upper part of the control bracket screw (4)
and the lower part of the metering valve roller (6),
below the link hook (5). Ensure that the caliper leg
does not enter the hook locating groove in the
metering valve roller.
Use the adjusting nut (2) to set the link length to the
dimension quoted in the Test Plan then hold the
adjusting nut with a spanner and tighten the
selflocking nut (1).
Re-check the link length with the caliper and
readjust it if necessary.
A1000
Note:
If fitting of the support bracket was earlier deferred, it should now be fitted.
1
5
Delphi
4-71
A1493b
IV REASSEMBLY
REASSEMBLY
B) Fitting the carriage return spring stop, the control plate screws and the maximum fuel screw
Place the spring stop (5) onto the governor control
plate (2) as shown and fit the small hexagon-headed
screw (6), leaving it finger tight. Fit the domeheaded screw (4), also leaving it finger tight.
3
4
5
Note:
No washers are fitted to these screws.
Fit new tab washers to the two remaining screws (1)
and (8) and fit the screws to the pump, ensuring that
the tabs are located correctly over the edge of the
control plate. Note that the screw (1) has a plain
extension to its shank that passes down through the
housing to locate the inner bearing.
Tighten all four screws to their specified torques
and bent the tabs to lock screws (1) and (8).
Check that the scroll link carriage moves smoothly.
6
8
A1492a
Fit a new retaining clip (9) to the fuel adjustment screw (3) and place the retaining clip into the angle plate with
its open side facing upwards as shown. Fit the threaded end of the screw to the scroll link plate at (7). Rotate the
adjustment screw either just enough to ensure that the thread has been engaged correctly, or to any other position
specified in the Test Plan.
Note:
If, during setting and testing, the position of the delivery screw has to be altered more than 10 times, the retaining
clip must be replaced to ensure satisfactory performance throughout the product life.
C) Fitting the governor linkage components
Place the linkage hook (7) over the metering valve
roller (8) with its open side positioned as shown. Fit
the large spring seat (6) to the hook, followed by the
spring (5) and the small spring seat (4). Fit the hook
through the small hole in the governor plate (9). Fit
the pivot ball washer (3) with its domed side
towards the governor plate, adjusting nut (2) and
self-locking nut (1) to the hook.
1 2 3 4
Delphi
A1491A
4-72
REASSEMBLY IV
REASSEMBLY
D) Fitting the scroll link plate return spring
Grip the spring pin (1) lightly with thin-nosed pliers
and place the spring (3) over the pin, holding the
spring in position. Place the plain end of the pin in
the relevant hole in the scroll link carriage (4) and
the shouldered end in the hole (2) in the spring stop.
Release the pin.
Check again that the scroll link carriage moves
smoothly and is returned fully to its rest position by
the spring.
A1491
Delphi
Adjust the nut (2) and lock nut (1) to obtain the
required dimension. Tighten the lock nut and check
that the setting has not been disturbed.
4-73
1 2
5
4
A1511
IV REASSEMBLY
REASSEMBLY
4.9
1
2
3
4
A1026
A1001
1 2 3 4
7 8
9 10
A958
Delphi
4-74
REASSEMBLY IV
REASSEMBLY
C) Fitting the governor cover
Moisten the shaft with clean test oil and push it up
through the hole (1) in the governor cover.
Press the shaft firmly into place. Place the cover
assembly onto the pump, locating the dowel pin (3),
if fitted, into the hole (2) in the cover, and secure the
cover with the four Torx screws, tightened to their
specified torque.
Note:
Some pumps use fitted Torx screws in place of the
dowel pin. Fit the four Torx screws leaving them
finger tight. Check that the throttle lever and
exhaust brake lever (if fitted) operate smoothly over
their full ranges before tightening the Torx screws
to their specified torque.
A1271
EVD015
B) Transfer tube
Lubricate two new O-rings (214) to the transfer tube
(275) fitted on the side of the pump body adjacent
to the hydraulic excess fuel chamber in the
governor cover.
Delphi
EVD016
4-75
IV REASSEMBLY
REASSEMBLY
C) Governor cover
At the later stage of assembly (depending on which
other features are fitted) when fitting the governor
cover, the hydraulic excess fuel device has to be
engaged with the scroll link assembly fork by
compressing the piston assembly and afterwards
checked for positive location.
Lower the governor cover onto the pump housing.
Press the excess fuel piston (813) in and locate the
head of the excess fuel pin (819) over the scroll link
assembly fork.
Temporarily secure the governor housing with two
diagonally opposite screws (508) finger tight. Insert
a suitable probe into the maximum fuel stop screw
hole to abut the scroll link plate assembly. Push the
probe in gently, but firmly. If the scroll link plate
assembly appears to be spring loaded, the excess
fuel pin is NOT correctly located and the procedure
for engaging the pin must be repeated.
EVD014
Delphi
A561
4-76
REASSEMBLY IV
REASSEMBLY
4.9.3 Governor cover fitted with boost control only
BOOST CONTROL DEVICE
Note:
The diaphragm assembly is a factory-assembled item.
If the boost control has been fully dismantled and removed from the governor control cover, carry out the following
reassembly and procedure.
A) Fitting the fuel adjustment screw
Use an Allen key (1) to screw the socket-headed fuel
adjustment screw (2) into the hexagon side (3) of
the diaphragm assembly, until the plain end
protrudes approximately 2mm above the bottom of
the spring cup (4) (not the bottom of the O-ring
recess). Fit a new O-ring (5) fully into the recess. The
adjustment screw will be finally set during testing.
A787
Delphi
4-77
6
3
2
1
5
4
A789
A795b
IV REASSEMBLY
REASSEMBLY
C) Fitting the diaphragm
Fit the specified thickness of spring shim (4) into the
boost control housing and over the stroke
adjustment screw body, followed by the spring (3).
Place the spring seat (2) into the spring cup of the
diaphragm assembly (1) and place the diaphragm
assembly over the spring, ensuring that the seat
remains in the cup.
A788
Note:
1 At this stage, the position of the boost pressure
inlet (1) is not important.
2
Note:
2 If the boost cover is a tamper resistant version,
then the use of an old cover allowing fitment of the
setting gauge will be required until after the stroke
and/or fuel settings have been made.
A791
Delphi
A796
4-78
REASSEMBLY IV
REASSEMBLY
b) Adjusting the stroke
If adjustment is required, remove the cover and dial
gauge and the inner components. Clockwise
rotation of the stroke adjustment screw (1) will
increase stroke. Replace the inner components,
cover, gauge and tool to check the stroke.
When the stroke has been set, remove the gauge
and tool from the cover and tighten the two housing
cover screws to their specified torques.
Note:
If the boost cover is a tamper resistant version, then
the use of an old cover allowing fitment of the
setting gauge will be required until after the stroke
and/or fuel settings have been made.
A797
F) Fitting the cover plug (non-tamper resistant version) and backleak connection
Using the specified protection sleeve fit a new Oring (2) to the closing plug (1). If specified, fit the
pre-load spring (4) into the cover and fit the shim (3)
to the plug. Fit the plug to the cover (5) and leave it
finger tight.
If a backleak pipe (11) is specified, fit a new rubber
olive (9) up to the swaged collar next to the tube nut
(10) on the backleak connection. Fit the connection
to the boost control body (8) and the governor
control cover, using new sealing washers (7) either
side of the banjo. Tighten the fuel return connection
(6) to its specified torque.
