Professional Documents
Culture Documents
DDNX121(EN)
2006
(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)
CONTENTS
INTRODUCTION
DISMANTLING
REASSEMBLY
TEST PROCEDURE
BC
CA
CP
DCU
ESOS
EVD
FIE
HP
LLA
PECSA
SECSA
SIN
TP
Boost Control
Cold Advance
Zero Backlash Drive
Diesel Control Unit
Electric Shut-Off Solenoid
Exploded View Diagram
Fuel injection Equipment
High Pressure
Light Load Advance
Pressure End Cold Servo Advance
Spring End Cold Servo Advance
Service Instruction Note
Transfer Pressure
Produced by:
Delphi Diesel Systems Ltd.
Diesel Aftermarket
Spartan Close
Warwick
CV34 6AG
UK
ii
CONTENTS
1
1.1
1.2
1.3
1.4
1.5
1.6
INTRODUCTION
The Pump ........................................................................................................................................................................7
General ............................................................................................................................................................................7
This Manual .....................................................................................................................................................................8
Equipment .......................................................................................................................................................................8
Replacement of Parts .....................................................................................................................................................8
Pump Name Plate ......................................................................................................................................................8 - 9
2
2.1
DISMANTLING
Preparation ....................................................................................................................................................................11
2.1.1 Cleaning and draining .......................................................................................................................................11
2.1.2 Mounting the pump ..........................................................................................................................................11
2.1.3 Removing sealing caps and locking wire ........................................................................................................11
2.1.4 Removing the drive hub (if fitted) ....................................................................................................................12
2.1.5 Measuring drive shaft end float .......................................................................................................................12
2.1.6 Measuring drive shaft radial play ....................................................................................................................12
Governor Cover, Control Levers & Link Assembly ....................................................................................................13
2.2.1 Removing the fuel return connections ............................................................................................................13
2.2.2 Removing the throttle lever stop screws, maximum fuel screw and torque control screw ......................13
2.2.3 Removing the throttle lever ..............................................................................................................................13
2.2.4 Removing the exhaust brake lever ..................................................................................................................14
2.2.5 Removing the electronic actuator throttle lever (rigid type) .........................................................................14
2.2.6 Removing the governor cover assembly .................................................................................................14 - 19
Dismantling the All-Speed Governor ..........................................................................................................................19
Removing the Control Bracket and Arm Assembly ...................................................................................................19
2.4.1 Removing the scroll link plate return spring ..................................................................................................19
2.4.2 Removing the governor control bracket assembly ........................................................................................20
2.4.3 Dismantling the governor control arm assembly ..........................................................................................20
2.4.4 Dismantling the governor control plate assembly for torque trimmer variant ..........................................20
High Pressure Outlets, End Plate Assembly, Electric Shut-off Solenoid (ESOS) & Transfer Pump ......................21
2.5.1 High pressure outlets ........................................................................................................................................21
2.5.2 Endplate assembly .....................................................................................................................................21 - 22
Electric Shut-off Solenoid (ESOS) ...............................................................................................................................22
Transfer Pump ...............................................................................................................................................................23
2.7.1 Removing the transfer pump components .....................................................................................................23
2.7.2 Slackening the transfer pump rotor .................................................................................................................23
Advance Device .....................................................................................................................................................23 - 24
2.8.1 Single piston design with 2 bolt cold advance ...............................................................................................24
2.8.2 Servo piston design with 2 bolt cold advance ........................................................................................25 - 26
2.8.3 Servo piston design with 4 bolt cold advance ........................................................................................26 - 27
2.8.4 Single piston design without cold advance ............................................................................................27 - 28
Removing the Head Locking Screws and Releasing the Hydraulic Head ...............................................................28
2.9.1 Head locking screws .........................................................................................................................................28
2.9.2 Removing and dismantling the LLA ................................................................................................................28
2.9.3 Removing and dismantling the latch valve ....................................................................................................29
2.9.4 Removing the hydraulic head ..........................................................................................................................29
Drive Shaft .....................................................................................................................................................................30
2.10.1 Dismantling the zero backlash drive assembly .......................................................................................30 - 31
2.10.2 Dismantling the splined drive assembly .........................................................................................................31
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
iii
CONTENTS
2.11
Dismantling the Hydraulic Head - Check and Cheek Plate Designs .........................................................................31
2.11.1 Releasing the drive plate screws .....................................................................................................................31
2.11.2 Dismantling the rotor components ..................................................................................................................32
