37141-92E10 Suzuki KEY (12)

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 running.Fuel nozzles should be cleaned, inspected, tested, and replaced if necessary. Refer to Special Instruction SEHS7292, for using the 8S2245 Nozzle Cleaning Kit. Consult with your Caterpillar dealer about fuel injection nozzle cleaning and testing.
Never wire brush or scrape a fuel injection nozzle. Wire brushing or scraping a fuel injection nozzle will damage the finely machined orifice. Proper tools for cleaning and testing fuel injection 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 fuel injection nozzle will be damaged if the top of the nozzle turns in the body. The engine will be damaged if a defective fuel injection nozzle is used because the fuel spray pattern that comes out of the nozzle will be incorrect. Fuel injection 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 fuel 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 nut is loosened and:* the exhaust smoking is partially or completely eliminated.* irregular running is not affected.A 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.Inspect, Rebuild or Exchange
If the engine is operated until the component(s) fails, additional engine damage can result. Caterpillar recommends that the following components be injected at the 5000 Hour maintenance interval.* Jacket Water Pump* Turbocharger* Alternator* Starting MotorCaterpillar Recommendation
To minimize downtime, Caterpillar recommends the use of Remanufactured components (subject to availability) as the most cost effective option.Removal and Installation
Refer to the Service Manual or contact your Caterpillar dealer for assistance with removal and installation of engine components.Jacket Water Pump
A failed water pump might cause severe engine overheating problems that could result in cracks in the cylinder head, a piston seizure or other potential damage to the engine.Visually inspect the water pump for leaks. If leaking is observed, replace all seals. Refer to the Service Manual for the procedure to replace the seals.Turbocharger
Refer to the Turbocharger topic in the Every 3000 Hours maintenance interval for information regarding turbocharger inspection. Refer to the Service Manual, or consult with your Caterpillar dealer for the complete turbocharger inspection procedure.Alternator and Starting Motor
Caterpillar recommends a scheduled inspection of the alternator. Inspect the alternator for loose connections and proper battery charging. Inspect the ammeter gauge during engine operation to ensure the batteries and/or electrical system is performing correctly. Make repairs as necessary. Refer to the Service Manual.Check the alternator and battery charger for proper operation. If the batteries are properly charged, ammeter reading should be very near zero. All batteries should be kept charged. The batteries should be kept warm because temperature affects the cranking power. If the battery is too cold, it will not crank the engine, even if the engine is warm.When the engine is not run for long periods of time or run for short periods, the batteries may not fully recharge. Ensure the alternator performs properly to charge the battery and to help prevent the battery from freezing.If the starting motor fails, the engine may not start in an emergency situation. Caterpillar recommends a schedule inspection/check of your starting motor. The starting motor should be checked for correct operation. All electrical connections should be cleaned and checked. Refer to the established procedure for inspection and specifications in the Service Manual, or contact your Caterpillar dealer for assistance.Repair Before Failure
Until recently, engine maintenance and repair management involved changing the oil when it was convenient and repairing the engine when it was damaged. This seemed to be the accepted way of managing a maintenance operation.However, due to a variety of circumstances, increasing competition have caused users to look for ways to prolong equipment life and lower operating costs so that they could be competitive.To assist Caterpillar engine users in prolonging engine life and reducing operating costs, the Value Planned Repair approach to engine maintenance was developed.The Value Planned Repair approach can be tailored for any engine. This approach, when properly structured, outlines every maintenance and repair service required to support an engine from the day it enters service until the day it is retired.To ensure the repair is performed efficiently and expediently, the Value Planned Repair concept approaches a given repair in three basis steps:1. Repair determination2. Evaluation of repair options3. Selection of the most appropriate optionThe Value Planned Repair approach addresses:* Services required to maintain an engine at optimum efficiency.* Scheduled maintenance, repairs and overhauls to minimize unscheduled downtime.* Preplanned repairs and overhauls that can be flat-rated, putting you in charge of costs.* Repair or overhaul options designed to restore the engine to proper operating condition.* Repair or overhaul options designed to renew the engine if a failure has occurred.Part of the Value Planned Repair approach is the repair before failure concept. The objective of the repair before failure concept is to repair the engine before a failure takes place.The fact that a failure has not taken place makes the repair before failure concept more economical since a high degree of parts such as pistons, liners, valves, etc., and major castings such as cylinder blocks, cylinder heads,