Reuse and Salvage for Fuel Injection Pumps and Nozzles on 3044, 3046, 3064, and 3066 Engines {1251} Caterpillar

Reuse and Salvage for Fuel Injection Pumps and Nozzles on 3044, 3046, 3064, and 3066 Engines {1251}

Usage:

554 1AM

Caterpillar Products: All 3000 Engines

Introduction

Show/hide table

Table 1
Revision	Summary of Changes in SEBF9041
3	Added effectivity.
1-2	Combined information from SEBF9040, SEBF9096, SEBF9249, and repaired 10 pixelated illustrations.
00	Added effectivity.

© 2019 Caterpillar® All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law.

Information contained in this document is considered Caterpillar: Confidential Yellow.

This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

Canceled Part Numbers and Replaced Part Numbers

This document may not include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Important Safety Information

Show/hide table




Illustration 1	g02139237

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and for other people to use. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

Show/hide table

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the safety alert symbol which is followed by a signal word such as danger, warning, or caution. The "WARNING" safety alert symbol is shown below.

Show/hide table




Illustration 2	g00008666

This safety alert symbol means:

Pay attention!

Become alert!

Your safety is involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, you must determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.

Summary

This guideline gives specifications and testing fuel injection pumps and nozzles 3044, 3046, 3064, and 3066 Engines.

Never install a part that does not meet the specifications in this guideline. During reconditioning, correct any conditions that might have caused the original failure.

Service Letters and Technical Information Bulletins

Show/hide table

NOTICE

The most recent Service Letters and Technical Information Bulletins that are related to this component shall be reviewed before beginning work. Often Service Letters and Technical Information Bulletins contain upgrades in repair procedures, parts, and safety information that pertain to the parts or components being repaired.

References

Show/hide table

Table 2
References
Media Number	Title
Channel1	"Why Reuse and Salvage Parts"
Channel1	https://channel1.mediaspace.kaltura.com/media/Why+Reuse+and+Salvage+Parts/0_ae9rhu2z
NEHS0594	Tool Operating Manual, "Using TMI for Finding Injection Pump Off Engine Test Specifications"
NEHS0607	Tool Operating Manual, " 9U-7840 Fuel Injection Equipment Calibration Fluid Test Kit".
NEHS0622	Tool Operating Manual, "Testing and Adjusting Fuel Injection Pump and Governor on 3064 and 3066 Engines". Disassembly and Assembly, "C175-16 and C175-20 Engines for Caterpillar Built Machines"
NEHS0631	Tool Operating Manual, "General Maintenance and Troubleshooting for Fuel Injection Equipment Test Stands (FIETS) and 5P-4150 Nozzle Testing Group".
SEBF9238	Reuse and Salvage Guidelines, "Fundamentals of Arc Spray for Reconditioning Components"
SEBF9240	Reuse and Salvage Guidelines, "Fundamentals of Flame Spray for Reconditioning Components"
SEHS7292	Tool Operating Manual, "Using the 5P-4150 Nozzle Testing Group"
SEHS8144	Specifications, "Nozzle Test Record"
SEHS8627	Special Instruction, "Use of 8S-2245 Injection Nozzle Cleaning Tool Group"
SEHS9031	Special Instructions, "Storage Procedure for Caterpillar Products"
SEHS9847	Special Instruction, "Creating Fuel Pump, and Fuel Nozzle reference Parts for Checking fuel Pump Test Stands and Nozzle Pop Testers".
SENR6572	Service Manual, "Zexel Fuel System" for more testing information on the 3064 and the 3066 engines.
SENR6573	Service Manual, "Nippondenso Fuel System" for more testing information on the 3064 and the 3066 engines.

The supplier Nippondenso has changed to Denso. Some of the documentation may refer to the Denso fuel injection pumps as Nippondenso.

Bosch has purchased Zexel. Although Bosch has purchased Zexel, some of the fuel injection pumps still have the name Zexel.

Tooling and Equipment

Show/hide table

NOTICE

Failure to follow the recommended procedure or the specified tooling that is required for the procedure could result in damage to components. To avoid component damage, follow the recommended procedure using the recommended tools.

Show/hide table

Table 3
Required Tooling and Equipment
Part Number	Description	Quantity
1U-8857	Extension	1
2F-2990	Sealing Plugs	1
5F-2807	Sealing Caps	1
5P-1720	Seal Pick	1
5P-4150	Tester Group	1
5P-4718⁽¹⁾	Adapter	1
5P-7448	Adapter	1
6V-2170	Tube Assembly	1
6V-6050	Ultrasonic Cleaner	1
6V-6068	Calibration Fluid	1
8S-2257	Eye Loupe	1
8S-2270	Fuel Collector	1
8T-5313	Filter	1
6V-6068	SAE J-967 Calibration Fluid	1
8S-2245	Injector Cleaning Tool Group	1
8T-7748	Polishing Wheel	1
152-0788	Storage Bag	1
162-5791	Lint Free Cloth	1

Show/hide table

⁽¹⁾	This adapter may be necessary on the earlier 3046 nozzles.

