Usage:
Governor and Air-Fuel Ratio Control
Check Set Point and Low Idle
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These adjustments are to be made only by an authorized Caterpillar engine dealer or a mechanic that has the correct training. |
Slow engine response and low power may indicate a need for adjustment or repair. Your authorized Caterpillar dealers are equipped with the necessary tools, personnel and procedures to perform this service.
Engine Valve Lash
Check and Adjust
NOTE: Initial valve lash adjustment on a new or rebuilt engine only, is recommended at the first scheduled oil change interval, due to initial wear and seating of valve train components.
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To prevent possible injury, do not use the starter motor to turn the flywheel. Hot engine components can cause burns. Allow additional time for the engine to cool before measuring valve clearance. |
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Measure the valve lash with the engine stopped. To obtain an accurate measurement, allow at least 20 minutes for the valves to cool the engine cylinder head and block temperature. |
When the valve lash (clearance) is checked, an adjustment is NOT necessary if the measurement is within the range given in the "Valve Clearance Check" chart shown below.
If the measurement is outside of the valve clearance check range shown above, an adjustment is necessary.
Set the clearance to the nominal clearance given in the "Valve Clearance Setting" chart shown below.
Refer to the Service Manual or your Caterpillar dealer for the complete valve adjustment procedure.
Engine Valve Rotators
Observe Rotation of Valves With Engine Idling After Setting the Valve Clearances
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When inspecting the valve rotators, protective glasses or face shield and protective clothing must be worn, to prevent being burned by hot oil spray. |
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After setting all valve clearances and before installing the valve cover:
- 1. Start the engine. Move the governor control to low idle position.
- 2. Watch the top surface on each valve rotator. Each valve rotator should turn slightly each time the valve closes. If a valve fails to rotate, contact your Caterpillar dealer.
Fuel Injection Nozzles
Test - Replace
Whenever the engine performs in such a manner that a fuel injection nozzle is suspected of causing irregular running, smoking or knocking, isolate each fuel injection nozzle, one at a time, to determine the malfunctioning nozzle.
NOTE: For complete fuel injection nozzle testing and cleaning, consult your authorized Caterpillar engine dealer.
- 1. Loosen the fuel injection line nut at the fuel pump, one at a time, with the engine running. Use a cloth or similar material to prevent fuel from spraying on hot exhaust component. Be sure to tighten each fuel line nut after the test, before the next fuel line nut is loosened.
- 2. When a cylinder is found where the loosened fuel line nut does not make a difference in engine performance or smoking, have that cylinder injection nozzle tested.
To Remove Injection Nozzles
- 1. Remove bolts that hold bracket assemblies (1) and (2) to the cylinder head.
- 2. Disconnect all fuel injection line nuts (3) at the fuel injection pump housing.
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Do not let tops of fuel nozzles (4) turn when the fuel lines are loosened. The nozzles will be damaged if the top of the nozzle turns in the body. The engine will be damaged if a defective fuel injection nozzle is used because of the shape of fuel (spray pattern) that comes out of the nozzles will not be correct. |
- 3. Hold tops on fuel nozzles (4) with a wrench and loosen the fuel line nuts at the nozzles.
- 4. Disconnect the fuel injection line nuts at the nozzles and remove the fuel injection lines.
- 5. Install protection covers on the nozzles, fuel lines and fuel injection pump to keep dirt out of the fuel system.
- 6. Remove bolt and clamp (5).
- 7. Install tool (A) 6V3129 Nozzle Puller. Move the screw out of the puller enough to engage the inside lip of the puller on the lower stepped diameter of the nozzle.
- 8. With nozzle bleed screw (6) seen through the clearance hole in tooling (A), turn the screw down until the tip of the button goes down into the thread in the hole for the nozzle clamp bolt.
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Do not exceed a torque of 1.7 N·m (15 lb in) on the screw in tooling (A) to remove the nozzle. Added force can cause the stem of the nozzle to bend or break off. |
- 9. If the nozzle can not be removed with tooling (A), tooling (B) FT1533 Nozzle Adapter and 1P74 Slide Hammer must be used.
- 10. Remove the protective cap and install tooling (B).
- 11. Use the slide hammer to remove fuel injection nozzle (4).
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Hold tool (B) so the center line of tool (B) is the same as the extended center line of fuel injection nozzle (4). This will prevent distortion of the fuel injection nozzle which can cause the nozzle to bend or break off. |
- 12. If tool (B) was used to remove the fuel injection nozzle, make a replacement of the nozzle.
- 13. If tool (A) was used to remove the fuel injection nozzle, remove the carbon dam seal on the end of the nozzle.
- 14. Have fuel injection nozzles (4) tested by an authorized Caterpillar engine dealer.
To Install Injection Nozzles
- 1. Tool (A) 6V4979 Carbon Seal Tool must be drilled out to a diameter of 8.5 mm (.334 inch) and a depth of 1.5 mm (.060 inch) before it can be used on the fuel nozzles. Use tool (A) to install a new carbon dam seal (2) on nozzle (1).
- 2. Make reference to Special Instruction SEHS7292 for the use of the 8S2245 Nozzle Cleaning Kit to clean the nozzles.
- 3. Install a new seal (2) on fuel injection nozzle (1).
