Workshop Manual: Dpa Fuel Injection Pump DDNX116A (EN)
Workshop Manual: Dpa Fuel Injection Pump DDNX116A (EN)
Workshop Manual: Dpa Fuel Injection Pump DDNX116A (EN)
DDNX116A(EN)
2007
(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)
(D)
Schutzbrille/Gesichtsschutz tragen.
(E)
(EN)
(F)
(IT)
(NL)
Veiligheidsbril/-masker gebruiken.
(P)
(D)
(E)
(EN)
(F)
(IT)
(NL)
(P)
(D)
(E)
(EN)
(F)
(IT)
(NL)
(P)
TABLE OF CONTENTS
INTRODUCTION
II
III
IV
Delphi
TABLE OF CONTENTS
VI
APPENDIX
VII
ii
Delphi
INTRODUCTION I
TABLE OF CONTENTS
1.
1.1
1.2
1.3
Delphi
1.4
1.5
1.6
INTRODUCTION
The Pump.......................................................................................................................................................................1-1
Description And Operation...........................................................................................................................................1-1
1.2.1
General..........................................................................................................................................................1-1
1.2.2
Working principles.......................................................................................................................................1-1
Overhaul.........................................................................................................................................................................1-3
1.3.1
Service problems.........................................................................................................................................1-3
1.3.2
General..........................................................................................................................................................1-3
Pump Name Plate..........................................................................................................................................................1-5
Overhaul Procedure......................................................................................................................................................1-6
Component Inspection..................................................................................................................................................1-6
iii
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
Delphi
2.
2.1
2.2
2.3
iv
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.11
3.12
3.13
3.14
3.15
3.16
3.17
3.18
3.19
3.20
3.21
Delphi
3.22
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
4.
4.1
4.2
vi
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15
5.16
5.17
5.18
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5.19
vii
5.21
5.22
5.19.3
Break-back throttle lever..........................................................................................................................5-79
Fitting The Governor Control External Components...............................................................................................5-80
5.20.1
Heavy duty throttle lever.........................................................................................................................5-80
5.20.2
Exhaust brake lever..................................................................................................................................5-80
5.20.3
Standard throttle and shut-off levers.......................................................................................................5-81
5.20.4
Spring-returned shut-off lever..................................................................................................................5-81
5.20.5
Torque adjustment screw..........................................................................................................................5-81
5.20.6
Other governor control cover fittings.......................................................................................................5-82
Fitting The High Pressure Outlet Connections And Other Components To The Pump........................................5-82
5.21.1
Backleak connection and inspection cover..............................................................................................5-82
5.21.2
High pressure outlets.................................................................................................................................5-83
Security........................................................................................................................................................................5-84
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5.20
viii
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
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6.11
6.12
ix
VII APPENDIX
TABLE OF CONTENTS
7.2
7.3
7.4
APPENDIX
Torques Values............................................................................................................................................................7-95
7.1.1
End plate, brackets, hydraulic head and rotor.........................................................................................7-95
7.1.2
Governor and housing assemblies...........................................................................................................7-96
7.1.3
Auto advance arrangement.......................................................................................................................7-97
7.1.4
Pump body and drive shaft.......................................................................................................................7-97
Special Tools For Repair.............................................................................................................................................7-98
Special Tools For Testing...........................................................................................................................................7-99
Abbreviations Used In This Manual........................................................................................................................7-100
Delphi
7.
7.1
INTRODUCTION I
INTRODUCTION
1.1
The Pump
The DPA distributor-type fuel injection pump, incorporating a sensitive all-speed governor, is a compact, self-contained
unit for high speed multi-cylinder diesel engines of up to 2 litres (122 in3) capacity per cylinder.
It is a relatively simple design, and incorporates no ball or roller bearings, gears, or highly-stressed springs. The number
of working parts does not increase significantly with an increase in the number of engine cylinders which the pump is
required to serve.
1.2
1.2.1 General
The pump is flange-mounted to the engine. It is oil-tight and, during operation, all moving parts are lubricated by
fuel oil under pressure, so that no additional lubrication system is required. Pressure maintained within the pump
housing prevents the ingress of dust, water, and other foreign matter.
Fuel injection is effected by a single pumping element having two, or four, opposed plungers located within a
transverse bore, or bores, in a central rotating member (or distributor rotor). The rotor revolves in a stationary
member known as the hydraulic head. The pumping plungers are actuated by internal lobes on a cam ring. Fuel
is metered to the plungers during their outward, or filling strokes, and the high pressure charges are distributed
to the engine cylinders through ports in the rotor and the hydraulic head.
The integral governor is of the mechanical, fly-weight, type, and gives accurate control of engine speed under
all load conditions. Most versions of the pump also have an automatic advance device which varies
commencement of injection, depending upon engine speed and load, to achieve optimum injection timing.
The single pumping element ensures uniform delivery of fuel to each engine cylinder and thus eliminates the
need to balance the deliveries from each of the high-pressure outlets (as is the case with inline injection pumps).
Delphi
1-1
I INTRODUCTION
INTRODUCTION
Delphi
Fuel entering the pump through the main inlet connection is pressurised by a sliding-vane transfer pump carried
on the rotor inside the hydraulic head. The pressure will rise with an increase in engine speed and is controlled
by a regulating valve assembly located in the pump end plate. The fuel flows from the transfer pump through
passageways in the hydraulic head via the electric shut-off solenoid (ESOS) (if fitted) and the metering valve to
the pumping element.
The outward travel of the opposed pumping plungers, under any conditions other than full-load, is determined
by the quantity of fuel metered, which varies in accordance with the setting of the metering valve. In consequence,
the rollers which operate the plungers do not follow the entire contour of the internal cam ring, but come into
contact with the cam lobes at positions which vary according to the degree of plunger displacement during the
charging cycle.
The maximum amount of fuel delivered under full-load is regulated by physically limiting the outward travel of
the plungers during the charging cycle.
As the rotor turns, the inlet port is cut off and the single distributor port in the rotor registers with an outlet port
in the hydraulic head. At the same time, the plungers are forced inwards by the rollers in contact with the cam
lobes; fuel under injection pressure passes along the central bore of the rotor and through the aligned ports to
one of the injectors. The rotor has as many inlet ports as the engine has cylinders. Normally, for low-output pumps,
only one port at a time will be used for filling or charging the rotor, but high-output pumps may utilise two or
more filling ports simultaneously, to ensure adequate filling.
The cam lobes are contoured to allow the plungers to travel outwards for a short distance immediately after
pumping ceases, to give a rapid reduction of pressure, and thus a sharp cut-off of fuel to prevent dribble at the
nozzles. If not prevented, fuel which entered the combustion chamber too late to burn correctly would give rise
to excessive exhaust emissions.
A control (or throttle) lever mounted on a shaft in the governor control cover is connected internally to one end
of a spring, the other end of which is connected to the governor control arm. As the control lever is moved towards
a position which corresponds to an increase in the speed or load demand on the engine, the load on the spring
is increased. That load is transmitted to the governor arm and thence to the governor weights via a thrust sleeve.
The weights are then forced inwards.
The governor control arm also carries a spring-loaded link which transmits movement of the weights to the
metering valve. As engine speed increases in response to the increase in pump output, so the weights move
outwards until a new equilibrium is attained between control spring load and the centrifugal force generated by
the weights.
The governor flyweight assembly is mounted on the drive shaft and the control linkage assembly is mounted on
the pump housing, therefore all of the mechanism is contained entirely within the pump housing.
