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D318 Capsules/Fuel Pumps/Rack Settings

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2 years 9 months ago #236063 by NickyWalnuts
Had the capsules tested at the local dealership in Stockton a couple days ago on Holt’s testing apparatus for my D6 8U. One good capsule, four that popped in spec but weren’t atomizing satisfactorily, and one bad. The gentleman helping me go through my machine insisted we all go watch the capsules being tested in person, because it was his experience in the past that most people testing them would call a capsule “good” and instruct someone to reuse it so long as it pops at the correct pressure and holds pressure like it’s supposed to, without giving much consideration to visual atomization. And I’m glad we took his advice and watched it in person, because the tech told us he would run a couple of them that weren’t up to my friend’s atomization standards. He worked in the service department there years ago with the tech that actually tested them for us.  We bought new capsules and had them tested. Big difference!  They even sounded different when they pop. They make a high pitched squeak when They pop and they’re good. I definitely got an education that day. I’m glad I’m going through this machine now. Holt’s tech that tested them is the only one there that knows how to do it, as relatively simple as it is. And he’s going to retire in a year. He said he used to rebuild at least one injection pump a week, but now he **maybe** does one per month, as everything modern is now computer controlled high pressure common rail. 

Today we opened the fuel tower. I don’t think you could put any more dirt in there. The filters have never been changed as long as we’ve owned it (easily 25 years). I really should have taken a picture to post how bad it was. I wanted to change the filters several years back, but against my better judgment, someone else convinced my father we didn’t need to because the pressure gauge read all the way in the green “normal” range. Ha! Anyhow, that prompted the gentleman helping me to want to drain the oil on the injection pump housing and open the side covers under the fuel pumps. A fair amount of of gritty crap was in there too and it was over-full. Some diesel had apparently seeped into there as well. 

We’re likely going to remove the fuel pumps and have them tested and I want to ensure proper rack settings once I put them back.  In researching settings and such, I came across an old post on here titled “capsule nozzles,” circa 2007.  EdB spoke of a couple of well-worn documents that he acquired copies of from the dealership he worked at that sounded like they were the holy grail of rack setting charts and data for many different models. I looked for them on the Technical Library but couldn’t find them. The documents mentioned in the post were Form 7272 and Form 30782, and Form 5683A.  Ed- if you see this and have a free minute, could you look through your document collection and see if you still have those somewhere and see if they can’t be added to the Technical Library?

Thanks!
-Nick
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2 years 9 months ago - 2 years 9 months ago #236065 by Fat Dan
This is what I've got.Hope this is what you're looking for.info from FORM 7272-DGood luck 

ACMOC Member
Traxcavator: 60, 955E 12A08263; 57, 955C 12A04040; 57, 955C 12A03563.
1954 No.12 Diesel Motor Grader 8T14777.
1945 No.12 Diesel Motor Grader 9K9320; 9K9982
1944-46 Adams Model No. 311 Motor Grader
1943 IH T9 Tractor w/ Bullgrader Blade
Last edit: 2 years 9 months ago by Fat Dan. Reason: Clarity
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2 years 9 months ago #236067 by trainzkid88
the injection reference is one of those i come with it tools. the kind you never let out of your sight. lest some bastard steals it.a mate had a warren & brown torque wrench you could borrow it but only in his shed as it was a few hundred bucks to buy
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2 years 9 months ago #236077 by Deebo
The Servicemen’s Reference for Fuel Injection Housings is in the Technical Library. Form number not listed. It’s an early copy, not the best quality, you have to know engine bore to decipher rack setting chart. I’m looking for a better version, hint hint!

 
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2 years 9 months ago #236079 by Old Magnet
This is all you need to know...




