SUPPLEMENT 3406B FUEL RATIO CONTROL Caterpillar


Testing and Adjusting

Usage:

Fuel Ratio Control and Governor Check

2W9161 Manual Shutoff Group.6V4186 Timing Pin.6V6070 Governor Adjusting Tool Group.
6V6106 Dial Indicator (metric). or8T1000 Electronic Position Indicator6V2030 Extension 12.7 mm (.50 in.) long.9S8903 Contact Point 2.4 mm (.094 in.) long.5P4814 Collet.8T9198 Bracket Assembly.2A0762 Bolt [1/4-20 NC × 15.88 mm (.625 in.) long].8H9178 Ground Body Bolt [1/4-20 NC × 25.4 mm (1.00 in.) long].

NOTE: The governor seals do not have to be cut or removed for the procedure that follows.


Fuel Injection Pump and Governor
(1) Cover (rack position indicator) (2) Plug (rack centering pin)

1. Remove plug (2) and cover (1) from the fuel injection pump housing.


Dial Indicator and Centering Pin Installed
(3) 6V4186 Timing Pin (4) 8T9198 Bracket Assembly (5) 2A0762 Bolt (6) 8H9178 Ground Body Bolt (7) 5P4814 Collet (8) 6V6106 Dial Indicator

2. Install the rack position indicator as follows:

a. Install the 5P4814 Collet (7) on the 8T9198 Bracket Assembly (4).


Slot in Fuel Injection Pump Rack
(9) Slot

b. Position the indicator arm in approximately the middle of its travel to make sure that it will engage in slot (9) in the rack. Put 8T9198 Bracket Assembly (4) in position on the fuel injection pump housing.

c. Install 8H9178 Ground Body Bolt (6) first. Then install 2A0762 Bolt (5).

d. Be sure the indicator arm moves freely.

e. Put dial indicator (8) or 8T1000 Electronic Position Indicator (10) in position in collet (7).

f. Put the 9S8903 Contact Point on the 6V2030 Extension and install on indicator (8) or (10).

NOTE: The 9S8903 Contact Point will not go through the collet and must be assembled after the indicator stem has passed through the collet.

g. Tighten collet (7) just enough to hold the dial or electronic indicator.


Electronic Indicator and Centering Pin Installed
(3) 6V4186 Timing Pin (4) 8T9198 Bracket Assembly (5) 2A0762 Bolt (6) 8H9178 Ground Body Bolt (7) 5P4814 Collet (10) 8T1000 Electronic Position Indicator

3. Turn the engine start key "ON" to activate the shutoff solenoid. Do not start the engine at this time.

4. Move the governor control linkage to the full "FUEL ON" position and hold or fasten it in this position.

5. Install 6V4186 Timing Pin (3) in the rack zeroing hole near the front of the fuel injection pump housing.

6. With the governor control lever in the full "FUEL ON" position, use a 1N9954 Lever and move the manual shutoff shaft slowly to the "FUEL OFF" position (counterclockwise). Watch and make sure the timing pin drops and engages with the slot in the fuel rack.

7. Release the manual shutoff shaft and zero the dial or electronic indicator. If using the dial indicator, move the indicator assembly in the collet and tighten the collet when all three needles are on zero. If using the electronic indicator simply press the zero button.

8. Remove 6V4186 Timing Pin (3) and note the change in indicator reading. The indicator should show movement in the fuel "ON" direction. If no movement occurs, repeat Steps 5, 6 and 7 to zero the indicator.

9. Release the governor control shaft and linkage.


Remove Boost Line
(11) Air line (12) fitting

10. Remove air line (11) from engine. Put plugs over the openings to keep dirt out of the system.

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

To help prevent an accident caused by parts in rotation, work carefully around an engine that has been started.

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

11. Start the engine and operate it for a minimum of five minutes to get the governor and engine up to normal operating temperatures.

12. Check the leak down rate of the fuel ratio control (with the engine operating at low idle) as follows:

a. Connect a pressure gauge, a shutoff valve, a pressure regulator and an air supply to fitting (12).

b. Apply 70 kPa (10 psi) air pressure to the fuel ratio control.

c. Turn the shutoff valve "OFF" and check the leak down rate. Leakage of 20 kPa (3 psi) in 30 seconds is acceptable.

d. If leakage is more than 20 kPa (3 psi) in 30 seconds, the fuel ratio control must be replaced before continuing to the next step.

e. Keep 70 kPa (10 psi) air pressure on the fuel ratio control for Step 13.

13. From low idle, rapidly move the governor control shaft to the full FUEL ON position and note the reading on the indicator. If using the dial indicator, read the indicator carefully because this reading will be a maximum for only a moment. The electronic indicator will hold and display the maximum reading. Make a record of the maximum indicator reading.

