Desamble Motor 3054

8/2/2019 Desamble Motor 3054

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Engine Design

SMCS - 1000

Type 1 Engines and 9RM Engines

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--------------------------------------------------------------------------------Illustration 1 g00296342

Cylinder and valve location for Type 1 engines and 9RM engines

(A) Exhaust valves

(B) Inlet valves

Note: Type 1 engines can be identified in two ways. The first method refers to

Illustration 1. When the valve cover is removed, look at the cylinder head valves. Type 1

engines have two exhaust valves in a row and two inlet valves that are in a row.

The second method does not require the removal of the valve cover. Refer to the inlet

manifold and the exhaust manifold. Type 1 engines have two exhaust ports in a row andtwo inlet ports that are in a row.


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Type ... Four cylinder and four stroke

Combustion system ... Direct injection

Nominal Bore ... 100 mm (3.937 inch)

Stroke ... 127 mm (5.00 inch)

Capacity ... 4 liters (243 in3)

Compression Ratio ... 16:1

Number of cylinders ... 4

Arrangement of cylinders ... in-line

Firing Order ... 1, 3, 4, 2

Valve Lash

Inlet valve ... 0.20 mm (.008 inch)Exhaust valve ... 0.45 mm (.018 inch)When the crankshaft is viewed from the front of the engine, the crankshaft rotates in the

following direction: ... Clockwise

When the camshaft is viewed from the front of the engine, the camshaft rotates in the


Note: The front end of the engine is opposite the flywheel end. The left side and the

right side of the engine are viewed from the flywheel end. The No. 1 cylinder is the frontcylinder.

Type 2 Engines and 7BJ Engines

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Illustration 2 g00296424

Cylinder and valve location for Type 2 engines and 7BJ engines

(A) Exhaust valves

(B) Inlet valves

Note: Type 2 engines can be identified in two ways. The first method refers toIllustration 2. When the valve cover is removed, look at the cylinder head valves. Type 2

engines alternate the exhaust valves and the inlet valves.

The second method does not require the removal of the valve cover. Refer to the inlet

manifold and the exhaust manifold. Type 2 engines alternate the exhaust ports and the

inlet ports.

Type ... Four cylinder and four stroke

Combustion system ... Direct injection

Nominal Bore ... 100 mm (3.937 inch)

Stroke ... 127 mm (5.00 inch)

Capacity ... 4 liters (243 in3)

Compression Ratio ... 17.25:1


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Number of cylinders ... 4

Arrangement of cylinders ... in-line

Firing Order ... 1, 3, 4, 2

Valve Lash

Inlet valve ... 0.20 mm (.008 inch)Exhaust valve ... 0.45 mm (.018 inch)

When the crankshaft is viewed from the front of the engine, the crankshaft rotates in the


When the camshaft is viewed from the front of the engine, the camshaft rotates in the


Note: The front end of the engine is opposite the flywheel end. The left side and the

right side of the engine are viewed from the flywheel end. The No. 1 cylinder is the frontcylinder.


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Fuel Filter Base - Remove and Install

SMCS - 1262-010

Removal Procedure

NOTICEKeep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.

NOTICECare 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 ordisassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for

tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.

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Illustration 1 g00556872Typical exampleDisconnect two fuel lines (1) at the fuel injection pump.

Cap the lines or plug the lines immediately.Ver imagen


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Typical exampleDisconnect fuel return line (2) .

Cap the lines or plug the lines immediately.

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Typical example

Disconnect two fuel lines (3) .

Cap the lines or plug the lines immediately.Verimagen


Typical example

Remove three bolts (4) that hold two fuel lines (3) on the rear of the engine.Ver imagen


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Illustration 5 g00556876Typical exampleRemove two bolts (5) .

Remove fuel filter base (6) .Note: Use the following steps in order to remove fuel filter (9). The fuel filter assembly

has a bayonet type lock ring that allows the fuel filter to drain into the canister for easy

removal.Remove cap (7). Remove the top plate, the O-ring, and the bayonet type lock ring from

fuel filter (9). This will allow fuel to flow into the canister of the fuel filter.

Turn collar (8) in the counterclockwise direction in order to remove fuel filter (9) .Pull fuel filter (9) from fuel filter base (6) .

Installation Procedure

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.Ver imagen

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Typical example

Install fuel filter base (6) on the engine.

Install two bolts (5) .

Note: If the fuel filter was removed, use the following steps to install the fuel filter.

Replace the seal on fuel filter base (6) .

Insert fuel filter (9) in fuel filter base (6) .

Install collar (8). Turn the collar in the clockwise direction in order to lock fuel filter (9)in place.

Install the bayonet type lock ring, the O-ring, and the top plate in fuel filter (9). Installcap (7) .

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Typical example

Install three bolts (4) that hold the fuel lines to the rear of the engine.

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Typical example

Connect two fuel lines (3) .

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Connect fuel return line (2) .

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Typical example

Connect two fuel lines (1) at the fuel injection pump.


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Fuel Transfer Pump - Remove

SMCS - 1256-011

Removal Procedure


Contaminants may cause rapid wear and shortened component life.

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 tocollect the fluid with suitable containers before opening any compartment or

disassembling any component containing fluids.


tools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.Ver imagen

Illustration 1 g00543616Typical exampleDisconnect two fuel lines (1) from fuel transfer pump (2). Plug all openings

immediately.

Remove four bolts (3) that mount fuel transfer pump (2) to the cylinder block.Remove two lock plates (4) .

Remove fuel transfer pump (2) and the gasket.Note: If the fuel transfer pump is difficult to remove, rotate the crankshaft until therocker arm of the fuel transfer pump is not under pressure.


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Fuel Transfer Pump - Disassemble

SMCS - 1256-015

Disassembly Procedure

Start By:Remove the fuel transfer pump. Refer to Disassembly and Assembly, "Fuel TransferPump - Remove".

NOTICE

Keep all parts clean from contaminants.




collect the fluid with suitable containers before opening any compartment or


Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" fortools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.Ver imagen


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Place an identification mark on each half of the fuel transfer pump for the assemblyprocedure.

Remove the screw that holds cover (1) .

Remove cover (1) and the gasket.Remove gauze (2) .

Remove the screws that hold the two halves of the fuel transfer pump together.

Rotate diaphragm assembly (5) at 90 degrees in order to remove the pull rod from linkarm (8) .

Remove diaphragm assembly (5) .

Remove stem seal (6), spring seat washer (7), and diaphragm spring (12) from the pullrod.

Note: Diaphragm assembly (5) and the pull rod are not serviced parts.

