005-016 Fuel Pump

Rotation Check

Remove the tachometer

drive cable from the fuel
pump.

Crank the engine and make

sure the tachometer drive
shaft is turning.

If the tachometer drive shaft

is not turning, Remove the
fuel pump and check the air
compressor and accessory
drive operation.

If the tachometer drive shaft

rotates, the gear pump
rotation must be checked.

Remove the fuel supply

hose at the gear pump.
 Look into the gear pump and
crank the engine. The gear
pump gears must turn.

If the gear pump gears do

not turn, replace the fuel
pump.

Preparatory Steps
All Applications Except Rail

WARNING
Fuel is flammable. Keep all
cigarettes, flames, pilot
lights, arcing equipment, and
switches out of the work
area and areas sharing
ventilation ot reduce the
possibility of severe personal
injury or death when working
 on the fuel system.

WARNING
Batteries can emit explosive
gases. To reduce the
possibility of personal injury,
always ventilate the
compartment before
servicing the batteries. To
reduce the possibility of
arcing, remove the negative
(-) battery cable first and
attach the negative (-) cable
last.

z Clean the fuel pump and

surrounding area.
z Disconnect the battery
cables.

Rail Applications

WARNING
Fuel is flammable. Keep all
cigarettes, flames, pilot
lights, arcing equipment, and
switches out of the work
area and areas sharing
ventilation ot reduce the
possibility of severe personal
injury or death when working
on the fuel system.

WARNING
Batteries can emit explosive
gases. To reduce the
possibility of personal injury,
always ventilate the
compartment before
servicing the batteries. To
reduce the possibility of
arcing, remove the negative
(-) battery cable first and
attach the negative (-) cable
last.

z Clean the fuel pump and

surrounding area.
 z Disconnect the battery
cables.
z Remove the lubricating oil
scavenge pump.

Remove

Remove the wire to the fuel

shutoff valve.

Remove the linkage from the

throttle lever.

NOTE: This step applies

only to engines equipped
with STC.

Remove the STC fuel rail

switch.

Remove the below listed

items:

z Fuel drain (1)

z Gear pump cooling
drain (2)
z Gear pump suction line
(3)
 z AFC fuel drain (4)
z Fuel supply to injectors
(5)
z AFC supply hose (6)
z Tachometer cable (7).

Remove the four fuel pump

mounting capscrews.

Remove the fuel pump.

Remove the drive coupling

(23).

Remove and discard the

gasket.

Clean and Inspect for Reuse

Clean the fuel pump and the

air compressor or accessory
drive mounting surfaces.

Inspect the mounting

surfaces for damage.

If the mounting surface is

damaged, the fuel pump
must be repaired or
replaced.
Inspect the spider coupling
for damage.

If the spider coupling is

damaged, it must be
replaced.

Disassemble

Mark the angle of the

variable speed throttle lever
on the variable speed
throttle shaft.

Remove the variable speed

throttle lever.

Remove the adjusting screw

lock nuts, jam nuts, and
copper washers.

Discard the copper washers.

Remove the variable speed
spring pack housing cover.

Loosen the set screw in the

variable speed throttle stop.

Remove the variable speed

throttle shaft from the cover.
Discard the o-rings.
Remove and discard the
shaft dust seals from the
cover.

If fuel is leaking between the

bushing and the cover, the
bushings must be replaced.

Press the bushing from the

cover.

Assemble

Press the new bushings into

the cover.
Install new dust seals into
the cover.

Install a new o-ring onto the

shaft near the lever end.

When installing the throttle

stop, the longest lever of the
stop goes towards the rear
adjusting screw.

Install the throttle stop into

the cover.

Install the shaft into the

cover and through the stop.

Push the shaft out of the

other side of the cover.

Install the remaining shaft o-

ring and push the shaft into
the cover.

Align the set screw hole in

the stop with the hole in the
shaft.

Install the set screw into the

stop.

