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    Bosch PE Manuals - Diesel Injection Pumps

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    Bosch PE Manuals - Diesel Injection Pumps

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    bosch pe pump

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    Bosch PE manuals - Diesel Injection Pumps

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    326 views59 pages

    Bosch PE Manuals - Diesel Injection Pumps

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    Anonymous 5tkF5bFwO
    bosch pe pump

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    ROBERT BOSCH MODEL PE(S)-6 MW FUEL INJECTION PUMP SERVICE MANUAL, FORM CGES-375 ‘SEPTEMBER, 1984 Printed in United States of America SERVICE MANUAL FORWARD This manual is part of a series of manuals intended to assist service technicians in maintaining International® Engines in accordance with the latest technical advancements. Due to a commitment of continuous research and development some procedures, specifications and parts may be altered to improve International® products and introduce technological advances. Periodic revisions may be made to this publication and mailed automatically to “Revision Service" subscribers, The following literature supporting the 400 Series Diesel Engine is available from International Harvester Company Forward Requests Printing, Procurement and Distribution to: 807 Blackhawk Drive Westmont, Ilinois 60559 FORM NO. DESCRIPTION CGES-185-3 300/400 Series Engine Service Manual 1171575 RL DTIDTI-466C Diesel Engine Operation Manual CGES-240-3 Diesel Engine Diagnostic Manual CGED-365 Diagnostic Form (DT/DTI-466C) (CGES-375 Printed in United States of America SERVICE MANUAL INTRODUCTION ‘This manual is arranged in sections with the pages numbered consecutively in each section. Any drawings are also numbered consecutively in each section. number. The bottom center of each page will show the manual form (i.e. CGES-375), Included at the top of each page is the section title, section number and page NOTE: Future revisions will be indicated by a dash one, dash two, etc. after the form number (Le. CGES-375-1 will be revision number one), Section Title} _________.- generat Section | HE SeRVice MASL AL, Page Section No. Page No. An index arranged according to sections will be found at the beginning of this manual. This manual is divided into six sections which are: SECTION ONE - SECTION TWO SECTION THREE SECTION FOUR SECTION FIVE - General Pump Information Disassembly Cleaning and inspection Reassembly Calibration (CGES-375 Printed in United States of America SERVICE MANUAL TABLE OF CONTENTS SECTION1- GENERAL Page Description... . . ene Identification Operation Principles Fuel Flow Metering... Pump Features Governor. Nozzle... Nozzle Holder Specifications. Service Tools Torque Chart. SECTION2- DISASSEMBLY Preparation Exploded View af Pump. Exploded View of Govemor Governor Disassembly Pump Disassembly SECTION3- CLEANING AND INSPECTION Inspection Chat... Governor Adjustment. SECTION 4- REASSEMBLY Pump Reassembly 1 Governor ReasseMbly ..nnnssesmninmnnnnnnnnnnnnenesnmnnnnnnrnrnnnmnnnnsnse 4 SECTIONS- CALIBRATION Calibration Stand Maintenance 1 Procedure 2 Data Sheets and Calibration Charts Pump Part No. 1 802 608 C92. 19 CGES-375 Printed in United States of America SERVICE MANUAL GENERAL Section 1 cc-9340 Figure 1. Robert Bosch Model MW Fuel injection Pump 1. Shutoff stop Screw 5. RQV Governor Housing 8. Mounting Adapter 2. Shutoff Lever 6 Fuel Supply Pump 10. Hand Priming Pump 3. High Idle Stop 7. Timing Pointer Plug 11. Plunger 4. Throttle Lever 8. Serial Number Plate 12. Aneroid DESCRIPTION injection pump (Figure 2). The nameplate on the rear of The Robert Bosch Model PE(S)-6MW Injection Pump is used on the International DT-486C diesel engine, The injection pump is an in-line, plunger type, with an individual plunger and barrel pumping element for each engine cylinder. The injection sequence is 1,5, 3, 6, 2, 4 The injection