SUBJECT: INTEGRATED FUEL SYSTEM (IFS) UNIT PUMP SERVICE

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Hugo Stevenson
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1 DATE: July 30, 2010 SERVICE BULLETIN SUPERSEDES: S.B. 560 dated November 22, 2008 NO: 560R1 SUBJECT: INTEGRATED FUEL SYSTEM (IFS) UNIT PUMP SERVICE RELATED PUBLICATIONS: IFS OPERATION AND INSTRUCTION MANUAL SERVICE LETTER 324 SERVICE BULLETIN 557 The IFS unit pump is a single plunger, inlet metered, submersible type fuel injection pump. A single unit pump combined with a compact pencil nozzle (CPN ) and a roller tappet assembly represents one complete IFS. There are two different unit pumps, seven different CPN s and two different roller tappets that get assembled into various configurations to make 25 separate integrated fuel system specifications. Refer to the Attachment for Unit Pump, CPN and Roller Tappet assembly part numbers for each IFS part number. This bulletin outlines the tools and procedures necessary for servicing the IFS unit pump only. For related information on the operation, service and settings of other IFS components and/or complete integrated fuel systems reference the publications listed above. IMPORTANT: Each IFS is calibrated and installed on engine as a matched set. Avoid mixing of system components. Following component service, each integrated fuel system must be assembled, calibrated and returned to the customer as a single system. The unit pump assembly (Figure 1) consists of a matched fit plunger and barrel assembly with an inlet filter, inner and outer springs, upper and lower spring seats, fuel line pressure retraction valve, metering arm, o- ring seals, and a timing shim. With the exception of the plunger and barrel assembly, all IFS unit pumps share the same serviceable parts shown in Figure 1. Sealing Washer (P/N 35896) Plunger and Barrel Assembly Upper Spring Seat Assembly (P/N 40016) Outer Spring Inner Spring Outer Spring Seat Inner Spring Seat Figure 1 Pressure Retraction Valve Assembly (P/N 36061) Inlet Filter Assembly (P/N 40015) O-Ring Seal (P/N 35639) Brown O-Ring Seal (P/N 35638) Black Metering Arm Assembly (P/N 36860) Screw (P/N 36838) Timing Shim Stanadyne Corporation 92 Deerfield Road, Windsor, CT 06095, U.S.A. Tel: (860) ; Fax: (860) ;

2 - 2 - S.B. 560R1 The serviceable components for IFS unit pumps are either packaged into service parts kits, available individually or are contained in assemblies as identified in the table below. Unit Pump Service Tools IFS Unit Pump Service Parts, Assemblies and Parts Kits Service Parts Kit Description (Indented items are included) Parts Included Pkg. Qty Fuel Line Pressure Retraction Valve Assembly PRV Assembly 1 Sealing Washer, PRV Sealing Washer, PRV Inlet Filter Parts Kit Metering Arm Assembly Upper Spring Seat Assembly Fuel Deflector Plate 1 Filter Guard 1 Filter 1 Filter Screw 1 Metering Arm 1 Metering Arm Pin 1 Upper Spring Seat 1 Upper Spring Seat Screw Upper Spring Seat Screw Unit Pump Spring Kit IFS Parts Kit Outer Spring 1 Inner Spring 1 Outer Spring Seat 1 Inner Spring Seat 1 O-Ring Seal - Brown (Unit Pump) O-Ring Seal - Black (Unit Pump) Carbon Stop Seal (CPN) Plain Washer (CPN) Carbon Stop Seal Installation Tool (CPN) Protective Sleeve (Pump & Tappet) Molded Cap (CPN) O-Ring Seal (CPN) Three new tools are available for servicing the IFS Unit Pump. They are the IFS Unit Pump Service Fixture, IFS Inlet Filter Wrench and the IFS Spring Seat Fork as shown in Figure 2. Each tool is available individually and are now included in the IFS Service Equipment Kit, P/N

3/16 hex key wrench (P/N 13322) - unit pump service fixture retaining screw 3mm hex head socket (P/N 39152) - upper spring seat assembly screw (included in 39105 IFS service equipment kit).

