3054B Industrial Engine Caterpillar

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NOTICE
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates.

Tests For The Air Inlet Heater

Illustration 1	g00659338
Right side of the engine (1) Air inlet heater (2) Fuel supply line (3) Fuel transfer pump

Illustration 2	g00538494
(4) Electrical connection (5) Fuel inlet (6) Ball valve (7) Valve holder (8) Wire coil (9) Ignition coil

The air inlet heater (1) is located in the air inlet manifold on the right side of the engine.

Basic Operation

The air inlet heater frequently appears to leak because the ignition coil (9) is wet. The air inlet heater may be wet because the diesel fuel does not burn completely. This condition is normal. This condition does not indicate that the ball valve (6) has fuel leakage. If a leak is suspected, perform the leakage test.

Check the heater operation by determining if the inlet manifold is warm to the touch near the heater after approximately 10 seconds of operation. The inlet manifold should be warm.

Inspect the fuel tank and the fuel supply line (2) to the air inlet heater for restrictions and leakage of fuel.

Check the fuel shutoff valve for correct operation. A poor seal on the fuel shutoff valve can cause air to enter the system which will cause extra cranking of the engine before starting. Be sure that all fuel connections are not leaking air.

Make sure that the battery condition and the battery charge are satisfactory. Make sure that all electrical connections are tight. The electrical system can have reduced voltage if the following conditions exist:

• A discharged battery

• A loose connection

Reduced voltage may cause slow cranking of the electric starting motor and failure of the heater unit to be activated.

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NOTICE
If operated for a long period of time, The air inlet heater can create excessive heat. Excessive heat can damage the air inlet heater.

Leak Test For The Air Inlet Heater On The Engine

Use the following procedure to test for a leak in the air inlet heater.

1. Disconnect the fuel supply line (2) and the electrical connection on the air inlet heater. Be sure that the electrical connector is insulated from contact with metal engine components. Remove the air inlet heater from the manifold. Place a suitable plug in the manifold to prevent debris from entering the air inlet manifold.

2. Connect the fuel supply line to the air inlet heater. Loosely tighten the connection fitting. Operate the priming lever of the fuel transfer pump until only fuel which is free of air flows from the connection. Tighten the connection fitting.
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   Work carefully around an engine that is running. Engine parts that are hot, or parts that are moving, can cause personal injury.

3. Start the engine and operate the engine at low speed. Check that there is no fuel leakage from the valve of the air inlet heater.

4. If leakage exists, the air inlet heater must be replaced. If no fuel leakage occurs, remove the plug from the inlet manifold and disconnect the fuel supply line from the air inlet heater. Install the air inlet heater in the air inlet manifold. Connect the fuel supply line to the heater. Operate the priming lever of the fuel transfer pump until only fuel which is free of air flows from the connection. Connect the electrical wire connector.

Leak Test For The Air Inlet Heater Off The Engine

Use this test to test for leakage of fuel in the air inlet heater if a pressurized air supply is available.

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NOTICE
The air inlet heater may be damaged if more than 140 kPa (20 psi) of air pressure is used.

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Pressurized air can cause personal injury. When pressurized air is used for cleaning, wear a protective face shield, protective clothing, and protective shoes.

1. Remove the air inlet heater from the inlet manifold. Connect an air supply to the fuel inlet passage. The maximum pressure of the air supply should be 140 kPa (20 psi).

2. Put the air inlet heater in a container of clean diesel fuel for 10 seconds. No air bubbles should be visible from the air inlet heater. If the air inlet heater is not faulty, remove the fuel from the air inlet heater. Reinstall the air inlet heater in the air inlet manifold. If leakage of air occurs, install a new air inlet heater.

Electrical Test

Table 1

Required Tools
Part Number	Part Name	Qty
5P-7277	Voltage Tester	1
8T-0900	Ammeter	1

Conduct this test to determine if sufficient electrical current is provided to the air inlet heater for proper operation.

1. Disconnect the electrical wire from the air inlet heater.

2. Connect the clamp lead of a 5P-7277 Voltage Tester to a good ground connection.

3. Connect the probe end of the tester to the disconnected electrical wire.

4. The light of the tester turns on to indicate that electrical continuity to the air inlet heater exists.

5. Connect a 8T-0900 Ammeter between the electrical supply and the air inlet heater. Turn the ignition switch to the ON position. Activate the switch for the air inlet heater. The normal current is 16 to 18 amperes at 12 volts.

