Professional Documents
Culture Documents
CATERPIILAR'
sENR5s45-03 1999 January
Sloc@ffiil@atnons
3064 and 3066 Engines For Gaterpllar b Built Machines
(Engine) 6LK1-Up (Engine) 7JK1-Up
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320i8, 32OE L, 32OB U, 32OB LU EXGAVATORS& 32OB LL FOREST HACI{INES Volume I (Engine, Electrical, Operation and tlaintenance) 4NRl-Up, SBRl-Up, 6GRl-Up' lDSl.Up' lESl.Up' 6LSl.Up' EESI-Up, gGSl-Up, 9JSl-Up' 4XWl-Up' SGWI.Up' 3tRl-UP' 4H Rl -Up, 9KR{ -Up' I GSI -U p' 2rII21.Up, 7ZZ1 -Up, 8G21.Up, AEDI-Up, BANI-Up, BBGI -Up
separately. Manualfor product.Theitemslistedcan be ordered this Service Thisformliststhe complete Note as and in added, theywill be announced PREVIEW shouldbe ordered they or supplements Whenitemsare updated and for contents form REG1139F, current Manual microfiche, Contents Referto the Service available. become numbers thismanual. of Scction Title Form No, SENR23OO SENR9241 SENR7733 SENR9242 SENR3130 SENR,2ETO SENR5545 SENR5546 SENR5553 SENR9243 sENRil996 RENR1998 RENRlOOT SENR9258 RENR1O58 RENR3725 SENRiIET4 sEBU6975 SEBU7O79 XEBU2571
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Binder Label Binder Safety Manual Contents Service ications Torqr.re Specif Engine Index Tab 3066Engine ErgineSpecifications and Adjusting 3066Engine Testing Operations, Systems 3066Engine and Disassembly Assembly 3066Engine Supplement and Disassembly Assembly Elecfical Srsterns & Opeatos Station Index Tab Control and Engine PumpElectronic SystemsOperation System and Starting Charging SystemsOPeration System Electrical Schematc ForestMachines Electrical System; Schematic (6151-Up, 9JS1-Up) Electrical System(7721-UP Schematic BBGl-Up) 8GZ1-Up, taintenance lndex Tab and Operation Maintenance -Up, (6LS1 9JS1'Up) Machines Forest and Maintenance Operation -Up,BANI-UP, (721 -Up, 8GZ1 and Operation Maintenance BBGl-Up)
For information, see Engine, Electrical& Maintenance information. Systems This manualcontains Note: pageRENR2982. Contents
03/09/00
CATERPILIAR'
10056692
lmportantSafety Information
t r = M o s t c c i d e n tts a ti n v o l v p r o d u co p e r a t i o m,a i n t e n a n c e d r e p a i a r ec a u s e c ; ' . - ' = - . e an a h n A. t b b o b s e r v b a s i c a f e t yu l e s r p r e c a u t i o n sn a c c i d e nc a no f t e n e a v o i d e d y r e : : a ' - - = : : ' e r t i a l l y e r s o hazardous A mustbe alertto pote-: -=-=-:: - s situations occurs. person before accident an i p e r s o n h o u l d l s oh a v e h en e c e s s a r r a i n i n g , i l l s n dt o o l s o p e r f o r mh e s e- - : : - : : ' - . - ' y s sk a t t a t ty lmproperoperation, or and lubrication, maintenance repairof this productcan be dangerous could result in injury or death. Do not operateor performany lubrication, maintenance repairon this product unt,i you have or read and understoodthe operation,lubrication,maintenanceand repair information
':-=:: Safetyprecautions and warnings are providedin this manualand on the procjlc: w a r n i n g s r e n o t h e e d e d b o d i l yi n j u r y r d e a t hc o u l d o c c u rt o y o u o r t o o t h e ' p e ' s : - : a , o The hazardsare identified the "Safety AlertSymbol"and followedby a "Signa by "WARNING" shownbelow. ",:': as
-,
Themeaning thissafety is of alertsymbol as follows: Attention!BecomeAlert! Your Safetyis Involved. and can ce the explains hazard Themessage appears that under warning the
pictorially presented. lace s cby Operations that may cause productdamageare identified "NOTICE" t n i sp u b l i c a t i o n .
-':^l n
3\
Caterpillarcannot anticipateevery possiblecircumstancethat might involve a PGri: *a n^zerd. not The warningsin this publication and on the productare, therefore, all indusite. a tool, procedure,work methodor operatingtechniquethat is not specifically recomHlc Caterpillaris used, you must satisfy yourselfthat it is safe for you and for others-Yc- s h o u l d also ensurethat the product will not be damagedor be made unsafeby the oPerabor - orication, maintenance repair proceduresthat you choose. or
-th^+ ar t T h ei n f o r m a t i o n ,e c i f i c a t i o a n di l l u s t r a t i oi n sh i sp u b l i c a t i o n eo n t h e : a s s - ' - ' : ' sp ns, : :: ,:: ::':-=: : Thespecifications was was available thetimethatthe publication wntten. at - : : : - , :- l = S C a n a c i l, ns d m e a s u r e m e n t d , u s t m e n itls u s t r a t i o a n , o t h e r t e m s a nc h a n g e t a n r ' : - : asj - _ J t --:-- = - - ^g^u{l ^ .v ^ ano the to that affect service is given theproductObtain complete mos::-":-the -:
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T\OS\
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3 Tableof Contents
f v
Tableof Contents
i' .,'
v.
4 icationsSection Specif N o t e :T h e f r o n te n c c ' : - : ; - I --: l t h e f l y w h e ee " o o ' : - : : - ) - = -.Lfro the f lywhee : -- - -- : -:=' . c y l i n d eirs t h e f r o n : ,
Section Specifications
r01020901
- : cositeof
- : -
--=
N o .1
EngineDesign
SMCS Code: 1201
3066Engine
3064Engine
lllustration 2 Cylinderand valve location lllustration 1 Cylinderand valve location (A) Exhaustvalves.(B) lnlet valves.
