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Introduction
Important Safety Information
Illustration 1 | g02139237 |
Think Safety |
European Union Compliant, CE marked
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.
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 Tool Operating Manual.
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" and followed by a "Signal Word" such as "DANGER", "WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.
A non-exhaustive list of 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 warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.
The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. 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 and most current information before you start any job.
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.
Literature Information
This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group
Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.
Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.
Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.
Safety Section
The Safety section lists basic safety precautions.
Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.
General Information Section
The General Information section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources.
Operation Section
The Operation section is a reference for the new operator and a refresher for the experienced operator.
Photographs and illustrations guide the operator through correct procedures for using the tool group.
Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and the tools capabilities.
Maintenance Section
The Maintenance section is a guide to tool inspection, cleaning, storage, and tool disposal
Service Parts Section
The Service Parts section is a reference for parts identification and available part numbers.
Safety Icon Nomenclature
Personal Protection/Important Information
Illustration 2 | g02166423 |
Personal Protection/Important Information |
Prohibited Action
No smoking |
Hazard Avoidance
Crushing hazard (foot) |
Crushing hazard (hand) |
Pinch point |
Fire hazard |
Electrical Shock - Hazard |
Fire hazard |
Safety Section
At operating temperature, the hydraulic tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure. |
Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak. |
NOTICE |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
NOTICE |
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To prevent dirt and contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. This action also lessens the chance of oil spills. |
General Information Section
Introduction
Certain test specification data for the Fuel Injection Equipment Test Stand is now available through TMI (Technical Marketing Information) on the CAT NETWORK. This new data requires the use of 9U-6705 Master Nozzles . Use of any other master nozzle is not permitted. The 9U-6705 Master Nozzles can be used in place of the 9U-6705 and 1U-5500 Master Nozzles for previously published data.
This publication will address the most reliable way to access data. There are additional paths to the data and you can consult the TMI manual (see Special Instruction, LEBQ0724) for details. The appropriate sections of the TMI manual will be referenced in this publication for additional information. For example... (TMI 1.06)
To access the data you must know the engine arrangement number or the engine arrangement level pump and governor group part number. The pump and governor group part number is stamped on the injection pump housing. In some cases you will have to know the injection pump serial number.
The data is presented in text format and is organized on electronic pages called data sets. These data sets are labeled DMXXXX-XX. The injection pump and governor group PHYSICAL DATA INQUIRY screens will refer you to the appropriate data set for that pump. Many pump and governor group part numbers can use the same data set. The change level of the data set is critical because different change levels will be a separate set of data. It is possible that a certain pump and governor group part number will have different data set change levels based on the injection pump serial number.
Paper copies of the data can be made from screen prints or from the use of a node printer. (Consult the TMI manual for these features). Care should be taken to insure the paper data is kept up to date. The data obtained from the computer screen is the best way to insure your specifications are current.
This publication will use a 3406C engine as an example.
Engine Arrangement Number : 6I3480
Pump and Go Part Number : 6I3060
Data Set Reference No : DM0161-00, DM0161-01
Additional Contact Information
For additional product support questions concerning this tool, contact the Dealer Service Tools Hotline at:
USA: 1-800-542-8665, Option 1International: 1-309-578-7372Locating Pump Part Numbers Through Engine Arrangement Part Number
Locating the pump and governor group part number can be accomplished in two ways. The preferred method is through the PHYSICAL DATA program, see Section ""Finding the Pump and Governor Group Part Number from the Engine Arrangement Number using the PHYSICAL DATA - ENGINE Program" ". This is the fastest way and will soon be automated all the way to the data set. However on some new pumps this method might not be available immediately. In this case, the PARTS CONSIST program, see Section ""Finding the Pump and Governor Group Part Number from the Engine Arrangement Number using the PARTS CONSIST Program" ", must be used as an alternate path to the data. This path is more complicated but should always work.
Finding the Pump and Governor Group Part Number From the Engine Arrangement Number Using the PHYSICAL DATA - ENGINE Program
At the ACF2/IMS ONLINE MENU SCREEN (1) press the enter key (2). (Figure 3, (TMI 1.04)
Illustration 3 | g02797722 |
This will display the ACF2/IMS APPLICATION SELECTION MENU. Figure 4 (1) (TMI 1.05)
Illustration 4 | g02797723 |
At the ACF2/IMS APPLICATION SELECTION MENU (1) press the tab key to position the cursor in front of the GKN401 TMI-GENERAL ENGINE DATA line and type an X to select (2), or type GKN401 in the APPLICATION SELECTION NO_field (3). Press the enter key. This will display the ACF2/IMS PROGRAM SELECTION MENU. Figure 5, (TMI 1.05)
Illustration 5 | g02797725 |
Use the tab key to place the cursor in front of line 12 (1) and type an X to select (2) or type 12 at the PROGRAM SELECTION NO _ (3). Press the enter key. This will display the PHYSICAL DATA INQUIRY Screen. Figure 6 (1) (TMI 2.12 p1).