5
2
A1030a
6
7
11
12
A953c
9 8
A1296a
1
5
2
3
4
A1026
Delphi
4-79
A1001
IV REASSEMBLY
REASSEMBLY
H) Throttle shaft and governor main spring
Fit the specified seal protection sleeve over the
throttle shaft (9); slide two new O-rings into position
at (7) and (8).
Fit the idling spring (2) and the pivot ball washer (3)
(with its spherical face towards the governor arm
(4)) to the spring guide (1). Fit the guide through the
large hole in the governor arm. Hook one end of the
governor main spring (5) through the hole in the
end of the guide and the other end through the hole
in the throttle shaft link (6).
1 2 3 4
7 8
Note:
Early designs of throttle shafts had 3 holes. The hole
to be used will be stated in the Test Plan.
9 10
A958
A1271
Delphi
Note:
Some pumps use fitted Torx screws in place of the
dowel pin. Fit the four Torx screws leaving them
finger tight. Check that the throttle lever and
exhaust brake lever (if fitted) operate smoothly over
their full ranges before tightening the Torx screws
to their specified torque.
4-80
REASSEMBLY IV
REASSEMBLY
4.9.4 Governor covers fitted with torque control and torque control plus boost control
A) Torque control only
Fitting the pivot-plug.
If the cam follower and pivot-plug were removed
during Dismantling, dip a new O-ring (2) in clean
test oil and fit it to the pivot-plug (1), using the
appropriate seal protection cap. Fit the pivot-plug
to the governor control cover and screw it in fingertight. Fit washer (4) to the pivot plug spindle (5) then
the cam follower (6) retained by a new circlip (3) as
shown.
4
5
A1473
3
6
A1472
Delphi
4-81
1
2
3
7
4
5
A1478a
IV REASSEMBLY
REASSEMBLY
C) Fitting the spindle
Place the shim (4) into the recess in the boost
control housing, followed by the spring (3). Fit the
spring plate (2) to the spindle (1) and place the
spindle assembly through the spring and the
adjustment screw (5).
Do not yet fit the cam follower to the spindle.
1
2
3
4
5
A1480
Note:
1 At this stage, the position of the boost pressure
inlet is not important.
Note:
2 If the boost cover is a tamper resistant version,
then the use of an old cover allowing fitment of the
setting gauge will be required until after the stroke
and/or fuel settings have been made.
A791b
3
4
Delphi
A796
4-82
REASSEMBLY IV
REASSEMBLY
b) Adjusting the stroke
If adjustment is required, remove the cover and dial
gauge and the inner components. Clockwise
rotation of the stroke adjustment screw (1) will
increase stroke. Replace the inner components,
cover, gauge and tool to check the stroke.
When the stroke has been set, remove the gauge
tool and temporarily remove the cover.
A797
1
2
A1472
A1476
Delphi
Note:
Later designs of cover may either be plain or have a small central plug bolt and sealing washer.
4-83
5
6
A1475b
IV REASSEMBLY
REASSEMBLY
H) Cover locating dowels (if fitted)
Examine the governor cover locating dowel pin (1)
(if specified) and check that its protrusion above the
flat surface of the pump housing is within the limits
of dimension "Y" shown.
Note:
Later pumps may not be fitted with dowel pins, but
may be specified with "fitted" governor cover fixing
screws to ensure that the components in the
governor cover and in the governor assembly
remain in their correct relative positions.
Section X - X
1
Y = 4.25 0.25 mm
A1519
7
3
8 9
10 11
A1474
Delphi
Dip a new O-ring (2) into clean test oil and fit it to the threaded pre-load plug (1), using the appropriate seal
protection cap. Fit the plug to the governor control cover and screw it in to the position specified in the relevant
Test Plan. If no position is specified, leave the plug protruding from the cover by approximately 4 mm. The final
position of the plug will be set during Testing.
4-84
REASSEMBLY IV
REASSEMBLY
J) Exhaust brake/manual shut-off control shaft and "trapped" O-ring
Fill the grease groove (3) on the shaft with the
specified grease. Using the appropriate seal
protection cap fit two new O-rings (1) to the grooves
(2) and (4). Fit the shaft into its bore in the governor
cover, ensuring that it is pushed fully into position.
Rotate the shaft until the "upturn" on the lever is
against the flat inside face of the governor cover (6).
Fit a new large O-ring (5) to the groove in the
governor cover.
1
2
3
4
A1026
A1001
1 2 3 4
7 8
Note:
Early designs of throttle shafts had 3 holes. The hole
to be used will be stated in the Test Plan.
9 10
A958
Delphi
Note:
Some pumps use fitted Torx screws in place of the
dowel pin. Fit the four Torx screws leaving them
finger tight. Check that the throttle lever and
exhaust brake lever (if fitted) operate smoothly over
their full ranges before tightening the Torx screws
to their specified torque.
4-85
A1271
IV REASSEMBLY
REASSEMBLY
4.9.5 Governor covers fitted with electronic actuator
The only items of the actuator that may be replaced
are the electrical connector (2), the gasket (1) and
the screws (3). The O-rings (557) must be replaced
each time the actuator is removed from the
governor cover.
Delphi
EVD05
4-86
REASSEMBLY IV
REASSEMBLY
Dip two new O-rings (557) in clean test oil and locate
them on the actuator shaft, using the appropriate
protection tool.
Gently slide the shaft of the actuator through the
governor cover ensuring that the two O-rings are
not damaged.
Locate the two washers (566 & 567) and the lever
(568) onto the shaft.
If fitted carefully fit a new circlip (569) to the end of
the shaft ensuring that the circlip fits into the
groove.
Note:
The circlip can be very easily over-stressed when
fitting, DO NOT use excess force when fitting it to
the shaft.
On later design types, the circlip (569) is replaced
by a washer (570) and lock nut (571), both of which
should be replaced.
The actuator must be turned anti-clockwise (viewed
from on top of the cover) so that the position of the
lever (568) is clear of the metering valve when fitting
the governor cover to the housing.
Fit a new O-ring (564) to the lever (565). From inside
the governor cover, fit the lever into the bore of the
cover.
Reconnect the governor spring to the correct hole
in the throttle link lever and carefully lower the
cover onto the pump housing. Replace the cover
fixing screws and tighten them to their specified
torque.
Turn the actuator so that the tamper-evident
washers and screws can be fitted to the governor
cover; lightly tighten the screws.
Delphi
EVD06
4-87
IV REASSEMBLY
REASSEMBLY
A) Exhaust brake/manual shut-off control shaft and "trapped" O-ring
Fill the grease groove (3) on the shaft with the
specified grease. Using the appropriate seal
protection cap fit two new O-rings (1) to the grooves
(2) and (4). Fit the shaft into its bore in the governor
cover, ensuring that it is pushed fully into position.
Rotate the shaft until the "upturn" on the lever is
against the flat inside face of the governor cover (6).
Fit a new large O-ring (5) to the groove in the
governor cover.
1
2
3
4
A1026
A1001
1 2 3 4
7 8
Note:
Early designs of throttle shafts had 3 holes. The hole
to be used will be stated in the Test Plan.
9 10
A958
A1271
Delphi
4-88
REASSEMBLY IV
REASSEMBLY
4.10
Note:
1 If a boost-control device is fitted, different
backleak connections may be specified (1).
Note:
2 In addition, a vent screw may be specified and
fitted in position (2). If so, fit the screw and a new
washer to the vent screw body; fit the vent screw
assembly to the governor cover and tighten it to the
specified torque.
