Service Manual

Cummins
Service Manual

PT
Fuel Pumps
and Injectors

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF

CUMMINS OR IT’S SUCCESSORS. CUMMINS AND IT’S SUCCESSORS
ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS,
AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

CUM-S-PT FUEL
Cummins
Diesel Engines
Unit Shop Manual

Compiled and Reproduced From Original by Jensales Inc.

Foreword Service Tools
This manual covers the operating principles, disassembly, Fuel Pump Service Tools
inspection, repair and assembly of the PT (type G) and PT
(type R) fuel pumps. Testing and calibration are covered in ST-302 Ball Joint Vise
separate manuals. Each part is disassembled, repaired and ST-419 Oil Seal Tool
assembled in separate sections. ST-422 "0" ring Assembly Tool (5/8")
ST-425 Peening Block-Governor Weights
Cummins Engine Company. Inc. ST-490 Reaming Fixture
Columbus, Indiana, U.S.A. ST-546 Mounting Plate
ST-586 Sleeve Puller, PT (type R)
ST-709 Pu Iler, Governor We ights
ST-835 "0" ring Assembly Tool (1/2")
ST-853 Driver, Governor Barrel Spring Dowel
ST-l032 Driver, Tachometer Oil Seal
ST-1224 Overspeed Stop Adjusting Tool
Table of Contents ST-1231
ST-1241
Governor Weight Gear Tool
Weight Assist Protrusion Checking Tool
ST-1249 Coupling Puller
ST-1250 Pressure Valve Tool

Group 5 PT Fuel Pump Other Fuel Pump Rebuild Tools

Operating Principles . 5-1 Dial Indicator (Starrett No. 196-B)

Fuel Pump Disassembly .5-7 .750 inch Reamer
Fuel Screens . . . . . . .5-9 Torque Wrenches (Inch pound and foot pound)
Fuel Pump Housing 5-10 Arbor Press
Gear Pump and Pulsation Damper 5-16 90 0 Block with Steel Puller
Shut Down Valves . . 5-19 "V" Block with Steel Puller
Front Cover Assembly . . . . . . 5-23 Oven,4000 F, Maximum
Governor Spring Pack . . . . . . 5-29 Cleaning Solvent
Pressure Regulator and Pressure Valve 5-38
Fuel Pump Assembly 5-40
Calibration . . . . . 5-46
Auxiliary Equipment 5-47

Compiled and Reproduced From Original by Jensales Inc.

Index List of Tables
Acceleration Retarder, Oil Actuated . 5-58 Table Description Page
Air Actuated Road Speed Governor 5-55
Air Actuated SVS and MVS Governor 5-58 5-1 Governor Plunger, PT (type G) 5- 11
Assembly of Fuel Pump 5-40 5-2 Governor Plunger, PT (type R) 5- 11
Calibration . . . . . . . 5-46 5-3 Torque Springs . . . . . . . . 5-14
Coo ling K it Installation 5-46 5-4 Gear Width and Pocket Depth 5-16
Disassembly, Fuel Pump · 5-7 5-5 Shut Down Valve Coil Resistance 5-19
Drive Cover Assembly 5-25 5-6 Dual Valve Assembly Parts .. 5-22
Drive Shaft Assembly and Disassembly 5-24 5-7 Governor Plungers, MVS 5-31
Filter Screen Installation . . . 5-40 5-8 Governor Weights and Springs 5-33
Front Drive Cover Disassembly 5-23 5-9 Governor Springs . . . . . . 5-34
Front Drive Cover Installation 5-45 5-10 Solenoid Plunger Stroke 5-37
Fuel Pump Screen . . . . . . · 5-9 5- 11 Throttle Shafts 1/2 inch PT (type G) 5-43
Gear Pump Cooling . . . . . . 5-17 5-12 Throttle Shafts 5/8 inch PT (type G) 5-43
Gear Pump Disassembly and Assembly 5-16 5-13 Throttle Shafts PT (type R) 5-43
Gear Pump Installation . . . . 5-45 5-14 Cooling Kits . . . 5-46
Governor Barrel and Plunger . 5-13 5-15 Overspeed Stops .. ... 5-48
Governor Barrel Replacement 5-11
Governor Operations . . . . . · 5-4
Governor Plunger Installation 5-44
Governor Spring Pack Disassembly and Assembly 5-29
Governor Spring Pack Installation 5-41
Governor Weight Carrier .. 5-24
High Torque Rise Fuel Pump 5-37
Hourmeters, Mechanical 5-58
Hydraulic Governor 5-37
Integral Cooling Feature 5-17
Load Balance Valve 5-47
Main Shaft Bushing . . . 5-10
Mechanical Variable Speed "MVS" Governor 5-31
Operating Principles · 5-1
Overspeed Stop Adjustment . . . . . . . .. 5-47
Pierce Governor . . . . . . . . . . . . . .. 5-56
Pressure Regulator Assembly and Disassembly 5-38
Pressure Valve . . . . . . . . . . . . . . . . 5-39
Pulsation Damper Disassembly and Assembly 5-18
Pul sation Damper Installation 5-45
Remove "MVS" Governor 5-33
Removal of Units . . . . . · 5-7
Road Speed Governor 5-36
Shut-down Valve (Electric) 5-19
Shut-down Valve (Manual) 5-20
Shut-down Valve Installation 5-45
Shut-down Valve, High Pressure 5-21
Special Variable Speed "SVS" Governor 5-32
Standard Automotive Spring Pack 5-29
Tachometer Cable . . . . . . 5-47
Tachometer Drive Installation 5-40
Tachometer Drive Rebuild 5-13
Tachometer, Electronic 5-58
Throttle Lever Installation 5-44
Throttle Shaft Installation 5-42
Torque Converter Governor 5-35
Torque Limiting Valve . . . 5-22
Variable Speed "VS" Governor 5-33
Weight Assist Plunger Checking 5-28
Woodward Hydraulic Governor 5-55