Replacement Parts

Consult the applicable Parts Identification manual for your engine.

Show/hide table

When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material.

Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

Measurement Requirements

Show/hide table

NOTICE

Precise measurements shall be made when the component and measurement equipment are at 20° (68° F). Measurements shall be made after both the component and measurement equipment have had sufficient time to soak at 20° (68° F). This will ensure that both the surface and core of the material is at the same temperature.

In-Line Pump Testing Information for the 3046 Engines

Currently, there are many documents that are published to support the testing of the fuel injection pumps. This document has been created to provide a list of media numbers that are pertinent to the fuel injection pumps.

There are many test stands that are available today. These test stands will allow an efficient method of testing fuel injection pumps. The documents that are referenced have a complete list of tooling for the Caterpillar test stands. If your test stand is from a different manufacturer, refer to the manufacturer's instructions for the list of tooling that is required.

When you are rebuilding a fuel injection pump, contamination control is important. The surrounding areas must be kept as clean as an operating room. The calibration fluid must be monitored often to keep the fuel injection pump from becoming contaminated.

Never test a fuel injection pump on a test bench without draining the fuel from the pump. Never test a fuel injection pump on a test bench without cleaning each of the components. If a contaminated pump is tested on a test bench, all the calibration fluid may become contaminated. Refer to the latest Contamination Control Guideline before attempting to service the fuel system components.

The following table provides a list of documents that contain the necessary information to test the fuel injection pumps for the 3046 engines.

The fuel injection pumps for these engines are manufactured by Denso.

Show/hide table

Table 4
3046 Documentation
Media Number	Title	Media	Sales Model	Engine Serial Numbers	Machine Serial Numbers
SENR6573	"Nippondenso Fuel System"	Service Manual	3046	5XK⁽¹⁾ MHK⁽²⁾	CJC, 9WW, ADC, AEJ, CFB, CFC, CFF, CFN, CFT, FDC, FDH, FDW AKE
NEHS0594	"Using The TMI System To Retrieve Specifications for Fuel Injection Test Stand"	Tool Operating Manual	3046	5XK⁽¹⁾ MHK⁽²⁾

Show/hide table

⁽¹⁾	Naturally Aspirated
⁽²⁾	Turbocharged

Testing Information for the Distributor Pumps on the 3044 and the 3046 Engines

The distributor pumps for these engines are manufactured by Denso.

Show/hide table

Table 5
Sales Model	Engine Serial Numbers	Machine Serial Numbers
3044	344	N/A
3044	CJS	CYC, HEN, LBA, MDH, MER, PAT, PDT, SCL, SCP, TAR, ZSA
3046	MHK	BYR, CJC, HYD, JMH, RKG, TLX, WGB

The fuel injection pumps for all the 3044 engines are distributor pumps. Some of the fuel injection pumps for the 3046 engines are distributor pumps. Caterpillar does not provide any service information for these pumps. If the distributor pump is outside of the warranty period and needs to be serviced, the pump must be sent to an authorized Denso service shop.

ADS is dedicated to the highest level of service on fuel injection systems for diesel engines.

The primary members of ADS are independent repair shops.

Each repair shop is authorized by the original manufacturer to service fuel injection equipment.

For more information on ADS, refer to the following information:

10 Laboratory Drive
PO Box 13966
Research Triangle Park, North Carolina
27709-3966 (USA)

http://www.diesel.org/index.html

(919) 406-8804 (USA)

Fax (919) 406-1306

In-Line Pump Testing Information for the 3064 and the 3066 Engines

The following table provides a list of documents that contain the necessary information to test the fuel injection pumps for the 3064 and the 3066 engines.

The fuel injection pumps for these engines are manufactured by Zexel.

Show/hide table

Table 6
3064 and 3066 Documentation
Media Number	Title	Media	Sales Model	Engine Serial Numbers	Machine Serial Numbers
NEHS0622	"Testing and Adjusting Fuel Injection Pump and Governor on 3064 and 3066 Engines"	Tool Operating Manual	3064 3066	6LK 7JK	6GK, 9LJ, AKR, BWH, CBA, CKE, DBN, FDS, KJA, PCA, 1ES, 1KL, 1XM, 2DL, 4NR, 4XW, 5BR, 5GW, 6CR, 8LK, 9CZ, 9KK, AKH, ALF, AMC, ANB, AXK, BBG, BBL, BCB, BCN, BDB, BDC, BDE, BEA, BER, BGB, BKK, BPR, BRX, BTG, CLM, CLZ, DAH, DBG, EGA, EGL, FAA, GAD, GLA, GNG, GPA, HBC, HKT, JPL, JTG, KGA, KGL, MAB, MAC, MCF, MDY, PAB, PAC, RAW, SAH, SBN, TBR
SENR6572	"Zexel Fuel System"	Service Manual
NEHS0594	"Using The TMI System To Retrieve Specifications for Fuel Injection Test Stand"	Tool Operating Manual

Reuse Criteria for the In-Line Fuel Injection Pumps on the 3064 and the 3066 Engines

If the components will be stored for a short period of time, the components must be coated in calibration fluid. The calibration fluid will serve as a rust preventive. Before the fuel pump is assembled, all the components must be cleaned in ISO 16/13 solvent.

