27/02/2020 Inyector unitario - Instalar (SENR1013)

SMCS - 1290 i07980105

Procedimiento de instalación
Herramientas necesarias 
Herramienta  Número de pieza  Parte Descripción  Cant. 
A  164-5924  Medidor de diámetro interior del inyector  1 
B  4C-5027  Llave inglesa  1 
C  4C-6161  Cepillo de tubo  1 
D  164-5927  
(1)
Cepillo de alambre  1 

mi  4C-6774  Kit de pistola de vacío  1 

F  8T-7765  Almohadilla de reacondicionamiento de superficie  1 
GRAMO  1U-5512  Material abrasivo  1 
H  9U-6862  Cepillo cónico  1 
I  4C-4057  Tubo  1 
J  1U-5718  Bomba aspiradora  1 
K  1U-5814  Ensamblaje de botella  1 

tabla 1
(1)
Esta herramienta es opcional. El cepillo de alambre 164-5927 tiene un mango acortado que facilita su uso en compartimentos de motor reducidos.

DARSE CUENTA
Mantenga todas las piezas limpias de contaminantes.

Los contaminantes pueden causar un desgaste rápido y acortar la

vida útil de los componentes.

DARSE CUENTA
Se debe tener cuidado para asegurar que los fluidos estén
contenidos durante la realización de la inspección, mantenimiento,
prueba, ajuste y reparación del producto. Esté preparado para
recolectar el fluido con recipientes adecuados antes de abrir
cualquier compartimiento o desmontar cualquier componente que
contenga fluidos.

Consulte la Publicación especial, PERJ1017, "Catálogo de

herramientas de servicio del distribuidor" para obtener
herramientas y suministros adecuados para recolectar y contener
fluidos en los productos Cat ® .

Deseche todos los fluidos de acuerdo con las regulaciones y

mandatos locales.

Limpiar los depósitos de carbono

Ilustración 1 g00337772
Este es un ejemplo de un manguito de inyector típico. (1) Superficie en ángulo de 120 grados del manguito del inyector. El sello de la junta tórica inferior hace contacto con el
manguito del inyector en esta área. (2) La punta del inyector encaja en este orificio del manguito del inyector.
Cleanliness is essential to the proper sealing of the injector. All carbon deposits should be removed from the injector sleeve and the bore (2).
Carbon deposits should also be removed from the 120 degree angled surface (1) at the bottom of the injector sleeve.

NOTICE
Failure to properly clean any of the listed areas may cause an
improper seal at the lower injector O-ring seal. This could result in
tip damage or injector failure due to leakage of combustion gas into
the fuel passage.

Illustration 2 g00337773
This is an example of a typical injector. The entire lower portion of the injector should be clean. Extra attention should be paid to the lower O-ring seal groove (3) and the
adjacent surface.

Clean The 120° Angled Surface Of The Injector Sleeve

The fine grade of the Scotch Brite material is preferred. Scotch Brite is available from the Tools And Shop Products Guide as the 1U-5512 Cut
& Polish Roll and as the 8T-7765 Surface Reconditioning Pad.

The following procedure is the preferred method of cleaning the 120° angled surface of the sleeve (1):

1. Place a 38 mm (1.5 inch) square piece of Scotch Brite material on the end of a 9U-6862 Tapered Brush.

2. Twist the 9U-6862 Tapered Brush with the 4C-5027 Tap Wrench against lower surface (1) of the sleeve bore.
Note: Cleaning the carbon deposits should not be difficult. The use of power tools is not necessary.
 3. When the angled surface of the sleeve is thoroughly cleaned, the surface will be smooth and shiny. The entire sleeve bore should be
cleaned so that any loose carbon particles will be removed.

Clean The Bore Of The Injector Sleeve

1. Clean the bore (2) of the injector sleeve. If the injector sleeve is installed in the engine, use the 4C-6161 Tube Brush or the 164-5927 Wire
Brush to clean the carbon deposits from the bore. If the injector sleeve has been removed from the engine, a 9U-6102 Reamer can be
used in addition to the brush to remove the carbon deposits from the bore.
Note: The 164-5927 Tube Brush may be substituted for the 4C-6161 Tube Brush. The 164-5927 Tube Brush has a shortened handle that
facilitates use in tight engine compartments.

Note: The 4C-6774 Vacuum Gun Kit is available for cleaning the loose material from the sleeve bore.