2.11.3 Removing the lower check or cheek plate ......................................................................................................32
2.11.4 Reverse thrust weight assembly ......................................................................................................................32
2.11.5 Lock-shaft timing ...............................................................................................................................................33
2.11.6 Removing the drive shaft seal/s .......................................................................................................................33
3
3.1
3.2
3.3
4
4.1
4.2
4.3
REASSEMBLY
Preparation ....................................................................................................................................................................39
Assembling the Hydraulic Head ..................................................................................................................................39
4.2.1 Rotor plug ...................................................................................................................................................39 - 40
4.2.2 Drive plate, rollers, shoes and retaining plates .......................................................................................40 - 42
Drive Shaft .....................................................................................................................................................................42
4.3.1 Zero backlash and splined drive with cheek plates ................................................................................42 - 45
4.3.2 Spline drive with check plate head and rotor .........................................................................................45 - 46
iv
CONTENTS
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
Securing the Hydraulic Head and Checking Drive Shaft End Float and Radial Play ..............................................46
4.4.1 Replacing the drive shaft seal/s .......................................................................................................................46
4.4.2 Securing the drive shaft ....................................................................................................................................46
4.4.3 Aligning the hydraulic head .............................................................................................................................47
4.4.4 Checking drive shaft end float ..........................................................................................................................47
4.4.5 Checking drive shaft radial play .......................................................................................................................47
4.4.6 Cam advance screw ..........................................................................................................................................48
4.4.7 Fitting the head locking screws, light load advance valve and latch valves ........................................48 - 49
Advance Device .............................................................................................................................................................49
4.5.1 Single piston design ..................................................................................................................................50 - 51
4.5.2 Servo piston designs .................................................................................................................................52 - 55
4.5.3 2 Bolt cold advance fitted to single piston design ..................................................................................55 - 56
4.5.4 2 bolt cold advance fited to servo piston design ...........................................................................................56
4.5.5 4 bolt cold advance fitted to servo piston design ..........................................................................................57
Transfer Pump and End Plate Assembly ...........................................................................................................................57
4.6.1 Transfer pump ...................................................................................................................................................57 - 58
4.6.2 Endplate assembly ...........................................................................................................................................58 - 60
ESOS and High Pressure Outlets .......................................................................................................................................61
4.7.1 ESOS or blanking plug ............................................................................................................................................61
4.7.2 High pressure outlets and clamp plate ..........................................................................................................61 - 62
Governor Linkage, Control Bracket and Cover .................................................................................................................62
4.8.1 Governor linkage ......................................................................................................................................................62
4.8.2 Fitting the governor assembly to the pump .........................................................................................................62
4.8.3 Fitting the scroll link plate return spring ...............................................................................................................63
4.8.4 Setting the governor link length ............................................................................................................................63
4.8.5 Fitting the governor assembly for torue trimmer variant ........................................................................63 - 65
Assembling the Governor Cover .......................................................................................................................................65
4.9.1 Governor cover only ........................................................................................................................................65 - 66
4.9.2 Governor cover fitted with hydraulic excess fuel .........................................................................................66 - 67
4.9.3 Governor cover fitted with boost control only ..............................................................................................68 - 70
4.9.4 Governor cover fitted with torque control and torque control plus boost control ..................................71 - 75
4.9.5 Governor cover fitted with electronic actuator .............................................................................................75 - 77
Governor Cover External Components .............................................................................................................................77
4.10.1 Fitting backleak components ..................................................................................................................................77
4.10.2 Fitting and aligning external levers .......................................................................................................................78
4.10.3 Control stop screws and plugs ...............................................................................................................................79
Shaft Locking Screw, Drain Plug and Cam Ring Access Plug ........................................................................................80
4.11.1 Shaft locking screw ..................................................................................................................................................80
4.11.2 Drain plug ..................................................................................................................................................................80
4.11.3 Cover ..........................................................................................................................................................................80