900523889
)',t295223
Bore...,..... Stroke
. . . 1 0 2m m ( 4 . 0 2i n c h ) 1 3 0 m m ( 5 . 1 2i n c h ) . . . 4 . 3L ( 2 6 0i n ' ) . .l n - l i n e
Stroke
icnlanomant
'-
5 1 2i n c h ) a:-.390in')
Displacement................
H
ii I ll
ll
Fuelinjection . . . .1 0 o r 1 6 c : ; - = = = : : - - ' = t o p c e n t e r timing Note:Referto the Engine -'-^'-.' -'-: -' p e r f o r m a n cs p e c i f i c a t r o ' e tnfo'-a::(Technical Marketing F u e lS e t t i n g n d R e l a t e c' ' - ^ ' - z ' a t h e c o r r e c tt i m i n g p e c ' : e . : - : s r M i n i m u mo m . . . . . . . . . . . . . . . is rotation ' :".:: The crankshaft end of the engine.Cranks-=: rotation - - : a:e for the ==':'to theTMI -' '-'-'to the : - ' : r o f i c h ef o r . . 9 0 0t 2 0 - -- -e flywheel - - -- erclockwise
rotationis vrewedfrom the flvwheelr i The crankshaft ' '..*'-' end of the engine.Crankshaft ....Counterclockwise rotation
Note:The frontend of the e-; -= . , ::osite of - -' s de of the l t h e f l y w h e ee n d o f t h e e n E ' = s e n g i n e n d t h e r i g h t i d ec ' : - : : - , ' : - - :a r ev i e w e d a -= No. 1 l f r o mt h e f l y w h e ee n d o f t l ' e : - : cylinderis the frontcylinder
\t\
5 icationsSection Specif
i01029707
) v
FuelInjection Lines
SMCSCode:1252
valveholderto the Tightenthe delivery f o l l o w i n go r q u e . . . 3 9 t o 4 4 N m ( 2 9 t o 3 2 l b f t ) t (3) Boltfor lock plate Tightenthe bolt for the lock plateto the f o l l o w i n go r q u e . . . . . .3 t o 5 N m ( 2 7 t o 4 4 l b i n ) t . ( 4 ) Boltfor fuel line Tightenthe bolt for the fuel lineto the following 1 0t o 1 3 N ' m ( 7 t o 1 0 l b f t ) torque.
rsut
-t\
/5\
FJ
-//
/4'
(6)
9oo53o3o7
lrllar crhqnrinn
lllustration3
to Tightenthe idlersubspring the following . . . . . . .1 6 t o 2 0 N ' m ( 1 2 1 o1 5 l b f t ) torque. (7) Nut Tighten the nut to the followlng 3 t o 5 N ' m ( 2 7t o 4 4 l i n ) torque.
i01029643
i v
Pump FuelIniection
SMCS Code: 1251,1290
FuelInjectionNozzles
SMCS Code:1254
lllustration5
g0O53O2B0
(3) Retainer fuel injection nozzle for boltto the following Tightenthe retaining . . , . . . .2 . N ' m ( 1 6 l b f t ) .2 torque.
( 1 ) B o : s f o rf u e li n j e c t i o l i n e n line T grten the boltsfor the fuel injection to the ' o , o w i n go r q u e . . . . . 2t0 2 5 N ' m ( 1 5t o 1 B l b f t ) t o (2) De rvery valveholder
6 Section Specifications
t01024279
ValveMechanism
S M C SC o d e : 1 1 0 2
o--P
3>#\g
n\-P Y
lllustration6
900530283
( ) Body for fuel injectionnozzle (5) Shims i m I n c r e a s i ns h i m sb y O . 1 O m ( . O O an c h )c h a n g e s g 1375 kPa pressureby approximately injection in psi).Shimsare avatlable nine sizesfrom (2OO a m O . ' 1 0 m ( , O O i n c h )t o 0 . 5 8m m ( . 0 2 3i n c h ) . (6) Pressure spring (7) Pressure Pin (B) Gasket (9) Pln nozzle (10) Tip for fuel injection nozzle nut (11) Retaining for fuel injection the nut to the following Tighten + ......34 5 N m (25talbfI) torque. valvesteExhaust ( 4 ) Diameterof valve s:el n l e tv a l v es t e m , m .-- c 7.955 m : ' * : : 3 1 3 2i n c h ) . - - : o 7 9 4 0m m -: :3126inch)
!., ^ - r , 3 . 1 1 0n c h ) i
lllustration7
/ I \ Qnrinn I ga n nv it h l l L l r r nr rv lva r l ur tec.' -^'^:
900526366
l51 rurus
. s t e m. , , ; . . . . . . . . . . . .
' - . = ' ^ a u s tv a l v e a e M i n i m u m l l o w a b l c e - =-' = ' i : : - - - ( . 3 0 9 1n c h ) stem........... - alve ! f C l e a r a n c eo r i n t a k e ' = : : -- - - - , 0 0 3 3i n c h ) o g u i d e . . 0 . 0 5t5 0 . 0 8 5 ^ valve i f C l e a r a n c eo r e x h a u s , a . = : ' = -- - - : : 0 0 4 1i n c h ) g u i d e, .0 . 0 7 0t o 0 . 1 0 5 ' - - : . ; i d ef o r i n l e t : a e M a x i m u m l l o w a b l c l e e ' a '-a = - - ' - ( 0 0 5 9i n c h ) v a l v e. . . .
