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9/3/2019 QuickServe Online | (3666193) ISB and QSB5.9-44
Troubleshooting and Repair Manual
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(/qs3/pubsys2/xml/en/manual/3666193/3666193-titlepage.html)
General InformationThe fuel injection pump (VP44) is an
electronic rotarydistributor pump. The pump performs four basic
functions:
1. Producing the high fuel pressure required for injection2.
Metering the exact amount of fuel for each injection cycle3.
Distributing the high-pressure, metered fuel to each
cylinder at the precise time4. Varying the timing relative to
engine speed.
A cam ring with three plungers, a rotor, and an
electronicallycontrolled fueling solenoid valve is used to develop
anddistribute the high pressure required for injection.
A worn or damaged internal transfer pump, plunger, or
fuelingvalve can affect the pressure and amount of fuel injected,
thusreducing the power from the engine. Generally, if the
fuelinjection pump is injecting fuel from one outlet, it will
deliverfrom all outlets.
VP44 Timing Principles
Timing in the VP44 is controlled by an internal timing
pistoncoupled to a cam ring inside the pump. The timing piston
ismoved by fuel pressure. The amount of fuel pressure in thetiming
piston assembly housing is controlled by an internaltransfer pump
and a pulsating timing solenoid valve.
As pump speed increases, the fuel pressure to the timingpiston
assembly also increases. Based on the inputs from thefuel pump
control module (FPCM), the timing solenoid valvepulses to vary the
pressure to move the timing piston, whichresults in the cam ring
moving to the desired position toachieve the commanded timing.
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Initial Check
The more pressure created by the internal transfer pump
andtiming solenoid valve, the more the timing will
advance;therefore, timing range capability is increased at higher
rpm.
WARNING
Depending on the circumstance, fuel is flammable. Keepall
cigarettes, flames, pilot lights, arcing equipment, andswitches out
of the work area and areas sharingventilation to reduce the
possibility of severe personalinjury or death when working on the
fuel system.
WARNING
Do not vent the fuel system on a hot engine; this cancause fuel
to spill onto a hot exhaust manifold, which cancause a fire.
Disconnect the VP44 fuel pump drain line from the T-fitting
andplug it.
Disconnect the vacuum gauge plastic tubing from the
cylinderhead's drain line and connect it to the VP44 fuel pump
inletline.
Note : All fuel must be drained from all fuel lines,
ifobserved.Apply the vacuum test to the fuel system and check
thevacuum gauge. The vacuum can not exceed 381 to 508 mm-Hg [15 to
20 in-Hg].
If the system holds the vacuum (if the reading on the gaugedoes
not reduce, the vacuum should not drop more than 2.54mm-Hg [0.1
in-Hg] in a minute), then there is no leak in the fuelsystem.
Note : The vacuum test is completed if the fuel systemholds
vacuum for at least 5 minutes.
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Preparatory Steps
If the system does not hold vacuum (the reading on the gaugedoes
not hold and reduce to 0 mm-Hg [0 in-Hg], then there is aleak in
the fuel system.
If the system does not hold a vacuum, check for leaks at theVP44
fuel pump.
Inspect the lines, fittings, washers, and VP44 fuel pump for
anydamage. Replace and install parts that are damaged.
Contact a Cummins® Authorized Repair Location forreplacement and
installation of the VP44 fuel pump, if required.
WARNING
Batteries can emit explosive gases. To reduce thepossibility of
personal injury, always ventilate thecompartment before servicing
the batteries. To reduce thepossibility of arcing, remove the
negative (-) battery cablefirst and attach the negative (-) battery
cable last.
WARNING
Depending on the circumstances, fuel is flammable. Keepall
cigarettes, flames, pilot lights, arcing equipment, andswitches out
of the work area and areas sharingventilation to reduce the
possibility of severe personalinjury or death when working on the
fuel system.
Disconnect the battery cables, negative (-) cable first.
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Troubleshooting and Repair Manual
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Remove
Disconnect the fuel return line. Refer to Procedure 006-013 in
Section 6.
(/qs3/pubsys2/xml/en/procedures/53/53-006-013.html)Disconnect the
fuel pump supply line. Refer to Procedure006-024 in Section
6.(/qs3/pubsys2/xml/en/procedures/53/53-006-024.html)Disconnect the
9-pin electrical connector from the fuelpump control module
(FPCM).Remove the crankcase breather and gear retaining nutand
washer. Refer to Procedure 003-018 in Section
3.(/qs3/pubsys2/xml/en/procedures/53/53-003-018.html)
Note : Doing the above will help prevent the fuel pumpkey from
falling into the housing if it is loose.
It is recommended to bar the engine over so the keyway on
thegear is at the 12-o'clock position when removing the fuel
pump.This position can be found by taking the oil fill or fuel
pumpgear access cap off, whichever applies, and aligning thekeyway
in the fuel pump gear to the top dead center (TDC)position on the
front cover. In this position the line on the fuelpump gear will be
approximately in the 5-o'clock position.
