09600-03960 PUMP ASSY, INJECTI Denso Cross

Introduction
Do not perform any procedure in this Special Instruction until you read this information and you understand this information.This Special Instruction provides information for proper set-up of the low-pressure fuel system. A low-pressure fuel system that has been set up incorrectly can allow air in the system. Air in the system can cause hard starting, erratic engine operation, and can also erode the unit injectors. This procedure can be used on new and existing installations to check pressure and must be done with clean primary and secondary fuel filters.Reference Material
ReferenceApplication and Installation Guide, LEBW4976, "Diesel Fuels and Diesel Fuel Systems"ReferenceApplication and Installation Guide, LEBW4985, "Diesel Engine Commissioning - 3600/C280"ReferenceOperation and Maintenance Manual, SEBU7003, "Cat 3600 Series and C280 Series Diesel Engine Fluids Recommendations"ReferenceSystems Operation/ Testing and Adjusting, SENR3599, "3606 and 3608 Engines"ReferenceSystems Operation/ Testing and Adjusting, SENR3593, "3612 and 3616 Engines"ReferenceSystems Operation/ Testing and Adjusting, RENR5083, "C280 Marine Engines"ReferenceSpecifications, SENR3598, "3606 and 3608 Engines"ReferenceSpecifications, SENR3592, "3612 and 3616 Engines"ReferenceSpecifications, RENR5082, "C280 Marine Engines"ReferenceEngine News, SEBD9307, "New Specification For The Minimum Fuel Pressure At The Inlet To The Fuel Transfer Pump"Required Tooling
Table 1
Tooling Part Number     Description     Quantity    
6V-7830     Pressure Gauge     1    
214-7568     O-Ring Seal     3    
6V-3965     Fitting     2    
8C-8456     Cap     3    Low-Pressure Fuel System Specifications
If multiple engines are using the same fuel manifold or day tank, operate and load all engines to set the system fuel pressure.
Make sure that the return is routed to the tank and not routed to the engine inlet.
If rated speed and load cannot be achieved, use Tables 2 and 3 to determine the pressure to set at the regulator. This setting is based on load and zero restriction to the transfer pump.
Inlet Fuel Pressure to the Transfer Pump (set at rated speed and load)
No less than −20 kPa (−3 psi) and no greater than 100 kPa (14.5 psi)
50 kPa (7.25 psi) if a priming pump is usedPrimary and Secondary Fuel Filter Differential Pressure
75 kPa (10.8 psi) maximumFuel System Pressure at the Pressure Regulator (set at rated speed and load)
MUI: 550 50 kPa (80 7 psi)
EUI: 820 20 kPa (119 3 psi)Return Fuel Line Restriction Pressure
Do not exceed 350 kPa (51 psi) at rated speed and load
Table 2
Mechanical Unit Injector (MUI)     With Fuel Transfer Pump Inlet Pressure at 0 kPa    
Percent of Load     kPa     PSI    
0     609     88    
25     594     86    
50     580     84    
75     565     82    
100     550     80    
Table 3
Electronic Unit Injector (EUI)     With Fuel Transfer Pump Inlet Pressure at 0 kPa    
Percent of Load     kPa     PSI    
0     879     127    
25     864     125    
50     850     123    
75     835     121    
100     820     119