4.11.4 Cam ring access plug ..............................................................................................................................................80
Drive Hub ..............................................................................................................................................................................80
Leak Testing ..........................................................................................................................................................................80
Storage ..................................................................................................................................................................................81
4.14.1 New pumps ...............................................................................................................................................................81
4.14.2 Overhauled pumps ..................................................................................................................................................81
4.14.3 Storage conditions ...................................................................................................................................................81
CONTENTS
5
5.1
5.4
TEST PROCEDURE
Preparation ....................................................................................................................................................................83
5.1.1 Leak testing ........................................................................................................................................................83
5.1.2 Test machine ......................................................................................................................................................83
5.1.3 Test machine drive ............................................................................................................................................83
5.1.4 Test conditions ...........................................................................................................................................83 - 84
5.1.5 Connecting fuel lines ........................................................................................................................................84
5.1.6 Machine test procedure .............................................................................................................................84 - 85
5.1.7 Transfer pressure measurement and initial setting .......................................................................................85
5.1.8 Cambox pressure measurement ......................................................................................................................85
5.1.9 Adjustments to be pre-set .........................................................................................................................86 - 87
Test Procedure ...............................................................................................................................................................87
5.2.1 Priming ...............................................................................................................................................................87
5.2.2 Checking and setting transfer pressure ...........................................................................................................88
5.2.3 Cambox pressure and backleakage checks .............................................................................................88 - 89
5.2.4 Speed advance setting ......................................................................................................................................89
5.2.5 Cold advance ..............................................................................................................................................89 - 90
5.2.6 Light load advance valve setting .....................................................................................................................90
5.2.7 Boost control with torque trimmer ..................................................................................................................91
5.2.8 Maximum fuel delivery setting .................................................................................................................91 - 92
5.2.9 Latch valve .........................................................................................................................................................93
5.2.10 Governor setting and testing ...........................................................................................................................93
5.2.11 Torque screw setting .........................................................................................................................................93
5.2.12 Idle setting ..........................................................................................................................................................94
5.2.13 Shut-off control check .......................................................................................................................................94
Timing ............................................................................................................................................................................94
5.3.1 General ........................................................................................................................................................94 - 95
5.3.2 Keyed drive shafts .....................................................................................................................................95 - 96
5.3.3 Keyless drive shafts ...................................................................................................................................96 - 99
Leakage Testing .............................................................................................................................................................99
6
6.1
6.2
6.3
5.2
5.3
vi
INTRODUCTION
DP200 PUMP
1.1
THE PUMP
The DP200 distributor-type fuel injection pump is a
compact, self-contained unit that is suitable for
direct injection engines of up to 33 BHP per cylinder
and with two, three, four or six cylinders. It is
primarily intended for the industrial and agricultural
markets.
All internal working parts are lubricated by fuel oil
and the pump housing is maintained at an internal
pressure that prevents the ingress of external dirt or
other foreign matter.
Standard features include automatic air venting,
compensation for variations in fuel viscosity.
It can be fitted with a range of options to produce
performances to match a wide variety of engine
requirements, including boost-pressure control of
fuel delivery level for turbocharged engines, and
load or speed dependent timing control.
Due to the complexity of this product, the need for
highly-trained personnel, and a high level of
investment in equipment and workshop resources,
together with the need for up-to-date Technical
Information, it can only be tested or serviced by
Delphi Authorised Distributors.
1.2
GENERAL
Fuel pumps may require off-engine workshop
attention for two main reasons:
(a)
(b)
1-7
INTRODUCTION
1.3
1.4
1.
2.
3.
THIS MANUAL
6.
4.
5.
1-8
INTRODUCTION
89 2
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.
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.
Note 1:
Note 2:
1-9
INTRODUCTION
1 - 10
DISMANTLING
2.1
PREPARATION
A list of all tools required to dismantle and
reassemble the pump is in Section 6.
A980
A950
2 - 11
DISMANTLING
A986
1
2
A952
A1005
2 - 12
Drive type
Max. play
Max. Difference
Belt
Gear or hub
0.22 mm
0.27 mm
0.1 mm
0.2 mm
DISMANTLING
2.2
5
6
A953
3
1 2
A1261
A978
A953
A1002
2.2.3.1
Rigid type
Slacken, remove and discard the self-locking nut
(1); remove washer (2), large washer (3), spring
(4), spacer (5), spring retainer (6), throttle lever
(7), and dust cap (8).
4
5
6
7
8
A1006
2.2.3.2
Break-back type
Slacken, remove and discard the self-locking nut
(1); remove washer (2), upper spring retainer (3),
spring (4), lower spring retainer (5), throttle lever
(6), break-back lever (7), and dust cover (8).
