Motor 3054#2

(1)

Camshaft Gear - Remove and I

Camshaft Gear - Remove and Installnstall SMCS - 1210-010-GE SMCS - 1210-010-GE

Table 1

Required Tools

Tool

Part Number

Part Name

Qty

A

_1P-0510

_Driver

_{Driver Group}

_Group

₁

Start By: Start By:

Remove the fan. Refer to

Remove the fan. Refer to Disassembly and AssemblyDisassembly and Assembly, "Fan - Remove and Install"., "Fan - Remove and Install". Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove". Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove".

Ver imagen Ver imagen T T Illustration 1 g00541128 Illustration 1 g00541128

Rotate the crankshaft until t

Rotate the crankshaft until t he timing marks on he timing marks on the crankshaft gearthe crankshaft gear, the camshaft , the camshaft geargear, and the , and the fuel injection pump gearfuel injection pump gear are aligned, as shown.

are aligned, as shown.

Note: The timing marks on the idler gear may not

Note: The timing marks on the idler gear may not be aligned. This is caused by the difference in the speed of the rotatiobe aligned. This is caused by the difference in the speed of the rotatio nn of the idler gear.

of the idler gear.

Ver imagen Ver imagen

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---Illustration 2 g00541130

Illustration 2 g00541130

Remove bolt (1) and the washer from the camshaft gear (2) . Remove bolt (1) and the washer from the camshaft gear (2) .

---Ver imagen Ver imagen ---Illustration 3 g00541131 Illustration 3 g00541131

Install Tooling (A) and remove camshaft gear. Install Tooling (A) and remove camshaft gear. Note: Do not

Note: Do not lose the key from lose the key from the camshaft gearthe camshaft gear..

Inspect the camshaft gear for wear and damage. Replace the gear, if necessary. Inspect the camshaft gear for wear and damage. Replace the gear, if necessary. Installation Procedure Installation Procedure ---Ver imagen Ver imagen

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Install camshaft gear (2) in the front

Install camshaft gear (2) in the front housing.housing. Note: When you install the camshaft gear

Note: When you install the camshaft gear, ensure that the teeth that have the , ensure that the teeth that have the timing marks are facing toward the front.timing marks are facing toward the front. Also, ensure that the key

Also, ensure that the key is aligned properly in tis aligned properly in t he keywayhe keyway. If necessary, tap the gear with a . If necessary, tap the gear with a soft hammer in order to soft hammer in order to seatseat the key in the keyway.

the key in the keyway.

If necessary

If necessary, remove the idler , remove the idler gear in order to aligear in order to ali gn the gear teeth correctly.gn the gear teeth correctly. Install the washer and bolt (1) on t

Install the washer and bolt (1) on t he camshaft gearhe camshaft gear. Tighten bolt (1) to . Tighten bolt (1) to a torque of 78 Nm (5a torque of 78 Nm (5 8 lb ft).8 lb ft). Note: Ensure that the

Note: Ensure that the timing marks on ttiming marks on t he camshaft gearhe camshaft gear, the crankshaft gear, the crankshaft gear, and the f, and the fuel injection pump gear areuel injection pump gear are aligned.

aligned.

If a new camshaft gear is used, check the backlash o

If a new camshaft gear is used, check the backlash o f the camshaft gearf the camshaft gear. The minimum backlash for a new gear is . The minimum backlash for a new gear is 0.080.08 mm (0.003 inch).

mm (0.003 inch). End By:

End By: Install the

Install the front coverfront cover. Refer to . Refer to Disassembly and AssemblyDisassembly and Assembly, "Front , "Front Cover - Install".Cover - Install". Install the fan.

Install the fan. Refer to Disassembly and Assembly, "FRefer to Disassembly and Assembly, "Fan - Remove and Installan - Remove and Install ".".

Camshaft - Remove and Install Camshaft - Remove and Install SMCS - 1210-010 SMCS - 1210-010 Removal Procedure Removal Procedure Start By: Start By:

Remove the rocker shaft and the

Remove the rocker shaft and the pushrods. Refer to Disassembly and Assemblypushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrods , "Rocker Shaft and Pushrods - Remove".- Remove". Remove the fuel

Remove the fuel transfer pump. Refer to transfer pump. Refer to Disassembly and AssemblyDisassembly and Assembly, "Fuel , "Fuel TTransfer Pump - ransfer Pump - Remove".Remove". Remove the front housing. Refer to

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

Remove the camshaft gear. Refer to . Refer to Disassembly and AssemblyDisassembly and Assembly, "Camshaft , "Camshaft Gear - Remove and Gear - Remove and Install".Install". NOTICE

NOTICE

Keep all parts clean from contaminants. Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component li Contaminants may cause rapid wear and shortened component li fe.fe.

NOTICE NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

disassembling any component containing fluids. Refer to Special Publication, NENG2500,

Refer to Special Publication, NENG2500, "Caterpillar T"Caterpillar Tools and Shop ools and Shop Products Guide" for tools and Products Guide" for tools and supplies suitable tosupplies suitable to collect and contain fluids on Caterpillar products.

(4)

Dispose of all fluids according to lo

Dispose of all fluids according to lo cal regulations and mandates.cal regulations and mandates. T

Turn the engine upside-down so the urn the engine upside-down so the valve lifters are held in valve lifters are held in a position away from a position away from the camshaft.the camshaft.

Illustration 1 g00546803 Illustration 1 g00546803

Remove thrust washer (1). Make a note of the location of

Remove thrust washer (1). Make a note of the location of the hollow dowel (X) for installation the hollow dowel (X) for installation purposes.purposes. Ver imagen Ver imagen Illustration 2 g00546869 Illustration 2 g00546869 NOTICE NOTICE

Do not damage the lobes or the

Do not damage the lobes or the bearings when the camshaft is removed or installed.bearings when the camshaft is removed or installed.

Carefully remove camshaft (2) from the engine. Carefully remove camshaft (2) from the engine. Installation Procedure

Installation Procedure

NOTICE NOTICE

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Ver imagen Ver imagen Illustration 3 g00546869 Illustration 3 g00546869 NOTICE NOTICE

Do not damage the lobes or the

Do not damage the lobes or the bearings when the camshaft is removed or installed.bearings when the camshaft is removed or installed. Note: Ensure that camshaft (2) is clean.

