john deere fuel injection pump repair & installation

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30-10-4 Diesel Fuel System --- Fuel and Air Repair BLEEDING FUEL SYSTEM FUEL INJECTION PUMP A. CAUTION: Escaping diesel fuel under .. pressure can have sufficient force to pen- etrate the skin, causing serious personal injury. Before disconnecting lines be sure to relieve all pressure. Before applying pressure to the system, be sure all connections are tight and that lines, pipes and hoses are not damaged. Fuel escaping from a very small hole can be almost invisible. Use a piece of cardboard or wood, rather than hands, to search for suspected leaks. If injured by escaping fuel, see a doctor at once. Serious infection or reaction can develop if proper medical treatment is not administered immediate- ly. Whenever the fuel system has been opened up for service (lines disconnected or filtersremoved), itwillbe necessary to bleed the air from system. To bleed the fuel system on "0" engines, loosen the bleed plug on the fuel filterbase (A, Fig.6) and operate the hand primer on the fuel pump until most of the air bubbles are expelled from the filter. Push the hand primer back (toward engine) as far as possible and tighten filter bleed plug. To bleed the fuel system on "T" and "A" engines, loosen the bleed plug (A, Fig. 6). Unscrew the hand primer knurled knob on the fuel pump, and loosen until it can be pulled up by hand. Operate the hand primer until most ofthe air bubbles are expelled fromthe glass bowl on the pump. Push hand primer down and tighten. Tighten bleed plug. NOTE: If the engine will not start, it may be neces- sary to loosen the fuel pipes at the injection nozzles to bleed air from the system. With the hand throttle pushed all the way in, turn the engine over with the starter until fuel without air flows from the loose fuel pipe connections. Tighten the connections. TM-1106 (Jan-79) Litho in U.S.A 4270D Removal Clean the injection pump, pipes, and area around the pump with cleaning solvent or a steam cleaner. IMPORTANT: Never steam clean or pour cold water on an injection pump while the pump is running or while it is warm. To do so may cause seizure of pump parts. Fig. 8-Removing 42700 Fuel Injection Pump 1. Set engine to No. 1 TDC compression (see page 10-05-03) . 2. Disconnect electrical fuel shut-off lead. 3. Disconnect speed control linkage (not shown). 4. Disconnect fuel inlet and return lines. 5. Disconnect tachometer drive cable. 6. Removefuel lines. Cap fittings on nozzles and on injection pump. 7. Remove hold-down nuts and lift injection pump from engine. Engines - 400 Series

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Page 1: John Deere Fuel Injection Pump Repair & Installation

30-10-4 Diesel Fuel System

---

Fuel and Air Repair

BLEEDING FUEL SYSTEM FUEL INJECTION PUMP

A. CAUTION:Escaping diesel fuel under.. pressure can have sufficient force to pen-etrate the skin, causing serious personal injury.Before disconnecting lines be sure to relieve allpressure. Before applying pressure to the system,be sure all connections are tight and that lines,pipes and hoses are not damaged. Fuel escapingfrom a very small hole can be almost invisible. Usea piece of cardboard or wood, rather than hands, tosearch for suspected leaks.

If injured by escaping fuel, see a doctor at once.Serious infection or reaction can develop if propermedical treatment is not administered immediate-ly.

Whenever the fuel system has been opened up forservice (linesdisconnected or filtersremoved), itwillbenecessary to bleed the air from system.

To bleed the fuel system on "0" engines, loosen thebleed plugon the fuelfilterbase (A,Fig.6) and operatethe hand primer on the fuel pump until most of the airbubbles are expelled from the filter.

Push the hand primer back (toward engine) as far aspossible and tighten filter bleed plug.

To bleed the fuel system on "T" and "A" engines,loosen the bleed plug (A, Fig. 6). Unscrew the handprimer knurled knob on the fuel pump, and loosen untilit can be pulled up by hand. Operate the hand primeruntil most ofthe air bubbles are expelled fromthe glassbowl on the pump.

Push hand primer down and tighten. Tighten bleedplug.

NOTE: If the engine will not start, it may be neces-sary to loosen the fuel pipes at the injection nozzlestobleed air from the system. With the hand throttlepushed all the way in, turn the engine over with thestarter until fuel without air flows from the loose fuelpipe connections. Tighten the connections.

