The following procedure for fuel injection pump calibration can be done with the fuel injection pump housing on or off the engine.
NOTE: If the fuel injection pump housing is installed on the engine a 146-1853 Hex Key (ball) is required to turn the 8S7271 Setscrew (11) instead of the 5P4205 Wrench.
Removal Of Shutoff Solenoid And Fuel Ratio Control
(9) Shutoff solenoid. (10) Fuel Ratio Control.
1. Remove the fuel shutoff solenoid (9) and fuel ratio control (10) from the fuel injection pump housing cover.
2. Remove the fuel that is in the fuel injection pump housing and the governor housing.
Remove Torque Control And High Idle Adjustment Covers
(11) Torque control cover. (12) High idle adjustment cover.
3. Remove torque control cover (11) and high idle adjustment cover (12).
Installation Of 3P1546 Calibration Pin
(15) 3P1546 Calibration Pin, (with 15.9410 on it).
4. Put 3P1546 Calibration Pin (15), in the fuel injection pump housing.
Install 145-1853 Calibration Fixture
(16) 145-1853 Calibration Fixture. (17) 8S7271 Setscrew. (18) Top Cover.
5. Put 145-1853 Calibration Fixture (16) over 3P1546 Calibration Pin (15). Put 8S7271 Setscrew (17) in the hole over 3P1546 Calibration Pin (15). Tighten 8S7271 Setscrew (16) to a torque of 2.3 to 2.8 N·m (20 to 25 lb in).
NOTE: If the fuel injection pump housing is installed on the engine a 146-1853 Hex Key (ball) is required to turn the 8S7271 Setscrew (11) instead of the 5P4205 Wrench.
6. Remove top cover (18) from the fuel injection pump housing.
Adjustment Of Low Idle Screw
(19) Lever control shaft. (20) Low idle screw. (21) Governor control shaft lever.
7. Adjust low idle screw (20) to position governor control shaft lever (21) to 9.0 ± 1.0 mm (.35 ± .04 in) from the governor housing boss.
Adjust Lever Control Shaft.
(19) Lever control shaft. (22) Dowel.
7. Adjust dowel (22) as needed to obtain lever control shaft (19) end play (X) of 0.30 ± 0.20 mm (.012 ± .008 in).
8. Adjust low idle screw (20) to position governor control shaft lever (21) 9.0 ± 1.0 mm (.35 ± .04 in) from the governor housing boss.
Adjustment Of Crossover Levers
(19) Control lever shaft. (23) Control lever shaft. (24) Feeler gauge. (25) 5P4209 Gauge. (26) Crossover lever. (27) Crossover lever.
9. Install 5P4209 Gauge (25) on control lever shafts (19) and (23). Slide 5P4209 Gauge (25) toward crossover levers (26) and (27) until dowel pin in crossover lever (26) goes into hole in 5P4209 Gauge (25). Use feeler gauge (24) to check the clearance.
Adjustment Of Crossover Levers
(26) Crossover lever. (27) Crossover lever. (28) Screws.
10. The dimension (A) to the dowel pin in crossover lever (26) (with the 3P1546 Calibration Pin installed) is 2.103 ± 0.100 mm (.0828 ± .0039 in).
11. If this dimension is out of tolerance loosen screw (28) and adjust crossover levers (26) and (27) as needed. Tighten screws (28) to a torque of 2.70 ± 0.25 N·m (24 ± 2 lb in).
12. Use the 8S2243 Wrench and remove the 4N0218 Bushing from each of the fuel injection pumps to be checked. Use a 131-3459 Sleeve Holder to remove
Fuel Injection Pump Assembly
(29) Sleeve. (30) Plunger.
NOTE: A 131-3459 Sleeve Holder is used to remove the fuel injection pump so that the sleeve (29) will remain on plunger (30). If sleeve (29) falls off plunger (30) during removal, find it immediately and replace it on plunger (30) before removal of another plunger (30). The original sleeve (29) must remain with the same plunger (30).
141-6727 Calibration Pump Assembly
(31) Barrel. (32) Spring. (33) O-ring seal. (34) Plunger (observe flat on plunger).
