BOLT-PLOW 1J0849 - Caterpillar

Introduction
Some photographs and illustrations in this book are of the DB2 Fuel Pump. The DB4 Fuel Pump is slightly different, but the procedures given are basically the same.
DB2 Fuel Pump
DB4 Fuel PumpThis section provides the setup and adjustment procedures for testing and adjusting Fuel Injection Pumps. The fuel injection pumps are tested using the Fuel Injection Equipment Test Stand. See Special Instruction SEHS8200, "Using the Fuel Injection Equipment Test Stand:" for operating instructions.These pumps can also be tested on earlier fuel injection test benches using the same tooling and procedures. See Special Instruction SEHS7465.
Fuel Injection PumpTooling
The tools listed are required to test the pump and governor assembly. These tools are not available in a group and must be purchased separately.
Mounting Tools
Calibration Fluid and Lube Line Tooling Pump
Mount Pump To Test Stand
Base Plate Attached To Rails Of Test Stand
(1) 6V9132 Base Plate(2) 6V9134 Lock Screw(3) 1U5366 Pump Mounting Plate1. Attach 6V9132 Base Plate (1) to test stand rails using 6V9138 Mounting Assembly (T-Bar) and 6V9134 Lock Screw (2).2. Attach 1U5366 Pump Mounting Plate (3) to base plate using four 0T0924 Bolts and 5M2894 Flat Washers.
Pump Mounted To Pump Mounting Plate
(3) 1U5366 Pump Mounting Plate(4) 0T0772 Bolt and 4S4191 Flat Washer3. Mount pump to pump mounting plate (3) using three 0T0772 Bolts and 4S4191 Flat Washers (4).Connect Pump Drive Adapters To Test Bench
Pump Adapter
(1) 9U7493 Drive Adapter(2) 118-1711 Nut1. Install 9U7493 Drive Adapter (1) with 118-1713 Flat Washer and 118-1711 Nut (2). Tighten nut (2) to 55 N m (40 lb ft).
Drive Adapter
(3) 6V6048 Drive Adapter(4) 2A4639 Bolts2. Install 6V6048 Drive Adapter (3) with two 2A4639 Bolts (4) and 5M2894 Flat Washers.
Drive Adapter3. Align keyway and connect the drive adapter to the chuck. Insert shaft approximately one inch into chuck.4. Tighten two bolts in chuck.a. Tighten lock screw on base plate.b. Install guards.Testing Pump
If the pump is equipped with an aneroid, the aneroid rod must be disconnected before the pump is run on the test stand.
Timing Cover
(1) Timing Cover1. Remove timing cover (1).
Timing Indicator Assembly
(2) 4C8126 Timing Indicator Assembly2. Attach 4C8126 Timing Indicator Assembly (2).
Pressure Tap Screw
(3) Pressure Tap Screw3. Remove pressure tap screw (3) and lock (8) from the transfer pump.
4C8054 Tap Fitting Assembled
(4) 5P6661 Fitting(5) 8T6864 Valve(6) 6K1019 Reducer(7) 4C8054 Tap Fitting(8) Lock4. Install reducer (6) in 4C8054 Tap Fitting (7). Install shutoff valve (5) on reducer (6). Install fitting (4) to shutoff valve (5).
Assembled 4C8054 Tap Fitting Installed
(7) 4C8054 Tap Fitting(8) Lock5. Put lock (8) on 4C8054 Tap Fitting (7). Install the assembled 4C8054 Tap Fitting (7) to check transfer pump pressure.
Line Connected To Transfer Pump Fittings
(9) 7G7105 Hose Assembly6. Connect hose (9) from the 1400 kPa auxiliary gauge to the transfer pump fittings.
Fuel Injector Test Tube Assemblies
(10) 127-4365 Fuel Injection Test Tube Assembly7. Connect 127-4365 Fuel Injection Test Tube Assemblies (10). Assemble from front of fuel pump to manifold block and tighten.
Fuel Inlet Connected To Test Bench
(11) 7G7105 Hose Assembly(12) 4C5710 Fitting8. Connect hose (11) to test bench.
Fuel Return Connected To Test Bench
(13) 7G7105 Hose Assembly(14)