l,w
icationsSection Specif
lv
lvlax mum allowable for clearance guide for . . 0 . 2 0 0m m ( 0 0 7 9 i n c h ) e x ^ a . r sv a l v e . . . t I -.s Ce diameter valveguide of of L.- :e diameter guidefor inlet .a.: .. m . 1 3 . 0 2 5o 1 3 . 0 3 5 m t ( . 5 1 2 8o . 5 1 3 2 n c h ) i t l - . s r e d i a m e t eo f g u i d ef o r e x h a u s t r .z .= . 1 3 . 0 2 5o 1 3 . 0 3 5 m m t ( . 5 1 2 8o . 5 1 3 2 n c h ) i t -s :e diameter guidefor new inlet of .... m t 8 . 0 1 0 o 8 . 0 3 5 m ( . 3 1 5 4 o . 3 1 6 3i n c h ) t - : - = i a m e t eo f o u i d ef o r n e w e x h a u s t r . : . = 8 . 0 1 0t o 8 . 0 2 5m m ( . 3 1 5 4 o 3 1 5 9 i n c h ) t ^ . ' ' , - J m i n s i d ed i a m e t efro r o u i d ef o r i n l e t
....
tl
A. v O u w
ml m l ll rl
/ ? 1rO v
\.u
innh\
llv1,/
. = .=
- - -occ nf lin
i 8 . 1 2r r m ( . 3 2 0 n c h )
lllustrationI
900527479
( 1 3 ) W d t h f v a l v es e a t . . . . . . . o
1 4 0 0 . 2 5m m ( . 0 5 5t . 0 1 0i n c h )
)L
',' - ---n allowable for valvelip thickness inlet . . 1 . 2 0m m ( . 0 4 7i n c h ) :-: :xlaust valves :- = ovalve ace.........,. f 30 degrees
permissible width of the valve Note:The maximum m s e a ti s 1 . B O m ( . 0 7 1i n c h ) . (14) Valveseat angle 30 degrees
E x h a u svt a l v e . . . . .
. . . . . . 0 . 5t0 0 . 2 5m m ( . 0 2 0t . 0 1 0i n c h )
I n l e v a | v e . . . . 0 . 4t 0 0 . 2 5m m ( . 0 1 6t . 0 1 0i n c h ) t p e T N o t e : h e m a x i m u m e r m i s s i b ld e p t h i s 1 . 1 0m m ( . 0 4 3i n c h ) .
trusira: i-
900526884
(Br l=c:^ of bore in head for valveseat -se': , . 9 , 5 t 0 . 1m m ( . 3 7 4x . . 0 0 4i n c h ) ( 9 ) C ^ a ' : f e ro f i n l e t a l v e . . . v ......40 egrees d
lllustration 10
gOA52749A
(16) Pushrod
8 Specifications Section
in Use a dial indicator orderto check all pushrods runout. for Replacethe pushrodif the runoutexceedsthe following value. 0.40 mm ..... ( . 0 1 6i n c h )
t01023644
.,
ValveRockerArm
SMCS Code: 1123
lllustration12
900526256
tl
^"'-
lllustration 11
900526252
_3at*
vJ:-/-
-/"
(1) Rocker rm bushing a Bore in rockerarm bushingfor . . . . . . . 0 . 0 1 1o 2 0 . 0 9 4 m m shaft........... 2 t (.7878o .791 inch) t 1 (2) Rockerarm shaft Diameterof rockerarm shaft...
lllustration13
-/"
900526257
- ^r rnlrn^
1 9 . 9 6 6o 1 9 . 9 8 4 m m t ( 7861to .7868inch)
Position rockershaftbrac.e = the bolts. (4) Long bolt Tightenthe long bolt to i-e ': . . .1 5 - " torque. (5) Shortbolt Tightenthe shortbolt to :^e':
of Clearance rockerarm bushingfor i s h a f t . ,..... . . 0 . 0 2t7 0 . 1 2 8m m ( . 0 0 1 1o . 0 0 5 0 n c h ) o t Replace the rockerarm bushingif the repairlimit Replace of 0.15 mm (.006inch) has been reached. the rockerarm bushingand the rockerarm shaft tf
11
tBlbft)
I?:::3': "tit
torque.
..,.15 =
v 11 + A lh ft\
I icationsSection Specif
141025762
CylinderHead
SMCS Code: '1100
900526261
Tur^ :^: crankshaft untilthe timingmark on the r c ' e ' - = - a ' : o u l l e yi s a l i g n e d i t ht h e p o i n t e o n t h e w : - - I :=ar houslngin orderto adjustthe valve as- :::^ the No, 1 inletvalveand the No 1 e / - . . : - . A v e n u s h r o d s u s tn o t b e i n t e n s i o n m
- --^.^^t,^. ^.^^
lllustraton 16
944527524
( 1 ) C y l i n d eh e a d r and Use a straightedge a feelergaugeto check head for warpage, the cylinder
i - : . : - : e x h a u sv a l v el a s h . . .0 . 2 5m m ( . 0 1 0i n c h ) t .
t01023202
) \,
ValveMechanism Cover
S M C SC o d e : 1 1 0 7
Resurface cylinder the head if the warpage ....0.20 m m amount exceedsthe following ( . 0 0 8i n c h )
of Gasketthickness cylinder h e a d . . . . . . . . . . . . 1t. 7 0 1 0m m ( . 0 7 0t . 0 0 4i n c h ) 0. . 0 T h i c k n e so f n e w h e a d . . . . . . . . . . . 9 5+00 , 1 0m m s (3.740t .004 inch) head.. 94.70mm thickness cvlinder of Minimum (3.728nch) i Note:The repairlimitof the contactsurfaceof the gasketand the repairlimitof the cylinderblock i s u r f a c e s 0 . 2 0m m ( . 0 0 8i n c h ) .
lluslra::-
900525829
15. 11-$
FoZ
5(!-Q)1s
10 icationsSection Specif
t\
o rC-Ot f9-O6 tt
900527527
Put clean engrne on the threadsof the cylinder oil the boltsand tightenthe boltsin head bolts.lnstall to numerical sequence the following the appropriate t . . . . . . . . 1 1 85 N ' m ( 8 7 t 4 l b f t ) torque.