Use a suitable lever in order to remove valves (4) and seat washers (3). The valves arepeened in.

Note: Some of the metal that is peened may need to be removed in order to remove

valves (4) .Hold rocker lever (11) in a vise and hit the body of the fuel transfer pump with a soft

hammer in order to release retainers (10). This will allow you to remove link arm (8) .NOTICEDo not damage the face on the body of the fuel transfer pump.Remove the following items: rocker lever (11), pin (9), link arm (8) and the return

spring.


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Fuel Transfer Pump - Assemble

SMCS - 1256-016

Assembly Procedure


Inspect the components of the fuel transfer pump for damage. Replace the componentsif necessary.

Clean all of the components before assembly.

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Install seat washers (3) .

Push valves (4) into position.Note: It is possible for the valves to be installed incorrectly. Refer to Illustration 1 for the

correct installation.


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When valves (4) are installed, peen the edge of the valve housing evenly in six places.

This will keep valves (4) in position.

Install rocker lever (11), pin (9), and link arm (8) into the bottom half of the fuel

transfer pump.

Install the return spring and ensure that the ends of the spring are installed correctly.

Using a soft hammer and a suitable adapter install two retainers (10) into the grooves.

Ensure that retainers (10) fasten the pin. Peen the open ends of the grooves in order to

fasten the retainers in position.

Install the diaphragm spring (12) under diaphragm assembly (5). Place spring seat

washer (7) and stem seal (6) on the pull rod.

NOTICEEnsure that the small diameter at the top of the seal is on the round section of the pull

rod.Place diaphragm assembly (5) over the lower half of the body of the fuel transfer pump.Ensure that the blade of the pull rod is aligned with the slot of link arm (8) .

Press lightly on diaphragm assembly (5) until the notch in the pull rod is in the slot of

link arm (8). Rotate diaphragm assembly (5) at 90 degrees in either direction. This will

engage the pull rod in the slot of link arm (8) .

Push rocker lever (11) toward the body of the fuel transfer pump. Push rocker lever (11

until diaphragm assembly (5) is level with the flange on the body of the fuel transferpump.

Install the top half of the body of the fuel transfer pump and align the marks on theflanges. Keep pressure on rocker lever (11). Install spring washers and the screws.Tighten the screws evenly.

Install gauze (2) .

Install the gasket and cover (1) .Note: Refer to the Testing and Adjusting, "Fuel Transfer Pump Pressure Test" for the

correct procedure.

End By: Install the fuel transfer pump. Refer to Disassembly and Assembly, "Fuel

Transfer Pump - Install".


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Fuel Transfer Pump - Install

SMCS - 1256-012


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NOTICE



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Typical example

Inspect the condition of the gasket. Replace the gasket, if necessary.

Ensure that the rocker arm for the fuel transfer pump is not under pressure.

Install the gasket and fuel transfer pump (2). If fuel transfer pump (2) is difficult toinstall, rotate the crankshaft.

Install two lock plates (4) .

Install four bolts (3). Tighten the bolts to a torque of 22 Nm (16 lb ft).

Connect two fuel lines (1) .

Loosen the vent screw on the top of the fuel filter and operate the priming lever on thefuel transfer pump in order to remove the air from the fuel system. When only fuelcomes out of the vent screw, tighten the vent screw.

Start the engine and check the fuel system for fuel leaks and for air leaks.


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Fuel Injection Lines - Remove and Install

SMCS - 1252-010

Removal Procedure

Start By:

Remove the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base -Remove and Install".NOTICE

Keep all parts clean from contaminants.Contaminants may cause rapid wear and shortened component life.

NOTICE

Care must be taken to ensure that fluids are contained during performance ofinspection, maintenance, testing, adjusting and repair of the product. Be prepared to




tools and supplies suitable to collect and contain fluids on Caterpillar products.



Disconnect four fuel injection lines (1) from the fuel injection nozzles.Cap all openings or plug all openings immediately.

Disconnect four fuel injection lines (1) from the fuel injection pump.Plug all openings immediately.

Note: Secure fittings (4) with a wrench when you remove fuel injection lines (1) at thefuel injection pump.

Remove four fuel injection lines (1) from the engine.

Remove four bolts (2) and eight washers.

Remove fuel return line (3) .


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Install fuel return line (3) .

Install four bolts (2) and eight new washers.

Install four fuel injection lines (1) .

Connect four fuel injection lines (1) at the fuel injection pump.

Note: Secure fittings (4) with a wrench when you connect fuel injection line (1) at thefuel injection pump.

Connect four fuel injection lines (1) to the fuel injection nozzles. Tighten the fuel

injection lines to a torque of 18 Nm (13 lb ft).End By: Install the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base- Remove and Install".


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Fuel Injection Nozzles - Remove - Type 1 Engines and 9RM

EnginesSMCS - 1254-011

Removal Procedure

Start By:

Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel InjectionLines - Remove and Install".

Note: For a complete description of Type 1 and Type 2 Engines, refer to the Disassembly

and Assembly, "Engine Design" topic.NOTICE


Contaminants may cause rapid wear and shortened component life.NOTICE





Dispose of all fluids according to local regulations and mandates.

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Illustration 1 g00545199 Remove two bolts (1) and clamp (2) from the cylinder head.Remove clamp (2) .Ver imagen


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Remove fuel injection nozzle (3) and the seat washer that is on the end of fuel injection

nozzle (3) .

Remove dust seal (5) and spacer (4) .


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Fuel Injection Nozzles - Remove

SMCS - 1254-011

Removal Procedure

Start By:


NOTICE










Loosen threaded nut (1) on the fuel injection nozzle.

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Remove fuel injection nozzle (2) from the cylinder block.

Remove seat washer (3) .

Note: If the original seat washer is not removed, the projection of the fuel injectionnozzle will be incorrect when a new seat washer is installed.


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Fuel Injection Nozzles - Install

SMCS - 1254-012Installation ProcedureNOTICE



Illustration 1 g00903765Thoroughly clean the threads on threaded nut (1) and the cylinder head.

Install a new seat washer (3) into the recess in the cylinder head.

Note: If the original seat washer is reused, the projection of the fuel injection nozzle wilbe incorrect.

Put a 2.0 mm (0.08 inch) bead of 4C-5591 Anti-Seize Compound on the first two thread

of threaded nut (1) .Ver imagen



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Put fuel injection nozzle (2) into position in the cylinder head. Make sure that the detent

ball in the fuel injection nozzle (2) is aligned correctly with ball Detent (X) in the cylindehead.

