Use Of 3P2200 Calibration Tool Group{0650, 1250} Caterpillar

Use Of 3P2200 Calibration Tool Group{0650, 1250}

Usage:

All Engines With Sleeve Metering Fuel Systems

The 3P2200 Calibration Tool Group, some tools from the 5P4203 Tool Group (field service) and some new tools, are needed to do the calibration procedure for the Sleeve Metering Fuel Pumps. Make reference to Page 4 of this instruction for the list of all tools that are needed.

Fuel pump calibration or crossover lever adjustment, can be checked and adjustments made with the fuel pump housing either on or off the engine, but the steps that follow (A, B and C) must always be done before any procedure is started.

A Disconnect the battery and shutoff the fuel supply to the fuel pump housing.

B Thoroughly clean the outside of the fuel pump housing, and the area around the fuel pump housing.

C Remove the fuel shut-off solenoid, the cover for the torque control group and the large cover on the fuel pump housing. Remove fuel from the inside of the fuel pump housing before removal of the side cover on 4 or 6 cylinder fuel systems; or after removal of the top cover on V8 fuel systems.

Tools Needed For Calibration Procedure

3P2200 Tool Group

Needed Parts From 5P4203 Tool Group

For earlier 3P2200 Calibration Tool Groups, remove the 1P7377 Spring and install the new 5P6557 Spring (5) on 3P1540 Pump Assembly (4) as shown.

Check The Calibration Of The Fuel Pumps - 4 Or 6 Cylinder Engine

(1) Remove the air-fuel ratio control, if so equipped.

(2) Install 3P1545 Pin (1) 17.3734 (0.6840") in hole (A). The pin length is given on the large diameter of the pin. Use 8S2243 Wrench to remove the fuel pumps that are to have the calibration check. Install 5P6602 Adapter (2) with 1D4538 Bolt and 1D4533 Bolt. Install 8S7271 Screw (3) in adapter (2). Use 2P8264 Socket with a torque wrench to tighten screw (3) to a torque of 2.3-2.8 N·m (20-25 lb. in.), to push pin (1) against the pump housing.

(3) Turn the governor control to full load and fasten it to this position.

(4) Check the spring (4) that is on the 3P1540 Calibration Pump (5). Calibration pump (5) must have the 5P6557 Spring (4). Earlier 3P1540 Calibration Pumps had a 1P7377 Spring. For those earlier calibration pumps, remove the 1P7377 Spring and install the 5P6557 Spring (4). See page 5 of this instruction.

(5) Clean the top of the pump, seat area and groove (8) of calibration pump (5). Put clean diesel fuel on the plunger for lubrication. Put pump (5) in a fuel pump bore so flat (B) is toward tang (6) on lever (7). When pump (5) is all the way in the fuel pump bore, turn pump (5) approximately 180°, in either direction, so tang (6) fits in groove (8). Install the 4N218 Bushing. Use the 8S2243 Wrench, with a torque wrench, and tighten the bushing to a torque of 80 ± 7 N·m (60 ± 5 lb. ft.).

(6) Assemble collet assembly (9) to 3P1568 Indicator (10) and tighten nut (C) on collet assembly (9).

NOTE: Tighten collet assembly (9) on the indicator approximately one and one-fourth revolutions through the indicator's range of travel. Do not tighten collet assembly (9) on the indicator (10) until the indicator reads zero, then tighten lock (D). After lock (D) is tightened, make sure indicator (10) still reads zero.

(7) Install a 6V190 Clamp (12) on the end (that is away from the governor) of sleeve shaft (13). Use a bolt to fasten the end of clamp (12) to the fuel pump housing as shown at location (E).