Sleeve Control Lever
(19), (23) Control lever shaft. (35) Control lever. (36) Control lever pin. (Y) Centerline of fuel injection pump barrel bore.
Installing 141-6727 Calibration Pump Assembly
(34) Plunger (observe flat on plunger). (35) Control lever. (37) 141-6727 Calibration Pump Assembly. (38) Control lever screws.
13. Clean the barrel and plunger of the 141-6727 Calibration Pump Assembly (37). Put clean diesel fuel on the 141-6727 Calibration Pump Assembly (37).
14. Be sure control levers (35) are free to rotate on their respective shafts. The control lever screws (38) must be free to turn without any friction. Any friction will result in improper torque readings.
15. Install 141-6727 Calibration Pump Assembly (37) in the fuel injection pump housing bore. The plunger (observe flat on plunger) must clear the control lever pin (36). Push down on the 141-6727 Calibration Pump Assembly (37) to compress the O-ring seal (33) on plunger (34). Turn 141-6727 Calibration Pump Assembly (37) counterclockwise approximately 45 degrees to index the plunger (34) on control lever pin (36). The control lever pin (36) is now in contact with the lower machined surface of the plunger (33). Install 7W8120 Bushing and tighten to a torque of 60 N·m (45 lb ft).
NOTE: Be sure the control lever pin (36) is properly aligned in plunger (34). If not properly aligned, difficulty in installing the 141-6727 Calibration Pump Assembly (37) on the other control lever pin (36) may result.
NOTE: Use 7W8120 Bushing and 141-6727 Calibration Pump Assembly (37) together. The contact surfaces of the standard bushing, fuel injection pump and the housing for the fuel injection pumps are sealing surfaces. Keep them clean and free of scratches to prevent leaks.
Putting 3P1568 Dial Indicator On Zero
(3) 1P7379 Microgauge. (4) 3P1568 Dial Indicator (with 3P2226 Collet). (39) Lockscrew. (40) Locknut. (41) 3P2226 Collet.
16. Put 3P1568 Dial Indicator (4) on 1P7379 Microgauge (3) and hold them together tightly. Loosen lockscrew (39) and turn the face of 3P1568 Dial Indicator (4) to put the pointer at “0”. Tighten lockscrew (39).
Remove 3P1568 Dial Indicator (4) from 1P7379 Microgauge (3). Look at the face of 3P1568 Dial Indicator (4) and put 3P1568 Dial Indicator (4) on 1P7379 Microgauge (3) again. The pointer must move through one to one and one half revolutions before stopping at exactly “0”. If the number of revolutions is not correct, loosen the locknut on 3P2226 Collet (41), and adjust the position of the dial indicator until the adjustment is correct.
NOTE: If locknut (40) on the 3P2226 Collet is too tight, it can cause interference in the operation of the dial indicator.
Setting 141-6737 Microgauge
(4) 3P1568 Dial Indicator (with 3P2226 Collet). (42) 141-6737 Microgauge.
17. Set 141-6737 Microgauge (42) for a minus .025 mm (.0010 in) with the 3P1568 Dial Indicator. 4C9508 Wicking Sealant is applied to the 141-6737 Microgauge (42) so the 3P1568 Dial Indicator reading does not change. Cure time is approximately one hour for full cure.
6V0190 Clamps Installed
(35) Control lever. (37) 141-6727 Calibration Pump Assembly. (38) Control lever screws. (42) 141-6737 Microgauge. (43) 6V0190 Clamps. (44) Torque wrench [1.7 N·m (15 lb in)].
18. Put 6V0190 Clamps (43) in position on the lever control shaft. When checking fuel injection pumps on the “slave side” [side opposite from governor lever (21)], put 6V0190 Clamps on both ends of the lever control shaft as shown.
NOTE: When checking the fuel injection pumps on the governor lever side, install a 6V0190 Clamp (43), next to the fuel transfer pump end. The 6V0190 clamp pushes the shaft down against the bottom of its bearing. The other end of the lever control shaft is held down against its bearing by the 3P1546 Calibration Pin (15) which is held by the 8S7271 Setscrew (17). The combination of forces from the 6V0190 Clamps (43) and 3P1546 Calibration Pin (15) is necessary to hold the lever control shaft in its normal operating position against the lifting force from the spring (32) in the 141-6727 Calibration Pump Assembly (37).
