Inspection and Modification of the 102-7459 Fuel Injection Control Linkage and the 4P-9048 Fuel Injection Control Linkage {1298} Caterpillar

Machine Engines:With Mechanical Unit Injection (MUI) 3114 3116 3126

Truck Engines:With Mechanical Unit Injection (MUI) 3114 3116

Commercial Engines:With Mechanical Unit Injection (MUI) 3114 3116 3126

Introduction

There are two types of fuel injection control linkages that are used on these engines.

• The current designs of the fuel injection control linkages are the 162-8756 Fuel Injection Control Linkage (used for 3116 engines and 3126 engines) and the 170-7670 Fuel Injection Control Linkage (used for 3114 engines). If you have a 162-8756 Fuel Injection Control Linkage or a 170-7670 Fuel Injection Control Linkage this publication is not applicable to your engine.

• The former designs of the fuel injection control linkages are the 102-7459 Fuel Injection Control Linkage (for 3116 and 3126 engines), and the 4P-9048 Fuel Injection Control Linkage (for 3114 engines).These fuel injection control linkages may be inspected and modified, if desired. Refer to Illustration 4.

• You may perform the "Inspection Procedure" in order to determine the type of fuel injection control linkage on your engine. Refer to Illustration 4 for visual identification of the current 162-8756 Fuel Injection Control Linkage or the current 170-7670 Fuel Injection Control Linkage .

This publication explains the inspection of the former 102-7459 Fuel Injection Control Linkage and the former 4P-9048 Fuel Injection Control Linkage . This publication also contains the procedures for the modification of the former 102-7459 Fuel Injection Control Linkage and the former 4P-9048 Fuel Injection Control Linkage . The former fuel injection control linkages may be modified by the installation of the 180-7956 Clamp Assembly Kit and the 180-7957 Bushing Assembly Kit , if desired. This modification does not apply to the current 170-7670 Fuel Injection Control Linkage or the current 162-8756 Fuel Injection Control Linkage .

Suggested Tools and Parts

Illustration 1	g00701990
136-4149 Governor Pliers (D)

The 136-4149 Governor Pliers must be modified slightly. The governor pliers have jaws that are covered with rubber. The rubber coating should be removed on the last 10 mm (0.04 inch) of the tips in order to expose the original metal teeth. Refer to Illustration 1. This modification will not affect the original function of the pliers.

The following parts that are listed in Table 2 may be used in order to install the 180-7956 Clamp Assembly Kit .

The following parts that are listed in Table 3 may be used in order to install the 180-7957 Bushing Assembly Kit . Refer to the "Inspection Procedure" section of this publication in order to determine if the rivet should be replaced with the 180-7957 Bushing Assembly Kit .

Inspection Procedure

1. Remove the valve cover and the valve cover gasket. Remove the Number 1 rocker arm assembly and the pushrods. Refer to the Disassembly and Assembly Service Manual Module for your engine.

   Note: Pushrods must be reinstalled in the same position. Note the position of the pushrods.

   Note: Be sure to install the lockwire and the "dealer seal" in order to lock the fuel setting.

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Illustration 2	g00655220
Illustration 2 is a photograph of the former 102-7459 Fuel Injection Control Linkage . Inspect rivet (1) .

2. Inspect rivet (1) in order to verify that you do not have the current design 162-8756 Fuel Injection Control Linkage (for 3116 and 3126 engines), or the current 170-7670 Fuel Injection Control Linkage (for 3114 engines). If you have the current 162-8756 Fuel Injection Control Linkage or the current 170-7670 Fuel Injection Control Linkage this publication is not applicable to your engine.

3. Use the following illustrations in order to identify the fuel injection control linkage.

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Illustration 3	g00661677
Illustration 3 is of the former 102-7459 Fuel Injection Control Linkage or the former 4P-9048 Fuel Injection Control Linkage . Notice that no washer is on rivet (1). Notice the direction of rivet (1) .

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Illustration 4	g00661684
Illustration 4 is of the current 162-8756 Fuel Injection Control Linkage or the current 170-7670 Fuel Injection Control Linkage . Notice the washer on rivet (2). Notice the direction of rivet (2) .