TM-1106 (Jan-79) Litho in U.S.A

4270D

Removal

Clean the injection pump, pipes, and area aroundthe pump with cleaning solvent or a steam cleaner.

IMPORTANT: Never steam clean or pour coldwater on an injection pump while the pump isrunning or while it is warm. To do so may causeseizure of pump parts.

Fig. 8-Removing 42700 Fuel Injection Pump

1. Set engine to No. 1 TDC compression (see page10-05-03) .

2. Disconnect electrical fuel shut-off lead.

3. Disconnect speed control linkage (not shown).

4. Disconnect fuel inlet and return lines.

5. Disconnect tachometer drive cable.

6. Removefuel lines. Cap fittings on nozzles and oninjection pump.

7. Remove hold-down nuts and lift injection pumpfrom engine.

Engines - 400 Series

Page 2: John Deere Fuel Injection Pump Repair & Installation

Fuel and Air Repair Diesel Fuel System 30-10-5

RepairFor injection pump repair information and specifica-

tions, refer to SM-2045 - "Testing and Servicing FuelInjection Pumps and Nozzles".

Installation

Inspect injection pump mounting hole in cylinderblock. If 1.0. of the mounting hole has a sharp edge,bevel the edge slightly with emery cloth. Remove allmetal chips and dust.

Verify that engine is set to No. 1 TDC compression.If not, set to No. 1 TDC compression.

Place thrust spring over tang on pump drive shaft.

Install injection pump in cylinder block, making surethat tang on pump drive shaft engages slot in oil pumpdrive gear.

Pump should sit squarely and solidly on mountingpad when a slight downward pressure is applied.

Install mounting nuts with washers but do not tight-en.

A-Weight RetainerTiming Line

B- Timing WindowC-Cam Timing Line

Fig. 9-lnjection Pump Timing Lines

TM-1106 (Jan-79) Litho in U.S.A.

Turn pump to align timing marks (Fig. 9). Tightenmounting nuts securely.

Rotate engine backward 1/4 revolution.

Turn engine in direction or rotation until injectionpump timing marks line up. The flywheel timing marksshould now be aligned. If not, remove and reinstallinjection pump.

IMPORTANT: The normal backlash of gears isenough to throw the injection pump timing off byseveral degrees, resulting in poor engine perfor-mance. Therefore, it is very important that thetiming of the pump be rechecked after installation.

Install fuel ines. Tighten fittings at injection nozzlesto 20 ft-Ibs (27 Nm) (2.7 kgm). Tighten hollow screwsat injection pump to 35 ft-Ibs (47 Nm) (4.7 kgm).

Connect electrical fuel shut-off lead.

Connect fuel inlet and return lines. Tighten fittings to20 ft-Ibs (27 Nm) (2.7 kgm).

Connect speed control linkage.

Do not remove timing window or connect tachome-ter drive cable.

Bleed fuel system (see page 30-10-04).

Adjust automatic speed advance. Refer to Section230, Group 10.

Engines - 400 Series

Page 3: John Deere Fuel Injection Pump Repair & Installation

30-10-6 Diesel Fuel System Fuel and Air Repair

FUEL INJECTION PUMP-Continued

6404D; 6466D

Removal

Clean the injection pump, pipes, and area aroundthe pump with cleaning solvent or a steam cleaner.

IMPORTANT: Never steam clean or pour coldwater on an injection pump while the pump isrunning or while it is warm. To do so may causeseizure of pump parts.

Use the following method to remove the fuel injec-tion pump:

1. Position engine at TDC, with No. 1 piston on thecompression stroke. (See page 10-05-04.)

NOTE: Obtaining TOG (No. 1 piston on compres-sion stroke) is not required for removing the injectionpump. However, it is required when installing back onthe engine. If the engine is to be disassembled orrotated after the pump has been removed, disregardthis step and proceed to Step 2.

A-Pump Gear B-Cap Screw

Fig. 10-lnjection Pump Removal Steps

2. Remove the timing hole cover (Fig. 10). Rotatethe engine until timing mark on governor weight re-tainer (B, Fig. 11) is in line with timing mark on cam ring(A).

TM-1106 (Jan-79) Litho in U.S.A.

A-Cam Ring B-Weight Retainer

Fig. 11-lnjection Pump Timing Marks

3. Remove fuel pump (page 30-10-1).

4. Disconnect the speed control linkage.

5. Disconnect injection pump inlet and pump-to-nozzle fuel pipes.

6. Disconnect electrical shut-oft lead.

7. Disconnect fuel return pipe.

8. Clean area around timing gear cover and removecover. Remove the three cap screws (B, Fig. 10) frompump drive gear (A).