Note: Ensure that camshaft (2) is clean. Lubricate camshaft (2) with clean engine oil prior to iLubricate camshaft (2) with clean engine oil prior to i nstallation.nstallation. Carefully install camshaft (2) in the

Carefully install camshaft (2) in the engine.engine. Ver imagen

Ver imagen

Put thrust washer (1) in position. Make sure that

Put thrust washer (1) in position. Make sure that thrust washer (1) is aligned with hollow dowel (X) .thrust washer (1) is aligned with hollow dowel (X) . End By:

End By: Install the

Install the camshaft gearcamshaft gear. Refer to . Refer to Disassembly and AssemblyDisassembly and Assembly, "Camshaft Gear , "Camshaft Gear - Remove and - Remove and Install".Install". Install the front

Install the front housing. Refer to Disassembly and housing. Refer to Disassembly and AssemblyAssembly, "Housing (Front) , "Housing (Front) - Install".- Install". Install the

Install the fuel transfer pump. Refer to fuel transfer pump. Refer to Disassembly and AssemblyDisassembly and Assembly, "Fuel , "Fuel TTransfer Pump - ransfer Pump - Install".Install". Install the rocker shaft

Install the rocker shaft and the pushrods. Refer to and the pushrods. Refer to Disassembly and AssemblyDisassembly and Assembly, "Rocker Shaft and Pushrods - , "Rocker Shaft and Pushrods - Install".Install".

Lifter Group - Remove

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SMCS - 1209-010 SMCS - 1209-010

Table 1

Required

Required T

Tools

ools

Tool

Part Number

Part Description

Qty

A

1U-7262

T

Telescoping

elescoping Magnet

Magnet

1

Start By: Start By:

Remove the camshaft. Refer to Disassembly and

Remove the camshaft. Refer to Disassembly and AssemblyAssembly, "Camshaft - Remove and Install"., "Camshaft - Remove and Install".

NOTICE NOTICE

Contaminants may cause rapid wear and shortened component li Contaminants may cause rapid wear and shortened component li fe.fe. Ver imagen

Ver imagen

Illustration 1 g00540954 Illustration 1 g00540954 Use T

Use Tooling (A) to ooling (A) to remove lifters (1) .remove lifters (1) . Note: Ensure that the

Note: Ensure that the lifters are marked with the lifters are marked with the appropriate cylinder number for installation purposes.appropriate cylinder number for installation purposes. Table 2

Table 2

Required

Required T

Tools

ools

Tool

Part Number

Part Description

Qty

A

1U-7262

T

Telescoping

elescoping Magnet

Magnet

1

NOTICE NOTICE

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Use T

Use Tooling (A) to install ooling (A) to install lifters (1) .lifters (1) .

Note: Ensure that the lifters are seated correctly and that the l

Note: Ensure that the lifters are seated correctly and that the l ifters are in the correct cylinders.ifters are in the correct cylinders. End By: Install

End By: Install the camshaft. Refer to Dthe camshaft. Refer to D isassembly and Assemblyisassembly and Assembly, "Camshaft - Remove and Install"., "Camshaft - Remove and Install".

Cylinder Head - Install Cylinder Head - Install SMCS - 1100-012 SMCS - 1100-012 Table 1

Table 1

Required

Required T

Tools

ools

Tool

Part Number

Part Description

Qty

A

9U-6238

Guide Bolt

Guide

Bolt

2

B

8T

8T-3052

-3052

Degree

Degree Wheel

Wheel

1

Thoroughly clean the top of t

Thoroughly clean the top of t he cylinder block and the bottom of the cylihe cylinder block and the bottom of the cyli nder head. Ensure that there is no debris in thender head. Ensure that there is no debris in the cylinder bores. cylinder bores. Ver imagen Ver imagen Illustration 1 g00550165 Illustration 1 g00550165

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Place cylinder head gasket (3) on dowels (4) on t

Place cylinder head gasket (3) on dowels (4) on t op of the cylinder block. The cylinder head gasket (3) is op of the cylinder block. The cylinder head gasket (3) is stamped "FRONTstamped "FRONT TOP". Do not use any sealant or compound on

TOP". Do not use any sealant or compound on the cylinder head gasket.the cylinder head gasket. Install T

Install Tool (A) in positions ool (A) in positions 15 and 20 in t15 and 20 in t he cylinder block. Refer to Illustration 4.he cylinder block. Refer to Illustration 4.

Ver imagen Ver imagen Illustration 2 g00550163 Illustration 2 g00550163 Typical example Typical example

Attach a suitable lifting device to cylinder head (2) . Attach a suitable lifting device to cylinder head (2) .

Place cylinder head (2) on the cylinder block. Ensure that t

Place cylinder head (2) on the cylinder block. Ensure that t he cylinder head is positioned on dowels (4) and that he cylinder head is positioned on dowels (4) and that cylindercylinder head gasket (3)

head gasket (3) is positioned correctly.is positioned correctly. Remove Tool (A) .

Remove Tool (A) . Ver imagen Ver imagen Illustration 3 g00550160 Illustration 3 g00550160 Typical example Typical example

Lubricate cylinder head bolts (1) with clean engine oil. Lubricate cylinder head bolts (1) with clean engine oil.

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Gradually tighten all of the bolts (1

Gradually tighten all of the bolts (1 through 22) in a numerical sequence to a tthrough 22) in a numerical sequence to a t orque of 110 Nm (80 orque of 110 Nm (80 lb ft).lb ft). Tighten all of the bolts (1

Tighten all of the bolts (1 through 22) again in a through 22) again in a numerical sequence to a torque of 110 Nm (80 numerical sequence to a torque of 110 Nm (80 lb ft).lb ft). Place an index mark on the bolts and

Place an index mark on the bolts and use Tuse Tool (B) in order to further tighten the ool (B) in order to further tighten the bolts. Refer to illustration 4.bolts. Refer to illustration 4. T

Turn the short bolts that are marked with an "S" for an urn the short bolts that are marked with an "S" for an additional 150 degrees (2.5 flats).additional 150 degrees (2.5 flats). T

Turn the medium length bolts that are marked with an "M" for an urn the medium length bolts that are marked with an "M" for an additional 180 degrees (3.0 flats).additional 180 degrees (3.0 flats). T

Turn the long bolts that are marked with an "L" fourn the long bolts that are marked with an "L" fo r an additional 210 degrees (3.5 flats).r an additional 210 degrees (3.5 flats). End By:

End By:

Install the rocker shaft

Install the rocker shaft assemblyassembly. Refer to . Refer to Disassembly and AssemblyDisassembly and Assembly, "Rocker Arm and Shaft - , "Rocker Arm and Shaft - Install".Install". Install the water outlet