There are two types of drive which may be specified for the DPA pump. They are:
A. Two-piece shaft-and-hub drive
At its drive end, the shaft is fitted into a drive hub which is carried in a plain bearing in the front of the pump
housing. The hub is fixed to the shaft by a central screw,
This type of shaft arrangement may be driven by the engine in one of two ways:
i.
Quill-shaft-driven
A short, external, quill-shaft, which has splines at each end, connects the drive hub to the engine pump
drive gear. The drive gear is carried in bearings within the engine timing cover.
ii.
Gear-driven
In this type of drive, the hub is designed to carry a gear which, when the pump is fitted to the engine, meshes
directly with the other timing gears. This eliminates the backlash due to the clearances between the splines
which exist in the quill-shaft design.
1-2
INTRODUCTION I
INTRODUCTION
B. Single-piece drive
i.
Splined shaft
The single-piece shaft has a spline at its drive end which fits into the engine drive arrangement.
ii.
Tapered single-piece shaft
The uprated single-piece shaft has a standard taper at its drive end, to which is fitted a pump drive
component.
The two-piece shaft may be specified with either a rigid or a cush-drive governor weight cage, dependent on
plunger size. As plunger diameter is increased to provide a higher delivery level, so the torsional oscillation of
the drive due to reaction to high pressure pumping loads increases. This has a detrimental effect on the quality
of governing. In the cush-drive weight cage, the effect of torsional oscillation on the governor mechanism is
greatly reduced.
Dependent upon the pump specification, the governor weight cage may be either removable or may be fixed
permanently to the shaft. In the latter case, the assembly cannot be dismantled and, if necessary, the drive shaft
and weight cage must be replaced as a unit.
All single-piece drive shafts are fitted with cush-drive weight cages.
1.3
Overhaul
Delphi
1.3.2 General
Any tools both standard and special, used for the servicing and repair of fuel injection equipment (FIE) must be
reserved solely for use on FIE. Worn or damaged tools can cause damage to critical components, as well as being
a safety hazard.
This Manual covers the dismantling and reassembly of the two main groups of DPA pumps. However, the features
described for each group are not necessarily exclusive to that group.
If any feature which is not described is encountered, carefully note the position of each component as it is removed
from the pump.
Except in the case of a complete overhaul, full dismantling is not always necessary. When a pump requires
attention, the recommended practice is to set it up on a test machine and check to locate specific faults or
maladjustments. Repairs or adjustments can then be undertaken on the basis of the test results.
Dismantling, assembly, testing and adjustment of the DPA pump must be carried out by trained personnel, using
specialised tools and test apparatus. The service tools listed in this publication must be used to obtain the closest
possible match to factory standards. Conditions of scrupulous cleanliness must be observed in workshops where
pump overhaul is carried out.
The minimum facilities required are:
1.
A bench, covered with non-rusting sheet metal or industrial-grade linoleum and fitted with an Engineers
vice with a jaw size of 100 mm (4 in), The vice jaws must be faced with either soft metal or fibre pads. The
bench must be kept scrupulously clean and used for fuel injection equipment only.
2.
A suitable pump-mounting plate for fitment into the vice or a universal positioning device such as the
Hydraclamp.
3.
Easily-cleaned compartmented trays for separate storage of dismantled components (Such as Part No.
99-708).
4.
All tools as listed in section 7.2 and section 7.3.
1-3
I INTRODUCTION
INTRODUCTION
6.
7.
8.
9.
A low-pressure washing facility using a suitable, approved, cleaning fluid (not water or water-based) to clean
pumps externally prior to dismantling. Cleaning must be carried out in a place separated from the clean
area.
A tank large enough to accommodate a complete pump and filled with clean test oil, near to a source of
clean, dry, variable pressure compressed air for carrying out leakage tests.
A supply of clean, lint-free (non-fluffy) cloths for cleaning and drying components. Cotton waste must
never be used.
A pump test machine which conforms to ISO 4008.
Adequate storage facilities for pumps, tools, and test equipment, with separate areas for pumps before and
after repair.
Note: All cleaning tanks, workshop and test facilities and fluids, must conform to any Fire Prevention or
Health and Safety Regulations in force at the time of use.
Delphi
5.
1-4
INTRODUCTION I
INTRODUCTION
1.4
The number stamped on the name plate attached to the pump housing identifies the type and model of the pump. Pumps
which are of identical build, but with modified settings for different applications, are further identified by the Setting
Code stamped beneath the Despatch Number.
Should the name plate be obscured by paint, care must be taken to ensure that the type details are not defaced when
removing the paint.
A typical Despatch Number could be as shown below:
R 3 2 4 8 F 39 0 Y
This character indicates whether or not an
ESOS is fitted to the pump and, if so, its
type. (For more details, see SIN DT294).
Prior to Design Change Letter D, i.e.
design changes A, B, and C, the
design change letter was placed at the
Delphi
Note: Pumps with Marketing Code M or P and Design Source code 8 are no longer serviced by Delphi, all enquiries
for part and test data should be referred to the engine or vehicle manufacturer / importer.
1-5
I INTRODUCTION
INTRODUCTION
1.5
Overhaul Procedure
When fitting new component parts or assemblies, always ensure that the part number is correct for the pump type. Part
numbers can be checked in the relevant pump Parts List on CD-ROM.
If any part in a mated assembly is damaged or worn, the complete assembly must be rejected. Any component showing
signs of fretting, wear, damage, corrosion, cracks, or distortion, must be discarded.
All O-rings, gaskets, tab washers, and locking and sealing devices must be discarded and new ones fitted. Gasket kits,
as designated in the Parts List, contain all necessary seals, gaskets and washers for most types of pump. In a few cases,
additional separate items are also required.
Drive shaft seals are used in various combinations according to pump type and application. They may be used singly or
in pairs. The lips of the seals may face inwards or outwards, and in twin-seal applications they may face towards or away
from each other. It is essential, therefore, that when the seal (or seals) is (are) removed, note is taken of the quantity and
how they were fitted, so that replacement seals will be correctly fitted during reassembly.
When investigating damage for which there is no obvious explanation, check that all related components are genuine
approved parts of the correct part number.
Only service parts supplied by Delphi Diesel Systems may be used as replacements. Parts supplied from alternative
sources may appear to be externally similar and may carry the same part numbers as the genuine item but may be
inferior in material specification or finish and lead to malfunction or premature failure.
For convenience, Dismantling and Reassembly of pumps fitted with the two classes of drive shaft are listed separately.
1.6
Component Inspection
Note the location of, and inspect, individual parts during dismantling, so that replacements can be obtained with the
minimum of delay. Always ensure that the components removed from any particular pump are correct according to the
relevant Parts List.
The following information lists possible defects, and indicates the main items that may require replacement.
The inspection requirements listed are the minimum advisable:
Check for damage to internal and external threads, especially on the transfer and distributor rotor, hydraulic head,
studs, inlet and outlet connections, and connections and screws liable to be removed or torque-loaded while the
pump is on the engine.
Look for distorted or fractured springs. Check that all springs quoted in the Parts List for the particular pump are
present. If there is evidence that a spring has been bearing against surrounding components, ensure that the correct
spring is fitted.
Check for any scoring, wear, corrosion, or any other damage to machined surfaces, including the pump body,
hydraulic head bore, cam ring, end plate, advance device and end plate mounting faces.
When fitting new O-rings and oil seals care must be taken to use the specified protection caps etc. to avoid damage.
Inspection of seals after assembly is recommended. Internal seals should be dipped in clean test oil prior to being
assembled; external seals should be lightly coated with grease.