pump assembly incorporates mechanical, flyweight type RQV variable speed governor. ‘The pump throttle lever and the high-speed stop screw are located on the left side of the governor assembly, The fuel shut off lever is also located on the left side of the governor. The injection pump is located on the left side of the engine. High pressure lines connect the pump to the nozzles. Operating and service instructions for the nozzles are given in CGES-200-2 Service Manual. IDENTIFICATION Identification of injection pump and governor can be made by referring to two nameplates, one on the rear of the governor housing, and one on the front top lett of the the governor gives the IH part number of the complete Pump and governor assembly and the Robert Bosch governor number, size and rating. The nameplate on the left side, gives ‘the Robert Bosch pump description umber. OPERATING PRINCIPLES The injection pump is the in-line type with an individuel plunger and barrel pumping element for each engine cylinder. Each plunger stroke is constant, but its effective pumping (metering) stroke is variable and is controlled by the positioning of a common control rack connected through linkage to the governor and the Vehicle's throttle lever. The individual plunger and barrel pumping elements receive fuel at supply pump pressure from the injection ump housing fuel gallery, and forces it under very high pressure through the injection nozzles into the engine combustion chamber. The injection pump plungers are moved by tappet assemblies which ride on the lobes of the injection pump camshaft. The injection pump camshaft is timed to the engine to inject fuel into each cylinder at the proper time. CGES-375 Printed in United States of America Page 1 SERVICE MANUAL GENERAL Section 1 * Code for Robert Bosch governor number RQV 350 1200 MW 43.5, R Fiyweight governor Q Fulcrum lever model V___= Variable speed governing (all-speed) 350 = Low dle pump speed 1200 = Full load rated speed MW = Fits on "MU" size pump 43-5 = Application number * Code for Robert Bosch combination number PES 6MW 100/320 RS 1108: PE = Inline injection pump s Flange mounted 6 = Number of cylinders Mw IW" size pump 100 = Plunger diameter in 1/10 mm. 1 = Pump model 320 = Number code for location of feed pump and governor R= Rotation of pump as seen from drive end (right hand clockwise) $1108 = Application number Figure 2. Injection Pump Identification Each plunger has a delivery valve above the plunger. The delivery valve, which is held on its seat by spring pressure, prevents fuel from draining out of the high pressure line between pumping cycles. The Injection cycle can be described by observing the plunger in its four principle positions in the barrel. The four positions are shown in Figure 3. ‘At bottom dead center the plunger is held down on the lowest point of the cam lobe by the plunger spring. Top of plunger is below the charging port of barrel. Fuel at supply pump pressure flows through the charging port to fil the area above the plunger. Figure 3. Four Principle Plunger Positions of infection cycle 1. Botlom Dead Center 3. Injection 2. Port Closure 4, End of Injection Port closure begins when the rising plunger covers the charging port and fuel is trapped above the plunger. Start of injection occurs as the plunger continues with Charging ports covered, fuel is forced upward under high pressure, unseats the delivery valve and is injected into the cylinder. End of injection occurs when the plunger moves up to the point where the charging port is again uncovered by the lower helix. Fuel pressure above the plunger is relieved to the charging gallery. This pressure drop allows delivery valve and injection nozzle to seat thus ending injection, ‘CGES-375 Printed in United States of America Page 2 SERVICE MANUAL GENERAL Section fut nevuan GHEGEYACYE | sreincn ip. mnimust FUEL TANK ra | (Vi | rtren 2p paimany UE FILTER subouy rome Negative Pres mmm Intermediate Pressure ———> High Presi EE Cow Pressure cam Figure 4. Fuel System Flow FUEL SYSTEM