When noticeable smoke rises from the exhaust, this problem can be caused by a defective fuel injection valve. However, this unusual smoke can also be caused by one or more of the following reasons:
- Not enough air for good combustion
- An overload at high altitude
- Oil leakage into combustion chamber
- Not enough compression
- Incorrect fuel injection timing
Fuel System Inspection
A problem with the components that send fuel to the engine can cause low fuel pressure. This can decrease engine performance. To inspect the fuel system, follow this procedure:
- Check the fuel level in the fuel tank. Inspect the fuel tank cap. Make sure that the vent is not filled with dirt.
- Check the fuel lines for fuel leakage. Make sure that none of the fuel lines have a restriction or a defective bend.
- Install a new fuel filter. Clean the primary fuel filter.
- Remove any air that may be in the fuel system.
If there is air in the fuel system, use the priming pump to move fuel through the low pressure part of the system. Fuel that contains air will return to the tank through the fuel return line.
When you are removing the air from the fuel injection lines, use the following procedure:
- Loosen the fuel line nuts at the fuel injector nozzle by 1/2 turn.
- Crank the engine with the starting motor until fuel without air flows from the fuel line connections.
- Tighten the fuel line nuts.
Note: The fuel priming pump will not provide enough pressure for pushing fuel through the orificed reverse flow check valves in the fuel injection pumps.
Fuel Transfer Pump
When the engine is operating at full load speed, the fuel transfer pump moves fuel through the secondary filter and the fuel injection pump housing at approximately 240 kPa (35 psi).
To check the fuel transfer pump pressure, disconnect the fuel line from the filter at the fuel injection pump housing inlet. Install a tee at the inlet and connect the fuel line to the tee. Connect a pressure gauge to the tee and start the engine.
Minimum fuel pressure must be 70 kPa (10 psi) of pressure at low idle. Minimum fuel pressure must be 170 kPa (25 psi) at full load speed with the engine under full load.
If the fuel pressure is not above the minimum specifications, stop the engine. Replace the primary fuel filter and the secondary fuel filter. Check the fuel lines and the hoses for damage or plugging.
Start the engine and again check the fuel pressure. If the fuel pressure is not above the minimum specification, a repair or replacement of the fuel transfer pump is needed.
Checking Engine Cylinders Separately
If any of the following conditions occur, check the individual engine cylinders:
- The engine runs rough.
- The engine misfires.
- The exhaust system blows out black smoke.
Use this procedure to check the engine cylinders separately:
- Run the engine at the roughest speed.
- Loosen the fuel line nut at a fuel injection pump. This will stop the flow of fuel to that engine cylinder.
After shutting off the fuel to the cylinder, the engine's performance should be rougher.
| NOTICE |
|---|
The fuel injection nozzles can be permanently damaged by twisting if only one wrench is used to loosen or tighten the fuel line nuts. Use one wrench to hold the nozzle and another to loosen the nut. |
- Tighten the fuel line nut.
- Repeat Step 1 through Step 3 with each engine cylinder in sequence until you discover a loosened fuel line that does NOT affect the engine's performance.
- When you find the engine cylinder that does NOT affect the engine's performance, perform the following operations:
- Test the fuel injection pump for that cylinder.
- Test the fuel injection nozzle.
When an engine runs at low idle rpm, the temperature of an exhaust manifold can indicate the condition of a fuel injection nozzle. A low temperature indicates that no fuel is reaching the cylinder. This can possibly signify that the fuel injection nozzle has a defect.
When an engine runs at low idle rpm and the temperature of an exhaust manifold is at an extra high temperature, too much fuel is probably flowing into the engine cylinder. This can also signify that the fuel injection nozzle has a defect.
The most common defects on fuel injection nozzles include the following defects:
- Plugging or blocking by carbon on the tip of an fuel injector nozzle
- Orifice wear due to abrasive particles in the fuel
- Wear from a wire brush on the nozzle's tip
Testing Fuel Injector Nozzles
| Required Tools | ||
| Part Number | Part Name | Qty |
| 5P-4150 | Nozzle Tester Group | 1 |
| 5P-4244 | Adapter | 1 |
| 8S-2270 | Fuel Collector | 1 |
| FT-1384 | Extension | 1 |
| 8S-2245 | Injector Cleaning Tool Group | 1 |
| 8S-2258 | Brass Wire Brush | 1 |
| 6V-4979 | Carbon Seal Installation Tool | 1 |
| 6V-6194 | Needle Nose Pliers | 1 |
| 6V-4980 | Torque Driver | 1 |
| FT-1743 | Line Assembly | 1 |
| 6V-6088 or 6V-6087 |
Calibration Fluid 19 L (5.0 US gal) or Calibration Fluid 208 L (55.0 US gal) |
1 |
Note: Refer to Special Instruction, SEHS7292, "Using the 5P-4150 Nozzle Testing Group " for more information.
 | |
| Illustration 1 | g00557100 |
5P-4150 Nozzle Testing Group (1) Nozzle assembly (A) FT-1743 (B) 5P-4244 (C) 5P-4721 (D) 8T-0859 Pressure Gauge (E) 8T-0856 Pressure Gauge (F) Gauge protector valve for 8T-0859 Pressure Gauge (G) FT-1384 Fuel Collector Extension and 8S-2270 Fuel Collector (H) Gauge protector valve for 8T-0856 Pressure Gauge (J) Gauge protector valve | |
 | |
| Illustration 2 | g00551190 |
5P-4150 Nozzle Testing Group (F) Gauge protector valve for 8T-0859 Pressure Gauge (K) Pump isolator valve (L) On/Off valve | |
| 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. |
| NOTICE |
|---|
Caterpillar recommends the use of Calibration Fluid (SAE J967) for testing the fuel injection nozzles. The temperature of the test fluid needs to be from 18° to 24°C (64° to 75°F). |
Note: It is necessary to have an accurate record of the test results for each nozzle that is tested. Make a record of the result for each nozzle test procedure on Form, SEHS8144, "Nozzle Test Record". These test sheets are available in a pad of 50 sheets.
Note: Refer to Special Instruction, SEHS9083, "Test Sequence For Caterpillar 7000 Series Fuel Nozzles".
Do not disassemble the fuel injection nozzle for cleaning or for adjustment. Use the following tests to determine if the nozzle's performance is acceptable:
- "Valve Opening Pressure Test"
- "Flush the Nozzle"
- "Tip Leakage Test"
- "Orifice Restriction Test"
- "Leakage Test for Air Purge Screw"
Performance Tests for the Fuel System
Preparing the Fuel Injector Nozzle for Testing
Note: Refer to Special Instruction, SEHS8627 for the instructions for cleaning the nozzles.
 | |
| Illustration 3 | g00557190 |
8S-2245 Cleaning Kit (1) 8S-2258 Cleaning Brush (2) 6V-4979 Carbon Seal Installation Tool (3) 8S-2250 Holding Tool | |
 | |
| Illustration 4 | g00557187 |
Removing A Carbon Dam (4) Fuel injection nozzle (5) Carbon dam (6) Seal | |
Before fuel injection nozzle (4) can be tested, remove all loose carbon deposits around the tip of the nozzle.