A956
2
3
4
A1273
5
6
7
A1272
3
4
1
5
6
7
8
9
10
Delphi
A1002a
4-89
A1006
IV REASSEMBLY
REASSEMBLY
C) Throttle lever ("break-back" type)
Fit the following components to the throttle shaft;
dust cover (8), throttle lever (7) (ensuring that the
flats in the hole of the lever engage with the flats on
the shaft). Break-back lever (6), spring seat (5),
spring (4) (engaging the legs of the spring with both
levers). Spring retainer (3), washer (2), and selflocking throttle shaft nut (1). Tighten the nut to the
specified torque.
Hold the throttle lever securely with one hand. With
the other hand move the throttle lever against the
spring; the throttle shaft should rotate. If it does not,
check that the flats in the break-back lever are
correctly located with those of the throttle shaft.
A1007
EVD07
Delphi
Note:
2 The final positions of all stop screws will be established during testing.
4-90
REASSEMBLY IV
REASSEMBLY
A) Idling
Fit the lock-nut (2) to the screw (1), followed by the
spring washer (3), and fit the screw through the lug
(4). The Test Plan will specify the initial setting
position for the screw.
A953a
A1262
B) Maximum speed
Fit the lock nut (6) to the screw (5), with the circular end of the nut facing the pillar (7) and fit the screw through
the pillar. The Test Plan will specify the initial setting position for the screw.
C) Torque screw
Fit the lock-nut (9) with its circular end facing the governor control cover, together with a new flexible sealing
washer (8) to the screw (10) and fit the screw to the cover. Rotate the screw about four turns, unless the Test Plan
specifies otherwise, and tighten the lock-nut to the specified torque.
If no torque screw is specified fit the plug (11), together with a new sealing washer (8) and tighten to its specified
torque.
D) Maximum fuel
Note:
If a boost control device is specified, the maximum
fuel stop will be incorporated within the device.
Fit the lock-nut (2), with its circular end facing the
governor control cover together with a new flexible
sealing washer (3), to the screw (1). Fit the screw to
the cover in the position shown. The initial setting
of the screw is set during the stabilisation period
when the pump is tested.
3
2
1
Delphi
A1278
4-91
A1003
IV REASSEMBLY
REASSEMBLY
E) Plug
Fit a new copper washer (2) to the plug (1); fit the
plug to the cover and tighten to its specified torque.
1
2
A1279
A1002
4.11
A950
3
2
1
6
4
5
EVD 013
A1276
4.11.3 Cover
Fit the cover (273) with a new gasket (274) and use bolts (272) to secure to the pump body finger tight.
Delphi
Fit a new O-ring (6) to the cam ring plug (7) and screw into the pump body finger tight.
4-92
REASSEMBLY IV
REASSEMBLY
4.12
Drive Hub
1
5
A950
4
4.13
A1282a
A981
Leak Testing
All pumps must be leak-tested both before and after performance testing and any leaks must be rectified. The leak test
procedure is described in Section 5.4.
4.14
Storage
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 degrees C and plus 60 degrees C. Humidity
must be between 0 and 80 percent.
Pumps must be stored with the axis horizontal; unboxed pumps must not 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 should be subjected to a full test according to the relevant Test Plan and the storage
procedure repeated.
4-93
IV REASSEMBLY
Delphi
REASSEMBLY
4-94
TEST PROCEDURE V
TEST PROCEDURE
5.1
Preparation
Delphi
Note:
Incorrect rotation will result in serious damage to the pump.
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:
the pump is firmly secured to the mounting.
the mounting is secured to the machine bed.
the drive adaptor is securely clamped.
5-95
V TEST PROCEDURE
TEST PROCEDURE
5.1.4 Test conditions
The ISO Test Conditions quoted on the Test Plan must be strictly adhered to, i.e.
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 on ambient conditions.
The test injector configuration must be as stated on the Test Plan. Nozzle opening pressures must be set to the
specified figure.
The high pressure (HP) pipes must be as stated.
Inlet feed pressure must be set to 0.1 bar unless otherwise stated. Minimum flow rate available at the pump inlet
should be 1000 cm3 per minute.
A pressure to be applied to the backleak return connection may be specified. This pressure will always be of a
similar value to that specified for the inlet connection. It is therefore permissible to interconnect the two
connections to enable the supply feed from the test bench to feed both points. See diagrams 1 & 2 below
Backleakage Pressure = Inlet Feed Pressure
Inlet and backleak pipes must be joined with a T-piece connector when testing DP200 pumps, where the test plan
states that the backleak pressure is the same as inlet pressure. e.g.
Inlet pressure = 0.3 bar
Backleak pressure = 0.3 bar
This ensures accurate cambox pressure and advance curve.
To measure backleakage flow, the backleak pipe must be connected to the return flow gauge, to take the reading,
then reconnected to the T-piece connector for all other tests.
Note:
If backleak temperature is greater than specified, suspend testing until cooled down.
AVM users can follow the diagrams below
T-Piece Connector
Pump
Diag 1
Delphi
When checking return fuel flow, turn the two way tap so that the pump backleakage flow goes directly to the flow
meter
5-96
TEST PROCEDURE V
TEST PROCEDURE
T-Piece Connector
P
Fuel Flow Meter
ALP310/2 Back
Leakage tap
Diag 2
Delphi
Note:
There are a number of versions of the shut-off solenoid that operate on the 'energise to stop' principle. If specified
for the pump under test, they must not be energised during testing, but only to check its effectiveness in stopping
delivery, when specified in the Test Plan.
Prime the pump by slackening the bleed screw or blanking plug on the governor cover and running the machine
at low speed. When air-free test oil is issuing from all injectors, backleak and the bleed screw, close the screw and
run the test machine for a period at high speed to stabilise the pump before commencing testing.
5-97
V TEST PROCEDURE
TEST PROCEDURE
Note:
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.
New test plans issued from 2000 onwards contain a section specially dedicated to over checking a pump. The
section has been developed in conjunction with the Original Equipment Manufacturer. Providing all values are
achieved, the pump settings will maintain the original homologated engine performance.
Note:
Do not run the pump for long periods at high speed and at low or zero output level or with the shut-off solenoid
de-energised.
The Test Plan will give specific instructions for both of these activities.
A1042
Delphi
When transfer pressure setting and checks have been completed, and if instructed to do so by the Test Plan,
disconnect the gauge. Remove the adaptor from the hydraulic head and refit the blanking plug or shut-off solenoid,
tightened to the specified torque. Connect the solenoid to the specified low-voltage DC supply before testing is
continued.
5-98
TEST PROCEDURE V
TEST PROCEDURE
5.1.8 Cambox pressure measurement
If it is specified that cambox pressure be measured,
remove the vent screw from the pump governor
cover or the drain plug from the cambox and fit an
adaptor and pressure gauge (0-2 bar) as shown.
A1041
Delphi
5-99
A1044
V TEST PROCEDURE
TEST PROCEDURE
B) Maximum fuel adjusting screw
This is set on the Test Bench by slackening the lock
nut (2) and turning the adjuster screw (1). In for
more fuel, out for less fuel. Tighten the lock nut.
A1042a
C) Boost control
Check that the control spring and pre-load spring shims and the initial stroke setting are as specified in the Test
Plan.