(8) Put indicator (10) on calibration pump (5) and hold the indicator tightly in position [in the center of calibration pump (5)]. Move sleeve control shaft (13) toward the governor end of the fuel pump housing to remove the end clearance. Flip lever (7) for the pump that is to be checked (as shown), several times, and write down the dimension that is on the indicator. (Flip: to cause the lever on the sleeve control shaft to have rotation toward the shut-off position; then the lever is released so it can return to the full load position). Do steps 4, 5, 6 and 7 for all of the fuel pumps. See step 9 for an explanation of how to read the dial indicator tolerances.

(9) See the dimensions you wrote down in step 8. All of these dimensions must be within range (J), clockwise from -.050 to +.050 on the dial indicator. Also, there must not be more than .050 difference between the dimensions of any two pumps. If any pump is outside this tolerance, recalibration of all pumps is necessary. See examples (K) and (L) above, which show two sets of dimensions that are within tolerance.

Adjustment Of The Fuel Pump Calibration - 4 Or 6 Cylinder Engine

(1) Remove the air-fuel ratio control, if so equipped.

(2) Install 3P1545 Pin (1) 17.3734 (0.6840") in hole (A). The pin length is given on the large diameter of the pin. Use the 8S2243 Wrench to remove the fuel pumps. Install 5P6602 Adapter (2) with 1D4538 Bolt and 1D4533 Bolt. Install 8S7271 Screw (3) in adapter (2). Use 2P8264 Socket with a torque wrench to tighten screw (3) to a torque of 2.3-2.8 N·m (20-25 lb. in.), to push pin (1) against the pump housing.

(3) Turn the governor control to full load and fasten it in this position.

(4) Check the spring (4) that is on the 3P1540 Calibration Pump (5). Calibration pump (5) must have the 5P6557 Spring (4). Earlier 3P1540 Calibration Pumps had a 1P7377 Spring. For those earlier calibration pumps, remove the 1P7377 Spring and Install the 5P6557 Spring (4). See page 5 of this instruction.

(5) Clean the top of the pump, seat area and groove (8) of calibration pump (5). Put clean diesel fuel on the plunger for lubrication. Put pump (5) in a fuel pump bore so flat (B) is toward tang (6) on lever (7). When pump (5) is all the way in the fuel pump bore, turn pump (5) approximately 180° in either direction, so tang (6) fits in groove (8). Install the 4N218 Bushing. Use the 8S2243 Wrench, with a torque wrench, and tighten the bushing to a torque of 80 ± 7 N·m (60 ± 5 lb.ft.).

(6) Assemble collet assembly (9) to 3P1568 Indicator (10) and tighten nut (C) on collet assembly (9).

NOTE: Tighten collet assembly (9) on the indicator approximately one and one-fourth revolutions through the indicator's range of travel. Do not tighten collet assembly too tight. With microgauge (11), make an adjustment to indicator (10) until the indicator reads zero, then tighten lock (D). After lock (D) is tightened, make sure indicator (10) still reads zero.

(7) Install 6V190 Clamp (12) on the end (that is away from the governor) of sleeve shaft (13). Use a bolt to fasten the end of clamp (12) to the fuel pump housing as shown at location (E).

(8) Loosen bolt (14) (that fastens lever (7) to the sleeve shaft) with 5P4206 Wrench (15). Lift the handle of wrench (15) a small amount [to lift the rear of lever (7)] and then lightly tighten bolt (14) so lever (7) will hold pump (5) stationary, but lever (7) can still be moved smoothly as wrench (15) is pushed down. Move the sleeve control shaft toward the governor to remove end play.

(9) Push down on the handle of wrench (15) to lift the plunger in pump (5) until the plunger is almost even with the top of the pump, as shown at location (F). Put indicator (10) on pump (5) and hold the indicator tightly in position [ in the center of calibration pump (5)] and move the handle end of wrench (15) downward slowly [tang (6) of lever (7) will move up] until the reading (dimension) on indicator (10) is ± 0.010 from zero.

NOTE: Normally, to get indicator (10) to read zero after bolt (14) is tightened, it is necessary to make an adjustment of 0.01 beyond zero. Each mark on the indicator is equal to 0.002. The ± 0.010 dimension then, is equal to ± 1 on the indicator, as shown above.

