Integrated Fuel System (IFS)

Operation and Instruction Manual

CONTENTS
GENERAL
A. Purpose of the Manual
B. Model Numbering System

SECTION 1
CONSTRUCTION AND OPERATION
A. Components and Function

SECTION 2
COMPACT PENCIL NOZZLE SERVICING
A. Special Service Tools
B. Preparation and Cleaning
C. Hydraulic Lock Up Elimination
D. Testing
E. Needle Lift Adjustment
F. Adjusting Opening Pressure
G. Replacement of the Carbon Stop Seal, Plain
Washer and O-Ring Seal

SECTION 3
TEST BENCH REQUIREMENTS AND
PROCEDURES
A. Special Test equipment Requirements
B. Cam Box Mounting Instructions
C. IFS Test As Recieved
D. System Settings: Following System Service
E. Product Preparation for Returning to
Customer

SECTION 4
TABLES
A. Identification and Cross Reference Table
B. Compact Pencil Nozzle Shims
C. Unit Pump Timing Shims
D. Torque Values and Gap Settings
i
GENERAL Unit Pump/System Identification
A. Purpose of the Manual
Eight Digit
This manual is expressly intended to provide Stanadyne
qualified, trained diesel fuel injection techni- System S/N
cians the information necessary to prepare to
and test the Standyne Integrated Fuel Sys-
tem. In addition to this manual all special tools
and test equipment as outlined herein are
needed, as well as all service pertinent litera-
ture and individual pump specifications con- X
X

taining the calibration information and parts X

X Customer
System P/N
breakdown. Date Code

This manual is not intended to be used by un- Fig. 1

trained, inexperienced persons to attempt to
service the product. Such unauthorized ser-
vice could result in violations of emission regu-
lations, pump damage, or possibly engine
damage. No service should be performed on Compact Pencil Nozzle
IFS’s before studying this manual and becom- Identification
ing familiar with the principles and instructions
which follow.
Eight Digit CPN
B. Model Numbering System Serial Number
Date Code
The system’s serial number, date code and
John Deere part number are located on the Stanadyne
unit pump’s upper shoulder surface. Refer to CPN P/N
the Identification and Cross Reference table
in Service Bulletin 557 to obtain the Stanadyne
system part number.
Compact Pencil Nozzles (CPN®) are marked Injector
with an injector serial number, injector part Inscription
number, date code and an injector inscription Code
code as shown in Figure 2. Again reference
Service Bulletin 557 to determine which CPN Fig. 2
is specified for each system.

ii
SECTION 1 - CONSTRUCTION AND on the plunger position, the charging port in
the pump body.
OPERATION
During the charging cycle the unit pump tappet
follows the backside of the cam, allowing the
Compact Pencil Nozzle
spring-loaded plunger to move downward. As
the plunger moves downward the helix’s top
edge uncovers the inlet port, allowing inlet fuel
to fill the pumping chamber (Fig. 1.2).

Pumping
Chamber
Helix

Unit Pump Assembly

Inlet Port
Open Plunger
Injection Pressure

Supply Gallery Pressure

Lube Oil Pressure

Fig. 1.2

As the unit pump tappet is forced to rise due

Unit Pump Tappet to the rotation of the engine driven cam, it
causes the plunger to lift towards the pump
Fig. 1.1 body. The helix part of the plunger at a point
defined by governor rack position closes off
the inlet port. Fuel will no longer be spilled
A. Components and Fuctions back through the inlet port; instead now it will
The Integrated Fuel System (IFS) is an be pumped at a much higher pressure to the
assembly of the following three components. injector (Fig. 1.3).
(A) The Unit Pump Tappet, (B) the Unit Pump
Assembly, and (C) the Compact Pencil Nozzle
(CPN). The unit pump is capable of pressures Helix
of 1200 bar with a maximum fuel delivery of
100mm3/stroke at 3600 engine rpm. The
injector is a Compact Pencil Nozzle designed
to operate at pressures up to 1500 bar. Since
Inlet Port
the CPN is designed with a no-leak-off feature, Closed
the entire system can be installed under the
engine valve cover.
At the pumping end of the plunger, a precision Fig. 1.3
ground helix covers and uncovers, dependent
1
As the plunger continues to be lifted by the Figure 1.6 is a layout of a typical helix. The
cam and tappet assembly, the bottom edge upper edge of the helix controls start of
of the helix will eventially uncover the charging pumping (timing). The lower ramp controls fuel
port. As this port starts to be uncovered, quantity delivered. The starting zone of the
injection pressure plus further displaced fuel helix produces an advance in timing and a
due to the plunger continuing to rise is spilled delivery of a large quantity of fuel, both of
out the port, thereby lowering the pressure in which are needed for engine starting. The full
the pumping chamber and ending the injection load zone provides less advance timing (lower
event. (Fig. 1.4). upper ramp location) and less fuel than the
starting zone. When the engine is operating
Helix in a no load -to- light load condition the
governor rotates the plunger so that the light
load zone of the helix controls the covering
and uncovering of the charging port as follows:
With a decrease in load, engine speed
increases causing the governor to rotate the
plunger which will cause a decrease in fuel
Bottom Edge with a corresponding increase in advance. As
of Helix Open load increases, engine speed drops and the
governor moves the plunger in the opposite
direction, which increases fuel and decreases
advance.
Upper Ramp
Fig. 1.4

