Description
This 205 page, International Harvester Diesel Pump 1 & 2 Plunger Service Manual is a reproduction of the original, out of print manual . This manual provides detailed service information, step-by-step repair instruction and maintenance specifications for Diesel Pump 1 & 2 Plunger used on Industrial Equipment such as: TD6, TD9, TD14, TD15, TD18, TD20, TD24, TD25, TD35 and TD40- 817 Engines. ID-6, ID-9 Dsl, ODS-6 Dsl, UD-14 Power Unit, UD-14A Power Unit, UD-16 Power Unit, UD-18 Power Unit, UD-18A Power Unit UD-24 Power Unit, UD-6 Power Unit, UD-370 Power Unit, UD-370 Dsl Power Unit, TD15 Crawler 150 and 151 Series, TD18A Diesel Crawler, TD18, TD20 Diesel Crawler,TD24 Diesel Crawler. UD-6 Power Unit, Adams 512 Diesel Grader, 412H Diesel Grader, 412 Diesel Grader and the 312 Diesel Grader.
Table of Contents
SECTION 1. CHARTS AND DATA
Diesel Fuel System Test Chart
Unit Replacement Chart
IH Diesel Fuel Injection Pump Service Chart
Introduction Dynamometer Testing of Rebuilt Engines
Procedures for Adjusting IH Injection Pumps on Engines During Dynmometer Run-in
Temperature and Barometric Correction Chart
Flow Bench Setting of IH Injection Pumps (Not Physical Dimension) (Charts 1 and 2)
Manifold Pressures , Exhaust Temperatures and Maximum Fuel Consumption
Speed Charts:
Prior to MA” Pumps (Std. App.)
“A” Pumps (Std. App.)
“B” and “C” Pumps (Std. and Special App. )
Manufacturer Customer (“A” Pumps)
35 and 4U Series (“A” and “B” Pumps)
Manufacturer Customer (“B”and “C” Pumps)
Plunger Identification Chart
Governor Spring Assembly
Chart for Testing IH Single-Plunger Pumps on Bosch Test Stand
Altitude Deration
Fuel System Diagrams
Description
Special Tools
Specifications
Checking Mechanical Problems
SECTION 2. INJECTION NOZZLES AND INJECTORS
Nozzles
Description
Removal
Disassembly
Inspection and Repair
Reassembly
Installation
Testing Injection Nozzles R
econditioning Nozzle Valves
Injectors
Description and Operation
Removal
Testing Injectors Prior to Reconditioning With A Tester (Kiene) Disassembly
Inspection and Reconditioning
Reassembly
Installation
Field Check for Fuel Pipe Fitting Leaks (on Engine)
SECTION 3. IH FUEL INJECTION PUMPS
Removal (Complete Injection Pump)
Installation (Complete Injection Pump)
Timing Injection Pump to the Engine ”In Chassis’1 High Idle Speeds
Pump Timing Chart
SECTION 4. DISTRIBUTOR
Removal
Disassembly
Inspection and Repair Reassembly
Installation
SECTION 5. PLUNGER
Removal
Disassembly
Inspection and Repair
Reassembly
Installation
SECTION 6. PRIMARY PUMP
Description
Removal
Disassembly
Inspection and Repair
Reassembly
Leakage Test for Primary Pump
Installation
SECTION 7. TORQUE CONTROL AND GOVERNOR SPRING
Removal
Disassembly
Inspection and Repair
Reassembly
Installation
SECTION 8. SCAVENGING VALVE
Removal and Disassembly
Inspection and Repair
Reassembly and Installation
SECTION 9. CAMSHAFT
Removal
Disassembly
Inspection and Repair
Reassembly
Installation
SECTION 10. GOVERNOR SHAFT, RACK AND CONTROL LEVER
Removal
Disassembly
Inspection and Repair
Reassembly
Installation
SECTION 11. TESTING AND ADJUSTING INJECTION PUMPS WITH TEST STAND
The Injection Pump Test Stand
Mounting the Injection Pump on Allen Test Stand
Mounting 16 or 24 Series, IH Twin Plunger Injection Pump on Allen Test Stand
Mounting 18A Series IH Twin Plunger Injection
Pump on Allen Test Stand Mounting the Injection Pump on Bacharach YRS
Test Stand
Primary Pressure Test
Preparation for Dimensional Adjustments
Torque Lever Stop Screw Dimensional Adjustment
Torque Spring Shoe Screw Dimensional Adjustment
Torque Lever Pick Up or Limiting Screw (Overload Gap) Dimensional Adjustment
Shutoff Stop Screw Dimensional Adjustment
Equalizing the Racks on Twin Plunger Pumps Fuel Delivery Test (Not FOUR SPEED FLOW METHOD)
Rack Positive Shutoff Adjustment
Torque Arm Stop Screw Dimensional Adjustment (Maximum Fuel Delivery)
High Speed Stop Screw Dimensional Adjustment
Bumper Spring Dimensional Adjustment
Conversion Chart
Four Speed Flow Method (Not Physical Dimension)
Solid Torque Arm Adjustment (For Pumps so Equipped)
Check and Reverse Check Valve Leakage Test
Reverse Check Valve Opening Pressure
Fuel Return Check Valve Opening Pressure
Scavenging System Leakage Test (“A” Pumps and Prior Only)
Distributor Valve and Stem Leakage Test
Plunger Leakage
Test Flow Delivery Tolerances
SECTION 11 A. LEAKAGE TESTS WITH PUMP DISASSEMBLED (ON TEST STAND)
Distributor Valve and Seat Leakage Test
Distributor Valve, Bushing and Gasket Leakage Test
Check and Reverse Check Block Leakage Test
Reverse Check Valve Opening Pressure Test
Plunger Leakage Test
SECTION 12. TESTING DIESEL FUEL SYSTEMS ON THE ENGINE
General Instructions
Nozzle Leakage and Opening Pressure Test
Comparative and Primary Pump Pressure
Check and Reverse Check Valve Leakage Test
Reverse Check Valve Opening Pressure Test
Fuel Return Check Valve Opening Pressure Test
Scavenging System Leakage Test
Distributor Valve and Stem Leakage Test
Test for Plunger Leakage and Degrees of Pump Rotation Between Distributor Valve Opening, Plunger Port Closing, Plunger Port Opening, and Distributor Valve Closing
Test Chart
Field Adjustment of Governor and Torque Arm Assembly
Solid Torque Arm Torque Control Settings
Rack Adjustment of Twin Plunger Pumps Mounted on the Engine
