Caterpillar Cat C32 Industrial Engine (Prefix TLD) Service Repair Manual (TLD00001 and up).pdf

Service Repair Manual
Models
C32 Locomotive Engine

Shutdown SIS
Previous Screen
Product: INDUSTRIAL ENGINE
Model: C32 INDUSTRIAL ENGINE TLD
Configuration: C32 Industrial Engine TLD00001-UP
Disassembly and Assembly
C27 and C32 Industrial Engines
Media Number -RENR9577-06 Publication Date -01/11/2017 Date Updated -20/11/2017
i05768549
Fuel Lines - Remove and Install
SMCS - 1250-010; 1252-010; 1274-010
Remove Nonmetallic Fuel Lines
NOTICE
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, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
Dispose of all fluids according to local regulations and mandates.
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Illustration 1 g02257273
1. Mark fuel lines (1) for reinstallation purposes. Remove fuel lines (1) .
2. If any hoses are worn or damaged, replace with new parts.
ReferenceRefer to the Operation and Maintenance Manual for information on when to replace the
fuel lines.
Install Nonmetallic Fuel Lines
Note: During installation, ensure that the hoses do not contact nearby parts. Pressure pulsations in
these hoses cause the hoses to flex. Inadvertent contact with nearby surfaces will produce
chafing/abrasion damage that could eventually lead to a leak. A properly installed hose will contact
only the hose clips.
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Rear Left Side View - Hose Length = 475 mm (18.7 inch)
Rear Right Side View - Hose Length = 620 mm (24.4 inch)
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Front Left Side View - Hose Length = 581 mm (22.9 inch)
Front Right Side View - Hose Length = 581 mm (22.9 inch)
1. Install fuel lines (1) .
2. Loosely install clips (2) . Position fuel lines (1) so that there is no contact with any other surfaces.
Tighten clips (2) . Tighten fuel lines using standard torque.
Best Practices for Installing Nonmetallic Fuel Lines
Use the following best practices for proper fuel line installation and maintenance.
1. Do not twist the hose when installing, allow the hose to find the natural position.
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(1) Torque wrench
(2) Back-up wrench
2. When torquing hose fittings, use a back-up wrench to prevent twisting as in Illustration 6.
3. Use the proper length of hose to prevent the hose being too tight or slack.
4. Keep the bending radius of the hose as large as possible to prevent kinking.
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5. Ensure proper alignment of the grommets when installed in the fuel line clips as shown in Illustration
8. Proper alignment of the opening of the grommet with the mating faces of the clips ensures proper
clamp load.
6. Clips should support the natural position of the fuel line and guide routing as in Illustration 9. Clips
should not create strain on the fuel hoses.
7. Use the proper torque to all line fasteners and connectors.
8. Recheck all fuel lines after completing installation to look for contact with surrounding components.
Fuel lines should only be in contact with rubber grommets and at the termination points.
Note: All third-party installations must meet prescribed installation guidelines. Third-party
components must not come in contact with Caterpillar components.
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9. Inspect fuel lines, grommets, and mounting hardware every 500 hours. Refer to the Operation and
Maintenance Manual maintenance schedule for replacement intervals of fuel system lines and
components.
Note: Certain components such as the side covers will need to be removed to conduct a proper
inspection of fuel lines and components.
The following illustrations below show proper line, clip, and grommet alignment to allow for sufficient
clearance from other components. Proper alignment creates gentle bends that guide fuel lines to the
termination points.
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Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Fri Nov 1 14:49:54 UTC+0800 2019
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Shutdown SIS
Previous Screen
i02436805
Fuel Filter and Water Separator - Remove and Install
SMCS - 1261-010; 1263-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 185-3630 Strap Wrench As 1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE
containing fluids.
Cat products.
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1. Turn the fuel supply to the “OFF” position.
2. Use Tooling (A) to remove the fuel filter and water separator (2) from base assembly (4).
3. Disconnect harness assembly (5).
4. Disconnect hose assemblies (1) and (6).
5. Remove bolts (3) and base assembly (4).
Installation Procedure
NOTICE
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1. Position base assembly (4) on the cylinder block and install bolts (3).
2. Connect hose assemblies (1) and (6).
3. Connect harness assembly (5).
4. Install a new fuel filter and water separator (2) on base assembly (4).
5. Turn the fuel supply to the “ON” position.
Fri Nov 1 14:50:50 UTC+0800 2019
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Shutdown SIS
Previous Screen
i02285574
Fuel Transfer Pump - Remove
SMCS - 1256-011
Removal Procedure
NOTICE
containing fluids.
Cat products.
NOTICE
1. Turn the fuel supply to the “OFF” position.
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2. Disconnect hose assemblies (3).
3. Remove bolts (2).
4. Remove fuel transfer pump (1) and the O-ring seal.
Fri Nov 1 14:51:46 UTC+0800 2019