An engine driven governor, through linkage

to the unit pumps, controls the rotational
Lower Ramp
position of the pumping plunger. By turning
the plunger different profiles on the helix will
control the opening and closing of the charging
Light Load
port, tailoring timing and fuel delivery (Fig. 1.5). Zone
Starting Zone
Full Load Zone Fig. 1.6

During cold engine operation, especially after

starting, fuel injected into the relatively cool
cylinders will take a longer period of time to
heat up to self-ignition temperature. If the
delay in ignition becomes too great some fuel
may not be burned, resulting in white smoke
emissions. Advancing the pump timing
increases the time that the fuel is exposed to
lower than normal heat in the combustion
chamber. During cold engine operation,
pressurized engine oil is sent to the cold
advance piston in the unit pump tappet. The
Fig. 1.5
cold advance piston and the unit pumps
2
plunger are lifted together to a higher position calibration at the factory and by the Authorized
(1.5mm) in relationship to the unit pump body, Service Dealers during the Pump Following
causing an advance in pump timing. A ball Service Calibration.
check at the base of the piston prevents
pumping forces from collapsing the advance.
When the engine reaches normal
temperatures, oil pressure to the cold start
advance is shut off. Residual pressure in the
piston cup bleeds out through the orifice
located in the cup end that contacts the
plunger allowing the piston to return to its
seated position (Fig 1.7).

1.5mm

Fig. 1.7

To meet today’s and future emission

standards, start of injection (SOI) to engine
timing is critical. As previously explained, start
of pumping that directly controls start of
injection commences when the plunger rises
in the pump body far enough that the pump
plunger helix covers the inlet port.
This pumping event timing is affected by
engine deck height and the tolerance stack-
up of pump components. Engine deck height
is the distance from the base circle (low point
on the cam lobe) of the cam to the IFS pump
seating surface on the cylinder head. To
account for both engine, unit pump tappet and
unit pump tolerances that would affect pump-
to-engine timing, a correction shim of a
specified thickness is placed under the unit
pumps seating surface. The correct timing
shim for each IFS is selected during pump
3
SECTION 2- COMPACT PENCIL Step 2 Hold the CPN in a position so that
NOZZLE SERVICING when unthreading the cap nut from the injector
A. Special Service Tools the spring and shim will not fall out of the cap
38021 Cap Nut Wrench nut. Tip the cap to drain the fuel from the cap
38474 Carbon Seal Re-sizing Tool while not allowing the spring, shim, spring seat,
38605 CPN Calibration Line and lift stop from falling out of the cap. Refer
37745 CPN Holding Fixture to Figure 2.2

B. Preparation and Cleaning

Refer to the 99002 Pencil Nozzle Repair
Manual

C. Hydraulic Lock-up Elimination

The CPN is a no-leak-off design with no
provisions for return fuel plumbing since the
Integrated Fuel System is located internally
in the engine. Unlike nozzle operation with an
injection pump, there is no reduction in line
pressure on a nozzle tester between
injections. This will cause the cap nut area to
fill with high pressure fuel, eventually balancing
the pressure in the nozzle body preventing the
valve from lifting off its seat. This at first will Fig. 2.2
cause non-repeatable pressure readings and
eventually an inoperable injector. Therefore,
Step 3 Apply a coating of clean calibrating
it is important to drain the cap prior to testing
and if these symptoms become apparent fluid to the 35685 o-ring seal (Reference
Figure 2.3) and hand tighten the cap nut onto
during testing, disconnect the injector from the
the CPN body. Place the CPN in the 37745
nozzle tester and drain the cap nut as follows:
holding fixture and using the 38021 CPN Cap
Step 1 Place the CPN in the vise supported Installation/Removal Tool tighten the cap to
37745 CPN Holding Fixture. Loosen the cap 110-120 lbf-·in (12.4-13.6 N•m) with a 3/4“
nut using the 38021 CPN Cap Installation/ (19mm) socket. Refer to Figure 2.3
Removal Tool and a 3/4 “ (19 mm) wrench.

Fig. 2.3

Fig. 2.1

4
D. Testing 4. Seat Condition – With the nozzle tip
1. Using the 38605 CPN Calibration Line, pointed downward and the gauge closed,
connect the CPN to the nozzle tester with the operate the tester rapidly to firmly seat the
CPN tip angled downward (Figure 2.4). valve. Dry the nozzle tip thoroughly. Open the
gauge valve and raise the pressure to 250 -
350 PSI (17-24 bar) below the measured
opening pressure. While maintaining the
pressure for 10 seconds, no droplet should
separate from the nozzle tip. Slight dampness
or a drop forming is permissible with a used
nozzle.

