Disassembly and Assembly of A900C-W Electronic Governor Actuator for P8 Fuel Injection Pump 2015-10-15 1

Actuator Components Fuel limit/shutdown assembly Housing Swing arm assembly Iron core 1

Disassembly 2

Step 1：Remove Small Cover 1.Loosen and remove 4 screws, and remove the small cover, see Fig 1. 1 3

Step 2：Remove Actuator (1) 1) Release the swing arm screw lock, see Fig.2. 2) Loosen and remove the swing arm screw, see Fig.3. 2 3 4

Step 3：Install Actuator (2) 1) Remove the swing arm from the shaft, see Fig.4. 2) Loosen and remove the 2 screws (M6X20) on the actuator housing, see Fig. 5. Shaft 4 Swing arm 5 5

Step 4：Install Actuator (3) 1) Loosen the 4 screws in the actuator housing, see Fig 6 and 7. 2) Remove the 2 upper screws. 6 7 6

Step 5: Install Actuator (4) 1) Move the actuator swing arm backwards, see Fig 8. 2) Remove the 2 lower screws, see Fig 9. 8 9 7

Step 6: Remove Connecting Pin 1) Release the nut lock. Hold the nut with a spanner (8 mm) and loosen the locking nut, see Fig 10. 2) Remove the locking nut, spring washer, larger plain washer and plain washer from the connecting pin that connecting the fuel pump rack and actuator, see Fig 11. 3) Remove the actuator knuckle bushing, see Fig 12; remove the plain washer, spacer, plain washer from the pin, see Fig. 13 4) Remove the pin from the rack and remove the nut and double-locking ear washer from the pin , see Fig 14. Spacer knuckle bushing Pin 13 14 12 Torque wrench and Adapter 10 11 8

17 15 16 Step 7：Remove Mid Plate Paper gasket 1) Loosen and remove the 6 screws (2 upper ones and 4 lower ones) , see Fig.15. 2) Remove the screws with spring washers and plain washers, see Fig.16. 3) Remove the mid Plate and discard the O-ring and paper gasket, see Fig 2 and 17. 4) Remove the trimming gaskets (ring gasket) from the camshaft. Keep the same number of trimming gaskets when assembly. Rack 2 upper screws 17 Mid plate 15 16 4 lower screws 9

Assembly 10

Step 1: Install Mid Plate & Paper Gasket 1) Install the paper gasket on the fuel injection pump end surface, see Fig.1. 2) Install the trimming gaskets on the fuel injection pump camshaft. The number of the gaskets must be the same as removed. Install the mid plate (see Fig 2) and move the trimming gaskets into the mid plate. 3) Install 6 screws with 6 plain washers and 6 spring washers, and tighten the screws to 6 N·m, see Fig 3. Note: After tightened, 4 lower screws should not be higher than the plate surface. Paper Gasket Rack 2 upper screws 1 Mid plate 3 2 4 lower screws 11

Step 2 : Install Connecting Pin 1) Install the nut and double-locking-ear washer on the connecting pin, see Fig 4. 2) Connect the connecting pin and the fuel pump rack through the hole in the rack, and install the plain washer, spacer and plain washer in turn on the pin, see Fig 5; 3) Install the actuator knuckle bushing on the pin, see Fig 6. And install the plain washer, larger washer, spring washer and locking nut in turn on the pin, see Fig. 7. 4) Hold the nut with a spanner (8 mm) and tighten the locking nut with torque wrench to 4 N·m, see Fig 8. Lock the nut by the 2 ears of double-locking-ear washer. Spacer knuckle bushing 5 6 4 Pin Torque wrench and adapter 7 8 12

Step 3: Install Actuator (1) 1) Install 2 sets of screws (M6X20, inner hex), plain washer and spring washer in the holes at the mid of the actuator, see Fig 9. 2) Pull out the swing arm of the actuator through the housing, see Fig 10. 3) Put the O-ring in the groove of the actuator and install the actuator onto the mid plate. 4) Tighten the 2 mid screws half way to connect the actuator to the mid plate, and install and pre-tighten the 2 upper screws (M6X25) fixing the actuator to the mid plate and the 2 screws (M6X20) fixing the actuator bracket to the mid plate in the same way as installing the mid screws, see Fig 11. 9 10 11 2 mid screws Swing arm 13

Step 4：Install Actuator (2) 1) Tighten the mid and upper screws to 6 N·m, see Fig 12. 2) Loosen 2 screws (M8X20, inner hex) connecting the actuator to its bracket, see Fig 13. 2 screws ((M8X20) 12 13 14

Step 5：Install Actuator (3) 1) Tighten the 2 screws (M6X20) connecting the actuator bracket to the mid plate to 6 N·m, see Fig 14. 2) Tighten the 2 screws (M8X20) connecting the actuator to its bracket to 15 N·m, see Fig 15. 14 15 15

Step 6：Install Actuator (4) 1) Install the actuator swing arm on the shaft, see Fig 16. 2)Tighten the swing arm screw with a spanner, see Fig 17. 3) Use a screwdriver to lock the screw with the locking washer, see Fig 18. 4) Make the ear of locking washer contact with one side of screw head with a pair of nipper pliers, see Fig 19. Shaft 1 16 17 Swing arm Locking washer 18 19 16

Step 7：Install Actuator (4) 1) Push the actuator swing arm with hand to check if the linkage of actuator and rack move smoothly. Check the shutdown stop to see if it is perpendicular. Push the actuator connecting lever to check and make sure that when the shutdown stop is at any position, the actuator connecting lever can return to its starting position smoothly if turning the shutdown handle, see Fig 20. 2) After making sure that the rack can move smoothly and a safe shutdown can be guaranteed, install the small cover with a new O-ring in its groove and tighten 4 screws to 4 N·m, see Fig 21. 9 20 21 17