0383591 JOHNSON LEAD, Solenoid to switch

Start By:a. remove valve covers 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. Remove fuel line (2) with Tool (B). Put protective caps on all fuel openings.2. Make a separation between rocker arm (1) and the push rod with Tool (A). Put identification on each valve bridge as to its location. Remove valve bridges (3). 3. Disconnect fuel lines (4) from fuel line adapters (5). Remove locks (6). Remove adapters (5).4. Remove bolts (8) that hold the rocker shaft assembly (7) to the cylinder head. Remove rocker shaft assembly (7).Install Rocker Shaft Assembly
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. Put rocker shaft assembly (2) into position on the head.2. Put clean engine oil on the threads of bolts (1) and install the bolts to hold rocker shaft assembly. Tighten the bolts as follows: a. Tighten bolts 1 through 6 in number sequence shown to a torque of 270 25 N m (200 20 lb ft).b. Tighten bolts 1 through 6 in number sequence shown again to a torque of 447 20 N m (330 15 lb ft).c. Tighten bolts 1 through 6 in number sequence shown again to a torque of 447 30 N m (330 15 lb ft). 3. Put clean engine oil on the O-ring for adapter (5). Install adapters (5) and locks.4. Connect fuel lines (3) to adapters (5). Tighten fuel line nuts to 40 7 N m (30 5 lb ft) with Tool (B).5. Put clean engine oil on the valve bridge dowels. Install valve bridges (7) in their correct locations on the cylinder head. Adjustment of the bridge is necessary only if valve grinding or other reconditioning of the cylinder head has been done. See the topic "Bridge Adjustment" in the Systems Operation, Testing and Adjusting Manual for this procedure.6. Put clean engine oil on the valve bridges. Make connection between the rocker arms (4) and push rods with Tool (A).7. Make an adjustment of the valve to have a clearance of .038 mm (.015 in) for intake and 0.76 mm (.030 in) for exhaust. See the topic "Valve Clearance Setting" in the Systems Operation, Testing & Adjusting Manual.8. Install the fuel lines to fuel valves (6). Tighten the fuel line nuts to 40 7 N m (30 5 lb ft) with Tool (B).End By:a. install valve coversDisassemble Rocker Shaft Assembly
Start By:a. remove rocker shaft assembly 1. Remove retainer (1) from the shaft.2. Remove the washers and rocker arm (2). 3. Use Tool (A) to remove the pin that holds bracket (3) to the rocker arm shaft.4. Remove bracket (3), rocker arm (4) and the spring.5. Remove the remainder of the rocker arms. The center brackets do not have pins.Assemble Rocker Shaft Assembly
Make sure all parts of the rocket shaft assembly are clean before assembly. 1. Put clean engine oil on shaft (3).2. Install the center springs, rocker arms and bracket.3. Install spring (1), rocker arm (4) and bracket (2).4. Put tape around the shaft on each side of bracket (2) as shown. Put the hole in bracket (2) in alignment with the hole in shaft (3). Put a mark on each piece of tape in alignment with the hole in bracket (2).5. Install pin (5) until it is extended 8.6 mm(.34 in) above the surface of bracket (2). Make sure pin (5) is in alignment with the marks on tape before pin is installed. Remove the tape. 6. Install rocker arm (6), washers (7) and retainer (8). Install enough washers until the end play on each end of the shaft is 0.12 to 1.01mm (.005 to .040 in).End By:a. install rocker shaft assembly