5. Return oil — Raise the pressure slowly to

at least 2600 PSI (179 bar). Release lever and
note the time it takes the pressure to decay
from 2500 PSI (172 bar) to 2000 PSI (138 bar),
5 seconds minimum. This check should be
performed using SAE J967 / ISO 4113
calibration fluid at room temperature (70º -
80ºF [21º– 27ºC]).
Fig. 2.4
E. Adjusting Opening Pressure
2. Chatter – Close the pressure gauge valve Step 1 Refer to the individual CPN
and operate the tester rapidly. The nozzle specification for the specified opening
should chatter. Chatter is a rapid opening and pressure and available shims for adjusting the
closing of the nozzle valve while fuel is being opening pressure.
pumped through the nozzle. It is audible and
can also be felt in the handle of the nozzle Step 2 If the opening pressure is out of
tester. At this time also check for quality of the specification, a shim change can be made to
spray pattern (an even finely atomized plume adjust the opening pressure.
from each spray orifice). If the nozzle does Step 3 Disconnect the injector from the
not operate, drain the cap nut as described nozzle tester. Mount the CPN in the 37745
under Hydraulic Lock Up Elimination, Holding Fixture. Using the 38021 Cap Nut
reconnect to nozzle tester and check for Wrench Tool loosen the Nozzle Holder Cap
chatter and spray again. Nut.

3. Nozzle Opening Pressure – Open the Step 4 Remove the Lift Stop, Pressure
nozzle tester gauge valve and raise the Adjusting Shim, Pressure Adjusting Spring and
pressure slowly until the nozzle valve opens. Spring Seat from the Nozzle Holder Body
Note what the maximum pressure reading is Assembly. Reference Figure 2.5.
on the gauge before the pressure sharply
drops off. Repeat several times and if large NOTE: Because components of individual
variations between these readings are noted, CPN’s are matched at the factory to control
disconnect the CPN from the nozzle tester, flow and needle lift, never intermix the
drain the cap nut as described in the Hydraulic components from one CPN with another.
Lock Up Elimination section and retest.

5
 Lift Stop Pressure Spring Fig. 2.5
Cap Nut Adjusting Pressure Seat
Shim Adjusting Cap Nut O-ring
Spring

Step 5 Measure the existing shim’s thickness.

Step 6 Replace the existing pressure

adjusting shim with an appropriate shim to
obtain the specified opening pressure. A change
of .001” (.025 mm) in shim thickness will cause
a 30 PSI (206 kPa) change in pressure (shims
are listed on the individual injector
specification). Assemble the components back
into the body assembly after lubricating the
35685 cap nut o-ring seal.

Step 7 Place the CPN into the holding fixture

and using the cap nut wrench, tighten the cap
nut to 110–120 lbf.-in. (12.4-13.6 N•m). Fig. 2.6
Step 8 Re-check opening pressure.

F. Needle Lift Adjustment

Fig. 2.7
At this time needle lift cannot be measured or
adjusted in the field.

G. Replacement of the Carbon Stop Seal,

Plain Washer and O-Ring Seal
The 16389 carbon stop seal, 35685 o-ring
seal, and the 35686 plain washer must be
replaced on all CPN’s that are serviced. These
components, along with the 36528 carbon stop
seal installation tool, are contained in the
36530 CPN Seal Kit. The installation
instructions are as follows:

Step 1 Slide the new plain washer onto the

nozzle holder assembly until it rests against
the line banjo.

6
Step 2 Place the carbon stop seal
installation tool over the nozzle tip and slide
the carbon stop seal over the 36528
installation tool (Reference Figures 2.6 and
2.7 ) until the seal drops into the groove on
the nozzle holder body assembly. Remove and
discard the installation tool.

Step 3 A newly installed Carbon Stop Seal

will not return to size immediately. To squeeze
the carbon seal’s outside diameter to the
correct size, with a rocking motion push the
38474 Carbon Seal Re-sizing Tool over the
end of the nozzle tip after installing a new
carbon seal as shown.

Fig. 2.7

7
SECTION 3 - TEST BENCH
B. Cam Box Mounting
REQUIREMENTS AND
PROCEDURES These instructions are for a typical test
bench set-up. Additional pipe/tube
fittings may be required in some cases
A. Test Equipment to properly connect the cam box to the
• Test bench: test bench.
10 HP direct drive Step 1 Remove the Cam Box
Lube oil pressure capability: subassembly from the storage case and
3.5 Bar (50 PSI) inspect the contents.
Mounting plate: 107mm pilot dia.
Drive coupling: 30 mm taper Mount the cam box to an appropriate
107 mm pilot diameter mounting plate
• Laptop Computer: (Not included) (Fig. 3.2) and install the mounting plate
DAQ Card and DAQ Cable and cam box assembly onto the test
Stanadyne Proprietary DE Fuel bench pedestal.
Injection System Software
CAUTION: The cam box assembly is
• 39105 IFS Service Equipment Kit heavy - approx. 68 lbs (30.8 kg).
(Reference Fig. 3.1)
1 39106 IFS Cam Box Fig. 3.2
2 39142 Hose & Fitting Kit
3 39152 Hex Bit Socket Assy. Cam Box
Subassembl
4 39155 Cable, Pump Interface
Module
5 39156 Pump Interface Module
6 39234 Tappet Extraction Tool
Mounting Plate
7 — IFS Cam Box Storage
Case
99972 IFS Software CD-ROM Step 2 Install the drive coupling,
(Not shown)
39136 lock washer, and 39135 hex nut
(Fig. 3.3) onto the drive shaft. Tighten
Fig. 3.1 the nut to 100 ft-lbs (135 N·m). NOTE:
Drive Coupling orientation to the Drive
5 Shaft key slot is not required.
7
1
Fig. 3.3
Cam Box
6
Hex Nut
2

