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Service Instruction

Instruction Note
D IESEL SEP 2002

Based on UK DT320(EN) SIN 509

DPG PUMPS (DPA)


EQUIPMENT: Pumps 3230F560T, 3349F250T, 3340F260T, 3260F530T and 3340F280T
fitted to gen set and constant speed applications. First customer
Wilsons gen sets equipped with Perkins engines.

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.

1.3 Removing the governor arm and control bracket assembly


Remove the stabiliser piston (450) from the body (453) by compressing the stabiliser spring
(449). Unscrew the piston from the spring whilst holding the spring. Unscrew the spring (449)
from the thread of the stud (447).
Using suitable circlip pliers, remove the circlip (451) retaining the stabiliser body (453), then
remove the body and compression spring (452) from the governor arm.
Unscrew and remove the nut (455) retaining the governor spring pin (456). Remove the pin
from the governor arm.
Press down the tabs on the studs and bracket screw tab washers (446, 448, 181). Remove the
studs (445, 447) and bracket screw (180) and discard their tab washers.
Lift off, as an assembly, the governor arm and control bracket assembly (113N), complete with
governor arm, metering valve, over speed spring assembly and the linkage hook assembly
(131B).
Note: Do not dismantle the governor arm/control bracket assembly and the over speed
spring assembly as, if any component is worn or damaged, the assembly must be
replaced completely.

1.4 Removing and dismantling the governor linkage


linkage assembly
Note: It is not essential to dismantle the linkage, as if any component is worn or
damaged, the assembly must be replaced completely.

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.

1.5 Remaining assemblies


Remove the advance device (if fitted), high pressure outlet connections, end plate assembly,
transfer pump assembly, hydraulic head and rotor assembly, cam ring and driveshaft assembly
in accordance with workshop manual DDNX116 (equivalent manual XNB134).
Note: Do not remove the drive rubber (elastomer ring clutch) from the drive shaft
assembly, if the component is worn or damaged, the assembly must be replaced
completely.
SIN 509 – Mar 02 - 3 of 9

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).

1.7 Assembling the governor control linkage


Fit the long spring to the lever actuator, then fit the linkage hook through the actuator and the
long spring, engaging the hook in the actuator slot. Fit the spring support washer (thick) to the
linkage hook, then the spring guide, short spring and spring support washer (thin). Pass the
linkage hook through the hole in the governor arm and then fit the pivot ball, pivot ball nut and
the self-locking nut. Dip the metering valve in clean test oil then fit the metering valve to the
hook.

1.8 Fitting the governor arm and control bracket assembly


Fit, as an assembly, the governor arm and control bracket assembly (113N), complete with
governor arm, metering valve, over speed spring assembly and the linkage hook assembly
(131B). Fit it 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 new tab washers (446, 448, 181) for the studs (445, 447) and bracket screw (180) on the
control bracket with the tails bent down over the bracket. Fit the stud and bracket screws, push
the control bracket assembly towards the hydraulic head and tighten the screws to the specified
torque values. Lock all tabs.
Fit the governor spring pin (456) through the governor arm with the governor spring hole
towards the metering valve. The pin must be positioned with the pin hole horizontal (i.e. flats
vertical). Retain the pin with the nut (455) and tighten the nut to the specified torque.
Fit the compression spring (452) to the stabiliser body (453), fit the body to the governor arm
with the orifice uppermost and retain the body with the circlip (451). Position the circlip with the
‘legs’ downwards.
Screw the end coil of the stabiliser spring (449) clockwise to the end of the thread on the stud
(447). Do not force it over the thread diameter. Dip the piston in clean test oil then screw the
piston (450) into the end coil of the stabiliser spring (449) to the end of the thread until tight.
Compress the spring and fit the piston into the body (453).
SIN 509 – Mar 02 - 4 of 9

1.9 Setting the governor link length

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.