- 4. Use tool (B) to clean the bore for the fuel injection nozzle. Use an open end wrench or tap driver to turn tool (B) 6V4089 Reamer Assembly.
- 5. Install fuel injection nozzle (1) and clamp (3) at the same time. Put the nozzle in position with bleed screw (4) away from the rocker arm cover.
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Do not let the tops of fuel nozzles turn when the fuel line nuts are tightened. The nozzles will be damaged if the top of the nozzle turns in the body. The engine will be damaged if a defective fuel injection nozzle is used because the shape of fuel (spray pattern) that comes out of the nozzles will not be correct. |
- 6. Remove protection covers from the fuel line connections. Put the fuel injection lines in position. Install the fuel injection line nuts finger tight only.
- 7. Hold the tops of fuel nozzles (1) and use tool (C) 5P144 Socket and a torque wrench to tighten the fuel injection line nuts to a torque of 40 ± 7 N·m (30 ± 5 lb ft).
- 8. Tighten all fuel injection line nuts (5) at the fuel injection pumps to a torque of 40 ± 7 N·m (30 ± 5 lb ft).
- 9. Install bolts that hold bracket assemblies (6) and (7) to the cylinder head.
- 10. Purge the fuel lines of air.
- 11. Start the engine and check for any fuel leaks. Stop the engine and correct any fuel leaks that may occur.
Turbocharger
Check
- 1. Remove the exhaust outlet piping from the turbocharger.
- 2. Turn the turbine and compressor wheel by hand. The assembly should turn freely.
- 3. If the assembly does not turn freely, refer to the Service Manual or consult your Caterpillar dealer.
Cooling System
Clean and Change
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At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury. |
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If the engine is to be stored in, or shipped to an area with freezing temperatures, the cooling system must be either protected to the lowest expected outside temperature or drained completely to prevent damage. |
Do not use Caterpillar cooling system conditioner or coolant conditioner elements with Dowtherm 209 Full-Fill coolant. Follow recommendations provided with Dowtherm 209 Full-Fill coolant.
- 1. Loosen the filler cap slowly to relieve any pressure and remove the cap.
- 2. Remove the cooling system drain plugs or open the drain valve and allow the coolant to drain.
- 3. Install the drain plugs or close the drain valve.
- 4. Fill the cooling system with a cleaning solution. Use a commercially available cleaner or 1 kg (2 lb) sodium bisulphate per 40 liters (10 U.S. gallons) water.
- 5. Start and run the engine 1/2 hour. Stop the engine and drain the cleaning solution.
- 6. Flush the system, with engine stopped, with water until the draining water is clear.
- 7. Install or close the drain valve. Fill the system with a commercially available neutralizer or 250 g (1/2 lb) sodium carbonate per 40 liters (10 U. S. gallons) water.
- 8. Start the engine and run it for 10 minutes. Stop the engine and drain the neutralizing solution.
- 9. Flush the system with clean water until draining water is clear.
- 10. Mix a solution of acceptable water, antifreeze and cooling system conditioner or if equipped with a coolant conditioner element, install a precharge element. Add 0.95 liters (1 quart) of Caterpillar cooling system conditioner per 30 liters (8 U.S. gallons) of cooling system capacity (for a 3% to 6% concentration).
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If the engine is equipped with a Caterpillar coolant conditioner element, to prevent over inhibiting do not use both the liquid cooling system conditioner and the coolant conditioner element at the same time. |
- 11. Fill the cooling system with the coolant solution at 20 liters (5 U.S. gallons) per minute or less to avoid air locks.
- 12. Start and run the engine with the filler cap removed. Allow the coolant to warm and the level to stabilize.
- 13. Add coolant if necessary to bring the coolant to the correct level.
- 14. Check the condition of the filler cap gasket. Replace it if damaged. Install the filler cap.
Thermostat
Replace Thermostat, Gasket and Seal
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At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury. |
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Remove Thermostat
- 1. Loosen the filler cap slowly to relieve any pressure and remove the cap.
- 2. Drain the coolant from the cooling system to a level below the thermostat housing.
- 3. Loosen clamps (1) and slide hose on elbow.
- 4. Remove four bolts (2) and elbow (3) from the cylinder head.
- 5. Remove thermostat (4) and gasket (5) from thermostat housing assembly.
NOTE: The thermostats can be reused if they are tested and meet the test specifications below and are not damaged or have excessive buildup of deposits.
NOTE: The thermostat should begin opening (bench test in atmospheric pressure) at approximately 80°C to 84°C (176°F to 183°F). Thermostats should fully open at approximately 90°C to 94°C (194°F to 201°F).
Install Thermostat
NOTE: Inspect gaskets before assembly and replace if worn or damaged.
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If the thermostat is installed wrong, it will cause the engine to overheat. |
- 1. Install thermostat (1) in the housing with spring toward the housing. Be sure that vent hole (2) is not plugged.
- 2. Install gasket (3) over the thermostat.
- 3. Put elbow (4) in position and install the bolts to hold it in place. Slide hose on elbow and install two clamps (5).
- 4. Add coolant to the cooling system to bring it to the proper level.
- 5. Start the engine and inspect for leaks and proper operating temperature.