Inspect for wear and damage to drive shafts, key-ways, splines and associated parts; this is especially important
on drive plates and quill shafts. Check the drive shaft end float if the thrust face of the housing is worn.
Check the drive shaft hub screw support washer for cracks.
On up-rated pumps, the complete drive shaft assembly must be discarded if any part is defective. The assembly
consists of drive shaft, governor weight cage, cush drive and mated drive plate.
Note: On many types of pump the drive shaft and drive plate are matched during manufacture to give a free fit,
with a controlled backlash. These parts should be kept together and, in the event of wear, the complete assembly
must be renewed.
Inspect for wear and scoring of all mechanical governor linkages, shafts, pivot points, arms and the governor weight
cage and weights. Ensure that the correct number and type of governor weights are fitted.
Delphi
1-6
INTRODUCTION I
INTRODUCTION
Inspect the pumping plungers for nicks, scratches, wear, corrosion, or other damage, and their respective bores
within the distributor rotor.
Note: Great care must be taken with pumping plungers and bores. Plungers must only be removed from the bore
if there is a need to inspect them, and then only for the short time required for inspection. Ensure that each plunger
is correctly replaced in the end of the bore from which it came, and the same way round. Plungers and bores must
be cleaned with clean test oil and reassembled wet. The plungers should be retained in the bore of the rotor by
plunger-retaining clips, or corks.
The rotor must be assembled to the hydraulic head, and the complete assembly immersed in a covered bath of
clean test oil, until required for assembly.
Examine the transfer pump for chipped, broken, or worn transfer pump blades. Blades may be either carbon, resinbonded material, or steel. They are identified by the fact that resin-bonded blades have a groove in the base of the
central slot; carbon blades have no groove. The blades are not interchangeable, and replacement blades MUST
be of the same type.
Inspect the rollers and shoes for damage. Examine roller surfaces and check for their free rotation in their shoes.
Roller and shoe assemblies must be kept together.
Check for valve wear or scoring. Pay special attention to the metering valve and its bore. Examine the metering
valve lever for looseness of its pin, which may be caused by severe operating conditions. Check the regulating
valve and pressurising valves.
Note: A few DPA pumps are fitted with hydraulic heads having an oversize metering valve bore and an oversize
metering valve to suit. Pumps fitted with an oversize metering valve have the number 6,375 etched on the hydraulic
head between the outlet connections adjacent to the metering valve bore. The Parts List will give the metering
valve part number for each individual pump.
Check for defects in the cambox outlet pressurising valve. Shake the assembly and listen for movement of the ball
or the valve; that will denote a collapsed spring.
Inspect for wear in the throttle and shut-off shafts and levers, and in the advance device components.
Delphi
Note: Some governor covers are fitted with bushes in the throttle and shut-off shaft bores. If the bushes are worn,
the complete governor cover must be replaced.
1-7
I INTRODUCTION
Delphi
INTRODUCTION
1-8
Preparation
If the pump is the subject of a warranty claim, carefully check that all anti-tamper seals specified in the Test Plan are
intact. If any seal shows that it has been disturbed, or is missing, it is probable that any claim may be rendered invalid.
Turn the pump on its side, with the inspection cover plate upwards. Remove and discard any sealing wire and seal from
the cover plate securing screws. Unscrew and remove the securing screws and shake proof washers.
Detach the cover plate and discard the gasket. Drain any remaining fuel from the pump into a suitable, clean container,
fitted with a suitable lid. Retain the fuel for subsequent examination if there is found to be corrosion or other
contamination within the pump, especially if the pump may be the subject of a warranty claim.
Examine the components as the pump is dismantled. Refer to section 1.6 (Component Inspection) for guidance.
2.2
Fit the pump to the fixture with the governor control cover (1) uppermost (see graphic below).
2.3
Delphi
2-9
Delphi
2-10
Delphi
2-11
2.6
Delphi
2-12
B) Two-spring linkage
Delphi
2-13
2.7
Note: If no automatic advance device is fitted, a head locating screw will be specified. It serves to locate the hydraulic
head within the pump housing and is one of three screws which retain the hydraulic head.
Invert the pump. Slacken and remove the head locating screw and washer. Discard the washer.
Delphi
Note: Care must be taken, as the head locating fitting is removed from the pump, that the small steel lock-off
ball is not mislaid.
2-14
Delphi
Note: The piston and advance housing are a matched assembly. If either the piston or the housing is damaged,
the complete assembly must be replaced.
2-15
Releasing The Cam Screw Or Cam Advance Screw And Removing The High Pressure Outlet Connections
A) Plain radial.
These are designed with a coned end for direct connection to the high pressure pipes. Remove each connection
and discard the sealing washer.
Note the position in which each banjo is fitted, remove the banjo bolt and discard the sealing washers.
2-16
Delphi
2.9
Delphi
Remove the seal (19), the transfer pump blades (17), and the transfer pump liner (18) from the hydraulic head.
2-17
2.10
Loosening The Transfer Pump Rotor And Removing The Hydraulic Head
Delphi
2-18
Removing The Drive Plate Screws, Top Adjusting Plate, And Rollers And Shoes
2.12
Delphi
2-19
2.13
Delphi
Hold the drive hub (1) with the special tool (3) and, using
the special tool (2), loosen the drive shaft screw by two
turns.
Gently tap the end of the tool holding the screw (as
shown) then remove the screw and spring washer.
Remove the support washer from the hub for
examination.
2-20
Delphi
2-21
Delphi
2-22
Fitting The Drive Hub Seal, Drive Hub And Drive Shaft Assembly
Delphi
Fit the hub (2) into the weight cage (6) and align the
two holes in the hub with the cut-outs (4) and (5)
in the cage. Fit the rubber inserts (3) between the
hub and the weight cage. Place the back plate (1) so
that the three notches slide over the heads of the
three rivets in the weight cage, then rotate the plate
until the double (or master) spline (7) aligns with
the double spline in the cush-drive hub.
3-23
Full
12 & 6 oclock
3.1.4 Fitting the drive shaft and tightening the drive shaft screw
Delphi
3-24
Delphi
Measure the gap between the rear face of the hub (1) and
the pump housing mounting spigot (2), using two sets of
feeler gauges 180 apart in the gap. If dimension A
exceeds 0.25mm (0.010 in), the weight cage and/or the
pump housing must be renewed, and the end float rechecked.
3-25
Delphi
3-26
3.5
Delphi
3-27
Fitting And Aligning The Top Adjusting Plate And The Drive Plate
Fit the top adjusting plate (1), with the chamfered edges
of the roller shoe ear scrolls facing downwards, and
engage the legs of the plate with the guide slots (7) and
(8) of the bottom adjusting plate. Locate the two plates
so that the fuel adjusting slot (4) in the top plate coincides
with the scribed line (2) on the distributor rotor head. Fit
the drive plate (5), with the machined recess facing
downwards, and align the cutaway, which is between
letters A and H, with the fuel adjustment slot as shown.
Fit the drive plate screws (3) and (6) and leave them
finger-tight. (Note that the holes in the drive plate are
offset so that the plate can only be fitted in one position).
Lift the head and rotor assembly and fit the transfer pump
rotor into the distributor rotor, leaving it finger-tight.
3.7
Fit the Stirrup Pipe (1) in the special tool set to two
diametrically-opposite high pressure outlet ports on the
hydraulic head as shown and connect it to a Nozzle
Testing Outfit (NTO). Operate the NTO to raise the
pressure to the figure specified in the Test Data sheet
(generally 30 atm).