4. Look at the fuel injection control linkage and determine the type of rivet that was used. The current design of the fuel injection control linkage has a washer around the peened portion of the rivet. The direction of the rivet is reversed when the rivet is compared to the former design. This publication is not applicable if the engine has the current design of the fuel injection control linkage. Proceed to step 5 if the fuel injection control linkage is the former design.

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Illustration 5	g00655275

5. Install 1U-6675 Spring Compressor (Tool (A) ) with 8T-4177 Bolt (Tool (B) ). Compress the spring on the fuel injector.

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Illustration 6	g00655645

6. Lock the 128-8823 Pliers (Tool (C) ) on the head of rivet (1) while you gently push fuel injector rack (3) toward the fuel injector. Use care in order to prevent damage to brass bearing.

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Illustration 7	g00655289

7. Gently turn the handles of tool (C). Turn the handles clockwise and turn the handles counterclockwise. Observe rivet (1). Rivet (1) is worn if rivet (1) has any wobble.

8. The linkage can be modified if rivet (1) is worn. Refer to the "Installation Of The 180-7951 Bushing Assembly " section of this publication.

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Illustration 8	g00655286
The 180-7956 Clamp Assembly Kit

9. You may install the 180-7956 Clamp Assembly Kit even if rivet (1) is not worn. The 180-7956 Clamp Assembly Kit will increase the strength of the joint. Refer to the "Installation of the 180-7956 Clamp Assembly Kit " section of this publication.

Installation Of The 180-7951 Bushing Assembly Kit

Note: The 180-7951 Bushing Assembly Kit is used for the former control linkages only.

1. Remove the fuel injector for cylinder number 1. Refer to the Disassembly and Assembly Service Manual Module for your engine.

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Illustration 9	g00655301

2. Install a protective layer of clean towels around the fuel injection control linkage.

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Illustration 10	g00655305

3. Place clean towels under fuel injection control linkage (4). Position the towels in order to catch the metal chips from cutting off the part of rivet (1) that has been peened.

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NOTICE
Do not use an abrasive stone in order to remove the part of the rivet that has been peened. Abrasive dust may enter the engine if an abrasive stone is used.

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Illustration 11	g00702181

4. Use a rotary file (E) in a tool that will run at a high rpm in order to cut off the part of rivet (1) that has been peened. The rotary file that is shown was obtained from Greenfield Industries. The following telephone number is for customer services: 888-434-4311. (part number 042-1023-20 ball nose burr , part number 046-1013-20 egg shaped burr )

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Illustration 12	g00655311

5. Rotate fuel injection control linkage (4) in order to gain the best access to the part of the rivet that has been peened.

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NOTICE
Do not let metal chips or pieces of the rivet fall into the engine.

6. Use tool (E) in order to cut off the part of rivet (1) that has been peened. Remove rivet (1) from fuel injection control linkage (4) .

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Illustration 13	g00702186
The 180-7951 Bushing Assembly Kit (F) Rack Control Shaft (G) Governor Link (4) Fuel Injection Control Linkage (7) 180-7952 Lever Bushing (8) 8L-5832 Hex Nut (9) 9X-8907 Hexagon Button Screw

7. Use the 180-7951 Bushing Assembly Kit in order to modify the linkage. Insert 9X-8907 Hexagon Button Screw (9) from the 180-7951 Bushing Assembly Kit into fuel injection control linkage (4). Refer to Illustration 13.

8. Apply 169-5464 Quick Cure Primer apply on the threads of 9X-8907 Hexagon Button Screw (9) and 8L-5832 Hex Nut (8). Allow the primer to dry. The Quick Cure Primer counteracts the effects of the Volatile Corrosion Inhibitor (VCI) paper that was used to package the parts.

