Usage:
Introduction
This section provides the setup and adjustment procedures for testing and adjusting Fuel Injection Pumps. The fuel injection pumps are tested using the Fuel Injection Equipment Test Stand. See Special Instruction SEHS8200, "Using the Fuel Injection Equipment Test Stand:" for operating instructions.
These pumps can also be tested on earlier fuel injection test benches using the same tooling and procedures. See Special Instruction SEHS7465.
Typical Fuel Injection Pump
Tooling
The tools listed are required to test the pump and governor assembly. These tools are not available in a group and must be purchased separately.
Mounting Tools
Calibration Fluid and Lube Line Tooling
Pump
Mount Pump To Test Stand
Base Plate Attached To Rails Of Test Stand
1. Attach 6V9132 Base Plate (1) to test stand rails using 6V9138 Mounting Assembly (T-Bar) and 6V9132 Lock Screw (2).
2. Attach 1U5366 Pump Mounting Plate (3) to base plate using four 0T0924 Bolts and 5M2894 Flat Washers.
Base Plate Attached To Pump Mounting Plate
Connect Pump Drive Adapters To Test Bench
Pump Adapter
1. Install drive adapters (1 and 3).
a. Install 9U7493 Drive Adapter (1) with 1181713 Flat Washer and 1181711 Nut (2). Tighten nut (2) to 55 N·m (40 lb ft).
Drive Adapter
Drive Adapter
2. Align keyway and connect the drive adapter to the chuck. Insert shaft approximately one inch into chuck.
3. Tighten two bolts in chuck.
a. Tighten lock screw on base plate.
b. Install guards.
Testing Pump
Timing Cover
1. Remove timing cover (1).
Timing Indicator Assembly
2. Attach 4C8126 Timing Indicator Assembly (2).
Pressure Tap Screw
3. Remove pressure tap screw (3) and lock (8) from the transfer pump.
4C8054 Tap Fitting Assembled
4. Install reducer (6) in 4C8054 Tap Fitting (7). Install shutoff valve (5) on reducer (6). Install fitting (4) to shutoff valve (5).
Assembled 4C8054 Tap Fitting Installed
5. Put lock (8) on 4C8054 Tap Fitting (7). Install the assembled 4C8054 Tap Fitting (7) to check transfer pump pressure.
Line Connected To Transfer Pump Fittings
6. Connect hose (9) from the 1400 kPa gauge to the transfer pump fittings.
Fuel Injector Test Tube Assemblies
7. Connect 1U5431 Fuel Injection Test Tube Assemblies (10). Assemble from front of fuel pump to manifold block and tighten.
Fuel Inlet Connected To Test Bench
8. Connect hose (11) to test bench.
Fuel Return Connected To Test Bench
9. Connect hose (13) to test bench.
Pressure Line Connected To Timing Indicator Assembly
10. Connect housing pressure line (16) to 4C8126 Timing Indicator Assembly (2).
Shutoff Device Connected
11. Connect cables (19) to terminals (18).
NOTE: This connects the energized-to-run shutoff device to the test bench. Polarity does not matter.
12. Be sure the 12/24 volt switch on back of the test bench is set to 12 volts and the circuit trip switch is in the "ON" position.
13. Be sure the lube oil switch is turned to the "OFF" position.
NOTE: Lube oil is not used with this pump.
14. Turn test switch "ON" and adjust pressure to specified pressure.
15. Adjust test oil temperature to 45 ± 2°C.
16. Be sure the test bench drives the pump in the specified direction.
Spring Connected to Throttle
17. Put one end of spring (20) on the throttle and hook the other end on a 1U5431 Fuel Line Assembly (10).
18. Operate the pump for 10 minutes at 500 rpm with the throttle in the completely open position. This procedure will bring the system to operating temperature and remove air from the system.
NOTE: If the pump has not been adjusted or disassembled, check the pump with the correct specifications from TMI. If the pump is within specifications, no adjustment is required. If the pump has been adjusted or disassembled go to the next step.
Idle adjustment Screws And Torque Screw
19. Back out low idle screw (21), high idle screw (22), and torque screw (23). Make sure the screws do not interfere with the following tests.
20. Check fuel shutoff device per specifications.
21. Check transfer pump lift:
a. Turn fuel pressure OFF at test bench and check to be sure that the bench gauge indicates the vacuum specified in TMI for this pump.
b. Turn bench fuel pressure ON as soon as specified vacuum is achieved.
22. Set transfer pump pressure by stopping the test bench, remove fuel inlet (11).
Fuel Inlet Line Removed
Setting Transfer Pump Pressure
22. To adjust pressure, turn internal adjusting screw with 4C6827 Screwdriver (24). Clockwise adjustment increases the pressure. Counterclockwise adjustment decreases the pressure. Repeat this step until the pressure is set correctly.
23. Close the transfer pump outlet line shutoff valve.
24. Check return test oil flow.
a. Connect pump return port to metered return port on test bench.
b. Run pump at specified speed in TMI and check return flow.
c. After the check is complete, connect the pump return port on test bench.
25. Check pump housing pressure.
a. Run the test bench to the specified speed.
Setting Timing Advance
26. Set the timing advance by loosening nut (26) and adjusting the trimmer screw with 4C6842 Screwdriver (25) until the specified timing is achieved.
27. Run the bench to the specified speed. Make sure flows are correct and the governor is operating properly.
28. If the governor is not operating properly, then stop then bench.
NOTE: The top cover should not need to be remove if the fuel pump was assembled properly. If the top cover does need to be removed, use the following procedures.
Drain Pan Installed
29. Put drain pan (26) under the pump to catch the fuel that will leak from the pump.
Remove Top Cover
30. Loosen bolt (27) to drain fuel from the pump. Remove bolt (27) and remove the three bolts (28) from the top cover (29). Remove top cover (29).
Adjusting Fuel Flow
31. If fuel flow is not correct, remove the front screw and spring. Adjust the internal screw with 4C6728 Screwdriver (30).
NOTE: If the roller-to-roller dimension was set correctly, this step is unnecessary.
32. Install the top cover (29).