After the fuel injection pump has been assembled, the fuel injection pump must be tested on a test stand. The calibration fluid that is in the test stand must meet the ISO 15/13 specifications.

Show/hide table

NOTICE

Do not connect a fuel injection pump with dirty fuel to a test stand. The dirty fuel will contaminate the calibration fluid within the test stand. Disassemble the fuel injection pump and clean the fuel injection pump before testing.

Inspection of the Fuel Pump

Show/hide table




Illustration 3	g06307855
(1) 096-9492 Plate (2) 125-2922 Housing (3) 5I-7508 Gasket (4) 085-9659 Stud (5) 085-9199 Plug (6) 125-2923 Adapter (7) 125-2924 Adapter (8) 085-9832 Cover (9) 096-9486 Screw (10) 099-2389 Gasket (11) 125-2925 Plug (12) 1R-9206 Nut (13) 096-8294 O-Ring Seal (14) 196-8124 Plunger (15) 125-2927 Valve (16) 125-2928 Spring (17) 096-8307 Gasket (18) 125-2929 Holder (19) 096-9491 Stop (20) 239-6440 Seal (21) 125-2930 Tappet (22) 096-9495 Pin (23) 125-2931 Roller (24) 125-2932 Bushing (25) 125-2933 Guide (26) 085-9888 Eyebolt (27) 5I-5147 Valve (28) 096-1118 Gasket (29) 5I-5148 Gasket (30) 190-5859 Eyebolt (31) 096-7632 Gasket (32) Shims (33) 096-8310 Spring (34) 096-9500 Seat (35) 096-9502 Seat (36) 096-9506 Control (37) 085-9838 Screw (38) 096-9503 Pinion (39) 096-9505 Sleeve (40) 085-9195 Screw (41) 125-2934 Camshaft (42) 096-8273 Bearing (42) 085-6723 Bearing (43) 5I-5146 Nut (44) 087-8884 Washer (45) 085-9259 Key (46) 096-9507 Ring (47) 096-9508 Ring (48) Shims (49) 096-7570 O-Ring Seal (50) 125-2935 Bearing (51) 125-2936 Screw (52) 096-9385 Gasket (53) 096-7571 Seal (54) 085-9197 Cover (55) 085-9258 Bolt (56) 125-2937 Gasket (149) 255-2969 Fuel Priming Pump Gp

Illustration 3 shows a typical fuel pump for these engines. Your fuel pump may have a different part number. For the correct part numbers for your machine, refer to the Parts Manual for your machine.

During the assembly of a fuel injection pump, always replace the following components:

Gaskets
O-rings
Seals
Copper Washers

Plungers and Barrels

Show/hide table




Illustration 4	g01231760
Upper and lower metering edge

Inspect the upper metering edge and the lower metering edge of the plunger. Verify that the metering edges are sharp edges. Inspect the helix on the plunger.

Show/hide table




Illustration 5	g01231767
Plunger with cavitation erosion

DO NOT USE AGAIN

Show/hide table




Illustration 6	g01231796
Wear on leading edges

DO NOT USE AGAIN

Note: Wear on the leading edges is generally caused by dirty fuel or high hours on the components.

Show/hide table




Illustration 7	g01231815
Heavy scratches on the plunger

DO NOT USE AGAIN

Any scratches, pitting, or scuffing on the surface that can be felt with a pick

Show/hide table




Illustration 8	g01231856
Nick on the metering edge

DO NOT USE AGAIN

Replace the plunger and the barrel if there is a nick or a burr on the metering edge.

Show/hide table




Illustration 9	g06307856

After cleaning the plunger, make sure that the plunger slides into the barrel smoothly. The plunger must slide into the barrel without being forced. The weight of the plunger is the only force that is required. The plunger and barrel must be held at a 60° angle. Turn the plunger in the barrel several times and repeat the process. If the plunger slides into the barrel too quickly, replace the plunger and the barrel. If the plunger does not slide smoothly, replace the plunger assembly.

Note: The plunger and barrel must be clean. The plunger and barrel must be coated in clean diesel fuel or calibration fluid that meets ISO 15/13 specifications. This type of procedure is performed in a clean room.

Delivery Valve

Show/hide table




Illustration 10	g01232414
Valve seat and retraction collar.

Inspect the valve seats for nicks, scratches, or burrs. Replace both components if any of these conditions exist.

Inspect the retraction collar for rust, erosion, or burrs. Replace both components if any of these conditions exist.