9. Assemble 180-7952 Lever Bushing (7) on 9X-8907 Hexagon Button Screw (9). Refer to Illustration 13.

10. Apply the 154-9731 Thread Lock Compound on the threads of 9X-8907 Hexagon Button Screw (9) and 8L-5832 Hex Nut (8) .

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Illustration 14	g00655322

11. Place 8L-5832 Hex Nut (8) on 9X-8907 Hexagon Button Screw (9). Tighten 8L-5832 Hex Nut (8) until hex nut (8) is snug. Tighten 8L-5832 Hex Nut (8) for an additional 180 degrees.

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NOTICE
Do not let metal chips or pieces of the rivet fall into the engine.

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Illustration 15	g00655325

12. Clean the fuel injection control linkage and clean the surfaces of the cylinder head that are adjacent to the fuel injection control linkage with shop solvent. Remove the towels and remove all debris very carefully.

13. Install the 180-7956 Clamp Assembly Kit . Refer to the "Installation Of The 180-7956 Clamp Assembly Kit " section of this publication.

Installation Of The 180-7956 Clamp Assembly Kit

Note: The 180-7956 Clamp Assembly Kit is used for the former control linkages only.

Note: If the 180-7956 Clamp Assembly Kit is installed, refer to ""Modification of the 128-9640 Injector Synchronization Fixture " ".

The 180-7956 Clamp Assembly Kit may be installed on the fuel injection control linkage. The 180-7956 Clamp Assembly Kit will increase the strength of the joint.

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Illustration 16	g00655326

1. Install 183-9390 Spacer (10) on fuel injection control linkage (4). Refer to Illustration 16.

2. Apply 169-5464 Quick Cure Primer to the threaded hole in the 180-7954 Clamp (11). Apply 169-5464 Quick Cure Primer to the threads of screw (13). Allow the primer to dry. The Quick Cure Primer counteracts the effects of the Volatile Corrosion Inhibitor (VCI) paper that was used to package the parts.

3. Apply 154-9731 Thread Lock Compound to the threaded hole in the 180-7954 Clamp (11). Apply 154-9731 Thread Lock Compound to the threads of screw (13) of clamp assembly. Loosely assemble 180-7954 Clamp (11) and 180-7987 Clamp (12) on fuel injection control linkage (4). Refer to Illustration 16. Be sure that the rivet head or bushing (14) is fully engaged into the counterbore of the clamp assembly.

   Note: If necessary, use a screwdriver in order to rotate the linkage.

4. Position the rivet head or the bushing completely into the counterbore of the clamp assembly. Be sure that spacer (10) is held tight between the clamp assembly and the fuel injection control linkage (4). Hold the clamp assembly against spacer (10). Tighten screw (13) on the clamp assembly until screw (13) is snug. Tighten screw (13) for an additional 240 degrees (2/3 turn).

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Illustration 17	g00655329

5. Gently push the power setting lever to open. Verify free movement of the power setting lever.

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Illustration 18	g00655331

6. Move the linkage rod toward the cylinder head with the linkage in the shutoff position. The clamp assembly must not contact the cylinder head. Remove the clamp assembly and grind the clamp assembly in order to provide clearance, if necessary.

7. Install the injector for cylinder number 1. Install the number 1 rocker arm assembly. Install the lockwire and install the dealer's seal on the fuel setting cover. Assemble the remainder of the engine. Refer to the Disassembly and Assembly Service Manual Module for your engine.

Modification of the 128-9640 Injector Synchronization Fixture

Note: The 128-9640 Injector Synchronization Fixture is included in the 128-8822 Fuel System and Governor Tool Group .

Note: If the 180-7956 Clamp is installed, the 128-9640 Injector Synchronization Fixture may need to be modified when the synchronization procedure is performed. The synchronization procedure is NOT necessary after performing the inspection and the modification of the fuel injection control linkage.

Illustration 19	g00702107
128-9640 Injector Synchronization Fixture

The 180-7956 Clamp may interfere with the 128-9640 Injector Synchronization Fixture Group during the synchronization procedure. The step in the tool must be lengthened by 6.5 mm (0.25 inch). This will leave 21 mm (0.83 inch) of the wide area at the rear of the base plate. The ends are now symmetrical. Refer to Illustration 19.