The following procedure for fuel injection pump calibration can be done with the fuel injection pump housing on or off the engine.
Removal Of Covers
(9) Shutoff solenoid. (10) Top cover.
1. Remove the fuel shutoff solenoid (9), top cover (1) of the fuel injection pump housing and the cover over the torque control group.
2. Remove the fuel that is in the fuel injection pump housing and the governor housing.
Installing Calibration Pin
(7) 3P1546 Calibration Pin (with 15.9410 on it).
3. Install 3P1546 Calibration Pin (7) in the calibration hole.
Installing 5P6602 Adapter And 8S7271 Screw
(11) 8S7271 Screw. (12) 1D4533 Bolt. (13) 5P6602 Adapter. (14) 1D4538 Bolt.
4. Install 5P6602 Adapter (13) as shown. Fasten it in position on the fuel injection pump housing with a 1D4533 Bolt (12) and a 1D4538 Bolt (14).
5. Put 8S7271 Screw (11) in the hole over 3P1546 Calibration Pin (7). Tighten 8S7271 Screw (11) to 2.3 to 2.8 N·m (20 to 25 lb in).
Adjustment Of Low Idle Screw
(15) Low idle screw. (16) Lever.
6. Adjust low idle screw (15) to position lever (16) to 8.9 ± 1.0 mm (.35 ± .04 in) from governor housing boss.
7. Use the 8S2243 Wrench and remove the fuel injection pumps to be checked.
NOTE: If a fuel injection pump is removed carefully, the sleeve will remain on the pump plunger. If the sleeve falls off the pump plunger during removal, find it immediately and replace it on the pump plunger before removal of another fuel injection pump. The original sleeve must remain with the same pump plunger.
NOTE: When sleeve is installed on pump plunger, the narrower of the two lands on the sleeve must be toward top of fuel injection pump (nearest the pump spring).
Installing 3P1540 Calibration Pump
(1) 3P1540 Calibration Pump.
8. Clean the barrel and plunger of 3P1540 Calibration Pump (1). Put clean diesel fuel on the 3P1540 Calibration Pump (1) for lubrication.
3P1540 Calibration Pump Springs
(1) 5P6557 Spring. (2) 1P7377 Spring.
NOTE: Be sure that the 3P1540 Calibration Pump (1) is the 5P6557 Spring instead of the 1P7377 Spring which was installed on earlier calibration pumps.
Calibration Pump Installed
(1) 3P1540 Calibration Pump. (17) Tang (on lever). (18) Lever. (19) Groove of calibration pump. (20) Flat on plunger.
9. Put 3P1540 Calibration Pump (1) in the place of the fuel injection pump to be checked with the flat place (20) on the plunger toward tang (17) on lever (18). When the 3P1540 Calibration Pump (1) is all the way in the bore, turn it 180 degrees in either clockwise or counterclockwise direction. Tang (17) on lever (18) is now in groove (19) of 3P1540 Calibration Pump (1). Then install 7W8120 Bushing (2). Use the 8S2243 Wrench and a torque wrench to tighten the 7W8120 Bushing (2) to 80 ± 7 N·m (60 ± 5 lb ft).
NOTE: Turning 3P1540 Calibration Pump (1) 180 degrees gives the same reference point for all measurements.
NOTE: Use 7W8120 Bushing (2) and 3P1540 Calibration Pump (1) together. The contact surfaces of the standard bushing, fuel injection pump and the fuel injection pump housing are sealing surfaces. Keep them clean and free of scratches to prevent leaks.
Putting Dial Indicator On Zero
(3) 1P7379 Microgauge. (4) 3P1568 Dial Indicator (with 3P2226 Collet). (21) Lockscrew. (22) Locknut. (23) 3P2226 Collet.
10. Put 3P1568 Dial Indicator (4) on 1P7379 Microgauge (3) and hold them together tightly. Loosen lockscrew (21) and turn the face of 3P1568 Dial Indicator (4) to put the pointer at “0”. Tighten lockscrew (21).
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 (23), and adjust the position of the 3P1568 Dial Indicator until the adjustment is correct.
NOTE: If locknut (22) on the 3P2226 Collet is too tight, it can cause interference in the operation of the 3P1568 Dial Indicator (4).
6V0190 Clamp Installed
(24) Shaft. (25) 6V0190 Clamp.
11. Put 6V0190 Clamp (25) in the position shown, next to the transfer pump end. 6V0190 Clamp (25) pushes shaft (24) down against the bottom of its bearing. The other end of shaft (24) is held down against its bearing by 3P1546 Calibration Pin (7) which is held by 8S7271 Screw (11).
The combination of forces from 6V0190 Clamp (25) and 3P1546 Calibration Pin (7) is necessary to hold shaft (24) is in its normal operating position against the lifting force from the spring in 3P1540 Calibration Pump (1).
Dial Indicator Position
(4) 3P1568 Dial Indicator (with 3P2226 Collet). (25) Clamp.
NOTE: When checking fuel injection pumps on the “slave” side [side opposite from governor control lever (16)], put clamp (25) on both ends of sleeve shaft as shown.
12. Put 3P1568 Dial Indicator (4) on the 3P1540 Calibration Pump (1) as shown. Hold it tightly in place. Move shaft (24) toward the governor end to remove end play. To remove any clearance in the linkage, lift the crossover lever dowel and rapidly let it go. Do this several times. Then look at the reading on the 3P1568 Dial Indicator (4).
Installing Clamp On “Slave” Side
(25) 6V0190 Clamps.
13. If the 3P1568 Dial Indicator (4) reading is more than ± 0.050 mm from “0.000” (outside the Total Tolerance), do Steps 17 through 20, Adjusting Fuel Pump Calibration.
3P1568 Dial Indicator Reading
Desired reading for all fuel injection pumps is “0.000”.
NOTE: Maximum permissible tolerance for fuel injection pump readings in any Fuel Injection Pump Group is 0.100 mm (-0.050 to +0.050 mm on dial indicator).
NOTE: Maximum permissible differences between any two fuel injection pumps in the same Fuel Injection Pump Group is 0.050 mm.
NOTE: Total Tolerance shows the maximum permissible range of pointer positions which are acceptable. If any reading is outside the range of Total Tolerance, do Adjusting Fuel Injection Pump Calibration for all fuel injection pumps.
NOTE: Band is an example only. It shows a 0.050 mm range. This range shows the maximum permissible difference between any two readings for all the fuel injection pumps. If any two readings are farther apart than the 0.050 mm range, do Adjusting Fuel Injection Pump Calibration for all fuel injection pumps.
If the 3P1568 Dial Indicator (4) reading is near either end of the Total Tolerance, check another pump. If the next reading is outside the Total Tolerance or if the two readings have a difference of 0.050 mm or more, do Steps 15 through 19, Adjustment Of Fuel Injection Pump Calibration.
NOTE: The service technician doing the checking must make the decisions of which and how many fuel injection pumps to check according to the symptoms of the fuel injection pump being tested.
14. If 3P1568 Dial Indicator (4) readings for all the fuel injection pumps are within the limits in Step 13, the calibration is acceptable. Remove the tooling, and install the parts which were removed.
NOTE: For troubleshooting purposes, if the 3P1568 Dial Indicator (4) reading is “0” or near “0”, the calibration of the other fuel injection pumps is probably in the tolerance.