Turn the pump rotor until the pumping plungers and
rollers are forced outwards to the maximum fuel
position. Carefully measure the overall roller-to-roller
dimension with a micrometer as shown. The dimension
must be set to the correct test specification figure by
movement of the adjusting plates.
Note: Relief Valve (2) (part of the special tool set) must
be fitted in the fuel line to ensure that the test pressure
of 30 atm. is not exceeded. When other test pressures are
stated on Test Plans this relief valve may be adjusted as
required. If it is not fitted to the tool, care must be taken
not to exceed the specified pressure. Excess pressure
can cause damage to the shoe assemblies and
adjusting plates.
Delphi
3-28
Hold the drive plate with the special tool (4) and tighten
the drive plate screws (1) evenly to the specified torque,
using the special offset tool (2) and (3) (see section 7.1
and Note (2) below).
Note: (1) As the hydraulic head is not yet fitted to the
pump, the screws may be tightened by the use of a
standard socket; however, a different torque to that
specified for the offset tool must be used (see section
7.1).
Now slacken these screws and re-tighten them to the
same torque value. It is important that this sequence
of tightening, slackening, and re-tightening is
followed. Tighten the screws evenly, to avoid rotor
distortion which could cause the plungers to stick.
Note: (2) In use, the torque wrench handle and spanner must form a straight line, with the handle extending away from
the spanner. The distance between the centre of the adaptor and the centre of the ring spanner is 127 mm (5,0 in). With
the superseded special tool the distance is 66 mm (2,6 in). See the list of Torque Values in section 7.1. Certain designs
of torque wrench are not suitable for this operation. If the tools are not kept in a straight line, the applied torque
will be incorrect.
Delphi
Check that the roller-to-roller dimension has not been altered during tightening of the screws.
Disconnect the nozzle testing outfit and remove the stirrup pipe from the high pressure outlets on the hydraulic head.
3-29
3.9.1 Single-stage
Place a new advance housing gasket (8) on the
pump housing. Check that the flat end of the
advance piston (9) is towards the oil feed drilling
(pressure) end of the advance housing (12). Fit the
advance housing and piston assembly to the pump
housing, ensuring that the cam advance screw
engages in the piston, and lightly secure the
assembly in place with the cap nut (1) and a new
Dowty washer (13).
Fit a new O-ring (10) to the pressure end plug (11)
and screw the plug into the advance housing. Fit the
advance spring(s) (7). Fit a new O-ring (6) to the
spring cap (4). Insert the shim washers (5) into the
recess in the cap and screw the cap into the advance
housing. Leave the cap and plug finger-tight.
Note: Refer to the relevant Test Plan for the correct
shim thickness.
Fit a new sealing washer (3) to the plug (2) and fit
the plug to the spring cap, leaving it finger-tight.
3.9.2 Light-load
Delphi
3-30
Delphi
Note: The pump may be fitted with a number of alternative head locking screws; plain, vent, or damper-type. In the
latter case a special tool must be used in conjunction with the torque wrench to gain access to the hexagon under the
head of the damper for tightening. Also, a variety of head locating fittings may be specified; plain (where no advance
assembly is fitted), with a lock-off ball, without a lock-off ball, with manual retard devices (toggle or screw-in), or with
a damper.
3-31
Tightening The Transfer Pump Rotor And Fitting The Transfer Pump Components
Clockwise
3 oclock
Anti-Clockwise
9 oclock
Delphi
3-32
3.13
Fit the sandwich plate (2) (if the end plate is a loose
sandwich plate version) to the end plate (1), ensuring
that the dowel pin in the end plate is fitted into the groove
(3) in the sandwich plate.
Note: Some sandwich plates are bonded to the end
plate.
Place the end plate, with the inlet connection uppermost,
against the hydraulic head, ensuring that the end plate
dowel engages with the slot in the rim of the transfer
pump liner. (The letter C (4) on the end plate signifies
the position in which the dowel is fitted for clockwise
rotation of the pump).
Secure the end plate with the four screws and washers
(items (14) and (13) in section 3.12). Tighten these
screws, and then the inlet connection, to their specified
torque values.
Delphi
Note: Some pump specifications may incorporate a high-pressure pipe support plate or plates (item (15) in section
3.12) held in position by the end plate securing screws. If so, fit the plate(s) in position as noted during dismantling.
3-33
Delphi
3-34
3.15
Delphi
3-35
Delphi
3-36
Throttle Link
3.17.1 Assembly
Place a new housing gasket onto the governor
housing face, with the gasket tongues placed in the
slots (7) of the control bracket. Slide the shut-off bar
(2) into the aperture (6) in the control bracket and
under the lip (1) of the tab washer. Fit the relevant
protection cap to the end of the throttle shaft (5) and
fit new O-rings to the groove(s) in the shaft. Place
the idling spring onto the idling spring guide (not
visible in the illustration see item A in section
3.17.2). Insert the guide into the hole in the governor
arm specified in the Setting Code in the Test Plan
and attach the governor spring (3) to the guide.
Insert the other end of the spring into the hole in the
throttle shaft link (4) also as specified in the Test
Plan. Interpretation of the Setting Code details is
given in the diagram in section 3.17.2).
3.18
Delphi
3.18.1 Fitting the control shafts to the cover and fitting the cover to the pump
Fit the relevant protection cap onto the shut-off shaft and place new shaft O-rings in the grooves. Insert the shaft
into the governor control cover then remove the protection cap. Place the peg on the lower face of the shaft
towards the edge of the cover.
Insert the throttle shaft into the governor control cover and, at the same time, fit the governor control cover onto
the two studs. Whilst lowering the governor control cover into position on the pump housing, engage the shutoff shaft peg with the hook of the shut-off bar. Remove the protection cap.
Fit the cover stud washers and nuts and tighten them to the specified torque. Fit a new sealing washer to the cover
vent screw assembly, fit the vent to the cover and tighten it to the specified torque.
3-37
Delphi
Fit the spring retainer (5) and the spring (4) over the
shaft. Place the lever (3) over the shaft, locating it
correctly onto the flats on the shaft, and hook the
spring into the small hole in the lever, with its other
end around the pillar on the governor cover, as
noted during dismantling. Fit the washer (2) and the
self-locking nut (1). Finally, tighten the nut to the
correct torque value. Check that the lever moves
easily through its full working range.
3-38
Delphi
Fit the spring retainer (8), washer (7), and spring (6)
(with the legs of the spring facing upwards) over
the throttle shaft. Fit the break-back lever (5) and
then the throttle lever (4), so that the spring legs
engage the outer edges of the two lugs (9) & (10)
and (11) & (12) on each lever (or as noted during
dismantling). Also, ensure that the flats in the
break-back lever hole engage with the flats on the
shaft. Fit the throttle lever guide (3), washer (2), and
self-locking nut (1). Tighten the nut to the specified
torque.
Check that the throttle lever operates correctly and
that, when further rotation of the break-back lever
is prevented by contact with the max. speed stop,
the throttle lever is able to rotate further, against the
spring.
3-39
3.20
3.21
Delphi
Fit a new sealing washer to each outlet connection, screw the connection into the hydraulic head and tighten it
to the specified torque.
3-40
3.22
Security
Delphi
Where possible, check that all components have been tightened to their specified torque values.
Fit sealing wire and seals loosely to the cover stud nuts as specified in the Test Plan. Attach locking sleeves and suitable
lengths of locking wire with new seals loosely to the pump for sealing the light load advance adjusting screw (after
Testing) and for the throttle adjusting screw (after final setting on the engine). Do not emboss the seals.