Illustration 6 | g02797727 |
Type the appropriate number in the ARRG/GP NUMBER field (2) and press the enter key. This will display another TMI GENERAL ENGINE DATA screen. Figure 7 (1) (TMI 2.12 p2).
Illustration 7 | g02797732 |
This screen lists some of the parts consists that make up the engine arrangement. If the pump and governor group is not listed on this screen, press key (2) to display additional data. Figure 8 (1) (TMI 2.02).
Illustration 8 | g02797872 |
When the pump group is displayed (1) type that number in the REF # CONSIST: ( ) field (2) and press the enter key. This will display type PHYSICAL DATA INQUIRY Screen. Figure 9 (1) (TMI 2.12).
Illustration 9 | g02797877 |
The DATA SET screen ID (3) for the correct group will be listed to the right of Line 11. FUEL INJECT PUMP BENCH TEST SPEC REF NUM (2) (TMI 2.12)
When the DATA SET id number has been determined write down and proceed to Section ""Displaying the DATA SET Screen When the DATA SET ID Number is Not Known" ".
Press pf3 to return to the ACF2 screen (4) .
Finding the Pump and Governor Group Part Number from the Engine Arrangement Number Using the PARTS CONSIST Program
At the ACF2/IMS ONLINE MENU SCREEN (1) press the enter key (2). (TMI 1.04)
Illustration 10 | g02797886 |
This will display the ACF2/IMS APPLICATION SELECTION MENU. Figure 11 (1) (TMI 1.05)
Illustration 11 | g02797893 |
At the ACF2/IMS APPLICATION SELECTION MENU press the tab key to position the cursor in front of the GKN401 TMI-GENERAL ENGINE DATA line and type an X to select (2). Press the enter key. This will display the ACF2/IMS PROGRAM SELECTION MENU. Figure 12, (1) (TMI 1.05)
Illustration 12 | g02797901 |
Use the tab key to place the cursor in front of line 02 and type an X to select (2) or type 02 at the PROGRAM SELECTION NO _ (3). Press the enter key. This will display the PART NUMBER CONSIST Screen. Figure 13 (1) (TMI 2.01).
Illustration 13 | g02797902 |
Type the engine arrangement PART NUMBER and SELECTION CODE into the appropriate fields (2), (3). Press the enter key. This will display another PART NUMBER CONSIST screen listing the groups consist. Figure 14 (1) (TMI 2.02).
Illustration 14 | g02797905 |
If the pump and governor group is not listed, press the enter key (2) to display additional data. Figure 15 (1).
Illustration 15 | g02797909 |
When the pump and governor part number is determined (2), write down number and proceed to Section ""Finding Test Specification Data When You Know the Engine Arrangement Level Pump and Governor Group Part Number" ".
Press the pf3 key to return to the acf2 screen (3) .
Finding Test Specification Data When You Know the Engine Arrangement Level Pump and Governor Group Part Number
Preferred Method - Used Most Often
Illustration 16 | g02797924 |
(1) Type "GKN401" (1) - cursor will jump to next field     |     |
(2) Type "12" (2)     | Press Enter     |
(3) Type pump part number at Arrangement No. field (3) (in this example "6I3060"     | Press Enter     |
(4) Read the correct line number (4)     |     |
(5) Type correct line number "011" (5)     |     |
(6) Scroll through data with enter key (6)     | Press Enter     |
Finding Test Specification Data When You Know the Engine Arrangement Level Pump And Governor Group Part Number
At the ACF2/IMS ONLINE MENU SYSTEM Screen (1) press the enter key. Figure 17 (2) (TMI 1.04)
Illustration 17 | g02797929 |
This will display the ACF2/IMS APPLICATION SELECTION MENU. Figure 18 (1) (TMI 1.05)
Illustration 18 | g02797933 |
Use the tab key to place the cursor in front of the line GKN401 TMI - GENERAL ENGINE DATA, type an X to select (2) or type GKN401 at the APPLICATION SELECTION NO. _. (3) Press the enter key. This will display the ACF2/IMS PROGRAM SELECTION MENU screen. Figure 19 (1) (TMI 1.06)
Illustration 19 | g02797937 |
Use the tab key to place the cursor in front of line 12 (2) and type an X to select (2) or type 12 at the PROGRAM SELECTION NO _. (3) Press the enter key. This will display the PHYSICAL DATA ENTRY screen. Figure 20 (1) (TMI 2.12 p1)
Illustration 20 | g02797941 |
Type the appropriate number in the ARRG/GP NUMBER field (2) and press the enter key. This will display another TMI GENERAL ENGINE DATA screen. Figure 21 (1) (TMI 2.12 p2)
Illustration 21 | g02797947 |
The DATA SET screen ID (2) for the correct group will be listed to the right of Line 011 FUEL INJECT PUMP BENCH TEST SPEC NUM (3). Write this number DMXXXX-XX down and proceed to Section ""Displaying the DATA SET Screen When the DATA SET ID Number is Not Known" ".
