1980/06/30 Caterpillar

Some customers have installed Kysor air-operated shutdown actuators on Caterpillar 3406, 3408 and 1693 Truck Engines. With these installations, service personnel will possibly find it necessary to make adjustments or do troubleshooting work on these units. For assistance with possible problems, the information that follows is a direct copy of Kysor Service Bulletin Number 80-04. This service bulletin gives information about the application, adjustment, and troubleshooting of Kysor air-operated shutdown actuators as used on Caterpillar 3406, 3408, and 1693 Truck Engines.

Caterpillar 3406, 3408 and 1693 Truck Engines equipped with KYSOR/Cadillac air operated shutdown actuators.

1. There are two types of actuators supplied for these engines:

a. For Serial Numbers 92U1-4436, 65B1-16748, 28V1-991: KYSOR 1030-39140-01 (12VDC) or KYSOR 1030-39140-04 (24VDC)

b. For Serial Numbers 92U4437-Up, 65B16749-Up, 28V992-Up: KYSOR 1030-39140-03 (12VDC) or KYSOR 1030-39140-06 (24VDC)

These two types of actuators differ in both appearance and function, and are NOT interchangeable. (See the topics that follow.)

2. Potential problems and causes:

a. Engine shuts down at odd times or will not start.

-Open coil in solenoid valve. Measure resistance with an ohmmeter. Resistance should be 15-21 ohms for 12 Volt coils; and 67-83 ohms for 24 Volt coils.

-Wiring to solenoid valve broken or has loose connections.

b. Engine will not shut down when key is turned off.

-Solenoid valve inlet plugged.

-Wrong actuator.

-Actuator adjustment wrong (See the topic that follows).

c. Power loss (Should be verified by using the rack ground stud on the pump, following Caterpillar service instructions.)

-Wrong actuator.

-Actuator adjustment wrong.

-Leaking solenoid valve (This can be verified by removing the valve from the actuator, connecting it to an air supply--120 psi MAX-connecting the brass to battery ground and the screw terminal to battery positive, and then placing a drop of oil on the outlet port (male threaded end). No bubbles should form. Bubbles indicate leakage and the valve should be replaced in such cases. See diagram below.)

--Power loss can also be caused by an intermittent binding condition in the governor/AFC section of the fuel pump. If all the above checks indicate correct actuator, correct adjustment, and no air leakage, then the power loss is due to either the binding condition or some other air/fuel/engine problem.

KYSOR Type 1030-39140-03 (12VDC) & 1030-39140-06 (24VDC)

Actuators for CAT 3406, 3408 & 1693 Truck Engines

Serial Numbers 92U4437-Up, 65B16749-Up, 28V992-Up

Service Part Numbers

Air Cylinder 1617-33770-03

12V Solenoid 4664-33335-01

24V Solenoid 4664-33335-02

Procedure

1. Start with piston rod in extended position as shown.

2. Adjusting tool should fit as shown if adjustment is OK.

3. If adjustment required, loosen locknut, rotate plunger head.

4. Tighten locknut when done. (60-70 inch pounds)

NOTE: Solenoid valve elbow and locknut were loctited during assembly. Light heat required to loosen.

2. Recess on locknut should face towards air cylinder.

KYSOR Type 1030-39140-01 (12VDC) & 1030-39140-04 (24VDC)

Actuators for CAT 3406, 3408 & 1693 Truck Engines Serial Numbers 92U1-4436, 65B1-16748, 28V1-991 Service Part Numbers

Air Cylinder 1617-33770-01

12V Solenoid 4664-33335-01

24V Solenoid 4664-33335-02

Procedure

1. Start with piston rod in extended position as shown, and remove gasket.

2. Plunger head should touch gauge when extended, and line up with gauge when retracted.

3. If adjustment required, loosen locknut, rotate plunger head, tighten locknut (60-70 inch pounds).

NOTE: Solenoid valve elbow and locknut were loctited during assembly. Light heat required to loosen.