Usage:
Start By:
a. remove rocker shaft assemblies
FLUID SPILLAGE CONTAINMENT
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.
1. Thoroughly clean the area around each fuel line connection. Disconnect fuel injection line (1) and fuel injection nozzle (2) from the adapter.
2. Remove clamp (3) and the spacer that holds the fuel injection nozzle in place.
| NOTICE |
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Do not use force to remove the fuel injection nozzles. If necessary, turn and pull the fuel injection nozzle out of the cylinder head. |
3. Remove adapter (4) and fuel injection nozzle (2).
NOTE: The following steps are for installation of the fuel injection nozzles.
| NOTICE |
|---|
Before the fuel injection nozzles are installed, check for fuel leakage, the pressure at which the injection nozzle opens, and the amount of fuel (spray pattern) that comes out of the nozzle with Tool (A). See the topic "Testing Fuel Injection Nozzles" in the Systems Operation, Testing & Adjusting Manual. |
4. Remove carbon seal dam (6) with pliers. Remove compression seal (5).
5. Install a new compression seal on the nozzle. Install a new carbon seal dam with Tool (B).
6. Make sure the bore in the cylinder head and the fuel inlet fittings are clean.
7. Install new O-ring seals on adapter (4) and fuel injection nozzle (2).
8. Install the fuel injection nozzle in the head. Turn and push the nozzle into its correct position. Do notput lubricant on the nozzle or bore in the cylinder head.
9. Install adapter (4) in the head. Connect nozzle (2) and fuel injection line (1) to the adapter. Tighten the nuts to a torque of 40 ± 7 N·m (30 ± 5 lb ft).
10. Install the spacer and clamp (3) that hold the nozzle to the cylinder head.
NOTE: For more detailed information regarding the fuel injection nozzles, see the topic "Fuel Injection Nozzles" in the Specifications Manual.
End By:
a. install rocker shaft assemblies
Disassemble & Assemble Fuel Injection Nozzles (
Start By:
a. remove fuel injection nozzles
Do not disassemble any nozzle until testing has shown that disassembly is needed. Check each nozzle with Tool (A) for leakage, opening pressure, and the shape and amount of fuel (spray pattern) coming out of the nozzle. Do notclean or make an adjustment to any nozzle that has a large (excessive) amount of return leakage. Excessive return leakage can be an indication of nozzle failures that can not be corrected with an adjustment or cleaning and can cause engine damage. See the topic "Testing 9L-7883 Fuel Injection Nozzles" in the Systems Operation, Testing & Adjusting Manual.
| NOTICE |
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Keep the work area and all tools extra clean. Be careful not to cause damage to the parts while the nozzles are disassembled and assembled. |
1. Put the nozzle in Tool (B). Put Tool (B) and the nozzle in a vise. Do notput any part of a nozzle directly in a vise. Loosen locknut (1).
2. Loosen adjusting screw (2) approximately three turns. Loosen pressure screw (3).
3. While the nozzle is held in one hand, tilt the nozzle and remove locknut (1), adjusting screw (2), pressure screw (3), shims (7), spring (6), seat (5), and valve (4).
4. If the valve does not slide out of the nozzle, install Tool (C) and remove valve (4) as follows:
a. Push valve (4) into the nozzle with Tool (C) until the valve is against the bottom of the nozzle.
b. Push down on the body of Tool (C) to engage the collet on valve (4).
c. Turn the nut counterclockwise to tighten the collet on the valve and remove valve (4) from the nozzle body.
5. Put the parts in solvent to loosen carbon and deposits of foreign material. The body is assembled with an epoxy material and must not be in contact with the solvent for more than one to two hours. See Special Instruction, SEHS7292 for the correct method of cleaning the nozzle.
NOTE: The following steps are for assembly of the fuel injection nozzles.
NOTE: Make sure all of the parts have been thoroughly cleaned before assembling the nozzles. Flush the body to remove any debris or lapping compound.
6. Put clean fuel on all of the parts.
7. Put valve (4) in position in the body as shown.
8. Install adjusting screw (2) into pressure screw (3). Turn the adjusting screw two or three turns and install locknut (1). Do nottighten the locknut.
9. Put shims (7), spring (6), and seat (5) in position on the adjusting screw. The thicker shim of shims (7) must be against the screw.
10. Put seat (5) in contact with valve (4) and push the valve into position in the body. Tighten pressure screw (3) by hand.
11. Put the nozzle in position in Tool (B). Put Tool (B) and the nozzle in a vise. Tighten pressure screw (3) to a torque of 8.5 to 9.1 N·m (75.00 to 80.00 lb in).
12. Check the opening pressure of the nozzle as controlled by shims (7) with Tool (A). See the topic "Testing 9L-7883 Fuel Injection Nozzles, Opening Pressure Test" in the Systems Operation, Testing & Adjusting Manual.