Show/hide table




Illustration 11	g01231241
Rust on the retraction collar and seat area that is seen at 30 times magnification

DO NOT USE AGAIN

Rust is generally caused by water in the fuel or by improper storage or handling procedures.

Show/hide table




Illustration 12	g01231258
Wear band on the valve seat that is seen at 30 times magnification

DO NOT USE AGAIN

This type of wear is generally caused by contaminated fuel.

Rack and Control Sleeve

Show/hide table




Illustration 13	g01232730
Bearing area and teeth

Inspect the areas of the rack that are in Illustration 13. Do not use the rack if any of the following conditions exist:

Wear on the pin
Wear on the teeth that can be felt with a pick
Bent rack

Show/hide table




Illustration 14	g01232745
Polished area from bearings on both ends

USE AGAIN

Note: If the worn area can be felt with a pick, do not use the rack again.

Show/hide table




Illustration 15	g01232753
Minor damage to the slot on the control sleeve

USE AGAIN

Inspect the screw for damage. Adjustment of the quantity of injection will be difficult if the screw is damaged.

Inspect the teeth on the pinion. If the wear on the teeth can be felt with a pick, do not use the control sleeve again.

Tappets

Show/hide table




Illustration 16	g01233105
Polished area on body

USE AGAIN

Do not use the tappet again if any of the following conditions exist:

Heavy scratches that can be felt with a pick
Rust
Pitting
Light wear on more than 25% of body

Show/hide table




Illustration 17	g01233146
Minor scratches on roller

USE AGAIN

Do not use the tappet again if any of the following conditions exist:

Heavy scratches that can be felt with a pick
Rust
Pitting
Wear steps from contact on camshaft

Note: If the tappet is damaged, thoroughly inspect the corresponding camshaft lobe for damage.

Note: A tappet receives heavy loads from the camshaft. Replace the tappet if the tappet is questionable. Replacing the tappet is more economical than replacing a camshaft.

Spring Seats

Show/hide table




Illustration 18	g01233364
Wear from plunger and spring

DO NOT USE AGAIN

This lower spring seat has worn areas that can be felt with a pick. If the worn area is polished, the lower spring seat can be used again.

This type of wear is normally caused by high hours.

Show/hide table




Illustration 19	g01233579
Wear from spring

DO NOT USE AGAIN

These upper spring seats have worn areas that can be felt with a pick. If the worn area is polished, the upper spring seat can be used again.

This type of wear is normally caused by high hours.

Camshaft

Show/hide table




Illustration 20	g01233599
Important features on the camshaft

Inspect the following areas of the camshaft for damage:

Threads
Taper
Key slot
Lobes
Bearing diameter
Area that seals

Show/hide table




Illustration 21	g01233676
Light scratches on camshaft lobe

USE AGAIN

Use the camshaft again if any of the following conditions exist:

Surface rust that can be removed by using the 8T-7748 Polishing Wheel
Stains that can be removed by using the 8T-7748 Polishing Wheel

Do not use the camshaft again if any of the following conditions exist:

Surface pitting
Rust that cannot be removed by the 8T-7748 Polishing Wheel

Show/hide table




Illustration 22	g01233699
Burr on the side of a lobe

USE AGAIN

The camshaft can be used again after the burr has been removed.

Do not use the camshaft again if the burr was in the area of the lobe that contacts the tappet.

If a camshaft is replaced for any reason, replace all the tappets. Starting with all new mating components is recommended.

Show/hide table




Illustration 23	g01233879
Worn area that seals

DO NOT USE AGAIN

Bearings

Show/hide table




Illustration 24	g01234939
Burrs on bearing area

DO NOT USE AGAIN

The bearing in Illustration 24 can be used again after the damage has been removed. Use a file to remove the burrs.

Inspect the areas of the center bearing that contacts the camshaft. If there is any wear or damage that can be felt with a pick, replace the bearing.

Show/hide table




Illustration 25	g01235950
Damage from removing race with too much force

DO NOT USE AGAIN

The bearing race in Illustration 25 has two types of damage. The vertical lines were caused by using too much force to remove the bearing race from the housing. This type of damage is known as brinelling.

The dark band was caused by contamination.

Replace the bearings if the contact surfaces are burnt, worn, or damaged.

Always replace the bearings and the race if one of the following conditions exist:

High hours
Catastrophic failure of any component
Signs of contamination
Brinelling
Rust
Pitting
Scratches

Note: Always replace the race and the roller bearings as a set.

Housing

Show/hide table




Illustration 26	g01235631

Inspect the housing in the following areas:

Bushings for the rack
Bores in the housing
Threaded holes

Replace the housing if the damage is beyond repair. If the damage is questionable, compare the damage to a new housing.