D) Throttle lever
A1046
Delphi
5-100
TEST PROCEDURE V
TEST PROCEDURE
E) Idling control
Set the idling screw (1) to the position stated in the
Test Plan; lightly tighten the lock nut.
A953
F) Torque screw
Set the torque screw (2) as required by the Test Plan. Lightly tighten the lock nut.
5.2
Test Procedure
Note:
Most aspects of pump performance are inter-related; if the specified figures for a test cannot be achieved, the fault must
be rectified before proceeding to the next test (continuation of the test sequence may assist in determining the cause,
but the earlier tests must be repeated after fault correction).
Errors in test results, which cannot be corrected by change of settings, should be rectified by change of component.
5.2.1 Priming
Switch on the test oil supply, set the pressure to that specified in the Test Plan and energise the stop solenoid (if
fitted). Confirm that the test machine is set to rotate in the correct direction, switch it on and set the speed to that
specified in the Test Plan for priming. Confirm that the temperature of the test oil has reached the specified figure.
Run the pump at that speed until delivery is obtained from all injectors and the flow of fuel from the backleak and
the governor cover vent is clear of air i.e. no further air bubbles appear in the backleak pipe. Close the vent.
Delphi
Note:
When testing pumps having equal fuel inlet and return pressure requirements, the backleak temperature must
not rise above 50C. Temperatures above 50C will affect the accuracy of the pump settings. It is advisable to
suspend pump setting until the temperature cools to below 50C.
5-101
V TEST PROCEDURE
TEST PROCEDURE
5.2.2 Checking and setting transfer pressure
To alter the pressure, engage the setting tool (1)
with the adjusting screw.
Clockwise rotation of the adjuster raises pressure
(thereby increasing the advance) and vice versa.
During adjustment, the adjuster must be fully raised
to avoid possible restriction of fuel flow through the
inlet adaptor before a transfer pressure reading is
taken. After final setting, the adjuster is to remain in
the fully raised position.
Refer to the Test Plan for detailed settings. Some
pump specifications may call for transfer pressure
settings designed to give particular advance
characteristics, eg. controlling LLA.
A1041a
TRANSFER PRESSURE
PUMP SPEED
A1285
Delphi
5-102
TEST PROCEDURE V
TEST PROCEDURE
5.2.3 Cambox pressure and backleakage checks
Cambox Pressure
psi
rpm
Diag 3
Delphi
5-103
ADVANCE
Note:
After first checking that the full specified advance
[A] can be obtained, stop the test machine and
confirm that the advance gauge still reads zero [B]
when stationary.
SPEED ADVANCE
START RETARD
SPEED
A1287
V TEST PROCEDURE
TEST PROCEDURE
5.2.5 Cold advance
A) Wax motor operation
An electrical current to the wax motor controls the
operation of the device .
The instructions contained within the Test Plan will
indicate when to supply or not supply a current to
the unit and effect a movement within the advance
device.
Failure to effect an advance movement may be due
to an open electrical circuit, a wax motor failure or
a restriction of movement within the advance
device.
A1461
B) Automatic operation
The operation of this type of mechanism relies upon the latch valve operation and its ability to switch fuel pressure
into the pressure end of the advance device. (See Latch Valve for failure to operate.)
2
1
Delphi
A1039
5-104
TEST PROCEDURE V
TEST PROCEDURE
5.2.7 Boost control with torque trimmer
At a specified point in the test procedure, it will be
necessary to adjust the position of the torque
trimmer cam spring pre-load cap to achieve a
specified delivery.
It will also be necessary to adjust fuel delivery.
Remove the delivery adjustment blanking-plug
from the governor control cover. Fit the adjuster
body (2) with the spindle (1) pulled fully out. Once
tightened, locate the spindle socket (3) over the
hexagonal head of the delivery adjustment screw
on the scroll link carriage. Slide the adjuster body
along the spindle, fit it into the governor control
cover and lightly tighten it.
Remove the adjuster and refit the blanking-plug as
indicated in the Test Plan.
FUEL DELIVERY
Note:
The setting of the combined features, boost and
torque control, is carried out in two stages. Setting
of the torque cam position is carried out first
followed by setting the boost control.
Tool2
SPEED
Chart1
Delphi
A1516
5-105
V TEST PROCEDURE
TEST PROCEDURE
5.2.8 Maximum fuel delivery setting
The maximum fuel delivery is controlled by the
scroll plates. The scroll plates, in turn, are controlled
by the maximum fuel screw, or the boost control
unit. The appropriate Test Plan will specify all
setting speeds and delivery levels.
A1043
PUMP SPEED
A1288
Delphi
b) Maximum boost
Set the Tester to zero air pressure. Fit the specified
tool in place of the pre-load spring, shim and plug;
screw the tool fully in to compress the diaphragm
and control spring.
This equates to a boost pressure of 0.8 bar, whilst
allowing adjustment of fuel level. Run the pump at
the specified test speed and note pump delivery [A].
If required, fit a 1.5 mm Allen key (1) to the fuel
adjustment screw and reset the delivery level; turn
it clockwise to increase fuel delivery.
When this test is completed, refit the pre-load
spring, shim, and plug into the boost control cover;
tighten the plug to the specified torque.
FUEL DELIVERY
A1040
5-106
TEST PROCEDURE V
TEST PROCEDURE
c) Re-check the fuel delivery
With the Boost Control Tester now set at the maximum boost pressure and with the test machine running at the
same speed as above, confirm that delivery is still as set at [A].
d) Minimum Boost
With the Tester now set at zero pressure [B], check delivery at the specified speed.
If delivery is outside the requirement, remove the cover, pre-load spring and diaphragm, and reset the stroke as
specified in the Test Plan.
e) Intermediate boost
The Test Plan may call for a delivery check [C] at an intermediate boost pressure.
If delivery is outside the specified limits, remove the same components as in the previous test and alter the
shimming beneath the control spring. Reassemble the boost control and re-check the delivery level.
Delphi
DDNX121A(EN) - Issue 1 of 08/2008
5-107
WITHOUT TORQUE
SCREW SET
FUEL DELIVERY
1
GOVERNOR
RUN-OUT
A953a
SPEED
A1289
V TEST PROCEDURE
TEST PROCEDURE
FUEL DELIVERY
WITH TORQUE
SCREW SET
A953a
SPEED
A1309
Delphi
A953
5-108
TEST PROCEDURE V
TEST PROCEDURE
5.2.13 Shut-off control check
Run the test machine at the specified speed, and
hold the throttle lever fully open.
Operate the exhaust brake lever (1) and check fuel
delivery.
A delivery greater than that specified will normally
indicate a worn metering valve or head and rotor,
or a mechanical failure of the stopping mechanism.
With the exhaust brake lever in the "run" position
disconnect the power supply to the shut-off
solenoid. Delivery should not exceed the figure
stated on the Test Plan.
Stop the test machine to enable the shut-off
solenoid to re-open the valve when re-energised.
A delivery greater than that specified will normally
indicate a failed ESOS plunger or head and rotor
seat, or internal leaks within the head and rotor.
A1002a
Note:
Do not run the pump for more than a few seconds at high speed with the exhaust brake lever or the solenoid in
the stop position.
5.3
Timing
5.3.1 General
Delphi
The timing point is determined by the application of pressurised fuel to a selected high pressure outlet, thereby
pushing the plungers out to the limit of their strokes as determined by the scroll plates. The pump is then rotated
by hand in its normal direction of rotation until the rollers contact the cam profile, thus preventing further
movement.
