Caterpillar Cat 3054B Industrial Engine (Prefix 5MF) Service Repair Manual (5MF00001 and up).pdf

Service Repair Manual
Models
3054B Industrial Engine

Shutdown SIS
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Product: INDUSTRIAL ENGINE
Model: 3054B INDUSTRIAL ENGINE 5MF
Configuration: 3054B Industrial Engine 5MF00001-UP
Disassembly and Assembly
Media Number -SENR5029-01 Publication Date -01/01/2010 Date Updated -13/01/2010
i01394338
Fuel Filter Base - Remove and Install
SMCS - 1262-010
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
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 Tools and Shop
Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
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Illustration 1 g00734776
Note: Put an identification mark on all of the fuel lines in order to install the fuel lines in the
original location.
1. Disconnect fuel return lines (2) and (3) from fuel filter base (7). Plug fuel return lines (2)
and (3) and cap the openings on fuel filter base (7) in order to help prevent contamination.
2. Disconnect fuel supply lines (1) and (6) from fuel filter base (7). Cap fuel supply lines (1)
and (6) and plug the openings in fuel filter base (7) in order to help prevent contamination.
3. Disconnect fuel supply line (8) from fuel filter base (7). Cap fuel supply line (8) and plug
the opening in fuel filter base (7) in order to help prevent contamination.
4. Disconnect fuel line (5) for the air inlet heater from fuel filter base (7). Cap fuel line (5) and
plug the opening in fuel filter base (7) in order to help prevent contamination.
5. Remove two bolts (4) that fasten fuel filter base (7) to the mounting bracket. Remove fuel
filter base (7) and the fuel filter from the mounting bracket.
6. Inspect the fuel lines and the fuel filter base for damage. If the fuel lines or the fuel filter
base are damaged, use new parts for replacement.
Installation Procedure
NOTICE
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1. Put fuel filter base (7) in position on the mounting bracket and install two bolts (4) .
Note: Remove the appropriate caps or the appropriate plugs from the fuel filter base and
from the fuel lines prior to connecting the fuel lines to the fuel filter base.
2. Connect fuel line (5) for the air inlet heater to fuel filter base (7) .
3. Connect fuel supply line (8) to fuel filter base (7) .
4. Connect fuel supply lines (6) and (1) to fuel filter base (7) .
5. Connect fuel return lines (3) and (2) to fuel filter base (7) .
6. Prime the fuel system before the engine is started. Refer to the Systems Operation, Testing
and Adjusting Module, "Fuel System - Prime" topic for information on priming the fuel
system.
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All Rights Reserved.
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Wed Oct 30 21:11:29 UTC+0800 2019
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Shutdown SIS
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i01203657
Fuel Transfer Pump - Remove
SMCS - 1256-011
Removal Procedure
NOTICE
NOTICE
containing fluids.
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1. Disconnect fuel line (1) from fuel transfer pump (2). Immediately cap the line or plug the
line in order to prevent contamination.
2. Remove four bolts (3) from fuel transfer pump (2).
3. Remove fuel transfer pump (2) and the gasket from the engine. Inspect the gasket for
damage. If the gasket is damaged, use a new part for replacement.
Note: If the fuel transfer pump is difficult to remove, rotate the crankshaft until the rocker arm of
the fuel transfer pump is not under pressure.
Wed Oct 30 21:12:24 UTC+0800 2019
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Shutdown SIS
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i01420527
Fuel Transfer Pump - Install
SMCS - 1256-012
NOTICE
1. Put the gasket and fuel transfer pump (2) in position on the engine. Ensure that the rocker
arm for the fuel transfer pump is not under pressure. If the rocker arm is under pressure,
rotate the crankshaft slowly until the fuel transfer pump can be installed easily.
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2. Apply 4C-4030 Thread Lock Compound to the first three threads of mounting bolts (3) or
the mounting studs.
3. Install four mounting bolts (3) and tighten the mounting bolts to a torque of 22 N·m (16 lb
ft).
4. Remove the cap or the plug from fuel transfer pump (2) and the fuel line. Connect fuel lines
(1) to fuel transfer pump (2) .
5. Loosen the vent screw on the top of the fuel filter base. Operate the priming lever on the
fuel transfer pump in order to remove the air from the fuel system. When only fuel that is
free of air comes out of the vent screw, tighten the vent screw.