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Shutdown SIS
Previous Screen
i02287501
Fuel Transfer Pump - Install
SMCS - 1256-012
NOTICE
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1. Install the O-ring seal on fuel transfer pump (1). Lubricate the O-ring seal with clean engine
oil.
2. Position fuel transfer pump (1) on the engine. Install bolts (2).
3. Connect hose assemblies (3).
4. Turn the fuel supply to the “ON” position.
Fri Nov 1 14:52:41 UTC+0800 2019
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Shutdown SIS
Previous Screen
i02591122
Electronic Unit Injector - Remove
SMCS - 1290-011
Removal Procedure
Table 1
Required Tools
A 5F-4764 Pry Bar 1
Start By:
a. Remove the rocker arms and the rocker arm shaft. Refer to Disassembly and Assembly,
"Rocker Arm and Shaft - Remove".
NOTICE
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1. Disconnect harness assembly (1).
2. Remove bridge assemblies (3).
NOTICE
If the injector hold down bolt is loose during the removal procedure,
inspect the injector bore for wear and debris. Replace the clamp and
spacer.
3. Remove bolt (4), spacer (5), and clamp (6).
4. Place an identification mark on electronic unit injectors (2) for installation purposes. Each
electronic unit injector must be reinstalled in the original location in the cylinder head.
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5. Use Tooling (A) to pry beneath the base and free electronic unit injector (2).
6. Remove electronic unit injector (2) from the cylinder head.
Fri Nov 1 14:53:37 UTC+0800 2019
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Shutdown SIS
Previous Screen
i02592997
Electronic Unit Injector - Install
SMCS - 1290-012
Table 1
Required Tools
B 8T-2998 Lubricant 1
C
1U-5718 Vacuum Pump 1
169-7372 Fluid Sampling Bottle 1
4C-4057
Tube
7.9 mm (0.31 inch) OD
1
D 4C-5552 Large Bore Brush 1
E 4C-6774 Vacuum Gun Kit 1
F 8T-7765 Surface Reconditioning Pad 1
NOTICE
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1. Use Tooling (C) to remove the fuel and oil from the cylinder. Evacuate as much fuel and oil
as possible from the cylinder before installing the electronic unit injector. Several
evacuations may be necessary.
2. Use Tooling (D) to clean the carbon deposit from the inside of the electronic unit injector
sleeve. Tooling (E) is available to clean loose material from the bore of the electronic unit
injector sleeve and the cylinder.
3. Use Tooling (F) to clean the carbon from the seat area that is inside of the electronic unit
injector sleeve.
4. Install the O-ring seals on the electronic unit injector. Lubricate the top two O-ring seals
with a 50/50 mixture of clean engine oil and Tooling (B).
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5. When you install a new injector the E-Trim value must be programmed into the engine
control module. The injector confirmation code may need to be programmed into the engine
control module. E-Trim Value (X) is a twelve digit alphanumeric code that is supplied with
the data sheet that comes with the new injectors. Injector Confirmation Code (Y) is a four
digit numeric code. Both of the codes are located on the top of electronic unit injector (2).
Use the following menu to program the E-Trim value.
◦ ECM Summary Screen
◦ Service Menu
◦ Calibration
◦ Injector Code Calibration
NOTICE
When an electronic unit injector is replaced, the new electronic
injector code must be programmed into the engine's personality
module software by using the calibration menu on the Electronic
Service Tool. If the new electronic injector code is not entered, the
characteristics of the previous electronic unit injector is assumed.
If it is not possible to immediately reprogram the electronic injector
code into the personality module software, the engine will not be
severely harmed. The new electronic injector code should be
reprogrammed as quickly as possible in order to optimize engine
performance.
6. Position electronic unit injector (2) in the cylinder head.
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7. Install spacer (5), clamp (6), and bolt (4). Tighten the bolt to a torque of 55 ± 10 N·m
(41 ± 7 lb ft).
8. Install bridge assemblies (3).
9. Connect harness assembly (1). Tighten the nuts to a torque of 2.5 ± 0.25 N·m (22 ± 2 lb in).
End By:
a. Install the rocker arms and the rocker arm shaft. Refer to Disassembly and Assembly,
"Rocker Arm and Shaft - Install".
Fri Nov 1 14:54:33 UTC+0800 2019
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Shutdown SIS
Previous Screen
i06729616
Electronic Unit Injector Sleeve - Remove
SMCS - 1713-011
Removal Procedure
Table 1
Required Tools
A 9U-6891 Injector Tool Group 1
Start By:
a. Remove the electronic unit injectors. Refer to Disassembly and Assembly, "Electronic Unit
Injector - Remove".
NOTICE
1. Drain the coolant from the cooling system into a suitable container for storage or disposal.
Refer to Operation and Maintenance Manual, "Cooling System Coolant - Change".
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2. Install Tooling (A) in electronic unit injector sleeve (1).
3. Tighten the nut on Tooling (A) until the electronic unit injector sleeve is pulled free of the
cylinder head.
4. Remove O-ring seals (2) and O-ring seal (3) from electronic unit injector sleeve (1).
Fri Nov 1 14:55:29 UTC+0800 2019
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Caterpillar Cat C32 Industrial Engine (Prefix TLD) Service Repair Manual (TLD00001 and up).pdf

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