9. Removemounting bolt nuts. The pump mountingflange on 64660 engine is secured with four nuts,whereas the 64040 engine uses three.

Remove pump. Be sure to cap all injection pumpand fuel pipe openings to prevent entry of contami-nants.

Repair

For injection pump repair information and specifica-tions, refer to TM-1064 "Fuel Injection Equipment-Roosa Master".

Installation

Check engine timing to make sure that No. 1 pistonis at TDC on the compression stroke. If the engine wasrotated after the injection pump was removed, crankthe engine until No. 1 piston is starting the compres-sion stroke. Install timing pin in cylinder block.

Engines - 400 Series

Page 4: John Deere Fuel Injection Pump Repair & Installation

Fuel and Air Repair Diesel Fuel System 30-10-7

FUEL INJECTION PUMP-Continued

Installation-Continued

The compression stroke can be determined by re-moving the rocker arm cover and turning the engineuntil both valves are closed on No. 1 cylinder, andincreased turning effort is noted. Continue turning theengine until timing pin engages the timing hole inflywheel.

Remove injection pump timing hole cover (Fig. 10).Rotate pump drive shaft and align the timing mark ongovernor weight carrier with the timing mark on thecam ring (Fig. 11).

Check pump mounting flange packing for damage orwear. Replace if necessary.

Install injection pump on the engine so the top edgeof the pump flange is parallel to the edge of the matingflange on the cylinder block. Tighten the mounting boltnuts to 20 ft-Ib (27 Nm) (2.7 kgm) torque.

Install the injection pumpgear on hub ("dish" in gearfacing outward toward front of engine), with the elon-gated holes in gear approximately centered with holesin hub. Recheck pump timing mark alignment. If cor-rect, install the timing gear-to-hub cap screws, andtighten to 35 ft-Ib (47 Nm) (4.7 kgm) torque.

Remove the timing pin from cylinder block. Rotatethe engine 1-1/2 revolutions in direction of rotation,then install timing pin in cylinder block. Continue to turnthe engine until timing pin engages the timing hole inflywheel. Recheck the alignment of injection pumptiming marks. If marks are not in line, loosen the pumpgear cap screws, and bring marks into alignment.Retighten cap screws to 35 ft-Ib (47 Nm) (4.7 kgm)torque.

IMPORTANT: The normal backlash of gears isenough to throw the pump timing off by severaldegrees, resulting in poor engine performance.Therefore, it is very important that the timing of thepump be rechecked after it has been installed.

Remove caps from injection pump and fuel pipeopenings.

TM-1106 (Jan-79) Litho in U.S.A.

Fig. 12-lnjection Pump-To-Nozzle Pipe Connections

Connect the Injection pump-to-nozzle pipes. Refer-ing to Fig. 12, connect No.1 outlet first and continuearound the pump head in a counterclockwise direction,attaching pipes in order of engine firing (1-5-3-6-2-4).

Tighten fuel pipe connectors to 20 ft-Ibs (27 Nm)(2.7 kgm) torque.

Connect the speed control rod, fuel inlet pipe, returnpipe to the injection pump, and electrical shut-off leadwire.

Install fuel pump (page 30-10-1), and open the fuelshut-off valve.

Remove timing pin and rotation tool from engine,and plug openings. Connect crankcase vent hose tolower vent tube.

Install injection pump timing hole cover, and enginetiming gear cover. Use new gaskets when necessary.

Bleed the fuel system (page 30-10-4).

After bleeding the fuel system, the automatic speedadvance should be checked for proper adjustment.Refer to Section 230, Group 10.

Engines - 400 Series

Page 5: John Deere Fuel Injection Pump Repair & Installation

30-10-8 Diesel Fuel System Fuel and Air Repair

FUEL INJECTION PUMP-Continued

6404T and A; 6466T and ARemoval

Clean the injection pump, pipes, and area aroundthe pump with cleaning solvent or a steam cleaner.

IMPORTANT:Never steam clean or pour coldwater on an injection pump while the pump isrunning or while it is warm. To do so may causeseizure of pump parts.