i01030322
lllustration 20
900530560
(6) Turbine shaft P l a c ea d i a l i n d l c a t o ' o -: - : shaft. Move the comPress:' in axialdirection orderto-= p l a y . . .0 . 0 5 7 o 0 . 1 0 3 . t rr-s: :: Note:The turbocharger m t h e t u r b o c h a r q e r u s tb e : - : : ' the end play is beyondt-? s:= :' :neturbine 1 ) r nt h e
-^^ ^t^,, E^ = ru Pray. Lrru
Turbocharger
,ri
i
SMCSGode:1052
. c . 0 0 4 1i n c h ) . =- . e m b J e d n d a - . : ' : l e a r a n c e si f
-: :^S,
0\
^-Y
19 lllustration
900530558
(3)Turbinehousing
(4) Compressor housing (5) Cartridge housing of Note: Mark the orieniation the compressor housing, the cartridgehousingand the turbine housingbeforedisassembly.
(7) Lock plates Position lock platesa^c the ..,, torque. the following -=^ the boltsto -- \'m (15lb ft)
11 Specifications Section
i01029608
ExhaustManifold
SMCS Code: 1059
900530562
!-'*"
lllustration24
900530254
( 1 ) Nuts for turbocharger to Tighten the nutsfor the turbocharger the 41 N'm (30 lb t) torque. foilowing
( 2 ) Studsfor turbocharger
tt
I -s:'a:3,^
ri ^;-n,
to the studsfor the turbocharger the Tighten 12 N'm (9 lb ft) torque. followlng
manifold (4) Nuts for exhaust to manifold the the nutsfor the exhaust Tighten 20 N'm (15 lb ft) torque. following
: : : . 5 P - 3 9 3 1A n t i - S e i zC o m p o u n do t h e t e the :--.:s of the clamp.Tighten clamp to the ': :,',.g torque. 4 t 1 N ' m( 3 5 t 9 l b i n ) Tac : a-: (8) lightlyaroundthe circumference. Tig^::- : amp (8) to the following . . 4 x 1 N ' m( 3 5 t 9 l b i n ) torc-?
te
Camshaft
SMCS Code: 1210
^f\,\ l )v ' \\ \
,\T,i
" f) ,v)
\iN
lllustration26
900527952
Note:
lllustraton25
900527937
(4) Camshaft lobe lift lobe l: camshaft Specified E x h a u sl to b e . . . . . . Inletlobe limitfor lobe liftfo' :'- =Service limitfor lobe liftfo' - =' Service t N o t e :R e p l a c e h e c a m s ' : the lobe lift is reached. (5) Camshaft iobe heigi:: - - - ( 2 8 9 1i n c h ) ^-(2633inch) . 6 . 8 4 4m m (.2695nch) i 6 . 1 8 9m m (.2437inch)
It,
Number Number of Journal of Journal for 3064 i for 3066 Engine Engine 1,2 1 , 2 ,3
Standard Diameter 53.94 to 53.96 mm (2.123to 2.124 inch) 52.94 to 52.96 mm (2.084to 2.085 inch)
53.90mm (2.122inch)
52.90 mm (2.083inch)
1. Measure camshafioc: -= the the 2. Measure base circie '--^:inStep2 the base circe :-=- . 3. Subtract - S t e p1 . T h e f r o mt h e l o b eh e i g h t n a : s ' - - - 'd i f f e r e n c ie t h e a c t u a c a - : - : s : : 3 l i f t( 4 ) .
(1)Theservice dimension the servce or limitis the maximum for that dimension is specified a part. limitis the minimum
Qptac th part i{ the se.vice limit is reached-
0b
v
Clearance between camshaft journalsand bushings
Standard Diameter
Repair Limit(1)
ooo,l3J0,3 "
.do7,""n1
mm
(1)The reoairlimitis the maximum or dimension the repairlimts the minimumdimensionthat is specifiedfor a part. Repairthe part if the repairlimit is reached.
l L l u S l ' l r O2 7 n
900528061
and blocksin orderto Note:Jse a dial indicator Takeone half :::='- 1e the runoutof the camshaft. readingas the runout. :' -: r al indicator
- --^h^{+ - = 5r tdlt
' , ' r x . n u mp e r m i s s i b lre n o u f o r u t . . . . . 0 0 2 0 m m ( . 0 0 0 8i n c h ) :a-shaft if S 'a ghtenthe camshaft runoutis lessthan the ' : c w i n ga m o u n t . 0 0 5 0 m m ( . 0 0 2 0i n c h ) :=i ace the camshaft runoutis morethan the if ': :,,,,lng 0.050mm (.0020inch) amount.
29 lllustration
900529304
in (9) Install the dial indicator orderto determine gear end play i t0 E n d p | a y . . . . 0 . . 1 o 0 . 2 5m m ( 0 0 4 t o . O 1 0 n c h ) the thrustplateif the end play exceeds Replace i m f o l l o w i na m o u n t. ,. . . . . . . . 0 . 3 0m ( . 0 ' 1 2n c h ) g the
.t-
I)\1
ti\
4i
t . T h r u s p l a t e h i c k n e s s . . , . 4.. 8 5m m ( . 1 9 1i n c h ) t
(-\r
\
-]l_,o
900528067
lllustral,cr28
R, i:-cn:fi l_raarinn
with lhe bearing a dialindicator. Meas-'e camshaft journal in of lne Suc:rac: diameter thecamshaft
n r n e ' ' o o i v e l - r e a r i n o l e a r a n c e s .R e f e r t o T a b l e 2 . c
lllustration30
M
900529307
I
(10) Tappetbore diameter ..... Tappetbore diameter ..22.000Io 22.021mm ( . 8 6 6 1 o . 8 6 7 0i n c h ) t M a x i m u ma p p e tb o r ed i a m e t e.r. . . ...2 2 . 0 5 5m m t ( . 8 6 8 3i n c h ) ,
I
' r'{: Clearanceof tappet to b o r e . . .0 . 0 3 5t o 0 . 0 8 6m m ( . 0 0 . 1 t4 . 0 0 3 4 n c h ) o Note: Replacethe tappet if the clearanceis exceeoeo.