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Carefully tighten threaded nut (1) to a torque of 30 Nm (22 lb ft). Remove any excess

Anti-Seize Compound from fuel injection nozzle.Note: Do not rotate the fuel injection nozzle after installation. The seal which is made by

the anti-seize compound may break. A broken seal may allow leakage past the seat ofthe fuel injection nozzle.

End By: Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel

Injection Lines - Remove and Install".


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Fuel Injection Nozzles - Install - Type 1 Engines and 9RM




and Assembly, "Engine Design" topic.

NOTICE



NOTICE






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Install dust seal (5) and spacer (4) .


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Install the seat washer on the end of fuel injection nozzle (3) .

Install fuel injection nozzle (3) into the cylinder head.

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Install clamp (2) and bolts (1). Tighten bolts (1) to a torque of 12 Nm (9 lb ft).

End By: Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel

Injection Lines - Remove and Install


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Fuel Injection Pump - Remove - Type 2 Engines and 7BJ


Removal Procedure Table 1

Required Tools

Tool Part Number Part Description Qty

A 150-3993 Timing Pin (2) 1

B

171-1085

or

173-9774

Tamper Resistant Tool

( 1 ) Tool (A) is required in order to remove Bosch fuel injection pumps.

( 2 ) Tool (A) is required in order to remove Delphi (Lucas) and Stanadyne fuel injection

pumps.

Start By:

Remove the water pump. Refer to Disassembly and Assembly, "Water Pump - Remove".




NOTICE








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Ensure that the No. 1 cylinder is at the top center position on the compression stroke.

Refer to the Testing and Adjusting, "Fuel System" topic for additional information.

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Loosen locking screw (2) (if equipped) until locking spacer (1) moves freely. Move

locking spacer (1) into position (B). Tighten locking screw (2) to a torque of 10 Nm (7lb ft).

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Typical example

Note: Do not remove hub nut (4) from the shaft of the fuel injection pump. The hub of

the fuel injection pump is installed in the correct position from the factory in order to

ensure proper timing. If hub nut (4) is removed and the hub is removed, the hub willneed to be accurately installed on the shaft of the fuel injection pump by the use of

special equipment. Refer to your Caterpillar Dealer for more information.

Note: Do not release Torx screws (5) (if equipped). If the Torx screws are released and

the timing plate is moved, the timing position that is set at the factory will be lost. If the

Torx screws are released, the No. 1 cylinder must be set to the top center position onthe compression stroke before the Torx screws are tightened.

Slowly rotate the crankshaft until hole (6) in the timing gear and hole (7) in the hub are

in alignment with hole (8) in the fuel injection pump body.

Note: The location of Tool (A) for Bosch fuel injection pumps will be located toward thetop of the fuel injection pump. The location of Tool (A) for Delphi (Lucas) and Stanadyne

fuel injection pumps will be located toward the bottom of the fuel injection pump.


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Install Tool (A) through hole (6) in the timing gear and hole (7) in the hub. Push Tool (A

into position in hole (8) in the fuel injection pump body. If Tool (A) can be fully seated,

the fuel injection pump timing is correct. No resistance should be felt when the timingpin is inserted into hole (8) of the fuel injection pump body.

Note: Some fuel injection pumps are installed with tamper proof bolts. Tool (B) may be

necessary in order to remove the tamper proof bolts.

Remove four bolts (3) that fasten the fuel injection pump gear to the fuel injectionpump. Timing gear (9) should be free from the fuel injection pump shaft.

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Typical example

Remove three flange nuts (10) and fuel injection pump (11) from the engine.

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Typical example

Remove O-ring seal (12) from fuel injection pump (11) .


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Fuel Injection Pump - Remove - Type 1 Engines and 9RM Engines

SMCS - 1251-011

Table 1

Required Tools


A 173-9774 Bolt Remover (1) 1

B 9U-6198 Crankshaft Turning Tool 1

C 8S-4712 Bolt 2

( 1 ) The bolt remover is required in order to remove the tamper proof bolts on theaccess cover for the fuel injection pump.

Start By:

Remove the water pump. Refer to Disassembly and Assembly, "Water Pump - Remove".Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel InjectionLines - Remove and Install".

Note: For a complete description of Type 1 and Type 2 engines, refer to the Disassembly




NOTICE






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Remove four bolts (1) .Note: Some engines may have four tamper proof bolts (1). Use Tool (A) in order to

remove the tamper proof bolts bolts.

Remove cover (2) .

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Remove nut (3) and the lockwasher.


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Use Tool (B) to rotate the crankshaft until keyway (X) is at 30 degrees from the verticalcenterline.

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Install Tool (C) .Disengage the gear from the fuel injection pump.

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Disconnect hose (7) from the fuel injection pump.

Remove three nuts (6) that hold fuel injection pump (5) in position.

Remove fuel injection pump (5) and the gasket.Note: Ensure that you do not lose the key when the fuel injection pump is removed. Also

notice the position of marks (4) in order to ensure proper alignment of fuel injection

pump (5) during installation.


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Fuel Injection Pump - Install - Type 2 Engines and 7BJ Engines

SMCS - 1251-012

Table 1

Required Tools


A 150-3993 Timing Pin (2) 1

B

171-1085

or173-9774

Tamper Resistant Tool Gp 1

( 1 ) Tooling (A) is required in order to install Bosch fuel injection pumps.

( 2 ) Tooling (A) is required in order to install Dephi (Lucas) and Stanadyne fuel

injection pumps.

NOTICE



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lustration 1 g01059878

Typical exampleCheck the condition of O-ring seal (13) on fuel injection pump (12). If the seal is worn

or damaged, replace the seal.

Lightly lubricate O-ring seal (13) with clean engine oil. Install O-ring seal (13) on fuel

injection pump (12) .


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NOTICE

The No. 1 cylinder must be at the top center position on the compression stroke beforethe fuel injection pump is installed. If the crankshaft needs to be rotated, the fuel

injection pump must be mounted temporarily or the loose gear could cause damage to

the front housing.

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Typical example

Put fuel injection pump (12) in position on the engine. Ensure that the timing gear is

aligned with the hub of fuel injection pump (12). Install three flange nuts (11) andtighten the flange nuts to a torque of 28 Nm (21 lb ft).

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Typical example

Position gear (9) on the shaft of the fuel injection pump.Note: Some fuel injection pumps are installed with tamper proof bolts. Tooling (B) may

be necessary in order to install the tamper proof bolts.

Put the timing gear plate in position and install four bolts (3). Tighten the four bolts

finger tight.