Use the following method to remove the fuel injec-tion pump:

1. Position engine at TDC, with No. 1 piston on thecompression stroke (see page 10-05-04).

NOTE: Obtaining TDG (No. 1 piston on compres-sion stroke) is not required for removing the injectionpump. However, it is required when installing back onthe engine. If the engine is to be disassembled orrotated after the pump has been removed, disregardthis step and proceed to Step 2.

Disconnect the crankcase vent hose and lower venttube from engine. Removetwo plastic cover plugs fromflywheel housing next to oil pressure sending unit.

Fig. 13-lnjection Pump Removal Steps(6466A Engine Without Aneroid Shown)

TM-1106 (Jan-79) Litho in U.S.A.

2. Remove timing gear cover (Fig. 13) from engine.Take out three cap screws (four on 6466A engines)that fasten injection pump drive gear to pump drivehub.

3. Disconnect supply pump inlet and outlet pipes.Cap all exposed fittings.

4. Disconnect and remove lubrication pipe. Thepipe connects oil filter base to aneroid activator.

A-Timing Hole Plug B-Drive Hub Mark C-Polnter Mark

Fig. 14-lnjection Pump Timing Marks (6466T Shown)

Install JDE-81-1 Engine Rotation Tool. Removetiming hole plug (A, Fig. 14) and by looking into hole,observe when pump drive hub mark (8) comes inalignmentwith pointer mark (C) as engine is turned. Atthis point, the JDE-81-4 Timing Pin should enter thehole in flywheel. Rotate engine slightly in either direc-tion until pin can be pushed into hole.

5. Disconnect injection pump fuel inlet line.

6. Disconnect fuel shut-off cable and speed controlrod.

7. Disconnect intake manifold-to-aneroid pipe (notshown).

8. Disconnect fuel delivery pipes using CS-2428Line Wrench. (Figs. 15 and 16). On 6404T and A and6466T engines, it is advisable to hold the hex portion ofpump delivery valve holder with another wrench whileloosening the fuel pipes.

On 6466A engines, hold the pump outlet fitting sta-tionary with JDE-90 Wrench while loosening fuel pipeswith CS-2428 Wrench.

9. Disconnect fuel return line.

Engines - 400 Series

Page 6: John Deere Fuel Injection Pump Repair & Installation

Fuel and Air Repair Diesel Fuel System 30-10-9

Fig. 15-Using CS-2428 Line Wrench

IMPORTANT: If a "P"-pump outlet fitting (6466Aengine) rotates while loosening or tightening a fuelpipe, the injection pump delivery will be altered,making recalibration on a test stand necessary.

R~?57NI- ~ ,Fig. 16-Using CS-2428 Line Wrench and JOE-gO

Serrated Wrench

10. On 6404T and A and 6466T engines, removethe four mounting nuts securing injection pump tocylinder block. Carefully remove injection pump.

NOTE: On 6466A engines, the injection pump cannot be removed unless the oil filter body (E, Fig. 17) isremoved.

On 6466A engines. thoroughly clean area aroundfilter body and remove dipstick (A). Drain filter body atplug (D). Remove oil filter element and disconnectturbocharger lubrication hose at (C). Remove mount-ing nuts and cap screw (B). Lift off filter body.

TM-1106 (Jan-79) Litho in U.S.A.

A-DipstickB-Mounting Stud

Nutsand CapScrew

C-Lubrication HoseD-Drain PlugE-Oil Filter Body

Fig. 17-Removing Oil Filter Bodyand Dipstick (6466A Only)

Remove the four mounting stud nuts which securethe injection pump to the cylinder block. Then, carefullyremove the injection pump.

11. Plug or cap all openings on engine and injectionpump, including pipes and hoses. (Not shown).

RepairGeneral Information

Do not attempt to disassemble or test the injectionpump unless the proper service equipment, test facili-ties, and qualified service personnel are available.

For injection pump repair information and specifica-tions refer to John Deere technical manual TM-1065,"Fuel Injection Equipment-Robert Bosch".

Engines - 400 Series

Page 7: John Deere Fuel Injection Pump Repair & Installation

30-10-10 Diesel Fuel System

--.-----..--.-....-.---.---.-

Fuel and Air Repair

FUEL INJECTION PUMP-Continued

Installation

Check engine timing to make sure that No. 1 pistonis at TOC on the compression stroke. If the engine wasrotated after the injection pump was removed, crankthe engine until No. 1 piston is starting the compres-sion stroke. Continue turning the engine until timing pinengages the timing hole in flywheel.