Note: A cold engine should start after the heater coil has operated for 20 seconds. If the engine does not start but the air inlet heater and the area of the inlet manifold around the air inlet heater are warm:The starting procedure has not been done correctly.orThe problem is not caused by the air inlet heater.

Pressure Test For The Fuel Transfer Pump

The fuel transfer pump is on the right side of the engine.

The pressure test measures the output pressure of the fuel transfer pump. Low fuel pressure and starting difficulty may be indications of problems with the fuel transfer pump.

1. Put a pressure gauge in the outlet of the fuel transfer pump.

2. Disconnect the fuel injection pump solenoid wire (if equipped). Put the fuel shutoff lever in the fuel shutoff position.

3. Crank the engine for 10 seconds. Record the maximum pressure. The pressure indication on the gauge should be in the following ranges:

   Maximum pressure ... 42 to 70 kPa (6 to 10 psi)

   Minimum pressure ... 30 kPa (4.4 psi)

4. Observe the amount of time for the maximum pressure that was recorded during cranking to decrease by one-half. If the time is less than 30 seconds, the fuel transfer pump must be replaced or repaired.
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   Illustration 3	g00659526
   (1) Strainer (2) Seal (3) Cover

5. If the pressure is less than the minimum pressure, the fuel transfer pump must be repaired or replaced. Refer to the Disassembly and Assembly, "Fuel Transfer Pump - Remove" for more information.

   If the pressure is low, remove cover (3) and seal (2). Inspect strainer (1) for debris.

   Clean the cover, the seal, and the strainer with a nonflammable solvent. Carefully wash any debris from the chamber of the pump.

6. Assemble the fuel transfer pump. Ensure that the cover of the fuel transfer pump is secure so that air cannot enter the system.

   Remove air from the fuel transfer pump. Refer to "Remove Air From The Fuel System" in this module.

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   Illustration 4	g00508433
   Inspect the components of the fuel transfer pump. (4) Pivot pin (5) Link arm (6) Rocker lever

7. Measure the fuel pressure again. If the pressure remains low, remove the pump from the engine. Inspect the installation of the pivot pin in the rocker lever and the link arm.

   If the pivot pin (4) fits loosely in the rocker lever (5) and link arm (6), replace the fuel transfer pump. If the pivot pin, the rocker lever, or the link arm are damaged, replace the fuel transfer pump.

8. Install the fuel transfer pump on the cylinder block. Clean the threads of the bolts or the studs and nuts. Apply 4C-4030 Thread Lock Compound to the first three threads of the bolts or studs. Refer to Specifications, "Fuel Transfer Pump" for the torque for tightening the bolts or the nuts and studs.

Setting The Top Center Compression Position For No. 1 Piston

Set The Top Center Position By Reverse Pin Timing

Table 2

Required Tools
Part Number	Part Name	Qty
150-3993	Timing Pin(1)	1

(1)	150-3993 Timing Pin is for (Lucas and Stanadyne) fuel injection pumps.

The timing position that was set at the factory is used to set the engine at the top center on the No. 1 cylinder of the compression stroke before the fuel injection pump is removed.

Illustration 5	g00309804
Fuel injection pump with timing pin (typical example) (1) Timing pin (3) Hub nut (4) Hole in the pump body (6) Hub slot

Illustration 6	g00309806
Timing gear and hub of the fuel injection pump (Lucas and Stanadyne) (1) Timing pin (2) Torx screws (3) Hub nut (4) Hole in the pump body (5) Slot for the timing gear (6) Hub slot

Note: Do not remove the hub nut (3) from the shaft of the fuel injection pump. The hub of the fuel injection pump is installed on the shaft of the pump in the factory to ensure that the fuel injection pump is in the correct position for timing. If the hub is removed, the hub will need to be accurately installed to the shaft of the pump by the use of special equipment. Refer to your Caterpillar Dealer for repairs to the fuel injection pump.

Note: Do not loosen the torx screws (2). If the torx screws are loosened and the timing plate is moved, the timing position that is set at the factory will be lost. If the torx screws are loosened, the engine must be set to top center of the No. 1 engine cylinder on the compression stroke before the torx screws are tightened.