(10) Use a 5P7253 Socket with a torque wrench and tighten bolt (14) to a torque of 2.8 ± 0.2 N·m (24 ± 2 lb.in.). Flip lever (7) (for the calibrated pump) several times. (This will remove any clearance in the linkage.) The dial indicator must still read zero. If it does not, do the adjustment procedure again.

(11) Do steps 8, 9 and 10 for all pumps that are to be calibrated.

Check The Adjustment Of The Crossover Levers - V8 Engine

NOTE: The illustrations in each procedure that follows, show the fuel pump housing off the engine. This is done to better show each step of each procedure. The illustrations also show all of the fuel pumps removed from the pump housing. This is not always necessary. The work that is to be done will give an indication of how many of the fuel pumps will have to be removed.

NOTE: If a check is made of the adjustment for the crossover levers, a calibration adjustment must be made to all fuel pumps.

(1) Remove the fuel shutoff solenoid, the top cover of the fuel pump housing and the cover over the torque control group.

(2) Install 3P1546 Pin (1) 15.9410 (0.6276") in hole (A). The pin length is given on the large diameter of the pin. Install the 5P6602 Adapter (2). Fasten adapter (2) in position with 1D4538 Bolt and 1D4533 Bolt. Install 8S7271 Screw (3) and use the 2P8264 Socket to tighten the screw to a torque of 2.3-2.8 N·m (20-25 lb. in.) to push pin (1) against the pump housing.

(3) Make an adjustment to low idle screw (4) to get the 9 ± 1 (.35" ± .04") dimension at location (B), between face (C) on low idle lever (5) and face (D) on boss (6). Tighten nut (7) to hold screw (4) in position.

(4) Loosen the bolts that hold sleeve levers (8), and slide the levers out of the way. Put 5P4209 Gauge (9) on shafts (10). Slide gauge (9) toward crossover levers (11) and (12). If crossover lever adjustment is correct, the gauge hole in gauge (9) will fit over dowel pin (13) without any movement of the crossover levers. If dowel pin (13) is below the gauge hole [crossover levers (11) and (12) have to be raised to let dowel pin (13) fit in the gauge hole] an adjustment must be made to the crossover levers. See ADJUSTMENT OF CROSSOVER LEVERS on Page 18.

(5) If dowel pin (13) is above the gauge hole, it is permissible to lift one end of gauge (9) off a sleeve shaft a maximum of .203 (.008") (while the other end is held on the sleeve shaft and a slight application of force is put on the center of the gauge) as shown. Use a feeler gauge (14) to check the clearance between the bottom of gauge (9) and the sleeve shaft. If the dimension needed to let dowel pin (13) fit in the gauge hole is more than .203 (.008"), an adjustment must be made to the crossover levers. See ADJUSTMENT OF CROSSOVER LEVERS on Page 18.

Adjustment Of The Crossover Levers - V8 Engine

NOTE: When an adjustment is made to the crossover levers, an adjustment must also be made to the calibration of all fuel pumps.

(1) Remove the fuel shutoff solenoid, the top cover of the fuel pump housing and the cover over the torque control group.

(4) Loosen the bolts that hold sleeve levers (8), and slide the levers out of the way. Loosen bolts (9) and (10) that fasten crossover levers (11) and (12) to sleeve shafts (13). Slide crossover lever (11) off dowel pin (14).

(5) Put 5P4209 Gauge (15) on shafts (13) and put lever (12) in position so dowel pin (14) will fit in the gauge hole. Hold gauge (15) in position and use a wrench as shown to tighten bolt (9) enough to hold the lever in position, then use a 5P7253 Socket with a torque wrench to tighten bolt (9) to a torque of 2.8 ± 0.2 N·m (24 ± 2 lb.in.). Now remove gauge (15) from the dowel.

