Cummins Fuel Injection Pump User Manual

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screw

and position washer.

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Table of Contents

Summary General Information

Preparatory Steps Remove

Front Gear Train

Rear Gear Train

Fuel Injection Pump, Rotary

(005-014)

Install

Front Gear Train

Rear Gear Train

Time Finishing Steps

Summary

Stepblock Stepblock

Stepblock

Front Gear Train: Remove access cap, gear retaining nut and washer.

Disengage pin after locating top dead center.

Prepare engine for removal of rotary fuel injection pump.

Stepblock

Locate top dead center for cylinder Number 1.

Stepblock

Loosen CAV fuel injection pump lock

Tighten lock screw against drive shaft. Torque: 7 N•m [62 in-lb]

Loosen injection pump lock screw and position washer.

Stepblock

Tighten lock screw until contact made with shaft.

Torque: 12 N•m [106 in-lb]

Stepblock

completion.

and

bolts.

Remove pump.

washer.

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Tighten screw against shaft. Torque: 30 N•m [22 ft-lb]

Stepblock

Pull drive gear loose from drive shaft.

Remove mounting nuts and pump.

Remove gasket and clean surface.

Rear Gear Train: Permanently mark pump flange to match mark on fuel pump mounting plate.

DO NOT

remove timing pin until repair

Special washer on Bosch® VE pump

be removed and lock screw

must

tightened.

Remove fuel pump mounting plate nuts

Remove pump, mounting plate and gear pump as assembly.

Remove gasket and clean surface.

Torque: 40 N•m [29 ft-lb]

Gear

must not

rotate during removal.

Stepblock

Mark a tooth on fuel gear pump relative to fuel pump mounting plate.

Stepblock

Remove retaining nut and washer. Remove gear.

Stepblock

Loosen fuel pump to mounting plate nuts.

Remove gasket material and clean surface.

Stepblock

Front Gear Train: Verify cylinder Number 1 at top dead center.

Stepblock

Stepblock Stepblock

Stepblock

Install new gasket.

Install pump drive shaft nut and spring

If installing original pump, rotate to align with scribe marks.

Install pump. Tighten mounting nuts.

Torque: 15 to 20 N•m [133 to 177 in-lb]

Torque: 24 N•m [18 ft-lb]

Finger tight. Pump move in slots.

must

be free to

Stepblock

If no scribe marks, rotate pump against direction of drive rotation. Tighten nuts.

Torque: 24 N•m [18 ft-lb]

Mark injection pump flange. Mark on housing.

Loosen CAV pump lock screw and position washer.

Torque: 20 N•m [177 in-lb]

Stepblock

crankshaft.

1

is at top dead center.

plate.

washer.

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Stepblock

Stanadyne DB4 Pump: Loosen pump lock screw and position washer. Tighten lock screw.

Loosen Bosch® pump lock timing screw and install special washer. Tighten lock timing screw.

Torque: 13 N•m [115 in-lb]

Stepblock

Disengage timing pin before rotating

Tighten pump retaining nut. See detail.

Install access cap.

Disengage timing pin.

Tighten pump retaining nut. See detail.

Install access cap.

Rear Gear Train: Verify cylinder number

Install new pump gasket on mounting

Install pump to mounting plate. Torque: 18 N•m [159 in-lb]

If installing original pump, rotate pump to align scribe marks.

Stepblock

Install pump gear on pump shaft, align mark on gear with mark on mounting plate.

Install drive shaft nut and spring washer. Tighten retaining nut.

Install new pump cover plate gasket, pump, mounting plate and gear to rear gear housing. Install cover plate gasket.

On Bosch® fuel pumps, install special washer, that is wired to pump, under lockscrew.

Disengage timing pin.

Tier 2/Stage II Timing Adjustment

Disengage timing pin. Remove special washer on Bosch® VE pumps and tighten lockscrew against drive shaft.

Remove access cap, retaining nut and

Torque: 98 N•m [72 ft-lb]

Torque: M8 = 18 N•m [159 in-lb]; M10 = 30 N•m [22 ft-lb]

See detail.

Stepblock

Remove fuel pump gear. See detail.

Stepblock

rotate.

is removed.

check

for leaks.

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Thoroughly clean and dry drive shaft taper and drive gear bore.

Use residue-free cleaner and compressed air.

Stepblock

Ensure engine is locked and can

Install pump gear onto shaft, with washer

Stepblock

and retaining nut. Remove top dead center timing pin from camshaft and timing pin on damper, if used.

Stepblock

Stepblock Stepblock

Stepblock

Tighten gear pump retaining nut. See detail.

Install access cap and check barring tool

Recheck timing. If timing within tolerance, remove gauge and replace plug.

Stepblock

Tighten pump retaining nut. See detail.

