0431628 JOHNSON MANIFOLD, Intake

Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.
Valve Lash Setting
The temperature of the engine does not change the valve lash setting.Valve Lash Setting Inlet valve ... 0.20 mm (0.008 inch)Exhaust valve ... 0.45 mm (0.018 inch)Valve Lash Adjustment
If the valve lash requires adjustment several times in a short period of time, excessive wear exists in a different part of the engine. Repair the problem in order to prevent more damage to the engine.Not enough valve lash can be the cause of rapid wear of the camshaft and valve lifters. Not enough valve lash can indicate that the seats for the cylinder head valves are worn.Cylinder head valves become damaged due to the following causes:
Fuel injection nozzles that operate incorrectly
Excessive dirt and oil are present on the filters for the inlet air.
Incorrect fuel settings on the fuel injection pump.
The load capacity of the engine is frequently exceeded.Too much valve lash can cause broken valve stems, springs, and spring retainers. Too much valve lash can be an indication of the following problems:
Worn camshaft and valve lifters
Worn rocker arms
Bent pushrods
Broken socket on the upper end of a pushrod
Loose adjustment screw for the valve lashIf the camshaft and valve lifters show rapid wear, look for fuel in the lubrication oil or dirty lubrication oil as a possible cause.The valve lash is measured between the top of the valve stem and the rocker arm lever.Note: Number 1 cylinder is at the front of the engine.
Illustration 1 g00323903
Setting the valve lash
(1) Adjustment screw
(2) Feeler gauge
Accidental engine starting can cause injury or death to personnel.To prevent accidental engine starting, turn the ignition switch to the OFF position, place a do not operate tag at the ignition switch location and disconnect and tape the electrical connection to the stop solenoid that is located on the fuel injection pump.
Remove the valve mechanism cover and perform the following procedure in order to adjust the valve lash:
Set the top center position for No. 1 piston on the compression stroke. Before adjustments are made, lightly tap each rocker arm at the top of the adjustment screw. Use a soft mallet to ensure that the lifter seats against the camshaft's base circle. Note: Later 3054 engines require the use of a TORX T27 driver to adjust valve lash.
Rotate the crankshaft in the normal rotation of the engine. When the inlet valve of the No. 4 cylinder has opened and the exhaust valve of the No. 4 cylinder has not completely closed measure the valve lash of the inlet valve and the exhaust valve of No. 1 cylinder. If necessary, make an adjustment to the inlet valve and the exhaust valve on No. 1 cylinder.
Loosen the valve adjustment screw locknut that is on adjustment screw (1).
Place appropriate feeler gauge (2) between the rocker arm and the valve. Turn adjustment screw (1) while the valve adjustment screw locknut is being held from turning. Adjust the valve lash until the correct specification is achieved.
After each adjustment, tighten the valve adjustment screw locknut while valve adjustment screw (1) is being held from turning.
Rotate the crankshaft in the normal rotation of the engine. When the inlet valve of the No. 2 cylinder has opened and the exhaust valve of the No. 2 cylinder has not completely closed measure the valve lash of the inlet valve and the exhaust valve of No. 3 cylinder. If necessary, make an adjustment to the inlet valve and the exhaust valve on No. 3 cylinder.
Loosen the valve adjustment screw locknut that is on adjustment screw (1).
Place appropriate feeler gauge (2) between the rocker arm and the valve. Turn adjustment screw (1) while the valve adjustment screw locknut is being held from turning. Adjust the valve lash until the correct specification is achieved.
After each adjustment, tighten the valve adjustment screw locknut while valve adjustment screw (1) is being held from turning.
Rotate the crankshaft in the normal rotation of the engine. When the inlet valve of the No. 1 cylinder has opened and the exhaust valve of the No. 1 cylinder has not completely closed measure the valve lash of the inlet valve and the exhaust valve of No. 4 cylinder. If necessary, make an adjustment to the inlet valve and the exhaust valve on No. 4 cylinder.
Loosen the valve adjustment screw locknut that is on adjustment screw (1).
Place appropriate feeler gauge (2) between the rocker arm and the valve. Turn adjustment screw (1) while the valve adjustment screw locknut is being held from turning. Adjust the valve lash until the correct specification is achieved.
After each adjustment, tighten the valve adjustment screw locknut while valve adjustment screw (1) is being held from turning.
Rotate the crankshaft in the normal rotation of the engine. When the inlet valve of the No. 3 cylinder has opened and the exhaust valve of the No. 3 cylinder has not completely closed measure the valve lash of the inlet valve and the exhaust valve of No. 2 cylinder. If necessary, make an adjustment to the inlet valve and the exhaust valve on No. 2 cylinder.
Loosen the valve adjustment screw locknut that is on adjustment screw (1) .
Place appropriate feeler gauge (2) between the rocker arm and the valve. Turn adjustment screw (1) while the valve adjustment screw locknut is being held from turning. Adjust the valve lash until the correct specification is achieved.
After each adjustment, tighten the valve adjustment screw locknut while valve adjustment screw (1) is being held from turning.