3-41
Delphi
3-42
4.2
Removing The Shaft Locking Screw, The Governor Control Cover Fittings, And The Cover
Delphi
4-43
Delphi
4-44
Delphi
4-45
4.3
Delphi
4-46
Delphi
4-47
4.5
Delphi
4-48
Delphi
Loosen and remove the cap nut (16) and discard the Dowty (or copper) washer (15). Gently ease the advance
housing (14), with its piston (11), from the pump housing. Remove the piston for inspection. If its condition is
satisfactory, re-fit the piston to the advance housing. Remove and discard the gasket (10) and place the advance
assembly in a container of clean test oil.
4-49
Use the special tool (1) to slacken the cam advance screw
(2). If the cam ring has become locked in the pump
housing, lightly tap the screw with a hide mallet to
release the cam ring (3).
4.7
Removing The Clamping Plate, Support Plate, And The High Pressure Outlet Connections
Delphi
4-50
ii.
Note: (1) The delivery valve holder has a sealing face designed with a conical (knife-edge) shape that does not
require a sealing washer between itself and the delivery valve body. If, for any reason, it is removed from the
hydraulic head, it must be replaced with a new holder.
Delphi
Note: (2) Each delivery valve and delivery valve body are a matched pair and must be kept together. Place the
delivery valve assemblies in clean test oil after examination
4-51
Removing The Support Bracket, End Plate, Sandwich Plate, And 'ESOS'
Delphi
4-52
Delphi
4-53
4.9
Delphi
4-54
Loosening The Transfer Pump Rotor And Removing The Hydraulic Head
4.11
Dismantling The Hydraulic Head Assembly And Removing The Cam Ring
Delphi
4-55
Delphi
Note: If a circlip is fitted which has neither straightedged ears nor a timing line, it will be fitted so that
the ears are not visible through the inspection
window.
4-56
Delphi
4-57
Delphi
4-58
Delphi
4-59
Delphi
4-60
Preparation
Delphi
Fit a new O-ring (2) to the screw (1). Fit the speciallyshaped washer (3) and screw to the pump housing,
ensuring that the narrow portion of the washer is
placed beneath the locking screw head, so that the
screw is prevented from being in contact with the
drive shaft. Tighten the screw to its running torque
(see section 7.1.4).
5-61
Full
12 & 6 oclock
Delphi
5-62
Delphi
5-63
5.4
Delphi
5-64
Fitting The Timing Circlip, the Cam Ring, And The Advance Screw
Note: The type of circlip specified will determine whether the ears of the circlip must be visible in the inspection
window for timing, or not.
There are two alternatives:
i.
This version has one rounded ear and one flat ear (as shown in the illustration above). This type is to be fitted
with the gap between the ears placed centrally in the inspection window.
Note: (1) For this type, the position of the circlip will be adjusted after testing is completed, to align either a line
stamped across the ear, or the flat edge, with a letter on the drive plate as designated in the Test Plan.
Note: (2) The circlip must also be positioned according to the direction of rotation of the pump, and the side of
the pump in which the window is placed. If the pump rotates clockwise and the window is on the right-hand side
when viewed from the drive end, the flat ear (or the ear with the stamped line) must be at the bottom of the window
(as shown in the illustration above).
Delphi
ii.
For other arrangements, the circlip must be placed so that the drive plate approaches the timing position across
the gap between the ears. This is important, to ensure accurate setting of timing.
In this version, the circlip is not used for timing the pump; the two circlip ears are of similar shape and must be
fitted approximately 180 away from the window.
Invert the pump and screw the cam advance screw into the cam ring. Tighten the screw to the specified torque
using the special tool. Remove the tool and, if the cam does not move freely in the pump housing, lightly tap it
with a hide mallet to release it.
5-65
5.7
Delphi
5-66
B) The dowel pins, rollers and shoes, and the bottom adjusting plate
Remove the rotor from the hydraulic head and invert it. Insert the dowel pins (2) and (7), with their radiused ends
uppermost, i.e. facing away from the drive plate. and insert the roller and shoe assemblies (3) into their slots in
the rotor head, ensuring that the scroll contours of their ears correspond to those on the adjusting plates. Fit the
bottom adjusting plate (1) into position over the radiused ends of the dowels and over the ears on the shoes. The
adjusting slot (9) in the bottom adjusting plate must be aligned with the matching slot in the top plate.
Note: In four-plunger rotors the plunger pairs have different lengths and are matched as pairs to the bores. The
longest plungers must be fitted into the plunger bore which is in-line with the distributor rotor outlet port (8).
Moisten the rotor with clean test oil and carefully re-fit it into the hydraulic head. Lift the assembly and fit the
transfer pump rotor, leaving it finger tight.
Delphi
Note: The design of the adjusting plates used in later pumps will be slightly different to those shown.
5-67
Setting The Roller-To-Roller Dimension (Two-Plunger Pumps) And Tightening The Drive Plate Screws
Delphi
Note: As the hydraulic head is not yet fitted to the pump, the screws may be tightened by the use of a standard
socket; however, a different torque to that specified for the offset tool must be used (see section 7.1).
5-68
Note: In use, the torque wrench handle and spanner must form a straight line, with the handle extending away
from the spanner. The distance between the centre of the adaptor and the centre of the ring spanner is 127 mm
(5,0 in). With the superseded special tool the distance is 66 mm (2,6 in). See the list of Torque Values in section
7.1. Certain designs of torque wrench are not suitable for this operation. If the tools are not kept in a straight
line, the applied torque will be incorrect.
Check that the roller-to-roller dimension has not been altered during tightening of the screws.
Disconnect the NTO and remove the stirrup pipe from the high pressure outlets on the hydraulic head.
5.9
Advance Device
5.9.1 Single-stage
Place a new advance housing gasket (8) on the
pump housing. Check that the flat end of the
advance piston (9) is towards the oil feed drilling
(pressure) end of the advance housing (12). Fit the
advance housing and piston assembly to the pump
housing, ensuring that the cam advance screw
engages in the piston, and lightly secure the
assembly in place with the cap nut (1) and a new
Dowty washer (13).
Fit a new O-ring (10) to the pressure end plug (11)
and screw the plug into the advance housing. Fit the
advance spring(s) (7). Fit a new O-ring (6) to the
spring cap (4). Insert the shim washers (5) into the
recess in the cap and screw the cap into the advance
housing. Leave the cap and plug finger-tight.
Note: Refer to the relevant Test Plan for the correct shim thickness.
Delphi
Fit a new sealing washer (3) to the plug (2) and fit the plug to the spring cap, leaving it finger-tight.
5-69
5.10
Inserting The Hydraulic Head And Fitting The Head Locking Screws
Delphi
Check that the head locking screw holes are also aligned correctly with their matching holes in the pump housing and
secure the head with the two screws (2) and (6), each fitted with new sealing washers (3) and (5), leaving them fingertight. Ensure that the head vent screw assembly (or damper) and head locking screw are in the same location as noted
when dismantling.
5-70
Fitting And Securing The Hydraulic Head And Tightening The Transfer Pump Rotor
Invert the pump; assemble the seals and steel ball to the
auto advance device head locating fitting (5) (or damper,
if specified). Screw in the fitting, thus securing the
advance housing to the pump housing. Then,
progressively and evenly, tighten the advance housing
cap nut (6), head locating fitting, head vent screw
assembly (2), and head locking screw (3) (or other
hydraulic head fixings) to their specified torques.