Clean a fuel injection nozzle with 8S-2258 Cleaning Brush (1) .
- Remove carbon dam (5) with needle nose pliers.
- Remove seal (6) from the nozzle.
| NOTICE |
|---|
Do not use a steel brush or wire wheel to clean the nozzle body or the nozzle tip. Use of these tools can cause a small reduction of orifice size, and this will cause a large reduction in engine horsepower. Too much use of a wire brush will also remove the coating that is on the fuel injection nozzle for protection. |
- Clean the groove for the carbon dam seal.
- Clean the body of the nozzle below with a 8S-2258 Brass Wire Brush (1).
- Carefully remove the carbon. The bristles of the brass wire brush can damage the body of the nozzle.
Note: A change of the color in the area below the groove is normal. This does not affect the body of the fuel injection nozzle.
- Remove the air purge screw and seal (7) .
Note: Whenever the air purge screw is loosened or removed a new washer (seal) must be installed in order to help prevent leakage. The air purge screw and the seal must be removed for all tests except the test for leakage around the air purge screw.
 | |
| Illustration 5 | g00557196 |
Fuel Injector Nozzle (7) Air purge screw and seal | |
Valve Opening Pressure Test (VOP)
- Install fuel injection nozzle with 5P-7448 Adapter.
| | |
| Illustration 6 | g00551190 |
5P-4150 Nozzle Testing Group (F) Gauge protector valve for 8T-0859 Pressure Gauge (K) Pump isolator valve (L) On/Off valve | |
- Point the fuel injection nozzle's tip downward.
Make sure that this nozzle's tip extends into both the FT-1384 Extension (G) and the 8S-2270 Fuel Collector (G) .
- Close on/off valve (L) .
 |
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. |
 |
Note: Place a shop towel around the upper part of the fuel injection nozzle. This shop towel should be used to absorb any fuel leakage.
- Open pump isolator valve (K) .
- Open gauge protector valve (F), and use the pump to create a slow increase in pressure. Continue operating the pump until the fuel injection nozzle begins to open.
- Read the maximum gauge pressure at the instance when the test fluid flows from the fuel injection nozzle's tip.
Note: It is possible for the pressure reading of the gauge to drop fast when the valve opens. It is also possible for the pressure reading of the gauge to be almost constant when the valve in the fuel injection nozzle opens.
Note: The check valve can make noise when the check valve is in good operating condition. The check valve can also spray a coarse vapor from the nozzle's orifices in Step 7.
If the opening pressure does not meet specifications, do not use the same fuel injection nozzle again. Review the specifications in Table 2.
| Specifications for VOP | |
11024 to 16200 kPa (1600 to 2350 psi) |
Flush the Nozzle
- Close gauge protector valve (F). Also, close on/off valve (L) .
- Then, open pump isolator valve (K) .
Note: Make sure that the fuel injection nozzle extends inside the top of FT-1384 Extension (6).
- Operate the pump rapidly for three full strokes.
Tip Leakage Test
- Use a clean cloth to remove all the fuel from the fuel injection nozzle's tip and from the body.
- Place a clean cloth around the body of the fuel injection nozzle. Use this cloth to catch any fuel leakage from the air purge screw's hole.
This will help prevent any fuel leakage from draining into the fuel injection nozzle's tip.
- Open gauge protector valve (F), and close on/off valve (L).
| | |
| Illustration 7 | g00551190 |
5P-4150 Nozzle Testing Group (F) Gauge protector valve for 8T-0859 Pressure Gauge (K) Pump isolator valve (L) On/Off valve | |
- Then, open pump isolator valve (K) .
- After you create a pressure of 1380 kPa (200 psi) less than the opening pressure that was measured in the VOP Test, hold this pressure for 15 seconds. Count the number of drops that fall into the fuel collector.
- Record the number of drops that fall. Refer to Table 3 for the maximum number of drops that are allowed.
Show/hide table
Table 3 Tip Leakage Specification No more than 3 drops should fall in 15 seconds.
- If the nozzle is not within the specifications, DO NOT USE the nozzle.
Orifice Restriction Test
- Close gauge protector valve (F) and on/off valve (L) .
- Then, open pump isolator valve (K) .
- Point the tip of the fuel injection nozzle into the extension and toward the fuel collector.
- Create a rapid pressure increase, and look at the orifice discharge when fluid begins to flow through the fuel injection nozzle.
In fact, look at the shape of this discharge. There should be a similar discharge through all six orifices. Any vertical change or any horizontal change indicates a defective nozzle. Review Illustrations 8 through 11.
 | |
| Illustration 8 | g00319183 |
A Good Nozzle That Can Be Used Again | |
 | |
| Illustration 9 | g00319184 |
Discharge of an Orifice with a Restriction | |
Replace this fuel injection nozzle.
 | |
| Illustration 10 | g00319185 |
Discharge of an Orifice with a Horizontal Distortion | |
Replace this fuel injection nozzle.
 | |
| Illustration 11 | g00319186 |
Discharge of an Orifice with a Vertical Distortion | |
Replace this fuel injection nozzle.
Leakage Test for Air Purge Screw
- Install air purge screw and seal (7) into the fuel injection nozzle. Torque the air purge screw to 2.2 ± .8 N·m (19 ± 7 lb in).
Note: Do not overtighten the air purge screw. The air purge screw or the seal can be damaged.
| | |
| Illustration 12 | g00557196 |
Fuel Injector Nozzle (7) Air purge screw and seal | |
| NOTICE |
|---|
Do not tighten the air purge screw more than the listed torque amounts. The air purge screw or the seal can be damaged. |
- Point the tip of the fuel injection nozzle into the extension and toward the fuel collector.
- Close on/off valve (L) .
- Open gauge protector valve (F) and pump isolator valve (K) .
- Pump the tester until the fuel injection nozzle fills with test fluid and the pressure gauge reads 20700 kPa (3000 psi).
Note: The pump may require 15 to 20 strokes in order to build 20700 kPa (3000 psi) of pressure.
Show/hide tableTable 4 Specification for Air Purge Screw No leakage can occur between the air purge screw and the fuel injector nozzle's body.
- If leakage occurs, follow this procedure:
- Replace the seal (15) .
- Inspect the seal face of the air purge screw for damage. Replace the air purge screw, if necessary.
- Retest the fuel injection nozzle. If leakage still occurs, the complete fuel injection nozzle needs to be replaced.
- If no leakage occurs, follow this procedure:
- Continue using the same fuel injection nozzle, but replace the seal.
Fuel Injection Lines
Fuel from the Fuel Injection Pumps to the Fuel Injector Nozzles
Fuel from the fuel injection pumps flows to the fuel injection nozzle through fuel injection lines.