Note: The fuel injection pump gear will only fit in one position. Install the gear with theletters "C" and "M" facing away from the engine.

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Illustration 4 g00808245Typical example

Loosen locking screw (2) (if equipped) until locking spacer (1) moves freely. Move

locking spacer (1) into position (A). Tighten locking screw (2) to a torque of 10 Nm (7lb ft).

Note: The location of Tooling (A) for Bosch fuel injection pumps will be located toward

the top of the fuel injection pump. The location of Tooling (A) for Dephi (Lucas) andStanadyne fuel injection pumps will be located toward the bottom of the fuel injectionpump.

Install Tooling (A) through hole (6) in the timing gear and hole (7) in the hub. PushTooling (A) into position in hole (8) in the fuel injection pump body. If Tooling (A) can be

fully seated, the fuel injection pump timing is correct. No resistance should be felt whenthe timing pin is inserted into hole (8) of the fuel injection pump body.NOTICE

The fuel injection pump may be supplied with the fuel injection pump shaft in the locked

position. The drive shaft of the fuel injection pump must not be rotated without thespacer in position under the locking screw. Damage to the drive shaft of the fuel

injection pump will result.

When the timing plate is installed, rotate gear (9) by hand in a counterclockwisedirection in order to remove the backlash between gear (9) and the idler gear. Do not

rotate the crankshaft or the fuel injection pump shaft. Tighten bolts (3) to a torque of 28Nm (21 lb ft).

Remove Tooling (A) from the fuel injection pump gear.

End By:Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines

Remove and Install".

Install the water pump. Refer to Disassembly and Assembly, "Water Pump - Install".


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Fuel Injection Pump - Install - Type 1 Engines and 9RM Engines

SMCS - 1251-012

Table 1

Required Tools


A 173-9774 Bolt Remover (1) 1

( 1 ) The bolt remover is required in order to install the tamper proof bolts on the

access cover for the fuel injection pump.





Inspect the condition of the gasket for the fuel injection pump. Replace the gasket, ifnecessary.

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Install the gasket and fuel injection pump (5) .

Note: Align marks (4) that are on fuel injection pump (5) and the timing gear cover.

Install the key.


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Install three nuts (6) that hold fuel injection pump (5) in position.

Connect hose (7) to fuel injection pump (5) .

Engage the gear with the fuel injection pump.

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Install the lockwasher and nut (3) .

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Install cover (2) and four bolts (1) .Note: Some engines have four tamper proof bolts (1). Use Tool (A) in order to install the

four bolts.

Set the timing of the fuel injection pump. Refer to the Testing and Adjusting Module for

the correct procedure.End By:

Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines Install".

Install the water pump. Refer to Disassembly and Assembly, "Water Pump - Install".


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Turbocharger - Remove

SMCS - 1052-011Removal Procedure

NOTICE



NOTICE






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Typical example

Loosen two clamps (1) .

Slide hose (2) away from turbocharger (3) .

Remove two bolts (4) and the gasket.

Disconnect oil return line (6) from the cylinder block and remove the gasket.

Remove nuts (5) .

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45/108


Typical example

Remove three bolts (7) .

Remove turbocharger (3) and the gaskets.Plug all openings immediately.


46/108

Turbocharger - Disassemble

SMCS - 1052-015

Disassembly Procedure

Start By:

Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger -Remove".NOTICE


NOTICE






Dispose of all fluids according to local regulations and mandates.Place an index mark on all of the components for the assembly procedure.

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Typical example

Remove elbow (1) and the O-ring seal.

Remove two bolts (2) .Remove hose assembly (3) and the gasket.

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Typical example

Remove six bolts (4) .Remove three clamps (5) .

Separate compressor housing (6) from cartridge (7) .Ver imagen


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Typical example

Remove six bolts (8) .Remove three clamps (9) .

Separate cartridge (7) from turbine housing (10) .


49/108

Turbocharger - Assemble

SMCS - 1052-016

Assembly ProcedureNOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.Inspect the condition of the gaskets. Replace the gaskets, if necessary.

Ver imagen


Typical exampleVer imagen



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Typical example

Assemble cartridge (7) and turbine housing (10) .Install three clamps (9) .

Apply 5P-3931 Anti-Seize Compound to six bolts (8). Tighten the bolts to a torque of 19

1 Nm (14 1 lb ft).Ver imagen


Typical example

Assemble compressor housing (6) and cartridge (7) .Install three clamps (5) .

Appy 5P-3931 Anti-Seize Compound to six bolts (4). Tighten the bolts to a torque of 15 4 Nm (11 3 lb ft).

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Install hose assembly (3) and the gasket.

Install two bolts (2) .Install elbow (1) and the O-ring seals.

End By: Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger -Install".


51/108

Turbocharger - Install

SMCS - 1052-012Installation Procedure



Inspect the condition of all gaskets. Replace the gaskets, if necessary.

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Illustration 1 g00545446Typical exampleInstall turbocharger (3) and the gaskets.

Install three bolts (7) .Ver imagen



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Typical example

Apply 5P-3931 Anti-Seize Compound to nuts (5). Tighten the nuts to a torque of 55 5

Nm (40 4 lb ft).

Install the gasket and oil return line (6) .

Install two bolts (4) .

Slide hose (2) onto the turbocharger (3) .

Tighten two clamps (1) .


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Exhaust Manifold - Remove and Install - Type 2 Engines and

7BJ EnginesSMCS - 1059-010

Removal Procedure

Start By:Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger -

Remove".

Remove the air inlet manifold. Refer to Disassembly and Assembly, "Air Inlet Manifold -Remove and Install".



NOTICE



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Typical example

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Remove exhaust manifold nuts or bolts (1) in reverse order of the numbered sequence.

Remove exhaust manifold (2) from the engine.

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Typical example

Remove exhaust manifold gaskets (3) from the engine.

Remove old sealant from stud threads.


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NOTICE


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Typical example

Inspect the condition of the gaskets. If the gaskets are damaged, use new parts for

replacement. Install exhaust manifold gaskets (3) on the cylinder head. Apply 4C-9507Retaining Compound to the stud threads.

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Typical example

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NOTICEDamage to the exhaust manifold can occur if the exhaust manifold is not aligned andtightened correctly.

Install exhaust manifold (2) on the cylinder head.

Note: Some of the exhaust manifolds have large clearance holes for the bolts. If a new

exhaust manifold is installed ensure that the 148-7132 Ferrule mountings that aresupplied with the exhaust manifold are installed.