The maximum indicator reading is the dynamic full torque fuel setting of the engine. This setting is 0.5 mm (.02 in.) greater than the static full torque setting given on the Engine Information Plate of later engines or in the FUEL SETTING AND RELATED INFORMATION FICHE. If dynamic full torque fuel setting is not reached, increase the air pressure to make sure there is full fuel ratio control movement. Do not exceed 100 kPa (15 psi).

14. Release all air pressure from the fuel ratio control. Start at 900 rpm and rapidly move the governor control shaft to the full FUEL ON position and note the reading on the indicator. If using the dial indicator, read the indicator carefully because this reading will be a maximum for only a moment. The electronic indicator will hold and display the maximum reading. Make a record of the maximum indicator reading. This is the dynamic fuel ratio control setting for the engine.

15. If the dynamic fuel ratio control setting is within ± 0.25 mm of the specification given on the Engine Information Plate or in the FUEL SETTING AND RELATED INFORMATION FICHE, an adjustment is not necessary.

16. For adjustment of the control see FUEL RATIO CONTROL ADJUSTMENT.

17. Check boost pressure that gives full torque rack travel, as follows:

a. Connect a pressure gauge, a pressure regulator and an air supply to fitting (12).

b. Apply 25 kPa (4 psi) air pressure to the fuel ratio control.

c. Start at 900 rpm and rapidly move the governor control shaft to the full "FUEL ON" position and make a record of the maximum indicator reading.

d. Repeat this procedure several times, each time increase the air pressure 5 kPa (.5 psi).

e. Make a record of the first air pressure setting that gives full torque fuel setting. Full torque fuel setting was measured in Step 13.

f. This is the boost pressure that moves the fuel ratio control out of the rack control position. This pressure permits dynamic full torque fuel setting. If the pressure recorded in Step e is less than rated boost, the fuel ratio control cannot be a cause of low power complaint.

Fuel Ratio Control Adjustment

2W9161 Manual Shutoff Group.
6V4186 Timing Pin.
6V6070 Governor Adjusting Tool Group.
6V6106 Dial Indicator (metric). or
8T1000 Electronic Position Indicator
6V2030 Extension 12.7 mm (.50 in.) long.
9S8903 Contact Point 2.4 mm (.094 in.) long.
5P4814 Collet.
8T9198 Bracket Assembly.
2A0762 Bolt [1/4-20 NC × 15.88 mm (.625 in.) long].
8H9178 Ground Body Bolt [1/4-20 NC × 25.4 mm (1.00 in.) long].

NOTE: Before the governor seals are cut or removed, see FUEL RATIO CONTROL AND GOVERNOR CHECK to make sure an adjustment is needed.

1. See the Engine Information Plate or the FUEL SETTING AND RELATED INFORMATION FICHE for the correct dynamic fuel ratio control setting specification. Before an adjustment is made, record the difference between the correct specification and the dynamic fuel ratio control reading recorded in Step 14 of FUEL RATIO CONTROL AND GOVERNOR CHECK.

2. Install and "zero" the rack position indicator group. See FUEL RATIO CONTROL AND GOVERNOR CHECK for this procedure.


Fuel Ratio Control
(1) Clamp plate (2) Bolt (3) Air line (4) Fuel ratio control (5) Fitting

3. Remove air line (3) from the engine. Put plugs over the openings to keep dirt out of the system.

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

To help prevent an accident caused by parts in rotation, work carefully around an engine that has been started.

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

4. Start the engine and operate it for a minimum of five minutes to get the governor and engine up to normal operating temperature.

5. Loosen bolts (2) on clamp plate (1). The mating surfaces of clamp plate (1) and fuel ratio control (4) are serrated or "notched". A movement of one "notch" will change the dynamic fuel ratio control setting by 0.02 mm (.0008 in.). Refer to the difference recorded in Step 1. Turn fuel ratio control (4) clockwise to get a more negative (less fuel) setting. Turn the control counterclockwise to get a more positive (more fuel) setting.

6. After adjustment is made, tighten bolts (2) and recheck the dynamic fuel ratio control setting. Start at 900 rpm and rapidly move the governor control shaft to the full FUEL ON position and note the reading on the indicator. If using the dial indicator, read the indicator carefully because this reading will be a maximum for only a moment. The electronic indicator will hold and display the maximum reading. Make a record of the maximum indicator reading. Compare this reading to the correct dynamic fuel ratio control setting specification. Repeat the adjustment procedure as required until the correct setting is achieved.

7. Stop the engine.

8. Install the wire and seal on the fuel ratio control.

9. Install air line (3) on the engine.

10. Remove the rack position indicator tooling.

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