When fuel injection lines are disconnected, always place caps on the end and plugs on the end. This will keep the dirt out of the lines. When fuel injection lines are installed, make sure that all clamps and all dampers are returned to original positions.
|
Be sure the fuel injection line clamps are installed in the correct location. Incorrectly installed clamps may allow the fuel injection lines to vibrate and become damaged. The damaged lines may leak and cause a fire. |
|
The nuts that connect a fuel injection line to both the fuel injection nozzle and the fuel injection pump must be tightened to the correct torque.
If the nuts are not tightened to the proper torque, the following problems may occur:
- If the nut is loose, fuel will leak from the connection.
- If the nut is too tight, the inside diameter of the line will become smaller. This causes a restriction to the fuel flow in the fuel line.
Use a torque wrench and a 5P-0144 Fuel Line Socket to tighten the fuel injection line nut to a torque of 40 ± 7 N·m (30 ± 5 lb ft).
|
Fuel injection lines that are bent, damaged, or rubbing against surfaces can leak and cause a fire. Replace any lines that are bent, or damaged when tightened to the correct torque. Correct or replace any lines that are rubbing when tightened to the correct torque. |
|
 | |
| Illustration 14 | g00493735 |
|
Ensure that the fuel injection line clamps are installed in the correct locations. Incorrectly installed clamps may allow the fuel injection lines to vibrate and become damaged. The damaged lines may leak and cause a fire. |
|
| Locations For The Fuel Injection Line Clamps | |
| Dimension | Distance From Reference |
| A | 281 ± 3 mm (11.03 ± .12 inch) |
| B | 187 ± 1 mm (7.36 ± .04 inch) |
| C | 35 ± 3 mm (1.38 ± .12 inch) |
| D | 185 ± 3 mm (7.28 ± .12 inch) |
| E | 282 ± 3 mm (11.10 ± .12 inch) |
| F | 529 ± 3 mm (20.83 ± .12 inch) |
Note: All dimensions are in reference to vertical line (1). The line corresponds to the center of the number one fuel injection pump outlet port.
(1) A vertical line through the number one injection pump
Tighten all the fuel injection line clamps to the following torque. ... 2.25 N·m (20 lb in)
Note: In order to correctly tighten the fuel injection line clamps, the 6V-4980 Torque Screwdriver Tool Group is available.
Checking the Plunger and Lifter of an Injection Pump
Note: If the pump plunger is worn, good contact will not occur. A pump plunger must be replaced if the pump plunger is damaged. A lifter must also be replaced if the lifter is worn. There are no different sizes of spacers that are available so you can adjust the timing dimension of the fuel injection pumps. Since there is no possible adjustment to the timing dimension, no off-engine adjustment procedure for the engine lifter setting procedure is available.
If the pump plunger on the fuel injector is worn, the lifter may also be worn. If either of these conditions exists, good contact will not be possible. Replace the lifters soon after you see wear on the pump plunger. Also, replace lifters that show any signs of wear.
 | |
| Illustration 15 | g00319239 |
Wear Between the Lifter and the Pump Plunger (1) The contact surface of a new pump plunger and surface of a new lifter (2) The contact surface of a pump plunger with considerable wear and surface of lifter with considerable wear (3) This section shows the relationship between the flat end of a new plunger and a worn lifter. This results in rapid wear to both parts. | |
A fuel injection pump can send a good fuel flow, yet this fuel injection pump may not be a good pump. Wear on the bottom end of the pump plunger causes slow timing. When you test a used fuel injection pump with a long life, use a micrometer to measure the length of the pump plunger.
If the length of the pump plunger is shorter than the minimum, specified length, replace the fuel injection pump. Any amount that is below the specified length indicates that the pump plunger is worn. See Table 6 for more information on the Fuel Pump Plunger.
| Specifications for Fuel Pump Plunger | |
| Length for new fuel pump plunger | 79.044 ± 0.013 mm (3.1120 ± .0005 inch) |
| Minimum length for worn fuel pump plunger | 79.031 mm (3.1115 inch) |
Also, look for wear at the top of the pump plunger. Check the operation according to the instructions in Testing and Adjusting, "Fuel Injection Test Bench".
Removal and Installation of Fuel Injection Pumps
| Required Parts | ||
| Part Number | Part Name | Quantity |
| 9U-5219 | Engine Tool Group | 1 |
| 8T-9198 | Bracket Assembly | 1 |
| 1U-5426 | Compressor Assembly | 1 |
| 8T-5287 | Wrench | 1 |
| 8S-2244 | Pump Extractor | 1 |
| 6V-4186 | Fuel Pump Timing Pin | 1 |
| 6V-7050 | Spring Compressor | 1 |
Before the 6V-7050 Spring Compressor is used for the first time, make the following adjustments:
- In order to work on a fuel injection pump, an adjacent fuel injection pump must also be installed. The second injection pump serves as the compressor mounting stud. If there are not two injection pumps next to each other, install two injection pumps without the lifter springs. Refer to Testing and Adjusting, "Installation Of Fuel Injection Pumps" for the correct alignment of the pump at assembly.
- Put bracket assembly (9) over one of the pump bonnets.
 | |
| Illustration 16 | g00548620 |
Adjustment of the 6V-7050 Spring Compressor (A) 6V-7015 (B) Bracket Assembly (C) 4B-2046 Nut (D) 8T-0937 (E) 2N-3476 Screw | |
- Put the clamp ram on the center of the other fuel injection pump bonnet with screw (E) in contact with the fuel line seat.
Note: The 6V-7015 Clamp should not be locked in the down position.
- Install nut (D). Tighten nut (D) .
- When the clamp ram is locked in the downward position, adjust the screw until the top of the bracket assembly (B) just starts to move .
- Tighten nut (C) in order to hold screw (E) in position.
Removal of Fuel Injection Pumps
| NOTICE |
|---|
Before any parts are removed from the fuel injection pump housing, thoroughly clean all dirt from the housing. Dirt that gets inside the pump housing will cause much damage. |
The following procedure can be done with the fuel injection pump housing on the engine or the procedure can be done with the fuel injection pump housing off the engine.
Note: The fuel rack must be in the center position before the fuel injection pumps can be removed or before the fuel injection pumps can be installed.
- Remove plug (1) and cover (2) from the fuel injection pump housing.
 | |
| Illustration 17 | g00548774 |
Fuel Injection Pump Housing (Plug for the rack centering pin) (Cover for the rack position indicator) | |
- Install the 6V-4186 Fuel Pump Timing Pin (3) in the top of the fuel injection pump housing. Make sure that the timing pin (3) engages in the slot of the fuel rack. Refer to Figure 18 for more information.
 | |
| Illustration 18 | g00548776 |
Fuel Rack Against Timing Pin In The Center Position (3) 6V-4186 Fuel Pump Timing Pin | |
- Install the bracket (4) on the fuel injection pump housing. Make sure that the lever of the bracket is engaged in the slot of the fuel rack.
 | |
| Illustration 19 | g00548787 |
Holding The Fuel Rack In The Center Position (3) 6V-4186 Fuel Pump Timing Pin (4) 8T-9198 Bracket (5) 1U-5426 Compressor Assembly | |
- Install the 1U-5426 Compressor Assembly all the way into the 8T-9198 Bracket in order to compress the spring.