1. Remove the water pump.

2. Rotate the crankshaft in a clockwise direction until the inlet valve on the No. 1 cylinder closes. Slowly rotate the crankshaft until the slot for the timing gear (5) and the hub slot (6) are aligned with the hole in the pump body (4).

   Note: The position of the slot for the timing gear, the hub slot, and the hole in the pump body is on the bottom of the fuel injection pump. The slot is for inserting the timing pin. The position of the slot is for the Lucas fuel injection pump and the Stanadyne fuel injection pump.

3. Insert the timing pin (1) through the timing gear and the hub slot. When the pin is inserted all the way, the engine is at the top center of the No. 1 cylinder on the compression stroke. No resistance should be felt when the timing pin is inserted into the hole of the pump body (4). The pin should be inserted all the way into the hole of the pump body.

Illustration 7	g06273572
Engine timing gears (1) Timing gear for the fuel injection pump (2) Timing gear for the camshaft (3) Timing gear for the crankshaft

Note: Damage to the timing case can occur if the following event occurs: the crankshaft (3) is rotated when the fuel injection pump is removed from the engine. If the crankshaft needs to be rotated, the fuel injection pump must be installed and the fasteners for the gears must be tightened.

Note: Perform the following functions after the fuel injection pump has been removed and the crankshaft has been rotated: Remove the timing case cover. and The timing marks on the face of the timing gears must be aligned. Aligning the timing marks of all the timing gears will approximately set the top center of the No. 1 cylinder on the compression stroke. Then, the timing pin can be inserted.

Set The Top Center Position By The Alternate Method

Table 3

Required Tools
Part Number	Part Name	Qty
150-3993	Timing Pin(1)	1

(1)	150-3993 Timing Pin is for (Lucas and Stanadyne) fuel injection pumps.

Illustration 8	g00309726
Setting top center compression position (1) Temporary pointer (2) Dial indicator

1. Fasten a temporary pointer (1) to the front cover. Put the tip of the pointer close to the edge of the damper on the crankshaft or close to the edge of the pulley.

2. Remove the valve mechanism cover.

3. Rotate the crankshaft clockwise when you face the front of the engine. Rotate the crankshaft until the pushrod for the inlet valve of the rear cylinder begins to tighten.

   Note: Be careful when you rotate the crankshaft. The No. 1 inlet valve will be held in position on top of the piston. If the crankshaft is not positioned properly, the valve may fall from the cylinder head.

4. Rotate the crankshaft further by 1/4 of a turn in a clockwise direction. Insert a suitable lever between the rocker arm and the valve spring cap of the No. 1 inlet valve. Open the inlet valve. Put a spacer that is approximately 5 mm (0.2 inch) thick between the valve stem and the rocker arm.

5. Slowly rotate the crankshaft in a counterclockwise direction until the piston contacts the open valve. Make a temporary mark on the damper or the pulley to align accurately with the tip of the pointer.

6. Rotate the crankshaft in a clockwise direction by one or 2.0 degrees. Remove the spacer that is between the valve stem and the rocker arm. Rotate the crankshaft by 1/4 of a turn in a counterclockwise direction. Put a spacer that is approximately 5 mm (0.2 inch) thick between the valve stem and the rocker arm.

7. Slowly rotate the crankshaft clockwise until the piston contacts the open valve. Make another temporary mark on the damper or the pulley to align accurately with the tip of the pointer.

8. Make a temporary mark at the center point between the two marks on the damper or the pulley. Remove the other two marks. Rotate the crankshaft by 1/8 of a turn in a counterclockwise direction. Remove the spacer between the valve stem and the rocker arm.

9. Slowly rotate the crankshaft in a clockwise direction until the mark on the damper or the pulley, which was made in Step 8, aligns with the tip of the pointer. The No. 1 piston is now at the top center on the compression stroke.

Timing Of The Fuel Injection Pump

Note: Repairs to the fuel injection pump must be performed through an authorized Caterpillar Dealer.

Table 4

Required Tools
Part Number	Part Name	Qty
150-3993	Timing Pin(1)	1

(1)	150-3993 Timing Pin is for (Lucas and Stanadyne) fuel injection pumps.

