Usage:
Fuel Line Installation
NOTE:
1. If new fuel lines are being used, be sure to install the new "O" rings on the riser end of fuel lines. Lubricate the "O" rings with clean engine oil before installing.
2. Remove the protective caps and plugs from nozzles and fuel lines.
3. Install the fuel lines on the engine. First hand tighten the retainer nuts. Then tighten nuts using the Caterpillar fuel line socket wrench to 30 lbft (41N·m).
4. Check the clearance between the fuel lines and the necked down portion of the mounting studs. A clearance of 0.125 in. (3.175mm) minimum to 0.375 in. (9.525mm) maximum is required. If insufficient clearance is found, reposition or interchange fuel lines until all lines meet clearance specifications.
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DO NOT BEND FUEL LINES AS FUEL LEAKAGE MAY RESULT. |
5. Install "O" ring on oil supply adapter. Place a small amount of grease on the adapter.
6. Before placing brake units on engine, loosen and backout the slave piston adjusting screw until slave piston is seated in its bore.
7. Carefully install the brake housing. Pay particular attention to the oil supply adapter to ensure proper alignment.
8. Install the Jacobs washer and the 3/8" capscrew through the housing and into the support bracket. Adjust bracket location as needed. Hand tighten only.
9. Torque the support bracket bolt to 200 lbft (270N·m). Retorque to 330 lbft (450N·m). Always repeat torquing of bolts as a check.
10. Place Caterpillar cylinder head bolt washers on to the 3/4" Jacobs holddown studs. Hand tighten the Jacobs holddown nuts onto the 3/4" holddown studs.
Reinstall the Jacobs 3/8" cap screw and washer.
Torque the Jacobs holddown nuts to 60 lbft (81.6N·m) and the 3/8" cap screw to 30 lbft (41N·m).
Retorque 3/8" cap screw to 47 lbft (64N·m) and the Jacobs holddown nuts to 100 lbft (135N·m). Repeat the last procedure to secure the brake housing.
Reinspect each fuel line location to ensure that there is no contact between brake components and the fuel lines.
Reset fuel lines if necessary.
NOW FOLLOW THE SAME PROCEDURES ON THE OTHER THREE CYLINDERS.
Valve Adjustment Procedure
11. Adjust the intake and exhaust valves on each cylinder. (See Table 1.) After setting the exhaust valve clearance and while the exhaust valve is closed and the bridge loose, the slave piston clearance can be set.
Adjust the intake and exhaust rocker lever clearance to Caterpillar specifications: Set lash at 0.015 in. (0.38mm) for intake and 0.030 in. (0.76mm) for exhaust.
Torque rocker adjusting screw lock nuts to 22 lbft (30N·m).
Slave Piston Adjustment Procedure
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PAY SPECIAL ATTENTION TO THIS ADJUSTMENT. TO ENSURE MAXIMUM BRAKE OPERATING EFFICIENCY AND TO PREVENT ENGINE DAMAGE, FOLLOW INSTRUCTIONS CAREFULLY. |
Slave piston adjustment must be made with the engine stopped and cold (stabilized water temperature of 140°F (60°C) or below). Exhaust valves on the Cylinder to be adjusted must be in the closed position. (See Table 1.)
1. Loosen and back off adjusting screw locknut. Use a screwdriver or hex wrench, as required, to back out slave piston adjusting screw until slave piston is seated in bore.
2. INSERT CORRECT JACOBS FEELER GAUGE BETWEEN THE SLAVE PISTON FEET AND BRIDGE. TURN THE ADJUSTING SCREW IN UNTIL A SLIGHT DRAG IS FELT ON FEELER GAUGE. TORQUE LOCK NUT TO 16 LBFT (22N·m). Remove timing bolt. Rotate the engine over to cylinder 6TDC, reinstall timing bolt and continue the valve and slave piston adjustment. Remove the timing bolt from the flywheel location when all valves and slave pistons are adjusted. The timing bolt and access cover can now be returned to their storage location.
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MAKE THIS ADJUSTMENT CAREFULLY. AFTER SLAVE PISTON ADJUSTING SCREW LOCKNUT IS PROPERLY TORQUED, RECHECK THE CLEARANCE WITH THE JACOBS FEELER GAUGE. OVERTORQUING LOCKNUT COULD DAMAGE SLAVE PISTON ADJUSTING SCREW. THIS WILL CAUSE ENGINE DAMAGE. |
Final Installation Procedures
1. Place the cover bases on the cylinder head. Check for interference between #3 and #6 exhaust valve bridges and the casting ribs.