Install the water outlet manifold. Refer to Disassembly and Assembly, "Wmanifold. Refer to Disassembly and Assembly, "Water Outlet Manifold ater Outlet Manifold - Install".- Install". Install the fuel

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

Install the fuel injection nozzles. Refer to injection nozzles. Refer to Disassembly and AssemblyDisassembly and Assembly, "Fuel Injection No, "Fuel Injection Nozzles - Install".zzles - Install". Install the exhaust

Install the exhaust manifold. Refer to Disassembly and manifold. Refer to Disassembly and AssemblyAssembly, "Exhaust Manifold , "Exhaust Manifold - Remove and Install".- Remove and Install". Install the inlet

Install the inlet manifold. Refer to Disassembly and manifold. Refer to Disassembly and AssemblyAssembly, "Air inlet Mani, "Air inlet Mani fold -Install".fold -Install". Fill the coolant system. If

Fill the coolant system. If the engine uses Extended Life Coolant (ELC), refer to Operation and Maintenance Manual,the engine uses Extended Life Coolant (ELC), refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change". If the engine uses Diesel Engine Antifreeze/Coolant (DEAC), refer to Operation "Cooling System Coolant (ELC) - Change". If the engine uses Diesel Engine Antifreeze/Coolant (DEAC), refer to Operation and Maintenance Manual, "Cooling System Coolant (DEAC) - Change".

and Maintenance Manual, "Cooling System Coolant (DEAC) - Change". Connect the electrical connections at

Connect the electrical connections at the batterythe battery..

Cylinder Head - Remove Cylinder Head - Remove SMCS - 1100-011 SMCS - 1100-011 Removal Procedure Removal Procedure Start By: Start By:

Disconnect the electrical connections at

Disconnect the electrical connections at the batterythe battery..

Drain the coolant system. If the engine uses Diesel Engine Antifreeze/Coolant (DEAC), refer to Operation and Maintenance Drain the coolant system. If the engine uses Diesel Engine Antifreeze/Coolant (DEAC), refer to Operation and Maintenance Manual, "Cooling System Coolant (DEAC) - Change". If the engine uses Extended Life Coolant (E

Manual, "Cooling System Coolant (DEAC) - Change". If the engine uses Extended Life Coolant (E LC), refer to OperationLC), refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change".

and Maintenance Manual, "Cooling System Coolant (ELC) - Change". Remove the air inlet manifold.

Remove the air inlet manifold. Refer to Disassembly and AssemblyRefer to Disassembly and Assembly, "Air Inlet Ma, "Air Inlet Ma nifold - Remove".nifold - Remove". Remove the exhaust manifold. Refer to

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Remove the fuel injection no

Remove the fuel injection no zzles. Refer to Disassembly and Assembly, "Fuel Injection Nozzles - Remove".zzles. Refer to Disassembly and Assembly, "Fuel Injection Nozzles - Remove". Remove the fuel filter base.

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

Remove the water outlet manifold. Refer to Disassembly and AssemblyDisassembly and Assembly, "Water Outlet Manifold - , "Water Outlet Manifold - Remove".Remove". Remove the rocker shaft assembly and the

Remove the rocker shaft assembly and the pushrods. Refer to Disassembly and Assemblypushrods. Refer to Disassembly and Assembly, "Rocker Arm and Shaft , "Rocker Arm and Shaft --Remove". Remove". ---Ver imagen Ver imagen --Illustration 1 g00550160 Illustration 1 g00550160 Typical example Typical example Ver imagen Ver imagen Illustration 2 g00550162 Illustration 2 g00550162

Gradually loosen 22 cylinder head bolts (1) in t

Gradually loosen 22 cylinder head bolts (1) in t he reverse order that is shown in Illustration 2. This will help preventhe reverse order that is shown in Illustration 2. This will help prevent distortion of the cylinder head.

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Attach a suitable lifting device to cylinder head (2). Carefully l

Attach a suitable lifting device to cylinder head (2). Carefully l ift cylinder head (2) off ift cylinder head (2) off the engine block. The weight of thethe engine block. The weight of the cylinder head is 41 kg (90 l

cylinder head is 41 kg (90 l b).b).

NOTICE NOTICE

Place the cylinder head on a surface that will

Place the cylinder head on a surface that will not scratch the face of the cylinder head.not scratch the face of the cylinder head.

Remove cylinder head gasket (3) . Remove cylinder head gasket (3) . Note the location of

Note the location of dowels (4) on each end of the dowels (4) on each end of the cylinder block. Dowels (4) hold cylinder head gasket (3) in place whilecylinder block. Dowels (4) hold cylinder head gasket (3) in place while cylinder head (2) is installed.

cylinder head (2) is installed. Ver imagen

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Align straight edge (7) with bolt (6) in order to

Align straight edge (7) with bolt (6) in order to check for distortion. If there is a check for distortion. If there is a visible reduction in the diameter of threadvisible reduction in the diameter of thread (8) that has not

(8) that has not been in engagement with the cylinder block, the bolts must be replaced.been in engagement with the cylinder block, the bolts must be replaced.

Rocker Shaft and Pushrod - Install Rocker Shaft and Pushrod - Install SMCS - 1102-012; 1208-012 SMCS - 1102-012; 1208-012 Installation Procedure Installation Procedure NOTICE NOTICE

(13)

Typical example Typical example

Install pushrods (4) . Install pushrods (4) .

Note: Ensure that the pushrods are installed in the original location

Note: Ensure that the pushrods are installed in the original location and that the pushrods are seated in the valve liftersand that the pushrods are seated in the valve lifters correctly.

correctly.

Install a new oil seal in

Install a new oil seal in the oil supply hole in tthe oil supply hole in t he cylinder head.he cylinder head.

Put rocker shaft assembly (3) in position o

Put rocker shaft assembly (3) in position o n the cylinder head. Make sure that the connection for tn the cylinder head. Make sure that the connection for t he oil supply is installedhe oil supply is installed correctly into the oil seal.

correctly into the oil seal.

Note: Ensure that the adjustment screws are properly seated in the ends of pushrods (4) . Note: Ensure that the adjustment screws are properly seated in the ends of pushrods (4) . Note: It may be necessary to loosen the

Note: It may be necessary to loosen the adjustment screws on each rocker arm. This will help prevent a bent valve or aadjustment screws on each rocker arm. This will help prevent a bent valve or a bent pushrod during the installation of the rocker shaft.

bent pushrod during the installation of the rocker shaft.

