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Old 07-06-2009, 09:48 AM   #21
CumminsDriver
 
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there is a way to check cp3 u have to do it by flow you cant just check pressure if u want to check it right flow test it. What you have to do is take the line going from the cp3 to the bottom of the rail. Loose it up from the cp3 take it completly off the rail and on the side that was connected to the rail put a tube on that side then tighten the other side back on the cp3... Grab a gradutated cylinder again and have someone get in the driver seat and have them crank on the truck till you get fuel to the end of the tube. Once you get fuel to that start feeding it in the gradutated cylinder while the person is cranking on it for 10 seconds after 10 seconds stop and the spec should be 70ml......hope this helps...let me know if you need more help


also if you dont have a gradutated cylinder that reads low enough just put water in the cylinder to what ever you first big number is to make it easier to read
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2003 DODGE RAM 3500 DUALLY 4X4 6SPD
455hp and 926tq
Sometimes you just gotta burn down the high school to get people out of it!
 
Old 07-06-2009, 12:40 PM   #22
SledPuller21
 
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Put the airdog and you'll be fine...if not I might be tweaking a pump that you could test out.
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2007.5 6.7 QCSB 6in Superlift Murdered on BMF 20's
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Old 07-06-2009, 03:20 PM   #23
homewrecker
 
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I have ran my truck with the Fass unplugged(not on purpose!) towing 15k before with zero issues.My friend just did the same thing the other month but actually went over a week with his Fass unplugged before he realized it,no problems for him either.Like mentioned earlier,these pumps are not like the vp's.They have built in measures to not starve themselves of internal lubrication.Inlet pressure to maintain lubrication has to be met before RP to run is achieved(I think this is the function of the cascade overflow valve).The fact your truck ran means you should be just fine.

This is what I have saved for the cp-3 operation.




DESCRIPTION
The fuel system on the 5.9L Common Rail Diesel Engine uses a rotary mechanical fuel injection pump and an Electronic Control Module (ECM) and is a drive-by-wire system, meaning there is no physical throttle cable.
The fuel delivery system consists of the:
- Accelerator pedal position-sensor module
- Air cleaner housing\element
- Fuel filter\water separator
- Fuel temperature sensor
- Fuel heater
- Fuel rail pressure relief valve
- Fuel rail pressure sensor
- Fuel injection pump
- Fuel injectors
- Fuel tank
- Fuel tank filler\vent tube assembly
- Fuel tank filler-tube cap
- Fuel tank module containing the electric lift pump, roll-over valve and a fuel gauge sending unit (fuel level sensor).
- Fuel tubing\lines\hoses
- High-pressure fuel injector lines
- Low-pressure fuel supply and return lines
- Low-pressure fuel return line
- Overflow valve
- Quantity control Fuel Control Actuator valve
- Quick-connect fittings
- Water sensor\drain module


FUEL INJECTION PUMP
The Cummins 5.9L CRD uses the Bosch CP3 injection pump, used also on the DMax 6.6L V8 CRD and the Jeep 2.8L CRD

DESCRIPTION
A radial, 3-piston pump, with a gearotor pump attached to the back, is used as the high-pressure pump for common-rail fuel pressure generation - in this system it is capable of pressures between 300-1600 bar (4351-23206 psi) .
A spring-loaded Cascade Overflow Valve regulates internal housing pressure
Regulated internal housing pressure is oem-specific
The pump shaft is driven by the timing belt at 1:1 ratio to the crankshaft.
Fuel pressure is generated independently of the injection process.
A Fuel Control Actuator solenoid valve regulates injection pressure
The pump is lubricated by the pumped Diesel fuel and is not responsible for fuel injection timing.

OPERATION

GEAROTOR PUMP

DESCRIPTION
The gearotor pump has two functions
- draws fuel from the fuel supply
- increases fuel pressure for regulation to housing pressure required for internal lubrication and supplying the high-pressure injection pump

OPERATION
This fuel system uses a gearotor supply-pump attached to the rear of the high-pressure pump. This medium-pressure fuel pump is driven by the end of the high-pressure pump shaft, and can generate 20" vacuum at the fuel inlet at high rpm.
The gearotor pump is supplied fuel from the lift pump in the fuel tank through the fuel manager\filter.

The outlet of the gearotor pump provides pressurized fuel to a branched circuit internal to the high-pressure pump flange, which supplies both the Fuel Control Actuator solenoid valve and the Cascade Overflow Valve\regulator. Because the gearotor pump increases fuel flow and pressure as engine rpm increases, the pressure and flow is regulated by the COV.

The COV and gearotor supply-pump are not serviced independently of the high-pressure pump.