6. Start the engine and check the fuel system for fuel leaks and for air leaks. For more
information on removing the air from the fuel system, refer to the Systems Operation,
Testing and Adjusting Module, "Air in Fuel - Test" topic.
Wed Oct 30 21:13:20 UTC+0800 2019
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Shutdown SIS
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i01394351
Fuel Injection Lines - Remove and Install
SMCS - 1252-010
Removal Procedure
NOTICE
NOTICE
containing fluids.
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1. Loosen four fittings (3) that fasten high pressure fuel lines (2) to the fuel injection pump.
2. Loosen four fittings (1) that fasten high pressure fuel lines (2) to the fuel injection nozzles.
3. Remove high pressure fuel lines (2) from the engine.
Note: Immediately cap all openings or plug all openings on the fuel injection pump and the
fuel injection nozzles in order to prevent contamination.
4. Loosen fitting (7) from fitting (5) for the fuel line.
5. Remove fitting (5) from the fuel injection nozzle and remove the two sealing washers.
Fitting (5) must be installed in the original location during assembly.
6. Remove three banjo bolts (6) and the nine sealing washers from the fuel injection nozzles.
Note: New sealing washers must be used during the installation of banjo bolts (6) .
7. Remove fuel return line (4) from the engine.
8. Inspect all of the fuel lines, fittings and banjo bolts for damage. If any of the parts are
damaged, use new parts for replacement.
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NOTICE
1. Put fuel return line (4) in position on the engine.
2. Install nine new sealing washers and three banjo bolts (6) that hold the fuel return line in
position on the fuel injection nozzles.
3. Install two sealing washers and fitting (5) in the original location on the fuel injection
nozzle. Tighten banjo bolts (6) and fitting (5) to a torque of 9 N·m (80 lb in). Tighten fitting
(7) to a torque of 9 N·m (80 lb in).
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4. Remove the caps or the plugs from the fuel injection pump and the fuel injection nozzles.
5. Put high pressure fuel lines (2) in position on the engine.
6. Tighten four fittings (1) that fasten high pressure fuel lines (2) to the fuel injection nozzles.
7. Tighten four fittings (3) that fasten high pressure fuel lines (2) to the fuel injection pump.
8. Tighten four fittings (1) and four fittings (3) to a torque of 22 N·m (16 lb ft).
9. Prime the fuel system in order to remove any air from the fuel system before the engine is
started. Refer to the Systems Operation, Testing and Adjusting Module, "Fuel System -
Prime" topic for information on priming the fuel system.
10. Start the engine and check the fuel system leaks. If air exists in the fuel system, refer to the
Systems Operation, Testing and Adjusting Module, "Air in Fuel - Test" topic for additional
information.
Wed Oct 30 21:14:16 UTC+0800 2019
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Shutdown SIS
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i01455465
Fuel Injection Nozzles - Remove
SMCS - 1254-011
Removal Procedure
Start By:
A. Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines
- Remove and Install".
NOTICE
NOTICE
containing fluids.
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1. Loosen union nut (3) on fuel injection nozzle (1) .
2. Remove fuel injection nozzle (1) from the cylinder head.
3. Ensure that seat washer (2) is removed from the bore of the cylinder head for fuel injection
nozzle (1) .
4. Repeat Steps 1 through 3 for the remaining fuel injection nozzles.
5. Inspect the fuel injection nozzles for wear or for damage. If the fuel injection nozzles are
worn or damaged, use new parts for replacement.
6. Test the fuel injection nozzles. Refer to the Systems Operation, Testing and Adjusting
Module, "Fuel Injection Nozzle - Test" topic for additional information.
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Shutdown SIS
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i01455772
Fuel Injection Nozzles - Install
SMCS - 1254-012
NOTICE
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1. Thoroughly clean the threads on union nut (1) and the threads in the cylinder head.
2. Ensure that wire clip (2) is in position on fuel injection nozzle (3) .
Note: Remove the original seat washer from the threaded hole for the fuel injection nozzle
which is located in the cylinder head. If the original seat washer is not removed, the
projection of the fuel injection nozzle will be incorrect when a new seat washer is installed.
Do not reuse seat washer (4) .
