Inspection of Fuel Injection Pumps on 3054C, C3.3, C4.4 (Mech), and C7.1 (Mech) Engines {1251} Caterpillar


Inspection of Fuel Injection Pumps on 3054C, C3.3, C4.4 (Mech), and C7.1 (Mech) Engines {1251}

Usage:

3054C 334
Asphalt Compactor
CB-534D (S/N: EAA1-UP; FEA1-UP; GCA1-UP; C2B1-UP; C4B1-UP; FGH1-UP; B5M1-UP; C8M1-UP)
CB-564D (S/N: C6D1-UP; D4M1-UP)
Asphalt Paver
AP-650B (S/N: A7P1-UP)
AP-800D (S/N: A5P1-UP)
AP300 (S/N: B2Y1-UP)
Backhoe Loader
414E (S/N: ELB1-UP)
416D (S/N: B2D1-UP; BKG1-UP; BGJ1-UP; BFP1-UP)
416E (S/N: SHA1-UP; BWC1-UP; CBD1-UP; LMS1-UP)
416E Series III (S/N: GRR1-UP)
416F (S/N: LWT1-UP)
416F2 (S/N: LYA1-UP; LBF1-UP)
420D (S/N: BMC1-UP; MBH1-UP; BLN1-UP; FDP1-UP)
420E (S/N: GAN1-UP; HLS1-UP; KMW1-UP)
420F (S/N: LTG1-UP; LKH1-UP)
420F2 (S/N: LBS1-UP)
420F2 IT (S/N: LYC1-UP)
420F2 ST (S/N: LYB1-UP)
422E (S/N: HBE1-UP; DSK1-UP; MAW1-UP)
422F (S/N: LRH1-UP)
422F2 (S/N: LYF1-UP)
424D (S/N: RXA1-UP; CJZ1-UP)
426 F2 (S/N: EJ21-UP; DJ41-UP; EJ41-UP)
428D (S/N: BXC1-UP; MBM1-UP; DSX1-UP)
428E (S/N: DXC1-UP; DPH1-UP; SNL1-UP)
428F (S/N: LBH1-UP)
428F2 (S/N: LYG1-UP)
430D (S/N: BNK1-UP; BML1-UP)
430E (S/N: DDT1-UP; EAT1-UP)
430F (S/N: LNH1-UP; LDY1-UP)
430F2 IT (S/N: LYE1-UP)
430F2 ST (S/N: LYD1-UP)
432D (S/N: WEP1-UP; TDR1-UP)
432E (S/N: JBA1-UP; BXE1-UP; RXS1-UP)
432F (S/N: LNR1-UP)
432F2 (S/N: LYJ1-UP)
434E (S/N: SXB1-UP; SEF1-UP; FSH1-UP; SJL1-UP)
434F (S/N: LDH1-UP)
434F2 (S/N: LYK1-UP)
442D (S/N: TBD1-UP; SMJ1-UP)
442E (S/N: EME1-UP; PCR1-UP; GKZ1-UP)
444E (S/N: NBA1-UP; HXB1-UP; LBE1-UP)
444F (S/N: LJJ1-UP)
444F2 (S/N: LYL1-UP)
Compact Wheel Loader
914G (S/N: PDF1-UP)
Engine
C3.3 (S/N: E3J1-UP)
Excavator
312D2 (S/N: EAB1-UP; FAB1-UP; KLE1-UP; DGF1-UP; HBF1-UP; MGJ1-UP; WHJ1-UP; GWN1-UP; MPP1-UP; BRW1-UP; TJY1-UP; RXZ1-UP)
313D2 (S/N: ZAA1-UP; PLD1-UP; GAJ1-UP; RKN1-UP)
318D2 (S/N: JEB1-UP; HAH1-UP; XAH1-UP; DPJ1-UP; WGR1-UP; TZS1-UP; XGS1-UP)
320D2 (S/N: GBA1-UP; LCA1-UP; LMA1-UP; YEA1-UP; PBB1-UP; NBF1-UP; TMF1-UP; WBF1-UP; MDJ1-UP; FKK1-UP; DFM1-UP; HDM1-UP; JFM1-UP; TDN1-UP; DNP1-UP; KHR1-UP; RAR1-UP; DNS1-UP; KBS1-UP; ZCS1-UP; EKT1-UP; NBT1-UP; RDZ1-UP; SDZ1-UP; TDZ1-UP)
Industrial Engine
3054C (S/N: 3341-UP)
C4.4 (MECH) (S/N: 4461-UP)
C7.1 (S/N: 6301-UP; 6731-UP)
Integrated Toolcarrier
IT14G (S/N: FWL1-UP; KZN1-UP)
Mobile Hydraulic Power Unit
320D2 MHPU (S/N: K221-UP; P9X1-UP)
OEM Excavator Based Specialty Solution
312D OEM (S/N: L441-UP)
Paving Compactor
CB-434D (S/N: CNH1-UP)
CD54 (S/N: C3B1-UP; J5R1-UP)
CP-323C (S/N: EAS1-UP)
CS-323C (S/N: DAR1-UP)
PF-300C (S/N: PFB1-UP)
PS-150C (S/N: NPK1-UP; FPS1-UP)
PS-300C (S/N: PFS1-UP)
PS-360C (S/N: PJF1-UP)
Telehandler
TH210 (S/N: MHT1-UP)
TH215 (S/N: MHS1-UP)
Vibratory Soil Compactor
CP-433E (S/N: ASN1-UP; BTY1-UP)
CP-533E (S/N: BZG1-UP; TLH1-UP; ASM1-UP)
CS-433E (S/N: ASR1-UP; BTT1-UP)
CS-533E (S/N: BZE1-UP; TBE1-UP; DAK1-UP; ASL1-UP; TJL1-UP)