Illustration 9	g00309806
Timing gear and hub of the fuel injection pump (Lucas and Stanadyne) (1) Timing pin (2) Torx screws (3) Hub nut (4) Hole in pump body (5) Slot for timing gear (6) Slot for hub

This procedure can only be used when the engine is set to the top center position on number one cylinder on the compression stroke. Refer to illustration 7.

Note: Do not remove the hub nut (3) from the shaft of the fuel injection pump. The hub of the fuel injection pump is installed on the shaft of the pump in the factory to ensure that the fuel injection pump is in the correct position for timing. If the hub is removed, the hub will need to be accurately installed to the shaft of the pump by the use of special equipment. Refer to your Caterpillar Dealer for repairs to the fuel injection pump.

Note: Do not loosen the torx screws (2). If the torx screws are loosened and the timing plate is moved, the timing position that is set at the factory will be lost. If the timing position is lost, the engine must be set to the top center position on the No. 1 cylinder on the compression stroke before the torx screws are tightened.

1. Set the piston of number one cylinder on the compression stroke.

2. Remove the water pump.

3. Insert the timing pin (1) through the slot for the timing gear (5). Continue to insert the timing pin through the slot for the hub (6). Push the pin all the way into the hole of the pump body (4). If the pin can be inserted all the way, the pump timing is correct. Resistance should not occur until the pin is inserted all the way into the hole of the pump body.

4. Remove the timing pin.

5. If the timing pin cannot be inserted all the way into the hole of the pump body, perform the following function:

   • Ensure that the engine is correctly set at the top center position of the number one cylinder on the compression stroke.

6. The fuel injection pump must be set by an authorized technician when the following conditions exist:

   Note: Refer to your Caterpillar Dealer for timing adjustment of the fuel injection pump.

   • The engine is set correctly at the top center.

   • The pin cannot be easily inserted.

   • The pin cannot be inserted all the way into the hole of the pump body.

   Refer to Disassembly And Assembly, "Fuel Injection Pump" for removal and installation procedures.

Remove Air From The Fuel System

If air enters the fuel system, the air must be purged before the engine can be started. Air can enter the system when the following events occur:

• The fuel tank is empty or the tank has been partially drained.

• The low-pressure fuel lines are disconnected.

• A leak exists in the low-pressure fuel system.

• The fuel filter is replaced.

Use the following procedure to remove air from the fuel system:

1. Fuel filter and venting the fuel filter
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   Illustration 10	g00310885
   Fuel filter and fuel filter base (Lucas Fuel Systems) (1) Vent plug (2) Fuel filter and fuel filter base

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   Illustration 11	g00310703
   (3) Fuel transfer pump

   1. Lucas fuel systems

      Loosen the vent plug (1) on top of the fuel filter and filter bases. Operate the priming lever on the bottom of the fuel transfer pump (3) until fuel, which is free of air, flows from the vent plug. Tighten the vent plug.

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      Illustration 12	g00310963
      Fuel filter and filter assemblies (Stanadyne Fuel System) (1) Vent plug for the fuel filter (if equipped) (2) Vent plug for the fuel filter

   2. Stanadyne fuel system

      Loosen the vent plug (1) on top of the fuel filter base. Operate the priming lever on the bottom of the fuel transfer pump (3) until fuel, which is free of air, flows from the vent plug. Tighten the vent plug.

      Loosen the vent plug (2) on top of the fuel filter. Operate the priming lever on the bottom of the fuel transfer pump (3) until fuel, which is free of air, flows from the vent plug. Tighten the vent plug.

      Note: If the drive cam of the fuel transfer pump is in the position of maximum cam lift, the priming lever will not operate. The crankshaft must be rotated one revolution.

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   Illustration 13	g00311106
   (4) Nut for the fuel line to the air inlet heater

2. If the fuel line for the air inlet heater has been drained, loosen the fuel line nut (4) at the air inlet heater. Operate the priming lever on the bottom of the fuel transfer pump (3) until fuel, which is free of air, flows from the fuel line. Tighten the fuel line nut (4) to a torque of 22 N·m (16 lb ft).
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   Illustration 14	g00311183
   (5) Nuts for the fuel line to the fuel injection nozzles

3. Loosen the connections for the high-pressure fuel lines on two fuel injection nozzles. Operate the starting motor until fuel, which is free of air, flows from the fuel line. Tighten the fuel line nuts (5) to a torque of 22 N·m (16 lb ft).