The individual pump specification may then call for further rotation (or "offset"), as indicated on an indexing tool,
in either the forward or reverse direction. It may also be necessary to apply a specified torque to the drive shaft.
When the drive shaft has been placed in the required timing position, one of two methods will be used to identify
that position when fitting the pump to the engine:
a.
A flange marking gauge will be used as a guide to scribe a line on a specified area of the pump mounting
flange for subsequent alignment with a matching mark on the engine.
b.
The drive shaft will be locked in position by means of a screw in the pump mounting flange.
The screw must not be released until the pump has been installed on the engine and the fixing screws or
nuts securing the pump to the engine and the drive hub to the gear or timing belt pulley have been tightened.
The screw is then released and a two-position spacer moved to its "running" position to keep the screw away
from the shaft; the screw is then tightened to its "running" torque.
5-109
V TEST PROCEDURE
TEST PROCEDURE
5.3.2 Keyed drive shafts
A) Shaft-lock timing (with torque)
If a specified torque is to be applied to the shaft and
the shaft is to be locked in the timing position, the
pump must be fitted to a test machine mounting
bracket. This must be placed the reverse way round
to normal running on the machine bed, so that the
pump drive end faces the rear of the test machine.
A1298
A1307
The pressure stated in the Test Plan must not be exceeded or the rotor and scroll plates may be damaged. It is
critical that any observations noted in the Test Plan are strictly adhered too, in order to establish the correct shaft
lock position e.g. the application of a torque value.
The high pressure supply must be connected to the
outlet specified in the Test Plan (and all the
remaining outlets must be blanked-off if specified
in the Test Plan).
Note:
If steel balls are used in conjunction with highpressure outlet nuts to blank-off each of the unused
outlets, do not use excessive torque when
tightening the nuts, to avoid distortion of the conical
seats.
Delphi
A1299
5-110
TEST PROCEDURE V
TEST PROCEDURE
Remove the drive hub, but leave the Woodruff key
in position. Set the flange marking gauge to the
angle specified in the Test Plan and fit it to the drive
shaft taper. Hold it in position with the drive shaft
nut, lightly tightened. Pressurise the outlet
connection to the specified value quoted on the Test
Plan and rotate the pump in the direction of normal
rotation until the position of hydraulic lock is
reached.
If specified on the Test Plan, use a torque wrench
set to the required torque, to rotate the shaft against
the pressure.
A1300
A1301
Delphi
5-111
V TEST PROCEDURE
TEST PROCEDURE
Apply the fuel pressure specified in the relevant Test Plan to the timing outlet and rotate the drive shaft in the
normal direction of rotation until the hydraulic lock position is obtained. Select the relevant mounting hole and
fit the plate securely to the drive shaft in a horizontal position. Tighten to a torque of 9.0 Nm (80 lbf/in).
Turn off the timing outlet fuel pressure and rotate the drive shaft at least 30 degrees against the normal direction
of rotation.
C) Setting the drive shaft position
Note:
A requirement to fit an advance piston positioning
tool may be specified.
Re-apply the pressure to the timing outlet and rotate
the drive shaft in the normal direction of rotation,
with the torque wrench set as specified to 11.5 Nm
(100 lbf/in.) until the hydraulic lock position is
obtained. Hold the drive shaft with the torque
wrench at this position and set the bubble in the
timing indicator plate to the horizontal position. For
accuracy, set one end of the 'bubble' against one of
the reference lines. Note the reading on the
graduated scale. (Ideally, this should be at the 'zero'
point.)
DT221/2 fig 1
Note:
For added accuracy, it is advisable that a mass equivalent to that which is required to maintain the torque 'break'
of 11.5 Nm (100 lbf/in), is suspended from the end of the torque wrench. This will enable the operator to use both
hands to carefully set the gauge without the drive shaft deviating from the hydraulic lock position.
D) Applying the off-set
With the drive shaft at the hydraulic lock position
(A), move the indicator plate (C) to the specified
offset position (B). This may be with or against the
normal direction of pump rotation and will be stated
on the relevant Test Plan.
Note:
The example shows the offset in the normal
direction of pump rotation, when the pump rotation
is clockwise.
The instructions on the Test Plan will
correspondingly read, 'Indicator plate offset x in
pump rotation. To centralise the bubble rotate drive
shaft against pump rotation.'
DT221/2 fig 2
Great care should be exercised in interpreting tool offset if the specified tooling is not used.
Switch off the fuel pressure supply.
Rotate the drive shaft, by using the drive shaft nut, not the timing gauge, to restore the bubble to the horizontal
position.
5-112
Delphi
Note:
An indicator plate offset in pump direction produces a drive shaft position prior to hydraulic lock. An indicator
plate offset against pump direction produces a drive shaft position after hydraulic lock position.
TEST PROCEDURE V
TEST PROCEDURE
Align the relevant end of the "bubble" to the reference line.
E) Setting the timing
Having rotated the drive shaft to the offset position,
the drive shaft locking screw must be tightened to
hold the drive shaft in position. Ensure the lockshaft
spacing washer is in the correct position to enable
the shaft to be locked. Refer to the Test Plan for the
correct tightening torque. Remove the Timing
Indicator Plate tool ensuring that the drive shaft is
not inadvertently rotated.
DT221/2 fig 3
Delphi
To check the timing, slacken the drive shaft locking screw, rotate the drive shaft at least 30 degrees against the
normal direction of rotation and repeat steps 5.3.3.2 to 5.3.3.5.
Finally tighten the drive shaft locking screw.
The 8mm diameter alignment pin should then pass through the flange slot and into the corresponding hole in the
pump housing.
Any resistance to the pin entering the housing hole will indicate misalignment. In such a case, the drive flange
must be removed and the timing procedure repeated from step 5.3.3.5.