Install exhaust manifold nuts or bolts (1). Tighten the exhaust manifold nuts or bolts in

the numerical sequence to a torque of 44 Nm (33 lb ft).

End By:

Install the air inlet manifold. Refer to Disassembly and Assembly, "Air Inlet Manifold -

Remove and Install".Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Install".


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Exhaust Manifold - Remove and Install - Type 1 Engines and

9RM EnginesSMCS - 1059-010Removal Procedure

Start By:

Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger -Remove".



NOTICE



Ver imagen


Typical exampleRemove exhaust manifold nuts (1) .

Remove exhaust manifold (2) and the gasket.





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Typical example

Inspect the condition of the gasket. Replace the gasket, if necessary.

Install the gasket and exhaust manifold (2) .

Install exhaust manifold nuts (1). Tighten the plated nuts to a torque of 44 Nm (32 lb

ft). Tighten the nuts that are not plated to a torque of 50 Nm (37 lb ft).End By: Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger -

Install".


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Inlet Manifold - Remove - Type 2 Engines and 7BJ Engines

SMCS - 1058-011

Removal Procedure

Note: For a complete description of Type 1 and Type 2 engines, refer to Disassembly andAssembly, "Engine Design".



NOTICE




Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" fortools and supplies suitable to collect and contain fluids on Caterpillar products.


Ver imagen


Typical example

Disconnect tube (1) from the air inlet heater.

Loosen hose clamps (3) and slide the hose toward the turbocharger.


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Remove four bolts (2) and remove elbow (4) from the air inlet manifold.

Ver imagen


Typical example

Remove bolts (5) that fasten air inlet manifold (6) to the engine.

Remove air inlet manifold (6) .


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Inlet Manifold - Remove - Type 1 Engines and 9RM Engines

SMCS - 1058-011

Removal Procedure




NOTICE




Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" fortools and supplies suitable to collect and contain fluids on Caterpillar products.


Ver imagen


Typical example

Ver imagen


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Typical example

Disconnect electrical connector (5) for the air inlet heater.

Disconnect fuel line (6) to the air inlet heater.

Remove two bolts (7) that hold the bracket for fuel line (6) in position.

Loosen two hose clamps (8) and slide hose (9) toward the turbocharger.

Remove four bolts (3) in order to remove elbow (2) and gasket (4) .

Disconnect boost pressure hose (10) .

Remove bolts (12) that hold the turbocharger support to air inlet manifold (14) .

Remove bolts (13) that hold air inlet manifold (14) to the cylinder head.

Remove air inlet manifold (14) and gaskets (11) .

Remove seal (1) .


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Inlet Manifold - Install - Type 1 Engines and 9RM Engines

SMCS - 1058-012


Note: For a complete description of Type 1 and Type 2 engines, refer to Disassembly and

Assembly, "Engine Design".

NOTICE



Inspect the gaskets for wear or damage. If the gaskets are worn or damaged, use newparts for replacement.

Ver imagen


Ver imagen


Typical example


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Install seal (1) on the engine.

Position gaskets (11) and air inlet manifold (14) on the engine.Note: Ensure that the front gaskets and the rear gaskets are installed with the notch at

the top left side. The center gasket can be installed in either direction.

Install bolts (13) .

Position the turbocharger support on air inlet manifold (14) and install bolts (12) .

Connect boost pressure hose (10) .

Install gasket (4) and elbow (2) with four bolts (3) .

Slide hose (9) in position and tighten hose clamps (8) .

Place the bracket for fuel line (6) in position and install two bolts (7) .

Connect fuel line (6) to the air inlet heater.

Connect electrical connector (5) for the air inlet heater

Inlet Manifold - Install - Type 2 Engines and 7BJ Engines


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SMCS - 1058-012





Inspect the gaskets for wear or damage. If the gaskets are worn or damaged, use new

parts for replacement.

Ver imagen


Typical example

Install the gasket and air inlet manifold (6) with bolts (5) . Tighten bolts (5) to a torqueof 33 Nm (24 lb ft).

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Put the gasket and elbow (4) in position on the air inlet manifold.

Install four bolts (2) .

Slide the hose into position and tighten hose clamps (3) .

Connect tube (1) to the air inlet heater.


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Inlet and Exhaust Valve Springs - Remove and Install

SMCS - 1108-010

Table 1

Required Tools


A 9U-6195 Valve Spring Compressor 1

Start By:

Remove the rocker shaft. Refer to Disassembly and Assembly, "Rocker Shaft andPushrod - Remove".

NOTICE


Contaminants may cause rapid wear and shortened component life.Note: Before you begin the removal of the valve springs, refer to the Specifications

Module, "Cylinder Head Valves" topic for appropriate information on the valve springs.

Ensure that the piston is at the top center position.Note: If the rocker arm assembly has not been removed, rotate the crankshaft in the

normal direction of rotation until the inlet valve of the appropriate cylinder has just

opened and the exhaust valve has not fully closed. If the rocker arm assembly has beenremoved, go to Step 2.

NOTICEDo not turn the crankshaft while the valve springs are removed.Ver imagen


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Install Tool (A) .

Compress the valve springs in order to open the valve.

Turn the crankshaft until the piston touches the valve.

Continue to turn the crankshaft and release the pressure of Tool (A) until the piston is atthe top center position.

Ver imagen


Install Tool (A) .

Compress valve springs (1). Remove two valve keepers (2) .

NOTICE

Ensure that the valve spring is compressed squarely or damage to the valve stem mayoccur.

Release the pressure on Tool (A). Remove valve spring retainer (3) and valve springs (1

.Note: If you are replacing all of the valve springs, the procedure can be done on twocylinders at the same time. The procedure can be done on cylinder 1 and cylinder 4, or

on cylinder 2 and cylinder 3.

NOTICE

Do not turn the crankshaft while the valve springs are removed.

Table 2


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Required Tools



NOTICE


Contaminants may cause rapid wear and shortened component life.Place the new valve springs into position.

Note: Ensure that the closed damper coils are toward the cylinder head if double valvesprings are used.Ver imagen


Install valve spring retainer (3) .

Install Tool (A). Compress valve springs (1) .NOTICE

Ensure that the valve spring is compressed squarely or damage to the valve stem may

occur.Install two valve keepers (2) .

Release the pressure slowly on Tool (A). Remove Tool (A). Strike the top of the valves

with a soft faced hammer in order to ensure that the valve keepers are properlyinstalled.

Note: If you are replacing all of the valve springs the procedure can be done on twocylinders at the same time. The procedure can be done on cylinder 1 and cylinder 4, oron cylinder 2 and cylinder 3.