Inspection of the Governor

Show/hide table




Illustration 27	g06307870
(57) 190-5860 Housing (58) 085-9211 Plug (59) 190-5861 Gasket (60) 190-5862 Cover (61) 085-7913 Bolt (62) 096-9585 Adapter (63) 085-9261 Bolt (64) 096-8292 O-Ring Seal (65) 190-8563 Shim (66) 190-5864 Bolt (67) 190-5865 Screw (68) 190-5887 Nut (69) 190-5909 Shim (70) 190-5871 Pin (71) 190-5880 O-Ring Seal (72) 085-9906 Limiter (73) 190-5890 Spring (74) 222-8218 Link (75) 190-5899 Connector (76) 190-5900 Pin (77) 190-5901 Pin (78) 190-5904 Oil Seal (79) 125-2939 Gasket (80) 190-5906 Bracket (81) 190-5907 Bolt (82) 190-5908 Nut (83) 085-9658 Bolt (84) 190-5881 Cover (85) 190-5885 Screw (86) 085-9865 Nut (87) 190-5886 Bolt (88) 085-9209 Screw (89) 085-9205 Nut (90) 085-9265 Bolt (91) 190-5888 Cover (92) 085-9909 Flyweight As (93) 085-9653 Key (94) 096-8280 Washer (95) 085-9267 Nut (96) 190-5889 Sleeve (97) 5I-5154 Capsule (98) 096-8356 Spring (99) 085-9914 Spring (100) 190-5891 Nut (101) 096-8274 Gasket (102) 085-9206 Nut (103) Shims (104) 085-9269 Nut (105) 190-5892 Lever (106) 190-5896 Lever As (107) 085-9645 Ring (108) 190-5897 Shim (109) 190-5902 Lever (110) 1R-9210 Gasket (111) 190-5905 Gasket (112) 085-9655 Gasket (113) 190-5910 Nut (114) 190-5866 Shaft (115) 190-5867 Lever (116) 190-5868 Bolt (117) 190-5869 Washer (118) 190-5872 Collar (119) 190-5873 Spring (120) 190-5874 Lever (121) 190-5875 Washer (122) 190-5876 Nut (123) Shims (124) 099-6495 Plug (125) 190-5893 Bushing (126) 096-8289 O-Ring Seal (127) 085-9271 Ring (128) 096-7567 Seal (129) 085-9887 Shim (130) 190-5894 Shim (131) 190-5895 Bushing (132) 085-9652 Key (133) 085-7916 Collar (134) 085-9207 Washer (135) 190-5903 Pin (136) 085-9936 Lever (137) 190-5911 Adapter (138) 190-5912 Eyebolt (139) 190-5913 Gasket (140) 190-5914 Gasket (141) 190-5870 Washer (142) 190-5883 Screw (143) 190-5884 Washer

Inspect all the internal components for damage. Look for signs of abnormal wear. If there is any damage to any part, replace the damaged part.

Flyweight

Show/hide table




Illustration 28	g01235344
Slight wear on the sliders

USE AGAIN

Do not use the flyweight again if the following conditions exist:

Heavy wear on the sliders
Excessive clearance between the pins and the sliders

Tension lever

Show/hide table




Illustration 29	g01235372
Wear on the pin, contact area, and spring retainer

DO NOT USE AGAIN

Show/hide table




Illustration 30	g06307874
Wear on the contact areas and the spring retainer.

DO NOT USE AGAIN

This type of wear is common to governors with high hours. If this type of wear is present on the tension lever, also inspect the guide lever.

Swivel Lever

Show/hide table




Illustration 31	g01235508
Wear on swivel lever

DO NOT USE AGAIN

This type of wear is common on governors with high hours. If this type of wear is present on the swivel lever, also inspect the bushings.

Guide Lever

Show/hide table




Illustration 32	g01235531
Wear on the shifter

DO NOT USE AGAIN

This type of wear is common on governors with high hours. If this type of wear is present on the guide lever, also inspect the tension lever.

Supply Pump Parts

There are two types of pumps that are available. One pump has a roller tappet and the other pump has a flat tappet.

For the roller tappet, refer to "Tappets" that is found in this guideline.

Show/hide table




Illustration 33	g01235131
(150) 5I-5159 Plug (151) 085-9222 Adapter (152) 085-9888 Eyebolt (153) 085-9899 Eyebolt (154) 095-2040 Washer (155) 095-2489 Valve (156) 095-2490 Spring (157) 096-8288 O-Ring Seal (158) 096-8336 Spring (159) 125-2940 Housing (160) 125-2941 Pushrod (161) 125-2942 Piston (162) 125-2943 Gasket (163) 239-6656 Fuel Priming Pump As

Piston

Show/hide table




Illustration 34	g01235096
Heavy scratches on the piston

DO NOT USE AGAIN

Do not use the piston again if any of the following conditions exist:

Scratches that can be felt with a pick
The area that contacts the tappet can be felt with a pick
Pitting or heavy rust

The piston can be used again if any of the following conditions exist:

Surface rust that can be removed by polishing
Stained areas
Light scratches that cannot be felt with a pick

Pushrod

Show/hide table




Illustration 35	g01235166
The pushrod is lightly polished.