i01030986
NOTICE Beforeoperation, the pump n!s: :: :ubricated with clean engineoil and the pump -,si turn freely by hand or damageto partscan 5e :-= result. N o t e :T h e m i n i m u m c c e c : a 3 - : - : s s ! r e a t l o w a = i d l e i s 1 O O P a( 1 5 p s i ) . k ( 1 ) D r i v e n e a ra s s e m b l y g (2) Drivegear assembly
/"\ f.\l ^r rmn ^a.r
N o t e : h e o i l p u m p g e e re ' : - : : ' , : g e a r T ' ' . . 3imo gear is assembly are not servicea:= removed.
el
Removethe oil pressurereliefvalve from the cylinderblock.Checkthe valveand the valveseat Inspectthe spring for abnormal contactpatterns. the oil pressure for weakness damage.Replace or reliefvalve, if necessary. p e t R e l i ev a l v eo p e n i n g r e s s u r . . . . . . 3 4 3 2 0 k P a f (50 t 3 psi)
i01 30415 0
EngineOil Pump
Code:1304 SMCS
,
1r
!..
i
lllustration 33
900530644
.:
14 ll
lllustration32
900530573
15 icationsSection Specif
1v
Heat the oil pump gear to 180' to 220'C (356" to 428"F) and supportthe end of the drive gear snaftin orderto install oil pump gear. the Pressthe oil pump gear untilthe oil pump gear is f lushwith the end of the shaft.
lllustration35
900530702
(7) Cover Measure insidediameters the boresof the of the shaftsin the cover(7) and the oll pump housing(6). Measure boresof the shafts. the The clearance between the gear shaftsand the . o i l p u m p h o u s i n g n d c o v e r . . . 0 . 0 4t o 0 . 0 7m m a ( 002 to .003 lnch)
900530697
llirs:'aton34
-.r
the Note:Replacethe oil pump gear assembly, cover, the oil pump housingif the clearance or exceedsthe servicelimitof 0.15 mm (.006inch). Note:Replace the drivegear and drivengear as an assemory.
r e i n : , f n . n . l' n r , '- r - i
rJmp gear
'.ieasure difference the lengthof the in the o a s s e m b rfy r t h e o i l p u m p g e a r a n d t h e d e p t h - : ^ e o , rp u m p h o u s i n g . 0.020to -0.034 mm I earance ( 0008 to - 00'13 inch) if Note:Replace the oil pump gear assembly the crea'a.ceexceedsthe servicelimitof -0.150 mm ( - C C 5 9r c h ) . the Meas-'e the clearance between oil pump gears g w a n c : ^ e o r lp u m p h o u s i n g i t ha f e e l e r a u g e .
t^-.^^^^
Note: Rep\aoe the oil pump gear assembly if the clea'a^ce exceeds the servce limit of -0.150 mm
900530704
( - 0 C 5 9r n c h ) .
( B ) l d l e rg e a rb u s h i n g I n s i d e i a m e t eo f i d l e rg e a r d r 25.000to 25.021mm bushing (.9843to .9851inch) Maximum diameter idlergear bushingfor oil of pump...... i . . . . . . . . . 2 5 . 0m 9 ( . 9 8 6 6 n c h ) 5m
16 Specifications Section
Openingpressure bypass . = = of
t\
i01030410
(l) The oil temperature must be 60'to 70"C (140'to 158"F) (2) Engineidle is 900 r 20 rpm.
i01030990
P"900530566
Tightenthe oil pan bc .-. torque. ( 2 ) O lp a n d r a i np l u g Tightenthe oil pan c'a - : -e foliowing 1 2 9 4 l b f t )
0 10 3 3 3 7 8
el
5I - 8010 WaterTemperature
Regulator
e T h ew a t e rt e m p e r a t u rre g - : . : ' : ' : ' - : o o p e n a t thefollowingtempelatule - - , ( 1 6 0 '+ 4 ' F ) The valveliftsmorethan '1: -following ,., temperature, - -:r) at the 85"C(185"F) Note:The oil bypassvalveis mountedlnsidethe oil pan alongthe rail of the oil pan. ('1)Valveseat Check the valve and the valve seat for abnormal contact patterns. (2) Spring Inspectthe springfor weakness damage. or Freelengthof spring 83.5 mm (3.29inch)
5I - 8020 WaterTemperature
Regulator
T h ew a t e rt e m p e r a t u rre g - a : : - : ' : " : : c o p e n a t e . the following temperature. 32"C(180'F) The valve liftsmorethan 10 -followingtemperature - -^) at the 36'C (204'F)
06
17 icationsSection Specif
i 0 1 0 3111 1
WaterPump
SMCS Code: 1361
The pressfit betweenthe water pump shaftand the is rmpeller the following t a m o u n t... . .0 . 0 3 2t o 0 . 0 6 5m m ( . 0 0 1 3 o . 0 0 2 6i n c h )
tO1a2B288
CylinderBlock
SMCS Gode: .1201
41 lllustraton l l l L s : ' a t o3 9 n
900530877
900529444
( 1 ) C y l i n d eb l o c k r the Measure amountof the warpageof the and biockwith a straightedge feeler cylinder gauge.Maximum allowable . . . . . . .0.. 0 5m m ( . 0 0 2i n c h ) , clearance Repailimit...... r . . . . . . . . . 0 . m0 ( . 0 0 8i n c h ) 2 m
'
-oeller
and the waterpump shaft Tr: 'aces of the impeller a'e' -sn. ( 2 1F a n g e (3r -i'e to fromthe face of the impeller the distance pump housing the following is .',are' .. a'nount. 21.00lo 21.70mm (.826to .854 inch)
42 lllustration 40 lllustraton
g00530BZB
900529446
T^e cress fit betweenthe water pump shaft and t a e ' a n g e i s t h ef o l l o w i n g .. ... 0.035to 0.065mm an:oint. ( . 0 0 1 4 o . 0 0 2 6i n c h ) t
18 icationsSection Specif
sleeve of Measure insidediameter the cylinder the Measure the to that is parallel the crankshaft. insidedrameter the cylindersleevethat ls in a of position the crankshaft. perpendicular Measure to the top, the middleand the bottomof the cylinder sleeve.Referto Table4 for tolerancesof the sleeves. cylinder
Table4
Q,(
standard Standard
n^--Repair
c^n,^^ Service
A""lirory
Inside Diameter
Limit{l)
Limit)
lllustration43
900529534
1 0 2 . 0 1t0 o 102.700 102.200 102.045 mm (4.0161 mm (4.0236 mm (4.0433 inch) inch) to 4.0175
inch)
m 0.010 m
(.0004inch) 0 . 0 1 5m m (.0006inch)
N/A
N/A
(1)The repairlimitis the maximum or dimension the repairlimitls the mnimumdimensionthat is specifiedfor a part. Repaira part if the repairlimit is reached. (2) The service lmts the maximumdimensionor the service limit is the minimumdimensionthat s specifiedfor a part. Replacethe part if the servicelimit is reached.