Remove the pressure end plug and ensure that the
advance piston is free to move; refit the plug and tighten
it and the spring cap to their respective torques.
Note: The special offset tool will be required to tighten
a damper-type head locating fitting.
Hold the drive shaft with the appropriate tool (1) and tighten the transfer pump rotor with the special tool (4) to the
specified torque. The transfer pump rotor is tightened in the opposite direction to pump rotation (as shown on the pump
name plate).
5.12
Insert the transfer pump liner (6) into the pump housing
with the slot (7) in the rim of the liner in the same position
which it occupied prior to dismantling. See the table
below:
If the liner has a recess in one face, that recess must be
placed at the 6 oclock position.
Fit the liner seal (8).
Carefully insert the transfer pump blades (1) into the
rotor (5). Take care to avoid damaging the edges of the
blades on the edges of the liner. Check the freedom of
movement of the transfer pump blades by rotating the
pump by hand. When lubricated, the grip of the seal
should prevent the liner from rotating as the blades turn.
If split steel blades (2) and (4) are specified, fit the
separating springs (3) to each pair of half-blades, and
insert each pair as an assembly. Ensure that the blades
are free to move within the rotor slots.
Liner groove position (viewed from the rotor end)
Clockwise
3 o'clock
Anti-Clockwise
9 o'clock
Delphi
5-71
Note: The end plate components specified for any particular pump may vary from those shown. It is therefore essential
that the components are noted during dismantling, and that the pump Parts List is consulted.
Fit the spring seat (11), and the sleeve retaining spring (10) into the end plate (13). Moisten the sleeve O-ring with
test oil and place the sleeve assembly, with the adjuster uppermost, into the end plate (use of the threaded
extractor tool, screwed into the sleeve, may ease fitment of the sleeve to the end plate). Fit the filter (3). Using the
appropriate protection sleeve, fit a new O-ring (2) to the fuel inlet connection (1) and screw the connection into
the end plate, leaving it finger-tight.
Delphi
Note: Various designs of fuel inlet connection may be specified with adapters; olive, push-on, or banjo
connectors, for connection to the low-pressure fuel supply pipe. (It may be necessary to fit a special female inlet
connection solely for testing).
5-72
5.14
Fitting The Support Bracket, The End Plate Assembly, And The ESOS
Delphi
Place the end plate, with the inlet connection uppermost, onto the hydraulic head, ensuring that the dowel on the
inner face of the end plate engages in the slot in the rim of the transfer pump liner.
Secure the end plate and high pressure outlet clamping plate(s) (if specified) with the end plate screws. Tighten
these screws and then the inlet connection to their specified torques.
5-73
5.15
Delphi
5-74
Delphi
5-75
Dip the metering valve into clean test oil. Fit the governor
control linkage assembly into the pump housing by
placing the toes on the lower end of the governor arm
onto the step of the thrust sleeve, and at the same time
insert the metering valve into the metering valve bore in
the hydraulic head.
Place the keep plate (1) on the control bracket (3) so that
the slotted end faces away from the linkage hook
assembly. Place two new tab washers (2) and (7) on the
keep plate, with their lips placed nearest to the metering
valve and engaging the long edge of the keep plate.
Screw in the two governor control cover studs (6) and (8)
and leave them finger-tight. Place a new tab washer (5)
on the control bracket in the correct position as shown,
with the tail bent down over that edge of the control
bracket lying under the linkage hook assembly. Insert the
bracket screw (4) and tighten the screw and control cover
studs to their specified torque values. Lock all tabs.
5.17
Delphi
5-76
5.18
Throttle Link
5.18.1 Assembly
Delphi
5-77
5.19
Fitting The Control Shafts To The Governor Control Cover And Fitting The Cover To The Pump
Delphi
5-78
Delphi
Rotate the throttle lever in either direction until the relevant stop on the break-back lever rests against its throttle
stop screw. The throttle shaft should also rotate. Continue to move the throttle lever, which should be capable of
moving further against the spring, but the throttle shaft should rotate no further. Repeat this action in the opposite
direction. Again, the throttle shaft should not rotate once the stop screw is reached. If the action is not as described,
check that the flats in the break-back lever are correctly located with those of the throttle shaft.
5-79
Delphi
Fit the dust cover (8) over the shaft. Place the
hooked end (6) of the spring (7) up through the
central hole (4) in the lever (5), with the turned-over
part (lug) (9) of the lever facing the spring. Whilst
holding the lever and spring together, place the
straight end of the spring against the throttle shaft
boss (10) on the governor control cover. Place the
slotted hole in the lever over the exhaust brake
shaft. Fit the screw (1) with the shake proof washer
(2) under its head and a plain washer (3) against the
lever. Tighten the screw to its specified torque.
5-80
Delphi
5-81
5.21
Fitting The High Pressure Outlet Connections And Other Components To The Pump
Delphi
5-82
ii.
iii.
Note: Do not tighten the holders after they have been fitted to the pump.
Delphi
Fit each banjo bolt (2), with new sealing washers (1), either side of the banjo, and fit each assembly to the hydraulic
head. If the banjos were in any position other than parallel to the axis of the pump prior to dismantling, ensure
that they are re-fitted in the same positions. Tighten the banjo bolts to their specified torque.
5-83
ii.
Pressurising valves
Fit a new sealing washer (1) into each high
pressure outlet, then fit the pressurising valve
(6). Tighten each pressurising valve to the
specified torque.
Axial outlet delivery valves
Fit a new sealing washer (1) into each high
pressure outlet, followed by the delivery valve
assembly (2). Fit the spring peg (4) and spring
(3) to a new delivery valve holder (5), and fit
the holder to the outlet.
Note: Delivery valve holders with conical (knife edge) sealing faces must not be used again, once they have
been removed from the hydraulic head).
Tighten each delivery valve holder, using the specified procedure for achieving the correct torque.
Note: There may be more than one type of high pressure outlet connection fitted to any particular pump. If this
is so, refer to the relevant Parts List, which will indicate the type of connection to be fitted to each outlet.
C) High pressure outlet clamping plate
If a high-pressure outlet clamping plate (2) is
specified with banjo connections and banjos, it
must be fitted to all of the banjos before the banjo
bolts are tightened. Fit a nut (1) to each banjo and
lightly clamp the banjos in position. Do not yet
tighten the nuts to their specified torque. The banjo
bolts may then be tightened to their specified
torque.
5.22
Security
Delphi
Where possible, check that all other components have been tightened to their specified torque values as listed in section
7.1.
Ensure that the appropriate locking sleeves and suitable lengths of locking wire with new seals (as specified in the Test
Plan) are loosely attached to the pump for sealing the governor control cover stud nuts, torque adjustment screw, and
the light-load adjusting screw (if fitted) after Testing, and for sealing the throttle lever maximum speed screw after final
setting on the engine.
5-84
Pre-Test Procedure
6.2
Test Preparation
2.
3.
Pump performance can be influenced by test machine design. To minimise variations in performance, Delphi
requires that their pumps be tested on Hartridge test machines, which conform to the design requirements
contained in the relevant International Standard on FIE testing (ISO 4008, Parts I and II.)
Hartridge test machines (e.g. models HA400, HA700, HA875, HA1100MkII, HA1150, HA2500, HA3000, AVM,
and PGM) have the ability to test the whole range of DPA pumps. If a Hartridge test machine is not available,
the use of a Universal Calibrator is recommended, in conjunction with a test machine of at least 5 kW (7.5
hp) power output, and conforming to ISO 4008 (Part I Drive Systems Requirements)
The details of pump mounting will depend upon the type of test machine available.
