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For DENSO Authorized

ECD Service Dealer Only

Diesel Injection Pump

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.

This manual applies to the following types of supply pumps:


Client Engine Model Supply Pump P/N Pump Type
ISUZU 6SD1 094000-0143
MITSUBISHI 6M60T 094000-0151
HP0
TOYOTA/HINO S05C 094000-0350
HINO K13C 094000-0390

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.

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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

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1. Foreword Performance Inspection Tool List
Part Number Part Name

95091-10840 Timer joint ( Ø 25)


95091-10960 Timer joint ( Ø 35 ) *for K13C
*1 There are two timer joint diameters: Ø25 and
Ø35.

95091-11310 Filter stand

95091-11320 Pump housing stand


(The installation hole is 90mm in width.)

Pump housing stand *for K13C


95091-11330 (The installation hole is 100mm in width.)

95091-11340 Suction hose

95091-10280 Jet pipe (Ø2 × Ø6 × L600 M14 - M14) × 2

95091-11400 Jet pipe (L500, internal threads)

95091-11410 Jet pipe (L900, internal threads)

95170-00130 Diagnostic tester set (DST-1)

ECD-U2 set
95191-00211 • Cartridge (95191-20711)
• Harness (95191-10342)

1
Part Number Part Name

95091-11430 A : Stand, pump

95092-11620 B : Stand, pump, rear

95502-10230 Digital multimeter AC/DC 400A probes

95095-10830 Adapter, swiveling nipple

95091-11420 Nipple joint Ǿ

QB0728

95095-00080 Pressure regulator

95095-10580 Cover plate

95191-20970 Cover shield

95191-20820 Magnet plate

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2. Performance Inspection Manual

• Test bench : Denso injection pump test bench

• Dedicated jigs : stand, pump housing, stand, filter, coupling

• Measurement instrument : common-rail pressure measurement gauge

• Control equipment : pressure regulator for controlling common-rail pressure

2.1 Setting up the bench


(1) Install the pump housing stand on the bench (by
tightening it temporarily).
Pump housing stand : 95091-11320
: 95091-11330

(2) Install the timer joint on the bench.


Timer joint : 95091-10840 (φ25)
: 95091-10960 (φ35)

(3) Install the supply pump on the pump housing


stand.

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) Connect the STT, which was installed on the


bench in step (2), and the coupling (by tighten-
ing it temporarily).
STT : 95091-10960

(5) Firmly tighten the STT, which was installed on


the bench in step (1), to the bench.
STT : 95091-11330

4
(6) While turning the drive shaft with the handle,
center it by aligning the camshaft and the rota-
tional shaft of the coupling.

(7) Tighten the nut for the coupling joint.

(8) Install the fuel filter mounting bracket on the


bench.
(9) Connect the suction hose to the feed pump fuel
inlet.

(10) Use the overflow hose to connect the pump


outlet to the "TO TANK" area of the bench.
Then, use the hose to connect the common-
rail pressure limiter to the "LEAKAGE" area.
Then, attach the safety cover (cover plate) to
the coupling.
Cover plate for ECD-V4 : 95095-10580

5
(11) Using the fuel hose, connect the fuel filter with
the hose.

(12) Attach one end of the self-suction hose to the


IN end of the feed pump, and the other end of
the hose to the fuel tank on the bench.
Suction hose (boreφ8, length 4.5m) :
95091-11340

(13) Piping directly connects the delivery valve and


nozzle.
Jet pipe : 95091-10280

(14) Connect the piping to the PCV and G sensor,


and connect the controller.
Note :
Refer to the procedures in the test specifications
for the PCV1, PCV2, G1 and G2 connection po-
sitions.

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

Data display Pump selection

40 50 60
30 70
20 80
1 2 3 10 90
0 100

Injection volume command value Duty cycle ratio command value

POWER FCV
QD0499E

<Switches for Displaying Data> <Switches for Selecting Pump>


: Unused : Unused
: Unused : Unused
: Unused 4cyl : For selecting 4 cylinder
: Unused 5cyl : For selecting 5 cylinder
Pc : Common rail Pressure (Mpa) 6cyl : For selecting 6 cylinder
+B : Power supply voltage 8cyl : For selecting 8 cylinder
Np : Pump speed (rpm) : Unused
TFE : Injection interval : Unused
command value ( ℃ A)
TFD : Injection duration : Unused
command value (μs)
: Unused : Unused
U2 : For adjusting supply pump for U2
U2P : For adjusting supply pump for U2P
<Duty Cycle Ratio Command Value Switch>
Although this switch is not used for U2, it must always be set to the "0" position when the controller is in
operation.

<Injection Volume Command Value Input Switch>


This switch inputs command values (between 000 and 500; values below the decimal point count fractions
of.5 and over as a unit and cut away the rest).

<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.

[2] Feed pump check


(1) Priming pump check
A. Thoroughly drain the fuel from the suction
hose, which extends from the test oil tank to
the fuel inlet of the feed pump.
B. Detach the hose (which extends from the fuel
outlet of the feed pump to the fuel inlet of the
fuel filter) at the fuel filter, and have a large
measurement cylinder ready to catch the fuel
that comes out.