USE AGAIN

Do not use the pushrod again if there is any change in size in the polished area. Measure the pushrod with a micrometer to determine if there has been any change in the diameter.

Springs

A spring needs to be inspected for signs of wear. Do not use the springs again if any of the following signs are present:

Cracks
Pitting
Rust
Abrasion

Testing Fuel Injection Nozzles on 3044, 3046, 3064, and 3066 Engines

During an engine rebuild, inspect, and test each nozzle to determine reusability. If the nozzle does not meet specifications, replace the nozzle or repair the nozzle.

If the nozzle is dropped by accident, replace the nozzle. Damage may occur internally to the nozzle that may not be evident by any of the tests.

The tooling must be operating properly. Verify that there are no leaks. Verify that the gauges are in good working condition. Calibrate the gauges annually.

A technician that will repair the nozzles must have excellent workmanship. The work that needs to be performed is precise. All the components and the work environment must be kept clean. Refer to the latest contamination control guideline before attempting to service the fuel system components.

There are several nozzles that are available for the engines that are listed above. The following graphics show examples of two of the nozzles and the internal components.

Show/hide table




Illustration 36	g06307771
Typical nozzle

(1) Fuel inlet

(2) Body

(3) Fuel return

(4) Retaining nut

(5) Pressure spring

(6) Nozzle tip assembly

Show/hide table




Illustration 37	g06307778

(7) Holder assembly

(8) Shim

(9) Spring

(10) Seat

(11) Spacer

(12) Pin

(13) Nozzle Tip Assembly

(14) Nut

Cleaning Of Fuel Injection Nozzles

Show/hide table

Personal injury can result from improper handling of chemicals.
Make sure you use all the necessary protective equipment required to do the job.
Make sure that you read and understand all directions and hazards described on the labels and material safety data sheet of any product used to clean the components.

Observe all safety precautions recommended by the chemical manufacturer for handling, storage, and disposal of cleaning agents.

Show/hide table

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.

Each nozzle should be properly cleaned prior to performing any tests. 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 or spray distortion. Dirt that is in the orifices of the nozzle tip can damage engine components. Dirt can also cause spray distortion.

Show/hide table




Illustration 38	g06307785
Remove carbon with the 8S-2258 Brass Wire Brush which is included in the 8S-2245 Injector Cleaning Tool Group.

Before the fuel injection nozzle can be tested, remove all loose carbon around the tip of the fuel injection nozzle. Use the 8S-2245 Injector Cleaning Tool Group to clean the fuel injection nozzle. Refer to Special Instruction, SEHS8627, "Use of 8S-2245 Injection Nozzle Cleaning Tool Group" for more information.

Remove the retaining nut from the body or the holder assembly. Remove the tip assembly of the fuel injection nozzle. Wash the needle valve, the body, and the tip assembly in clean solvent. The solvent must meet ISO 16/13.
Note: Do not mix the needle valve and bodies of different nozzle tip assemblies. The components of the nozzle tip assembly are a precise fit. The components must not be exchanged with other components. Do not touch the sliding surfaces of the needle valve.

Tighten the retaining nut to the proper torque. Refer to Table 7 for the proper torque value.

Show/hide table

Table 7
Engine	Torque Value
3044	34 to 39 N·m (25.0 to 29.0 lb ft)⁽¹⁾ 25 to 34 N·m (18.0 to 25.0 lb ft)⁽²⁾
3046	29 to 39 N·m (21.0 to 29.0 lb ft)
3064	30 to 39 N·m (22.0 to 29.0 lb ft)
3066	30 to 39 N·m (22.0 to 29.0 lb ft)

Show/hide table

⁽¹⁾	Naturally aspirated
⁽²⁾	Turbocharged

Replace the nozzle tip if the discharge pattern is still unacceptable.
Note: Some nozzle tips are not available. It may be necessary to replace the complete nozzle if the discharge pattern is still unacceptable. Refer to the Parts Manual for your engine for the different levels of service.
Note: It may be necessary to clean the internal components of the nozzle before assembling. If necessary, use the 6V-6050 Ultrasonic Cleaner or the 6V-6060 Ultrasonic Cleaner.

Pressure Test

Show/hide table

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.

Show/hide table

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.

Show/hide table




Illustration 39	g06307789
Test the pressure for the fuel injection nozzle by using 5P-4150 Nozzle Testing Group. (15) Adapter (16) Fuel injection nozzle (17) 6V-2170 Tube As (18) 1U-8857 Extension Tube (19) 8S-2270 Fuel Collector (20) 8T-5313 Filter

Connect fuel injection nozzle (16) to the tooling that is shown in Illustration 39.
The spray from the fuel injection nozzle must be directed into 1U-8857 Extension Tube (18) and 8S-2270 Fuel Collector (19).
Use clean 6V-6068 Calibration Fluid when the fuel injection nozzles are tested. The calibration fluid is similar to SAE J-967 (ISO 4113) oil.
Close the gauge protector valve. Close the shutoff valve. Open the pump isolator valve. Flush the fuel injection nozzle by operating the nozzle tester. Operate the nozzle tester for 10 to 15 strokes at a rate of approximately sixty strokes per minute.