Drive Coupling
Lock Washer
4 (30mm Taper)
3 P/N 39136

8
Step 3 Position the mounting Install the pipe-to-tube adapter (3/8”
pedestal and connect the drive coupling NPT to 3/8” Tube) into the lube oil return
to the test bench. port (Fig. 3.6) and tighten it securely.
Step 4 Assemble the CPN Nozzle Calibrating Oil
Block onto the cam box (Fig 3.4). Index Return Port
the diamond shaped alignment pin and
install the two 5/16–18 x 1.5" cap screws. Steel Braided
Hose
Tighten the cap screws to 180-220 lbf-in
(20-25 N·m).

CPN Nozzle
Block Lube Oil
Return Port

Fig. 3.6
Alignment
Install the pipe nipple (3/8” NPT to 1/4”
NPT - Fig. 3.7a), into the Cold Start
Mounting Advance (CSA) port (Fig. 3.7b) and
Screws tighten it securely. Turn the Lube oil
(5/16-18x1.5”) Fig. 3.4 Supply 90˚ elbow until it is tight in the
position shown in Fig. 3.5 & Fig.3.7b.
Install the 39142 Hose and Fitting Kit Securely assemble the remaining
components in Figure 3.7a into the
NOTE: Use a suitable thread sealant
configuration shown in Fig. 3.7b.
on all tapered pipe thread (NPT)
fittings. Pipe Nipple

Step 5 Install the three 90˚ elbow CSA Actuation Valve

fittings (1/4” NPT to 1/4” Tube) into the
following cam box ports: calibrating oil “Tee” - Fitting
supply and lube oil supply ports shown Flexible Tubing
in Figure 3.5, and the calibrating oil
return port shown in Figure 3.6. Do not
Lube Oil
tighten at this time. Needle Valve Fig. 3.7a
Fig. 3.5 Calibrating Oil
Supply Port Lube Oil Supply Port CSA Port
Flexible
Lube Oil Tubing CSA
Supply Port Actuation
Valve
Lube Oil
Needle
Valve “Tee” -
Fitting
CSA Port
Fig. 3.7b Lube Oil supply

9
Before tightening the remaining fittings,
determine a safe routing for the test Nozzle Block
bench's Lube Oil and Calibrating Oil
tubing. Tighten the brass fittings SOI
securely in the cam box and connect the Pressure
Transducer
test bench hoses.
Adjust lube oil needle valve: Turn the Flow
needle in until it lightly bottoms and then Restriction
backing it out 1/4 to 1/2 turn. Fig. 3.8 Connector

NOTE: Only a small amount of oil flow is precise rack position orientation and
required for proper lubrication. Should consistency between cam boxes. The
the flow of lube oil become excessive, offset dimension is stamped on the cam
the cam shaft cavity will fill and overflow box nameplate as shown in Fig. 3.9. and
through the rack adjusting hole. Should is pre-set at the factory.
this happen, close the needle valve Micrometer Offset
slightly.

Step 6 Ensure the “red” O-ring seal

(P/N 27607) is seated on the Flow IFS1001 09/24/2007
Restriction Connector (Fig 3.7). Thread
the flow restriction connector into the 49.99 38.996 24.42
nozzle block (Fig. 3.8) and tighten to 25.9
110-130 lbf-in (12.4-14.7 N·m). Connect
the steel braided hose (Fig. 3.6) to the
TDC Offset Angle Fig. 3.9
flow restriction connector and to one of
the test bench’s fuel delivery To verify the micrometer offset: Remove
measurement systems “cylinders”. The the o-ring seal from the micrometer
steel braided hose has 36˚ tapered tube adapter. Place the micrometer and
fittings on each end. . adapter assembly on a flat surface, turn
the micrometer in until it’s spindle
Flow Restriction O-ring Seal contacts the flat surface (Fig. 3.10). The
Connector P/N 27607 reading should match the micrometer
offset number stamped on the cam box
Fig. 3.7
nameplate (Fig. 3.9).
Apply thread sealant to the threads of
the Start of Injection (SOI) Pressure Micrometer
Transducer and install it into the nozzle Body Micrometer
block (Fig. 3.8) tightening securely. Offset

NOTE: Use care when applying thread

sealant, to prevent sealant material from
entering the transducer feed hole.
Micrometer
Adapter
Step 7 Due to manufacturing
tolerances, each cam box has a unique Fig. 3.10
Set Screw
micrometer offset. This setting ensures

