Installation of 4P0705 Exhaust Restricter Retrofit Kit{1050} Caterpillar

Introduction

Installation of the exhaust restricter will increase engine exhaust pressure, and reduce white smoke that is produced during a cold start of the engine. The exhaust restricter will begin to open as engine speed is increased. As engine speed increases, the effectiveness of the exhaust restricter will decrease.

This means that results will be the best when the engine is operated at Low Idle speed, with the transmission in the NEUTRAL position.

White smoke decreases quickly when the marine gear is engaged and the engine is under load.

When the retrofit kit is installed, it will be necessary to shorten the exhaust pipe that connects to the engine. This is because the exhaust restricter housing installs on the back of the turbocharger.

Before starting the installation procedure, make sure there is an additional 106.5 mm (4 3/16") of space at the back of the turbocharger. This much additional room is needed for installation of the exhaust restricter housing.

For some early engines, it will be necessary to remove the oil filter bracket/lifting bracket and make a modification to the bracket. This modification consists of drilling and tapping two new holes in the oil filter bracket/lifting bracket. This instruction will give the necessary details.

Do not perform any procedure, outlined in this publication, or order any parts until you read and understand the information contained within.

Reference: Service Manual, Operation and Maintenance Manual.

Installation of 7E8661 Cable Assembly (Push/Pull) to Oil Filter Bracket/Lifting Bracket

NOTE: If mounting holes for attaching the 7E8661 Cable Assembly (push/pull) do not exist in oil filter bracket/lifting bracket (3), the bracket must be removed from the engine and modified to include the necessary holes. Refer to the topic entitled Modification of the Oil Filter Bracket/Lifting Bracket in this publication.

1. Remove the oil filter base from engine oil filter bracket/lifting bracket (3) and move it out of the way.

* Do not disconnect the oil lines.

2. Put 7E8661 Cable Assembly (1) in position. Route cable (1) under aftercooler housing (2) in the Vee of the engine, then direct it between oil filter bracket/lifting bracket (3) and the turbocharger, at the rear of the engine.

3. Use two 5M6755 Screws, two 4B4274 Washers, one 7L7786 Shim and one 7L7785 Clamp (4) to fasten cable assembly (1) to oil filter bracket/lifting bracket (3) as shown. (The shim must be installed beneath the clamp.)

NOTE: It will be easier to first fasten the clamp and shim with one screw and washer. Turn the clamp over the cable assembly, then turn the shim so it is in its correct position, before installing the second screw and washer.

4. Install the oil filter base on the oil filter bracket/lifting bracket.

Modification of Governor Control Linkage

1. Remove throttle lever (6) from bracket (5). Remove throttle control rod (7) from engine governor lever (8).

2. Remove the rod end and nut from the end of rod (7) that connected to governor lever (8). Install the rod end and nut on the new 7E9274 Rod. Install the 9L3334 Nut and 367232 Rod End on the other end of the new rod.

3. Install the rod ends so there is an equal amount of thread engagement at each end. Adjust the rod ends so the center-to-center distance between them, dimension (A), is 197.5 ± 1.0 mm (7.9 ± 0.04") as shown. Tighten the locknuts.

4. Using one 7B2742 Bolt, six 5P0537 Washers and one 9S8750 Nut, connect the rod to lever (8) on the fuel injection pump, and to the new 7E9913 Lever Assembly.

* The 4P0705 Exhaust Restricter Retrofit Kit contains only five of the six 5P0537 Washers needed. The additional one washer needed can be obtained from the washers removed in the disconnection and removal of rod (7).

NOTE: At installation of new 7E9913 Lever Assembly (9), the long end of the connecting pin in the lever assembly must face toward the left side of the engine (as seen from the rear of the engine).

The rod end that was installed on the new 7E9274 Rod must install on the right side of the 7E9913 Lever Assembly.

5. Loosely install one 7L7786 Shim, one 7L7785 Clamp (12) and one 5M6755 Screw with a 4B4274 Washer on 7E7927 Strap Assembly (13). (The shim must be installed beneath the clamp.)

6. Insert the parts from Step 5 under the fuel lines. (The clamp must face toward the rear of the engine.)

7. Put 7E8661 Cable Assembly (1) under 7L7785 Clamp (12) as shown, then install one additional 5M6755 Screw with a 4B4274 Washer, in clamp (12). Tighten the screws.

NOTE: It will be easier to first fasten the clamp and shim with one screw and washer. Turn the clamp over the cable assembly, then turn the shim so it is in its correct position, before installing the second screw and washer.

8. Using one 5M6755 Screw with one 4B4274 Washer, loosely fasten 7E8662 Bracket Assembly (10) to 7E7927 Strap Assembly (13).

9. Using one 7B2742 Bolt (let it remain loose for now), two 5P0537 Washers, one 9S8750 Nut and one 7E9275 Spacer, loosely fasten 7E7927 Strap Assembly (13) and 7E9913 Lever Assembly (9) to throttle bracket (5) on the front of the engine.

10. Use two 0S1571 Bolts (11) with 5M2894 Washers in the holes shown, to fasten 7E8662 Bracket Assembly (10) to the aftercooler housing.

11. Tighten the bolts that secure the brackets.

Top view of parts installation just completed: (1) 7E8661 Cable Assembly. (4) 7L7785 Clamp. (9) 7E9913 Lever Assembly. (10) 7E8662 Bracket Assembly. (12) 7L7785 Clamp. (13) 7E7927 Strap Assembly. (14) 7L7786 Shim (install one at each location as needed).

