1228599 Volvo.Penta Cushion

Fuel Injection Nozzles
Exchange
Whenever the engine performs in such a manner that a fuel injection nozzle is suspected of causing irregular running, smoking or knocking, isolate each fuel injection nozzle, one at a time, to determine the malfunctioning nozzle. For complete fuel injection nozzle information, consult your authorized Caterpillar dealer.1. Start the engine. 2. Loosen the fuel injection line nut at the cylinder head, one at a time, with the engine running.3. When a cylinder is found where the loosened fuel line nut does not make a difference in engine performance or smoking, have that cylinder injection nozzle exchanged.Be sure to tighten each fuel line nut after the test, before the next fuel line nut is loosened. Tighten fuel line nuts to a torque of 40 7 N m (30 5 lb ft). Do not over torque the fuel injection line nut since this could cause permanent damage to the ends of the fuel injection line. Damaged fuel injection lines cannot be reused.4. Stop the engine.Maintenance Options
Dealer Test - Your Caterpillar dealer can test your nozzles for valve opening pressure, internal return leakage and external leakage, etc. Refer to Special Instruction, form SEHS7292, for information regarding fuel nozzle test procedures and tools required. Remanufactured - This process uses manufacturing techniques and procedures to restore fuel injection nozzles to "like-new" performance capability. This process always involves an end product which conforms to the manufacturer's original functional specification.Your Caterpillar Remanufactured nozzles have been tested for valve opening pressure, steady flow, internal return leakage, external leakage and an orifice inspection. New - Replace with new fuel injection nozzles.Before deciding which method is best, you should make sure you have considered all of the options and costs associated with repair. Some considerations are: * Downtime costs while the product is being rebuilt or repaired.* Total parts and labor costs for repairs versus the actual Remanufactured component cost.* Remanufactured components from Caterpillar are covered by a national factory warranty.Caterpillar Recommendation
To minimize downtime and provide you with the lowest cost and highest value, Caterpillar recommends the following: * Dealer Testing, if maintenance is being performed at an approved Caterpillar servicing facility.* Remanufactured components, when a nozzle test tool is not readily available. For complete fuel injection nozzle testing and cleaning, consult your authorized Caterpillar engine dealer.To Remove and Install Injection Nozzles
Refer to the Service Manual for your engine to remove and install fuel injection nozzles.Air Compressor
Rebuild or Exchange
Visually check for fluid leaks.Our recommendation to maintain the air compressor before it fails will be less costly to you than repairing the air compressor after failure.If you operate the engine until the air compressor fails, you could cause additional damage to your engine. For example: A failed air compressor could contaminate the engine oil with foreign material since engine oil also lubricates the air compressor. The circulation of these contaminants through the engine lubricating system could damage the engine's main and connecting rod bearings.Maintenance Options
Repair Kits - These useful kits can be obtained from your Caterpillar dealer. These kits include all the necessary parts, special tools and instructions to repair your air compressor in either your own maintenance shop or at your servicing dealer's facility. Repair kits simplify parts ordering, help speed repairs and reduce parts cost. Exchange - This is a cost cutting service that permits you to exchange your worn air compressor for a dealer or OEM factory rebuilt air compressor on an over-the-counter basis. They are available when you need them at a substantial savings in both time and money. New - Replace with a new air compressor.Caterpillar Recommendation
The most cost effective repair option is to rebuild the air compressor with a repair kit that can be obtained from your Caterpillar dealer.Refer to the Service Manual for your engine to remove and install the air compressor.Turbocharger
Rebuild or Exchange
If you operate the engine until the turbocharger fails, you could cause severe damage to the turbocharger's compressor wheel and/or your engine. For example: severe damage to the turbocharger compressor wheel could cause parts from the compressor wheel to enter the engine cylinder and cause additional damage to the piston, valve and cylinder head.Maintenance Options
Repair Kits - These useful kits can be obtained from your Caterpillar dealer. These kits include all the necessary parts and instructions to repair your turbocharger in either your own maintenance shop or at your servicing dealer's facility. Repair kits simplify parts ordering, help speed repairs and reduce parts costs. Remanufactured - This process uses manufacturing techniques and procedures to restore your turbocharger to "like-new" performance capability. This process always involves an end product which conforms to the manufacturer's original functional specification. New - Replace with a new turbocharger.Before deciding which method is best, you should make sure you have considered all of the options and costs associated with repair. Some considerations are: * The costs associated with using separate parts from inventory versus the cost of a repair kit.* Downtime costs while the product is being rebuilt or repaired.* Total parts and labor costs for repairs versus the actual Remanufactured cost.* Remanufactured components from Caterpillar are covered by a national factory warranty.Caterpillar Recommendation
To minimize downtime, Caterpillar recommends the use of a Remanufactured turbocharger.There are two levels of pricing for Remanufactured turbochargers.* The first level is primarily based on damage to the turbocharger before failure.* The second level is primarily based on damage to the turbocharger after failure.If you choose to operate your engine until the turbocharger fails, your repair cost could be as much as ten times the repair before failure cost due to additional turbocharger and engine damage that could have been prevented.Refer to the Service Manual for your engine to remove and install the turbocharger.Valve Lash
Check/Adjust
Be sure the engine cannot be started while this maintenance is being performed. To prevent possible injury, do not use the starting motor to turn the flywheel. Hot engine components can cause burns. Allow additional time for the engine to cool before measuring valve clearance.The PEEC uses high voltage to the unit injectors.