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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

(2) Feed pump suction capacity check


A. Again, thoroughly drain the fuel from the pipe,
which extends from the tank to the feed pump.
B. Disconnect the hose at the end that discharges
fuel to the filter, and have a large measurement
cylinder ready to catch the fuel that comes out.
C. Operate the pump at the specified speed. Ver-
ify that the pump draws and discharges fuel
within the standard time.
Standard : Refer to each test specification

[3] Feed pump feed quantity check


(1) Disconnect the fuel return pipe and have a large
measurement cylinder ready to catch the fuel
that comes out.
(2) Set the ECD controller.

(3) Turn ON the constant voltage power supply and


set it to 28.0 ± 0.2V.

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(4) Select the type of pump selection switch

(5) Turn ON the power supply of the ECD control-


ler.

(6) Verify that the data display shows "U2".

(7) Verify that the "U2" eventually disappears from


the data display.

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.

[4] G sensor output check


(1) Turn the data display switch to TFD and enter
the command value.
(2) Then, turn the data display switch to TFE and
enter the command value.
(3) Lastly, turn the data display switch to Np.

(4) Connect the DST-1 probe to the DST-1 jack on


the back of the ECD controller. Connect the
other end to the DST-1 connector.

(5) Operate the pump at the specified speed, and


verify the G sensor output waveforms on the
DST-1
Standard : 0.38 - 1.50 V
Range : 50 ms
: 500 mV

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.

(4) Operate the pump at the specified speed, and


verify the noise voltage on the DST-1.
Standard : 0.288V maximum
Range : 500µs
: 100 mV
Note :
As the exploded view of the waveform shown on
the right indicates, the noise voltage is below 0V
(indicated by the white triangles in this example).
Verify the maximum noise among the three
peaks.
QU0291

[6] PCV operation check


(1) Adjust the ECD controller voltage to between
28V and 16V.
Note :
Align the data display switch to +B, and set so
that the data display shows 16.0.

(2) Connect the ECD controller, DST-1, PCV, and


G sensor with wiring harnesses.
(3) Attach the AC/DC 400A probes.

(4) Turn the data display switch to TFD and enter


the command value specified in test specifica-
tion sheet.
(5) Then, turn the data display switch to TFE and
enter the command value specified in test
specification sheet.
(6) Lastly, turn the data display switch to Np.
(7) Set the voltage based on the test specification.

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.

A. Recommended Connection Point for the Cover


Shield Ground Terminal
a. Connect the cover shield ground terminal beside
the "vehicle connection" connector on the DST-
1 side.
* Secure the ground terminal using the DST-1 screw.

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.

(8) Operate the pump at the specified speed and


verify on the DST-1 the drive current wave-
forms of the PCV. Measure the length of time
from the rise and the fall of the No. 1 waveform
shown in the diagram.Switch the probe to mea-
sure PCV2.
Standard : 4.5 - 5.0 msec
Range : 1 ms
: 20 mV

[7] Fuel delivery quantity check at high pres-


sure
(1) Bench setting (Pressure Regulator Connection)
Pressure regulator : 95095-00080

A. Disconnect the piping from the PCV to the noz-


zle and nozzle holder.

B. Set the pressure regulator.

15
C. Connect the pipe between the pressure regula-
tor and PCV1.
jet pipe : 95091-11400

D. Install the swiveling nipple adaptor to the


PCV2, and connect it to "RETURN" with the
hose.
Adaptor, swiveling nipple : 95095-10830

E. Install the hose to the pressure limiter pressure


regulator, and connect the other end to
"RETURN".
joint, nipple : 95292-22480

F. Connect the pressure regulator adjusting valve


and joint to the jet pipe, and install the handle.
Following this, connect the ECD controller wir-
ing harness to the PC sensor.
Jet pipe : 95091-11410

16
G. Example of Actual Bench Setting

H. Bench Setting Piping Layout (During High-Pressure Delivery Quantity Check)


[7] Pumping quantity check at high pressure Pipe
Pipe Ø4 × Ø8 × 500
Hose (overflow)
Solenoid valve

Outlet
To return
Filter

ECD controller
To return Pressure limiter

Using STT*
176 Pc sensor

+0

Inlet Pressure regurator


Bench
Hose
To return

Coupling block Flow meter

Pump stand Bench


Return

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.

D. Set to the specified speed (Np) in the test


specifications.
E. Use the pressure regulator to increase pres-
sure. Check the pressure at this time on the
controller display.
F. Read the delivery quantity value.
G. Stop the pump after lowering the pressure.

H. Switch the PCV pipe to measure PCV2.


I. Repeat the above steps D) to G).

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Published: April 2004

[Duplication prohibited without permission]


Edited and published by:
Service Department, DENSO Corporation
1-1 Showa-cho, Kariya, Aichi Prefecture, Japan

[DTP]

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