3 - 3 - S.B. 560R1 IFS Unit Pump Service Fixture P/N IFS Unit Pump Spring Seat Fork P/N Figure 2 IFS Unit Pump Inlet Filter Wrench P/N Additional tools required for unit pump service include: 3/16 hex key wrench (P/N 13322) - unit pump service fixture retaining screw 3mm hex head socket (P/N 39152) - upper spring seat assembly screw (included in IFS service equipment kit). 5/8 socket - inlet filter wrench 19mm socket - PRV assembly Torque wrench capabilities: lbf-in (0-17 N m) - upper spring seat screw, inlet filter screw lbf-ft (0-135 N m) - PRV assembly Small screwdriver or pick - inlet filter components, PRV sealing washer Needle-nose pliers - inner spring seat IFS Service Equipment Kit (P/N 39105) - IFS calibration (Reference S.L. 324). The IFS Unit Pump Service Fixture is comprised of the components shown in Figure 3. The fixture is designed to be mounted in a bench vise for stability. The unit pump mounting block has a machined counter bore to accommodate the flange on the pump barrel assembly. The unit pump retaining screw is positioned Spring Compression Screw Assembly Spring Seat Cup Bench Vise Unit Pump Retaining Screw Unit Pump Mounting Block T-Handle Pump Rest Compression Screw Block Spring Seat Cup Guide Charge Port (Air) Fixture Base Figure 3

- 4 - S.B. 560R1 such that it can secure a unit pump in the mounting block in either direction of pump insertion.

The charge port has a 1/8 x 27 NPT thread. IFS Unit Pump Springs The inner and outer springs are always replaced as a set.

Mount the 39908 IFS unit pump service fixture in a bench vise. Use the T- handle and back-out the spring compression screw assembly until it is fully retracted (Figure 4).

4 - 4 - S.B. 560R1 such that it can secure a unit pump in the mounting block in either direction of pump insertion. The top of the mounting block also has a charge port used to introduce clean, dry compressed air to hold the plunger extended during unit pump spring service. The charge port has a 1/8 x 27 NPT thread. IFS Unit Pump Springs The inner and outer springs are always replaced as a set. Both springs and lower spring seats are packaged together in the IFS Unit Pump Spring Kit (P/N 40017). These components are not available individually. Spring Removal and Installation 1. Mount the IFS unit pump service fixture in a bench vise. Use the T- handle and back-out the spring compression screw assembly until it is fully retracted (Figure 4). Ensure that the unit pump retaining screw is backed out far enough to prevent interference during pump installation. 2. Lubricate the o-ring seals with calibration oil or assembly grease. Spring Compression Screw Fully Retracted IFS Unit Pump Service Fixture P/N Figure 4 Charge Port for Air (1/8 x27 NPT) IFS Unit Pump Retaining Screw Unit Pump in Mounting Block Unit Pump Flange Hole Lubricate O-Rings 3. With the unit pump flange hole facing upward, insert the spring end into the pump mounting block until the flange is seated in the counter bore. Slightly rotate the unit pump until the flange hole indexes with the retaining screw. Tighten the screw until it bottoms lightly in the flange hole. 4. Turn the spring compression screw assembly in until the outer spring seat fits into the recess of the spring seat cup as shown in Figure 5. Spring Seat Cup - Outer Spring Seat Recess Outer Spring Seat Figure 5 5. Connect psi ( kpa) of clean, dry, compressed air to the charge port on top of the pump mounting block (Figure 4).

- 5 - S.B. 560R1 6. Using the fixture s spring compression screw assembly, compress the unit pump springs far enough to expose the inner spring seat (Figure 6a).

Compress the springs fully by turning the spring compression screw in until it stops.

With a pair of needle nose pliers, grasp the inner spring seat and rotate it so that the cut-out is facing downward.

Needle Nose Pliers Inner Spring Seat with Opening Facing Downward IFS Unit Pump Spring Seat Fork (P/N 39910) IFS Unit Pump Plunger Figure 7 8.

Continue to back out the spring compression screw until it is fully retracted as shown in Figure 4 9.

5 - 5 - S.B. 560R1 6. Using the fixture s spring compression screw assembly, compress the unit pump springs far enough to expose the inner spring seat (Figure 6a). Insert the IFS unit pump spring seat fork between the inner and the outer spring seats and into the recess of the spring seat cup (Figure 6b). Compress the springs fully by turning the spring compression screw in until it stops. IFS Unit Pump Spring Seat Fork (P/N 39910) Between Inner & Outer Spring Seats Inner Spring Seat Outer Spring Seat Fork Recess in Spring Seat Cup Figure 6a Figure 6b 7. With a pair of needle nose pliers, grasp the inner spring seat and rotate it so that the cut-out is facing downward. Remove the inner spring seat from the end of the unit pump plunger and the fixture s seat cup. Needle Nose Pliers Inner Spring Seat with Opening Facing Downward IFS Unit Pump Spring Seat Fork (P/N 39910) IFS Unit Pump Plunger Figure 7 8. Turn off the compressed air and back-out the spring compression screw assembly until the IFS unit pump spring seat fork can be removed. Continue to back out the spring compression screw until it is fully retracted as shown in Figure 4 9. Loosen the unit pump retaining screw and slide the unit pump out of the fixture s pump mounting block far enough to remove the outer spring seat and both inner and outer springs. Remove the barrel and plunger assembly from the fixture. 10. Spring installation is the reverse of the removal process. During assembly, both springs are installed so the flat ends with sharp corners on the inside diameter are facing upward toward the upper spring seat assembly (Figure 8). Sharp Corner on Outside Diameter Sharp Corner on Inside Diameter Figure 8 Down Up

rotational motion of the pumping plunger.