FLOW As fuel travels through the fuel system, it will be under suction (negative pressure), intermediate pressure, high pressure (Injection pressure) and low pressure (Figure 4) Negative Pressure The piston type supply pump creates a suction at its inlet and pulls fuel from the fuel tank, through the fuel supply lines and through the primary fuel fier. No fiter is used (on the fuel suction line extending into the fuel tank because wax particles could plug the filter in cold weather. Fuel lines and fitings between the supply pump inlet and the fuel tank must be a minimum of three-eighths inches inside diameter. Small diameter fuel supply lines or fitings will reduce fuel flow and can reduce engine power output. Intermediate Pressure The supply pump produces an intermediate pressure, called supply pump pressure, at its outlet and forces fuel through the final fuel filter and into the injection pump. housing. Fuel under intermediate pressure surrounds each barrel assembly. Fuel pressure in the housing is, controlled by the orificed fiting in the fuel return hose located “downstream” of the fuel return check valve and the supply pump piston spring calibration. special rubber hose between the final filter outlet and the injection pump housing dampens pressure waves from the supply pump. Substitute hoses can cause lower engine power even though supply pump pressure can be within specifications. High Pressure The injection pump meters and delivers fuel at high pressure, up to an instantaneous 9000 psi pressure after ozle valve opening, through the injection pipes or lines to the injection nozzle assemblies. This high pressure fuel causes the nozzle valve to open and fuel flows through the nozzle orifices into the combustion chamber. ‘The amount of fuel delivered is controlled by the injection ump governor. A small amount of low pressure fuel reluns from the nozzle assemblies to the fuel tank through the leakoff lines. Low Pressure ‘An orifice fitting in the end of fuel hose from the fuel retum check valve limits the amount of fuel returned to the fuel tanks. After fuel passes through the orifice, itis, at low pressure, CGES-375 Printed in United States of America Page 3 SERVICE MANUAL GENERAL Section 1 METERING Metering (providing proper amount of fuel to meet engine requirements at various loads and speeds) is accomplished by rotating the plunger in its barrel to change the effective pumping stroke. The effective stroke is the distance traveled upward by the plunger from the time the charging port is covered until itis again uncovered by the lower helix. A short effective stroke means a small amount of fuel is injected. As effective stroke increases, the amount of fuel injected increases ‘The metering function can be described by observing the relationship of plunger helix to barrel charging port under various metering positions as shown in Figure 5. rh, 5 War or « ers cuss ‘ Figure 5. Helix and Charging Port Metering Positions Start Position (Charging Port Closed) Idle Position (Charging Port Closed) Full Load Position (Charging Port Closed) ‘Stop Postion (Charging Port Open) Effective Stroke ‘Charging Port Position Starting (Excess Fuel) For starting, plunger is rotated by control rack to a point ‘where the maximum effective stroke (port closing to port opening) is obtained. When engine starts, release accelerator pedal. This rotates plunger out of start fuel position to decrease fuel delivery. Engine Operating (Metered Delivery) ‘At engine operating speeds from idle through maximum governed speed, the quantity of fuel delivered is determined by effective stroke (port closing to port opening) as controlled by the position of the throttle lever and governor. Engine Stop (No Delivery) To stop the engine, plungers are rotated so that vertical slots (stop slots) are in line with barrel ports. As plunger moves up and down fuel is transferred back and forth from top of plunger through vertical slots and into charging gallery. The ports do not close - thus, no delivery. Plungers are