(6) Check the adjustment again. Put the 5P4209 Gauge (15) on shafts (13) and slide the gauge toward lever (12) so dowel pin (14) can go into the gauge hole. If lever (12) must be raised to let the dowel pin fit in the gauge hole, the adjustment must be done again. See steps 4 and 5. If dowel pin (14) is above the gauge hole, it is permissible to lift one end of gauge (15) off a sleeve shaft a maximum of .203 (.008") on one end (while the other end is held on the sleeve shaft and a slight application of force is put on the center of the gauge) as shown. Use a feeler gauge (16) to check the clearance between the bottom of gauge (15) and the sleeve shaft. If the dimension needed to let dowel pin (14) fit in the gauge hole is more than .203 (.008"), the adjustment must be done again. See steps 4 and 5.

(7) When the adjustment of lever (12) is correct, remove the 5P4209 Gauge (15). Put lever (11) in position on dowel pin (14) and tighten bolt (10) that fastens lever (11) to the sleeve shaft as shown. Use a 5P7253 Socket with a torque wrench to tighten bolt (10) to a torque of 2.8 ± .2 N·m (24 ± 2 lb.in.). Put gauge (15) on shafts (13) and again check the adjustment.

Check The Calibration Of The Fuel Pumps - V8 Engine

(1) Remove the fuel shutoff solenoid, the top cover of the fuel pump housing and the cover over the torque control group.

(3) Make an adjustment to low idle screw (4) to get the 9 ± 1 (.35" ± .04") dimension at location (B) between face (C) on low idle lever (5) and face (D) on boss (6). Tighten nut (7) to hold screw (4) in position. Remove the fuel pumps that are to have the calibration check.

(4) Check the spring (8) that is on the 3P1540 Calibration Pump (9). Calibration pump (9) must have the 5P6557 Spring (8). Earlier 3P1540 Calibration Pumps had a 1P7377 Spring. For those earlier calibration pumps with the 1P7377 Spring, remove the spring and install the 5P6557 Spring (8). See page 5 of this instruction.

(5) Clean the top of the pump, seat area and groove (12) of calibration pump (9). Put clean diesel fuel on the plunger for lubrication. Put pump (9) in a fuel pump bore so flat (E) is toward tang (10) on lever (11). When pump (9) is all the way in the fuel pump bore, turn pump (9) approximately 180°, in either direction, so tang (10) fits in groove (12). Install the 4N218 Bushing. Use the 8S2243 Wrench, with a torque wrench, and tighten the bushing to a torque of 80 ± 7 N·m (60 ± 5 lb.ft.).

(6) Assemble collet assembly (13) to the 3P1568 Indicator (14) and tighten nut (F) on collet assembly (13).

NOTE: Tighten collet assembly (13) on the indicator approximately one and one-fourth revolutions through the indicator's range of travel. Do not tighten collet assembly (13) on the indicator too tightly. With microgauge (15), make an adjustment to indicator (14) until the indicator reads zero, then tighten lock (G). After lock (G) is tightened, make sure indicator (14) still reads zero.

(7) To check the calibration of the fuel pumps on the left side of the fuel pump housing (as seen from the governor end of the fuel pump housing), install a 6V190 Clamp (16) on sleeve shaft (17) (end away from the governor). Use a bolt as shown at location (H), to hold the clamp in position. To check the calibration of the fuel pumps on the right side of the fuel pump housing, (as seen from the governor end of the fuel pump housing), install a 6V190 Clamp (16) at each end of sleeve shaft (18) on the right side. Use a bolt at each location (J) to hold the clamps in position as shown.

(8) Put indicator (14) on calibration pump (9) and hold the indicator tightly in position [in the center of calibration pump (9)]. Move the sleeve control shaft toward the governor end of the fuel pump housing to remove the end clearance. Lift the dowel pin for the crossover levers with a finger, and then let go of the dowel pin so the crossover levers will drop. Do this quickly (fast), several times. (This will remove any end play in the linkage.) Write down the dimension of the needle on the indicator. Do steps 5, 6, 7 and 8 for all of the fuel pumps. See step 9 for an explanation of how to read the dial indicator tolerances.