6 - 6 - S.B. 560R1 Metering Arm Assembly and Upper Spring Seat Assembly In response to the engine s governor, the metering arm assembly (P/N 36860) transfers the linear motion of the fuel control rack into rotational motion of the pumping plunger. The upper spring seat assembly (P/N 40016) has a flat mounting surface for both inner and outer springs and also contains a clamping screw positioning of the metering arm slot (Figure 9). The position of the metering arm slot orients the plunger position in the barrel for low idle fuel delivery and also standardizes the relative position of the slot for each IFS. The metering arm assembly consists of a tapered pin pressed into an arm which has a hole shaped to fit the unit pump plunger (Figure 9). The upper spring seat assembly uses a clamping screw to retain the upper spring seat assembly s position on the unit pump barrel assembly. During IFS factory calibration, the upper spring seat and the unit pump barrel assembly are stamped with an alignment mark (Figure 10). For service, replacement IFS unit pumps are not factory tested and therefore do not contain an alignment mark. Likewise, replacement upper spring seat assemblies (P/N 40016) will not have a mark either. For IFS unit pump assembly and service, the barrel and upper spring seat are oriented as shown in Figure 10. Metering Arm Assembly (P/N 36860) Metering Arm Pin Figure 9 Plunger Hole with Flats Upper Spring Seat Alignment Figure 10 Factory Alignment Marks Metering Arm & Upper Spring Seat Removal and Installation Upper Spring Seat Assembly (P/N 40016) Clamping Screw (P/N 36838) Metering Arm Slot Spring Seat Surfaces 1. Remove the springs and re-install the pump in the fixture as described in the IFS Unit Pump Spring section of this bulletin. 2. Using a 3 mm hex socket (P/N 39152), loosen but do not remove the upper spring seat clamping screw. 3. Remove the metering arm assembly and upper spring seat assembly from the pump barrel and plunger. NOTE: Handle the pump with care once the metering arm assembly is removed, as the plunger is no longer retained in the barrel assembly.

- 7 - S.B. 560R1 4. To assemble, insert the metering arm assembly into the slot in the upper spring seat. The metering arm pin taper faces toward the spring side of the spring seat (Figure 9) 5.

7 - 7 - S.B. 560R1 4. To assemble, insert the metering arm assembly into the slot in the upper spring seat. The metering arm pin taper faces toward the spring side of the spring seat (Figure 9) 5. Match the plunger flats with the flats in the metering arm plunger hole and place the metering arm (within the upper spring seat assembly) onto the plunger. The plunger and metering arm must be correctly oriented within the barrel assembly as described in the Unit Pump Barrel and Plunger Assembly section below (Figure 11). 6. Rotate the upper spring seat so the vertical slot is in line with the flange hole, or if applicable align the factory orientation marks (Figure 10). Tighten the screw to lbf-in ( N m). IMPORTANT: Prior to installing the springs, check the plunger and metering arm for freedom of movement. There should be no lash between the plunger and metering arm assembly. The plunger must be able to move uninhibited through its entire range of stroke and rotation. 7. Re-install springs as described in the IFS Unit Pump Spring section. Unit Pump Barrel and Plunger Assembly The unit pump barrel and plunger assemblies are match fit sets which have no serviceable components and are not available for service replacement. The two different unit pump barrel and plunger assemblies in use differ by the geometry of the plunger helix. Because these are precision fit components, the plunger should be carefully handled. Always grasp the lower end of the plunger in the spring seat area since contamination from skin oils can damage the surface finish. Use a slight twisting motion to aid in extracting and inserting the plunger in the barrel assembly. Important: As shown in Figure 11, the plunger must be correctly oriented with the helix facing the inlet port on the barrel assembly. Inlet Port Barrel Assembly Plunger Helix Plunger Figure 11 Metering Arm Pin Flat on the Sides / Radius Front and Rear