- Tighten the collet on bracket (4) in order to hold compressor assembly (5). Spring force now holds the fuel rack against timing pin (3) in the center position.
- Remove the fuel injection line from the pump that needs to be removed. The fuel injection lines on each side of the pump need to be removed.
- Use 8T-5287 Wrench in order to loosen bushing (8). Loosen the bushing about one quarter of a turn. Do not remove the bushing at this time.
|
There is a spring force on the fuel injection pump plunger and barrel assembly. Removal of the retainer bushing without the 6V-7050 Pump Spring Compressor correctly installed can cause bodily injury. |
|
 | |
| Illustration 20 | g00548833 |
(3) 6V-4186 Fuel Pump Timing Pin (6) 8T-5287 Wrench (7) 6V-7050 (8) Retainer bushing | |
- Install 6V-7050 Spring Compressor on the pump housing over 8T-5287 Wrench. Lower the screw in the clamp ram to the fuel line seat before the nut is tightened in order to hold the compressor in position. This centers the compressor.
- Use 8T-5287 Wrench to loosen retainer bushing (8) until the bushing is out of the threads. Slowly raise the compressor tool handle in order to release the spring force.
 | |
| Illustration 21 | g00549773 |
Releasing The Spring Force (3) 6V-4186 Fuel Pump Timing Pin (6) 8T-5287 Wrench (7) 6V-7050 (8) Retainer bushing | |
- Remove 6V-7050 Spring Compressor and the 8T-5287 Wrench. Install the 8S-2244 Pump Extractor (9) on the injection pump threads. Remove the pump by carefully pulling the pump straight up. Do not hit the pump on the side of the bore. Remove the spacer from the pump housing bore.
 | |
| Illustration 22 | g00549775 |
Extracting The Fuel Injection Pump (9) 8S-2244 Pump Extractor | |
Be careful when an injection pump is disassembled. Do not damage the surface on the plunger. The plunger and barrel are made as a set. Do not put the plunger of one pump in the barrel of another pump. If one part is worn, install a complete new pump assembly. Be careful when the plunger is put into the bore of the barrel. When injection pumps are removed from the fuel injection pump housing, keep the parts together so the parts can be installed in the same location in the housing.
Installation of Fuel Injection Pumps
| NOTICE |
|---|
The fuel rack must be in the center position before hte correct incstallation of an injection pump is possible. |
- Put the fuel rack in the center position. Refer to Testing and Adjusting, "Removal Of Fuel Injection Pumps" for more information.
- Put 8S-2244 Pump Extractor (1) on the threads of the fuel injection pump.
 | |
| Illustration 23 | g00549817 |
- Make sure that the lifter for the pump is at the bottom of the travel.
- Put the groove in barrel (2) in alignment with the slot in gear segment (3) .
- Be sure that the spacer is in the correct position in the pump housing bore.
- Carefully install the pump into the pump housing bore. Keep the pump straight with the pump housing bore.
Note: The slot in gear segment (3) must be in alignment with pin (4) in the side of the lifter. The groove in barrel (2) must be in alignment with dowel (5) in the housing bore.
 | |
| Illustration 24 | g00549822 |
Fuel Injection Pump Housing (Top View) (4) Pin (5) Dowel | |
- Remove the 8S-2244 Pump Extractor. Put the O-ring seal, retainer bushing (9) and 8T-5287 Wrench (7) in position on the top of the injection pump. Install 6V-7050 Spring Compressor (8).
| | |
| Illustration 25 | g00549773 |
Compressing The Spring (3) 6V-4186 Fuel Pump Timing Pin (6) 8T-5287 Wrench (7) 6V-7050 (8) Retainer bushing | |
- Slowly move the handle of the 6V-7050 Spring Compressor in the downward direction in order to push the injection pump into the bore.
| NOTICE |
|---|
The handle of the 6V-7050 must move smoothly down to the lock position. Do not force the handle if it stops. If the handle does not move smoothly down to the lock position, raise the handle, remove the 6V-7050 , and repeat Steps 3 through 8. |
- Put the O-ring seal in position in the pump housing bore. Use the 8T-5287 Wrench to install the retainer bushing.
- Remove the 6V-7050 Spring Compressor. Tighten the retainer bushing to 230 ± 15 N·m (170 ± 11 lb ft).
| NOTICE |
|---|
The bushing must be tightened to the correct torque. Damage to the housing will be the result if the bushing is too tight. If the bushing is not tight enough, the pump will have leakage. |
- Install the fuel injection lines to the pump and tighten to 40 ± 7 N·m (30 ± 5 lb ft). The following steps can be used to ensure correct installation and operation of any number of individual replacement pumps on most truck engines.
|
Be sure the fuel injection line clamps are installed in the correct location. Incorrectly installed clamps may allow the fuel injection lines to vibrate and become damaged. The damaged lines may leak and cause a fire. |
|
- Either remove the shutoff solenoid or activate the shutoff solenoid if the solenoid is installed in the rack actuator housing.
Note: The manual shutoff override lever can be used to move the shutoff solenoid out of the way so that the fuel rack can be moved.
Note: To check the installation of a replacement pump, it is necessary to have full rack travel in both directions. The center location of the timing pin and the rack are not used to check the installation of the replacement pumps.
- Remove the compressor and bracket assembly (10) from the fuel injection pump housing.
 | |
| Illustration 26 | g00549829 |
Checking Fuel Rack Travel (6) 6V-4186 Fuel Pump Timing Pin (10) 8T-9198 Bracket | |
- Raise the timing pin and move the rack to the full load position. Finger pressure should be used to check for full rack travel.
 | |
| Illustration 27 | g00549835 |
- If the fuel injection pump installation is correct, the following condition will be true. When the timing pin is lowered, the timing pin will rest on the rack. Refer Figure 27 for the correct orientation of the pin to the rack.
- Lower the timing pin. If the fuel injection pump installation is incorrect, the timing pin position will vary by the following amount for each tooth position out of alignment:
The timing pin position varies by 1.91 mm (.075 inch) toward the slot. Refer to Figure 28 for a graphic representation. This will reduce fuel rack travel. This may not affect the rack setting because of additional rack travel at static conditions.
 | |
| Illustration 28 | g00549153 |
Incorrect Installation (?) 1.91 mm (.0752 inch) | |
- Raise the timing pin. Move the rack to the fuel-off position.
 | |
| Illustration 29 | g00549132 |
- Lower the timing pin. If the fuel injection pump installation is correct, the timing pin will be less than 1.91 mm (.075 inch) from the rear face of the slot. Refer to Figure 29 for a graphic representation.