Install access cap.

not

Loosen Bosch® pump lock timing screw and install special washer. Tighten lock timing screw.

Torque: 10 N•m [89 in-lb]

Torque: 13 N•m [115 in-lb]

Stepblock

Install remaining components. See detail.

Connect batteries, operate engine and

General Information

Fuel System Identification

The B Series engine uses many different fuel injection pumps, depending on the horsepower rating and application.

The Lucas CAV DPA distributor-type fuel injection pump can be found on the following engine applications:



Marine



Industrial.

TOC

SMALL | MEDIUM | LARGE



European and U.K. automotive ratings.

SMALL | MEDIUM | LARGE

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The Delphi DP210 distributor-type fuel injection pump can be found on the following applications:



Industrial (Tier 2/Stage II Certified).

The Bosch® VE distributor-type fuel injection pump can be found on the following engine applications:

SMALL | MEDIUM | LARGE



Industrial



1991 low-horsepower automotive ratings.

The Stanadyne DB4 distributor-type fuel injection pump can be found on the following engine application:

Gen Sets



SMALL | MEDIUM | LARGE

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Fuel Injection Pump (Distributor Type)

The fuel injection pumps, Bosch® VE, Lucas CAV DPA, Stanadyne DB4, Lucas CAV DPS, and Delphi DP210, are rotary distributor pumps. These pumps perform the four basic functions of:

1. Producing the high fuel pressure required for injection

2. Metering the exact amount of fuel for each injection cycle

3. Distributing the high-pressure, metered fuel to each cylinder at the precise time

4. Varying the timing relative to engine speed.

Distributor-Type Pump Governor

SMALL | MEDIUM | LARGE

Balance between the governor flyweights and control lever position controls the metering of the amount of fuel to be injected.

The fuel injection pump governor performance and setting can affect engine power. Special equipment and qualified personnel are required to verify governor performance. If the seals are broken on the external Bosch® VE adjustment screw, the fuel rate can, perhaps, be out of adjustment.

The Lucas CAV DPA/DPS fuel injection pump uses a coded spring connection to change the governor setting. Incorrect connection of the governor spring can affect performance.

Adjustments and rating changes are described in the Master Repair Manual, Injector Pumps and Injectors,

SMALL | MEDIUM | LARGE

Bulletin 3666037.

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SMALL | MEDIUM | LARGE

Manual Shutdown Levers

Both fuel injection pumps are equipped with mechanical shutdown levers. These levers are spring-loaded in the run position.

all applications will use these manual

Not

shutdown controls and there will be no cable or rod connected to the lever.

NOTE: Partial actuation of the mechanical shutdown levers will affect fuel flow and engine power.

Advance Timing Mechanism

SMALL | MEDIUM | LARGE

Regulated pressure produced by a vane supply pump in both fuel injection pumps is used to advance the timing as the engine speed increases. A return spring is used to retard the timing as the engine speed is reduced. If a spring breaks, the timing will go to the advance position, resulting in torque loss, fuel knock, and possible engine overheating.

Retarded (late) timing will result in torque loss, high fuel consumption, and white to black smoke.

The Lucas CAV DPA/DPS advance timing mechanism uses a check ball in the circuit which, if omitted during assembly, will result in no timing advance. If the fuel injection pump has been replaced or the mechanism has been removed to fix a leak, the problem can be that the check ball is missing.

SMALL | MEDIUM | LARGE

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Electrical Shutoff Valves

The fuel injection pumps are equipped with electrical shutoff valves. These solenoid-operated valves block the supply of fuel to the high-pressure pumping and distribution components.

The Bosch® VE shutoff valve is located at the top rear of the pump.

The Lucas CAV DPA/DPS shutoff valve is located at the bottom rear of the pump.

SMALL | MEDIUM | LARGE

Both 12- and 24-VDC activate-to-run and activate-to-stop solenoids are available.

The Stanadyne DB4 shutdown solenoid is located under the governor cover.

Both 12-VDC and 24-VDC activate-to-run and activate-tostop solenoids are available.

SMALL | MEDIUM | LARGE

indexed to the shaft

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Preparatory Steps

Batteries can emit explosive gases. To reduce the possibility of personal injury, always ventilate the compartment before servicing the batteries. To reduce the possibility of arcing, remove the negative (-) battery cable first and attach the negative (-) battery cable last.

WARNING

TOC

SMALL | MEDIUM | LARGE



Disconnect the batteries.

CAUTION

Do not remove the control lever. The fuel control lever on the Bosch® VE fuel injection pump is during pump calibration. If the lever has been removed and reinstalled incorrectly, engine speed and power will be affected.

Rotary Distributor Type Fuel Injection Pumps

Bosch® VE, Lucas CAV DPA, Stanadyne DB4, and Delphi DP210

SMALL | MEDIUM | LARGE