Using the TMI System to Retrieve Off Engine Injection Pump Test Specifications for the Fuel Injection Equipment Test Stand{0706, 0782, 1251, 1286} Caterpillar


Using the TMI System to Retrieve Off Engine Injection Pump Test Specifications for the Fuel Injection Equipment Test Stand{0706, 0782, 1251, 1286}

Usage:

769C 01X
Caterpillar Products: All

Introduction

Important Safety Information




Illustration 1g02139237

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 2g02166423

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

------ WARNING! ------

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.

----------------------

------ WARNING! ------

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

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

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: 1-309-578-7372

Locating 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 3g02797722

This will display the ACF2/IMS APPLICATION SELECTION MENU. Figure 4 (1) (TMI 1.05)




Illustration 4g02797723

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 5g02797725

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 6g02797727

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 7g02797732

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 8g02797872

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 9g02797877

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 10g02797886

This will display the ACF2/IMS APPLICATION SELECTION MENU. Figure 11 (1) (TMI 1.05)




Illustration 11g02797893

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 12g02797901

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 13g02797902

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 14g02797905

If the pump and governor group is not listed, press the enter key (2) to display additional data. Figure 15 (1).




Illustration 15g02797909

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 16g02797924

Table 1
(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 17g02797929

This will display the ACF2/IMS APPLICATION SELECTION MENU. Figure 18 (1) (TMI 1.05)




Illustration 18g02797933

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 19g02797937

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 20g02797941

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 21g02797947

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 22g02797952

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 23g02797956

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 24g02797958

This will display the ACF2/IMS APPLICATION SELECTION MENU. Figure 25 (1) (TMI 1.05)




Illustration 25g02797959

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 26g02797960

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 27g02797962

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 28g02797963

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 29g02797964

Table 2
(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 30g02798238

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.

Caterpillar Information System:

2012/03/02 Improved Turbocharger Oil Drain Tubes Are Used on Certain C18 and 3406E Commercial Engines {1052, 1307}
2011/12/15 Procedure to Remedy Loose V-belts on Certain C18 and C32 Marine Engines {1207, 1358, 1359, 1397}
2014/07/07 An Improved Guide Spring and Valve Lifter Assembly Are Used in Certain C-9, C9 ACERT Engines, and C9.3 ACERT Engines {1108}
2011/12/22 A New O-ring and Oil Pan Drain Plug Are Now Used on Certain C12 Marine Engines {1302, 7553, 7555}
2011/12/19 Use the FT3193 Harness Assembly to Communicate with the Adem II 6X/6U ECM on Certain Industrial Engines {1408, 1901}
2011/12/19 Use the FT3193 Harness Assembly to Communicate with the Adem II 6X/6U ECM on Certain Truck Engines {1408, 1901}
D Series Excavator Monitoring System Configuration Mode
3516C Generator Set Engines Crankshaft Position for Fuel Injector Adjustment and Valve Lash Setting
C175-16 and C175-20 Generator Set Engines Fuel Temperature Is High - Sensor is Located at the Fuel Manifold
PL87 Pipelayer Machine Systems Alternator
2012/09/11 Generator Maintenance and Protective Relays Benefit the Service Life of Generator on Certain Cat® Products {4450}
2011/12/15 New Software Is Now Available for Product Link (PL 121) {7602, 7610, 7620}
G3500 Generator Sets Maintenance Interval Schedule - Prime
C175-16 and C175-20 Generator Set Engines Fuel Rail Temperature Is High
C9.3 Engines for Caterpillar Built Machines Fuel Filter Base - Remove and Install
C9.3 Engines for Caterpillar Built Machines Fuel Transfer Pump - Remove and Install
C9.3 Engines for Caterpillar Built Machines Fuel Manifold - Remove and Install - Return
C9.3 Engines for Caterpillar Built Machines Relief Valve (Fuel) - Remove and Install
Using the 265-4177, 265-4209 Service Tool Groups to Install Sensors in Position-Sensing Hydraulic Cylinders{0599, 0709, 0738, 1439, 7562, 7562} Using the 265-4177, 265-4209 Service Tool Groups to Install Sensors in Position-Sensing Hydraulic Cylinders{0599, 0709, 0738, 1439, 7562, 7562}
G3500 Generator Sets Maintenance Interval Schedule - Landfill
C9.3 Engines for Caterpillar Built Machines Fuel Injection Pump - Remove and Install
2012/07/20 New High-Pressure Fuel Pumps Are Used for C175 Off-Highway Truck Engines {1251}
2012/07/19 New High-Pressure Fuel Pumps Are Used for C175-16 Engines {1251}
C15 and C18 Engines for Caterpillar Built Machines Ignition Coil - Remove and Install
Back to top
The names Caterpillar, John Deere, JD, JCB, Hyundai or any other original equipment manufacturers are registered trademarks of the respective original equipment manufacturers. All names, descriptions, numbers and symbols are used for reference purposes only.
CH-Part.com is in no way associated with any of the manufacturers we have listed. All manufacturer's names and descriptions are for reference only.