- Lower the timing pin. If the fuel injection pump installation is incorrect, the timing pin position will be more than 1.91 mm (.075 inch) from the rear face of the timing slot in the rack. Refer to Figure 30 for a graphic representation.
 | |
| Illustration 30 | g00549131 |
- When all the replacement fuel injection pumps are installed correctly, remove the 6V-4186 Fuel Pump Timing Pin (6) from the fuel injection pump housing. Install the plug.
- Install the gasket and the cover over the fuel rack on the side of the fuel injection pump housing.
- Remove the air cleaner pipe from the turbocharger. Leave the air inlet open. Refer to Figure 31.
| NOTICE |
|---|
If one or more of the fuel injection pumps have been installed wrong, it is possible for the engine to run out of control when started. When any of the fuel injection pumps have been removed and installed with the fuel injection pump housing on the engine, take the precautions (steps) that follow to stop the engine if it starts to overspeed (run out of control. |
 | |
| Illustration 31 | g00549129 |
- Set the governor control at low idle. Do not apply any pressure to the accelerator pedal.
- Start the engine. If the engine starts to overspeed, put a steel plate over the air inlet. Refer to Figure 32.
|
Be careful when plate is put against the air inlet opening. Excessive suction can pull the plate quickly against the air inlet opening. To avoid crushed fingers, do not put fingers between plate and air inlet opening. |
|
 | |
| Illustration 32 | g00549127 |
Stopping The Engine | |
Finding the Top Center Position For No. 1 Piston
| Tools Needed Quantity |
||
| Part Number | Part Name | Quantity |
| 9S-9082 | Engine Turning Tool | 1 |
The No. 1 piston must be at the top center position on the compression stroke before any timing procedures can be started.
Note: Some engines have two threaded holes in the flywheel. These holes are in alignment with the holes with plugs in the left and right front of the flywheel housing. The two holes in the flywheel are at a different distance from the center of the flywheel so the timing bolt cannot be put in the wrong hole.
- The timing bolt (1) is kept in storage at location (3). The timing bolt can be installed in either the left side of the engine at location (2) or in the right side of the engine at location (4). Remove the bolts and the cover from the flywheel housing. Remove the plug from the timing hole in the flywheel housing.
 | |
| Illustration 33 | g00549882 |
Locating The Top Center Position On Left Side Of Engine (1) Timing bolt (2) Timing bolt location (3) Storage location | |
 | |
| Illustration 34 | g00549889 |
Locating The Top Center Position On Right Side Of Engine (4) Timing Bolt Location | |
- Put timing bolt (1) through the timing hole in the flywheel housing. Use the 9S-9082 Engine Turning Tool and a 1/2 inch drive ratchet in order to turn the engine flywheel in the direction of normal engine rotation. The normal engine rotation is counterclockwise when the engine is viewed from the flywheel end of the engine. Turn the engine until the timing bolt engages with the threaded hole in the flywheel.
 | |
| Illustration 35 | g00551198 |
Rotating The Engine (1) Timing Bolt (5) 9S-9082 Engine Turning Tool | |
Note: If the flywheel is turned beyond the point of engagement, the flywheel must be turned in the direction that is reverse of normal engine rotation. Turn the flywheel by approximately 45 degrees. Then turn the flywheel in the direction of normal rotation until the timing bolt engages with the threaded hole. This procedure removes the play from the gears when the No. 1 piston is at the top center position.
- Remove the front valve cover from the engine.
- The intake and exhaust valves for the No. 1 cylinder are fully closed if No. 1 piston is on the compression stroke and the rocker arms can be moved by hand. If the rocker arms can not be moved and the valves are slightly open the No. 1 piston is on the exhaust stroke.
Note: When the actual stroke position is identified, and the other stroke position is needed, remove the timing bolt from the flywheel. Then turn the flywheel by 360 degrees in the direction of normal engine rotation. Reinstall the timing bolt.
Checking Engine Timing And Timing Advance With 8T-5300 Engine Timing Indicator Group
| Tools Needed Quantity |
||
| Part Number | Part Name | Quantity |
| 8T-5300 | Engine Timing Indicator Group | 1 |
| 8T-5301 | Diesel Engine Timing Adapter Group | 1 |
| 8T-6797 | Software, NEXG4522 | 1 |
Note: The Software, NEXG4522 is available with a subscription.
Note: The Electronic Technician (ET) can be used instead of ECAP.
- Turn off the engine at the ignition switch.
- Disconnect the PEEC III data link connector from the truck wiring harness. Connect the 8T-8697 Electronic Control Analyzer Programmer (ECAP) .
- Refer to Special Instruction, SEHS8580 for the correct installation and operation of the 8T-5300 Engine Timing Indicator Group. Install the injection transducer adapter and the injection transducer in either the No. 1 fuel line or the No. 6 fuel line at the fuel injection pump. Install the indicator for the top center position in the flywheel housing and connect the cables to the engine timing indicator. Perform a calibration check.
 | |
| Illustration 36 | g00551610 |
Transducer in Position (1) Injection transducer (2) Fuel injection line for No. 6 cylinder | |
 | |
| Illustration 37 | g00551616 |
Transducer In Position (3) Transducer for the top center position | |
- Start the engine. Run the engine at low idle until the engine has warmed up. The engine needs to be in the warm mode operation. The cruise control on/off switch must be in the OFF position.
- Select the status mode on the ECAP that has the following displays: timing advance, desired timing advance, static timing specification and estimated dynamic timing. Refer to Special Instruction, SEHS8741 for more information on the procedure to select the status screen.
- Use the cruise control switches and run the engine at several different speeds in the PTO mode control. Make a record of the following measurements after the readings have stabilized on the tooling:
- the estimated dynamic timing
- the timing angle on the timing indicator
- the difference between the desired timing advance and the actual timing advance
- the estimated dynamic timing
- The estimated dynamic timing reading should be equal to the timing angle reading within ± 2.50 degrees. This indicates that the timing advance actuator and the timing position sensor are working correctly. Also, the static injection timing is correctly set.
If the estimated dynamic timing reading and the timing angle are not within ± 2.50 degrees, a problem persists. If the difference is constant for all engine speeds, this indicates that the timing advance actuator and the timing position sensor are working correctly. The static fuel injection timing is not correct. Refer to Testing and Adjusting, "Checking Engine Timing By Timing Pin Method" for the correct procedure for setting the static fuel injection timing. Repeat Steps 2 and 3 after checking and adjusting the static timing.
If the timing advance reading varies by more than ± 0.30 degrees from the desired timing advance angle, the timing actuator and the timing position sensor are not working correctly. To troubleshoot the timing advance actuator, refer to Troubleshooting, "SENR5503".
Note: Use the measurements from Step 3 with Steps 1,3 and 3 in order to determine if an adjustment or a repair is needed.