Compiled and Reproduced From Original by Jensales Inc.

 Fig. 1, F 5235. PT (type G) fuel pump - right handed gear pump

Fig. 2, F5236. PT (type R) fuel pump

Compiled and Reproduced From Original by Jensales Inc.

5-56 Shop Manual
PT Fuel Pumps
Auxiliary Equipment

Fig. 5-119, NG33. Speed droop adjusting screw Fig. 5-120, F5185. Pierce governor adjustments

3. Start engine and adjust low speed stop screw (atop the yoke, and a counterclockwise (also viewed from the
governor head) for desired idling speed. spring end) moment due to the spring tension acting
through a moment arm equal in length to a perpendicular
dropped from the center of the shaft (pivot point) to the
Speed Droop Adjustment line of action of the spring tension. The linkage to the fuel
pump is made so that the clockwise (weight) moment acts
1. Remove the top cover from the governor to expose the to decrease fuel, and counterclockwise (spring) moment
speed droop mechanism and adjustments. Fig. 5-119. acts to increase fuel. When the system is at rest, the spring
force holds the throttle wide open, and when the system is
2. The speed droop bracket is clamped to the terminal level in equilibrium the two moments are equal. Fig. 5-120.
by the slotted screw. When loosened, it can be moved to
the front or rear. Moving bracket to the rear produces more A decrease in speed due to added load results in a decrease
speed droop. of the clockwise (weight) moment; the counterclockwise
(spring) moment then opens the throttle until it (the
3. This speed droop lever movement thus produces a speed counterclockwise monent) again balances the clockwise
setting which is a function of terminal shaft position with (weight) moment. As the throttle opens, the spring
speed decreasing as fuel flow increases. This is speed droop. deflection is reduced; hence the spring moment is reduced
until a balance is reached.
4. Speed droop is increased by moving the bracket to the
rear and is reduced to approximately zero when the pivot Conversely, an increase in speed due to decrease in load
pin is all the way forward. Since there is no calibration for gives an increase of the clockwise (weight) moment which
the droop adjustment, the zero droop position may be closes the throttle. As the throttle is closed the spring
precisely set only by trial and error on the engine or by use tension is increased, equilibrium being reached when the
of a dial indicator on the speed droop lever during manual two moments again balance.
rotation of the termi nal shaft.
Droop is adjustable by changing the length of the moment
5. Speed droop is required when using SG Woodward arm through wh ich the spring tension acts .. With a given set
Governors. I t must be set by operation on the engine. The of conditions, 50 rpm speed increase will give a certain
speed droop bracket is adjusted to obtain the desired speed increase in clockwise (weight) moment. With a short
droop between full load and no load. moment arm, a great spring deflection will be required
before the counterclockwise (spring) moment increases to
the new equilibrium value. With a longer moment arm, a
lesser deflection of the spring wi II be required to reach
Pierce Governor
equilibrium. If the spring deflection is large, throttle travel
Operation will of course also be large, and the converse is true. Large
throttle travel per speed change means less droop, while
The shaft to which the terminal lever, yoke and spring small throttle travel per speed change means more droop.
retaining arm are fastened may be considered a pivot point. Hence, a short moment arm will give low droop, and a long
Acting about this pivot point are a clockwise (viewed from moment arm will result in a large amount of droop.
the spring end) moment due to the weights acting through

Compiled and Reproduced From Original by Jensales Inc.

