Beruflich Dokumente
Kultur Dokumente
Instruction Note
D IESEL SEP 2002
SUBJECT:
SUBJECT : Dismantling/Re-
Dismantling/Re-assembly and test procedures.
This note should be used in conjunction with DPA Workshop Manual DDNX116 (equivalent
manual XNB134) and Service Instruction Note SIN 508 (UK note DT319).
1. DISMANTLING/REASSEMBLY
DISMANTLING/REASSEMBLY PROCEDURES
For consistency, parts list line sequence numbers have been used to identify the
components referred to in the text of the dismantling/assembly procedures (refer to Fig. 2
on page 6 of 9).
1.1 Dismantling
Fit the pump to the mounting fixture with the governor control cover uppermost.
1.2 Removing the governor control cover fittings and the cover.
Slacken the throttle lever trunnion locknut (420) and the throttle shaft locknut (157).
Slacken the throttle lever adjusting screw nut (423), then unscrew the adjusting screw (424)
from the throttle lever trunnion (422). Unscrew the nut (423) from the throttle lever adjusting
screw, then remove the screw from the cover.
Unscrew and remove the throttle shaft locknut (157) and washer (163). Remove the throttle
lever (164) and the dust cap (354). Unscrew and remove the locknut (420), washer (421) and
trunnion from the throttle lever.
Slacken the droop screw locknut (428).
Unscrew and remove the cover sealing plug (435) using tool 1804-625. Discard the O-ring seal
(436).
Remove the cover vent screw (153A) and discard the washer (153).
Note:
Note The governor cover must be removed as follows to avoid damaging the governor
spring.
Unscrew and remove the four governor cover screws (438).
Delphi Diesel Aftermarket 1624 Meijer Drive Troy, Michigan 48084 USA
Tel: [1] 248.288.2000 Fax: [1] 248.280.8280 © Delphi Diesel Systems
SIN 509 – Mar 02 - 2 of 9
Fit protection cap 7144-459A to the throttle shaft (175). Rotate the throttle shaft fully clockwise to
clear the metering valve stop (431). Lift off the governor cover and at the same time press
down the protection cap/throttle shaft. The shaft must be pressed fully through the cover, to
remain with the pump and connected to the governor spring. Unhook and remove the governor
spring (127) from the governor spring pin (456) and throttle shaft link. Discard the governor
cover trapped seal (426) and throttle shaft O-rings (131).
From the cover, slacken the over speed adjusting screw locknut (441), then remove the
adjusting screw (440) (if fitted). Remove the nut (441) from the screw (440) and discard the
locknut seal (442). Remove the droop adjusting screw locknut (428) and discard the seal (429).
Remove the droop adjusting screw (430) and metering valve stop (431) by screwing the adjuster
clockwise into the cover, then detach the metering valve stop from the screw.
Remove the spring linkage components from the linkage hook in the following sequence: self
locking nut, pivot ball nut, pivot ball; remove the hook from the governor arm and then remove
the spring support washer (thin), short spring, spring guide, spring support washer (thick), then
the long spring and lever actuator together. Remove the linkage hook from the metering valve.
Immerse the metering valve in clean test oil.
1.6 Reassembly
Reassembly
Fit the pump housing components, driveshaft assembly, cam ring, hydraulic head and rotor
assembly, advance device (if fitted), transfer pump assembly, end plate assembly and high
pressure connections in accordance with workshop manual DDNX116 (equivalent manual
XNB134).
L
Set the link length (‘L’ --- Fig 1) with a vernier caliper, so
that the dimension specified in the test plan is obtained
between the outer face of the metering valve pin and the
end face of the pump housing. Caution: Ensure that the
‘leg’ of the vernier caliper does not slip into the groove
between the pin and the ‘roller’ top. When setting apply
light pressure to the governor control arm to hold the
metering valve in the fully open position. After setting,
tighten the linkage locknut and re-check the link length to
ensure that it has not changed.