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 will happen when valve needle rises from the nozzle seat. Refer to Table 8 for the correct pressure setting.

Show/hide table

Table 8
Engine	Opening Pressure
3044	11770 to 12750 kPa (1707 to 1849 psi)⁽¹⁾ 18142 to 19123 kPa (2631.4 to 2773.6 psi)⁽²⁾
3046	18142 to 19123 kPa (2631.4 to 2773.6 psi)
3064	22060 to 23050 kPa (3200 to 3343 psi)
3066	22060 to 23050 kPa (3200 to 3343 psi)

Show/hide table

⁽¹⁾	Naturally aspirated
⁽²⁾	Turbocharged

If necessary, add shims to meet the specifications. Increasing shims by 0.10 mm (0.004 inch) changes injection pressure by approximately 1375 kPa (200 psi). Shims are available in many sizes. Refer to the Parts Manual for the different levels of service.

Back Leakage Test

Show/hide table

Connect fuel injection nozzle (16) to the tooling that is shown in Illustration 39.
Position the fuel injection nozzle so that the direction of the fuel spray is into 1U-8857 Extension Tube (18) and 8S-2270 Fuel Collector (19).
Note: Wipe the nozzle with a lint free cloth to remove any fuel or calibration fluid from the nozzle.
Open the gauge protector valve.
Pump the pressure slightly below the opening pressure of the fuel injection nozzle. Refer to Table 9 for the approximate pump 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 damaged, the time will not be less than 5 seconds or more than 45 seconds.
Show/hide table
Table 9
Engine Pressure

3044 11200 kPa (1625.0 psi)⁽¹⁾
18615 kPa (2700.0 psi)⁽²⁾

3046 16550 kPa (2400.0 psi)

3064 20680 kPa (3000.0 psi)

3066 20680 kPa (3000.0 psi)

Show/hide table

⁽¹⁾ Naturally aspirated

⁽²⁾ Turbocharged

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 or replace the nozzle tip.
Show/hide table

Illustration 40 g06307790

Leakage test after ten seconds
(A) Acceptable
(B) Unacceptable
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 through 3.

Fuel Injector Nozzle And Seat Test

Show/hide table

Connect fuel injection nozzle (16) to the tooling that is shown in Illustration 39.
Position fuel injection nozzle so that the direction of the fuel spray is into 1U-8857 Extension Tube (18) and 8S-2270 Fuel Collector (19).
Note: Wipe the nozzle with a clean towel to remove any fuel or calibration fluid from the nozzle.
Open the gauge protector valve.
Pump the pressure slightly below the opening pressure of the fuel injection nozzle. Refer to Table 9 for the approximate pump pressure. Fuel should not collect on the tip of the fuel injection nozzle in a sufficient quantity to drip from the tip for at least ten seconds. A light dampness is acceptable.
If necessary, replace the seat. If necessary, replace the nozzle tip. If any of the components need to be replaced, repeat the previous tests.
Note: Refer to the Parts Manual for the different levels of service for the nozzles.

Test The Spray Pattern

Show/hide table

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

Show/hide table




Illustration 41	g06307794
(A) Indirect injected nozzle (B) Direct injected nozzle

Connect fuel injection nozzle (16) to tooling that is shown in Illustration 39.
Position fuel injection nozzle so that the direction of fuel spray is into 1U-8857 Extension Tube (18) and 8S-2270 Fuel Collector (19).
Close the gauge protector valve and the shutoff valve. Open the pump isolator valve.
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. The nozzle must produce atomized fuel. A difference in the nozzle spray patterns indicates that fuel injection nozzle is damaged. Refer to the correct spray pattern in Illustration 41.
Note: Be sure that the gauge protector valve is closed before fuel injection nozzle is removed from the nozzle tester. Closing the gauge protector valve will prevent damage to the pressure gauge.
Once the nozzles have been tested, do not flush the calibration fluid from the nozzles. The calibration fluid will lubricate the nozzle. The calibration fluid will prevent the nozzle from rusting during storage.