Lubricate nuts (1) and bolt (2)

Lubricate nuts (1) and bolt (2) with clean engine oil.with clean engine oil. Install nuts (1) and bolt (2) .

Install nuts (1) and bolt (2) .

Alternately tighten the nuts and the bolt. Start

Alternately tighten the nuts and the bolt. Start from the center and work toward the outside. Tighten the nuts and the boltfrom the center and work toward the outside. Tighten the nuts and the bolt on an aluminum bracket to a torque of

on an aluminum bracket to a torque of 40 Nm (30 lb ft). 40 Nm (30 lb ft). Tighten the nuts and the bolt oTighten the nuts and the bolt o n a cast iron or a steel bracket ton a cast iron or a steel bracket to a torque of 75 Nm (55 lb ft).

a torque of 75 Nm (55 lb ft). Adjust the inlet valve lash to 0.20

Adjust the inlet valve lash to 0.20 mm (0.008 inch) and adjust the exhaust mm (0.008 inch) and adjust the exhaust valve lash to 0.45 mm (0.018 valve lash to 0.45 mm (0.018 inch). Refer toinch). Refer to T

Testing and Adjusting, "Air Inlet esting and Adjusting, "Air Inlet and Exhaust System" for more and Exhaust System" for more information on adjusting the information on adjusting the valve lash.valve lash. End By:

End By: Install the Install the valve mechanism covervalve mechanism cover. Refer to . Refer to Disassembly and AssemblyDisassembly and Assembly, "Valve Mechanism Cover - , "Valve Mechanism Cover - Remove andRemove and Install".

Install".

Rocker Shaft -

Rocker Shaft - AssembleAssemble SMCS - 1102-016

SMCS - 1102-016

Assembly Procedure Assembly Procedure

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Lubricate all of the components with clean engine oil. Lubricate all of the components with clean engine oil.

---Ver imagen Ver imagen Illustration 1 g00550062 Illustration 1 g00550062 (1) Retaining ring (1) Retaining ring

(2) Washer on the end of the rocker shaft (2) Washer on the end of the rocker shaft (3) Rocker arm assembly

(3) Rocker arm assembly (4) Rocker shaft bracket (4) Rocker shaft bracket (5) Spring on the rocker shaft (5) Spring on the rocker shaft (6) Washer (6) Washer (7) Rocker shaft (7) Rocker shaft (8) Bolt (8) Bolt

(9) Oil supply connection (9) Oil supply connection (10) Rocker arm bushing (10) Rocker arm bushing

Install oil supply connection (9) and bolt (8) on rocker shaft (7) . Install oil supply connection (9) and bolt (8) on rocker shaft (7) . Note: Ensure that the bolt and t

Note: Ensure that the bolt and t he connection are correctly positioned on the rocker shaft.he connection are correctly positioned on the rocker shaft. Note: Ensure that all of t

Note: Ensure that all of t he oil holes in the rocker shaft and he oil holes in the rocker shaft and in the rocker arms are not plugged before you begin thein the rocker arms are not plugged before you begin the assembly procedure.

assembly procedure.

Install rocker arm bushing (10) in rocker arm assembly (3) with a suitable press. Ream the bushing to a clearance of 0 Install rocker arm bushing (10) in rocker arm assembly (3) with a suitable press. Ream the bushing to a clearance of 0 .06.06 ± 0.03 mm (0.0024 ±

± 0.03 mm (0.0024 ± 0.0012 inch), if 0.0012 inch), if necessarynecessary.. Install each of the components in the

Install each of the components in the correct order onto rocker shaft (7). See Illustration 1.correct order onto rocker shaft (7). See Illustration 1.

---Ver imagen

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Install retaining ring (1). Install retaining ring (1). End By: Install

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

Rocker Shaft -

Rocker Shaft - DisassembDisassemblele SMCS - 1102-015

SMCS - 1102-015

Table 1

Required

Required T

Tools

ools

Tool

Part Number

Part Description

Qty

A

1P-0510

Driver

Driver Group

Group

1

Start By: Start By:

Remove the rocker shaft

Remove the rocker shaft assemblyassembly. Refer to . Refer to Disassembly and AssemblyDisassembly and Assembly, "Rocker Shaft , "Rocker Shaft and Pushrod - and Pushrod - Remove".Remove".

Use a screwdriver or a similar

Use a screwdriver or a similar tool to remove retaining tool to remove retaining ring (1) from both ring (1) from both ends of the rocker shaft ends of the rocker shaft assemblyassembly..

(16)

(1) Retaining ring (1) Retaining ring

(2) Washer on the end of the rocker shaft (2) Washer on the end of the rocker shaft (3) Rocker arm assembly

(3) Rocker arm assembly (4) Rocker shaft bracket (4) Rocker shaft bracket (5) Spring on the rocker shaft (5) Spring on the rocker shaft (6) Washer (6) Washer (7) Rocker shaft (7) Rocker shaft (8) Bolt (8) Bolt

(9) Oil supply connection (9) Oil supply connection (10) Rocker arm bushing (10) Rocker arm bushing

Remove the rocker arms and the rocker shaft

Remove the rocker arms and the rocker shaft brackets from the rocker shaft assembly.brackets from the rocker shaft assembly. Note: Place an identification mark on

Note: Place an identification mark on each of the components for the proper order for installation.each of the components for the proper order for installation. Check the clearance between rocker arm assembly (3) and

Check the clearance between rocker arm assembly (3) and rocker shaft (7). Replace rocker arm bushing (1rocker shaft (7). Replace rocker arm bushing (1 0) if the0) if the clearance is larger than 0.13

clearance is larger than 0.13 mm (0.005 inch). mm (0.005 inch). Use TUse Tool (A) and ool (A) and a suitable press in order to a suitable press in order to remove rocker arm bushingremove rocker arm bushing (10) from rocker arm assembly

(10) from rocker arm assembly (3), if (3), if necessarynecessary.. Remove rocker shaft brack

Remove rocker shaft bracket (4) from rocker shaft (7) et (4) from rocker shaft (7) ..

Remove springs (5), washer (6), bolt (8) and oil supply connection (9)

Remove springs (5), washer (6), bolt (8) and oil supply connection (9) from rocker shaft (7) .from rocker shaft (7) .