rotated to the various metering positions by the control rack. Rack movement is controlled by the throttle lever and governor speed PUMP FEATURES: Mounting Adapter ‘A mounting adapter (9, Figure 1) incorporating four studs attaches to the injection pump housing. Capscrews through the injection pump drive gear cover secure the ‘mounting adapter to the engine front plate. Removal of the timing pointer plug (7, Figure 1) in the adapter is, necessary when verifying or adjusting pump to engine timing, The mounting adapter is an integral part of the injection pump because it contains the timing pointer. During. injection pump calibration, a port closure mark is stamped on the injection pump hub directly in line with the pointer. Because the timing pointer is located on the mounting adapter and the mounting adapter is fastened to the injection pump housing by the four studs and nuts, these four nuts should not be loosened. Loosening the nuts and rotating the pump housing in relationship to the mounting adapter will change the relationship of the timing pointer/hub mark which was established during injection pump calibration, CGES-375 Printed in United States of America SERVICE MANUAL GENERAL Section 1 ‘Supply Pump With Hand Priming Pump. The piston-type supply pump (6, Figure 1) is activated by the eccentric on the injection pump camshaft and serves {as a mount for the hand priming pump (10, Figure 2). ‘Since all fuel entering the injection pump must be filtered to ensure long pump life, the hand priming pump should be used when changing fuel filters. Always install the fuel filters “dry” and use the hand pump to fill the filters and bleed air from the fuel system, Aneroid Assembly Exhaust smoke levels during engine acceleration are controlled by using an aneroid (12, Figure 1). The aneroid limits fuel delivery during acceleration until the turbocharger speed is sufficient to provide adequate air for complete combustion. An external line connects the intake manifold to the aneroid to allow manifold pressure to activate the aneroid. A leak in the aneroid diaphragm or intake manifold to aneroid line will cause the injection pump to stay in the "cutback" position, and reduce engine power. Fuel Return Valve A fuel retum check valve is mounted to the injection pump housing (1, Figure 6) and all fuel that is not injected passes through the check valve and then through a special orificed rubber hose. The function of the fuel return check valve is to provide ‘Ce 10196 Figure 6. Right Side View of Injection Pump 1. Fuel Return Valve 2. Delivery Valve Holder 3. Drive Gear posttive seal to prevent fuel from draining out of the pump housing when the engine is stopped. The fuel relumn check valve opens at approximately 18 psi Therefore, total fuel flow through the injection pump. housing is controlled by the orifice in the rubber hose as long as the supply pump pressure is above 18 psi. After the fuel flows through the orifice, the fuel pressure drops from the intermediate pressure ahead of the orifice to low pressure (Figure 4). GOVERNOR ‘The mechanical fiyweight governor (5, Figure 1) which is mounted on the injection pump, is the variable speed ‘ype, identified by the manufacturer as ROV 350-1200 (or -1300). The 350-1200 (or -1300) designation refers to the injection pump speed range in which the governor functions. This corresponds to 700 to 2400 (or 2600) engine RPM, since the pump camshaft rotates at 1/2 engine speed. Figure 7 illustrates a typical cut-away view of the RQV governor Figure 7. Cut-Away View of Govemor Assembly 1, Stop Shackle 7. $-Plate 2. Rack Link 8 Guide Pin 3. Control Rack 9. Adjusting Pin 4. Governor Springs 10. Guide Lever 5. Bell Crank 11. Rocker Arm 6. Sliding Block 12. Aneroid CGES-375 Printed in United States of America Page 5 SERVICE MANUAL GENERAL Section 1 ‘The functions of the governor are: (2) Iimit minimum (Jo-idle) engine speed, (2) limit maximum engine speed and (3) maintain smooth speed control (without stalling, surging or hunting) within the limits of its