This article mainly introduces caterpillar 3208 Diesel Truck Engine Checking Fuel Pump Calibration
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The following procedure for fuel pump calibration canbe done with the housing for the fuel injection pumps on or off the engine.
NOTICE Before any service work is done on this fuel system.
the outside of the injection pump housing and alil parts connected to it must be clean.
1. Remove the fuel shutoff solenoid (9), top cover(10)
of the fuel pump housing and the cover over the torque control group.
2. Remove the fuel that is in the injection pump housing and the governor housing
4. Install 5P6602Adapter(13) as shown. Fasten it in position on the injection purmp housing with a
1D4533 Bolt(12) and a 1D4538 Bolt (14).
5. Put 8S7271 Screw (11) in the hole over calibration pin(7). Tighten screw(11) to 2.3 to 2.8 N·m(20 to
25 Ib in).
6. Adjust low idle screw (15) to position lever (16) to
8.9±1.0mm(35±.04in) from governor housing boss.
7. Use the 8S2243 Wrench and remove the fuel injection pumps to be checked.
NOTE: If pump is removed carefuly, the sleeve will remain on the plunger. If the sleeve falls off the pumpplunger during removal, find it immediately and replace it on the pump plunger before removal of another 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 pump(nearest the pump spring).
8. Clean the barel and plunger of calibration pump
(1). Put clean diesel fuel on the calibration pump for lubrication.
NOTE: Be sure that the spring on the calibration pump(1) is the 5P6557 Spring instead of the 1P7377 Spring which was installed on earlier calibration pumps.
9. Put calitbration pump(1) in the place of the pump to be checked with the flat place(20) on the plungertoward tang(17) on lever(18). When the calibration pump(1) is al the way in the bore, turn it 180°in either clockwise or counterclockwise direction. Tang
(17) on lever(18) is now in groove(19) of calibration pump(1). Then install 4N218 Bushing(2). Use the
8S2243 Wrench and a torque wrench to tighten the bushing to 80±7 N·m(60±5ib ft).
NOTE: Turning calibration pump(1)180° gives the same reference point for all measurements.
Calibration Pump Installed
(1)3P1540 Calibration Pump.(17) Tang on lever.(18) Lever.
(19) Groove of calibration pump.(20) Fiat on plunger.
NOTE: Use 4N0218 Bushing (2) and calibration pump
(1) together. The contact surfaces of the standard bushing, fuel injection pump and the housing for thefuel injection pumps are sealing surfaces. Keep them clean and free of scratches to prevent leaks.
Putting Dial Indicator On Zero
(3) Microgauge.(4)3P1568 Dial Indicator with 3P2226 Collet.
(21) Lockscrevw.(22) Locknut.(23)3P2226 Collet.
10. Put dial indicator (4) on microgauge(3) and hold them together tightly. Loosen lockscrew(21) and turn the face of dial indicator (4) to put the pointer at 0". Tighten lockscrew(21).
Remove dial indicator (4) from microgauge (3). Look at the face of dial indicator(4) and put dial indicator(4)
on microgauge(3) again. The pointer must move through one to one and one half revolutions before stopping at exacty "O". If the number of revolutions is not correct, loosen the locknut on 3P2226 Colet(23).
11. Put 6V0190 Clamp(25) in the position shown, next to the transfer pump end. Clamp (25) pushes shaft(24) down against the bottorn 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 frorm clamp (25) and calibration pin(7) is necessary to hold shaft (24) is in its normal operating position against the lifting force from the spring in calitbration pump(1).
[ side opposite frorm governor control lever(16)] put clamp(25) on both ends of sleeve shaft as shown.
12. Put dial indicator(4) on the calitbration 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.
hen look at the reading on the dial indicator(4).
13.If the dial indicator（4）reading is more than士
0.050 mm from"0.000"（outside the Total Tolerance），do Steps 17 through 20.Adjusting Fuel Pump Calilbration.
Maximum permissible tolerance for pump readings in any Fuel Injection Pump Group is
0.100mm(-0.050 to +0.050 mm on dial indicator).
Maximum permissible differences between any two pumps in the same Fuel Injection Pump Group is 0.050mm.
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 Pump Calibration for all pumps.
Band is an example only. It shows a 0.050mm range. This range shows the maximum permissible difference between any two readings for all the pumps. If any two readings are farther apart than the 0.050 mm range, do Adjusting Fuel Pump Calibration for all pumps.
If the 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 the Steps 15 through 19, Adjustment Of Fuel Pump Calibration.
NOTE: The mechanic doing the checking must make the decisions of which and how many pumps to check according to the symptoms of the fuel injection pump being tested
14. If dial indicator (4) readings for all the 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 dial indicator(4) reading is "0"or near "O", the calibration of the other pumps is probably in the tolerance.
Adjustment of Fuel Pump Calibration
15. Remove all pumps with 8S2243 Wrench.
16. Clean the barel and pump of calitbration pump(1).
17. Install calitbration pump (1) in the place of one of the pumps according to the procedure in Step 9.
18. Loosen bolt(26) with 1S9836 Wrench (8) or
5P4206 Wrench. Turn the lever(18) on shaft(24)
enough to move the top of plunger (28) of calibration pump (1) below top surface (27) of calibration pump(1). Tighten boit(26) just enough for lever(18) to hold plunger (28) stationary
NOTE: When bolt (26) has the correct torque, pushing with a small amount of force on lever (18) through the wrench moves plunger (28) in calibration pump(1).
19. Move shaft(24) toward the governor to remove end play. Then push down on lever(18) through the wrench until top of plunger (28) is almost even with top surface(27) of calibration pump(1) as shown.
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20. Check dial indicator(4) according to Step 10. Then put dial indicator (4) in place over the center of calibration pump(1) and hold it there tightly. Now move plunger (28) of calibration pump (1) by pushing on lever (18) through the wrench. Stop moving the plunger when the dial indicator is at approximately 0.009 mm past "0.000. Tighten bolt
(26) to 2.8±0.2N·m(24±2lbin).
NOTE: When moving plunger (28), make sure that the last direction of plunger(28) movement is in the up direction. If plunger (28) goes up too far, move plunger
(28) down to a position below that desired. Then move plunger (28) up to the desired position.
NOTE: The action of tightening bolt (26) usually changes the reading on dial indicator(4) by approximately (0.010 mm) in the minus direction.
Move shaft(24) toward shutoff several times to remove clearance in the linkage. Dial indicator(4) reading must be (0.000±0.010 mm) as shown.
When the pump calitbration is correct make a record and then do the same procedure for all the other pumps.
NOTE: When calibrating pumps on the "slave' side
[ side opposite from governor control lever (16)], put clamp(25) on both ends of the sleeve shaft as shown.