Water Outlet Manifold - Install Water Outlet Manifold - Install SMCS - 1362-012 SMCS - 1362-012 Installation Procedure Installation Procedure NOTICE NOTICE

(17)

Ver imagen Ver imagen ---Illustration 1 g00553902 Illustration 1 g00553902 Typical example Typical example

Inspect the condition of

Inspect the condition of the gasket. Replace the gasket, if the gasket. Replace the gasket, if necessarynecessary.. Put water outlet manifold (5) and t

Put water outlet manifold (5) and t he gasket in position on the engine.he gasket in position on the engine. Install bolts (4) that secure water outlet manifold

Install bolts (4) that secure water outlet manifold (5) to the engine.(5) to the engine. ---Ver imagen Ver imagen ---Illustration 2 g00553901 Illustration 2 g00553901 Typical example Typical example

Connect hose (3) and tighten clamp (2) . Connect hose (3) and tighten clamp (2) . Install clamp (1) for the boost line. Install clamp (1) for the boost line.

(18)

Install the upper radiator hose and fill the cooling system with cool

Install the upper radiator hose and fill the cooling system with cool ant to the correct level. Refer to the Operation andant to the correct level. Refer to the Operation and Maintenance Manual for the

Maintenance Manual for the correct procedure.correct procedure.

Water Outlet Manifold - Remove Water Outlet Manifold - Remove SMCS - 1362-011 SMCS - 1362-011 Removal Procedure Removal Procedure NOTICE NOTICE

NOTICE NOTICE

collect and contain fluids on Caterpillar products. Dispose of all fluids according to lo

Dispose of all fluids according to lo cal regulations and mandates.cal regulations and mandates.

Drain the coolant from the cooling system i

Drain the coolant from the cooling system i nto a suitable container for storage or disposal.nto a suitable container for storage or disposal. Ver imagen Ver imagen ---Illustration 1 g00553901 Illustration 1 g00553901 Typical example Typical example

Remove clamp (1) for the boost line. Remove clamp (1) for the boost line.

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

---Ver imagen

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---Illustration 2 g00553902 Illustration 2 g00553902 Typical example Typical example

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

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

Remove water outlet manifold (5) and the gasket.

Water Temperature Regulator - Remove and

Water Temperature Regulator - Remove and InstallInstall SMCS - 1355-010 SMCS - 1355-010 Removal Procedure Removal Procedure NOTICE NOTICE

NOTICE NOTICE

Dispose of all fluids according to lo cal regulations and mandates.cal regulations and mandates. Drain the coolant from the cooling system i

Drain the coolant from the cooling system i nto a suitable container for storage or disposal.nto a suitable container for storage or disposal. Ver imagen

(20)

T

Typical example of ypical example of TType 1 ype 1 and 9RM and 9RM enginesengines Note: For a complete description of

Note: For a complete description of TType 1 and ype 1 and TType 2 engines, refer to ype 2 engines, refer to the Disassembly and Assembly, "Engine Design"the Disassembly and Assembly, "Engine Design" topic.

topic.

Remove six bolts (1) that hold cover (2) and

Remove six bolts (1) that hold cover (2) and bracket (3) in position.bracket (3) in position. Note: Ty

Note: Type 2 engines and 7BJ engines have four mounting bolts (1) pe 2 engines and 7BJ engines have four mounting bolts (1) that hold cover (2) in position.that hold cover (2) in position. Remove bracket (3) and cover (2) from

Remove bracket (3) and cover (2) from the water temperature regulator housing.the water temperature regulator housing. Ver imagen

Ver imagen

T

Typical example of ypical example of TType 1 ype 1 and 9RM and 9RM enginesengines Remove water temperatur

Remove water temperature regulator (4) and e regulator (4) and the gasket from water temperature regulator housing (5) the gasket from water temperature regulator housing (5) .. Note: Typ

Note: Type 1 and e 1 and 9RM engines may have t9RM engines may have t wo water temperature regulators for some engine ratings. Type 2 and 7BJwo water temperature regulators for some engine ratings. Type 2 and 7BJ engines will have one

engines will have one water temperaturwater temperature regulator for all e regulator for all engine ratings.engine ratings. Note: Refer to

Note: Refer to the Testhe Testing and ting and Adjusting Module for Adjusting Module for the correct procedure on the correct procedure on testing the water testing the water temperaturtemperature regulatore regulator.. Installation Procedure

Installation Procedure NOTICE

NOTICE

Contaminants may cause rapid wear and shortened component li Contaminants may cause rapid wear and shortened component li fe.fe. Inspect the condition of

Inspect the condition of the gasket. Replace the gasket, if the gasket. Replace the gasket, if necessarynecessary.. Ver imagen

(21)

T

Typical example of ypical example of TType 1 ype 1 and 9RM and 9RM enginesengines

Note: For a complete description of

topic. Note: Typ

Note: Type 1 and e 1 and 9RM engines may have t9RM engines may have t wo water temperature regulators for some engine ratings. Type 2 and 7BJwo water temperature regulators for some engine ratings. Type 2 and 7BJ engines will have one

engines will have one water temperaturwater temperature regulator for all e regulator for all engine ratings.engine ratings.

Install water temperature regu

Install water temperature regulator (4) and the gasket into lator (4) and the gasket into housing (5) .housing (5) . Ver imagen

Ver imagen

T

Typical example of ypical example of TType 1 ype 1 and 9RM and 9RM enginesengines

Install bracket (3) and cover (2)

Install bracket (3) and cover (2) on the water temperature regulator housing.on the water temperature regulator housing. Install six bolts (1) that

Install six bolts (1) that fasten cover (2) and bracket (3) to the water temperature regulator housing.fasten cover (2) and bracket (3) to the water temperature regulator housing. Note: Typ

Note: Type 2 engines e 2 engines and 7BJ engines have foand 7BJ engines have fo ur mounting bolts (1) ur mounting bolts (1) for the coverfor the cover..

Install the upper radiator hose and fill the radiator to the correct level with coolant. Install the upper radiator hose and fill the radiator to the correct level with coolant. Note: Refer to the

Note: Refer to the Operation and Maintenance Manual for tOperation and Maintenance Manual for t he correct procedure.he correct procedure. Water Pump - Install

Water Pump - Install SMCS - 1361-012 SMCS - 1361-012 Installation Procedure Installation Procedure NOTICE NOTICE

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Inspect the condition of

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

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

Install the gasket and water pump (3) to the front housing.housing. Install eight bolts (1) and install

Install eight bolts (1) and install two nuts (2) that fasten two nuts (2) that fasten the water pump (3) to the front housing.the water pump (3) to the front housing. Fill the cooling system. If t

Fill the cooling system. If t he engine uses diesel engine antifreeze/coolant, refer to Operation and Maintenance Manual,he engine uses diesel engine antifreeze/coolant, refer to Operation and Maintenance Manual, "Cooling System Coolant (DEAC) - Change". If the engine uses extended life coolant, refer to

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

Manual, "Cooling System Coolant (ELC) - Change".