5-113
V TEST PROCEDURE
TEST PROCEDURE
5.4
Leakage Testing
A1047
Delphi
5-114
Tooling
Description
6408-79
7244-581
7144-482
YDT140
7244-590
7244-590/2
AE3/1
HB343
AE7
AE3/2
7244-584
YDB328
HB246
YDT146
ARD20/1
7244-582
YDT136
YDB314
ADC132
ADC136
APB94
ADC139
APB195
APB194
ADC183
7244-404
7144-939
7244-633
YDB288
Edge Filter
7133-110
5936-95Q
7244-231
7244-604
Delphi
Part Number
6-115
AHP134
AHP133
YDB372
Hydra-clamp
AI51
Injector for AVM & PGM Test Bench - Fitted with YDB286 Nozzle
AI53
Injector for AVM & PGM Test Bench - Fitted with YDB287 Nozzle
AI52
Injector for HA2500 & HA700 Test Bench - Fitted with YDB286 Nozzle
AI54
Injector for HA2500 & HA700 Test Bench - Fitted with YDB287 Nozzle
YDA333
6408-80A
YWB208
Multimeter
YDB286
YDB287
YDB289
Nozzle Holder
7185-950
7185-950GX
7244-631
7244-275A
ALP211
7044-898
7244-625
7244-627
7244-626
7244-624
7244-620
7144-900
1804-429
Protection Cap for Housing Drain Screw / TP Advance Screw / Timing Cover Plate Plug
7244-621
7244-621A
7144-458C
Protection Cap for Latch Valve Body / Throttle & Exhaust Shafts
7244-623
7244-623A
6408-68
7044-897
7244-628
7244-629
Part Number
6-116
7244-622
7244-622A
1804-411
6408-59
7174-62
7244-275/3
YWB206
Signal Generator
7244-125B
7044-889
7244-24
7244-590/1
7244-411
7244-405
6408-78
7244-439A
7244-439
7244-437
7244-438
7244-598
7244-597
7244-603
YDT146
60620197
Dismantling tray available through Delphi Diesel Aftermarket, Service Operations Department
Delphi
Part Number
6-117
Torque Values
NM
Description
Part
Number
from
to
101
7182-189
82.00
82.00
101
7182-189
90.40
101
7185-631
101
114
from
to
Head Type
Comments
720
720
22 mm AF
90.40
800
800
22 mm AF
90.00
90.00
796
796
22 mm AF
7185-758
90.00
90.00
796
796
22 mm AF
5334-245
18.00
18.00
160
160
8 mm Bi Hex
114
5334-245
28.00
28.00
250
250
8 mm Bi Hex
118
7174-349A
2.80
2.80
25
25
T10
124
7174-350A
4.00
4.00
35
35
T15
129
7123-975
51.00
51.00
450
450
1/4" Flats
129
7182-923
57.00
57.00
500
500
Special
129
7185-314
57.00
57.00
500
500
14 mm AF
135
5335-684
3.20
3.20
28
28
3/32" Allen
141
7182-245
7.40
7.40
65
65
Special
141
7182-245A
7.40
7.40
65
65
Special
151
Endplate Screw
7185-015
5.10
5.10
45
45
4mm Allen
154
TP Accumulator
7185-299
13.50
16.50
120
146
22 mm AF
201
Latch Valve
7185-362
34.00
34.00
300
300
22 mm AF
201
Latch Valve
7185-362A
34.00
34.00
300
300
22 mm AF
201
Latch Valve
7185-484
34.00
34.00
300
300
22 mm AF
201
Latch Valve
7185-484A
34.00
34.00
300
300
22 mm AF
201
Latch Valve
7185-484B
34.00
34.00
300
300
22 mm AF
201
Latch Valve
7185-484D
34.00
34.00
300
300
22 mm AF
203
7167-895
4.50
4.50
40
40
1/2" AF
205
Adjusting Sleeve
7182-334
16.00
16.00
140
140
5/8" AF
208
7185-483
34.00
34.00
300
300
22 mm AF
211
7185-171
34.00
34.00
300
300
19 mm AF
211
7185-356
34.00
34.00
300
300
19 mm AF
211
7185-479
34.00
34.00
300
300
19 mm AF
211
7185-497
34.00
34.00
300
300
19 mm AF
219
7185-221
34.00
34.00
300
300
19 mm AF
219
7185-358
34.00
34.00
300
300
19 mm AF
Delphi
LSN
LBF.IN
6-118
Part
Number
from
to
to
Head Type
219
7185-480
34.00
34.00
300
300
19 mm AF
219
7185-480A
34.00
34.00
300
300
19 mm AF
219
7185-480B
34.00
34.00
300
300
19 mm AF
219
7185-691
34.00
34.00
300
300
19 mm AF
219
7185-691A
34.00
34.00
300
300
19 mm AF
219
7185-691B
34.00
34.00
300
300
19 mm AF
224
7185-219
4.50
4.50
40
40
15 mm AF
225
7185-171
34.00
34.00
300
300
19 mm AF
225
7185-479
34.00
34.00
300
300
19 mm AF
225
7185-497
34.00
34.00
300
300
19 mm AF
225
7185-698
34.00
34.00
300
300
19 mm AF
225
7185-698A
34.00
34.00
300
300
19 mm AF
225
7185-698B
34.00
34.00
300
300
19 mm AF
225
7185-747
34.00
34.00
300
300
19 mm AF
228
Blanking Plug
7167-523
15.00
15.00
130
130
17 mm AF
232
Nut
NU11-3Z1
2.30
2.30
20
20
8 mm AF
235
Stop Solenoid
7167-620B
15.00
15.00
130
130
24 mm AF
235
Stop Solenoid
7167-620D
15.00
15.00
130
130
24 mm AF
235
Stop Solenoid
7180-212A
15.00
15.00
130
130
24 mm AF
235
Stop Solenoid
7180-49A
15.00
15.00
130
130
24 mm AF
235
Stop Solenoid
7180-49D
15.00
15.00
130
130
24 mm AF
235
Stop Solenoid
7185-762F
15.00
15.00
130
130
24 mm AF
235
Stop Solenoid
7185-900E
15.00
15.00
130
130
24 mm AF
235
Stop Solenoid
7185-900G
15.00
15.00
130
130
24 mm AF
235
Stop Solenoid
7185-900H
15.00
15.00
130
130
24 mm AF
235
Stop Solenoid
7185-900K
15.00
15.00
130
130
24 mm AF
235
Stop Solenoid
7185-900T
15.00
15.00
130
130
24 mm AF
235
Stop Solenoid
7185-900W
15.00
15.00
130
130
24 mm AF
240
Inlet Connection
7133-037Q
34.00
34.00
300
300
27 mm AF
240
Inlet Connection
7133-37E
34.00
34.00
300
300
24 mm AF
240
Inlet Connection
7133-37G
34.00
34.00
300
300
24 mm AF
240
Inlet Connection
7133-37M
34.00
34.00
300
300
27 mm AF
240
Inlet Connection
7133-37N
34.00
34.00
300
300
24 mm AF
Delphi
LSN
LBF.IN
6-119
from
Comments
Part
Number
from
to
240
Inlet Connection
7180-348H
34.00
34.00
240
Inlet Connection
7180-348J
34.00
240
Inlet Connection
7180-348N
240
Inlet Connection
252
from
to
Head Type
Comments
300
300
24 mm AF
34.00
300
300
24 mm AF
34.00
34.00
300
300
27 mm AF
7180-348P
34.00
34.00
300
300
27 mm AF
7185-177
12.00
12.00
103
103
10 mm AF
Run Position
252
7185-177
13.00
13.00
115
115
10 mm AF
Locked Position
255
Blanking Plug
7182-691
11.00
11.00
100
100
3/4" AF
257
7167-299
2.30
2.30
20
20
5/16" AF
257
7167-299B
2.25
2.75
20
24
5/16" AF
259
5335-694
6.80
6.80
60
60
None
265
DV Holder
7185-130D
8.00
12.00
70
103
16 mm AF
265
DV Holder
7185-130J
8.00
12.00
70
103
16 mm AF
265
DV Holder
7185-130K
8.00
12.00
70
103
16 mm AF
265
DV Holder
7185-130L
8.00
12.00
70
103
16 mm AF