A1003
5
A1007
2 - 13
DISMANTLING
2
3
4
5
6
A1256
A954
EVD15
2
4
5
A1048
2.2.6.2
813
814
815
816
817
818
819
A485a
A562a
2 - 14
DISMANTLING
2.2.6.3
a)
b)
A955
1
A788
c)
A787
d)
A568
2 - 15
DISMANTLING
e)
f)
2.2.6.4
a)
5
4
3
2
1
A1257
1
A1469
A1465
1
5
6
A1467
A1466
2 - 16
DISMANTLING
b)
A1473
c)
3
4
7
8
5
2
A1475
1
A1456
3
4
A1476
d)
2 - 17
A1477
2
1
5
3
6
A1048
A1260
DISMANTLING
e)
f)
g)
1
4
A1470
3
4
A1471
1
2
3
4
5
A1473
A1472
2 - 18
DISMANTLING
2.2.6.5
a)
b)
2.3
DT237/2 fig 1
2.4
A958
2
2 - 19
A959
DISMANTLING
5
8
A1049
1 2 3
A961
2
3
1
A1492
2 - 20
DISMANTLING
2.4.4.2
2
1
3
A493A
2.5
5
4
A962
A985b
EVD017
3
2 - 21
A963
DISMANTLING
2.5.2.2
13
a)
b)
2
3
4
5
A1302
14
7
8
11
12
A1008
9
10
A1018
286
285
284
242
240
241
288
248
287
245
A493
2.6
A1258
JPT
2 - 22
DISMANTLING
2.7
TRANSFER PUMP
2.8
b)
A964
A965
A1038
ADVANCE DEVICE
DP200 utilises a number of different advance
devices. They fall into two main categories;
a)
2 - 23
DISMANTLING
A1485
2.8.1.2
2
1
A1486
2.8.1.3
6
5
4
3
2
1
A1487
2 - 24
DISMANTLING
2.8.2.2
A1485
2.8.2.3
2 - 25
DT167 fig 1
DISMANTLING
2.8.2.4
EVD010
2.8.3.2
2.8.3.3
DT157 fig 1
2 - 26
DISMANTLING
2.8.3.4
2.8.4.2
10
12
11
A1250
9
8
7
6
4
A1009
2 - 27
10
3
4
9
8
5
6
7
A1294
DISMANTLING
2.8.4.3
1
A967
2.9
A1251
6
5
a)
b)
3
1
A1011b
277
219
218
217
278
DT228 fig 4
222
221
220
2 - 28
DISMANTLING
b)
9 10 11
A1518
11
10
b
6
DT228 fig 3
A1495
2.9.4.2
2 - 29
A1496
DISMANTLING
A970
A1497
2.10.1.2
1
2.10.1.3
A1498
3
2
2.10.1.4
1
5
A1499
2 - 30
DISMANTLING
2.10.1.5
A1500
2.10.2.2
A1004
1
2
3
4
5
6
7
8
A972
3
4
A1290
2 - 31
DISMANTLING
Remove the rollers and shoes (1), (3), (5) and (7).
Remove the dowel pins (2) and (4) fitted to the cheek
plate design and the upper cheek or check plate (6).
1
6
A975a
A1304
A1254
A1501b
EVD01
2 - 32
DISMANTLING
2
3
2 - 33
A977
DISMANTLING
2 - 34
3.1
CLEANING
3.2.3 Seals
3.2 GENERAL
3.2.1 Mated and matched assemblies
The hydraulic head and rotor should be separated
and examined; they should be re-mated
immediately after examination and immersed in a
covered bath of clean test oil until required for
reassembly into the pump.
Note: If light load advance is specified, the metering
valve will be matched to the hydraulic head.
The following groups are matched and must be kept
assembled in their sets:
Rollers and shoes
Advance housing and piston
Cam ring and scroll plates
Stop solenoid plunger and body
Regulating sleeve, piston and adjusting screw
Governor cover and torque control piston
If any part of a matched set is considered to be unfit
for further service, the whole set must be replaced.
Note: The pump housing drive shaft bush is not a
service repair item; if the bearing is worn, the
housing must be replaced.
3.3 DETAILS
3.3.1 Hydraulic head rotor
Withdraw the rotor from the hydraulic head.
Examine the running surface very closely for signs
of erosion, particularly the area around the delivery
port. If significant erosion is evident, the head and
rotor assembly must be replaced. Also check the
condition of the drive tang on CP drive pumps.
(a)
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)
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)
Damage
Inspect all parts for damage or bending due to
abuse, especially external levers and controls.
3 - 35
3.3.6 Endplate
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.
3.3.19 Orifices
Examine all orifices for blockage and carefully clear
any obstruction with dry compressed air.