   Note: Damage to the fuel injection pump, the battery, and the starter motor can occur if the starter motor is used excessively.

4. The engine is now ready to start. If the engine stops or if the engine runs roughly, check for air in the fuel system. If air is in the fuel system, leakage in the low-pressure fuel system probably exists.

   Note: Operate the engine at low idle for a minimum of 5 minutes immediately after air has been removed from the fuel system. Running the engine for this time will help ensure that the pump is free of air. Damage to the internal parts of the pump which is caused by metal to metal contact will be prevented.

Adjustment Of Low Idle And High Idle

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Illustration 15	g00311324
Lucas Fuel Injection Pump (1) Low idle adjustment screw (2) High idle adjustment screw

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Illustration 16	g00311363
Stanadyne Fuel Injection Pump (1) Low idle adjustment screw (2) High idle adjustment screw

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Work carefully around an engine that is running. Engine parts that are hot, or parts that are moving, can cause personal injury.

1. Low Idle Adjustment

   Run the engine until the normal operating temperature is reached. Check the rpm at low idle . Use the adjustment screw (1) to adjust the low idle. Loosen the locknut and turn the screw clockwise to increase the rpm. Turn the adjustment screw counterclockwise to decrease the rpm.

   Note: Refer to your Caterpillar Dealer for the correct rpm for low idle.

2. High Idle Adjustment

   The high idle has been preset at the factory. Tamper proof adjustment screws have been installed on the high idle adjustment. The setting of the high idle of these engines should not be adjusted. Adjusting the high idle setting can void the fuel injection pump warranty, engine warranty, and emissions standards. A seal is installed on the high idle screw (2) to help prevent tampering. Adjustment of the high idle should be made only by personnel that have the correct training.

   Run the engine until normal operating temperature is reached. Check the maximum high idle. High idle must be checked under conditions with no load on the engine.

Fuel Injection Nozzle Tests

Table 5

Required Tools
Part Number	Part Name	Qty
5P-4150	Nozzle Testing Group	1
5P-7448	Adapter	1
6V-2170	Tube	1
8S-2270	Fuel Collector	1
1U-8857	Extension Tube	1
6V-6068	Calibration Fluid	1

Illustration 17	g00293085
(1) Connection for the nut (not shown) of the fuel supply line (2) Threaded hole for the banjo bolt of the fuel return line (3) Nut of the fuel injection nozzle (4) Wire clip (5) Seat washer

Illustration 18	g00313043
Fuel injection nozzles and lines (1) Nut for the fuel supply line (2) Banjo bolt (6) Fuel supply line (7) Fuel return line

1. Run the engine at low idle.

2. Loosen the nut for the fuel supply line (1) at each fuel injection nozzle. Listen for the low idle to decrease or listen for the low idle to become rough at each engine cylinder.

3. The fuel injection nozzle is faulty when the fuel supply line (1) is loosened and the following events occur:

   • The engine rpm does not decrease.

   • The engine does not idle roughly.

   Remove the fuel injection nozzle for more testing.

   Note: If leakage occurs at the nut for the fuel supply line (1), make sure that the fuel supply line (6) and the nut for the fuel supply line (1) are correctly aligned with the inlet connection of the fuel injection nozzle (1). Do not tighten the nut for the fuel supply line (1) on the high-pressure fuel line more than the recommended torque. If the nut is tightened more, the fuel line may become restricted or the threads of the fuel injection nozzle and the nut may be damaged.

Cleaning of Fuel Injection Nozzles

Before a fuel injection nozzle is tested, remove any loose carbon from the tip of the fuel injection nozzle. Do not use abrasive material or a wire brush to clean the nozzle.

The fuel injection nozzle is not a serviceable part. Disassembling or adjusting the nozzle will violate the standards for emissions.

Note: Extra care should be used in handling the fuel injection nozzle to prevent damage to the nozzle tip. A scratch or a burr could cause needle leakage. A scratch or a burr can also cause spray distortion. Keep the nozzle tip clean. Dirt in the orifices can damage engine components. Dirt in the orifices can also cause spray distortion.

Perform the following procedures to determine if a fuel injection nozzle does not work correctly.