5-2-2 Shop Manual
PT (type G) Fuel Pump
Aneroids

Fig. 5·2-2, F5244. Aneroid cutaway

6, The lever arm connected to piston (8) by actuating shaft

(6), rotates shaft; closi ng valve port. The lever is rotated by
action of air intake manifold pressure (11) against piston
and diaphragm (7), moving actuati ng shaft downwa rd
against resisting spring force. Fig. 5-2-2.

7. Anytime engine intake manifold air pressure is above F i9, 5-2-3, F 5287. Adj usting aneroid fuel screw
preset bellows "air actuation pressure," aneroid is "out of
system, "

8. The aneroid begins dumping when intake manifold air

pressure drops below preset value as happens after
deceleration in traffic, deceleration during gear shifts, down Testing Aneroid
grade motoring with closed throttle or down grade
operation on light load portion of governor droop curve. Adjusting Fuel Screw
9. The aneroid does not by-pass fuel under full throttle lug
1, Mount a fuel pump on fuel pump test stand which has
down conditions until speed is low enough to reduce intake
been calibrated to the same code as that on, or will be used,
man ifo Id air pressu re to aneroid operati ng range (usual Iy
on engine. For instance, if aneroid is intended for use on an
below engine stall-out speed).
engine equipped with fuel pump calibrated to code No.
2049, use a pump set at same code (2049) to set aneroid.

2. Plumb aneroid to fuel pump in the normal manner. Fig.

Installing Aneroids On Fuel Pump Test Stands 5-2-5 and 5-2-6.

Precision setting and/or checking of aneroids is 3. Start fuel pump test stand and purge all air from system.
accomplished by simulating engine operation on a fuel
pump test stand. Cummins ST-848 Fuel Pump Test Stand 4, Adjust air regulator to apply 30 inch [76,2 cm) Hg,
must be equ ipped as follows: pressure on aneroid bellows.

1. Fabricate a suitable bracket or mount the aneroid on fuel 5. Set fuel pump at rated speed calibration point (Manifold
pump test stand. This bracket may be used to mount an air PSI @ RPM and Flow Reading) specified for pump code.
regulator, such as used on ST-790 or ST-990 Injector Test
Stands, and a mercury manometer of suitable scale length CAUTION
or 30 inch pressure gauge of known accuracy.
The flow control valve setting must not be altered during
2. Air pressure from regulator must be piped to top of the following checks. Altering flow will give false
aneroid to actuate bellows, adjustments.

3, Tee off regulator air line (outlet) into manometer or 6. Reduce test stand speed to that shown in Table 5-2-1
pressure gauge. Service Tool is ST-1256. under BHP @ Speed.

Compiled and Reproduced From Original by Jensales Inc.

6-1-8 Shop Manual
Injector Cleaning and Repair

Fig. 6-1-15, F60163. Testing injector spring Fig. 6-1-17, F60105. New injector cup tip

62123 8091-1

Fig. 6-1-16, F60109. Injector springs Fig. 6-1-18, F60223. Cup tip damaged by wire brushing

Table 6-1-4: Injector Spring Data

Approximate Wire load Required to Compress Springs to length

Part Free length No. Dia. length New Min. New Max. Worn limit
No. Inches [mm] Coils Inches [mm] Inch [mm] lb. [kg] lb. [kg] lb. [kg]

9337 1-7/8 [47.6] 8-1/2 0.177 [4.50] 1-9/16 [39.7] 135 [61] 149 [68] 130 [59]

62123 2-1/32 [51.6] 7 0.1875 [4.77] 1-9/16 [39.7] 135 [61] 149 [68] 130 [59]

8091-1 2-7/16 [61.9] 7 0.2625 [6.65] 1-7/8 [47.6] 228 [163] 252 [114] 218 [99]

128040 2-1/2 [63.5] *7 0.1875 [4.77] 1.975 [50.2] 133 [60] 147 [67] 128 [58]

166009 1.95 [49.7] 8 0.187 [4.75] 1.663 [42.2] 143.25 [65] 158.75 [72] 138 [63]

*Earlier model springs have 9.5 coils with two closely spaced as shown in Fig. 6-1-15, these may be used interchangeably.

Compiled and Reproduced From Original by Jensales Inc.