3.3.12 Linkages
Inspect all mechanical governor linkages, shafts,
pivot pins and arms for wear, cracks or scoring of
their mating surfaces.
3 - 36
3 - 37
A1488
3 - 38
REASSEMBLY
4.1
PREPARATION
Before using thread-locking compound, if specified,
ensure that the mating surfaces are completely oilfree 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
4 - 39
1
2
3
5
A979
REASSEMBLY
3
4
4.2.2.1
a)
b)
Drive plate
Place the drive plate onto the rotor head, slotted
face downwards. Align the two screw holes.
Caution: 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 incorrectly-assembled example.
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.
A975
1
3
2
4
5
6
A989
A1291
4 - 40
REASSEMBLY
a)
b)
c)
A1252
4 - 41
A1512a
d)
U
333
4.2.2.2
->
c)
A1512b
A989
REASSEMBLY
e)
2
U
333
->
A1512c
4.3
DRIVE SHAFT
1
3
A1500
4.3.1.2
4
1
5
A1499
4 - 42
REASSEMBLY
4.3.1.3
4.3.1.4
4.3.1.5
A1498
2
3
A1503
EVD01
A1502
A1504
4 - 43
REASSEMBLY
4.3.1.6
2
A1505
4.3.1.7
5
1
4
3
8
9
A1506
A1507
4.3.1.8
A1508
4 - 44
REASSEMBLY
4.3.1.9
A1509
4.3.2.2
4.3.2.3
4 - 45
2
3
A1515
REASSEMBLY
4.3.2.4
4.3.2.5
A1781
4.3.2.6
A1495
4.4
A970
4 - 46
REASSEMBLY
3
A952
Max. play
Max. Difference
Belt
Gear or hub
0.22 mm
0.27 mm
0.1 mm
0.2 mm
4 - 47
120
A1259
REASSEMBLY
A997
EVD09
4.4.7.2
7
4
b)
Cap type
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.
3
2
A1011b
277
219
218
217
278
DT228 fig 4
222
221
220
4 - 48
a)
REASSEMBLY
4.4.7.3
a)
b)
4.5
Latch valve
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 locknut (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.
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.
ADVANCE DEVICE
DP200 uses a number of different advance devices.
They will fall into two main categories:
a)
b)
4 - 49
10 11
A1518
DT228 fig 3
REASSEMBLY
4.5.1.1
4.5.1.2
2
1
10
9
A1013
7
8
1
2
3
4
5
6
7
8
A1014
A1295
4 - 50
REASSEMBLY
4.5.1.3
A1015
4.5.1.4
4 - 51
9
8
7
6
5
4
3
2
1
A1016
REASSEMBLY
EVD011
Fit the spring (320), shim (319), spacer (318), stop
plate (317), spring (316), plate (315) and shim
(314).
Using a large flat steel washer having an internal
hole diameter of between 7 & 8 mm, compress
the spring assembly sufficiently enough to fit a
new retaining circlip (313) on to the end of the
servo valve rod.
Check the servo valve for freedom of movement
within the advance piston.
The shims (319) and (314) are of pre-set sizes and
are dedicated for each application and under no
circumstances can the shim sizes be changed.
For identification of the shim sizes, Table A
states the relative dimensions for each part
number specified in the relevant parts list.
EVD010
Table A
Part No.
7185-436A
7185-436B
7185-436C
7185-436D
b)
4 - 52
Thickness
0.76 mm
1.52 mm
2.28 mm
3.04 mm
REASSEMBLY
c)
d)
4.5.2.2
a)
2
1
3
5
A1013
1
2
4 - 53
3
4
5
6
7
8
A1014
A1295
REASSEMBLY
b)
c)
d)
EVD02
e)
5
A1013
4 - 54
REASSEMBLY
f)
4.5.3
4.5.3.1
3
4
5
6
7
8
A1295
A1014
4 - 55
7
6
5
4
3
2
1
A1487
REASSEMBLY
4.5.3.2
A1486
A1485
4.5.3.3
1
2
3
5
6
A1489
4.5.3.4
EVD03
4 - 56
REASSEMBLY
EVD04
4.6
A1038
4.6.1.2
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.