Water Pump - Assemble -

Water Pump - Assemble - Type 1 Engines and 9RM Type 1 Engines and 9RM EnginesEngines SMCS - 1361-016

SMCS - 1361-016

Assembly Procedure Assembly Procedure

Note: For a complete description of

topic.

NOTICE NOTICE

Note: The water pump for

Note: The water pump for TType 2 Engines and ype 2 Engines and 7BJ Engines is not 7BJ Engines is not serviceable. Contact your Caterpillar dealer for moreserviceable. Contact your Caterpillar dealer for more replacement information.

(23)

Clean the inside of

Clean the inside of the pump body. Ensure that the bearing bore and the the pump body. Ensure that the bearing bore and the counterbore for the water seal are particularlycounterbore for the water seal are particularly clean.

clean.

Apply 4C-9507 Retaining Compound to the outer surface of the bearing. Keep the compound away from the ends of the Apply 4C-9507 Retaining Compound to the outer surface of the bearing. Keep the compound away from the ends of the bearing. bearing. Ver imagen Ver imagen Illustration 1 g00546128 Illustration 1 g00546128

Support the gear end of

Support the gear end of the water pump body.the water pump body.

Place the bearing and shaft (6) square in the pump body. Ensure that the shortest end of shaft (6) i

Place the bearing and shaft (6) square in the pump body. Ensure that the shortest end of shaft (6) i s in housing (9) .s in housing (9) . Use a suitable press and a suitable adapter that will apply force to the

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

shaft. Press the bearing onto the shaft until the end of the bearing is level with the end of the bearing is level with the bottom of the counterbore for thethe bottom of the counterbore for the water seal.

water seal.

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

Install seal (7) . Install seal (7) . Ver imagen Ver imagen Illustration 2 g00546127 Illustration 2 g00546127

(24)

NOTICE NOTICE

Ensure that the water seal is not contaminated by oil

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

damage the ring of green sealant that is applied to the body of the water seal behind the flange.of the water seal behind the flange.

Hold water seal (5) by the edge of the fl

Hold water seal (5) by the edge of the fl ange. Push the seal onto shaft ange. Push the seal onto shaft (6) until the seal is against t(6) until the seal is against t he chamfer of thehe chamfer of the counterbore. Only apply force to the outer flange of t

counterbore. Only apply force to the outer flange of t he seal.he seal. Note: Ensure that the wide end of t

Note: Ensure that the wide end of t he seal is toward the bearing and that the seal is square with the counterbore.he seal is toward the bearing and that the seal is square with the counterbore.

Continue to apply force and hold water seal (5)

Continue to apply force and hold water seal (5) for ten seconds. This ensures that the water seal will remain in place.for ten seconds. This ensures that the water seal will remain in place. Hold the water pump with the gear end of the shaft o

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

freely.

Note: Apply 4C-9507 Retaining Compound to impeller (8) if the original impeller is used. Remove excess compound after Note: Apply 4C-9507 Retaining Compound to impeller (8) if the original impeller is used. Remove excess compound after assembly. assembly. Ver imagen Ver imagen Illustration 3 g00546587 Illustration 3 g00546587

Lubricate oil seal (3) with clean engine oil.

Lubricate oil seal (3) with clean engine oil. Install oil seal (3) Install oil seal (3) with the flat surface toward the bearing. Press oil seal (3)with the flat surface toward the bearing. Press oil seal (3) into the body with a

into the body with a suitable adapter until the rear of the seal is level with suitable adapter until the rear of the seal is level with the end of the pump.the end of the pump. Continue to apply force and hold oil

Continue to apply force and hold oil seal (3) in position for ten seal (3) in position for ten seconds. This ensures that the seal will remain in place.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) .

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

Note: Apply 4C-9507 Retaining Compound to gear (4) if the original gear is used. Remove excess compused. Remove excess compound afteround after assembly.

assembly.

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Install a new gasket

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

Install six bolts (1). Tighten the bolts to a torque of 9 Nm (80 lb in). Install six bolts (1). Tighten the bolts to a torque of 9 Nm (80 lb in). End By: Install

End By: Install the water pump. Refer to Disassembly and Assembly, "Wthe water pump. Refer to Disassembly and Assembly, "Water Pump - Install".ater Pump - Install". Water Pump - Disassemble - Type

Water Pump - Disassemble - Type 1 Engines and 9RM Engines1 Engines and 9RM Engines SMCS - 1361-015

SMCS - 1361-015

Table 1

Required

Required T

Tools

ools

Tool

Part Number

Part Description

Qty

A

_7X-0290

_Bolt

₂

Start By: Start By:

Remove the water pump. Refer to

Remove the water pump. Refer to Disassembly and AssemblyDisassembly and Assembly, "Water Pump - , "Water Pump - Remove".Remove". Note: For a complete description of

topic.

NOTICE NOTICE

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

(26)

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

Illustration 2 g00546104 Illustration 2 g00546104 Remove O-ring seal (3) . Remove O-ring seal (3) . Ver imagen

(27)

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

Use a suitable lever in order to remove seal (5) . Use a suitable lever in order to remove seal (5) .

Use a suitable press in order to remove shaft (6), seal (7),

Use a suitable press in order to remove shaft (6), seal (7), and impeller (8) from housing (9) .and impeller (8) from housing (9) . Note: The water pump for

Note: The water pump for TType 2 Engines and ype 2 Engines and 7BJ Engines is not 7BJ Engines is not serviceable. Contact your Caterpillar dealer for moreserviceable. Contact your Caterpillar dealer for more replacement information.

(28)

Water Pump - Remove Water Pump - Remove SMCS - 1361-011 SMCS - 1361-011 Removal Procedure Removal Procedure NOTICE NOTICE

Contaminants may cause rapid wear and shortened component li Contaminants may cause rapid wear and shortened component li fe.fe. NOTICE

NOTICE

Drain the coolant from the cooling system i

Drain the coolant from the cooling system i nto a suitable container for storage or disposal.nto a suitable container for storage or disposal.

Remove eight bolts (1) and two nuts (2) t

Remove eight bolts (1) and two nuts (2) t hat fasten the water pump to the front housing.hat fasten the water pump to the front housing. T

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Remove water pump (3) and the

Remove water pump (3) and the gasket.gasket.