2. After the injector sleeve has been cleaned with the 9U-6102 Reamer or the 4C-6161 Tube Brush, use the 164-5924 Injector Sleeve Bore
Gauge to determine that an adequate amount of carbon has been removed.

Illustration 3 g00811595

3. Gauge (A) should be inserted into the injector sleeve until the cross pin contacts the top of sleeve (4). This ensures that the gauge will
extend completely through the hole. The gauge should not contact the piston. If the gauge can be easily seated, enough of the carbon
has been cleaned out.

4. If the gauge cannot pass through the sleeve bore and the seat correctly, additional cleaning is necessary.

5. If additional cleaning has been tried and the gauge will not pass through the injector sleeve, the sleeve should be replaced. Refer to
Disassembly And Assembly, "Unit Injector Sleeve - Remove" for the proper procedures for removal of the injector sleeve.

. Evacuate as much fuel and oil as possible from the cylinder before installation of the injector. Use the 1U-5718 Vacuum Pump, 1U-5814
Bottle Assembly, and the 4C-4057 Tube to evacuate the fluid. Several evacuations may be necessary. More than one bottle of fluid may
be in the cylinder. Crank the engine with the disabled injectors after the evacuation of the cylinder.

Installation Of The Unit Injector

Illustration 4 g00811616
 (5) O-ring seal. (6) O-ring seal. (7) Angled seat. (8) Injector tip.

1. Clean the carbon from the following areas of the injector:

The angled seat (7) on the injector

The angled seat in the injector sleeve

Note: If you choose to clean the angled seat on the injector with a wire brush, the wire brush should not contact the tip (8). A wire brush
may damage the fuel injection nozzle holes.

2. Install a new O-ring seal (5) and a new O-ring seal (6). Lubricate the O-ring seals and the injector bore sparingly with clean engine oil.

3. Install the injector in the original location in the injector sleeve.

Illustration 5 g00811627
(9) Fuel injector clamp. (10) Bolt. (11) O-ring seal.

4. Place clamp (9) in the proper position. Place the jumper tube in position to ensure alignment of the bolt holes. Adjust the orientation of
the injector until the alignment is satisfactory. Torque bolt (10) to the following torque. Remove the jumper tube.
Torque for bolt ... 47 ± 9 N·m (35 ± 7 lb ft)

Illustration 6 g00811632
(12) O-ring seal in the injector jumper tube. (13) O-ring seal in the cylinder head.

5. Replace used O-ring seal (11), and O-ring seals (12) and (13) in the jumper tube and in the cylinder head.
 Illustration 7 g00811636
(14) Jumper tube. (15) Horizontal bolts. (16) Adapter. (17) Socket head screws. (18) Vertical bolts

. Place jumper tube (14) and the adapter (16) into position.

NOTICE
If the adapter was previously installed on the injector, loosen the
socket head screws. Failure to loosen the socket head screws
before continuing with Step 8 can result in injector failure.

7. Install socket head screws (17), horizontal bolts (15), and vertical bolts (18) finger tight.
Note: The mating surfaces should be brought into complete contact and into alignment before the final torque procedure is started.

Illustration 8 g00811648
(17) Socket head screws.

Illustration 9 g00811651
(15) Two horizontal bolts. (18) Two vertical bolts. (17) Two socket head screws

. Tighten socket head screws (17), two horizontal bolts (15), and two vertical bolts (18) finger tight.

9. Tighten socket head screws (17) to an initial torque of 1 ± .2 N·m (9 ± 2 lb in).

10. Tighten horizontal bolts (15) to an initial torque of 5 ± 3 N·m (44 ± 27 lb in).

11. Tighten vertical bolts (18) to an initial torque of 5 ± 3 N·m (44 ± 27 lb in).

12. Tighten socket head screws (17) to a final torque of 12 ± 3 N·m (9 ± 2 lb ft).

13. Tighten horizontal bolts (15) to a final torque of 47 ± 9 N·m (35 ± 7 lb ft).

14. Tighten vertical bolts (18) to a final torque of 47 ± 9 N·m (35 ± 7 lb ft).

15. Repeat Step 1 through Step 15 for the remainder of the injectors.

1 . Check the fuel system for leaks by cranking the engine with the disabled injection. Then check the hydraulic pressure. Compare the
pressure to the desired pressure.

Cranking Without Injecting

Cranking the engine with the disabled injection may be performed by one of the following methods:

Disconnect the injector harness of the cylinders which have been reinstalled. Allow the engine to idle. Visually inspect the injector's
components for high-pressure oil leaks.

