Piston Height Check Procedure for C9.3 through C18 Tier 4 Engines {1000, 108C, 1214} Caterpillar

Articulated Truck

725C (S/N: TFB1-UP)

730C (S/N: TFF1-UP)

730C EJECTOR (S/N: TFH1-UP)

735B (S/N: T4P1-UP; E4R1-UP)

735C (S/N: TFJ1-UP)

740B (S/N: T4R1-UP; E4S1-UP)

740B EJECTOR (S/N: T4S1-UP)

740C EJECTOR (S/N: TFN1-UP)

745C (S/N: JE81-UP; TFK1-UP)

Cold Planer

PM620 (S/N: JB91-UP)

PM622 (S/N: JFC1-UP)

Electric Power Generation

C13GENSET (S/N: X3M1-UP)

C15 PET GEN SET (S/N: LWR1-UP)

XQ375 (S/N: X3F1-UP)

Engine

C13 (S/N: N3F1-UP; KWJ1-UP)

C15 (S/N: MG21-UP; N5F1-UP; LDN1-UP)

C18 (S/N: BE21-UP; N8F1-UP; BDN1-UP; ZPS1-UP)

Excavator

336E (S/N: JEA1-UP; RZA1-UP; YCE1-UP; TEG1-UP; FJH1-UP; GTJ1-UP; JRJ1-UP; SSL1-UP; YEP1-UP; HDW1-UP; BZY1-UP; GNY1-UP; TMZ1-UP)

336F (S/N: TZA1-UP; RKB1-UP; YFD1-UP; KGH1-UP; LCL1-UP; NBL1-UP; LTP1-UP; KFT1-UP; DSW1-UP; WTZ1-UP)

349E (S/N: FJB1-UP; ETC1-UP; DGE1-UP; SPG1-UP; TFG1-UP; RGH1-UP; FEJ1-UP; KCN1-UP; MZW1-UP; KFX1-UP; MPZ1-UP; WHZ1-UP)

349F (S/N: BZ21-UP; KEA1-UP; HLB1-UP; HPD1-UP; TEW1-UP)

352F (S/N: WNA1-UP; YEG1-UP; A9J1-UP; KBP1-UP)

374F (S/N: DNM1-UP)

390F (S/N: TYE1-UP; MGF1-UP; HSM1-UP)

Forest Machine

568 (S/N: BRB1-UP; YJX1-UP)

Generator Set

C15 GEN SET (S/N: T4A1-UP; JJF1-UP; X5M1-UP)

C18 GEN SET (S/N: X5F1-UP; T4X1-UP)

Industrial Engine

C13 INDUSTRIAL (S/N: RRA1-UP)

C9.3 (S/N: CS91-UP; C9N1-UP; D9N1-UP)

Landfill Compactor

826K (S/N: 2321-UP)

836K (S/N: TWZ1-UP)

Mobile Hydraulic Power Unit

336E MHPU (S/N: PCE1-UP; RBS1-UP; T3Z1-UP)

349E MHPU (S/N: JAE1-UP; S3P1-UP; MTS1-UP)

374F MHPU (S/N: DP41-UP)

390F MHPU (S/N: B371-UP)

Motor Grader

12M Series 2 (S/N: F9B1-UP; F9M1-UP)

12M Series 3 (S/N: N9B1-UP; N9F1-UP; N9P1-UP; N9R1-UP)

140M Series 2 (S/N: M9D1-UP; R9G1-UP; M9J1-UP; R9M1-UP)

140M Series 3 (S/N: N9D1-UP; N9G1-UP; N9J1-UP; N9M1-UP)

160M Series 2 (S/N: M9E1-UP; M9K1-UP; R9L1-UP; R9T1-UP)

160M Series 3 (S/N: N9E1-UP; N9K1-UP; N9L1-UP; N9T1-UP)

16M Series 3 (S/N: N9Y1-UP)

18M Series 3 (S/N: N9A1-UP)

OEM Excavator Based Specialty Solution

390F OEM (S/N: PT71-UP)

Off-Highway Truck/Tractor

770G (S/N: RMA1-UP; KDH1-UP)

772G (S/N: RME1-UP; KEX1-UP)

Petroleum Power Train Package

CX31-P600-C18I (S/N: PDC1-UP)

CX35-P800-C18I (S/N: PCF1-UP)

Pipelayer

PL72 (S/N: P721-UP)

PL83 (S/N: CB21-UP)

PL87 (S/N: TEC1-UP)

Reclaimer Mixer

RM500B (S/N: MB91-UP)

Road Reclaimer/Soil Stabilizer

RM-500 (S/N: ASW1-UP)

Site Prep Tractor

2864C (S/N: SP41-UP)

586C (S/N: SP51-UP)

Soil Compactor

825K (S/N: 2331-UP)

Track-Type Tractor

D6T (S/N: CR31-UP; CG81-UP; SGA1-UP; KSB1-UP; ZJB1-UP; JZC1-UP; DTD1-UP; RAD1-UP; STE1-UP; EJJ1-UP; SLJ1-UP; GMK1-UP; RRK1-UP; MEL1-UP; TSM1-UP; WLM1-UP; WRN1-UP; KMR1-UP; PLR1-UP; WES1-UP; SGT1-UP; JRW1-UP; RCW1-UP; TMY1-UP; HTZ1-UP)

D7E (S/N: HKA1-UP; TJA1-UP; SSH1-UP; TAN1-UP)

D8T (S/N: AW41-UP; FMC1-UP; MLN1-UP; FCT1-UP)

D9T (S/N: REX1-UP)

Wheel Dozer

824K (S/N: 2341-UP)

834K (S/N: TWY1-UP)