Tighten the setscrew.

Torque
Value: 7 n.m [60 in-lb]

Install a new gasket and the

cover onto the fuel pump.

Install new copper washers

and the lock nuts.

Install new copper washers

between the jam nuts and
lock nuts.

Install the jam nuts.

Align the lever with the mark

on the idle shaft.

Install the lever onto the idle

 shaft.

Tighten the lever retaining

nut to secure the lever to the
shaft.

Install

All K19 engines use a white

nylon or light green fuel
pump drive coupling.

Install the drive coupling

(23).

Install the gasket, fuel pump

and four capscrews.

Tighten the capscrews.

Torque
Value: 45 n.m [33 ft-lb]

Install the following items:

z Fuel drain (1)

z Gear pump cooling
drain (2)
z Gear pump suction line
(3)
z AFC fuel drain (4)
z Fuel supply to the
injectors (5)
z AFC air supply hose
(6)
z Tachometer cable (7).
 NOTE: This step applies
only to engines equipped
with STC.

Install the STC pressure

switch.

Connect the hose to the

switch and to the fuel
pressure tube fitting on the
fuel pump.

Make sure the wire

connection nut and ground
post are clean.

Install the electric wire to the

fuel shutoff valve.

Tighten the nut.

Install the linkage to the

throttle lever.

Finishing Steps
All Applications Except Rail

WARNING
Batteries can emit explosive
gases. To reduce the
possibility of personal injury,
always ventilate the
compartment before
 servicing the batteries. To
reduce the possibility of
arcing, remove the negative
(-) battery cable first and
attach the negative (-) cable
last.

z Connect the battery

cables.

Rail Applications

WARNING
Batteries can emit explosive
gases. To reduce the
possibility of personal injury,
always ventilate the
compartment before
servicing the batteries. To
reduce the possibility of
arcing, remove the negative
(-) battery cable first and
attach the negative (-) cable
last.

z Connect the battery

cables.
z Install the lubricating oil
scavenge pump.

Prime

To reduce engine cranking

time, the fuel pump can be
primed.

NOTE: Only fuel pumps

with an automotive
governor contain a
priming plug.

Remove the plug from the

top of the housing.

Fill the housing with clean

fuel.

Install the plug into the top of

the housing.

Tighten the plug.

Torque
Value: 30 n.m [20 ft-lb]

If the priming plug is hard to

remove, or the fuel pump is
a variable speed type,
remove the fuel supply hose
to the gear pump.

Fill the gear pump with clean

engine lubricating oil. Engine
lubricating oil will seal the
gears in the fuel pump and
cause fuel to be sucked into
the pump.

Install the supply hose to the

gear pump.

Loosen the fuel outlet

connection at the shutoff
valve.
 Use the starter to crank the
engine until fuel escapes the
connection.

Tighten the connection.

If fuel does not escape from

the fuel pump, refer to
Procedure 006-003.

Start the engine.

Operate at high idle until all

air is removed from the fuel
lines.

Inspect the engine for leaks.

Check the governor speed

adjustments.

Last Modified: 31-Jul-2006

Copyright © 2000-2010 Cummins Inc. All rights reserved.

005-024 Fuel Pump Fuel Rate with Throttle Shaft
Plunger

Adjust

To raise or lower the

fuel rate, the ball
must be removed
from the end of the
throttle shaft.

Mark the ball with a

center punch.

Drill a 4 mm [0.187 in]

hole in the ball.

Use an easy out

extractor or a slide
hammer to remove
the ball.

Adjust the throttle shaft

plunger screw to raise or
lower the fuel rate.

Turn the screw

clockwise to lower the
fuel rate.

Adjust the fuel rate with

the screw.

CAUTION

Do not turn the plunger out

closer than 6 mm [0.250 in]
from the end of the shaft.
The fuel pressure can push
the plunger out of the shaft.
Spilled fuel is a hazard.