NOTE: The compression stroke can be determinedby removing the engine valve cover and turning theengine until both valves are closed on No. 1 cylinder.

Installa new O-ring (C, Fig. 18) on bearing plate (B).Lightly lubricate the O-ring to make installation of thepump easier and also to help prevent damage to theO-ring.

Rotate injection pump drive hub (A) until marks onhub are aligned with mark on pointer (0).

Removethe filler plug (E, Fig. 18, or bold arrow, Fig.19)from side of pump and add 3/4 U.S. pint (0.47 L) ofengine oil in pump crankcase. Oil should be of thesame grade as that used in the engine. Install fillerplug. Excess oil will drain out holes near O-ring at frontof pump to automatically provide the correct oil in thepump housing.

Mount the injection pump on engine, being carefulnot to damage the O-ring during installation. Installmounting stud nuts and washers.

Place injection pump drive gear in timing gearhousing (if previously removed) with the part numberon gear facing forward (see Fig. 20).

TM-1106 (Jan-79) Litho in U.S.A.

A-Drive HubB-Bearing PlateC-O-Ring

D-PointerE-Oil Filler Plug

Fig. 18-Preparing Injection Pump For Installation On Engine(A-2000 Illustrated - 6404T and 6466T)

R 24895N

Fig. 19-0il Filler Plug On P-110 Pump(6466A)

Engines - 400 Series

Page 8: John Deere Fuel Injection Pump Repair & Installation

Fuel and Air Repair

..-...--...-...--......--.-.-.-.--

Diesel Fuel System 30-10-11

Fig. 2O-lnjection Pump DriveGear Installation

Install the drive gear on pump drive hub, positioninggear so that the cap screws which secure the gear tothe drive hub will be in the approximate center of gearslots. Doing so, will permit the pump timing to bechanged, should the need arise.

Rotate the engine 1-1/2 revolutions in direction ofrotation. Continue to turn the engine until the timing pindrops in flywheel hole for TDC.

Recheck the alignment of the injection pump timingmarks. If the marks are not in line, loosen the pumpgear cap screws, and bring marks into alignment.

IMPORTANT: The normal backlash of gears isenough to throw the pump timing off by severaldegrees, resulting in poor engine performance.Therefore, it is very important that the timing of thepump be rechecked after it has been installed. Toavoid backlash, always approach the timing markon pointer by turning engine in direction of rota-tion.

Tighten drive gear cap screws and pump mountingstud nuts to 35 ft-Ibs (47 Nm) (4.7 kgm) torque. Installtiming hole plug (E, Fig. 14) and cover plate (2, Fig.13).

Remove all protective caps from pipe and hoseconnections.

Reverse the numbered removal steps found onpage 10-8 except for Step 6. Leave the speed controlrod and fuel shut-oft cable disconnected until the pumpidle speeds have been checked. (See "Adjustments",Section 230.)

Open the fuel shut-oft valve, and bleed the fuelsystem.

Start engine and check for leaks. Especially checkfor leaks at pump lubrication pipe connections to pre-vent loss of engine lubricating oil. Repair as required,to stop leakage of fuel and lubricating oil.

TM-1106 (Jan-79) Litho in U.S.A.

ANEROID ("T" and "A" Engines)General Information

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Fig. 21-Aneroid

Some 6404T and A and 6466T and A engines areequipped with an aneroid (Fig. 21), which is a dia-phragm-type control unit that mounts on top of injectionpump governor housing.

Its purpose is to limit the black smoke producedduring acceleration under two conditions:

(1) When load is moderate to heavy with enginespeeds from 800 to approximately 1000 rpm.

(2) When load is light at any engine speed.

Repair

Refer to TM-1065 "Fuel Injection Equipment -Robert Bosch", Section 30, Group 10 and 15 for in-structions on how to repair and adjust the aneroid.

The aneroid controls fuel delivery when intakemanifold pressure is about 10 psi (1 bar) (1 kg/cm2) orless. Therefore, all final adjustments are to be made onthe test stand with aneroid mounted on injection pump.

IMPORTANT:Correct aneroid adjustments areessential for satisfactory engine performance.Whenever the aneroid has been disassembled orthe adjustments have been altered, the injectionpump (including aneroid) must be calibrated on thetest stand before releasing the pump for service.

Engines - 400 Series