-\// ,
ba
oversize Bore the cylinderto the specified the repair reaches if dimension the insidedtameter does not reachthe diameter limitbut the inside servicelimit.Referto Table5. Hone the sleeveto +0.25 mm (+ 010 inch) Hone the or +0.50 mm (+.020 inch) oversize. sleeveto an accuracywithin0.010to 0.045 mm ( . 0 0 0 4 o . 0 0 1 8i n c h ) . t that is necessary dimension the Determine oversize in orderto clean up the cylinderif any sleevehas unevenwear. that are in excessof sleeves all Replace cylinder the serviceIimit. Note: Refinishall sleevesto the same oversize dimensron. Use a ridge reamerin order to cut the ridge of the cylinderif the sleeveis in good Hone the cvlinderbore. condition.
Table5
--*$z
| :, I
?*
LI
lllustration44 Cylindersleeves
900529962
'iil
1l
I
^e 1 . S e t u p a b o r i n gm a c n : - - '= = , n d e r b l o c k . :enter of the A l i g nt h e b o r i n gm a c r , ^ e, ' , '.re lessworn of the cylinders e:. : bottom
B ==.e, ecareful
= = .e w i t ht h e t o p
OversizeBore
CylinderBore Size
mm ( to 102.000 102.035
. 10 1 7 1i n c h ) .
LI
19 icationsSection Specif
Put sealanton the contact surface betweenthe Put slingerand the crankshaft. clean engineoil on the surfaceof the rear sealassembly (6) Distance from rearsealassembly end of to 6.0 mm (.24 inch) crankshaft
r01022388
Crankshaft Seals
1 S M C SC o d e :1 1 6 0 : 1 6 1
Connecting Rod Bearing Journal Originalsize journal(l) journal Undersize 0 . 2 5 m m ( . 0 1 0i n c h ) journal Undersize 0 . 5 0 m m ( . 0 2 0i n c h ) journal Undersize 0 . 7 5 m m ( . 0 3 0i n c h ) 59.945to 59.965mm (2.3600to 2.3608inch) 5 9 . 6 9 5t o 5 9 . 7 1 5m m (2.3502to 2.3510inch) 59.445 to 59.465 mm (2.3404to 2.3411 inch) 5 9 . 1 9 5o 5 9 . 2 1 5 m t m ( 2 . 3 3 0 5 o 2 . 3 3 1 3i n c h ) t
lc
; -Si'3i l' =.--45 -^^l
(1) Regrindthe connectingrod journalsto the next undersize dimension the repairlmitof 59.980mm (2.3614inch) is if exceeded.
betweena new bearingand a new The clearance j o u r n ails t h e f o l l o w i n g a l u e . . . . . . 0 3 5t o 0 . 1 0 0m m v 0 ( 0014 to .0039inch) if bearingis required the clearance An undersized rod the between connecting journaland the bearing is in excessof the servicelimitof 0 200 mm (.0079inch).lf the crankshaft worn excessively, or is bearing is an if the crankshaft uneven, undersized bearingis required, lf is required, an undersized listedin Table6. grindthe crankshaft a dimension to for tolerance rod bearing Note:The allowable journalsthat are out of round is 0.010 mm repairlimitis 0.030mm (.0004inch).The maximum , ( . 0 0 1 2 n c h ) .l f t h e r e p a i rl i m i ti s e x c e e d e dr e g r i n d i journals the specified the bearing to dimension.
900525904
f 2 =:='seaassembly
Nter --: .oar eeat assembly and the s l i n g e r a r e
<
-^a/
Note
:-:
i-: =:2'
sealassembly
Note
r =:
t
:
t
20 Specifications Section
P u tt h e m a i n D e a '- : : = : :
nrlin|or horrinn iinhion hln hnJtc tho rrz D - ) =u-' I = ,- r-:
\01022652
MainBearing Journal
SMCSCode:1203
/?\
torque.
iel indininr
+h^ UtY -^ IIrd
-:J- :
t .:{ln: I
f \r ^ ^ ^ , ,,^ fvfuclutv
-==
Clearance betweer c'a'. :' 0earrng Note:Replace bear- : s :' ' the t o t h e n e x tu n d e ' s ' z e = 2 " c clearance exceeosO 2a -T a b l e f o r d i r r e i ^ s , o ra ' - - : = 7 s
ot.
lllustration46
90052534i
journal (1) Crankshaft main bearing Measure the main bearingjournal. The diameter of journalis givenin Table the crankshaft main bearing 7.