Wheel Loader

966K (S/N: PBG1-UP; TFS1-UP)

966K Series XE (S/N: NGX1-UP)

966M (S/N: EJA1-UP; DYC1-UP; KJP1-UP)

966M Series XE (S/N: P6C1-UP)

972K (S/N: PEM1-UP)

972M (S/N: LSJ1-UP; A8P1-UP; JPR1-UP)

972M Series XE (S/N: EDW1-UP)

980K (S/N: W7K1-UP; NEP1-UP)

980M (S/N: KRS1-UP; N8T1-UP)

982M (S/N: F9A1-UP; K1Y1-UP)

986H (S/N: L8S1-UP)

988K (S/N: TWX1-UP)

Wheel Tractor-Scraper

621H (S/N: DBK1-UP; HKK1-UP)

621K (S/N: WTA1-UP; WTE1-UP)

623H (S/N: DBF1-UP)

623K (S/N: WTB1-UP)

627H (S/N: DBW1-UP)

627K (S/N: WTC1-UP)

637K (S/N: WTS1-UP; WTT1-UP; WTX1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the information. This Special Instruction covers the procedure for checking the height of the piston for C9.3 through C18 engines.

Caterpillar Channel1 Video

Note: A CWS login is required to access Caterpillar Channel1. Scan the QR code below with a QR enabled device or copy the link that follows.

Illustration 1	g06431684

Reference: For more information, refer to "Piston Height Check Procedure (C9.3 through C18 Tier 4 Engines)" on Caterpillar Channel1.

Safety Section

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Disconnect batteries before performance of any service work.

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

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Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.

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Contact with high pressure fuel may cause personal injury or death. Wait 60 seconds after the engine has stopped to allow fuel pressure to purge before any service or repair is performed on the engine fuel lines.

Reference

Reference: Disassembly and Assembly , UENR0184 , Rocker Arm and Shaft - Remove and Install

Reference: Disassembly and Assembly , UENR0185 , Rocker Arm and Shaft - Remove and Install

Required Tools

Table 1 contains the tooling required for this procedure.

Height Check Procedure

Table 2 contains the specifications for each engine size and platform.

The measurement that is obtained with the piston height tool should be greater than the tolerance provided in the table above. If the measurement is lower, the cylinder head needs to be removed and the connecting rods inspected for being bent. Refer to the appropriate Disassembly and Assembly manual for the removing of the related components.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

Note: DO NOT TURN THE ENGINE OVER WITH KEY SWITCH.

1. Turn the engine over by hand with turning tool to see if engine is hydro-locked.

   Note: Normal engine rotation is counter-clockwise using the engine flywheel or clockwise if viewing rotation from the engine damper.

   1. If the engine abruptly stops, coolant is present in a cylinder and the fuel injectors need removed.

   2. Remove the coolant and check the piston height, refer to Disassembly and Assembly, Electronic Unit Injector – Remove and Install.

      Check he piston height if the machine was started or attempted to be started with the engine hydro-locked. Or check the piston height if there is suspicion of engine hydro-locked caused by NRS cooler failure.

2. Remove all the coolant from the cylinders by using a vacuum pump called out in Disassembly and Assembly, Electronic Unit Injector – Remove and Install.

   Note: For C9.3 engines, the rocker mechanisms do not need to be removed to access the fuel injectors or perform the piston height check.

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   Illustration 2	g06256316
   Example of piston height tool for the C9.3 Tier 4 Interim engines

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   Illustration 3	g06256320
   Example of piston height tool for the C9.3 Tier 4 Final engines

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   Illustration 4	g06256321
   Example of piston height tool for the C13 Tier 4 Interim and Tier 4 Final engines

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   Illustration 5	g06256322
   Example of piston height tool for the C15 and C18 Tier 4 Interim and Tier 4 Final engines

3. Install tool group (1) in cylinder 1 and cylinder 6. Make sure that the dial indicator is zeroed before installation.

   1. Use the injector hold-downs to hold the tooling in place. Make sure that the injector hold-down is tight against the cylinder head.

   2. Turn the engine over by hand with the engine turning tool.

   3. Pin the engine at Top Dead Center (TDC) of piston 1. At this point, the engine now should be at TDC of piston 1 and piston 6.

   4. The dial indicator should now be at the highest point of measurement. Refer to the table above that lists the specifications for the measurements.

   5. If the height is within the specification, then proceed to the Test Step 4.

4. Install the tool group in cylinder 2 and cylinder 5.

   1. Use the injector hold-downs to hold the tooling in place. Make sure that the injector hold-down is tight against the cylinder head.

   2. Turn the engine over by hand with the engine turning tool.

   3. The dial indicator should now be at the highest point of measurement. Refer to the table above that lists the specifications for the measurements.

   4. If the height is within the specification, then proceed to the Test Step 5.

   Note: Cylinder 3 and cylinder 4 are directly inlined with the intake making these cylinder most likely to be affected by a hydro-locked engine.

5. Install the tool group in cylinder 3 and cylinder 4.

   1. Use the injector hold-downs to hold the tooling in place. Make sure that the injector hold-down is tight against the cylinder head.

   2. Turn the engine over by hand with the engine turning tool.

   3. The dial indicator should now be at the highest point of measurement. Refer to the table above that lists the specifications for the measurements.

   4. If the height is within the specification, then proceed to the Test Step 6.

6. If a bent connecting rod is not found, reassemble the top end of the engine back together referring to the appropriate Disassembly and Assembly procedures.

7. If a bent connecting rod is found, the engine will need to be torn down. The bent connecting rod/rods will need to be removed and replaced. Refer to the Disassembly and Assembly and Reuse and Salvage Guidelines for the appropriate procedures to make the repairs.