Pressure Test

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Ensure that you wear eye protection at all times during testing. When fuel injection nozzles are tested, test fluids travel through the orifices of the nozzle tip with high pressure. Under this amount of pressure, the test fluid can pierce the skin and cause serious injury to the operator. Always keep the tip of the fuel injection nozzle pointed away from the operator and into the fuel collector and extension.

Illustration 19	g00322849
5P-4150 Nozzle Testing Group (8) 5P-7448 Adapter (9) Fuel injection nozzle (10) 6V-2170 Tube (11) 1U-8857 Extension Tube (12) 8S-2270 Fuel Collector (13) 8T-5313 Filter

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NOTICE
Do not use dirty test fluids when you test fuel injection nozzles. Also, do not test fuel injection nozzles unless you have the correct service tools.The use of dirty test fluids and the use of incorrect service tools will result in damage to fuel injection nozzles.

1. Connect the fuel injection nozzle (9) to the tooling that is shown in Illustration 19.

   The spray from the fuel injection nozzle must be directed into the 1U-8857 Extension Tube (11) and the 8S-2270 Fuel Collector (12).

   Refer to the table in the Specifications Module, "Fuel Injection Nozzles" for the correct pressure settings. If the opening pressure is not within the range of the setting which is specified in the table, the fuel injection nozzle must be replaced.

   Use clean 6V-6068 Calibration Fluid when the fuel injection nozzles are tested. The calibration fluid is equivalent to SAE J-967 (ISO 4113) oil.

2. Close the gauge protector valve. Close the shutoff valve. Open the pump isolator valve. To flush the fuel injection nozzle, operate the nozzle tester for 10 to 15 strokes at a rate of approximately 60 strokes per minute.

3. Open the gauge protector valve. Slowly increase the pressure until the valve in the fuel injection nozzle opens. Note the highest pressure indication on the dial indicator before the pointer moves to 0 kPa (0 psi). This highest pressure indication is the opening pressure of the fuel injection nozzle. The opening pressure is defined when the needle valve is lifted from the valve seat.

   Refer to the table in the Specifications Module, "Fuel Injection Nozzles" for correct pressure settings. If the opening pressure is not within the range of the setting that is specified in the table, the fuel injection nozzle must be replaced.

Back Leakage Test

1. Connect the fuel injection nozzle (9) to the tooling. Refer to Illustration 19 for more information.

   Position the fuel injection nozzle so that the direction of the fuel spray is into the 1U-8857 Extension Tube (11) and the 8S-2270 Fuel Collector (12).

2. Pump the pressure to about 1030 kPa (150 psi) below the opening pressure of the fuel injection nozzle. Refer to the Specifications Module, "Fuel Injection Nozzles" for the correct setting of the opening pressure. Release the handle. When the pressure begins to decrease, note the time that is required for the pressure to decrease to approximately 0 kPa (0 psi). If the fuel injection nozzle is not faulty, the time will not be less than 5 seconds or more than 45 seconds.

   If the time that is required for the pressure to decrease to 0 kPa (0 psi) is less than 5 seconds, too much fuel is leaking around the valve needle. Replace the fuel injection nozzle.

3. Look for any leakage from the pressure faces of the holder and the retaining nut of the fuel injection nozzle. If leakage is visible, make sure that the components are tightened to the correct torque.

   If leakage continues to occur, unscrew the retaining nut from the body. Inspect the threaded surfaces for foreign particles and damage. If the faces are clean and undamaged, test the fuel injection nozzle. Repeat Steps 1 and 2.

Fuel Injector Nozzle and Seat Test

1. Connect the fuel injection nozzle (9) to the tooling. Refer to Illustration 19 for more information.

   Position the fuel injection nozzle so that the direction of the fuel spray is into the 1U-8857 Extension Tube (11) and the 8S-2270 Fuel Collector (12).

2. Pump the pressure of the nozzle tester to approximately 1030 kPa (150 psi) below the opening pressure of the fuel injection nozzle. Fuel should not collect on the tip of the fuel injection nozzle in a sufficient quantity to drip from the tip for at least 10 seconds. Light dampness is acceptable.

   If the results of the tests are not acceptable, replace the fuel injection nozzle.