265
DV Holder
7185-680
8.00
12.00
70
103
16 mm AF
266
HP Valve Assy
7185-022C
41.00
41.00
360
360
16 mm AF
267
Bracket Screw
7167-667A
14.00
14.00
120
120
5 mm Allen
267
Bracket Screw
7187-129C
14.00
14.00
120
120
5 mm A/F
268
NU7-32Y1
30.40
30.40
270
270
18 mm AF
272
5334-274
2.30
2.30
20
20
5/16" AF
276
NOTE-26-A5
16.00
16.00
140
140
14 mm AF
283
7185-679
31.00
31.00
270
270
14 mm AF
301
CA Housing Screw
7185-304
9.50
9.50
85
85
4 mm Allen
301
CA Housing Screw
7185-304A
9.50
9.50
85
85
4 mm Allen
301
CA Housing Screw
7187-129D
8.00
8.00
70
70
301
CA Housing Screw
7187-129D
5.40
6.60
48
58
307
7185-312
13.50
16.50
120
146
22 mm AF
325
7123-473
28.00
28.00
250
250
15/16" AF
325
7123-473B
28.00
28.00
250
250
15/16" AF
325
7123-473E
28.00
28.00
250
250
15/16" AF
325
7123-473F
28.00
28.00
250
250
15/16" AF
325
7123-473G
28.00
28.00
250
250
15/16" AF
325
7123-473H
28.00
28.00
250
250
15/16" AF
Delphi
LSN
LBF.IN
6-120
Part
Number
from
to
to
Head Type
325
7123-473J
28.00
28.00
250
250
15/16" AF
325
7123-473L
28.00
28.00
250
250
15/16" AF
325
7123-473M
28.00
28.00
250
250
15/16" AF
325
7123-473N
28.00
28.00
250
250
15/16" AF
325
7123-473P
28.00
28.00
250
250
15/16" AF
325
7123-473S
28.00
28.00
250
250
15/16" AF
325
7185-336N
28.00
28.00
250
250
24 mm AF
325
7185-383A
28.00
28.00
250
250
24 mm AF
325
7185-383B
28.00
28.00
250
250
24 mm AF
333
CIA Spindle
7185-297
1.60
2.00
14
18
1.2mm Slot
336
Nut
NU11-3T
2.30
2.30
20
20
8 mm AF
411
7167-299
2.30
2.30
20
20
5/16" AF
411
7167-299B
2.25
2.75
20
24
5/16" AF
413
7167-300A
28.00
28.00
250
250
15/16" AF
413
7167-300C
28.00
28.00
250
250
15/16" AF
413
7167-300D
28.00
28.00
250
250
15/16" AF
413
7167-300E
28.00
28.00
250
250
15/16" AF
413
7167-300F
28.00
28.00
250
250
15/16" AF
413
7167-300G
28.00
28.00
250
250
15/16" AF
413
7167-300J
28.00
28.00
250
250
15/16" AF
413
7167-300K
28.00
28.00
250
250
15/16" AF
413
7167-300L
28.00
28.00
250
250
15/16" AF
413
7167-300M
28.00
28.00
250
250
15/16" AF
413
7167-300N
28.00
28.00
250
250
15/16" AF
413
7167-304B
28.00
28.00
250
250
15/16" AF
413
7167-304E
28.00
28.00
250
250
15/16" AF
413
7185-393E
28.00
28.00
250
250
24 mm AF
413
7185-393F
28.00
28.00
250
250
24 mm AF
413
7185-635D
28.00
28.00
250
250
13 mm AF
413
7185-635E
28.00
28.00
250
250
13mm AF
413
7185-635F
28.00
28.00
250
250
13 mm AF
417
5330-362
15.00
15.00
130
130
1/2" AF
417
5330-362C
28.00
28.00
240
240
1/2" AF
Delphi
LSN
LBF.IN
6-121
from
Comments
Part
Number
from
to
420
Hd Locating Fitting
7174-660AA
40.00
40.00
420
Hd Locating Fitting
7174-660AB
40.00
420
Hd Locating Fitting
7174-660U
420
Hd Locating Fitting
420
from
to
Head Type
350
350
3/4" AF
40.00
350
350
3/4" AF
36.00
36.00
315
385
3/4" AF
7174-660W
36.00
36.00
315
385
3/4" AF
Hd Locating Fitting
7174-660Y
40.00
40.00
350
350
3/4" AF
504
7174-917B
6.80
6.80
60
60
13 mm AF
504
7174-917C
6.80
6.80
60
60
13 mm AF
506
7182-569A
5.10
5.10
45
45
10 mm AF
508
7174-336A
4.50
4.50
40
40
4 mm Allen
508
7174-895C
4.00
4.00
35
35
T25
508
7174-895D
4.00
4.00
35
35
T25
512
7174-917
6.80
6.80
60
60
13 mm AF
512
7174-917B
6.80
6.80
60
60
13 mm AF
515
NU11-4Z1
5.70
5.70
50
50
10 mm AF
517
7174-637
5.70
5.70
50
50
10 mm AF
531
7182-352A
2.30
2.30
20
20
7 mm AF
537
7182-569A
5.10
5.10
45
45
10 mm AF
537
7185-309
6.30
7.70
56
68
4 mm Allen
537
7185-641
6.30
7.70
56
68
Torx
539
7182-569A
5.10
5.10
45
45
10 mm AF
541
7174-917
6.80
6.80
60
60
13 mm AF
541
7174-917B
6.80
6.80
60
60
13 mm AF
551
Screw
7185-567
9.50
9.50
85
85
Special
558
7182-352A
2.30
2.30
20
20
7 mm AF
562
7174-917B
6.80
6.80
60
60
13 mm AF
571
7174-637B
1.60
1.60
14
14
7 mm AF
613
7182-23
5.10
5.10
45
45
8 mm AF
615
7182-23
5.10
5.10
45
45
8 mm AF
615
7182-23A
5.10
5.10
45
45
8 mm AF
620
7174-798
2.30
2.30
20
20
2.5 mm Allen
620
NS277-6Y1
2.30
2.30
20
20
7 mm AF
621
7174-798
2.30
2.30
20
20
2.5 mm Allen
621
NS277-6Y1
2.30
2.30
20
20
7 mm AF
Comments
Delphi
LSN
LBF.IN
6-122
Part
Number
from
to
to
Head Type
631
Backleak Connection
7182-792D
14.00
14.00
120
120
16 mm AF
631
Backleak Connection
7182-797E
14.00
14.00
120
120
16 mm AF
631
Backleak Connection
7185-550
14.00
14.00
120
120
17 mm AF
631
Backleak Connection
7185-563
20.00
20.00
180
180
17 mm AF
631
Backleak Connection
7185-744F
20.00
20.00
180
180
17 mm AF
631
Backleak Connection
7185-772A
14.00
14.00
120
120
16 mm AF
631
Backleak Connection
7185-772B
10.20
10.20
90
90
16 mm AF
631
Backleak Connection
7185-773A
14.00
14.00
120
120
16 mm AF
633
Backleak Adaptor
7185-414
20.00
20.00
180
180
634
Non-Return Valve
7139-854M
20.00
20.00
180
180
17 mm AF
634
Non-Return Valve
7139-854S
20.00
20.00
180
180
17 mm AF
634
Non-Return Valve
7139-854W
20.00
20.00
180
180
17 mm AF
634
Non-Return Valve
7139-854X
20.00
20.00
180
180
17 mm AF
634
Non-Return Valve
7139-854Z
20.00
20.00
180
180
17 mm AF
634
Non-Return Valve
7182-797E
14.00
14.00
120
120
16 mm AF
634
Non-Return Valve
7185-550
14.00
14.00
120
120
17 mm AF
634
Non-Return Valve
7185-563
20.00
20.00
180
180
17 mm AF
634
Non-Return Valve
7185-564
20.00
20.00
180
180
17 mm AF
634
Non-Return Valve
7185-564A
20.00
20.00
180
180
17 mm AF
634
Non-Return Valve
7185-744E
20.00
20.00
180
180
17 mm AF
634
Non-Return Valve
7185-744F
20.00
20.00
180
180
17 mm AF
636
Vent Screw
7180-371
4.50
4.50
40
40
5/16" AF
637
Vent Body
7185-214
7.40
7.40
65
65
13 mm AF
640
Backleak Adaptor
7182-792A
10.20
10.20
90
90
16 mm AF
640
Backleak Adaptor
7182-792B
10.20
10.20
90
90
16 mm AF
640
Backleak Adaptor
7182-792E
10.20
10.20
90
90
16 mm AF
640
Backleak Adaptor