Pump Housing end face

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 a new governor cover trapped seal (426) to 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

2. ADDITIONAL TORQUE VALUES


VALUES
Governor bracket stud LSN 445 45.0 lbf in 5.1 Nm
Governor bracket stud LSN 447 45.0 lbf in 5.1 Nm
Governor bracket screw LSN 180 19.0 lbf in 2.1 Nm
Governor spring pin nut LSN 455 16.0 lbf in 1.8 Nm
Governor cover screws LSN 438 35.0 lbf in 4.0 Nm
Throttle lever setting screw LSN 423 50.0 lbf in 5.7 Nm
Throttle shaft locknut LSN 157 30.0 lbf in 3.4 Nm
Cover sealing plug LSN 435 62.0 lbf in 7.0 Nm
Over speed screw locknut LSN 441 40.0 lbf in 4.5 Nm
Droop control adjusting screw locknut LSN 428 40.0 lbf in 4.5 Nm
Throttle lever trunnion locknut LSN 420 50.0 lbf in 5.7 Nm
Bleed screw LSN 153A 120.0 lbf in 14.0 Nm
Blank plug --- over speed ------------ 45.0 lbf in 5.1 Nm
Actuator fixing screws ------------ 35.0 lbf in 4.0 Nm
SIN 509 – Mar 02 - 7 of 9

3. TEST CONDITIONS AND PROCEDURES


3.1 Test conditions
Test Plans for DPG pumps will use EURO test conditions (using the same conditions as DP200
EURO) and will be listed under the heading ‘DPA EURO PUMPS’. They will also include an
overcheck procedure.

There are two test plans for each pump despatch number, one for mechanical governor
operation and the other for electronic governor operation.

e.g. Mechanical: Test Plan number 3230560


Electronic: Test Plan number 3230560EG

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.

3.2 Test procedures


Mechanical governor operation:
Use the applicable non 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.

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.

3.3 Preparing and fitting the actuator


Lubricate the o-ring on the actuator spigot with test oil.
Holding the actuator with the sealing face uppermost, rotate the actuator lever fully clockwise.
Position the actuator with the electrical connector facing towards you and the lever downwards.
Align the actuator fixing holes with those on the cover and gently lower the actuator into position
on the pump. The actuator must be pressed into position against the cover as the O-ring
engages. It should not be rotated out of alignment with the cover bosses during fitting, as this
could cause incorrect engagement with the control linkage.
Fit and tighten the actuator fixing screws.
Refer to the engine/generator set manufacturer’s additional fitting instructions to complete the
conversion.

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

Fault Possible causes


Low delivery --- 750 rpm Over speed screw set too far in.
Droop adjuster set too far in.
Transfer pressure set too low.
Low delivery --- 900 rpm Transfer pressure set too low.
Test nozzle flow restriction .
Pump spec build incorrect.
Unable to set fuel with throttle setting screw Incorrect link length .
at 785 rpm Incorrect governor hook-up.
Incorrect governor spring.
Governor spring damage due to incorrect
assembly (i.e. stretched/damaged spring)
Unable to set fuel with droop screw at 765 Over speed screw set too far in Incorrect link
rpm length
SIN 509 – Mar 02 - 9 of 9

b) Engine

Fault Possible causes


Low power Over speed screw set too far in.
Droop adjuster set too far in.
Engine unstable Droop adjuster set too far out.
Air in pump cambox.
Fuel filter blocked causing aeration of fuel
at pump inlet.

Governor droop excessive Droop adjuster set too far in.


Over speed screw set too far in.
Engine no load speed too high Throttle setting screw set too high.

Engine no load speed too low Over speed screw set too far in.
Throttle setting screw set too low .

c) Gen set

Fault Possible causes

Low power Over speed screw set too far in.


Engine stalls Over speed screw set too far in.
Droop adjuster set too far in
Engine shuts down after start up Over speed screw set too far out allowing
generator set over speed trip to operate.
Throttle setting screw set too high allowing
generator set over speed trip to operate
Engine unstable Droop adjuster set too far out.
Air in pump cambox.
Fuel filter blocked causing aeration of fuel at
pump inlet.
Running out of fuel.
Output frequency change excessive Droop adjuster set too far in.
Over speed screw set too far in.
Output frequency too high Throttle setting screw set too high.
Output frequency too low Throttle setting screw set too low .
Over speed screw set too far in.

5. WARRANTY
SIN510 (UK note DW027) details the terms and conditions for this pump fitted with or
without an EG device.