If the maximum flow

(1) the pump can be
adjusted to is below
the correct value,
replace the fuel pump,
refer to Procedure
005-016

After the fuel rate is

 adjusted to the correct
value, install a new
ball in the end of the
throttle shaft.

This will help prevent

tampering.

Last Modified: 29-Oct-2004

Copyright © 2000-2010 Cummins Inc. All rights reserved.

005-026 Fuel Pump Gear Pump Check Valve

Initial Check

If the check valve

in the gear pump
return elbow
stays open or
closed, the check
elbow must be
replaced.

Remove

Remove the
drain line.

Remove the
check valve
elbow.
Inspect for Reuse

Check the elbow

threads.

Do not install an
elbow that has
straight machine
threads in a hole
that has pipe
threads.

A gear pump that

has straight
threads will have
a 19 mm [0.750
in] spot face in
the valve area.

A gear pump that

has pipe threads
will have a 16
mm [0.625 in]
spot face or no
spot face.
Install

Install the check

valve elbow that
has machine
threads to the
maximum thread
depth.

Turn the elbow

until it is pointing
toward the drain
line.

Tighten the jam

nut.

Torque Value: 5
to 6 n.m [45 to
50 in-lb]

Install the check

valve elbow that
has pipe threads
until it is tight and
pointed towards
the drain line.

Install the drain

line.
Last Modified: 29-Oct-2004

Copyright © 2000-2010 Cummins Inc. All rights reserved.

005-029 Fuel Pump Idle Speed

Adjust

The engine speed

can be checked with
one of the listed
tachometers:

z Vehicle
tachometer
z Hand
tachometer,
Part Number
ST-744
z Digital
tachometer,
Part Number
3375631
z Optical
tachometer,
Part Number
3377462.

Remote starter, Part

Number 3376506,
can be used to start
the engine.

The leads are

marked for
connection points.
 Install the
tachometer in the
fuel pump drive.

If using the
optical
tachometer,
place reflective
tape on the
vibration damper.

Operate the
engine at low idle
and record the
rpm.

Automotive Applications

The engine low

idle speed is
adjusted from
650 to 725 rpm.

This adjustment
is sometimes
necessary on a
new engine to
compensate for
the added engine
driven
accessories that
are installed by
the truck or
vehicle
manufacturers.

Stop the engine.

Remove the plug

from the spring
pack cover.

Install the fuel

pump idle
adjusting tool,
Part Number
3375981, in the
plug hole.
Operate the engine
at high idle for 30
seconds to remove
the air from the
system.

Make sure the

engine coolant
temperature is at or
above 70°C [160°F].

To adjust the idle

speed, turn the
screw clockwise to
increase the idle
rpm.

Turn the screw

counterclockwise
to decrease the idle
rpm.

Remove the tool

and install the
plug.
 Check the idle
speed again.

Governor

To adjust the VS
idle speed,
remove the lock
nut and jam nut
from the screw in
the rear of the VS
cover.

Discard the
copper washers.

Install a new
copper washer
and the jam nut.

Start the engine.

Hold the VS lever

in the idle
position.

Adjust the idle

screw to the
correct rpm and
tighten the jam
nut.
Install a new
copper washer
and lock nut.

Check the idle

speed again.

To adjust the VS
high speed,
remove the lock
nut and jam nut
form the top
screw of the VS
cover.

Discard the
copper washers.

Install a new
copper washer
and the jam nut.
 Start the engine.

Hold the VS lever

clockwise (in the
high speed
position).

Adjust the screw

to the correct
rpm.

Tighten the jam

nut.

Install a new
copper washer
and lock nut.

Check the idle

speed again.

Last Modified: 29-Oct-2004

Copyright © 2000-2010 Cummins Inc. All rights reserved.

005-031 Fuel Pump Pulsation Damper

Remove

Remove the fuel

inlet connection
and pulsation
damper or the filter
head damper
assembly. Discard
the rubber o-rings.