End By: Install the rocker shaft. Refer to Disassembly and Assembly, "Rocker Shaft and

Pushrod - Install".


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Inlet and Exhaust Valves - Remove and Install

SMCS - 1105-010

Table 1

Required Tools



Start By:

Remove the cylinder head assembly. Refer to Disassembly and Assembly, "Cylinder Head

- Remove".

NOTICE



Clean the bottom face of the cylinder head. Use a dial indicator to check the depth of thevalves below the face of the cylinder head before the valve springs are removed. Refer

to Specifications, RENR2401, "Cylinder Head Valves" for the correct dimensions.

Place an index mark on the heads of the inlet valves and the exhaust valves for

installation purposes.

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Use Tooling (A) to compress inner springs (3) and outer springs (4) .

Note: Some engines may have only a single inlet valve spring and a single exhaust valvespring.

Remove valve keepers (1) .

The valve keepers can be thrown from the valve when the valve spring compressor is

released. Ensure that the valve keepers are properly installed on the valve stem. To helpprevent personal injury, keep away from the front of the valve keepers and valve spring

during the installation of the valves.

Slowly release the pressure on Tooling (A) and remove Tooling (A) .Remove valve spring retainers (2) .

ReMove inner springs (3) and outer springs (4) .

Remove seals (5) .Remove valve spring seat washers (6) .


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Remove inlet valves (7) and exhaust valves (7) .

Installation ProcedureTable 2

Required Tools




Ver imagen


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Lubricate the stems of inlet valves (7) and the stems of exhaust valves (7) with clean

engine oil.

Install inlet valves (7) and exhaust valves (7) in the respective positions.

Install valve spring seat washers (6) .

Install new seals (5) .

Install inner springs (3) and outer springs (4) .

Note: Install inner springs (3) and outer springs (4) on the valve spring seat washerswith the damper coils toward the cylinder head. This is done with double valve springs.

If single valve springs are used, the springs can be installed in either way.

Install valve spring retainers (2) .

The valve keepers can be thrown from the valve when the valve spring compressor isreleased. Ensure that the valve keepers are properly installed on the valve stem. To helpprevent personal injury, keep away from the front of the valve keepers and valve spring

during the installation of the valves.

Use Tooling (A) to compress inner springs (3) and outer springs (4) .

Note: Some engines may have only a single inlet valve spring and a single exhaust valvespring.

Install valve keepers (1) .

Slowly release the pressure on Tooling (A) and remove Tooling (A). Strike the top of the

valves with a soft hammer in order to ensure that the valve keepers are properlyinstalled.Note: Refer to Specifications, RENR2401, "Cylinder Head Valves" for more information

on inlet valves and exhaust valves.

Use a dial indicator to check the depth of the new valves below the cylinder head. If the

depth of the new valves is below the correct depth, the valve seat inserts must bereplaced. Refer to Disassembly and Assembly, "Inlet and Exhaust Valve Seat Inserts -

Remove and Install".End By: Install the cylinder head assembly. Refer to Disassembly and Assembly,"Cylinder Head - Install".


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Inlet and Exhaust Valve Guides - Remove and Install

SMCS - 1104-010

Removal ProcedureTable 1

Required Tools

Tool PartNumber

PartDescription

Qty

A 1U-9169Valve GuideDriver

1

Start By:

A.Remove the inlet valves and the exhaust valves. Refer to Disassembly and

Assembly, "Inlet and Exhaust Valves - Remove and Install".

NOTICE


Contaminants may cause rapid wear and shortenedcomponent life.

Ver imagen


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Illustratio

n 1

g006321

75

Typical example

1. Use Tooling (A) in order to remove the valve guides from the cylinder head.

1. Repeat the procedure for the remaining valve guides.

Installation ProcedureTable 2

Required Tools

Tool Part

Number

Part

Description

Qty

A 1U-9169Valve Guide

Driver1

B 9U-6220 Stop Collar 1

C 157-3720Valve Seat Cutter

1

NOTICE


Contaminants may cause rapid wear and shortened

component life.

Illustratio g006321


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n 276

Typical example

1. Put the valve guide in position. Carefully tap the valve guide in order to start theinstallation. Use Tooling (A) and Tooling (B) to seat the valve guide in the cylinder

head.

Note: After installing the unfinished valve guides and valve seat inserts, you must

ream the valve guides and valve seat inserts to the finished diameter. The valveguides and valve seat inserts are cut and reamed in one operation. This operation

is performed by using the 157-3720 Valve Seat Cutter. Refer to Specifications,RENR2401, "Cylinder Head Valves" for the finished diameter of the valve guidesand valve seat inserts.

1. Check the protrusion of the valve guides. The valve guides should protrude 14.85to 15.15 mm (0.585 to 0.597 inch) above the valve spring recess.

1. Repeat the procedure for the remaining valve guides.

End By: Install the inlet valves and the exhaust valves. Refer to Disassembly and

Assembly, "Inlet and Exhaust Valves - Remove and Install".

Inlet and Exhaust Valve Seat Inserts - Remove and Install


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SMCS - 1103-010

Start By:

Remove the inlet valves and the exhaust valves. Refer to Disassembly and Assembly,

"Inlet and Exhaust Valves - Remove and Install".



Ver imagenTable 1

Required Tools


A 9S-3095 Puller Handle 1

Illustration 1 g00545912Ver imagen

Table 2

Required Tools


A 157-3717 Valve Seat Driver (1) 1


Use Tooling (A) with appropriate extractor (2) and channel (3) in order to remove valve

seat inserts (1) .

Remove valve seat inserts (1) from the cylinder head.

Repeat the procedure for the remaining valve seat inserts.

( 1 ) This tool is used for valve guides and valve seats that are not finished.


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NOTICE





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Use the appropriate parts of Tooling (A) in order to install the valve seat insert into thecylinder head assembly.

Repeat the procedure for the remaining valve seat inserts.Note: Refer to the Specifications Module for more information on the valve seat inserts.

End By: Install the inlet valves and the exhaust valves. Refer to Disassembly andAssembly, "Inlet and Exhaust Valves - Remove and Install".

Engine Oil Filter Base - RemoveSMCS - 1306-011


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Removal Procedure








Ver imagen


Typical example

Loosen two hose clamps (1) and disconnect the hoses.

Remove three bolts (2) .

Remove nut (3) that holds the hose clamp and move the hose clamp.

Remove engine oil filter base (4) from the engine block. Plug all openings immediately.