3. Install a new seat washer (4) into the recess in the cylinder head.
4. Put a 2 mm (0.08 inch) bead of 4C-5591 Anti-Seize Compound on the first two threads of
union nut (1) .
5. Put fuel injection nozzle (3) into position in the cylinder head. Make sure that the detent ball
in the fuel injection nozzle is aligned correctly with ball detent (X) in the cylinder head.
6. Carefully tighten union nut (1) to a torque of 30 N·m (22 lb ft). Remove any excess Anti-
Seize Compound from fuel injection nozzle (3) .
Note: Do not rotate the fuel injection nozzle after installation. The seal which is made by
the anti-seize compound may break. A broken seal may allow leakage past the seat of the
fuel injection nozzle.
End By: Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines
Wed Oct 30 21:16:07 UTC+0800 2019
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Shutdown SIS
Previous Screen
i01554038
Fuel Injection Pump - Remove
SMCS - 1251-011
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
150-3992 Timing Pin (1)
1
150-3993 Timing Pin (2)
1
B 171-1085 Tamper Resistant Tool Gp 1
( 1 )
Tool (A) is required in order to remove Bosch fuel injection pumps.
( 2 )
Tool (A) is required in order to remove Delphi (Lucas) and Stanadyne fuel injection pumps.
Start By:
A. Remove the water pump. Refer to Disassembly and Assembly, "Water Pump - Remove".
B. Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines
NOTICE
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NOTICE
containing fluids.
1. Ensure that the No. 1 cylinder is at the top center position on the compression stroke. Refer
to the Testing and Adjusting, "Fuel System" topic for additional information.
2. Loosen locking screw (2) (if equipped) until locking spacer (1) moves freely. Move locking
spacer (1) into position (B). Tighten locking screw (2) to a torque of 10 N·m (7 lb ft).
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Typical example
Note: Do not remove hub nut (4) from the shaft of the fuel injection pump. The hub of the
fuel injection pump is installed in the correct position from the factory in order to ensure
proper timing. If hub nut (4) is removed and the hub is removed, the hub will need to be
accurately installed on the shaft of the fuel injection pump by the use of special equipment.
Refer to your Caterpillar Dealer for more information.
Note: Do not release torx screws (5) (if equipped). If the torx screws are released and the
timing plate is moved, the timing position that is set at the factory will be lost. If the torx
screws are released, the No. 1 cylinder must be set to the top center position on the
compression stroke before the torx screws are tightened.
3. Slowly rotate the crankshaft until hole (6) in the timing gear and hole (7) in the hub are in
alignment with hole (8) in the fuel injection pump body.
Note: The location of Tool (A) for Bosch fuel injection pumps will be located toward the
top of the fuel injection pump. The location of Tool (A) for Delphi (Lucas) and Stanadyne
fuel injection pumps will be located toward the bottom of the fuel injection pump.
4. Install Tool (A) through hole (6) in the timing gear and hole (7) in the hub. Push Tool (A)
into position in hole (8) in the fuel injection pump body. If Tool (A) can be fully seated, the
fuel injection pump timing is correct. No resistance should be felt when the timing pin is
inserted into hole (8) of the fuel injection pump body.
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Note: Some fuel injection pumps are installed with tamper proof bolts. Tool (B) may be
necessary in order to remove the tamper proof bolts.
5. Remove four bolts (3) that fasten the fuel injection pump gear to the fuel injection pump.
Timing gear (9) should be free from the fuel injection pump shaft.
Typical example
6. Remove three flange nuts (10) and fuel injection pump (11) from the engine.
Typical example
7. Remove O-ring seal (12) from fuel injection pump (11) .
Wed Oct 30 21:17:03 UTC+0800 2019
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Shutdown SIS
Previous Screen
i01555368
Fuel Injection Pump - Install
SMCS - 1251-012
Table 1
Required Tools
Tool Part Number Part Description Qty
A
150-3992 Timing Pin (1)
1
150-3993 Timing Pin (2)
1
B 171-1085 Tamper Resistant Tool Gp 1
( 1 )
Tool (A) is required in order to install Bosch fuel injection pumps.
( 2 )
Tool (A) is required in order to install Dephi (Lucas) and Stanadyne fuel injection pumps.
NOTICE
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Caterpillar Cat 3054B Industrial Engine (Prefix 5MF) Service Repair Manual (5MF00001 and up).pdf

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