Inspect for Reuse

Remove the
housing from the
cover. Remove the
spring steel
diaphragm.
Discard the o-
rings. Inspect the
nylon washer and
discard it if is
damaged.

Check for
corrosion, wear, or
 cracks in the cover
or the diaphragm.
Replace the
damaged parts.

To check the
diaphragm for
hidden cracks,
drop it on a flat
hard surface. It
must have a clear
ring. If it has a flat
sound, replace the
diaphragm.

Install

Install new o-rings in

the grooves and a
new nylon washer.

Clean the diaphragm.

Coat the diaphragm
with clean engine oil.
Install the diaphragm
in the cover.

Assemble the cover to

the housing.

Tighten the
capscrews.

Torque
Value: 18 n.m [13 ft-
lb]

Remove the two

damper mounting
capscrews. Install the
damper assembly with
a new o-ring on the
gear pump.
 Tighten the
capscrews.

Torque
Value: 18 n.m [13 ft-
lb]

NOTE: If a fuel filter

and damper
assembly are
mounted on the gear
pump, remove the
four mounting
capscrews.

Install the fuel pump

inlet connection.

Be careful not to let

dirt enter the fuel
pump.

Check for free rotation

of the gear pump.

Last Modified: 29-Oct-2004

Copyright © 2000-2010 Cummins Inc. All rights reserved.

005-035 Fuel Pump Throttle Lever

Adjust
Automotive Applications

For the throttle

break over test,
make sure the
throttle linkage is
adjusted so the
throttle lever
breaks over 3 to
6 mm [0.125 to
0.250 in] when
the lever is in the
full throttle
position.

The throttle lever

must contact the
front throttle stop
screw.

To adjust the
variable speed
throttle linkage:

Remove the
throttle linkage
from the variable
speed throttle
lever.

Hold the variable

speed throttle
lever in the idle
position.

Move the linkage

to the idle
position.

If the lever and

the linkage are
not aligned,
adjust the
linkage.

Move the variable

speed throttle
lever and linkage
to the maximum
speed position.

If the lever and

the linkage are
not aligned,
adjust the lever.

Throttle travel on
a variable speed
lever is not
adjustable. The
pump can be
recalibrated with
a stiffer governor
spring to reduce
the throttle travel.

Install the linkage

on the lever.
Last Modified: 29-Oct-2004

Copyright © 2000-2010 Cummins Inc. All rights reserved.

005-043 Fuel Shutoff Valve

Test

Check the override screw to be

sure the shutoff valve is open.

Turn the screw in a clockwise

direction to open the valve.

Turn the screw in a counter

clockwise direction to close the
valve and shut off the fuel.

To start the engine, in case of an

electrical failure, turn the valve
knob on the shut off valve
clockwise to open the valve.

Most of the valves are internally

grounded.

If the valve has a long post and a

short post, the short post is internally
grounded.

Make sure all of the wire

connection nuts are tight, whether
a wire is attached or not.
Use a wire brush to clean
corroded terminal posts.

Make sure the shutoff valve coil is

the correct voltage.

The coil voltage and part number

are cast into the terminal
connection end of the coil.

Turn the vehicle ignition ON.

Use a multimeter and check the

voltage, as shown. If the voltage
is not correct check the electrical
system.
 Disconnect the wires from the
solenoid.

Measure the coil resistance with a

multimeter.

Fuel System Shutoff Valve

Specifications
Resistance Resistance
Voltage Minimum Maximum
(Ohms) (Ohms)
6 VDC 1 5
12 VDC 6 15
24 VDC 24 50
32 VDC 42 80
36 VDC 46 87
48 VDC 92 145
74 VDC 315 375
115
645 735
VAC

If the coil is not within

specifications, it must be replaced.

Last Modified: 21-Jan-2013

Copyright © 2000-2010 Cummins Inc. All rights reserved.