Certain pump and governor groups will have multiple DATA SETS. Change in pump design will be tracked by pump serial number. Figure 22 is an example of a serial l number break in the data (1). The original DATA SET DMXXXX number is kept (2) but the new DATA SET has a different change level (3).
Illustration 22 | g02797952 |
Note: Soon you will be able to use the tab key to place the cursor in front of this line. Type an X to select, Figure 21 (4). Press the enter key. The data will be displayed automatically. For now though the data will have to be displayed manually. Figure 23 (1)
Illustration 23 | g02797956 |
Press the pf3 key to return to the ACF2 screen (2) .
Proceed to Section ""Displaying the DATA SET Screen When the DATA SET ID Number is Not Known" ".
Displaying the DATA SET Screen When the DATA SET ID Number is Not Known
At the ACF2/IMS ONLINE MENU SYSTEM screen (1) (TMI 1.04) press the enter key (2). Figure 24
Illustration 24 | g02797958 |
This will display the ACF2/IMS APPLICATION SELECTION MENU. Figure 25 (1) (TMI 1.05)
Illustration 25 | g02797959 |
Use the tab key to place the cursor in front of the line GKN402 TMI - ENGINE AND COMP PERF, type an X to select (2) or type GKN402 at the APPLICATION SELECTION NO. _. (3) Press the enter key. This will display the ACF2/IMS PROGRAM SELECTION MENU screen. Figure 26 (1)
Illustration 26 | g02797960 |
Use the tab key to place the cursor in front of line 03 and type an X to select (2) or type 03 at the PROGRAM SELECTION NO _ (3). Press the enter key. This will display the PERFORMANCE PARAMETERS INQUIRY screen. Figure 27 (1) (TMI 3.03 p1)
Illustration 27 | g02797962 |
Type the appropriate numbers in the DATA REFERENCE NUMBER and CHANGE LEVEL fields (2). Press the enter key. The data set will be displayed on the next screen. Figure 28 (TMI 3.03)
Illustration 28 | g02797963 |
Press the pf3 key to return to the ACF2 screen (1) .
Interpreting the Specification Data Set Screens
The following screen contains flow specifications and physical parameters necessary to evaluate a fuel injection pump. Additional parameters such as calibration fluid temperatures and pressures are listed in the manual for the test bench. See Special Instruction, SEHS8200. These screens still apply to this data.
Every data set (DMXXXX screen) contains data for many injection pump and governor group part numbers. The data is sorted by the profile or geometry of the basic cam and the lowest level part number of the plunger and barrel group. Most part numbers with the same basic cam, plunger, and barrel groups use the same data.
Pages of data in the DATA SETS are arranged in descending pump rpm. Five or six rpm choices are listed. When the data is viewed on the screen, only a portion of a page is visible. Figure 29 is a typical screen of data.
Illustration 29 | g02797964 |
(1) DATA SET ID Number     |
(2) DATA SET Change Level     |
(3) Screen Number or Current Data Set (Typically 12 screens)     |
(4) Master Nozzle Part Number that must be used to correlate with this data.     |
(5) Correct Fuel Line to connect the Injection Pump to the Master Nozzle.     |
(6) Correct rotation of the Drive Coupling facing the bench console.     |
(7) Basic Cam part number in the Current Injection Pump Group.     |
(8) Plunger and Barrel part number in the current Injection Pump Group.     |
(9) Is the 9U-7219 Cooled Master Nozzle Holding Block required. (Used for aggressive cams and high rack setting.)     |
(10) Injection Pump RPM.     |
(11) Number of Strokes.     |
(12) Rack Position for test.     |
(13) Maximum Delivery for a New Pump.     |
(14) Minimum Delivery for a New Pump.     |
(15) Minimum Delivery for a Used Pump.     |
(16) Pf Key to return to the APPLICATION SELECTION MENU.     |
(17) Pf key to return to the PROGRAM SELECTION MENU.     |
(18) Enter Key to display Additional Data.     |
Illustration 30 | g02798238 |
Figure 30 is a full page of data. This page has all the data for a given pump at 1000 RPM (1). Typically it takes three screens to display one page of data (Figure 29). When the data is viewed, pressing the enter key advances through all the screen of data for a given DATA SET. Typically this will be 1000, 900, 800, 700, 600 RPM. These RPMs can change from pump to pump in the future but the concept will remain the same.