Checking Engine Timing By The Timing Pin Method
| Tools Needed Quantity |
||
| Part Number | Part Name | Quantity |
| 9S-9082 | Engine Turning Tool | 1 |
| 6V-4186 | Timing Pin | 1 |
- Put the No. 1 piston at the top center position on the compression stroke. Refer to Testing and Adjusting, "Finding Top Center Compression Position For No. 1 Piston". Remove the timing bolt from the flywheel. Use the 9S-9082 Engine Turning Tool in order to rotate the crankshaft clockwise. Rotate the crankshaft in the opposite direction from the normal engine rotation. Rotate the flywheel through 45 degrees.
- Remove plug (1) from the fuel injection pump housing.
 | |
| Illustration 38 | g00551964 |
Fuel Injection Pump (1) Plug for timing pin hole | |
- Install the 6V-4186 Fuel Pump Timing Pin (2) in the fuel injection pump housing. Refer to Figure 39. Slowly rotate the crankshaft in the direction of normal engine rotation until the timing pin (2) falls into the slot in the fuel pump camshaft.
 | |
| Illustration 39 | g00551968 |
Fuel Pump Timing Pin (2) 6V-4186 Fuel Pump Timing Pin | |
- Remove the timing position sensor cover (3) from housing (4).
 | |
| Illustration 40 | g00557293 |
Timing Position Sensor Cover (3) Cover (4) Housing (5) Timing Solenoid (BTM) | |
- Rotate the crankshaft through 15 degrees in the direction that is opposite of the normal engine rotation. Observe the motion of the timing advance power piston through housing (4).
- Rotate the crankshaft in the counterclockwise direction until the timing advance power piston moves to the fully retracted position and light pressure is applied to the timing pin (2). The pump is viewed from the rear of the engine.
| NOTICE |
|---|
Do not apply excessive force to rotate the engine with the timing pin installed. Excessive force will shear off the timing pin and/or cause fuel pump damage. Apply only enough force to retract the timing actuator power piston. |
 | |
| Illustration 41 | g00557295 |
Installing The Timing Bolt (6) 9S-9082 Engine Turning Tool (7) Timing bolt | |
- Put the timing bolt in the timing hole in the flywheel housing. If the bolt can be installed in the timing hole in the flywheel, the static injection timing of the fuel injection pump is correct.
- If the timing bolt does not go into the timing hole in the flywheel, the timing is not correct. Perform the following steps in order to adjust the fuel injection pump static timing.
- Remove timing advance solenoid (5) .
- Remove timing advance housing (4) .
- Loosen the four bolts (8) on the timing advance. Make sure that the timing pin is installed in the fuel pump and that the timing bolt is removed from the flywheel. Rotate the crankshaft through 30 degrees in the direction that is opposite of the normal engine rotation. Make sure that the timing advance power piston does not move from the fully retracted position.
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Illustration 42 g00557298
Automatic Timing Advance Unit
(8) Bolts
- Lightly tighten two of the four timing advance bolts to 2.3 N·m (21 lb in). Only finger tighten the bolts in order to prevent the timing pin from being bent.
Note: Only finger tighten the bolts in order to prevent bending the timing pin.
- Slowly rotate the crankshaft in the direction of normal engine rotation until the timing bolt can be installed in the flywheel. The No. 1 piston is now at the top center position.
- Tighten the four timing advance bolts (8) to 10 N·m (7 lb ft). Remove the timing pin from the fuel injection pump.
- Tighten the four timing advance bolts to a torque of 55 ± 7 N·m (41 ± 5 lb ft).
- Remove the timing bolt from the flywheel. Turn the crankshaft through two complete revolutions in the direction of normal engine rotation in order to make sure that the timing advance piston is in the fully retracted position. Repeat Steps 6 and 7 in order to check the timing. Make sure that the timing pin will go into the groove in the fuel pump camshaft and that the timing bolt will go into the flywheel.
- If the timing is not correct repeat Steps 8.c through 8.h again.
- If the timing is correct, remove the timing bolt from the flywheel and remove the timing pin from the fuel pump.
- Rotate the timing position sensor bellcrank clockwise by inserting a No. 2 Phillips screwdriver between the arm of the bellcrank that is in contact with the timing position sensor. Rotate the timing position sensor bellcrank until the screwdriver can be inserted into the hole that is in the cover in order to hold the bellcrank in position.
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Illustration 43 g00557326
Location Of The Screwdriver
- Install the gasket and timing advance housing (4) .
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Illustration 44 g00557331
Holding The Timing Position Sensor Bellcrank In Position
- Remove the screwdriver in order to allow the bellcrank to contact the power piston.
- Refer to Testing and Adjusting, "Timing Position Sensor Calibration" for the procedure to calibrate the timing position sensor.
- Install the timing solenoid. Make sure that the arm of the timing solenoid is in the center groove of the control spool collar.
- Install the timing advance position sensor cover (3) .
Timing Position Sensor Calibration
| Tools Needed Quantity |
||
| Part Number | Part Name | Quantity |
| 9U-5219 | Tool Group | 1 |
| 9S-9082 | Engine Turning Tool | 1 |
| 8T-8697 | Electronic Control Analyzer Programmer (ECAP) | 1 |
Note: The Software, NEXG4522 is required in order to use the ECAP on this engine. The software is available as a subscription. The software is likely to change over time.
Note: The Electronic Technician can be used instead of using the ECAP tool.
Refer to Special Instruction, SEHS8746, "Using the 9U-5219 Tool Group " for more information.
- Turn off the engine. Turn the key to the OFF position.
 | |
| Illustration 45 | g00557334 |
Removal Of The Cover And The Timing Advance Solenoid (1) Solenoid wires (2) Cover (3) Timing solenoid (BTM) | |
- Remove the timing position sensor cover (2). Disconnect the connector that connects the solenoid wires (1) to the engine wiring harness.
- Remove timing solenoid (3) from the timing advance housing.
- Install the 6V-4186 Fuel Pump Timing Pin (4) in the fuel injection pump housing. Slowly rotate the crankshaft in the direction of normal engine rotation until the timing pin (4) goes into the slot in the fuel pump camshaft.
Note: Use the 9S-9082 Engine Turning Tool in order to turn the engine crankshaft.
When the timing pin is installed in the slot in the fuel injection pump camshaft, slowly rotate the crankshaft in the counterclockwise direction until a stop is felt.
This procedure makes sure that the timing advance power piston is in the fully retracted position. Movement can be checked through the top of the timing advance housing by watching the collar that is engaged by the timing solenoid.
| NOTICE |
|---|
Rotation of the crankshaft after the stop is felt will cause the timing pin to shear off in the fuel injection pump camshaft slot. |
 | |
| Illustration 46 | g00557343 |
Installing The Timing Pin In The Fuel Injection Pump (4) 6V-4186 Fuel Pump Timing Pin | |
- Install the 1U-5425 Timing Gauge Assembly (5) through the timing solenoid hole on the inboard side of the timing advance housing.
The gauge assembly must be positioned between the bearing on the power piston and the timing position sensor bellcrank (6). The gauge assembly is inserted and rotated around the timing spool valve. Make sure that the tool is correctly seated on the bearing race and that the bellcrank is on the flat surface of the gauge block.
 | |
| Illustration 47 | g00557345 |
Installing The Timing Gauge Assembly (5) 1U-5425 Timing Gauge Assembly (6) Bellcrank | |
- Connect the ECAP to the engine data link connector.