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Remove the engine oil filter base. Refer to Disassembly and Assembly, "Engine Oil Filter

Base - Remove".

NOTICE



NOTICE








Typical example

Remove engine oil filter (1) from engine oil filter base (2) .

Remove cap (3) from engine oil cooler (4) (if equipped).

Remove engine oil cooler (4) from engine oil filter base (2), if necessary.


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Engine Oil Filter Base - AssembleSMCS - 1306-016Assembly Procedure

NOTICE


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Ver imagen


Typical example

Install engine oil cooler (4) on engine oil filter base (2) .

Place cap (3) on engine oil cooler (4) (if equipped).

Install engine oil filter (1) on engine oil filter base (2) .End By: Install the engine oil filter base. Refer to Disassembly and Assembly, "Engine Oi

Filter Base - Install".

Engine Oil Filter Base - Install

SMCS - 1306-012


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Ver imagen


Typical example

Install engine oil filter base (4) on the engine block.

Place the hose clamp in position and install nut (3) .

Install three bolts (2) .

Connect two hoses and tighten two hose clamps (1) .

Engine Oil Relief Valve - Remove and Install

SMCS - 1315-010

Removal ProcedureStart By:


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Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan -

Remove".

NOTICE



Ver imagen

Illustration 1 g00552240Remove two bolts (1) that fasten the engine oil relief valve to the engine oil pump.

Remove bolt (3) that holds engine oil relief valve (4) in position.

Remove engine oil relief valve (4) and the gasket from the engine. Inspect the conditionof the gasket. Replace the gasket, if necessary.

Disconnect oil tube (2) and remove the O-ring seals from the oil tube.

Installation ProcedureNOTICE




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Install new O-ring seals on oil tube (2) and connect oil tube (2) to the engine oil pump.Put the gasket in position and install engine oil relief valve (4) on the engine.

Install bolt (3) that holds engine oil relief valve (4) in position. Tighten bolt (3) to a

torque of 44 Nm (33 lb ft).Install two bolts (1) that fasten the engine oil relief valve to the engine oil pump.

End By: Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan -

Install".

Engine Oil Pump - RemoveSMCS - 1304-011

Table 1Required Tools


A 1P-1855 Retaining Ring Pliers 1

B 9U-6282 Torque Wrench Extension 1

Start By:


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Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan -

Remove and Install".

Remove the front housing. Refer to Disassembly and Assembly, "Housing (Front) -Remove".

Note: The engine oil pump is mounted on the No. 1 crankshaft main bearing cap. The

engine oil pump can be removed without removing the front housing if the No. 1crankshaft main bearing cap is removed. Use Tool (B) in order to remove the No. 1

crankshaft main bearing cap. The engine oil pump is then removed from the No. 1

crankshaft main bearing cap.



NOTICE






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Remove two bolts (1) that fasten the strainer and suction pipe to the engine oil pump.


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Remove bolt (2) that holds the strainer in position.

Remove the strainer, suction pipe (3), and the gasket from the engine.

Remove the engine oil relief valve. Refer to the Disassembly and Assembly Module,

"Engine Oil Relief Valve - Remove".

Ver imagen


Use Tool (A) to remove retaining ring (4) from the idler gear shaft.

Remove idler gear (5) from the idler gear shaft. Inspect the idler gear shaft for wear or

damage. If the idler gear shaft is worn or damaged, use a new part for replacement. Us

a suitable press to remove the idler gear shaft from the No. 1 main bearing cap.

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Remove three bolts (6) from the No. 1 main bearing cap.

Remove engine oil pump (7) from the engine.

Engine Oil Pump - InstallSMCS - 1304-012

Table 1

Required Tools


A 1P-1855 Retaining Ring Pliers 1



NOTICEIf any of the parts on the engine oil pump are worn or damaged, the entire pump must

be replaced.

Note: If the No. 1 crankshaft main bearing cap was removed, install the No. 1 crankshaf

main bearing cap with the engine oil pump. Tighten the bolts for the No. 1 crankshaft


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main bearing cap to a torque of 265 Nm (195 lb ft).

If the shaft for the idler gear on the engine oil pump was removed, remove the excessLoctite 603. Apply a new layer of Loctite 603 to the bore in the main bearing cap and

install the shaft.

Ver imagen


Fill engine oil pump (7) with clean engine oil. Install engine oil pump (7) on the engine.

Install three bolts (6). Tighten the bolts to a torque of 22 Nm (16 lb ft).Ver imagen


Install idler gear (5) .

Use Tool (A) to install retaining ring (4) .

Note: After you install the engine oil pump and the idler gear, ensure that there is aminimum of 0.08 mm (.003 inch) backlash between the gear on the engine oil pump

and the idler gear.Install the engine oil relief valve. Refer to Disassembly and Assembly, "Engine Oil Relief


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Valve - Install".

Ver imagen


Install the strainer, suction pipe (3), and the gasket.Install bolt (2). Tighten the bolt to a torque of 22 Nm (16 lb ft).

Install two bolts (1). Tighten the bolts to a torque of 22 Nm (16 lb ft).End By: Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) Install".

Water Pump - Remove

SMCS - 1361-011

Removal Procedure



NOTICE


inspection, maintenance, testing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before opening any compartment ordisassembling any component containing fluids.Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for


Dispose of all fluids according to local regulations and mandates.Drain the coolant from the cooling system into a suitable container for storage or

disposal.

Ver imagen


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Typical example

Remove eight bolts (1) and two nuts (2) that fasten the water pump to the fronthousing.

Tap water pump (3) with a soft hammer in order to loosen water pump (3) .

Remove water pump (3) and the gasket.

Water Pump - Disassemble - Type 1 Engines and 9RM EnginesSMCS - 1361-015

Table 1

Required Tools


A 7X-0290 Bolt 2

Start By:

Remove the water pump. Refer to Disassembly and Assembly, "Water Pump - Remove".Note: For a complete description of Type 1 and Type 2 engines, refer to the Disassemblyand Assembly, "Engine Design" topic.

NOTICE




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NOTICE



disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for



Ver imagen


Remove six bolts (1). Remove cover (2) and the gasket.

Ver imagen



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Remove O-ring seal (3) .

Ver imagen


Install Tool (A). Remove gear (4) .

Ver imagen

Illustration 4 g00546127Use a suitable lever in order to remove seal (5) .

Ver imagen


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Use a suitable press in order to remove shaft (6), seal (7), and impeller (8) from

housing (9) .

Note: The water pump for Type 2 Engines and 7BJ Engines is not serviceable. Contactyour Caterpillar dealer for more replacement information.