EVD05
4 - 57
REASSEMBLY
4.6.1.3
1
Fit the transfer pump liner (1) into the head. The
cut-out (6) in one end face of the liner must be
positioned at the lowest point in the liner cavity
i.e. approximately the 6 oclock 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
A1019
13
6
14
A1018b
4 - 58
REASSEMBLY
4.6.2.2
4.6.2.3
286
285
284
242
241
240
150
245
287
248
288
A493b
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
4.6.2.4
4 - 59
A1305a
REASSEMBLY
4.6.2.5
A1490
4.6.2.6
2
3
1
4
A1021
4 - 60
REASSEMBLY
4.7
2
3
4
6
7
A1022
A1035
4.7.2.1
7
1
2
3
5
Pressurising valves
4.7.2.2
A1292
Delivery valves
A1023
4 - 61
REASSEMBLY
4.8
2155
1 2 3
9
10
11
12
A1037
A961
1
4 5
A1025b
A999
1
11
A998
10
A1049
4 - 62
REASSEMBLY
A959
1 2
A1000
1
5
4 - 63
A1493B
REASSEMBLY
4.8.5.2
2
3
4
5
A1492A
12 3 4
4.8.5.3
A1491A
4 - 64
REASSEMBLY
4.8.5.4
4.8.5.5
4.9
A1491
3
A1511
4 - 65
3
4
A1026
A1001
REASSEMBLY
4.9.1.2
1 2 3 4
10
A958
4.9.1.3
1
A1271
EVD015
4 - 66
REASSEMBLY
4.9.2.2
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.
EVD016
4.9.2.3
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.
508
EVD014
4.9.2.4
812
811
810
4 - 67
A561
REASSEMBLY
4.9.3.1
1
A787
4.9.3.2
3
2
1
7
5
4
A789
A795b
1
2
4.9.3.3
4
5
A788
4 - 68
REASSEMBLY
4.9.3.4
4.9.3.5
a)
A791
b)
4.9.3.6
A796
A797
5
4
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.
4 - 69
3
2
1
A1030a
6
7
11
A953c
10
A1296a
REASSEMBLY
4.9.3.7
1
6
2
4
A1026
A1001
4.9.3.8
1 2 3 4
10
A958
4.9.3.9
A1271
4 - 70
REASSEMBLY
4.9.4.1
4.9.4.2
A1473
3
6
A1472
4.9.4.3
2
3
7
4
5
A1478a
1
2
3
4
5
A1480
4 - 71
REASSEMBLY
4.9.4.4
2
A791b
4.9.4.5
a)
b)
3
4
A796
A797
4 - 72
REASSEMBLY
4.9.4.6
1
2
4.9.4.7
A1472
4.9.4.8
A1476
6
A1475b
A1519
4 - 73
REASSEMBLY
4.9.4.9
1
3
4
8 9
10
11
A1474
4.9.4.10
1
2
3
4
A1026
A1001
4 - 74
REASSEMBLY
4.9.4.11
4.9.4.12
1 2 3 4
10
A958
A1271
3
3
EVD05
4 - 75
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.
EVD06
4.9.5.1
1
2
3
4
A1026
A1001
4 - 76
REASSEMBLY
4.9.5.2
4.9.5.3
1 2 3 4
10
A958
A1271
4 - 77
A956
REASSEMBLY
2
3
4
5
A1273
6
7
A1272
4.10.2.2
3
4
5
6
7
8
9
10
A1002a
1
A1006
2
4.10.2.3
A1007
4.10.2.4
EVD07
4 - 78
REASSEMBLY
4.10.3.1
Idling
5
4.10.3.2
9 10
4
11
Torque screw
A1262
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
A1278
4.10.3.5
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
4.10.3.4
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.
4.10.3.3
A1003
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 - 79
REASSEMBLY
A950
2
6
1
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.
A950
4
A1282a
A981
4 - 80
REASSEMBLY
4.14 STORAGE
4.14.1 New pumps
New pumps must be stored in their as received
condition, with their original packaging intact
4 - 81
REASSEMBLY
4 - 82
TEST PROCEDURE
5.1
PREPARATION
5 - 83
TEST PROCEDURE
Diag 1
When checking return fuel flow, turn the twoway tap so that the pump backleakage flow goes
directly to the flow meter.
T-Piece Connector
P
u
Fuel
Flow
Meter
L/hr
Diag 2
5 - 84
TEST PROCEDURE
A1042
A1041
5 - 85
TEST PROCEDURE
5.1.9.1
Speed advance
a)
Electronic Advance
The adaptor kit HB343 is required to enable the
electronic probe assembly to be fitted to the
access point in the pump housing for the probe to
contact directly on to the cam ring.
b) Universal Advance Gauge - part no. 7244-590
i) Fitting the gauge
To fit the gauge to the advance device, the plug is
removed from the spring end cap (1). Select a
similar sized test plug to the spring end cap just
removed and fit the gauge assembly to the
pump.
ii) Setting
With the gauge fitted to the advance housing,
slacken the knurled tube-locking nut (4) and
rotate the tube so that the required scale (3) is
uppermost; lightly tighten the locking nut.
