0915116 JOHNSON BOLT, Bellcrank

Jacket Water Aftercooler Core
Clean/Inspect
Caterpillar recommends that the aftercooler core be removed, cleaned, inspected, and pressure tested at the Every 2400 service hours or Two Years interval. It is also recommended that the aftercooler core be cleaned and pressure tested if a turbocharger failure occurs, or if the turbocharger develops an oil leak.Refer to the Service Manual or consult with your Caterpillar dealer for aftercooler removal procedure.Cleaning Procedure
Do not use caustic cleaners to clean the core. Caustic cleaners will attack the internal metals of the core and cause leaks.
1. Remove the core. Turn the core upside down to remove debris from the inlet.2. Back flush internally with cleaner to loosen foreign substances and to remove oil. Caterpillar recommends the use of Caterpillar Hydrosolv Liquid Cleaners. The following chart lists part numbers and quantities of recommended cleaners available from your Caterpillar dealer. 3. Steam clean the core to remove any cleaner film. Flush the aftercooler core fins. Remove any other trapped debris.4. Wash the core with hot, soapy water. Rinse thoroughly with clean water.5. Dry the core with compressed air. Blow the air in reverse direction of the normal flow. Use all necessary safety equipment while working with compressed air.6. Inspect the system to ensure cleanliness. Test and repair the core as necessary. Install the core. This cleaning procedure may also be used for cleaning the oil cooler core.Consult with your Caterpillar dealer for more information about cleaning the aftercooler core.Fuel Injection Nozzles
Test/Exchange
Fuel injection nozzles are subject of tip wear. Tip wear, a result of fuel contamination, can cause:* increased fuel consumption* black smoke* misfire* rough runningNozzles should be cleaned, inspected, tested, and replaced if necessary. Refer to Special Instruction SEHS7292, for using the 8S-2245 Nozzle Cleaning Kit. Consult with your Caterpillar dealer about nozzle cleaning and testing.
Never wire brush or scrape a nozzle. Wire brushing or scraping a nozzle will damage the finely machined orifice. Proper tools for cleaning and testing nozzles can be obtained from authorized Caterpillar dealers.
Abnormal engine running, smoke emission, and engine knock can be symptoms of nozzle malfunction. Each nozzle must be isolated one at a time in order to determine the malfunctioning nozzle.1. Start the engine.
A nozzle will be damaged if the top of the nozzle turns in the body. The engine will be damaged if a defective nozzle is used because the fuel spray pattern that comes out of the nozzle will be incorrect. Nozzles can be permanently damaged by twisting if only one wrench is used to loosen or tighten the fuel line nuts. Do NOT let the tops of the nozzles turn when the fuel lines are loosened. Use one wrench to hold the nozzle and another to loosen the fuel line nut.
2. Loosen each fuel line nut at the fuel injection pump, one at a time. A cloth or similar material must be used to prevent fuel from spraying on the hot exhaust components. Tighten each nut before loosening the next nut.3. A defective nozzle may be identified when a fuel line nut is loosened and:* the exhaust smoking is partially or completely eliminated* engine performance is not affectedA nozzle suspected of being defective should be removed. A new nozzle should be installed in the cylinder to determine if the removed nozzle is defective.Removing and Installing Fuel Injection Nozzles
Special tooling is required to remove and install nozzles. Refer to the Service Manual for information. Consult with your Caterpillar dealer for assistance.Fuel Ratio Control, Set Point, and Low Idle
Check/Adjust
The fuel ratio control limits the amount of fuel to the cylinders during acceleration. This affects the amount of exhaust smoke. The set point check is a method for diagnosing engine performance. Slow engine response and low power indicate that a fuel control adjustment or repair is necessary.Emission certified engines are equipped with a protection group that discourages any tampering with the fuel ratio control setting. This is required by emissions regulations. Standard bolts have been replaced by tamper resistant bolts.On emissions certified engines, the fuel ratio control setting is locked in order to discourage tampering. Changing the fuel ratio control could cause the engine to exceed emissions standards.
Adjustments and repairs should be made by an authorized Caterpillar dealer.
The fuel ratio control, set point, and idle speed checking and adjusting should only be performed by Caterpillar authorized service personnel or other properly trained mechanics. Consult with your Caterpillar dealer for assistance. Authorized Caterpillar dealers are equipped to properly perform these services.Fuel Pump/Governor Housing
Drain Water
The fuel shutoff solenoid (1) is mounted on the fuel pump/governor housing (2). Condensation can collect over time in the fuel pump/governor housing. There are two drains located at the rear (bottom) of the fuel pump/governor housing. To drain water from the fuel pump/governor housing:1. Remove the bolt (3) and plug (4).2. After the water and sediment has drained, install the bolt (3) and plug (4). Refer to the Torque Specifications in this manual. The air must then be purged from the fuel system. Refer to the Priming the Fuel System topic in this manual.