Test The Spray Pattern

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Ensure that you wear eye protection at all times during testing. When fuel injection nozzles are tested, test fluids travel through the orifices of the nozzle tip with high pressure. Under this amount of pressure, the test fluid can pierce the skin and cause serious injury to the operator. Always keep the tip of the fuel injection nozzle pointed away from the operator and into the fuel collector and extension.

The pressure adjustment must be correct before the spray pattern is tested.

Illustration 20	g00322083
Correct spray pattern for fuel injection nozzles

1. Connect the fuel injection nozzle (9) to the tooling. Refer to Illustration 19 for more information.

   Position the fuel injection nozzle so that direction of the fuel spray is into the 1U-8857 Extension Tube (11) and 8S-2270 Fuel Collector (12).

2. Close the gauge protector valve and the shutoff valve. Open the pump isolator valve.

3. Quickly pump the nozzle tester and look at the spray pattern when the fluid begins to flow through the orifices of the fuel injection nozzle.

   The spray, which flows from all the orifices, must have the same pattern. Refer to the correct spray pattern in Illustration 20. Any vertical change or any horizontal change from the correct spray pattern indicates a faulty fuel injection nozzle.

   Note: Be sure that the gauge protector valve is closed before the fuel injection nozzle is removed from the nozzle tester. Closing the valve will prevent damage to the pressure gauge.

Installation of Fuel Injection Nozzles

1. When a fuel injection nozzle is removed from the cylinder head, replace the seat washer (5). Refer to Illustration 17 for more information.

   Note: If a seat washer remains in the recess of the cylinder head for the fuel injection nozzle, the protrusion of the fuel injection nozzle into the engine cylinder will be incorrect. Also, if the seat washer is damaged, the protrusion of the fuel injection nozzle into the engine cylinder will be incorrect.

2. Place a 2 mm (0.1 inch) bead of 4C-5591 Anti-Seize Compound on the first two threads of the fuel injection nozzle below the nut (3). Refer to Illustration 17 for more information.

   Note: Do not rotate the fuel injection nozzle after the fuel injection nozzle has been tightened to the specified torque. Rotating the fuel injection nozzle will cause a broken seal of the anti-seize compound between the threads. A seal which is broken may allow leakage of combustion gas through the threads.

Cold Start Advance Unit

Some of the Lucas, Bosch, and Stanadyne fuel injection pumps have a cold start advance unit. The cold start advance unit holds the timing of the fuel injection pump in an advanced position when the engine is cold.

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NOTICE
It is important that the electrical connections to the sender unit are connected correctly. If the cold start advance unit fails to operate correctly, engine damage may result because the engine timing will be fully advanced for normal engine operation.

The cold start advance unit is on the rear of the timing case on the left side of the engine.

The cold start advance units on the Lucas and the Bosch fuel injection pumps operate in a similar manner. As the engine begins to reach normal operating temperature, the cold start advance unit energizes. By energizing, the fuel injection pump timing is retarded to the correct timing for normal operation.

The cold start advance unit on the Stanadyne fuel injection pump operates differently. As the engine begins to reach normal operating temperature, the cold start advance unit will de-energize. By de-energizing, the fuel injection pump timing is retarded to the correct timing for normal operation.

Serviceable replacement parts are available for the cold start advance units on Stanadyne fuel injection pumps. These replaceable parts allow the cold start advance unit to be repaired without removing the fuel injection pump from the engine. Refer to your Caterpillar Dealer for information of the fuel injection pumps with this advantage.

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NOTICE
Damage to the engine will occur if the engine is load tested at more than 80 percent of full load with the cold start advance unit disconnected.

Illustration 21	g00523697
Lucas DP200 fuel injection pump (1) Engine stop solenoid (2) 3 Amp wire (3) Sending unit (4) 3 Amp wire (5) 6 Amp wire (6) Fuel injection pump (7) Cold start advance unit (8) Start switch

Illustration 22	g00523698
Bosch fuel injection pump (1) Fuel injection pump (2) 3 Amp wire (3) Engine stop solenoid (4) Sending unit (5) 3 Amp wire (6) Cold start advance unit (7) 6 Amp wire (8) Start switch

Illustration 23	g00523699
Stanadyne fuel injection pump (1) Engine stop solenoid (2) 3 Amp wire (3) 6 Amp wire (4) Fuel injection pump (5) Cold start advance unit (6) 3 Amp wire (7) Sending unit (8) Start switch