regulation throughout the operating speed range of the engine. ‘The allespeed governor provides speed control at any fixed position of the control lever (accelerator pedal) This provides the vehicle operator with the most satisfactory driving characteristics. The governor tends to keep engine speed constant at the level determined by position of the accelerator pedal and automatically increases or reduces fuel delivery in response to minute changes in engine speeds without a significant change in road speed and without the operator changing position of the accelerator pedal. The transfer pump, a single action none positive displacement plunger type pump, is driven by the injection pump camshaft The transfer pump can supply more fuel than is required for injection. Excess fuel, utlized for cooling injection pump, is routed from the injection pump fuel gallery back to the fuel pump, NOZZLE The American Bosch ADB-M type nozzles (Figure 8) are of the closed differential hydraulically-operated type. ables Fuel, under high pressure, flows into the fuel duct in the body and enters the pressure chamber. When fuel pressure in the pressure chamber exerts sufficient force on the differential area of the nozzle valve to overcome the opposing spring preload, the nozzle valve is lifted, allowing fuel 10 enter the nozzle body sac and flow through the spray holes. The fuel flowing through the spray holes is atomized as it enters the combustion chamber. When the end of the pumping stroke occurs, there is @ sudden drop in line pressure. As a result, the pressure in the nozzle pressure chamber drops rapidly. Since the pressure adjusting spring is exerting a downward force on the nozzle valve and is no longer being opposed by fuel pressure, the nozzle valve moves downward rapidly Until it seats’ in the nozzle body - the nozzle is now closed. Since there is a slight amount of clearance (controlled) between the nozzle valve and body, a small amount of leakage between the valve and body will occur. This leakage is necessary for valve O.D. and body ILD. lubrication, NOZZLE HOLDER ‘The American Bosch AKN-M type nozzle holder (Figure 8) is a unit which retains the nozzle in the cylinder head and transfers the fuel from the high pressure tubing to the nozzle duct. The holder C © Figure 8. Exploded View of Fuel Injection Nozzle and Holder Assembly 1. Holder Body 5. Valve Stop Spacer 2. Shim(s) 6. Nozzle Body and Nozzle Valve 3. Pressure Adjusting Spring 7. Cap Nut 4. Spring Seat Guide 8. Copper Gasket CGES-375 Printed in United States of America Page 6 SERVICE MANUAL GENERAL Section 1 assembly consists of a holder body, doweled nozzle spacer, lower spring seat, pressure adjusting spring, shims and a nozzle retaining nut. ‘The holder body contains a high pressure tubing connection at the upper end, a high pressure fuel duct, a leak-off duct and drain connection. The lower end is Counterbored to accept the pressure adjusting spring and shims. The lower face is lapped to a fine surface finish ‘and contains two locating dowel pin holes. The lower spring seat provides a seat for the spring and a contact, surface for the nozzle valve stem. The nozzle spacer Contains two locating dowel pins which locate the nozzle radially to the holder body to insure proper spray pattern orientation. Both faces of the spacer are lapped fo a fine surface finish to provide gaskelless, high pressure seals between the holder body face, spacer faces and nozzle body face. The spacer also acts as the nozzle valve stop. The cap nut clamps the nozzle and spacer to the holder body. Fuel flowing through the high pressure tubing enters the nozzle holder and flows down the high pressure duct, through the spacer duct and to the nozzle. The slight fuel leakage between the nozzle valve and body enters. the spring chamber in the holder body and flows through fa return duct to a drain connection, PUMP SPECIFICATIONS Injection Pump Type In-Line Plunger Pump Speed One-Half Engine Speed Pump Rotation (Viewed From Drive End) Clockwise Firing Order 15.3,62.4 "Slider-to-Housing” Distance 39.15 0.2 mm (1.54: 008 in) Basic Setting of S-Plate 21.5 £ 0.2 mm (.847 + .008in.) ‘Camshaft Protusion 20.7 - 22.2 mm (817 - 877 in) ‘Axial End Play of Govemor Weight Assembly 05 - .10 mm (.002 - .004) CGES-375 Printed in United States of America Page 7 SERVICE MANUAL GENERAL Section 1 TOOLS Robert Bosch Quantity Required Part Number Description 1 KDEP 2919/4, Holding Fixture 1 KDEP 2088 ‘Camshaft Slotted Cylindrical Nut Remover {also used for reassembly). 