Rotate the end-plug (2) to align the scale zero
with the groove in the rod.
Before taking readings, run the pump at low
speed and vent any air in the gauge by slackening
the bleed screw (1).
1
2
A1044
5.1.9.2
5.1.9.3
Boost control
Check that the control spring and pre-load spring
shims and the initial stroke setting are as
specified in the Test Plan.
A1042a
5 - 86
TEST PROCEDURE
5.1.9.4
Throttle lever
The throttle lever should normally be secured in
the fully open position.
In the case of Test Plans that demand that the
throttle travel be measured or set to a particular
figure, use a throttle movement gauge (3). Fit
gauge rod (6) to the throttle lever and fit the other
end of the gauge over the peg (2) on the bracket
(1). The bracket is fitted to a convenient part of
the drive adaptor. Use the lock-screw (not visible
in the illustration) in the block (5) to hold the
throttle lever in the required position.
Pointer (4) indicates lever position against the
scale on the gauge.
5.1.9.5
Idling control
A1046
1
5.1.9.6
Torque screw
Set the torque screw (2) as required by the Test
Plan. Lightly tighten the lock nut.
5.2
TEST PROCEDURE
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.
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 - 87
A953
TEST PROCEDURE
TRANSFER PRESSURE
A1041a
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.
Run the test machine at very low speed [A] as
specified in the test plan (typically 100 rev/min).
Confirm that the pressure is above the minimum
specified.
Failure to meet the minimum pressure normally
indicates badly worn transfer pressure pump
components.
If, at the Test Plan transfer pressure check at higher
speed [B] the pressure cannot be obtained, check the
end plate assembly for correct components.
Transfer pressure must be correct, as advance
performance and delivery levels depend upon
accurate setting.
PUMP SPEED
A1285
psi
Diag 3
rpm
5 - 88
TEST PROCEDURE
Backleakage is usually checked at about the midpoint in the working speed range. Excessive
backleakage may be due to an internal leak e.g. worn
advance device or damaged or missing seals.
Low backleakage could be attributed to poor fuel
supply to the transfer pressure pump or restriction of
fuel flow from the H & R into the pump cambox via
advance assembly or restriction orifice.
SPEED ADVANCE
D
START RETARD
B
SPEED
A1287
5 - 89
TEST PROCEDURE
5.2.5.2
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.)
A1039
5 - 90
TEST PROCEDURE
Tool2
Chart1
A1516
5.2.8.1
5 - 91
A1043
TEST PROCEDURE
5.2.8.2
Boost control
a) Boost control tester
The stroke of the boost control diaphragm
should have been pre-set during assembly. Fit
an approved Boost Control Tester (1) to the test
machine and connect it to a supply of dry, clean,
compressed air. Connect the outlet of the Tester
to the boost control inlet.
FUEL DELIVERY
A1040
A1288
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.
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.
A
C
B
PUMP SPEED
5 - 92
TEST PROCEDURE
FUEL DELIVERY
GOVERNOR
RUN-OUT
A953a
SPEED
A1289
FUEL DELIVERY
WITH TORQUE
SCREW SET
A953a
SPEED
5 - 93
A1309
TEST PROCEDURE
A953
A1002a
5.3
TIMING
5.3.1 General
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:
5 - 94
TEST PROCEDURE
A1298
5.3.2.2
5 - 95
A1307
TEST PROCEDURE
A1299
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
If specified, scribe a line on the pump housing
flange, using the guide on the gauge.
If an offset is specified, de-pressurise the pump
outlet and rotate the shaft by the specified angle
and in the required direction.
Alternatively, slide the shaft locking screw
washer into the position that will allow the screw
to contact the shaft and tighten the screw to the
specified torque.
A1301
Procedure
Note: A pump fitted with a drive flange should
have the timing checked according to the
instruction in Section 5.3.3.7 before the flange is
removed. The flange being keyless, has no
positive register with the drive shaft and once
removed the timing angle is lost.
Therefore for warranty purposes it is essential to
check timing before pump test.