10
If the micrometer offset position is magnetic pick-up (3). Connect the DAQ
incorrect, the micrometer must be cable (5) to the Pump Interface Module
repositioned in the micrometer adapter (4) and to the DAQ card in the
as follows: computer (6).
Ensure the o-ring seal in the micrometer Fig. 3.13
2
adapter is removed. Adjust the 6
micrometer to the factory offset
dimension. Loosen the set screw. Hold 1
the adapter flush to the flat surface and
firmly push the micrometer body down in 3
the adapter until the spindle contacts the
5 4
flat surface. Verify the micrometer offset
reading and tighten the set screw
securely. Step 11 Load the IFS Service
Equipment Software 99972 by inserting
Step 8 Insert the o-ring seal (P/N the CD-ROM into the CD drive. The IFS
30343) into the groove in the Calibration Software installation wizard
micrometer adapter. Using the two 1/4”- will guide you through the installation
20 x .75” screws, mount the micrometer process which only takes a few minutes
adapter to the cam box (Fig. 3.12). to complete.
Tighten the screws to 60-70 lbf-in (6.8-
7.9 N·m). The operator will be requested to verify
a destination location for the programs
Fig. 3.12 installation. The default location is
Micrometer Mounting
C:\Program Files\IFS Calibration\.
Screws Once the installation is complete, a
(1/4”-20 x .75”)
shortcut icon is automatically placed on
the computers desktop.
Step 12 To access the IFS program,
select the IFS icon on the desktop and
open the program. The first time the
Step 9 Slowly rotate the drive while program is opened, the operator is
looking into the TDC sensor hole on the requested to input a “TDC Offset
cam box, visibly center the pin on the number” (Fig. 3.14). This number is
cam shaft in the hole. Thread the TDC
sensor all the way in until it lightly
contacts the pin then back it out
approximately 1/8 - 1/4 of a turn.
Holding the sensor stationary, tighten
the jam nut securely.
Step 10 As shown in Figure 3.13,
connect the Pump Interface Module
Cable (1). Connect the cable to the
39156 Pump Interface Module (4), the
SOI pressure Sensor (2) and the TDC Fig. 3.14

11
specific to each cam box and is Step 1 Inspect the cam follower
stamped on the cam box nameplate in roller for rotation and condition. Ensure
the location shown in Figure 3.9. Once the CSA piston moves within the tappet
this information has been entered it will body bore. Inspect the cam follower
be used as the default value and will springs on the unit pump to ensure that
not need to be entered again for future neither the inner or outer springs are
tests. broken.
Step 13 To begin a test sequence, Step 2 Check the pumping plunger
select the “New Test” button. Some for rotation without binding (Fig. 3.15).
basic identification data must be entered
Step 3 Verify that the upper spring
and the specific model number and test
seat slot location is within the width of
routine selected prior to testing.
the alignment hole diameter in the pump
Because the IFS serial number is used body (Fig. 3.15)
in the test results file name, the number
must be entered twice to verify that it is Pump Fig. 3.15
entered correctly. Once the serial Body
number entry has been verified it will Alignment
O-ring Hole
change to a Green font color.
P/N 35638
Upper
Service Dealer identification numbers Spring Seat
are matched to an internal table of Slot located
authorized service agencies. Once the O-ring
within the
number has been verified it will change width of the
P/N 35639
in font color to Green. Once this Alignment
Hole
information has been entered it will be Diameter
used as the default value and will not Plunger
need to be entered again for future should
tests. Rotate Upper
Freely Spring
The IFS model number that is to be without Seat
tested is chosen from a pull down menu, Binding Slot
accessed by selecting the arrow in the
Step 4 Measure and record the
“Pump Model Number” field.
shim thickness if supplied (Fig. 3.16).
Choose the desired test routine from the Otherwise, use a 1.65mm thick timing
pull down menu activated in the “Select shim (P/N 35998) for initial testing*.
Test Routine” field. * For this reason timing is not used
NOTE: The Manual Mode is not as a consideration for warranty.
functional at this time.
Fig. 3.16
C. System Calibration Checks: As Digital Calipers
Received for Service
When an IFS system is received for
service it should be cleaned and visually
inspected prior to mounting in the IFS
cam box. Timing Shim

12
Step 5 Replace the upper o-ring Step 4 Center the position of the
seal (Fig. 3.15) P/N 35639 (brown) and control rack metering arm pin slot within
the lower o-ring seal P/N 35638 (black). the pump mounting bore (Fig. 3.18).

Mounting the Unit Pump into the IFS Pump Mounting Bore
Cam Box:
Step 1 Remove the CPN from the
Unit Pump.
Control Rack Metering
Step 2 Look into the pump mounting Arm Pin Slot Centered in
hole and rotate the drive until the base Pump Mounting Bore
circle (low side) of the cam lobe is
visible in the hole.
Step 3 Place the tappet assembly Fig. 3.18 Control Rack
on to the magnetic end of the 39234
Tappet Extraction Tool (Fig. 3.17).
Orient the CSA feed hole position to the Step 5 Lubricate the upper and
flat side of the tool. In this position the lower o-ring seals on the pump body
tappet’s guide pin slot will align with the (Fig. 3.19).
guide pin in the tappet bore.
Step 6 Position the Metering Arm so
Fig. 3.17 Tappet that the metering arm pin lines up with
Flat Side Installation the pump body fixture hole as is shown
and Removal in Figure 3.19.
Tool
P/N 39234
Alignment
Hole
Tappet CSA Feed Orient the
Assembly Hole Lubricate Metering Arm
o-rings Pin in line
with the
Pump Alignment
Mounting Hole in the
Bore Pump Body
Metering Arm
Pin