1 KDEP 2886 ‘Governor Flyweight Remover 1 KDEP 1056 Side Plug Puller 3 KDEP 1068 ‘Tappet Holder 1 KDEP 1505 ‘Tappet Depressor 1 KDEP 1066 Assembly Jig 1 9 681 238 902 ‘Spacer Ring Installer 3 KDEP 1052 Plunger Retainer 2 KDEP 1057 ‘Spacer Plate 1 KDEP 1059 Bearing Installer 1 KDEP 1069 Ball Bearing installer 1 KDEP 1058 Side Plug Installer 1 1.682 329 038 Guide Bolt Gauge 1 9 681 238 904 'S-Plate Gauge 1 KDEP 2949 ‘Screwdriver Bit 1 1.418 462 040, Plug 1 2916 710 611 Copper Gasket 1 11 688 130 030, Bracket (Rack Travel) 1 1687 233 015, Dial indicator 2 9.683 233 302 Fuel Gallery Plug 1/4 NPT (for high pressure phasing) 1 1.413 462 040, Fuel Gallery Plug M16 Thread (LPC) 1 1.683 350 065, ‘Adapter Bushing 1 1.682 012 008 Pin for LPC (lit-1o-port closure) Gauge 1 1.688 130 135 Plunger Lift Device 1 1687 233 012 Dial indicator (LPC) 1 1.683 350 066 Adapter Bushing (LPC) 1 KDEP 2989 Governor Spring Adjusting Wrench 1 KDEP 1047 Aneroid Too! (Full Load) 1 KDEP 1048 Aneroid Too! (Cutback) 6 1.688 901 016 Test Nozzle Holder Assy (5 mm orifice) CGES-375 Printed in United States of America Pages SERVICE MANUAL GENERAL Section 1 ‘Additional Tools Required When Using Robert Bosch Test Stand 9 681 236 402 9.681 237 201 Drive Coupling Aneroid Tester Robert Bosch Quantity Required Part Number Description 1 KDEP 2885 Coupling Wrench 1 KDEP 2916 Coupling Puller a KDEP 2963 Pump Holding Bracket 1 (0.681 440 006 Governor Setting Protractor 2 1.683 457 020 Fuel Gallery Adapter 1 1685 720 060 Mounting Flange 1 1.687 233 015 Dial indicator 2 11.688 030 122 Support Bracket 1 1.688 130 095 Dial indicator Stand 6 1688 901 016 Test Nozzle Holder Assy (.6 mm orifice) 1 4 Bacharach Calibration Stand Accessories* ‘Bacharach Quantity Required Part Number Description 1 67-6635 “Adapter 6 77-0194 Fuel Lines (6 mm OD x 2 mm ID x 600 mm Length) 1 67-6973 Spacer Assembly 1 67-5387 Flange Mounting Bracket, use #67-4125 {for Rail Type Stands. 1 67-2863 Drive Hub 25 mm 1 67-5649 Throttle Arm Positioner, use #67-3905 for Rail Type Stands. 2 67-0916 Rubber Hose Assembly (1/2 ID x 36") 2 67-0915 PVC Hose (1/2 ID x 36") 1 67-5538 Base Bracket, use #67-2861 for Rall ‘Type Stands. *Calibration Stand of 10 HP or more is recommended. Existing 5 HP bench is acceptable. Robert Bosch Corporation 2800 South 25th Avenue Broadview, IL 60153 TOOL SOURCE ADDRESS LIST Viscosity Oil Company Bacharach Instruments 3200 South Western Avenue —_Division of United Technologies Chicago, IL 60608 625 Allpha Drive RLD.C. Industrial Park Pittsburgh, PA 15238 CGES-375 Printed in United States of America Page® ” 18 SERVICE MANUAL GENERAL TORQUE CHART Figure 9. Torque Section 1 KEARKKSS PF w 6610808 1. Delivery Valve Holder 60 minus 10 Nem 10. Oil Inlet Fitting 3040 Nem (22-30 ft-lbs) (43 minus 7 ft-lbs) 11. Camshaft 100-120 N-m (74-88 ft-lbs) 2. Barrel Flange Nut 20-25 Nem (14-28 ft-lbs) 12. Lock Plate Screws 4-7 Nem (3-5 ft-lbs) 3. Barrel Stud 8-13 Nem (6-10 ft-lbs) 13. Camshaft Support Bearing Screw 8-10 Nem 4. Lift to Port Closure Plug 3040 Nem (6-7 ftlbs) (22-30 ft-lbs) 14. Fuel Return Valve 20-40 Nem (22-30 ft-lbs) 5. Injection Pump Hub Nut 85-100 Nem 15. Fuel Fitting 30-40 Nem (22-30 ft-lbs) (63-74 ft-lbs) 16. Fuel Inlet Fitting 30-40 Nem (22-30 ft-lbs) 6. Bearing End Plate 10-12 Nem (7-8 ft-lbs) 17. Rack Housing Plug 45-55 Nem (33-40 ft-lbs) 7. Transfer Pump Mounting Studs 3-4 Nem 18. Adapter Nuts 45-50 Nem (33-36 ft-lbs) (2-3 ft-lbs) 19. Adapter Nut 100-110 Nem (74-81 ft-lbs) Transfer Pump Mounting Nuts 4-7 Nem 20. Governor Weight Nut 54 Nem (40 