Engine Oil Pump - Install Engine Oil Pump - Install SMCS - 1304-012

SMCS - 1304-012

NOTICE NOTICE

NOTICE If any of the

If any of the parts on the engine oil pump are worn or damaged, the entire pump must be replaced.parts on the engine oil pump are worn or damaged, the entire pump must be replaced. Note: If the No. 1

Note: If the No. 1 crankshaft main bearing cap was removecrankshaft main bearing cap was removed, install the No. 1 d, install the No. 1 crankshaft main bearing cap with thecrankshaft main bearing cap with the engine oil pump. Tighten the bolts for the No.

engine oil pump. Tighten the bolts for the No. 1 crankshaft main bearing cap to a torque of 265 1 crankshaft main bearing cap to a torque of 265 Nm (195 lb ft).Nm (195 lb ft). If the shaft for t

If the shaft for t he idler gear on the engine oil pump was removed, remove the excess Loctite 603. Apply a new layer of he idler gear on the engine oil pump was removed, remove the excess Loctite 603. Apply a new layer of Loctite 603 to the

Loctite 603 to the bore in the main bearing cap and install the shaft.bore in the main bearing cap and install the shaft. Ver imagen

Ver imagen

Fill engine oil pump (7) with clean

Fill engine oil pump (7) with clean engine oil. Install engine oil pump (7) engine oil. Install engine oil pump (7) on the engine.on the engine. Install three bolts (6). Tighten the bolts to a torque of 22 Nm (16 lb ft).

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

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Illustration 2 g00545971 Illustration 2 g00545971 Install idler gear (5) . Install idler gear (5) . Use T

Use Tool (A) to iool (A) to install retaining ring (4) .nstall retaining ring (4) . Note: After you install the engine oil

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

backlash between the gear on t he engine oil pump and he engine oil pump and the idler gearthe idler gear..

Install the engine oil

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

Illustration 3 g00552238 Illustration 3 g00552238 Install the strainer

Install the strainer, suction pipe (3, suction pipe (3 ), and the ), and the gasket.gasket.

Install bolt (2). Tighten the bolt to a torque of 22 Nm (16 lb ft). Install bolt (2). Tighten the bolt to a torque of 22 Nm (16 lb ft).

Install two bolts (1). Tighten the bolts to a torque of 22 Nm (16 lb ft). Install two bolts (1). Tighten the bolts to a torque of 22 Nm (16 lb ft). End By: Install the front

End By: Install the front housing. Refer to Disassembly and Assemblyhousing. Refer to Disassembly and Assembly, "Housing (Front) - Install"., "Housing (Front) - Install".

Engine Oil Pump - Remove Engine Oil Pump - Remove SMCS - 1304-011

SMCS - 1304-011 Table 1

(31)

Required

Required T

Tools

ools

Tool

Part Number

Part

Part Descriptio

Description

n

Qty

A

1P-1855

Retaining

Retaining Ring

Ring Pliers

Pliers

1

B

9U-6282

T

Torque

orque Wrench

Wrench Extension

Extension

1

Start By: Start By:

Remove the engine oil pan.

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

Remove the front housing. Refer to Disassembly and AssemblyDisassembly and Assembly, "Housing (Front) , "Housing (Front) - Remove".- Remove". Note: The engine oil pump is mounted on the

Note: The engine oil pump is mounted on the No. 1 crankshaft main bearing cap. The engine oil pump can be removedNo. 1 crankshaft main bearing cap. The engine oil pump can be removed without removing the front housing if t

without removing the front housing if t he No. 1 crankshaft main bearing cap is removed. Use The No. 1 crankshaft main bearing cap is removed. Use Tool (B) in order to removeool (B) in order to remove the No. 1 crankshaft main bearing cap. The engine oil pump is then removed from the No.

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

NOTICE NOTICE

NOTICE

Remove two bolts (1) that fasten the strainer and suction pipe to the

Remove two bolts (1) that fasten the strainer and suction pipe to the engine oil pump.engine oil pump. Remove bolt (2) that holds the strainer in position.

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

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

(32)

Use T

Use Tool (A) tool (A) to remove retaining ring (4) o remove retaining ring (4) from the idler gear shaft.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 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. Use a suitable press to remove the idler gear shaft from the No. 1 worn or damaged, use a new part for replacement. Use a suitable press to remove the idler gear shaft from the No. 1 main bearing cap.

main bearing cap.

Remove three bolts (6) from the No. 1 main bearing cap. Remove three bolts (6) from the No. 1 main bearing cap. Remove engine oil pump (7) from the engine.

Remove engine oil pump (7) from the engine. Engine Oil Relief Valve - Remove and Install Engine Oil Relief Valve - Remove and Install SMCS - 1315-010

SMCS - 1315-010 Removal Procedure Removal Procedure

(33)

Start By: Start By:

Remove the engine oil pan.

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

NOTICE

Ver imagen

Remove two bolts (1) that fasten the engine oil

Remove two bolts (1) that fasten the engine oil relief valve to the engine oil pump.relief valve to the engine oil pump. Remove bolt (3) that holds engine oil relief valve (4)

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

Remove engine oil relief valve (4) and the gasket from the engine. Inspect the condition of

Remove engine oil relief valve (4) and the gasket from the engine. Inspect the condition of the gasket. Replace thethe gasket. Replace the gasket, if

gasket, if necessarynecessary..

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

Installation Procedure NOTICE

NOTICE

Ver imagen

Install new O-ring seals on oil tube (2)

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

Put the gasket in position and i nstall engine oil relief valve (4) on tnstall engine oil relief valve (4) on t he engine.he engine.

Install bolt (3) that holds engine oil relief valve (4) in position. Tighten bolt (3) to a torque of 44 Nm (33 lb ft). Install bolt (3) that holds engine oil relief valve (4) in position. Tighten bolt (3) to a torque of 44 Nm (33 lb ft). Install two bolts (1) t

(34)

End By: Install

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

Engine Oil Filter Base -

Engine Oil Filter Base - InstallInstall SMCS - 1306-012 SMCS - 1306-012 Installation Procedure Installation Procedure NOTICE NOTICE

Contaminants may cause rapid wear and shortened component li Contaminants may cause rapid wear and shortened component li fe.fe. Ver imagen Ver imagen Illustration 1 g00554000 Illustration 1 g00554000 Typical example Typical example

Install engine oil filter base (4) o

Install engine oil filter base (4) o n the engine block.n the engine block. Place the hose clamp in position and i

Place the hose clamp in position and i nstall nut (3) .nstall nut (3) . Install three bolts (2) .