7182-797
14.00
14.00
120
120
16 mm AF
640
Backleak Adaptor
7182-797B
7.40
7.40
65
65
16 mm AF
640
Backleak Adaptor
7182-797C
7.40
7.40
65
65
16 mm AF
640
Backleak Adaptor
7185-309
6.30
7.70
56
68
4 mm Allen
640
Backleak Adaptor
7185-587A
18.00
18.00
160
160
17 mm AF
640
Backleak Adaptor
7185-641
6.30
7.70
56
68
640
Backleak Adaptor
7185-772A
14.00
14.00
120
120
Delphi
LSN
LBF.IN
6-123
from
Torx
16 mm AF
Comments
LBF.IN
LSN
Description
Part
Number
from
to
to
Head Type
640
Backleak Adaptor
7185-772B
10.20
10.20
90
90
16 mm AF
640
Backleak Adaptor
7185-773B
7.40
7.40
65
65
16 mm AF
641
Blanking Plug
7185-251
7.40
7.40
65
65
14 mm AF
719
Pivot Plug
7185-316
16.65
20.35
144
176
6 mm Allen
719
Pivot Plug
7185-638
725
7182-576
18.40
18.40
160
160
Special
734
5334-274B
2.30
2.30
20
20
5/16" AF
734
7185-645
2.30
2.30
20
20
Torx
738
7185-641
6.30
7.70
56
68
Torx
738
9045-976A
4.00
4.00
35
35
24 mm AF
804
7182-833
6.80
6.80
60
60
10 mm AF
804
7185-175
6.80
6.80
60
60
10 mm AF
804
7185-388
6.80
6.80
60
60
10 mm AF
804
7185-443
6.80
6.80
60
60
10 mm AF
804
7185-557
6.80
6.80
60
60
10 mm AF
804
7185-811
11.00
11.00
100
100
11 mm AF
804
7185-812
11.00
11.00
100
100
11 mm AF
804
7185-813
11.00
11.00
100
100
11 mm AF
804
7185-814
11.00
11.00
100
100
11 mm AF
901
Nut
7185-657
21.00
26.00
186
230
13 mm AF
902
Stud
7185-656
9.00
9.00
80
80
Special
906
7174-839
1.70
1.70
15
15
3 mm Allen
908
7182-397
3.40
3.40
30
30
7 mm AF
910
Lock Nut
7174-637B
1.60
1.60
14
14
7 mm AF
918
NU11-3Z1
2.30
2.30
20
20
8 mm AF
919
7182-352A
2.30
2.30
20
20
7 mm AF
923
7185-559
2.26
2.26
20
20
8 mm AF
924
Screw
9107-034A
2.00
2.00
18
18
Special
926
Nut
9007-172E
20.00
20.00
180
180
24 mm AF
931
NU11-4Z1
5.70
5.70
50
50
10 mm AF
22 mm AF
Comments
Delphi
from
6-124
Delphi
DP200
(026)
01 / 1999
1/11
6.3
6-125
Delphi
DP200
(026)
05 / 2006
2/11
6-126
Delphi
DP200
(026)
07 / 2004
3/11
6-127
Delphi
DP200
(026)
05 / 2001
4/11
6-128
Delphi
DP200
(026)
02 / 2002
5/11
6-129
Delphi
DP200
(026)
06 / 2004
6/11
6-130
Delphi
DP200
(026)
12 / 2003
7/11
6-131
Delphi
DP200
(026)
10 / 2001
8/11
6-132
Delphi
DP200
(026)
08 / 1997
9/11
6-133
Delphi
DP200
(026)
09 / 2002
10/11
6-134
Delphi
DP200
(026)
09 / 2002
11/11
6-135
Delphi
6-136
APPENDIX VII
APPENDIX
7.1
Delphi
BC
CA
CP
DCU
ESOS
EVD
FIE
HP
LLA
PECSA
SECSA
SIN
TP
7-137
APPENDIX VII
Delphi
NOTES
8-138
APPENDIX VII
Delphi
NOTES
8-139
VII APPENDIX
Delphi
NOTES
8-140
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 t apport une attention particulire pour garantir l'exactitude des renseignements contenus dans cette publication par Delphi Diesel Systems Ltd, mais la socit dcline toute responsabilit lgale cet gard. Delphi Diesel
Systems Ltd poursuit un programme intensif de conception et de dveloppement qui peut entraner la modification
des spcifications des produits. Delphi Diesel Systems Ltd se rserve le droit de modifier les spcifications, sans
pravis et si cela est ncessaire, pour assurer les performances optimales de sa gamme de produits.
Tous droits rservs
Toute reproduction, mmorisation dans un systme informatique ou transmission sous quelle que forme que ce
soit, ou par tout moyen lectronique, mcanique, par photocopie, enregistrement ou autre de cette publication est
interdit sans l'autorisation pralable de Delphi Diesel Systems Ltd.
Bei der Zusammenstellung der in dieser Verffentlichung enthaltenen Informationen wurde mit grtmglicher
Sorgfalt vorgegangen. Delphi Diesel Systems Ltd. kann jedoch rechtlich nicht fr etwaige Ungenauigkeiten zur
Verantwortung gezogen werden. Delphi Diesel Systems Ltd. fhrt ein fortlaufendes Designund Entwicklungsprogramm durch, weshalb es mglich ist, da sich Produktdaten ndern. Delphi Diesel Systems Ltd. behlt sich das
Recht vor, ohne Vorankndigung Spezifikationen jederzeit zu ndern, um die optimale Leistung seiner Produkte
sicherzustellen.
Alle Rechte vorbehalten.
Kein Teil dieser Verffentlichung 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, bertragen werden.
Anche se ogni cura stata adottata nel compilare le informazioni di questa pubblicazione, Delphi Diesel Systems
Ltd. Declina qualsiasi responsabilit 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 pu 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 publicacin, 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 diseo e investigacin el cual podra en cualquier momento
alterar la especificacin de los productos. Delphi Diesel Systems Ltd se reserva el derecho de alterar las especificaciones sin notificacin 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 publicacin de ninguna forma o medio
electrnico, mecnico, de fotocopia, grabacin o cualquier otro, sin autorizacin previa de Delphi Diesel Systems
Ltd.
Ainda que se tenha lido o mximo cuidado na compilao da informao contida nesta publicao, a Delphi Diesel
Systems Ltd, no pode aceitar qualquer responsabilidade legal por inexactides. A Delphi Diesel Systems Ltd.
tem um programa intensivo de projecto e desenvolvimento que pode porventura alterar as especificaes do
produto. A Delphi Diesel Systems Ltd. reserva o direito de alterar especificaes sem aviso e sempre que seja
necessario para assegurar um desempenho ptimo da sua linha de produtos.
Todos os direitos reservados.
Nenhuma parte desta publicao pode ser reproduzida, armazenada num sistema de onde possa ser recuperada
ou transmitida de alguma forma, ou por quaisquer meios, electrnico, mecnico, de fotocpia, gravao ou outros,
sem autorizao antecipada de Delphi Diesel Systems Ltd.