Disconnect the 9-pin electrical connector from the fuel
pumpcontrol module (FPCM).
Remove the fuel pump support bracket.
Remove the fuel pump gear retaining nut and washer.
Use Fuel Pump Gear Puller, Part Number 3163381, to pull thefuel
injection pump drive gear loose from the pump driveshaft.
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Clean
Note : Do not drop the drive gear key when removingthe
pump.Remove the four mounting nuts, and remove the fuel
injectionpump.
Once the damaged fuel pump is removed, it must be
properlylabeled with the Engine Serial Number (ESN).
Record the engine serial number (ESN) on the wire tag
(1)provided with the replacement pump. Insert the tag into
theplastic sleeve if one was provided to protect it from
fuelsaturation. Securely fasten the tag to the damaged pump
byinserting the wires through one of fuel pump mounting boltholes
and twisting wires together.
Drain the fuel from the damaged pump.
Use the plugs and the caps from the replacement pump to plugthe
threaded holes and cap the delivery nozzles on thedamaged pump.
Place the damaged pump in a plastic bag to prepare
forshipping.
Use a clean, dry cloth to wipe all of the oil off the back of
thegear housing mounting surface and pump housing.
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Inspect for Reuse
Install
Inspect the mounting surfaces for damage.
Inspect the fuel pump mounting o-ring for cuts or damage.
CAUTION
The driveshaft must be clean and free of all oil
beforeinstallation. Failure to do so can result in the drive
gear
slipping on the shaft.
The keyed gear and shaft allow for the fuel injection pump tobe
installed in any position, as long as the markings on thefront gear
train align and a gear has not slipped.
The Woodruff key part number (identification code) is locatedon
the data plate on the side of the VP44 pump. The correctkey number
must be used so correct timing can be achieved.
The arrow on the key must be pointing toward the fuel
injectionpump and away from the gear housing.
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Use an evaporative cleanser (e.g., brake cleaner,
isopropylalcohol) to clean the pump shaft and gear bore.
Note : Barring the engine so the keyway is at the 12-o'clock
position will aid in aligning the key into thekeyway.Note : The
fuel injection pump shaft must be rotated toalign with the keyway
in the gear.It is recommended to bar the engine over so the keyway
on thegear is at the 12-o'clock position when installing the fuel
pump.This position can be found by taking the oil fill or fuel
pumpgear access cap off, whichever applies, and aligning thekeyway
in the fuel pump gear to the top dead center (TDC)position on the
front cover. In this position the line on the fuelpump gear will be
approximately in the 5-o'clock position.
Install the pump. Make sure the key does not fall into the
gearhousing. Take care not to damage the pump mounting o-ring.
Note : When installing the fuel pump, the dowel in theback of
the gear housing must line up with the hole inthe pump mounting
flange, as well as the keyway in thegear.
Hand-tighten the four mounting nuts.
Install the pump driveshaft nut and spring washer.
Torque Value: 36 n•m [ 27 ft-lb ]
Note : Do not overtighten; this is not the final torque.
Tighten the fuel injection pump mounting nuts.
Torque Value: 43 n•m [ 32 ft-lb ]
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Finishing Steps
Install the injection pump support bracket. Finger-tighten
allcapscrews before final tightening.
Tighten the brackets in the following sequence:
1. Bracket-to-fuel pump capscrews2. Brace-to-block capscrews3.
Bracket-to-fuel pump brace capscrews.
Tighten all capscrews on the support bracket.
Torque Value: 24 n•m [ 212 in-lb ]Connect the 9-pin connector to
the VP44 fuel pump.
Tighten the pump driveshaft retaining nut.
Torque Value: 170 n•m [ 125 ft-lb ]
WARNING
Batteries can emit explosive gases. To reduce thepossibility of
personal injury, always ventilate thecompartment before servicing
the batteries. To reduce the
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Troubleshooting and Repair Manual
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Last Modified: 06-May-2009
possibility of arcing, remove the negative (-) battery
cablefirst and attach the negative (-) battery cable last.
Install the low-pressure fuel lines. Refer to Procedure 006-024
in Section 6
(/qs3/pubsys2/xml/en/procedures/53/53-006-024.html).Install the
fuel return lines. Refer to Procedure 006-013 inSection 6.
(/qs3/pubsys2/xml/en/procedures/53/53-006-013.html)Install the
high-pressure line. Refer to Procedure 006-051in Section 6.
(/qs3/pubsys2/xml/en/procedures/53/53-006-051.html)Install the
crankcase breather. Refer to Procedure 003-018 in Section 3.
(/qs3/pubsys2/xml/en/procedures/53/53-003-018.html)Connect the
battery cables, negative (-) cable last.Vent all air from the fuel
system. Refer to Procedure 006-003 in Section 6.
(/qs3/pubsys2/xml/en/procedures/53/53-006-003.html)Operate the
engine and check for leaks.
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