8 - 8 - S.B. 560R1 Fuel Line Pressure Retraction Valve (PRV) The PRV assembly maintains enough fuel pressure in the high pressure line between injection events to prevent complete line evacuation. A check valve is also incorporated to prevent fuel under high pressure from returning back into the unit pump. The PRV assembly is serviced by complete assembly replacement only. PRV Removal and Installation Mount the unit pump in the IFS Unit Pump Service Fixture as described in the IFS Unit Pump Spring section. 1. Using a 19mm socket, loosen and remove the PRV assembly from the unit pump barrel. With a small screw driver or pick, remove the sealing washer from the PRV bore in the barrel assembly. Discard the sealing washer. NOTE: Do not re-use sealing washers. Replacement PRV assemblies are packaged with one sealing washer. Additional PRV sealing washers are available separately. 2. Installation is the reverse of removal. Ensure the barrel s PRV bore is clean and install a new sealing washer. 3. Apply a small amount of calibrating oil or assembly grease to the PRV threads and assemble the PRV into the unit pump barrel. Tighten the PRV assembly to lbf-ft ( lbf-in) ( N m). Inlet Filter Assembly The inlet filter assembly is located within the inlet port of the barrel assembly and consists of the inlet filter service parts kit (P/N 40015) components shown in Figure 12. The filter screw has two holes in it for inlet flow and for wrench engagement. The filter has a black polymer casing for sealing. The filter guard and fuel deflector plate act to reduce the effects of cavitation erosion. Inlet Filter Removal and Installation Fuel Deflector Plate Figure 12 Filter Guard Inlet Filter Inlet Filter Service Parts Kit (P/N 40015) Inlet Filter Screw 1. Mount the unit pump in the IFS unit pump service fixtures pump block from the PRV end. With the flange seated in the counter bore, the unit pump barrel will be supported by the pump rest (Figure 13). Secure the unit pump in the fixture by indexing and lightly bottoming the retaining screw in the unit pump flange hole. 2. Insert the two pins on the bottom of the Inlet Filter Screw Wrench into the inlet filter screw holes (Figure 13). Using a 5/8 wrench or socket, loosen and remove the filter screw.

- 9 - S.B. 560R1 Inlet Filter Screw Wrench (P/N 39909) 5/8 inch Hex Pins engage with Inlet Filter Screw Holes IFS Unit Pump Service Fixture (P/N 39908) Inlet Filter Screw 100-110 lbf-in (11.3-12.

With a small screw driver or pick, remove and discard the filter, filter guard and fuel deflector plate (Figure 12). NOTE: Do not re-use filter components 4.

9 - 9 - S.B. 560R1 Inlet Filter Screw Wrench (P/N 39909) 5/8 inch Hex Pins engage with Inlet Filter Screw Holes IFS Unit Pump Service Fixture (P/N 39908) Inlet Filter Screw lbf-in ( N m) Unit Pump Installed with PRV End in Pump Mounting Block Figure 13 Unit Pump Supported by Service Fixture s Pump Rest 3. With a small screw driver or pick, remove and discard the filter, filter guard and fuel deflector plate (Figure 12). NOTE: Do not re-use filter components 4. Using a inlet filter service parts kit (P/N 40015) install the new filter components in the reverse order as removal. Tighten the inlet filter screw to lbf-in ( N m). Technical Service Group Product Support Department Revision Date Description 1 7/30/10 Attachment with component and IFS part number information added

10 Attachment S.B. 560R1 Integrated Fuel System Component and Cross Reference Information Stanadyne IFS John Deere IFS Application Unit Pump Roller Tappet CPN Supersedes IFS RE Skid Steer Loader, OEM 4T (Light) RE /320/325 Skid Steer Loader, OEM 4T/5T, 344J/244J 4WD Loader RE Skid Steer Loader, OEM 5Tw RE OEM 4T/5T RE OEM 5Tw RE Skid Steer Loader RE OEM 5H RE Tractor RE /4720/5325 Tractor RE OEM 4T (Light) RE Generator (1500 ERPM) RE Generator (1500 ERPM) RE Generator (1800 ERPM) RE Generator (1800 ERPM) RE Generator (1500 ERPM) RE /320/325 Skid Steer Loader, OEM 4T/5T RE Skid Steer Loader, OEM 5Tw RE Generator (1800 ERPM) RE /4320 Tractor RE /4720 Tractor RE /4320 Tractor RE Tractor RE Tractor RE OEM 4T (Light) RE /315 Skid Steer Loader July 30, 2010

DATE: April 5, 2005 SUPERSEDES: S.B. 373AR1 dated 2/26/99

NO: 373AR2 SERVICE BULLETIN DATE: April 5, 2005 SUPERSEDES: S.B. 373AR1 dated 2/26/99 SUBJECT: COLD START ADVANCE MECHANISMS Diesel engines have a tendency of producing white exhaust smoke during startup