Adjust the rod ends so the centerline of the 7E8661 Cable Assembly connecting pin on 7E9913 Lever Assembly (9) intersects with the centerline of the engine shutoff solenoid. Tighten the locknuts.

Installation of Exhaust Restricter Housing

1. Check/adjust the OPEN position stop screw for the exhaust restricter plate within the exhaust restricter housing. The exhaust restricter plate (within the housing) should travel 3° over-center when it is in the OPEN position.

2. Drain the coolant from the engine cylinder block.

3. Disconnect the exhaust piping at the rear of the turbocharger.

Rear view of engine.

4. Remove water line (15) that goes from the top of the turbocharger to the left side exhaust manifold.

5. Remove adapter (16) from the 90° fitting in the exhaust manifold.

Rear view of engine.

6. Install 4W8527 Nipple (20) as a replacement for adapter (16) (removed in Step 5). Use 5P3413 Pipe Sealant, or equivalent, on the nipple threads. Cut 9Y1642 Hose (19) to length and install it on nipple (20).

NOTE: It will be necessary to reposition the angle of the elbow so 4W8527 Nipple (20) will be in correct alignment as shown. This is necessary to permit correct installation orientation for the exhaust restricter housing coolant connection.

7. Install an 8T1117 Hose Clamp to secure the hose to the nipple. Put an additional 8T1117 Hose Clamp loosely over the hose.

8. Position a 4N3955 Gasket into the outlet of the turbocharger. Exhaust restricter housing (21) must be positioned so lever (22) is located on the left side of the engine. (Left side and/or right side is determined when looking forward from the flywheel end of the engine.)

NOTE: Shaft (23) within the exhaust restricter housing must be in a horizontal position, as shown.

9. Position the coolant connection on exhaust restricter housing (21) so it is in 9Y1642 Hose (19). Now slide the pilot end, location (B), of exhaust restricter housing (21) into the turbocharger.

10. Use four 0S1594 Bolts to fasten exhaust restricter housing (21) to the turbocharger. Tighten the remaining 8T1117 Hose Clamp to fasten hose (19) to exhaust restricter housing (21).

11. Install 7J7187 Connector (18) with the 4K1388 O-ring Seal in exhaust restricter housing (21). Install 7E8664 Tube Assembly (17) to complete the coolant connections.

12. Shorten the exhaust pipes as necessary. Use the remaining 4N3955 Gasket to connect the exhaust piping to exhaust restricter housing (21).

13. Fill the engine cooling system to its correct level. Refer to the Operation and Maintenance Manual for the correct amount and type of coolant for this engine application.

Adjustment of Control Mechanism

1. Start the engine and run it at Low Idle speed.

2. Move the exhaust restricter to the CLOSED position (check lever for position), then adjust the Low Idle bolt to obtain 650 rpm.

3. Stop the engine.

4. Put the threaded end of 7E8671 Pin Assembly (25) through the hole in lever (22) on the exhaust restricter housing as shown. Install star washer (29) and the nut. Tighten the nut.

5. Install two 7E8660 Cable Ends, (24) and (26), on 7E8661 Cable Assembly (1). Put a 1 mm (.04") thick shim between the governor lever and the Low Idle stop bolt.

Move the exhaust restricter plate (within the exhaust restricter housing) so it is in the CLOSED position. Adjust the cable ends and connect them to the levers as follows:

* Slide three 4B4277 Washers (27) over the end of pin (25). Put 7E8660 Cable End (26) in position on 7E8671 Pin Assembly (25). Install C-clip (28) to secure 7E8660 Cable End (26) to pin (25) [on exhaust restricter lever (22)].

* Using one 4B4277 Washer and a 7H9737 Cotter Pin, connect 7E8660 Cable End (24) to the right side of 7E9913 Lever Assembly (9) as shown.

6. Remove the 1 mm (.04") shim.

7. Check throttle movement to make sure there is smooth movement from Low Idle position (governor lever is against the Low Idle stop bolt) to High Idle position (slight tension from governor lever over-center spring can be felt).

NOTE: Do not force exhaust restricter lever (22) to override the spring during adjustment of the cable ends on 7E8661 Cable Assembly (1).

Adjustment of Boat Throttle Control Cable

When properly adjusted, the boat throttle cable must be adjusted so it has a slight compressive force that holds the governor lever against the Low Idle adjustment bolt. To make this adjustment, proceed as follows:

* Put the pilot house throttle control lever at the Low Idle position.

* At the engine end of the throttle cable, push on the rod end of the cable to remove any end play (slack) in the cable. Adjust the cable rod end so a slight force is needed to connect the rod end to the governor lever when the lever is in the Low Idle position.

Exhaust Restricter Operational Test Procedure

1. Remove 0S1591 Bolt (30) with washer from exhaust restricter housing (21). Use an appropriate fitting to connect the 1U5470 Engine Pressure Group to the exhaust restricter housing.

2. Start the engine and let it run at Low Idle speed with no load (transmission in NEUTRAL position). The exhaust back pressure should be a minimum of 31.0 kPa (4.5 psi).

3. If the back pressure reading is below the 31.0 kPa (4.5 psi) required minimum, check the adjustment of the exhaust restricter plate. (The exhaust restricter plate is within the exhaust restricter housing.)

Refer to the topic entitled Installation of Exhaust Restricter Housing in this publication.

Modification of the Oil Filter Bracket/Lifting Bracket

Using the included template, mark and drill two 3.9 mm (5/32") diameter holes at locations (C). Use a tap to put 10-24 threads in these holes.

Install the bracket in its original position on the engine. Tighten the mounting bolts to a torque of 135 ± 13 N·m (100 ± 10 lb ft).