Hold the 39234 Tappet Tool with tappet

Fig. 3.19
over the pump mounting bore so that
the flat portion of the tool is facing the
control rack. Insert the tappet assembly Step 7 Install the unit pump into the
into the unit pump bore. Ensure that the Cam Box. Use the alignment hole as a
tappet’s guide pin slot indexes with the reference to index the metering arm pin
pin in the tappet block and that the cam with the control rack slot (Fig. 3.19).
follower roller is fully seated against the Step 8 Install the pump hold-down
cam shaft. Push down on the plunger to clamp and screw. Tighten the hold-down
release the tappet assembly from the clamp screw to draw the unit pump
magnet. down into the cam box (Fig. 3.20).

13
 Step 3 Re-check the clocking
dimension. Turn the micrometer thimble
out several turns. Turn the micrometer in
Unit Pump
Clamp until it stops. A reading of between 2.63
and 2.81mm should be attained. If the
Draw Unit Pump Down,
Tighten Screw Snugly then
micrometer reading is outside of these
Loosen and Re-Tighten to parameters, return to Step 1.
10 to 15 lbs-in (1.1 –1.7 N·m) Fig. 3.20 Mount the CPN
Step 1 Remove the Carbon Stop Seal
Step 9 After seating the pump body (P/N 16389) and Plain Washer (P/N
in the cam box, loosen the hold down 35686) as shown in Figure 3.22.
screw slightly and then tighten it to
approximately 10 to 15 lbs-in (1.1 –1.7
N•m) as shown in Figure 3.21. This will Plain Washer
provide a slight drag while rotating the (P/N 35686)
unit pump during the clocking
procedure.
Carbon Stop Seal
Fig. 3.22 (P/N 16389)

Step 2 The CPN must be purged of

Torque
Wrench air prior to system testing or the injection
For Clocking, Tighten to
timing may be skewed during the test. To
10-15 lbf-in (1.0-1.4 N·m) ensure that no air is entrapped within the
Final Torque injector, the CPN should be hydraulically
37 lbf-ft (50.2 N·m) Fig. 3.21 locked using a suitable nozzle tester.
Slowly increase the tester pressure until
the nozzle opens, return to a pressure
Pump Clocking just below the nozzle opening pressure
Step 1 Move the control rack to the and maintain this pressure until the CPN
maximum fuel position by setting the is hydraulically locked (Reference Service
micrometer to 2.63mm. Bulletin 557).
Step 3 Install a new plain washer
Step 2 Turn the pump body slightly
and carbon stop seal (Fig. 3.23)
(about 1/4—1/2 of a turn) in a
provided in the IFS Parts Kit (P/N
counterclockwise direction to remove
36529).
any pre-load on the metering arm pin.
Then turn the unit pump clockwise (a
slight drag should be felt) until the pump Carbon
Plain Stop Seal
stops rotating. This will remove any
Washer
remaining clearance between the
metering arm, control rack and
micrometer spindle. Hold the pump Carbon Stop
Seal Installation
stationary and tighten the hold down Tool
clamp to 37 lbs-ft. (50.2 N·m).
Fig. 3.23

14
Step 4 Allow the Carbon Stop Seal Step 2 Select the appropriate IFS
to relax for a few minutes. Then use the system number and test routine in the
Carbon Stop Seal Re-sizing Tool in a software and follow the instructions
slight rocking motion to squeeze the displayed in the text box of the IFS
seal into its final size (Fig. 3.24). program.
Carbon Stop Seal Re-sizing Tool Step 3 Unit pump assemblies may
P/N 36474 require setting of the metering arm
maximum and minimum stop positions.
NOTE: Replacement unit pump
assemblies are not preset at the
Fig. 3.24 factory and w ill require this
adjustment. Original equipment unit
pump assemblies will have an
Step 5 Apply a thin coat of assembly
alignment line scribed on the pump
grease to the carbon stop seal.
body and upper spring seat (Fig. 3.25).
Step 6 Guide the CPN nozzle tip
into the nozzle block, align the CPN inlet Unit Pump Body
tubing with the discharge fitting of the Alignment
pump. Line

Step 7 Use the injector clamp to

Upper Spring Seat
draw the nozzle tip and carbon stop seal
into the nozzle block. Tighten the injector
Fig. 3.25
clamp screw to 20 lbf-ft (27.1 N•m).
Step 8 Tighten the injector inlet The stop positions are adjusted by
piping nut to 23 lbf-ft (31.2 N•m) using a changing the radial position of the Upper
17mm flare nut socket while holding the Spring Seat. This is accomplished by first
unit pump discharge fitting stationary adjusting the unit pump assembly in the
with a 19mm wrench. cam box to a specified low idle fuel
Step 9 Select the appropriate IFS delivery. Then repositioning the upper
model number test routine in the spring seat to the full fuel rack position.
software and follow the instructions Low Idle Fuel Delivery Setting
displayed in the text box of the IFS
program. The IFS test following service routine
asks the user to verify the upper spring
D. System Settings: Following seat position by checking the fuel
System Service delivery at low idle speed using a specific
Step 1 With the test bench and cam rack position.
box set assembled as described earlier.
NOTE: The speeds and rack positions
Use either the original timing shim or a
differ for each IFS model, always
1.65mm timing shim (P/N 35998), install
reference the individual system test
and clock the IFS as described in part “C
routine or service specification for
System Calibration Checks: As Received
actual setting parameters.
for Service” in this section.