ft-ibs) (3-5 ftlbs) Not pictured - governor mounting screws 6-8 9. Bottom Cover Screws 4-7 Nem (3-5 ft-lbs) Nem (4-6 ft-lbs) CGES-375 Printed in United States of America Page 10 SERVICE MANUAL GENERAL Section 1 DISASSEMBLY 5. Remove fuel supply pump mounting bolts (Figure 2). Remove supply pump and drain lubricating oil into a Special Tools container. To overhaul the pump assembly, metric wrenches and 6 Remove fuel retum valve. Hold adapter in place with sockets will be required. Special rebuild tools called out a 3/4 inch wrench while removing elbow and valve throughout the text will speed repair and protect parts body (Figure 3), from damage. See Service Tool Chart (Section 1, Page 8), PREPARATION Pump and governor repair should be performed in a clean area free from airborne dirt. A separate injection room is preferred. Work bench, vise and tools should be clean. The use of trays is recommenced for keeping injection pump pars in order. The pump assembly should be thoroughly cleaned before disassembly. Use only clean solvent and clean filtered test oil to clean injection pump parts Figure 2, Removing Fuel Supply Pump Prepare the pump for disassembly as follows: 1. Fuel Supply Pump 1. Drain fuel and lubricating oil from pump and 2. Mounting Bolts governor housings. 2. Cap or plug fuel and lube oil openings after draining. 3. Use clean diesel fuel or kerosene to clean exterior of pump and governor assembly. 4. Clamp holding fiture KDEP 2919/4 (Figure 1) in vise. Remove two pump housing to adapter bolts. ‘Secure injection pump assembly to holding fixture. Figure 3. Fuel Retum Valve Removal Figure 1. Injection Pump Mounted in Holding Fixture 1 Fuel Retum Valve 1. Holding Fixture KDEP 2019/4 2.344 Inch Wrench CGES-375 Printed in United States of America Page 1 SERVICE MANUAL GENERAL Section 1 Figure 4. Exploded View of Pump Housing CGES-375 Printed in United States of America Page 2 SERVICE MANUAL, DISASSEMBLY Section 2 Legend for Figure 57. 1. Housing Screw Plug 41. Injection Pump Hub 2. Housing Stud and Plunger Plate Lock Spacer 42. Pump Drive Hub Lock Washer 3. Housing Stud and Plunger Plate Lock Nut 43. Pump Drive Hub Nut 4. Housing Stud and Plunger Plate Lock Washer 44. Control Rack Screw 5. Housing Plunger Spacer 45. Control Rack Washer 6 Housing Plunger O-Ring 48. Plunger Control Rack 7. Plunger and Barrel Shim 47. Pump Rack Pin 8 Pump Housing Stud 48. Stop Plate Pin 9. Check Valve Assembly 49. Stop Plate 10. Plug 50. Camshaft Rear Nut 12, Piston Plug Gasket 51. Camshaft Rear Lock Washer 12, Washer (0.3 mm) 52. Camshaft Rear Bearing 13. Piston Spring 53. Overflow Elbow 14. Valve Stem 54. Delivery Valve Sealing Cap 15. Valve Body 55. Roller Tappet Assembly 16. Piston Plug 56. Pump Housing Fuel Supply Stud 17. Fuel in & Out Fitting 57. Fuel Supply Pump Gasket 18. Fuel In & Out Fitting Gasket 58. Lock Washer 19. Plunger Lock Plate 59. Supply Pump Stud Nut 20. Housing Rack Plug 60. Camshaft Spacer 21, Housing Plug Gasket 61. Camshaft Plug 22. Housing Screw Plug 62. Port Closure Plug Gasket 23. Injection Pump Camshaft 63. Port Closure Plug 24. Camshaft Woodruff Key 64. Bottom Cover Gasket 25. Pump Housing Assembly 65. Housing Bottom Cover 26. Camshaft Support 66. Cover Screw Lock Washer 27. Support Lock Washer 67. Bottom Cover Screw 28. Camshaft Support Screw 68. Delivery Valve Holder 29. Front Bearing Housing Washer 69. Valve Spring Washer 30. Front Bearing Housing Screw 70. Delivery Valve Spring 31, Camshaft Front Bearing 71. Delivery Valve With Cap 32, Front Bearing Housing Gasket 72 Delivery Valve Gasket 33, Front Bearing Housing 73. Plunger and Barrel 34. Front Bearing Housing Ring 74. Lower Spring Seat 35. Adapter Stud Nut 75. Impact Cap O-Ring 36. Adapter Stud Washer 76. Control Sleeve 37. Timing Pointer 77. Upper Spring Seat 38. Adapter Stud 78. Impact Cap 39. Dowel Pin 79. Cap Retainer Snap Ring 40. Pump Mounting Adapter Assembly 80. Tappet Roller Spring CGES-375 Printed in United States of America Page3 SERVICE MANUAL

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