Activate the system "Crank Without Inject" if the option is available. On Track-Type Tractors, a "Crank Without Inject" plug can be
assembled in the engine harness. On Off-Highway Trucks, the "Ground Level Shutdown" can be activated if the option is available.

When you are using the CAT ET or the ECAP, the injection may be disabled by interactive diagnostics. The engine can be left idling while
the injectors' components on the affected cylinders are visually examined for high-pressure oil leaks.

Checking For Leaks, Air In The System, And Combustion Gas Leakage
Fuel could leak from the upper O-ring seal on the injector. Oil under high pressure may leak from the connections at the jumper tube.
The high-pressure oil is discharged out of the injector onto the cylinder head during engine operation. This is not a leak.

If air has entered the fuel supply system, multiple injectors on one bank may malfunction. If the injectors were not properly tightened,
combustion gas and air could enter the injector through the lower O-ring seal. If the lower O-ring seal should fail, replace the O-ring seal.
Perform the torque sequence again.

Note: Air in the system may be detected by gently touching the flexible return line. Check for extreme pulsations and pressure spikes through
each line. As an alternative, install a sight glass in each return line. Run the engine. Check for air bubbles in the sight glass.

Combustion gas leakage can occur from the base of the injector. Combustion gas leakage will usually affect the injector that has the leak first.
The leakage will then affect the injectors that are downstream of the leak.

NOTICE
Failure to follow any of the procedures in this instruction may result
in injector damage or malfunction, and possible major engine
damage.

Install the Wire Harness

1. Place a 161-3568 Grommet on the top of each injector prior to installing the wiring harness.
Note: The following steps should be read and understood before you begin work on the engine. Failure to follow the instructions can
result in serious engine damage.

Illustration 10 g00811620
(19) White connector. (20) "F" mark. (21) Sleeve. (22) "R" mark. (23) Black connector.

Illustration 11 g00628376
(A) Connector identification for the rear cylinder
(B) Connector identification for the front cylinder
(C) Flywheel housing
(D) Cylinder
(E) Rear of engine

Note: The front of the engine is opposite the flywheel housing end. The left side and the right side of the engine are viewed from the
flywheel housing. The front of the machine may not be the front of the engine. The front of the machine should not be used as a
reference for determining the orientation of the engine.

Illustration 12 g00811663
(19) White connector. (20) "F" mark. (21) Sleeve. (22) "R" mark. (23) Black connector. (24) Nuts. (25) Flywheel housing. (26) Centerline of the crankshaft.

2. Each harness assembly has a white connector that is marked "F" (front) and a black connector that is marked "R" (rear). One harness
assembly is used for two cylinders under each valve cover. The white connector must be installed on the injector toward the front of the
engine. The black connector must be installed on the injector toward the rear of the engine. The wires for the white connector are
enclosed within a sleeve. The cylinder numbers 1, 2, 5, 6, 9, and 10 are printed on the sleeve. The wires for the black connector are not
enclosed within a sleeve.

3. The white connector (19) is marked "F" (front). Assemble white connector (19) to the injector on the front cylinder for the wire harness.
The front cylinder numbers are number 1, number 5, and number 9 on the left side of the engine. The front cylinder numbers are number
2, number 6, and number 10 on the right side of the engine.

4. Torque nuts (24) to the following torque.

Torque for nuts ... 2.5 ± 0.25 N·m (22 ± 2 lb in)

5. The black connector (23) is marked "R" (rear). Assemble black connector (23) to the injector on the rear cylinder for the wire harness. The
rear cylinder numbers are number 3, number 7, and number 11 on the left side of the engine. The rear cylinder numbers are number 4,
number 8, and number 12 on the right side of the engine.

. Torque nuts (24) to the following torque.

Torque for nuts ... 2.5 ± 0.25 N·m (22 ± 2 lb in)

Note: Cylinders 9, 10, 11, and 12 are not applicable to a 3408E engine.
 Note: A film is supplied with the wiring harness. The film illustrates the correct combination of the harness connector and injector.
Install the film on top of the rear left or on top of the rear right valve cover. The film should be legible from the side of the engine. There
should be one film on each side of the engine. If a film is already installed on the valve cover, disregard the film that is supplied with
the harness.

End By:

a. Install the valve covers. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Install".

PIP-10443204
2021/05/26
15:34:11-04:00
i01062905
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