Table7
Main BearingJournal
Originalsize journal(t) journal Undersize 0 . 2 5 m m ( . 0 1 0i n c h ) 89.95 to 89.97 mm (3.541to 3.542 inch) 89.70 to 89.72 mm (3.531to 3.532 inch) 89.45 to 89.47 mm (3.521to 3.522 inch) journal Undersize 0.75 mm (.030 inch)
(1)
, '-: crankshaft : = : a C et h e
: i . ' ,I ' n D e y O n O
89.20 to 89.22 mm ( 3 . 5 1 2 o 3 . 5 1 3i n c h ) t
Begrindthe main bearingjournalsto the next undersize dimensionif the repair limit of 89.85 mm (3.537 inch) is exceeded.
lllustration48 Typicalexample
900525380
'-.- ;t exceeds
ra
Note:The maximumrepairlimitis 0.300 mm (.01 8inch). 1 thrustplatesif the end play the standard Replace Threeoversize standardclearance. exceedsthe if as thrustplatesare available replacements the limit. Generally, end play stillexceedsthe maximum than to the rearjournalis likely be worn morerapidly the rearthrust replace the frontjournal.lf necessary, thrustplates. plate.Referto TableB for oversize
Table8 Dimensions for Grinding of Crankshaft Oversize Thrust Plates lllustration49
900525383
Tolerance
+0.039mm (+.0015 inch) +0.039mm (+.0015 inch) +0.039mm (+.0015 inch)
journal
3 3 . 3 0m m 3 3 . 1 5m m + 0 . 1 5m m i ( + . 0 0 6 n c h ) ( 1 . 3 0 5i n c h ) ( 1 . 3 1 1 n c h ) i
I
lllustration50
ryfr
900525387
ConnectingRod
S M C SG o d e : 1 2 1 8
(6) Put the main bearingand thrustplatesin the Put the blockand install crankshaft. clean engineoil on the bolt threadsTightenthe bolts 137 t 5 N'm torque. to the following ( 1 0 1t 4 l b f t )
lllustration 52
q00525099
( 1 ) M a t c n i nm a r k s g
51 lllustrahon
1 9005254 3
22 Specifications Section
put Beforeassembly, c ea- =- I -= cil on the b o l tt h r e a d s n d a l l s u r l a : = - - : * a K e c o n t a c t a b e t w e e n h e b o l ta n d c o - - = - ' ' , - : l c a p s . t T i g h t e nh e c o n n e c : ' a ' - = - - ' : - - - e f o l l o w l n g t il:-: .--z6t4lbft) torque. ( 4 ) M e a s u r e h e b o r e sa ' e r : - : t rods and recordthe c -:-. : _ 1nna^trnn
t(
-- e bores.
lllustration 53
9 0 0 5 2 50 3 1
(A) The upper oil hole is 40 degreesabove the horizontal centerline. (B) The loweroil hole is 30 degreesbelowthe horizontal centerline, (C) The end of the pistonpin bearingis 30 degrees belowthe loweroil hole.
lllustration 55
9 0 0 5 2 59 4 1
N o t e :R e p l a c e h e c o n n e : . I ' : : t -:e x c e e d s . 5 0m m ( A 2 i 0
an
ntq\/
'l I
\/
h(
\\
V/
/uI
Cl:---'
illu$raon 54
lllustration 56
900525201
(6) Piston (7) Markings piston on ' A s s e m b l eh e p i s t o na n d c c - - = : - = ' : d s . E n s u r e t :-: themarks o t h a tt h e m a r k i n g s n t h e p , s : : o o n t h e c o n n e c t i nrg d ( 1 )a t e . - - - = = : ' n es i d e .
The clearancebetweenthe piston pin bearing and the piston pin is 0.023to 0.054 mm (.0009to .0021inch). Note:A clearancefor the pistonpin to the pistonpin bearingover 0.010 mm (.0004inch) is excessive. Replacethe piston pin or replacethe bearingif the clearanceis excessive.
tC
Plstonprojection
. . 0 . 5 5 o 1 . 1 5m m t ( . 0 2 2 1 o . 0 4 5n c h ) i
\a1421241
Pistonand Rings
SMCS Code: 1214,1215
lllustraton57
90o525206
withthe marks(1) on (B) Install pistonassembly the . the connecting towardthe camshaft (8). rod
lllustration59
900524461
(9) Pistonprojection procedure measure the to Use the following block. lf helghtof each pistonabovethe cylinder range,inspect are clearances not in the acceptable for the components wear or damage. of the 1. Determine top centerposition the piston assemblY. with a dial indicator
on the top of 2- inetalt the dia.t indicator assembly the block. Set the needle of the dal indicator to
which are stampedon Each pistonhas markings are used to algn The markings top of the piston. side of the to the plstonassembly the camshaft cylinderblock, (2) Pistondiameter that are for Table9 givesthe dimensions prstons for Table9 also givesthe dimensions standard, pistons that are oversize. alongthe the pistondiameter Note:Measure perpendicular the pistonpin bore. of
zero. (9) 3. Measureprojection at three places on the top of the piston.Take an averageof the the in threemeasurements orderto determine from the projection. Subtractthe projection head gasketin of thickness the cylinder installed the between the orderto determine clearance head. top of the pistonand the cylinder read of thickness the cylinoer Installed . . 1 1 0 t 0 1 0 m n r ( . 0 7 0t . 0 0 4i n c h ) gasket
lza
ications Section Specif
ir^^^,,,^ +A^ -^ i-' : -: '
gear (5) Crankshaft Note:Ensure that the markson the timinggearsare in alignment.
faolor ac' r^a Qcj;' 'trflaraaar h v l. ' ' . " . - r .J rvrur vuqr v
900527864
lllustration 67
/?\ \/,/ r^^i!^ ilt>rLrg :i^-^+^' Ljrdr rErur ^. v C:. :_: : . _ _
j00527912
-c
and rotatethe idler gear Install dial indicator a (2) back and forthin orderto measurebacklash. exceedsthe Replacethe idlergear if the backlash servicelimit.Referto Table11.
