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E
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SERVICE MANUAL
HP0 Supply pump Adjustment Manual
REPAIR
April, 2004
00400068E
-2
Foreword
This manual describes the procedures for disassembling, reassembling, and inspecting the sup-
ply pump (HP0) for the common-rail type electronically controlled fuel injection system. Please
read the contents thoroughly and apply them in your service and maintenance work.
Service Precautions
• Be careful with any fuel or oil leaks as they could cause a fire.
• Be careful with hot fuel as it could cause burns.
• The fuel in the fuel pipe reaches an extremely high pressure. Therefore, gradually re-
duce the fuel pressure (to atmospheric pressure) before disconnecting parts or high-
pressure pipes during a test.
• Pay particular attention to preventing the introduction of dust or debris into the fuel
system, as it could cause the supply pump to malfunction.
• Use specially sized injection pipes of an outer diameter of 8mm and an inner diameter
of 4mm.
-1
Table of Contents
1. Performance Inspection Tool List ------------------------------------------------------ 1
2. Performance inspection manual -------------------------------------------------------- 3
2-1 Setting up the bench ------------------------------------------------------------------ 3
2-2 Supply pump performance test ---------------------------------------------------- 9
[1]Test conditions --------------------------------------------------------------------------- 9
[2] Feed pump check ----------------------------------------------------------------------- 9
[3] Feed pump feed quantity check ----------------------------------------------------- 10
[4] G sensor output check ----------------------------------------------------------------- 12
[5] G sensor noise check ------------------------------------------------------------------ 13
[6] PCV operate check --------------------------------------------------------------------- 13
[7] Fuel delivery quantity check at high pressure ------------------------------------ 15
0
1. Foreword Performance Inspection Tool List
Part Number Part Name
ECD-U2 set
95191-00211 • Cartridge (95191-20711)
• Harness (95191-10342)
1
Part Number Part Name
QB0728
2
2. Performance Inspection Manual
3
Note :
If the supply pump is the flange type, remove the
O-ring from the flange mounting area and install
it on the flange.
4
(6) While turning the drive shaft with the handle,
center it by aligning the camshaft and the rota-
tional shaft of the coupling.
5
(11) Using the fuel hose, connect the fuel filter with
the hose.
6
• Piping Layout (Test Bench)
[1] Test condition - [6] PCV operation check Pipe
Pipe Ø2 × Ø6 × 600
Hose (overflow)
Solenoid valve
Outlet
Filter
ECD controller
Inlet
With nozzle
Bench
17.4 Mpa 17.4 Mpa
Flow meter
Coupling block
Bench
Pump stand
Return
Fuel tank
Q000762E
7
• Controller Specification Settings (Rated Power Supply: 30V minimum, 10A minimum)
Pc +B
8cyl
Np 6cyl
TFE 5cyl
TFD 4cyl U2
U2P
40 50 60
30 70
20 80
1 2 3 10 90
0 100
POWER FCV
QD0499E
<Other Switches>
Power : power supply switch for the controller
FCV : unused (it must always be set to the "OFF" position)
8
ECD controller
To Pc sensor
PCV 1
PCV 2 8A
PCV for G1
No.1 cylinder G1 GND Fuse (8A)
PCV for G2
No.2 cylinder G2 GND Stabilized power supply
To G sensor 1 Terminal for
G sensor signal check
To G sensor 2
Battery cord
Q000726E
Note :
Refer to the test specifications of the respective pump for the cylinder numbers of the pump.
2.2 Supply pump performance test
[1] Test conditions
Recheck the test conditions such as the direction of the pump rotation, the length of the pipes,
and the valve opening pressure of the nozzles.
Refer to the values indicated in the individual test specifications to obtain the standard values
for the respective items indicated below.
Perform the test steps indicated below for each cylinder.
Connect ECD controller, G sensor, PCV1, PCV2 and Pc sensor by harness.
9
C. Operate the priming pump at a rate of 1 stroke
per second (60 strokes per minute) and verify
that it draws fuel up at the standard stroke
rate, at the maximum. (Pump speed: 0 rpm)
Standard : Refer to each test specification
10
(4) Select the type of pump selection switch
11
(8) Select the number of cylinders on the pump se-
lection switch.
Note :
Align the data display switch to +B, and set so
that the data display shows 28.0.
(9) Turn the data display switch to TFD and enter
the command value.
(10) Then, turn the data display switch to TFE and
enter the command value.
(11) Turn the data display switch to Np.
(12) Operate the pump at the specified speed and
verify.
QU0290
12
[5] G sensor noise check
(1) Turn the data display switch to TFD and enter
the specified command value.
(2) Then, turn the data display switch to TFE and
enter the specified command value.
(3) Lastly, turn the data display switch to Np.
13
Note :
While connecting the PCV, precisely wind one of
the two PCV wires twice around an AC/DC 400A
probe. Then, connect the terminal of the AC/DC
400A probe to the DST-1 connector.
This winding has been already made on wire har-
ness.
Range : 40A
Note :
When winding the PCV wiring around the AC/DC
400A probe, wind it in the direction shown on the
right. If there is a large amount of noise infiltra-
tion, also wind on a shield to prevent noise in the
probe wiring harness.
QD0493
Supplementary Explanation
Procedures for Setting Up the Cover Shield and
DST-1 Adaptor
The cover shield (95191-20970) covers the
AC400A probe wiring harness, making it difficult
for noise to penetrate.When using this product,
pay careful attention to the following cautions.
* The product does not fully prevent noise infiltration.
14
b. Secure the cover shield ground terminal to the
DC power supply ground terminal (or terminal
1).
* In this case, the DST-1 AC adaptor should be connect-
ed using the same socket as the DC power supply.
15
C. Connect the pipe between the pressure regula-
tor and PCV1.
jet pipe : 95091-11400
16
G. Example of Actual Bench Setting
Outlet
To return
Filter
ECD controller
To return Pressure limiter
Using STT*
176 Pc sensor
+0
Fuel tank
* STT P/N: 95095-10830 Q000765E
17
(2) High-Pressure Delivery Quantity Check
A. Adjust the ECD controller voltage to 28V.
Note :
Align the data display switch to +B, and set so
that the data display shows 28.0.
B. Set to the command values TFD and TFE in
the test specifications.
C. Turn the controller dial to Pc.
18
Published: April 2004
[DTP]
19