- Turn the key to the ON position but do not try to start the engine.
On the ECAP tool, select the status display that has "Timing Advance Position" from the main menu.
| NOTICE |
|---|
Do not engage the starter or damage to the engine will be the result. |
- Read the "Timing Advance Position" on the ECAP display.
- If the timing advance reading is 13.7 ± .4 degrees the timing position sensor is correctly calibrated.
- If the timing advance reading is not 13.7 ± .4 degrees, the timing position sensor needs the following adjustment.
- Keep electrical power on the ECM. On the ECAP tool, select "Calibrate/Monitor Sensor". Then select "Timing Position Sensor Calibration" from the main menu.
- Use the 1U-5536 Wrench to loosen locknut (8).
 | |
| Illustration 48 | g00557360 |
Adjustment Of Timing Position Sensor (7) Timing Position Sensor (8) Locknut | |
- Adjust timing position sensor (7) until the ECAP tool indicates that the timing position sensor is calibrated.
- Tighten the locknut (8) to 55 ± 7 N·m (41 ± 5 lb ft).
- After tightening the locknut, recheck the timing position calibration reading on the ECAP tool.
- Turn the key to the OFF position.
- Disconnect the ECAP from the ECM. Connect the PEEC III Data Link Connector to the truck harness.
- Remove the 1U-5425 Timing Gauge Assembly .
- Remove the 6V-4186 Fuel Pump Timing Pin. Rotate the crankshaft in the direction that is opposite of the normal engine rotation. This releases the pressure on the timing pin.
- Install the timing solenoid (BTM) and make sure that the arm on the timing solenoid (BTM) is assembled in the groove of the timing advance servo collar.
- Connect the timing solenoid (BTM) to the wiring harness. Install the timing position sensor cover.
Rack Position Sensor Calibration
| Tools Needed Quantity |
||
| Part Number | Part Name | Quantity |
| 9U-5219 | Tool Group | 1 |
| 9S-9082 | Engine Turning Tool | 1 |
| 8T-8697 | Electronic Control Analyzer Programmer (ECAP) | 1 |
Note: The Software, NEXG4522 is required in order to use the ECAP on this engine. The software is available as a subscription. The software is likely to change over time.
Note: The Electronic Technician can be used instead of the ECAP tool.
Refer to Special Instruction, SEHS8746, "Using The 9U-5219 Tool Group Tool Group" for more information.
- Turn off the engine. Turn the key to the OFF position.
- Connect the ECAP tool to the engine data link connector.
- Turn the ignition switch to the ON position, but do not start the engine. Select "Calibrate/Monitor" from the main menu. Then select "Rack Position Sensor Calibration" in order to monitor the rack position.
- Remove plug (1) and cover (2) from the fuel injection pump housing.
| | |
| Illustration 49 | g00548774 |
Fuel Injection Pump Housing (1) Plug for rack centering pin (2) Cover for the rack position indicator | |
- Install the 6V-4186 Fuel Pump Timing Pin (3) in the top of the fuel injection pump housing. Make sure that the timing pin (3) engages in the slot of the fuel rack.
| | |
| Illustration 50 | g00548776 |
Fuel Rack Against The Timing Pin (3) 6V-4186 Fuel Pump Timing Pin | |
- Install bracket assembly (4) on the fuel injection pump housing. Make sure that the lever of the bracket assembly is engaged in the slot of the fuel rack.
| NOTICE |
|---|
Do not start the engine with bracket assembly (4) and compressor assembly (5) installed on the fuel injection pump housing. Engine overspeed can result. |
| | |
| Illustration 51 | g00548787 |
Holding The Fuel Rack In The Center Position (3) 6V-4186 Fuel Pump Timing Pin (4) 8T-9198 Bracket (5) 1U-5426 Compressor Assembly | |
- Install the 1U-5426 Compressor Assembly (5) all the way into the 8T-9198 Bracket (4) in order to compress the spring.
- Tighten the collet on the bracket assembly (4) in order to hold the compressor assembly (5). The spring force now holds the fuel rack against the timing pin (3) in the center position.
- When the rack is held back against the centered pin, read the "Rack Position" on the ECAP display.
- If the "Rack Position" reading is 9.50 ± 0.20 mm (.37 ± .008 inch) the rack position sensor is calibrated correctly.
- If the "Rack Position" reading is not 9.50 ± 0.20 mm (.37 ± .008 inch), the rack position sensor needs the following adjustments:
- Remove the wiring connectors from clip assembly (6). Do not disconnect any wiring at this time.
 | |
| Illustration 52 | g00557362 |
Fuel Injection Pump And Rack Actuator Housing (6) Clip assembly (7) Cover | |
- Remove the five bolts and cover (7) from the rack actuator housing.
- Use the 1U-5536 Wrench and a ratchet to loosen the locknut on rack position sensor (10).
 | |
| Illustration 53 | g00557384 |
Rack Position Sensor Adjustment (8) Wiring for transducer module (9) Wiring for rack position sensor (10) Rack position sensor | |
- Make sure that the rack position sensor wiring (9) is connected to the transducer module wiring (8).
- With electrical power to the ECM, select the "Calibrate/Monitor" display that has "Rack Position Sensor Calibration" from the main menu on the ECAP.
- Hold the rack back against the timing pin. Adjust the collar on the rack position sensor until the ECAP tool indicates that the rack position sensor is calibrated.
- Tighten the locknut to 55 ± 7 N·m (41 ± 5 lb ft).
- After tightening the locknut on the rack position sensor, recheck the rack position calibration reading on the ECAP tool.
- Turn the key to the OFF position.
- Install cover (7) and clip assembly (6) on the rack actuator housing. Make sure that no wires are pinched between the cover and the housing.
- Install wiring connectors in clip assembly (6).
- Remove the 1U-5426 Compressor Assembly (5) and the 8T-9198 Bracket (4). Install the gasket and the cover on the side of the fuel injection pump housing.
- Remove the 6V-4186 Fuel Pump Timing Pin and install the plug in the top of the fuel injection pump housing.
- Disconnect the ECAP tool from the engine data link connector.
Engine Speed Sensor Adjustment
| Tools Needed Quantity |
||
| Part Number | Part Name | Quantity |
| 9U-5219 | Tool Group | 1 |
- Remove the wiring connections from the clip assembly (1) .
 | |
| Illustration 54 | g00557390 |
Fuel Injection Pump And Rack Actuator Housing (1) Clip assembly (2) Cover | |
- Remove the five bolts and cover (2) from the rack actuator housing.
