2001/02/12 Caterpillar


A New Fuel Ratio Control (FRC) is Available for Stanadyne Fuel Injection Pumps on some 3054 and 3056 Turbocharged Engines {1278}

Usage:

554 1AM
Machine Engines:
3054 (S/N: 5HK1-UP)
3054 (S/N: 7BJ1-UP)
3056 (S/N: 8XJ1-UP)

Description of Change: Some 3054 and 3056 turbocharged engines use Stanadyne fuel injection pumps. Some of these Stanadyne fuel injection pumps have a 116-8642 Fuel Ratio Control Assembly that is installed on the exterior of the pump body. The fuel ratio control limits the output of the fuel injection pump until the turbocharger boost pressure is high enough to act on the diaphragm that is inside the fuel ratio control. This will allow full output of the fuel injection pump to the engine. The diaphragm that is inside the fuel ratio control may split in applications which require the fuel ratio control to cycle frequently. This is due to fluctuations in engine load. Excessive wear of the diaphragm may also be created by the fluctuations in engine loads. If a hole is worn completely through the diaphragm, the fuel injection pump output will be limited. This will result in a low power complaint.

A new 192-9155 Fuel Ratio Control Assembly is now available to replace the 116-8642 Fuel Ratio Control Assembly .

Adaptable To: The new 192-9155 Fuel Ratio Control Assembly is available to replace a worn 116-8642 Fuel Ratio Control Assembly. The new fuel ratio control is adaptable to 3054 (S/N: 5HK1-UP; 7BJ1-UP) engines and 3056 (S/N: 8XJ1-UP) engines.

Use the following procedures in order to check the fuel ratio control. Use the following procedures in order to replace the fuel ratio control.

Procedure to Check the Fuel Ratio Control

Table 1
Required Tools    
Part Number     Part Description     Qty    
195-0761     Vacuum Pump Gp     1    



    Illustration 1g00769604

  1. To check the diaphragm of the fuel ratio control for damage, attach a tube from the 195-0761 Vacuum Pump Gp to fitting (1) on fuel ratio control (2) .

    Note: If the air can be regulated according to this procedure, an alternate source of air can be used.

  1. Use the vacuum pump to apply 48 to 55 kPa (7 to 8 psi) of pressure to the fuel ratio control. Ensure that there are no leaks in the hose or the vacuum pump. If the pressure drops within 30 seconds, the fuel ratio control is damaged.

    Use the following procedures to replace the fuel ratio control.

Removal Procedure

Table 2
Required Tools    
Part Number     Part Description     Qty    
1P-2852     Spanner Wrench     1    
171-1085     Tamper Resistant Tool Gp     1    

  1. Remove the fuel injection pump from the engine. Refer to the appropriate Service Manual for the correct procedures.

    Note: If the fuel injection pump can be easily accessed on the engine, there is no need to remove the fuel injection pump.




    Illustration 2g00769611

    Note: Some fuel injection pumps may be equipped with a shield that is installed around fuel ratio control (2). The shield may be held in position with tamperproof bolts. Use the 171-1085 Tamper Resistant Tool Gp to remove the shield. It is not necessary to reinstall the shield on the fuel injection pump after the shield is removed.

  1. Remove the 116-8648 Ring (3) in order to disconnect the rod from the fuel injection pump lever.



    Illustration 3g00769617

  1. Loosen spanner nut (5) with the 1P-2852 Spanner Wrench while you hold fuel ratio control (2) in position.

  1. Remove fuel ratio control (2) from bracket (4) on the fuel injection pump.

Installation Procedure

Table 3
Required Tools    
Part Number     Part Description     Qty    
1P-2852     Spanner Wrench     1    



    Illustration 4g00769617

  1. Put fuel ratio control (2) in position on bracket (4) .

  1. Install spanner nut (5) onto fuel ratio control (2) with the 1P-2852 Spanner Wrench while you hold the fuel ratio control in position.



    Illustration 5g00769611

  1. Insert the rod from fuel ratio control (2) into the fuel injection pump lever and install the 116-8648 Ring (3) .

  1. Install the fuel injection pump on the engine. Refer to the appropriate Service Manual for the correct procedures.

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