Delphi
1.
6-85
Locate the relevant Test Plan, referring to the pump Despatch Number on the pump name plate. The Test
Plan includes information necessary for the correct mounting of the pump on the test machine.
Fit a suitable test drive adaptor to the pump drive shaft. Ensure that the adaptor is fully tightened.
Fit the relevant adaptor ring to the pump mounting plate.
Ensure that the test machine drive is set to be compatible with the pump drive, as described in section 6.2.2
1a above. (Refer to the test machine manufacturers instructions for setting the drive).
Ensure that the direction of rotation of the test machine is selected according to the pump name plate.
Note: Incorrect rotation will result in serious damage to the pump.
7.
Ensure that no end-loading is applied to the pump when it is fitted to the drive adaptor. Rotate the drive by
hand in the direction of normal rotation to check that the pump is free to rotate. Before starting the machine,
check the following:
that the pump is firmly secured to the mounting
that the mounting is secured to the machine bed
that the drive adaptor is securely clamped
4.
The fuel supply pipe to the pump inlet in the end plate.
Backleakage from the outlet connection(s) as appropriate to the pump under test and the test machine being
used.
Transfer pressure gauge either in place of the ESOS, the blanking plug, or a head locking screw. (Refit the
ESOS or blanking plug when instructed by the Test Plan).
Delphi
2.
3.
6-86
6.3
1.
2.
3.
Cam box pressure, from a modified inspection cover plate, or from the governor control cover vent screw
hole.
Test Procedure
General Explanatory Notes and an individual Test Plan, quoting the Despatch Numbers of the range of pumps to
which it may be applied, are published for each different model of pump. The sequence of operations listed in the
Test Plan gives the test performance requirements at various pump speeds, the timing procedure, and any special
precautions necessary to safeguard the pump.
Set the fuel feed pressure as instructed in the Test Plan.
Energise the ESOS, if fitted, with the voltage specified in the Test Plan, or as indicated by the pump Despatch
Number suffix letter (see SIN D054).
Note: There is one version of the ESOS which operates on the energise to stop principle. If specified for the
pump under test, it must not be energised during testing, but only to check its effectiveness in stopping delivery,
when specified in the Test Plan.
4.
Prime the pump thoroughly before testing and at other times during the test, as directed in the Test Plan. Any
variations from the following procedure for certain pumps will be explained in the Test Plan.
i.
Slacken both the vent valve on the governor control cover and the head vent screw.
ii.
Turn on the oil supply to the specified feed pressure (0.14 kg cm2 (0.1 bar)) to fill the pump. Run the pump
at 100 rpm. When test oil, free from bubbles, issues from the vents, re-tighten the vent valve and the vent on
the head locking screw.
iii. Slacken the connections at the injector end of the high pressure pipes or, if fitted on the test machine, open
the bleed valves at the injectors.
iv. Run the pump at 100 rpm. When test oil, free from bubbles, issues from all high pressure pipes, re-tighten
the connections, or close the bleed valves.
v.
Examine the pump after priming for oil leaks at all jointing faces, connections and oil seals. Pumps must be
free from leaks, both when running and when stationary.
Note: (1) If the pump is to undergo a test before dismantling, ensure that all diesel fuel is drained out before
it is mounted on the test machine; leave the HP and backleak pipes loose and collect the discharged fuel until
test oil starts to appear. Discard the oil and tighten the connections.
Note: (2) Do not run the pump for long periods at high speed and at low or zero output. The Test Plan will
give specific instructions for both of these activities.
6.4
Delphi
Fuel delivery is checked at full throttle setting at one or more speeds by measuring the volume passing through each
injector. All critical fuel delivery levels are quoted in the Test Plan in mm3/stroke and the shot count used should be
adjusted to give a minimum volume of 40 % with one operation of the shot count mechanism, when using open-top
glass graduates. All other fuel delivery checks are quoted over 200 shots.
The Test Plan will quote the maximum fuel delivery, overall tolerance, and the maximum permissible delivery variation
spread between injectors.
6-87
6.6
Delphi
The test pressure gauge is connected to the governor control cover vent screw hole or to a modified inspection cover.
On self-venting pumps this must allow the pressure to be read without restricting the permanent bleeding operation.
This can be carried out by using the requisite tools from the special service kit.
On some pumps the cam box is pressurised during running by a spring-loaded ball pressurising valve located in the
backleak connection in the inspection cover.
Pressure limits are given in the appropriate Test Plan. If pressure is incorrect, check that the pump is not leaking and
there is no restriction in the backleak passageways. If the pressurising valve is faulty, a new inspection cover complete
with valve must be fitted.
6-88
6.7.1 Preparation
The Test Plan will specify the type of advance device fitted, and details the tests required. Advance devices may
be tested using either of two special tools:
A) The early advance gauge (quadrant type)
This tool consists of a gauge with a scale covering
0 to 18 and a feeler pin. To fit this tool, proceed as
follows:
Remove the small screw from the piston spring cap
on the advance device.
Pass the threaded bush of the feeler pin assembly
through the hole in the tool bracket.
Insert the end of the plunger into the hole in the
spring cap and screw the bush into the spring cap
hole. This will clamp the bracket between the spring
cap and the shoulder on the threaded bush.
Zero the gauge by moving the scale relative to the
pointer.
Delphi
To fit the gauge to the advance device, remove the small plug from the spring cap (1) and fit the gauge body in
its place. There is a small plug (10) from which any air may be bled before commencing testing.
With the gauge fitted to the advance device, slacken the knurled tube-locking nut (2) and rotate the tube so that
the required scale is uppermost. Lightly tighten the locking nut.
Rotate the end-plug to align the scale zero with the groove in the rod.
Run the pump at low speed and vent any trapped air by slackening the bleed screw.
6-89
6.8
The maximum fuel delivery is checked at a specified speed, with the throttle and shut-off controls fully open.
If output is not within the specified limits, stop the test machine and adjust the pump as follows:
1.
Slacken the screws securing the inspection cover, and drain the pump.
2.
Remove the inspection cover.
3.
Slacken the two drive plate screws.
4.
Engage the special tool with the slot in the periphery of the adjusting plate.
5.
Adjust the plate by lightly tapping the knurled end of the tool. The direction in which the drive plate is turned to
increase or to decrease fuelling depends on the type of adjusting plates fitted.
6.
Tighten the drive plate screws evenly to the specified torque value, using the special adaptor tool, the special
spanner tool, and a torque wrench.
Note: (1) It will be necessary to prevent the drive from rotating by placing a suitable bar in the test bench drive.
Ensure that the test bench is switched off before doing this.
Note: (2) When the special adaptor tool is used with the spanner tool (now superseded) the centre of the spanner
must be 66 mm (2,6 in) from the centre of the adaptor. When using the later, recommended, spanner tool the
distance between the spanner and adaptor centres is 127 mm (5,0 in). The torque spanner and the ring spanner
must form a straight line when tightening the screws and care must be taken to ensure that the spanner does not
strike the side of the inspection aperture.
Replace and secure the inspection cover, refill the pump, vent it as necessary and re-check the maximum fuel
delivery. Repeat until the delivery volumes are within the specified limits.
Delphi
7.
6-90
6.10
Timing
On completion of all testing, the drive hub screw of a hub-drive pump must be slackened and re-tightened three times
to the correct torque value.
6.10.1 Introduction
All pumps require timing, to enable them to be fitted correctly to the engine. See the Test Plan for relevant details.