(9) See the dimensions you wrote down in step 8. All of these dimensions must be within range (K), clockwise from -.050 to +.050 on the dial indicator. Also, there must not be more than .050 difference between the dimensions of any two pumps. If any pump is outside this tolerance, recalibration of all pumps is necessary. See examples (L) and (M) above, which show two sets of dimensions that are within tolerance.

Adjustment of the Fuel Pump Calibration - V8 Engine

(1) Remove the fuel shutoff solenoid, the top cover of the fuel pump housing and the cover over the torque control group.

(5) Clean the top of the pump, seat area and groove (12) of calibration pump (9). Put clean diesel fuel on the plunger for lubrication. Put pump (9) in a fuel pump bore so flat (E) is toward tang (10) on lever (11). When pump (9) is all the way in the fuel pump bore, turn pump (9) approximately 180° in either direction, so tang (10) fits in groove (12). Install the 4N218 Bushing. Use the 8S2243 Wrench, with a torque wrench, and tighten the bushing to a torque of 80 ± 7 N·m (60 ± 5 lb. ft.).

(6) Assemble collet assembly (13) to the 3P1568 Indicator (14) and tighten nut (F) on collet assembly (13).

(7) To make adjustment to the calibration of the fuel pumps on the left side of the fuel pump housing (as seen from the governor end of the fuel pump housing), install a 6V190 Clamp (16) on sleeve shaft (17) (end away from the governor). Use a bolt as shown at location (H) to hold the clamp in position. To make an adjustment to the calibration of the fuel pumps on the right side of the fuel pump housing (as seen from the governor end of the fuel pump housing), install a 6V190 Clamp (16) at each end of sleeve shaft (18) on the right side, as shown. Use a bolt at each location (J) to hold the clamps in position as shown.

(8) Loosen bolt (19) (that fastens lever (11) to the sleeve shaft) with the 5P4206 Wrench (20). Lift the handle of wrench (20) a small amount [to lift the rear of lever (11)] and then lightly tighten bolt (19) so lever (11) will hold pump (9) stationary, but lever (11) can still be moved smoothly by pushing down on wrench (20).

(9) Push down on wrench (20) to lift the plunger in pump (9) until the plunger is almost even with the top of the pump, as shown at location (K). Move the sleeve control shaft toward the governor to remove end play. Put indicator (14) on pump (9) and hold the indicator tightly in position [in the center of calibration pump (9)], and move the handle end of wrench (20) downward slowly [tang (10) of lever (11) will move up] until the reading (dimension) on indicator (14) is ± 0.010 from zero.

NOTE: Normally, to get indicator (14) to read zero after bolt (19) is tightened, it is necessary to make an adjustment of 0.01 beyond zero. Each mark on the indicator is equal to 0.002. The ± 0.010 dimension then, is equal to ± 1 on the indicator, as shown above.

NOTE: The acceptable tolerance for a check of fuel pump calibration is ± .050 (.002") (See the explanation in CHECK THE ADJUSTMENT OF THE FUEL PUMPS, STEP 9): this makes up for tool differences, and different mechanics. The acceptable tolerance for adjustment of fuel pump calibration is ± .010, so all fuel pumps are adjusted as close to zero as possible.

(10) Use a 5P7253 Socket with a torque wrench to tighten bolt (19) to a torque of 2.8 ± 2 N·m (24 ± 2 lb.in.). Lift the dowel pin for the crossover levers with a finger, and then let go of the dowel pin so the crossover levers will drop. Do this quickly (fast) several times. (This will remove any clearance in the linkage.) The dial indicator must still read ± 0.010. If it does not, do the adjustment procedure again.

(11) Do steps 5 through 10 for each pump that is to have the calibration adjustment.