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Fuel Injection Nozzles
The fuel systems for direct injection (DI) and precombustion chamber (PC) engines are essentially the same. The absence of the precombustion chamber requires a different fuel injection nozzle and adapter.Externally the direct injection fuel nozzle is longer in length than the precombustion chamber nozzle. Nozzle testing and replacement procedures for direct injection (DI) is the same as precombustion chamber (PC) engines except that a fuel nozzle adapter wrench is used to remove the injection nozzle adapter. The seal on the adapter should be inspected and replaced if damaged.Test/Exchange
Fuel nozzles are subject to tip wear as a result of fuel contamination. This damage can cause an increase in fuel consumption, the engine to emit black smoke, misfire or run rough. Inspect, test and replace if necessary. Fuel nozzles can be tested by an authorized Caterpillar engine dealer.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 testing and cleaning, consult your Caterpillar dealer. Refer to to Special Instruction SEHS7292 for the use of the 8S2245 Nozzle Cleaning Kit to clean the nozzles.1. Start the engine by following the procedure in the Engine Starting topic in this manual.
Do NOT loosen nuts at the top of fuel nozzles or let top of fuel nozzles turn when the fuel lines are loosened. The nozzles will be damaged if the top of the nozzle turns in the body when the fuel lines are loosened.The engine will be damaged if a defective fuel injection nozzle is used because of the shape of fuel (spray pattern) that comes out of the nozzles will not be correct.
2. Loosen the fuel injection line nut at the fuel pump, one at a time, with the engine running. Use a cloth or similar material to prevent fuel from spraying on hot exhaust component. Be sure to tighten each fuel line nut after the test, before the next fuel line nut is loosened.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 tested. Purge the fuel lines of air.4. Check for any fuel leaks. Stop the engine by following the procedure in the Engine Stopping topic in this manual and correct any fuel leaks that may occur.To Remove Injection Nozzles
Special tooling is required. See the Service Manual for this engine or your Caterpillar dealer.Turbocharger, Jacket Water Pump and Raw Water Pump
Operation of the engine until the turbocharger fails, can cause severe damage to the turbocharger's compressor wheel and/or the engine. For example, 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.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.Inspect/Rebuild or Exchange Turbocharger
Turbocharger bearing failures can cause large quantities of oil to enter the air intake and exhaust systems. Loss of engine lubricant can result in serious engine damage.Minor leakage of a turbocharger housing under extended low idle operation will not cause problems as long as no turbocharger bearing failure occurred.When a turbocharger bearing failure is accompanied by a significant engine performance loss (exhaust smoke or engine speed up at no load), DO NOT continue engine operation until the turbocharger is repaired or replaced.
1. Remove the exhaust outlet piping and inlet piping from the turbocharger. Visually check for oil leaks.2. Turn the turbine and compressor wheel by hand.3. The assembly should turn freely.4. Inspect the turbine wheel and compressor wheel for contact with the turbocharger housing.5. There should NOT be any visible signs of contact between the turbine or compressor wheel and the turbocharger housing.Check the compressor wheel for cleanliness. If only the blade side of the wheel is dirty, dirt and/or moisture is passing through the air filtering system.If oil is found only on the back side of the wheel, it indicates a turbo oil seal leak. The leak may be the result of extended engine operation at low idle or an intake air line restriction (plugged filters).Maintain the compressor wheel/turbo housing by cleaning with standard shop solvents and a soft bristle brush.6. Check the end play and bearing clearance on the turbine wheel and shaft with a dial indicator. Attach the indicator and position the pointer on the end of turbocharger shaft. Push and pull on the other end of the shaft observing the dial indicator for total reading. End play should read between 0.076 to 0.203 mm (.003 to .008 inch). If indicator reading exceeds this tolerance, the turbocharger should be rebuilt or replaced. If indicator reading is less than 0.076 mm (.003 inch), it may be an indication of carbon build-up on the turbine wheel. The turbocharger should be disassembled, cleaned and inspected.If the measurements are not within specifications, the turbocharger must be repaired or replaced.7. When installing or replacing V-band clamps, position the gap (tightening screw) down if possible so any accumulation of moisture will drain away.Turbocharger components require precision clearances and balancing due to operation at high rotational (torsional) speeds. Severe Service Applications can accelerate component wear and may suggest the need to Inspect/Repair/Replace the cartridge at reduced intervals to ensure maximum reliability and retention of full core value.The following conditions can indicate severe service operation.* High altitude operation above 1500 M (5,000 ft).* Extended operation at low idle.* Arctic operation (regular cold starts at temperatures below -18°C [0°F]).* Extending lube and air system maintenance intervals.* Frequent hot shutdowns (minimum cool down periods after high load factor operation).Inspect/Rebuild or Exchange Water Pumps
Jacket Water Pump
Raw Water PumpVisually inspect the water pumps for leaks. If leaking is observed, replace all seals. Refer to the Service Manual for the procedure to replace the seals.Inspect the component for wear,