Install three bolts (2) .

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

(35)

Alternator Alternator SMCS - 1405-015; 1405-016 SMCS - 1405-015; 1405-016 Disassemble Alternator Disassemble Alternator

NOTE: The disassembly and assembly that follo

NOTE: The disassembly and assembly that follo ws is of ws is of a K1, 12V a K1, 12V alternator (7T2876). The alternator (7T2876). The other alternators are similarother alternators are similar.. START BY: START BY: a. remove alternator a. remove alternator Ver imagen Ver imagen

1. Remove the two

1. Remove the two screws and regulator (1).screws and regulator (1). 2. Disconnect capacitor lead

2. Disconnect capacitor lead (2) from the (2) from the back of the back of the alternatoralternator. Remove the screw and capacitor (3).. Remove the screw and capacitor (3).

3. Remove the pulley nut, washer

3. Remove the pulley nut, washer, pulley (4), fan , pulley (4), fan (5) and the key from the rotor (5) and the key from the rotor shaft.shaft.

(36)

4. Mark the front and rear f

4. Mark the front and rear f rame assemblies for proper rame assemblies for proper assemblyassembly. Remove four screws (6) (one has a nut o. Remove four screws (6) (one has a nut o n it on the backn it on the back of the alternator).

of the alternator). 5. Separate the front f

5. Separate the front f rame and rotor assembly from the rear frame rame and rotor assembly from the rear frame and stator assemblyand stator assembly. Watch for the wave washer. Watch for the wave washer, at, at the back of the rear frame assembly

the back of the rear frame assembly, to fall , to fall out.out.

6. Remove four screws (7) and rotor (8) from the f

6. Remove four screws (7) and rotor (8) from the f ront frame.ront frame.

7. Remove spacer (10) and front

7. Remove spacer (10) and front bearing (11), with a bearing (11), with a suitable pullersuitable puller. Remove bearing cover (9) from . Remove bearing cover (9) from the rotorthe rotor..

(37)

8. Remove rear bearing (12) with

8. Remove rear bearing (12) with a suitable pullera suitable puller. Unsolder both rotor . Unsolder both rotor winding leads from slip ring (1winding leads from slip ring (1 3). Remove slip ring3). Remove slip ring (13) with a suitable puller.

(13) with a suitable puller.

9. Remove terminal nuts (14), (15) and (16

9. Remove terminal nuts (14), (15) and (16 ). Remove all of the washers and insulators.). Remove all of the washers and insulators.

10. Remove three screws (17). Remove the

10. Remove three screws (17). Remove the stator and rectifier assembly from the stator and rectifier assembly from the rear frame. Remove the remainingrear frame. Remove the remaining insulators from the terminal studs.

insulators from the terminal studs.

(38)

11. Unsolder the three stator leads and separate rectifier (18) from stator (19). 11. Unsolder the three stator leads and separate rectifier (18) from stator (19).

K1 Alternator K1 Alternator

(1) Regulator. (4) Pulley. (5) Fan. (6) Screws. (8) Rotor. (9) Bearing cover. (11) Front bearing. (12) Rear bearing. (13) Slip (1) Regulator. (4) Pulley. (5) Fan. (6) Screws. (8) Rotor. (9) Bearing cover. (11) Front bearing. (12) Rear bearing. (13) Slip ring. (18) Rectifier. (19) Stator.

ring. (18) Rectifier. (19) Stator. Assemble Alternator

Assemble Alternator Ver imagen

(39)

1. Connect and solder stator (19) leads to

1. Connect and solder stator (19) leads to the positive (+) diodes of rectifier (18).the positive (+) diodes of rectifier (18).

2. Position the insulators on the

2. Position the insulators on the rectifier terminal studs. Position rectifier (18) and stator (19) into rectifier terminal studs. Position rectifier (18) and stator (19) into the rear frame, andthe rear frame, and install the three screws. Install the terminal insulators, washers and nuts. Position wave washer (20) into the bearing bore install the three screws. Install the terminal insulators, washers and nuts. Position wave washer (20) into the bearing bore of the rear frame.

of the rear frame.

3. Install slip ring (13) o

3. Install slip ring (13) o n the rotorn the rotor. Connect and solder the rotor leads to the . Connect and solder the rotor leads to the slip ring. Install rear bearing (12).slip ring. Install rear bearing (12).

(40)

4. Install bearing cover (9),

4. Install bearing cover (9), front bearing (11), and front bearing (11), and spacer (10) on tspacer (10) on t he rotorhe rotor..

5. Install rotor (8)

5. Install rotor (8) and the four screws into the front frame.and the four screws into the front frame.

6. Assemble front frame and rotor assembly (22) into rear frame and stator assembly (21). Make sure the wave washer is 6. Assemble front frame and rotor assembly (22) into rear frame and stator assembly (21). Make sure the wave washer is in the rear frame bearing bore. Align

in the rear frame bearing bore. Align the front and the front and rear frame marks made at disassembly for rear frame marks made at disassembly for correct assemblycorrect assembly. Install the. Install the four screws.

four screws.

(41)

7. Install the key, fan (5), pulley (4), washer and pulley nut. Tighten t

7. Install the key, fan (5), pulley (4), washer and pulley nut. Tighten t he nut to a torque of:he nut to a torque of: 3E7295, 9X0341 ... 70 ± 5 Nm (50 ± 4 lb ft) 3E7295, 9X0341 ... 70 ± 5 Nm (50 ± 4 lb ft) 8C5535, 7T2876, 2Y4212, 2Y8310 ... 35 ± 10 Nm (25 ± 7 lb ft) 8C5535, 7T2876, 2Y4212, 2Y8310 ... 35 ± 10 Nm (25 ± 7 lb ft) 9W3043 ... 50 ± 5 Nm (37 ± 4 lb ft). 9W3043 ... 50 ± 5 Nm (37 ± 4 lb ft). Ver imagen Ver imagen

8. Install the capacitor and connect capacitor lead (2) to

8. Install the capacitor and connect capacitor lead (2) to the back of the alternatorthe back of the alternator.. 9. Install regulator (1). 9. Install regulator (1). END BY: END BY: a. install alternator a. install alternator

(42)

Alternator Alternator Ver imagen Ver imagen Ver imagen Ver imagen 8C5535, 7T2876, 2Y4212

(43)

8C5535, 7T2876, 2Y4212

8C5535, 7T2876, 2Y4212 And 2Y8310 Alternators End ViewAnd 2Y8310 Alternators End View Ver imagen