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2 years 9 months ago #236086 by neil
You'll be glad you cleaned it out. When I did my 5U, the filter elements were sitting in sediment about halfway up, and the fuel gallery in the injection pump body was also choked about halfway up. I'm really surprised that the injection pumps still work. I just took out the plunger, rinsed everything in clean fuel, reassembled and away it went

Cheers,
Neil

Pittsford, NY
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2 years 8 months ago - 2 years 8 months ago #236195 by NickyWalnuts
Thanks for all the replies. Last week we pulled the fuel pumps and had them tested by a local independent Cat mechanic that has the apparatus to do so. At first he thought they were shot because the numbers were so low, but he ended up having to run them three times to get all the crud out of them so they would work properly. They all ended up being in spec. It cost me a little bit to have him do it, but I suppose it was worth it to get them clean, and I think they are pretty time consuming to set up on the testing machine. ​​​​​​​Everything is about clean and ready to go back together. Started to clean out the fuel tank today. It got plugged up several times in the process with crud. The red dye looks more orange than red. I’m thinking I may have to send the tank out to be blasted and epoxy coated internally to eliminate the apparent rust/sediment issue. I used a local “gas tank renu” outfit a few years back on a military jeep fuel tank and they did a nice job and it’s worked wonders. I have a feeling it won’t come cheap as big and cumbersome as that tank will be for them to handle.   The mechanic with all the fuel testing equipment is going to come help us set the injection pump lifter settings. Book spec is 1.736 He wants to set it to his modified setting of 1.726   He claims this will advance it a touch and basically inject the fuel a touch earlier in the stroke and will give a more complete combustion and has a tendency to really wake these things up on the ones he's done in the past. Hopefully its a good move…..interested in your thoughts about this.

Finally, I'm kinda doing a bit of a photo dump....I tried doing it directly off the iphone, but it wouldn't play well with uploading the pics on the site last night so I'm giving it a go using a junky old laptop....

First of all, I have to show you the subject of all my posts lately.....pretty unique, I know   I don't know if I mentioned it in my previous posts, but we'll see if you can guess it's purpose:
 

3 of the 4 very dirty fuel filters:
 

Filter tower and lid:
 
 

Bottom cover of filter tower opened for cleaning:
 

New o-ring seal and new ferrule installed between filter tower and injection pump housing (note the guide bolts to help align the installation of the injection pump housing):
 

Not pictured, new lip seal installed on the back end of the injection pump camshaft where it mates to the filter tower.  Old seal was made of leather and was shot.

Thanks!
-Nick




 
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Last edit: 2 years 8 months ago by NickyWalnuts. Reason: bad spelling....sticking keys on keyboard of junk laptop
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2 years 8 months ago #236197 by Fat Dan
Thanks for the pictures ... WOW !!!! That is a tall drink of water. One of the most interesting track rigs I've ever seen. Very nice.

ACMOC Member
Traxcavator: 60, 955E 12A08263; 57, 955C 12A04040; 57, 955C 12A03563.
1954 No.12 Diesel Motor Grader 8T14777.
1945 No.12 Diesel Motor Grader 9K9320; 9K9982
1944-46 Adams Model No. 311 Motor Grader
1943 IH T9 Tractor w/ Bullgrader Blade

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2 years 8 months ago #236200 by neil
All your pictures look right on target for cleanliness so you're taking care of business. For the crawler, I'd guess it's in your name - I'm going with a walnut lifter? Or some kind of plant lifter where the plant is a tree no more than 5-6' tall? : )

Cheers,
Neil

Pittsford, NY
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2 years 8 months ago #236214 by NickyWalnuts
You got it Neil! It’s to dig up our nursery trees. We have grown our own walnut trees for years. My dad had this machine put up when I was in grade-school. It drives over the trees and the U in the back cuts the roots. The plate welded in the U lifts them up out of the ground.

I drained the rest of the sour fuel from the tank today. It did not drain nearly as fast as it should have. Lots of sediment and crud obstructing the flow. I am hoping that with the fuel system all clean and flowing freely, this thing will have extra power previously unknown to us.
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