Fig. 1
1.10 Fitting the governor control cov
cover
er fittings and the cover
Fit the metering valve stop (431) to the droop adjusting screw (430). Fit the droop adjusting
screw and metering valve stop from inside the cover. Screw in the adjuster anti-clockwise into
the cover using a suitable Allen key. Screw the adjuster until the metering valve stop is
completely inside the cover (i.e. not protruding beyond the seating face of the cover).
Fit protection cap 7144-459A to the end of the throttle shaft (175) and fit new shaft O-ring seals
(131).
Attach the governor spring (127) to the pin and insert the other end of the spring into the hole in
the throttle shaft link as specified in the Test Plan.
NOTE: The governor arm has only two holes (the top hole is omitted) therefore only
spring linkage codes 4 to 9 will be used.
Fit the protection cap/throttle shaft into the governor cover whilst lowering the cover into
position on the pump housing. Remove the shaft protection cap.
Secure the cover with the four governor cover screws (438) and tighten the screws to the
specified torque.
Fit the trunnion (422) and locknut (420) to the throttle lever with washer (421).
Fit the throttle shaft dust cover (354), throttle lever assembly (164), washer (163) and locknut
(157). Tighten the nut to the specified torque.
Fit the throttle lever adjusting screw (424) through the lug in the cover, then fit the nut (423) to
the screw.
Screw the adjusting screw into the throttle lever trunnion (422). Do not lock the screw with the
nut at this stage.
SIN 509 – Mar 02 - 5 of 9
Fit the lock-nut (428) and a new sealing washer (429) to the droop adjusting screw (430). The
setting for this screw will be specified on the test plan.
Fit the vent screw (153A) with a new sealing washer (153). Tighten the screw to the specified
torque.
Fit the cover sealing plug (435) with a new O-ring seal (436) using tool 1804-625. Tighten the
plug to the specified torque.
Fit the locknut (441) and a new sealing washer (442) to the over speed adjusting screw (440) (if
fitted). Turn the screw into the cover approximately three turns, then tighten the locknut. The
setting for this screw will be specified on the Test Plan.
SIN 509 – Mar 02 - 6 of 9
Fig. 2
There are two test plans for each pump despatch number, one for mechanical governor
operation and the other for electronic governor operation.
If a DPG pump is received in service, first determine whether it is set for mechanical governor
operation or has been converted for use with an electronic governor (EG).
Mechanical governor operation: The governor cover will have a plug in the actuator hole (435
fig. 2).
EG operation: Pumps may be received with the EG device fitted or removed (i.e. actuator hole
unplugged). The overspeed protection screw (440 fig. 2) will be removed and the hole plugged.
EG operation:
Remove the EG device (if fitted)
Fit a plug in the actuator hole
Use the applicable EG version test plan
Check the pump to the overcheck test plan (return pump to customer if no fault found).
Rectify any fault found.
Reset pump to the main test plan.
Remove the plug from the actuator hole and refit the EG device (if originally fitted) as
described in 3.3.
Note: All DPG pumps supplied in service will be set for mechanical governor operation.
If a replacement pump is required for a pump with an EG device, it must first be
reset to the EG test plan, then the overspeed protection screw and locknut
removed and the hole plugged before re-fitting the original EG device (plug part
number 7182-569A, washer part number 7022-180S).
If the EG device was previously removed by the customer (i.e. original pump
received with the actuator hole unplugged) there are two options:
- Return the replacement pump advising the customer to reset the pump in
accordance with the electronic conversion procedure.
SIN 509 – Mar 02 - 8 of 9
- At the request of the customer reset the pump to the EG test plan before
returning the pump.
4. DPG DIAGNOSTICS
The DPG pump has introduced a number of new features that could give rise to problems during
setting/adjustments.
It is probable that the pump’s initial calibration settings will need to be ‘fine tuned’ in order to get
the optimum performance on the engine or generator.
The tables below give guidance on faults which could be attributed to the new features.
a) Test Bench
b) Engine
Engine no load speed too low Over speed screw set too far in.
Throttle setting screw set too low .
c) Gen set
5. WARRANTY
SIN510 (UK note DW027) details the terms and conditions for this pump fitted with or
without an EG device.