- Disconnect the engine speed sensor wiring (6) and the wiring for rack position sensor (4) from transducer module wiring (5).
 | |
| Illustration 55 | g00557392 |
Removal Of The Rack Actuator Housing (3) Housing (4) Rack position sensor (5) Wiring for transducer module (6) Wiring for engine speed sensor | |
- Remove the shutoff lever and the clip assembly (7) from the center of the housing (3).
 | |
| Illustration 56 | g00557402 |
Removal Of The Shutoff Lever Assembly (3) Housing (7) Shutoff lever and clip assembly (8) Rack solenoid (BTM) | |
- Use the 5P-0326 Wrench and a ratchet in order to loosen the locknut on the engine speed sensor (9).
 | |
| Illustration 57 | g00557428 |
Engine Speed Sensor Adjustment (9) Engine speed sensor | |
- Turn the engine speed sensor (9) into the threads until the sensor makes contact with the gear tooth that is on the fuel pump camshaft retainer. Turn the engine speed sensor in the counterclockwise direction in the amount of 180 ± 30 degrees.. This gives a clearance of 0.76 ± 0.15 mm (.030 ± .006 inch) between the camshaft retainer and the magnet on the end of engine speed sensor (9).
- Use the 5P-0326 Wrench and tighten the locknut on engine speed sensor (9) to a torque of 13 ± 2 N·m (10 ± 1 lb ft). Be careful in order to prevent the rotation of the engine speed sensor while the locknut is being tightened.
Note: Do not exceed the recommended torque for the locknut. Damage to the engine speed sensor may result.
- In order to prevent damage to the rack position sensor, install the gasket and the housing (3) in the following manner:
- Push the plunger into the rack position sensor (4). The distance is equal to 3/4 of the available travel.
- Push the fuel rack and the magnetic connection toward the front of the engine.
- Put the gasket and housing (3) in position and install the bolts.
- Slowly pull the fuel rack and the rack position sensor plunger together until the magnet holds the two parts together.
 | |
| Illustration 58 | g00557434 |
Installing The Rack Actuator Housing (3) Housing (4) Rack position sensor | |
- Install the shutoff lever and the clip assembly in the following manner:
- Put the shutoff lever and the clip assembly in position. Make sure that the wiring from the transducer module is positioned over the top of the shutoff lever and the clip assembly.
- Push the shutoff solenoid plunger into the solenoid and hold the plunger in this position.
- Make sure that the pin (11) is engaged correctly with the manual shutoff lever (12) .
- Make sure that the lever (10) is in the correct position behind the end of the rack servo valve.
- Install the bolts in order to hold the shutoff lever and the clip assembly in the housing (3) .
- Check for the correct operation of the manual shutoff lever.
 | |
| Illustration 59 | g00557436 |
Installing The Shutoff Lever Assembly (10) Lever (11) Pin (12) Lever | |
- Connect the wiring for Rack Position Sensor (4) and the wiring for the engine speed sensor to the transducer module wiring.
- Check and adjust the rack position sensor if an adjustment is needed. Refer to Testing and Adjusting, "Rack Position Sensor Calibration" for the correct procedure.
- Install the rack solenoid (BTM) in housing (3). Make sure that the lever on the rack solenoid engages correctly in the sleeve that is on the rack servo valve.
- Install the gasket, the cover and the connector clip on the end of the housing (3).
- Fasten the wiring connections in position on the clip assembly (1).
Throttle Position Sensor Adjustment
Note: If the vehicle is equipped with the pedal mounted throttle position sensor, no adjustment is required. If the vehicle is equipped with the throttle position sensor the following adjustments should be made.
- Inspect the throttle linkage for the following components:
- loose
- bent
- broken
- missing
- worn
The throttle linkage should work smoothly without excessive drag. The throttle linkage should return to the low idle position without assistance in less than one second. Replace parts as parts are needed.
- loose
 | |
| Illustration 60 | g00557446 |
Throttle Position Sensor (1) Rotary disc (2) Pin (3) Low idle edge indicator (4) Mechanical stop | |
- Disconnect the PEEC III Data Link connector from the truck's wiring harness. Connect the ECAP tool to the PEEC III Data Link connector.
- Turn the ignition switch to the ON position in order to provide power to the ECM.
- Select the "Status Mode" from the main menu that has "Throttle Position" for one of the displays. The ECAP tool will display the percent throttle readings. The readings are from 3 percent throttle to 100 percent throttle.
- Observe the duty cycle of the throttle signal with the throttle at the low idle position by using the ECAP tool. At low idle, the duty cycle readings are from 15 percent to 20 percent. A slight movement of the pedal off the low idle stop should increase the duty cycle readings.
- Actuate the throttle and return to the low idle position.
- Adjust either the linkage low idle stop or the throttle linkage until the pin (2) is centered between the mechanical stop and the low idle edge indicator.
 | |
| Illustration 61 | g00557453 |
Correct Low Idle Position Adjustment (3) Low idle edge indicator (4) Mechanical stop | |
- Advance the throttle to the high idle position. Adjust the throttle linkage until the pin (2) is centered between the mechanical stop and the high idle edge indicator.
 | |
| Illustration 62 | g00557457 |
Correct High Idle Position Adjustment (5) High idle position adjustment (6) Mechanical stop | |
- A duty cycle reading of 80 to 85% should be displayed on the ECAP with the throttle at the high idle position. A slight movement of the pedal off the high idle stop should decrease the duty cycle readings.
- Repeat Steps 5 through 9 until the low idle adjustments are correct and the high idle adjustments are correct.
- Turn the key to the OFF position.
| NOTICE |
|---|
Continued operation with pin (2) in contact with one of the mechanical stops can result in failure of the sensor. 11. |
- Disconnect the ECAP from the ECM. Connect the PEEC III Data Link Connector to the truck harness.
Pedal Mounted Throttle Position Sensor (If Equipped)
If the vehicle is equipped with the pedal mounted throttle position sensor, no adjustment is required.
The pedal mounted throttle position sensor can be installed in place of the throttle position sensor on earlier engines as long as the engine has the correct personality module.
The pedal mounted throttle position sensor is mounted on the back of the OEM supplied pedal. No adjustments are required for the pedal mounted throttle position sensor. Calibration of the pedal mounted throttle position sensor is done automatically by the ECM. The correct calibration can be displayed with the ECAP tool. The correct percent throttle reading is 3 percent when the throttle is completely opened. The correct percent throttle reading is 100 percent when the throttle is completely depressed.
Engine Speed Measurement
 | |
| Illustration 63 | g00286276 |
9U-7400 Multitach | |
The 9U-7400 Multitach can measure engine speed from a magnetic pickup on the flywheel housing. The multitach also has the ability to measure the engine speed from visual engine parts in rotation. The 9U-7401 Multitach Tool Group can be used. The tool can also be used on all Caterpillar diesel engines that are equipped with 6 mm (.25 inch) single wall fuel injection lines. The tool can do the following tasks:
- Measure engine speed quickly.
- Measure engine speed automatically.
- Measure engine speed accurately with a tolerance of ±1 rpm.
Refer to Special Instruction, SEHS8029 for instructions on the use of the 6V-4950 Speed Pickup .
Note: The ECAP tool can also be used to check engine rpm.