If there is interference, remove base and grind away the rib as necessary. Clean the base thoroughly and reinstall.
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NEVER GRIND BRIDGE TO OBTAIN CLEARANCE. |
2. Fasten the valve mechanism cover bases in the four indicated locations with Jacobs mounting studs and washers (see Figure 3-8). Short threaded end of stud must go into engine head. Use the Caterpillar nuts and washers in the other two locations. Torque spacer studs and nuts to 10 lbft (13.5N·m).
NOTE MOUNTING STUD LOCATIONS
3. Tighten the terminal leadout assembly in the spacer using a hex box socket wrench until leadout assembly is seated in the spacer.
4. Install the Jacobs gaskets in the spacers.
5. Install the spacers on top of the valve mechanism cover bases and over the mounting studs.
Install the Jacobs vibration-proof nuts on the four mounting studs.
6. Install the Jacobs serrated capscrews in the two noted locations.
Torque both the capscrews and the nuts to 13 lbft (18N·m).
7. Install the solenoid valve harness and its clamp. The tab end of the harness attaches to the solenoid. The other end attaches to the inside terminal of the leadout assembly in the spacer.
Torque the harness clamp screw to 60 lbin (7N·m).
Final Adjustments
The Jacobs Engine Brake housing installation is now completed. The following procedures and adjustments should be made.
Recheck the housing installation. Be certain no foreign objects have been left behind and all correct clearance requirements have been met.
Brake Unit Bleed And Operation Check
1. Start engine and allow to run 5 to 10 minutes.
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WEAR EYE PROTECTION AND DO NOT EXPOSE YOUR FACE OVER ENGINE AREA. TAKE PRECAUTIONS TO PREVENT OIL LEAKAGE DOWN ON THE ENGINE. WHENEVER ENGINE IS RUNNING AND VALVE COVERS ARE REMOVED, OIL SPLASHING IN THE ENGINE BRAKE AREA COULD CAUSE PERSONAL INJURY. |
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2. With the engine at low idle, manually depress the solenoid armature five or six times in succession. This permits oil to fill the passages in the brake housing and readies the brake for operation.
Inspect the installation for any abnormal oil or fuel leakage and component interference. If either is found, the problem must be corrected at this time.
3. If the engine fails to start or misfires, the following Caterpillar procedure must be initiated:
TO PRIME THE SYSTEM: If air is trapped in the fuel system, the diesel engine will either not start, or will misfire. Then it is necessary to prime the system. A fuel priming pump is located either on the engine, or remotely mounted for convenience.
a. Be sure the fuel line valve is open and the engine shutoff control is off.
b. Loosen the fuel line nuts (one at a time) at the pump housing.
c. Unlock the fuel priming pump.
d. Operate priming pump until clear fuel flows from fuel pump. Tighten fuel line nut.
e. Repeat for each fuel line.
f. Lock fuel priming pump.
(If engine continues to misfire or smoke, further bleeding is necessary. With engine running, loosen fuel line nuts, one at a time, several times in succession and allow fuel to run until free of air bubbles. Tighten fuel line nuts to 30 lbft (41N·m).
4. Before replacing the Caterpillar valve mechanism cover, check for interference at oilfill and breather locations. If interference is found, remove sufficient material from the cover to ensure clearance with engine brake housing.
5. Clean and install covers. Torque holddown nuts to 13 lbft (18N·m).
NOTE: On DIT and PCT engines only, a boss may be located on the bottom of the crossover pipe connecting flange on the Caterpillar 7N2446 Elbow. The boss interferes with the valve cover when the brake is installed.
6. On DIT and PCT engines only, remove the Caterpillar 7N2446 Elbow and grind away boss to remove interference, clean the elbow after rework and check the Caterpillar 2N8630 gasket between elbow and intake manifold before reassembly.
7. On engines which have the oil breather mounted on the front valve cover, install the rubber breather pipe extension hose from the kit.
8. On engines with the oil breather mounted on the rear value cover relocate breather pipe brackets as necessary on engines with the oil breather mounted on the rear valve cover to ensure adequate retention of the breather pipe.