15
If the fuel delivery is acceptable, the micrometer out, then turning it in until
program will prompt the user to proceed it stops. Repeat the upper spring
to Step 3d to record it. If the fuel delivery seat setting if necessary.
is outside of the given parameters, the
Spring Seat Torque
user will be requested to proceed to Step Tool
3a where the upper spring seat is P/N 39152
adjusted as follows:
a. Adjust the bench speed to 0 RPM.
Loosen the CPN Line Nut and the
Unit Pump Clamp. Rotate the Unit
Pump in the direction shown in Fig. 3.27
Figure 3.26 to adjust the fuel
delivery. d. Set the micrometer position and the
test bench speed as specified in the
NOTE: The amount of pump rotation
test routine. Record the fuel
required for adjustment is very small.
delivery. If the fuel delivery is
Tighten the unit pump clamp and incorrect return to step a.
CPN line nut.
Step 4 The rest of the test routine
Fig. 3.26 includes check points for fuel delivery,
cold start advance operation and
injection timing at various speeds.

Injection Timing Adjustment

The injection timing is monitored
Increase fuel Decrease fuel continuously while the test routine is in
operation. However, a specific step in
b. Return the test bench to the speed the “Test Following Service” routine to
specified in the test routine and verify the timing for adjustment
verify the micrometer setting. Check purposes. Injection timing is adjusted by
the fuel delivery - if it is incorrect placing a timing shim under the unit
repeat step a; if it is within tolerance pump body collar to change the
proceed to step c. relational position of the roller tappet
c. Stop the test bench (0 RPM). Loosen and the cam lobe
the upper spring seat screw with the The program user will be prompted to
Spring Seat Torque Tool (P/N “Check Shim”. When selected, the
39152). Apply enough pressure to actual injection timing is compared to
the screw to hold the spring seat in the specified timing parameters. The
contact with the metering arm and program will then return an appropriate
micrometer. Adjust the micrometer to set of instructions based on the results
2.63mm and tighten the upper spring of the comparison. The user is then
seat screw to 18-22 lbf-in (2.0–2.5 either instructed to proceed to the next
N•m) as shown in Figure 3.27. step (timing is within tolerance) or to
Check the micrometer setting for replace the timing shim (timing is out of
2.63-2.81mm by backing the tolerance).

16
If the injection timing is out of tolerance, program will check the timing and
the program will calculate the either prompt the user to repeat the
dimensional difference of the timing timing shim replacement or
shim in use versus the shim size that is proceed to the next step.
required. A positive or negative number
in millimeters will be displayed. If Cold Start Advance Operation
positive add or, if negative subtract that
amount to or from the existing shim The test routine verifies cold start
thickness (Reference Fig. 3.16, Page advance operation by prompting the
12). Using the resulting thickness user to open the CSA activation valve
dimension determine the correct shim (Reference Figure 3.7b, Page 9).
part number from the Unit Pump Timing
Shims table at the end of this manual or Should the CSA fail to activate, ensure
on the individual IFS service that the lube oil needle valve is set to
specification. Replace the timing shim 1/2 turn out from the seated position. If
as follows: the CSA continues to fail operationally,
inspect the tappet assembly and CSA
a. Remove the CPN from the unit piston. If the piston fit is incorrect (very
pump and remove the unit pump loose, difficult to move by hand or
assembly from the Cam Box. seized in the bore) the tappet assembly
will need to be replaced.
b. Visually check the location of the
upper spring seat. If the seat Step 5 For the remainder of the
position is not within the acceptable system settings follow the latest edition
limits as shown in Figure 3.15 on of the individual IFS specification and
page 12, the IFS assembly is worn the appropriate test routine from the
beyond acceptable limits and latest version of the IFS service
should be replaced. equipment program.
If the upper spring seat position is
within the limits, replace the timing E. Preparation for Returning an IFS
shim with the correct shim. to the Customer.
The IFS seal kit (P/N 36529) contains
NOTE: If shim replacement is not the seals necessary for unit pump and
required, the inspection of the CPN engine installation. A protective
upper spring seat location will sleeve and shipping cap for the CPN are
need to be performed when the also provided to prevent contamination
pump is removed at the during handling.
conclusion of the test routine.
1. Replace the two o-ring seals on the
c. Mount the IFS assembly in the cam
unit pump.
box and clock unit pump assembly
as described earlier in part “C” of 2. Replace the carbon dam seal and
this section. the plain washer on the CPN.
d. Return the micrometer position and 3. Carefully put the protective shipping
test bench speed to the required cap (P/N 26888) over the valve end
settings, select “Verify Shim”. The of the CPN.