5 - 96
TEST PROCEDURE
5.3.3.2
5.3.3.3
5 - 97
DT221/2 fig 1
TEST PROCEDURE
5.3.3.4
A
DT221/2 fig 2
5.3.3.5
5.3.3.6
DT221/2 fig 3
5 - 98
TEST PROCEDURE
5.3.3.7
5.4
LEAKAGE TESTING
All pumps must be pressure tested after machine
testing.
Drain test oil from the pump. Connect a supply of
clean, dry, variable pressure compressed air to the
pump fuel inlet and return connections. Immerse
the pump in a tank of clean test oil.
Raise the pressure to 1.4 bar (20 lbf/in2). Leave the
pump immersed for ten minutes and then look for
leaks.
If leaks are detected remove and rectify. Some or
the entire Test Plan may need to be repeated,
depending upon the rectification necessary.
If no leaks are detected, reduce the pressure to 0.14
bar (2 lbf/in2) for 30 seconds. If no leaks appear,
return the pressure to 1.4 bar (20 lbf/in2) and wait for
30 seconds. If there is still no air leak, the pump may
be passed as leak-free. The setting devices must be
sealed with wire and lead seals (embossed with an
authorised stamp) or other methods as specified.
5 - 99
A1047
TEST PROCEDURE
5 - 100
6.1
TOOLING
Part Number
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
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
6 - 101
Part Number
Description
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
7244-622
7244-622A
1804-411
6408-59
7174-62
7244-275/3
YWB206
Signal Generator
7244-125B
7044-889
7244-24
6 - 102
Part Number
Description
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
6 - 103
6.2
TORQUE VALUES
NM
LBF.IN
LSN Description
Part Number
from
to
from
to
Head Type
101
7182-189
82.00
82.00
720
720
22 mm AF
Comments
101
7182-189
90.40
90.40
800
800
22 mm AF
101
7185-631
90.00
90.00
796
796
22 mm AF
101
7185-758
90.00
90.00
796
796
22 mm AF
114
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
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
6 - 104
NM
LSN Description
Part Number
from
LBF.IN
to
from
to
Head Type
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
Comments
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
240
Inlet Connection
7180-348H
34.00
34.00
300
300
24 mm AF
240
Inlet Connection
7180-348J
34.00
34.00
300
300
24 mm AF
240
Inlet Connection
7180-348N
34.00
34.00
300
300
27 mm AF
240
Inlet Connection
7180-348P
34.00
34.00
300
300
27 mm AF
252
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
6 - 105
NM
LSN Description
307
325
Part Number
7185-312
7123-473
from
LBF.IN
to
from
to
Head Type
13.50
16.50
120
146
22 mm AF
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
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
420
Hd Locating Fitting
7174-660AA
40.00
40.00
350
350
3/4" AF
420
Hd Locating Fitting
7174-660AB
40.00
40.00
350
350
3/4" AF
420
Hd Locating Fitting
7174-660U
36.00
36.00
315
385
3/4" AF
420
Hd Locating Fitting
7174-660W
36.00
36.00
315
385
3/4" AF
420
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
6 - 106
Comments
NM
LBF.IN
LSN Description
Part Number
from
to
from
to
Head Type
504
7174-917C
6.80
506
7182-569A
5.10
6.80
60
60
13 mm AF
5.10
45
45
508
7174-336A
10 mm AF
4.50
4.50
40
40
508
7174-895C
4 mm Allen
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
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
6 - 107
Comments
NM
LBF.IN
LSN Description
Part Number
from
to
from
to
Head Type
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
Torx
640
Backleak Adaptor
7185-772A
14.00
14.00
120
120
16 mm AF
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
22 mm AF
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
6 - 108
Comments
6 - 109
6 - 110
6 - 111
6 - 112
6 - 113
6 - 114
738
737
730
740
729
736
728
734
727
726
733
725
732
724
743
731
723
719
735
6 - 115
722
718
739
537
715
702
538
703
704
705
706
742
721
708
707
709
710
711
611
712
741
713
714
701
720
6 - 116
6 - 117
1001
1013
1026
1012
1017
1016
1019
1020
6 - 118
1007
1004
1002
1008
1009
1010
1011
1025
1024
1021
1018
1022
1023
1006
1005
1003
1001
09 / 2002
1015
1014
1102
1101
1105
1106
1104
1107
1108
1103
1109
1110
6 - 119
507
1111
603
607
604
741
09 / 2002
602
610
6 - 120
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.