Table11
/ Q\
lrilar
noe
r c h af t
\ v / , v ' v '
0r028537
rtrtil?.,
. clearance
('br+ ncn)
m 0.100 m (.0039 inch)
0.35mm
Flywheel
S M C SC o d e : 1 1 5 6
i ii
I t
I
ili
to o.oog o.ogo
, 1 i
lllustration 68
900529633
l'
lllustration66
9 0 0 5 2 7 90 1
(1) Flywheel
--^ | t^^ ^,.1:^l l P l a c et h e f l y w h e eo n a s - ' - = : : : '.iness of the n i n d i c a t oi r o r d e rt o m e a s - ' = ' - = f lywheel. ' ..0 15mm Standardat assemblyo' ..,', ==
/ OA
\.vvv
i nrn r \r / h v
27 icationsSection Specif
r01053076
BeltTensioner
SMCS Code: 1358
lllustration69
q00529634 lllustration70
q0054632 1
face with a (2) Measure runouton the flywheel the f M d i a li n d i c a t o r . a x i m u ma c e r u n o u t .. . 0 . 1 5m m ( . 0 0 6i n c h ) l R e p a i r i m i to f f a c e r u n o u t . . . . . 0 . 5 0m m ( . 0 2 0i n c h ) if the Note:Refinish flywheel the repairlimitis exceeoeo. o' temperature the ring gear Maxnrm permissible withoutusinga on for installatlon the flywheel ( . .. 150"C302'F) rorcn.,,..,.... on Note:The ring gear is pressed the flywheel. boltsto the following the Tighten flywheel 83 t 5 N'm (61 t 4 lb ft) torque o N u m b e r f t e e t ho f t h e f l y w h e erli n gg e a r . . . . .... . 1 2 7
(1) Bolt. Apply pressureto each belt midway betweenthe Adjust pulleysin orderto inspectthe belt tension. is if the bolt for the alternator the tension incorrect. the fan belttensionis approximately Proper .12.0 mm (.50 inch) . deflection. following
28 icationsSection Specif
i01031047
Belt Tensioner
SMCS Gode: 1358
Alternator
SMCS Code: 1405
o,o.,r.,f (
lllustration71
900530808
lllustration 72
900530887
(1) Bolt
Apply pressureto each belt midway betweenthe Adjust pulleysin orderto inspectthe belt tension. if ifre Oottfor the alternator the tensionis incorrect the is Properfan belt tension approximately . . . . . 1 2 0m m ( . 5 0i n c h ) d following eflection.
( 1 ) N u tf o r a l t e r n a t o r u l r e . ' P t T i g h t e nh e n u tf o rt t e z ' . ' ' . t f o l l o w i n go r q u e,., . Polarity Rotation Speedfor testing(rPm) :- ey to tne 'i2 t o 1 6 2N ' m l - t o 1 1 9l b f t ) - = ; a t i v eg r o u n d : :rer direction . 5000 rPm . 2 8 . 0t . 5 V 504
II
.a
-!
29 icationsSection Specif
1 00 3 1 3 7 8 1
lllustration 73
900530889
(1)Terminnuts al
Tighten termrnal nutsto the following the torque. . . . . . . 1 1 1 N ' m( 9 7t 9 t b i n ) t The rotationis viewed from the drive end of the electncstarting motor.Rotation electricstarting of motor...,..... clockwise No load conditions S p e e d( r p m ) . . . Maximum current(draw) Voltage 3 3 0 0r p m m i n l m u m ...85 A ...............23\/
30 lndexSection
lndex
A Alternator .-'.'28 P a Piston nd Rings . . . . . . . . ' . . . 2.3' . .
B BefTensioner................ t 27,28
c
.'.'.'12 Camshaft 2. . . . . . . . . . . . . . . . . . . 1" ' C o n n e c t i nR o d . . . . . . . . . . . g ...'..19 Journal Rod Bearing Connecting . . . . . . . . . . . . . . . . .1.9 . " . . C r a n k s h a St e a l s. . . . . . . . . f '...'."17 C y l i n d e8 1 o c k . . . . . . . . . r . . . . . ' . .9' . C y l i n d eH e a d. . . . . . . . . r E M ElectriStarting otor......... c D Engine esign 3 0 6 4E n g i n e 3 0 6 6E n g i n e . V O Engine ilBypass alve ......" f n g i n eO i l P a n O engine il Pressure Valve Relief fngine Oil Pressure f n g i n eO i l P u m P E x h a u sM a n i f o l d t F Flywheel n F u e lI n j e c t i oL i n e s n F u e lI n j e c t i oN o z z l e s n F u e lI n j e c t i o P u m P '.."..26 ".'.......5 . " . . . " . . . . ' . . . ' . . . .5 ' . . . ........'.5 '."'.-....".29 .'-.....'.'.'...'.4 '..'.'.".'...'....4 '-.-.'."...'..'.'-4 .-........16 1. . . . . . . . . . . . . . 6. . 1 . . . . . . . .6 .-.'.'.'14 '.".""'...14 .'..'.'.....11 r V a l v eR o c k e A r m . . . . . . . . . . . . .'....',..",.....8
w
.......'.."'..'..17 . W a t eP u m p . . . . . . . . r 16 ' .'............... Regulator Temperature Water = .6 - 8 0 1 a t eT e m p e r a t u r::: - l a t o r . . . . ' . . .1 . . . W r 5I =e "" - 8 0 2 0W a t eT e m p e r a t u r= : - l a t o r . ' . . . . "1 6 r 5I
(
.....................25
"--.-.--....'.2
20
tI