17
4. Hand tighten the CPN to the Unit
Pump Body.
5. Slide the Roller Tappet Assembly
into the woven protection sleeve,
then slide the Unit Pump spring into
the other end of the sleeve.
6. If possible, it is also recommended
that each assembled IFS be placed
in a poly bag.

18
SECTION 4 - TABLES
A. Identification and Cross Reference Table

Stanadyne John Deere

CPN Part Inscription IFS Part IFS Part
Number Code Number Number Application

37740 RE527597 4T LT OEM

38231 RE530788 4T LT OEM
36595 J 38232 RE530793 1500 Generator Set
38239 RE530802 1800 Generator Set
38262 RE530869 4T LT OEM

37741 RE527598 4T/5T OEM, 317, 320, 325 SSL & 304J, 244J,
4WDL
37742 RE527599 5TW OEM, 328 Skid Steer Loader
38225 RE530790 4T/4TW, 5T OEM
36597 K 38226 RE530792 5TW OEM
38234 RE530795 1800 Generator Set
38236 RE530797 1500 Generator Set
38237 RE530800 4T/5T OEM, 317, 320, 325 Skid Steer Loader
38238 RE530801 5TW OEM, 328 Skid Steer Loader

38227 RE530789 332 Skid Steer Loader

38228 RE530791 5H OEM
36601 M 38233 RE530794 1500 Generator Set
38235 RE530796 1800 Generator Set

36848 R 38230 RE530798 4520, 4720, & 5325 Tractor

38243 RE530824 5325 Tractor

38229 RE530799 5225 Tractor

36850 S 38240 RE530803 4120/4320 Tractor
38244 RE530825 5225 Tractor

38145 T 38242 RE530823 4120/4320 Tractor

39185 RE534688 313/315 Skid Steer Loader

38147 V 38241 RE530822 4520/4720 Tractor

B. Compact Pencil Nozzle Shims

Part Thickness Part Thickness

No. Inches (mm) No. Inches (mm)

35646 0.0945 (2.40) 35654 0.0787 (2.00)

35647 0.0925 (2.35) 35655 0.0768 (1.95)
35648 0.0906 (2.30) 35656 0.0748 (1.90)
35649 0.0886 (2.25) 35657 0.0728 (1.85)
35650 0.0866 (2.20) 35658 0.0709 (1.80)
35651 0.0846 (2.15) 35659 0.0689 (1.75)
35652 0.0827 (2.10) 35660 0.0669 (1.70)
35653 0.0807 (2.05) 35661 0.0650 (1.65)

19
C. Unit Pump Timing Shims

Part No. Size (mm) Part No. Size (mm)

35991 1.3 36189 1.825
36179 1.325 36001 1.85
35992 1.35 36190 1.875
36180 1.375 36002 1.9
35993 1.4 36191 1.925
36181 1.425 36003 1.95
35994 1.45 36192 1.975
36182 1.475 36004 2.0
35995 1.5 36193 2.025
36183 1.525 36005 2.05
35996 1.55 36194 2.075
36184 1.575 36006 2.1
35997 1.6 36195 2.125
36185 1.625 36007 2.15
35998 1.65 36196 2.175
36186 1.675 36008 2.2
35999 1.7 36197 2.225
36187 1.725 36009 2.25
35716 1.75 36845 2.275
36188 1.775 36846 2.3
36000 1.8

D. Torque Values & Cam Box Settings

1. Compact Pencil Nozzle - Cap Nut 110-120 lbf-in (12.4-13.6 Nm)

2. CPN Inlet Piping Nut 23 lbf-ft (30 Nm)
3. Upper Spring Seat Screw 18-22 lbf-in (2.0-2.5 Nm)
4. Unit Pump Mounting Clamp 37 lbf-ft (50.2 Nm)
5. CPN Mounting Clamp 20 lbf-ft (27.1 Nm)
6. Drive Hub Retaining Nut 100 lbf-ft (135 Nm)
7. Nozzle Block Mounting Screws 180-220 lbf-in (20-25 Nm)
8. Micrometer Adapter Mounting Screws 60-70 lbf-in (7-8 Nm)
9. Flow Restriction Connector 110-130 lbf-in (12.4-14.7 Nm)

10. Lube Oil Needle Valve Turn in till contact, back out
1/2 turn
11. TDC Sensor Air Gap .005 in. (.12mm), Turn in till
contact, back out 1/4 turn

20
 Stanadyne Corporation
92 Deerfield Road, Windsor, CT 06095, U.S.A
Tel: (860) 525-0821
Fax: (860) 683-4581
www.stanadyne.com

Stanadyne S.p.A.
Via Matteotti 158
25014 Castenedolo (Brescia), Italia
Tel: (39) 030 213 0070

Stanadyne Amalgamations Private Ltd.

9 Industrial Area 2, Marai Malai Nagar, Kanchi Puram District 603209, India
Tel: (91) 4114-453294

Stanadyne Changshu Corporation

Intersection of Jinmen Road and Huangshan Road, Jiangsu, China
Tel: 86 (0) 512 5235 8100

99976 Printed in U.S.A. Rev. 4/09