Introduction

There have been some isolated instances of issues with fuel injection pumps on certain 3054C, C3.3, C4.4 (Mech), and C7.1 (Mech) engines. These issues with the fuel injection pump cause the engine to suffer from low power, issues with starting the engine, and excessive smoke.

Solution

Ensure that the correct diagnosis procedures have been carried out. Ensure that the following tests have been carried out. Refer to Systems Operation Testing and Adjusting for further information.

  • Fuel System - Inspect

  • Air in Fuel - Test

  • Fuel Injection Nozzle - Test

  • Fuel Quality - Test

  • Fuel System - Prime

  • Fuel System Pressure - Test

If the diagnosis procedures determine that the fuel injection pump has an issue, remove the fuel injection pump from the engine. Refer to Disassembly and Assembly, "Fuel Injection Pump - Remove" for the correct procedure. Once the fuel injection pump is removed, follow steps 1 to 9to inspect the fuel injection pump.

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

Personal injury can result from being struck by parts propelled by a released spring force.

Make sure to wear all necessary protective equipment.

Follow the recommended procedure and use all recommended tooling to release the spring force.



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.

Dispose of all fluids according to local regulations and mandates.


  1. If possible, take the fuel injection pump to a clean work area.

  2. Clean the outside surfaces of the fuel injection pump.


    Illustration 1g03117860
    Typical example

  3. Place a suitable container under the fuel injection pump to collect any fuel from the fuel injection pump. Use a suitable tool to loosen the drain plug (1). If necessary, retain the fuel collected for analysis if required.


    Illustration 2g03117878
    Typical example

  4. Use a suitable pair of pliers to remove the throttle return spring (2).

    Note: Care should be taken when the spring is removed.



    Illustration 3g03117896
    Typical example

  5. Loosen self-locking nut (3). Do not remove the nut.


    Illustration 4g03117916
    Typical example

  6. Use a suitable pair of pliers to lift and disconnect throttle spring (4). Remove self-locking nut (3), washer, upper retainer, spring, lower retainer, spacer, lever, and dust cap.

    Note: Care should be taken when the spring is removed.



    Illustration 5g03117938
    Typical example

  7. Remove four screws (6) in the governor cover (7). Gently push the throttle shaft (5) down into the cover (7).


    Illustration 6g03117956
    Typical example

  8. To inspect the internal components of the fuel injection pump, gently lift and rotate the cover (7).

    Note: The cover is still connected internally, if resistance is felt, lower the cover and move the cover backwards. Attempt to lift the cover again.

  9. Inspect the internal components of the fuel injection pump. Refer to steps 9.a and 9.b.


      Illustration 7g03117961
      Typical example

    1. If good quality fuel is being used the components will be clean. Refer to illustration 7. Take photographs of the identification plate of the fuel injection pump and any evidence found. Attach the photographs to support the claim story.


      Illustration 8g03118119
      Typical example


      Illustration 9g03118121
      Typical example

    2. If the injection pump has been run with excessive water in the fuel it will show signs of rust and oxidization of the steel components. Refer to illustration 8. Fuel with dirt ingress will show a build-up of dirt on the components. Refer to illustration 9.

      Note: Issues with the fuel injection pump that are due to dirt and water void Caterpillar warranty. The customer needs to be advised on the correct fuel, maintenance, and fuel storage procedures. Refer to the relevant Operation and Maintenance Manual for more information.

If the fuel injection pump shows signs that contaminated fuel is the root cause of the problem, the evidence can be shown to the customer immediately.

After the fuel injection pump has been inspected, the fuel injection pump must not be used in service.

Rebuild the fuel injection pump. Refer to steps 1 to 6

  1. Lower the cover (7) back into position. Ensure the throttle shaft (5), has been returned to the original position.

  2. Install the four screws (6) to the cover (7). Tighten the screws finger tight.

  3. Install the dust cap, lever, spacer, lower retainer, spring, upper retainer, washer, and self-locking nut (3). Use a suitable pair of pliers to connect and lower throttle spring (4) into position.

  4. Tighten the self-locking nut (3) finger tight.

  5. Use a suitable pair of pliers to install the throttle return spring (2).

  6. Tighten the drain plug (1). Return or retain the fuel injection pump as required.

If necessary, a replacement fuel injection pump may be obtained. Refer to Disassembly and Assembly, "Fuel Injection Pump - Install" for the correct procedure to install a replacement fuel injection pump.

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