After completion of tests remove the pump from the test machine and drain it by slackening the inspection cover
screws. Remove the inspection cover.
Delphi
A) Radial outlets
Connect the stirrup pipe to the fuel outlet specified on the test plan and to the outlet diametrically opposite. Fit
the relief valve to the stirrup pipe, and connect the complete tool through a high-pressure pipe to a Nozzle Testing
Outfit (NTO).
For 3-cylinder pumps, connect one branch of the stirrup pipe to the specified outlet; arrange the other branch to
face away from the pump and seal it off with a blanking plug.
6-91
Slide the shaft locking screw washer into the position which will allow the screw to contact the drive shaft and
tighten the screw to the specified torque (do not exceed the specified torque) to avoid damage to the drive shaft.
This screw will remain tightened until the pump is secured to its engine. Then the screw must be loosened and
the two-position washer moved completely across, to allow the screw to be re-tightened without interfering with
the drive shaft.
6-92
Delphi
Sealing Of Pumps
After test, the inspection cover, with the exception of those pumps which are internally-timed, must be made tamperproof by passing sealing wire through the heads of the two securing screws and affixing a lead seal. The same must be
applied to the governor cover dome nuts, and both seals must be embossed with an authorised stamp.
A sleeve must be fitted over the torque screw on externally-adjusted pumps and secured with wire and lead seal, also
embossed. Governor maximum speed screws cannot be sealed until the governor is set on the engine, so the cover, the
wire and the lead seal should be loosely attached to the pump in order that the pump can be made tamper-proof after
final adjustment.
6.12
Storage Of Pumps
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 30C and plus 60C. Humidity must be between
0 and 80 percent.
Pumps must be stored with the axis horizontal; un-boxed pumps must never be stored one on top of another.
A stock-rotation system must be observed, to minimise storage time of any individual pump. If a pump has been
stored for one year, it must be subjected to a full test according to the relevant Test Plan, and the storage procedure
repeated.
6-93
Delphi
6-94
APPENDIX VII
APPENDIX
7.1
Torques Values
The torque values are correct at the time of printing. Any variations made necessary by modifications or changes in
design will be published in the relevant Service Instruction Notes and the latest information must be followed.
Remarks
Nm
kg m
ib in
5.1
0.52
45.0
31.0
3.10
270.0
31.0
3.10
270.0
36.0
3.60
320.0
31.0
3.10
270.0
36.0
3.60
320.0
41.0
4.20
360.0
10.0 plus 65 5
3.10
91.0
41.0
4.10
360.0
41.0
4.10
360.0
14.0
1.40
120.0
50.8
5.18
450.0
19.1
1.95
170.0
7.3
0.75
65.0
13.5
1.38
120.0
3.1
0.32
28.0
15.0
1.53
130.0
18.1
1.85
160.0
28.4
2.90
250.0
15.7
1.60
140.0
24.3
2.48
215.0
13.0
1.33
115.0
20.6
2.10
180.0
Delphi
Torque
(A) obtained with spanner 7144-511 and adaptor 7144-482 (66 mm centre distance)
(B) obtained with spanner 7144-511A and adaptor 7144-482 (127 mm centre distance)
(C) obtained with spanner 7244-404 and adaptor 7144-482 (127 mm centre distance)
7-95
VII APPENDIX
APPENDIX
Note: Drive plate screws are tightened using a special technique with either Spanner Tool Part No 7144-511A or
7244-404, and an adaptor fitted in a torque wrench. In use, the torque wrench handle and spanner must form a
straight line with the handle extending away from the spanner. The distance between the centre of the adaptor
and the centre of the ring spanner is 127 mm (5.0 in). If superseded Spanner Tool Part No 7144-511 is used, this
distance is 66 mm (2.16 in). Certain designs of torque wrench are not suitable for this operation.
Torque
Remarks
Nm
kg m
ib in
27.1
2.76
240.0
40.7
4.15
360.0
7.3
0.75
65.0
2.3
0.24
20.0
5.7
0.58
50.0
Locking screw
0.7
0.07
6.0
Lock nut
6.8
0.69
60.0
Lock nut
6.8
0.69
60.0
4.5
0.46
40.0
3.4
0.35
30.0
4.5
0.45
40.0
4.5
0.45
40.0
2.3
0.24
21.0
3.4
0.35
30.0
4.5
0.46
40.0
6.8
0.69
60.0
2.2
0.23
20.0
Delphi
7-96
APPENDIX VII
APPENDIX
7.1.3 Auto advance arrangement
Torque
Item
Remarks
Nm
kg m
ib in
Spring cap
28.4
2.90
250.0
33.8
3.45
300.0
50.6
5.18
450.0
Piston plug
28.4
2.90
250.0
29.9
3.05
265.0
4.5
0.46
40.0
Cap nut
14.7
1.50
130.0
32.4
3.30
285.0
39.5
4.03
350.0
Housing stud
6.8
0.69
60.0
33.8
3.45
300.0
Self-venting pump
Torque
Nm
kg m
ib in
32.3
3.30
285.0
Remarks
Slacken and tighten to the correct torque value.
Carry out this operation three times.
36.3
3.70
320.0
81.4
8.30
720.0
81.4
8.30
720.0
Backleak connection
20.6
2.10
180.0
6.8
0.69
60.0
In 'locked' position
20.0
2.10
180.0
In 'running' position
Delphi
7-97
VII APPENDIX
APPENDIX
7.2
Dial gauge
1000-317
1804-14
Solenoid socket
1804-15A
1804-526
1804-528
TP rotor spanner
7044-889
7144-260A
7144-261
7144-262
7144-482
7244-404
7144-744
7144-773
7244-23A
7244-24
7244-125B
Drive extractor
7244-231
7244-334A
7244-405
7144-900
7044-897
7044-898
7144-11
7144-18
Seal protection cap, throttle and shut-off shaft, latch valve sleeve nut and switch
7144-458C
7244-184
7144-459A
7144-894
1804-449
Delphi
Description
7-98
APPENDIX VII
APPENDIX
7.3
DPA202A
7244-275A
TP adjuster, M12
7244-410A
TP adjuster, M14
7244-571
7244-597
7244-417
7244-590
7244-590/1
7244-590/2
7244-27
46 mm ring
7244-26D
50 mm ring
7244-26E
7244-28
7244-30
7244-31
7244-32
7244-29
7144-875
7144-559A
7144-760
Delphi
Description
7-99
VII APPENDIX
APPENDIX
Abbreviations Used In This Manual
C
AA
atm
ESOS
FIE
in
ISO
kg cm2
lb/in2
Max
mm
NTO
SIN
TP
degrees Celsius
Automatic Advance
Atmospheres
Electric Shut-Off Solenoid
Fuel Injection Equipment
inches
International Standards Organisation
Kilograms Per Centimetre
Pounds Per Square Inch
Maximum
Millimetres
Nozzle Testing Outfit
Service Information Notes
Transfer Pressure
Delphi
7.4
7-100
APPENDIX VII
Delphi
NOTES
8-101
Whilst every care has been taken in compiling the information in this publication, Delphi Diesel Systems Ltd. cannot accept legal liability for any inaccuracies.
Delphi Diesel Systems Ltd. has an intensive programme of design and development which may well alter product specification. Delphi Diesel Systems Ltd.
reserve the right to alter specifications without notice and whenever necessary to ensure optimum performance from its product range.
All Rights Reserved
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form, or by any means, electronic, mechanical, photocopying,
recording or otherwise, without the prior permission of Delphi Diesel Systems Ltd.
Il a 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.