13. Check the valve lift adjustment as controlled by adjusting screw (2) with Tool (A). See the topic "Testing 9L-7883 Fuel Injection Nozzles, Valve Lift Adjustment" in the Systems Operation, Testing & Adjusting Manual.
14. Hold adjusting screw (2) with a screwdriver and tighten locknut (1) until the adjusting screw will not turn.
15. Tighten the locknut to a torque of 4.0 to 4.5 N·m (35.00 to 40.00 lb in).
NOTE: For more detailed information regarding the fuel injection nozzles, see the topic "Fuel Injection Nozzles" in the Specifications Manual.
End By:
a. install fuel injection nozzles
Disassemble & Assemble Fuel Injection Nozzles (
Start By:
a. remove fuel injection nozzles
Do not disassemble any nozzle until test has shown it is needed. Check each nozzle with Tool (A) for leakage, the pressure at which the nozzle opens, and the shape and amount of fuel (spray pattern) that comes out of the nozzle. Do notclean or make an adjustment to any nozzle that has a large (excessive) amount of return leakage. Excessive return leakage can be an indication of nozzle failures that can not be corrected with an adjustment or cleaning and can cause engine damage. See the topic "Testing 9L-6969 & 9N-3979 Fuel Injection Nozzles" in the Systems Operation, Testing & Adjusting Manual.
| NOTICE |
|---|
Keep the work area and all tools extra clean. Be careful not to cause damage to the the parts while the nozzles are disassembled and assembled. |
1. Remove cap (1) from the fuel injection nozzle.
| NOTICE |
|---|
If the lift adjustment screw is not turned counterclockwise one turn, the valve can be bent or the seat for the valve can be damaged when the pressure adjustment screw is turned. |
2. Put the nozzle in Tool (B). Put Tool (B) and the nozzle in a vise. Do notput any part of a nozzle directly in a vise. Hold lift adjustment screw (3) with a (5/64 in) Hex Wrenchand loosen locknut (2). Turn the lift adjustment screw counterclockwise one turn. Remove locknut (2).
3. Use Tool (D) to hold the pressure adjustment screw and loosen locknut (4).
4. While the nozzle is held in one hand, tilt the nozzle and remove lift adjustment screw (3), locknut (4), pressure adjustment screw (8), spring (7), seat (6), and valve (5).
5. If the valve does not slide out of the nozzle, install Tool (C) and remove valve (5) as follows:
a. Push valve (5) into the nozzle with Tool (C) until the valve is against the bottom of the nozzle.
b. Push down on the body of Tool (C) to engage the collet on valve (5).
c. Turn the nut counterclockwise to tighten the collet on the valve and remove valve (5) from the nozzle body.
6. Put the parts in solvent to loosen carbon and deposits of foreign material. The body is assembled with an epoxy material and must not be in contact with the solvent for more than one to two hours. See Special Instruction, SEHS7292 for the correct method of cleaning the nozzle.
NOTE: The following steps are for assembly of the fuel injection nozzles.
NOTE: Make sure all of the parts have been thoroughly cleaned before assembling the nozzles. Flush the body to remove any debris or lapping compound.
7. Put clean fuel on all of the parts.
8. Put valve (5) in position in the body as shown.
9. Install lift adjustment screw (3) into pressure adjustment screw (8). Turn the lift adjusting screw two or three turns and install locknut (2) on the lift adjusting screw. Install locknut (4) on pressure adjustment screw (8).
10. Put spring (7), and seat (6) in position on pressure adjustment screw (8).
11. Put seat (6) in contact with valve (5) and push the valve into position in the body. Tighten the pressure adjustment screw by hand.
12. Make an adjustment to the opening pressure of the nozzle as controlled by the pressure adjusting screw with Tool (A). See the topic "Testing 9L-6969 & 9N-3979 Fuel Injection Nozzles, Opening Pressure Test" in the Systems Operation, Testing & Adjusting Manual.
13. Make an adjustment to the valve lift as controlled by the lift adjustment screw with Tool (A). See the topic "Testing 9L-6969 & 9N-3979 Fuel Injection Nozzles, Valve Lift Adjusting" in the Systems Operation, Testing & Adjusting Manual.
14. Put the nozzle in position in Tool (B). Put Tool (B) and the nozzle in a vise. Hold lift adjustment screw (3) with a 5/64 ( in) Hex Wrenchand tighten locknut (2) until the lift adjustment screw will not turn.
15. Tighten locknut (4) for pressure adjustment screw (8) to a torque of 8.0 to 9.1 N·m (70.00 to 80.00 lb in).
16. Tighten locknut (2) for lift adjustment screw (3) to a torque of 4.0 to 5.1 N·m (35.00 to 45.00 lb in).
17. Install cap (1) on the fuel injection nozzle. Use Tool (E) to tighten the cap to a torque of 12.4 to 13.6 N·m (110.00 to 120.00 lb in).
NOTE: For more detailed information regarding the fuel injection nozzles, see the topic "Fuel Injection Nozzles" in the Specifications Manual.
End By:
a. install fuel injection nozzle