19. Position 141-6737 Microgauge (42) on top of the 141-6727 Calibration Pump Assembly (37). The plunger (33) of the 141-6727 Calibration Pump Assembly (37) will be .025 mm (.0010 in) above the top of the barrel (31). When the control lever screws (38) are installed, the plunger (33) and barrel (31) will become near flush with each other.
20. With the torque wrench [1.7 N·m (15 lb in)] (44), tighten either of the control lever screws (38) until it makes contact with control lever (35). Now, tighten the second control lever screw until it makes contact with the control lever.
21. Go back to the first control lever screw and alternatingly, tighten each control lever screw approximately 15 degrees until each control lever screw is tightened 1.7 N·m (15 lb in).
3P1568 Dial Indicator Position
(4) 3P1568 Dial Indicator (with 3P2226 Collet). (37) 141-6727 Calibration Pump Assembly. (45) Crossover lever dowel.
22. Put 3P1568 Dial Indicator (4) on the 141-6727 Calibration Pump Assembly (37) as shown. Hold it tightly in place. To remove any clearance in the linkage, lift crossover lever dowel (45) and rapidly let it go. Do this several times. The 3P1568 Dial Indicator (4) should read .000 ± .010 mm (.0000 ± .0004 in).
Checking With 3P1568 Dial Indicator In Position
(4) 3P1568 Dial Indicator (with 3P2226 Collet). (37) 141-6727 Calibration Pump Assembly. (38) Control lever screws. (44) Torque wrench [1.7 N·m (15 lb in)]. (46) 7W8120 Bushing.
23. Tighten control lever screw (38) as needed to obtain correct reading of .000 ± .010 mm (.0000 ± .0004 in). An additional torque of up to 3.4 N·m (30 lb in) may be used if necessary. If a minus out of tolerance reading is indicated on the 3P1568 Dial Indicator (4), control lever screw (38) was tightened too tight. Loosen control lever screw (38) (according to the 3P1568 Dial Indicator) approximately .08 to .10 mm (.003 to .004 in) with torque wrench [1.7 N·m (15 lb in)] (44).
24. If the 3P1568 Dial Indicator (4) reading is too high on the positive side, tighten control lever screw (38) up to an additional 3.4 N·m (30 lb in) as needed. Do Not exceed 3.4 N·m (30 lb in).
NOTE: If the proper tolerance cannot be obtained with a torque of 3.4 N·m (30 lb in), repeat the procedure.
25. Remove 7W8120 Bushing (46) and 141-6727 Calibration Pump Assembly (37) from the fuel injection pump housing bore. Install 141-6727 Calibration Pump Assembly (37) in the adjacent fuel injection pump housing bore. Tighten the 7W8120 Bushing (46) to a torque of 60 N·m (45 lb ft).
Checking With 3P1568 Dial Indicator In Position
(4) 3P1568 Dial Indicator (with 3P2226 Collet). (38) Control lever screws. (44) Torque wrench [1.7 N·m (15 lb in)].
26. Put 3P1568 Dial Indicator (4) on the 141-6727 Calibration Pump Assembly (37) as shown. Hold it tightly in place. To remove any clearance in the linkage, lift crossover lever dowel (45) and rapidly let it go. Do this several times. The 3P1568 Dial Indicator (4) should read .000 ± .010 mm (.0000 ± .0004 in). Tighten control lever screw (38) as needed to obtain correct reading of .000 ± .010 mm (.0000 ± .0004 in). An additional torque of up to 3.4 N·m (30 lb in) may be used if necessary. If the 3P1568 Dial Indicator (4) reading is too high on the positive side, tighten control lever screw (38) up to an additional 3.4 N·m (30 lb in) as needed. Do Not exceed 3.4 N·m (30 lb in).
27. Repeat the preceeding procedures as necessary to set the remaining fuel injection pumps.