CASCADE OVERFLOW VALVE

DESCRIPTION
The COV is located on the front cover of the high pressure pump.
The Cascade Overflow Valve has three functions:
- regulation of lubrication fuel to the internal moving parts of the high-pressure pump
- regulation of the fuel pressure being supplied to the Fuel Control Actuator solenoid valve
- return excess fuel to the fuel tank
This regulated internal pressure, known as housing pressure, is determined by engine displacement and power requirements - the 5.9L CRD requires 5-12.4 bar (80-180 psi)
For comparison, the 2.8L 4-cyl Jeep CRD requires 5bar maximum (73psi)

OPERATION
The COV has a spring-loaded center spool-piece that has a drilled channel with three passages: one for initial low-pressure lubrication, one for lubrication at housing-pressure , and one for overflow. The valve is operated in three stages based on the level of pressure at the inlet.

Stage 1
When the fuel pressure entering the tip of the COV is between 0 and 3 bar (43psi), pressure is too low to overcome regulator spring tension and fuel flows through the center channel, only . This passage always allows fuel flow through to the pump center-ring and lubricates the pump bearings and internal moving parts. This circuit also allows air to bleed during initial cranking and returns the air to the fuel tank.
The COV is in Stage 1 during cranking, only.

Stage 2
When the fuel entering the COV exceeds 5bar (73psi), but is less than 12.4bar (180psi), the spool-piece moves against spring tension aligning a second passage for lubrication purposes.
Stage 2 can be reached during cranking and initial start up.


Stage 3
When fuel pressure exceeds 12.4bar (180psi), the spool-piece aligns with the overflow passage. This stage relieves the pressure into an overflow circuit that sends the fuel back to the inlet side of the gearotor pump, thus limiting maximum fuel pressure to 12.4bar (180psi).
Lubrication fuel continues to flow through all channeled passages during this stage.
Excess fuel is sent back to the fuel tank through the fuel-return circuit
Stage 3 is reached at over-pressure

FUEL CONTROL ACTUATOR

DESCRIPTION
The Fuel Control Actuator solenoid valve is located on the back of the front cover of the high-pressure pump. The solenoid is pulse-width modulated by the ECM and meters the amount of fuel that flows into the high-pressure elements inside the high-pressure pump.
The solenoid is inactive up to 30 seconds after IGNition switch is initially keyed to ON position to allow maximum fuel pressure to the fuel rail during cranking and start up. ECM assumes FCA valve control when CPS signal and rail pressure are within acceptable limits

OPERATION
The Fuel Control Actuator solenoid valve is a pulse-width modulated valve that controls the amount of fuel sent or delayed to the high-pressure pump elements inside the high-pressure pump. The ECM determines the fuel pressure set point based on engine sensor and rail-pressure inputs. If the actual fuel-rail pressure is too low, the ECM commands the solenoid to allow more fuel to flow to the high-pressure pump. This minimizes the difference between the actual fuel-rail pressure reading and the set point. The ECM will also operate the solenoid to delay fuel, reducing flow-rate, if the fuel-rail pressure becomes too high.
The FCA valve is commanded open by the ECM to allow the high-pressure pump to build maximum pressure (1600bar, 23,206psi), or closed to reduce rail pressure.
Thus, rail fuel-pressure can be increased or decreased independent of engine speed


High Pressure Pumping Plungers
The FQS valve supplies three high pressure pumping chambers. The pumping chambers have one-way inlet valves that allow fuel to flow into the chambers. The valves then close as the fuel is compressed, causing the high pressure fuel to overcome a spring-loaded ball-and-seat outlet valve.
All three pumping chambers are tied together in one circuit internal to the pump and provide high pressure fuel between 300bar (4351psi) and 1600bar (23,206psi) through a steel line to the fuel rail.
The pump is driven at 1:1 engine speed and is not responsible for injection timing.
Pump function is to provide fuel at high-pressure, while the ECM controls injection pressure and timing.
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Old 07-06-2009, 04:06 PM   #24
CumminsDriver
 
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But you will still damage a dodge cp3 by not having some kind of lift pump> I have seen it many many times and other people have to. Running your truck without a lift pump maybe be fine for a lil bit but running it like a duramax pump it will stress it out and cause damage which in return cause damage to the injectors.


In that whole list of stuff up above a dodge cp3 is not the same as a duramax cp3. close but there are differences which will allow you not to have a lift pump
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Old 07-06-2009, 10:00 PM   #25
SledPuller21
 
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Long story short, dont worry bout it your fine.
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Old 07-06-2009, 10:19 PM   #26
02psd7.3
 
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Ok dustin now I need details what you tweakin now I thought you were leavin the new truck alone
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Old 07-07-2009, 08:29 PM   #27
SledPuller21
 
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Just been tinkering with the pump sitting here...also I never said I was keeping this one stock. Just going for a mild 600-650 and still be able tow the puller.
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Old 07-07-2009, 08:49 PM   #28
TopFueler
 
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Quote:
Originally Posted by SledPuller21 View Post
Just been tinkering with the pump sitting here...also I never said I was keeping this one stock. Just going for a mild 600-650 and still be able tow the puller.
We can test CP3 pumps in house. We have the Bosch authorized test stand and we have a Roboti test stand that can test them as well. We test every pump we send out new or rebuilt. Thanks 1-800-955-0476
 
Old 07-07-2009, 09:54 PM   #29
SledPuller21
 
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