Water Pump - Assemble - Type 1 Engines and 9RM Engines


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SMCS - 1361-016

Assembly Procedure

Note: For a complete description of Type 1 and Type 2 engines, refer to the Disassembly


NOTICE



Note: The water pump for Type 2 Engines and 7BJ Engines is not serviceable. Contact

your Caterpillar dealer for more replacement information.

Clean the inside of the pump body. Ensure that the bearing bore and the counterbore fo

the water seal are particularly clean.

Apply 4C-9507 Retaining Compound to the outer surface of the bearing. Keep the

compound away from the ends of the bearing.

Ver imagen


Support the gear end of the water pump body.

Place the bearing and shaft (6) square in the pump body. Ensure that the shortest endof shaft (6) is in housing (9) .

Use a suitable press and a suitable adapter that will apply force to the bearing. Theadapter should not apply force to the shaft. Press the bearing onto the shaft until the

end of the bearing is level with the bottom of the counterbore for the water seal.

Note: Remove the excess compound from the end of the bearing.

Install seal (7) .


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Ver imagen


NOTICE

Ensure that the water seal is not contaminated by oil or grease. Hold the seal only bythe edge of the flange. Do not damage the ring of green sealant that is applied to the

body of the water seal behind the flange.

Hold water seal (5) by the edge of the flange. Push the seal onto shaft (6) until the seal

is against the chamfer of the counterbore. Only apply force to the outer flange of the

seal.Note: Ensure that the wide end of the seal is toward the bearing and that the seal is

square with the counterbore.Continue to apply force and hold water seal (5) for ten seconds. This ensures that thewater seal will remain in place.

Hold the water pump with the gear end of the shaft on a suitable support. Use a flat barin order to press impeller (8) onto shaft (6) to a depth of 8.30 0.20 mm (.320 .010inch). After installation, ensure that the impeller will turn freely.

Note: Apply 4C-9507 Retaining Compound to impeller (8) if the original impeller is used.

Remove excess compound after assembly.Ver imagen


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Lubricate oil seal (3) with clean engine oil. Install oil seal (3) with the flat surface towardthe bearing. Press oil seal (3) into the body with a suitable adapter until the rear of the

seal is level with the end of the pump.

Continue to apply force and hold oil seal (3) in position for ten seconds. This ensures

that the seal will remain in place.

Press gear (4) onto shaft (6) to a depth of 1.60 1.00 mm (.015 .005 inch) .

Note: Apply 4C-9507 Retaining Compound to gear (4) if the original gear is used.

Remove excess compound after assembly.

Ver imagen


Install a new gasket and cover (2) on the pump body.

Install six bolts (1). Tighten the bolts to a torque of 9 Nm (80 lb in).End By: Install the water pump. Refer to Disassembly and Assembly, "Water Pump -

Install".


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Water Pump - Install

SMCS - 1361-012Installation Procedure

NOTICE



Inspect the condition of the gasket. Replace the gaskets, if necessary.

Ver imagen


Typical example

Install the gasket and water pump (3) to the front housing.

Install eight bolts (1) and install two nuts (2) that fasten the water pump (3) to the fronhousing.

Fill the cooling system. If the engine uses diesel engine antifreeze/coolant, refer to

Operation and Maintenance Manual, "Cooling System Coolant (DEAC) - Change". If theengine uses extended life coolant, refer to Operation and Maintenance Manual, "Cooling

System Coolant (ELC) - Change".


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Water Outlet Manifold - Remove

SMCS - 1362-011

Removal ProcedureNOTICE


Contaminants may cause rapid wear and shortened component life.NOTICE




Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" fortools and supplies suitable to collect and contain fluids on Caterpillar products.Dispose of all fluids according to local regulations and mandates.

Drain the coolant from the cooling system into a suitable container for storage ordisposal.

Ver imagen

Illustration 1 g00553901 Typical example

Remove clamp (1) for the boost line.

Loosen clamp (2) and disconnect hose (3) .Ver imagen


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Typical example

Remove all bolts (4) that hold water outlet manifold (5) in position.

Remove water outlet manifold (5) and the gasket.

Water Outlet Manifold - Install


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SMCS - 1362-012


NOTICE



Ver imagen


Typical example

Inspect the condition of the gasket. Replace the gasket, if necessary.Put water outlet manifold (5) and the gasket in position on the engine.

Install bolts (4) that secure water outlet manifold (5) to the engine.

Ver imagen


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Typical example

Connect hose (3) and tighten clamp (2) .

Install clamp (1) for the boost line.

Install the upper radiator hose and fill the cooling system with coolant to the correct

level. Refer to the Operation and Maintenance Manual for the correct procedure.


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Electric Starting Motor

SMCS - 145312 Volt Starting MotorVer imagen

Illustration 1 g00295928 - Starting Motor (Side View)Ver imagen


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End view of the starting motor which shows the electrical connectionsNo load conditions at 25 C (77 F)

Rpm of shaft ... 7000 minimum

Current draw ... 130 amperes maximumVoltage ... 11.5 volts

Rated voltage ... 12 volts

(1) Tighten the battery terminal nut to the following torque: ... 24 to 32 Nm (18 to 24lb ft)

(2) Tighten the nut for the switch terminal to the following torque: ... 1.0 to 1.3 Nm (9

to 12 lb in)

Tension of the spring for the motor brush ... 8.34 to 11.00 N (1.9 to 2.5 lb)

Minimum resistance of the starter cable at 200 C (392 F) and at 12 volts ... 0.0017

ohms

Start Relays

9G-4368 Relay

Ver imagen


Voltage ... 12 VDC

Resistance between "W1" terminal and "W2" terminal ... 15 1.5 ohms069-5466 Relay

Ver imagen


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Voltage ... 6 VDC

Resistance between terminal "A" and terminal "B" ... 30 to 34 ohms

2 4Volt Starting MotorNo load conditions at 25 C (77 F)

Rpm of shaft ... 7000 minimum

Current draw ... 85 amperes maximumVoltage ... 23 volts

Rated voltage ... 24 volts

Minimum pull-in voltage ... 18 voltsBrush length:

Minimum brush length ... 15.5 mm (0.61 inch)

Armature end play ... 0.1 to 0.3 mm (0.004 to 0.012 inch)Install shims or remove shims in order to adjust the armature end play to the correct

specification.CommutatorNew diameter ... 45 mm (1.77 inch)

Minimum diameter ... 42.5 mm (1.67 inch)


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Desamble Motor 3054

Documents

Transcript of Desamble Motor 3054