Thermal Spray Procedures for 3064 And 3066 Engines Fuel Injection Pump Camshaft

Part Description

Show/hide table

Table 10
Base Metal	Steel casting or forging
Hardness	60 Rc

Arc Spray Equipment and Procedure

Show/hide table

Table 11
Maximum Surface Texture	1.6 µm (62.99213 µinch)
Reason for Spraying	Wear or grooving
Mating Part Contact Area & Material	Bearing
Arc Spray Equipment Type	SmartArc by Oerlikon Metco, TAFA 8830 MHU, or TAFA 8835 MHU
Wire	TAFA 95 MXC Wire Top Coat, TAFA 75B Bond Coat
Finish Thickness	As Required
Spray Angle	90°
Substrate Pre-Heat Temperature	66° C (150° F) Do not direct arc on area to be sprayed
Substrate Temperature During Spraying Not to Exceed	148° C (300° F)
Auxiliary Cooling	Filtered shop air
Rotation/Traverse Device	Lathe or head stock / tail stock arrangement, rotary turntable
Rotation Speed	92.0 SMPM (300.00 SFPM)
Surface Preparation Method	Undercut and Grit blast
Equipment Required	Turn (Horizontal or Vertical) Lathe
Recommended Cutting Tool	ISCAR DNMG 432TFIC507
Blast Media Recommendation	Pressure Type Only (Aluminum Oxide Grit)

Show/hide table

Table 12
Arc Spray		Procedure		Check List
Clean Part		Degrease in hot Aluminum safe cleaner
Undercut		To "tru-up" surface
Chamfer		If required - 1.0 mm (0.039 inch) x 45°
Remove Oxide		Use emery cloth or glass bead blaster
Clean Spray Area		Commercial degreaser
Mask for Grit Blaster		Duct tape, metal shield, or rubber
Grit Blast Equipment		Pressure type only
Grit Type and Size		20 mesh aluminum oxide
Blast Air Pressure		690 kPa (100.0 psi)
Blast Nozzle to Work Distance		51 to 150 mm (2.0 to 6.0 inch)
Remove Blast Mask		Make sure that surface is clean
Mask for Metal Spray		AntiBond or Blue Layout Dye
Metal Spray Equipment Type		Smart Arc by Oerlikon Metco	TAFA
	Consumable (Bondcoat)	TAFA 75B	TAFA 75B
	Clamp Pressure	275 kPa (40 psi)
	Air Jets/Pressure	415 kPa (60 psi)	415 kPa (60 psi)
	Arc Load Volts	30V	30V
	Amps	125 Amps	150 Amps
	Gun to Work Distance (Standoff)	128 mm (5.0 inch)	128 mm (5.0 inch)
	Spray Rate/Bond Pass	0.038 mm (0.0015 inch)/pass	0.038 mm (0.0015 inch)/pass
	Consumable (Topcoat)	TAFA 95 MXC	TAFA 95 MXC
	Clamp Pressure	275 kPa (40 psi)
	Air Jets/Pressure	415 kPa (60 psi)	415 kPa (60 psi)
	Arc Load Volts	31V	33V
	Amps	50 Amps	75 Amps
	Gun to Work Distance (Standoff)	102 mm (4.0 inch)	102 mm (4.0 inch)
	Spray Rate/Build Up	0.038 mm (0.0015 inch)/pass	0.038 mm (0.0015 inch)/pass
	Rotation Speed of Part (RPM)	RPM varies depending on diameter
	Rotation Speed of Part	92.0 SMPM (300.00 SFPM)
	Traverse Rate of Gun	11.0 SMPM (40.00 SFPM)
Gun Fixturing Method		Machine mount or hand held
Finishing Equipment		Lathe
Part/Cutter Rotation Roughing		12.0 SMPM (40.00 SFPM)
Part/Cutter Rotation Finishing		15.0 SMPM (50.00 SFPM)
Coolant		Oil base synthetic - 40:1 ratio
Traverse Speed		0.30 mm (0.012 inch)
Depth of Rough Cut		0.51 mm (0.020 inch)
Depth of Finish Cut		0.25 mm (0.010 inch)

Specifications

Show/hide table




Illustration 42	g03135400

Show/hide table

Table 13
Fuel Injection Pump Camshaft
Model	Dimension A	Dimension B	Dimension C	Dimension D	Dimension E
3064 3066	40.72 ± 0.25 mm (1.603 ± 0.010 inch)	20.003 ± 0.005 mm (0.7875 ± 0.0002 inch)	11.13 ± 0.25 mm (0.438 ± 0.010 inch)	16.955 ± 0.005 mm (0.6675 ± 0.0002 inch)	16.26 ± 0.25 mm (0.640 ± 0.010 inch)

Note: All sprayed edges should be rounded with a 0.795 mm (0.0313 inch) radius.

Storage Procedures

Proper protection of the components from corrosion is important. Corrosion will start in as little as one hour after the components have been cleaned.

When the components will not be inspected for one hour or less the components should be coated with a rust or corrosion inhibitor or coated with clean engine oil. The components should be individually wrapped to prevent contamination, and should be stored in a protected area to avoid damage. See Illustration 43.

When the components will not be inspected in two days or more the components should be coated with a rust or corrosion inhibitor or coated with clean engine oil and should be placed in a container which is clean and structurally solid. The container should be covered or wrapped in plastic to prevent damage and contamination to the components. See Illustration 44.

Refer to SEHS9031Special Instruction, "Storage Procedure for Caterpillar Products" for more information.

Show/hide table