torques motor 3066

(1)

CATERPIILAR'

sENR5s45-03

January

January 99

99 Sloc@ffiil@atnons

Sloc@ffiil@atnons

3064

3066

3066 Engines

Engines For Gaterp¡llar

For Gaterp¡llar

Built

Built Machines

Machines

6LK1-Up

6LK1-UpEngine)

Engine)

7JK1-Up

(2)

\-,

Systems

SystemsOperation

Operation

Systems

SystemsOPeration

OPeration

Schemat¡c

Schematic

taintenance

taintenance lndex

lndex Ta

Ta

Operation

Operationnd Maintenance

nd Maintenance

Operation

Operation nd

nd Maintenance

Maintenance

Operation

Operation nd

ndMaintenance

Maintenance

Engine

Engine nd

ndPump

PumpElectronic

Electronic ontrol

ontrol

System

Starting

Starting nd

ndCharging

Charging

Electrical

Electrical ystem

ystem

Electrical ystem;

Electrical ystem;Forest

ForestMachines

Machines

(6151-Up,

(6151-Up,JS1-Up)

JS1-Up)

Electrical

Electrical ystem

ystem 7721

7721 UP

UP

8GZ1-Up,

8GZ1-Up,BGl-Up)

BGl-Up)

Forest

Forest achines

achines6LS1

6LS1Up

Up 9JS1'Up)

9JS1'Up)

(721

(721 -Up,

-Up, GZ

GZ Up

Up BANI

BANI UP

UP

BBGl-Up)

sENR9242-12

Contents for

for

Service Manual

Service Manual SENR924O

SENR924O

Form No,

SENR23OO

SENR9241

SENR7733

SENR9242

SENR3130

SENR,2ETO

SENR5545

SENR5546

SENR5553

SENR9243

sENRil996

RENR1998

RENRlOOT

SENR9258

RENR1O58

RENR3725

SENRiIET4

sEBU6975

SEBU7O79

XEBU2571

320i8, 32OE L, 32OB

320i8, 32OE L, 32OB U,

U, 32OB

32OB LU EXGAVATORS

LU EXGAVATORS& 32OB

& 32OB LL

LL FOREST

FOREST

HACI{INES

Volume I

Volume I (Engine,

(Engine, Electrical,

Electrical, Operation and tlaintenance)

Operation and tlaintenance)

4NRl-Up,

4NRl-Up, SBRl-Up,

SBRl-Up,6GRl-Up'

6GRl-Up' lDSl.Up'

lDSl.Up' lESl.Up'

lESl.Up' 6LSl.Up'

6LSl.Up'

EESI-Up,

EESI-Up, gGSl-Up,

gGSl-Up, 9JSl-Up'

9JSl-Up' 4XWl-Up' SGWI.Up'

4XWl-Up' SGWI.Up' 3tRl-UP'

3tRl-UP'

4H Rl

4H Rl -Up,

-Up, 9KR{

9KR{ -Up'

-Up' I G

I G -U

-Up'p' 2rII21.Up, 7ZZ1

2rII21.Up, 7ZZ1 Up

Up 8G21.Up,

8G21.Up,

AEDI-Up,

AEDI-Up, BANI-Up,

BANI-Up, BBGI

BBGI Up

Up

Note¡

This orm ists he

This orm

ists he complete ervice

complete erviceManualfor

Manualforhi

hi product.

product.Th

Th tems

tems isted

isted an

an be

beordered eparately.

ordered eparately.

When

When tems

temsare updated

are updated r supplements

r supplementsdded,

dded,he

he will

willbe announced

be announced PREVIEW nd should

PREVIEW nd should e ordered

e ordered s they

s they

vailable.

vailable.Refer

Refero the Service

o the ServiceManual

ManualContents

Contents icrofiche,

icrofiche, EG1139F,

EG1139F,or

or current

current ontents

ontents nd

nd or

or

numbers

numbers f his

f hismanual.

manual.

Scction

Title

Binder

Binder abel

abel

Safety

Service

ServiceManual

ManualContents

Torq .re pecif

Torq .re pecifcations

cations

Engine

Engine Index Tab

Index Tab

Ergine

ErgineSpecifications

Specifications

3066

3066Engine

Engine

Systems

SystemsOperations,

Operations,esting

esting nd

ndAdjusting 3066

Adjusting 3066Engine

Engine

Disassembly

Disassemblynd

ndAssembly

Assembly

3066

3066Engine

Engine

Disassembly

Disassemblynd

ndAssembly

Assembly upplement

upplement

3066

3066Engine

Engine

Elecfical

Elecfical S¡rsterns

S¡rsterns & Ope¡atoÉs

& Ope¡atoÉs Station

Station Index

Index Tab

Tab

Note:

This

Thismanualcontains

manualcontains ngine, lectrical& aintenance

ngine, lectrical& aintenancenformation.

nformation.or

orSystems

Systemsnformation,

nformation,ee

ee

Contents ag

ag RENR2982.

RENR2982.

03/09/00

(3)

10056692

lmportantSafety nformation

Most ccidents nvolveroduct peration,aintenance epair recausec ;'. -'=-.

observeasic afetyules precautions.accident often e avoided y re::a'

=::'ertially

hazardousituationsefore n accident ccurs. personmustbe alert o pote-: -=-=-::

personhould

necessaryraining,kills nd ools performhese

:-: :'-.-'y

lmproperoperation,ubrication,maintenance r repairof this productcan be dangerous nd

could result n injuryor death.

Do not operate perform ny lubrication,maintenance r repair this product unt,iyo have

readand understood he operation,ubrication,maintenance nd repair nformation

Safety recautions nd warnings re provided this manualand on the procjlc: ':-=:: warnings heeded, odily njury r death ouldoccur o or to othe'pe's:-:

hazards re dentified y the "Safety lertSymbol" followed "Signa ",:': WARNING" shownbelow.

-,

meaningf thissafety lert ymbols ollows:

Attention!BecomeAlert! YourSafety s Involved.

message appears nder hewarning xplains hazard nd can

ictorially resented.

Operations causeproductdamage dentified "NOTICE" s tnispublication.

Caterpillar annot anticipateeverypossiblecircumstance ha might involve PGri: *a

The warnings n this publication

on th productare, herefore, ot all indusite.

procedure,work methodor operating echnique hat is not specifically ecomÍHléc

Caterpillar s used yo must satisfy yourself hat it is safe for yo an for others-Yc

also ensure hat the productwill not be damagedor be made unsafeby th oPerabor

maintenance repairproceduresha yo choose.

- ' : ^ l n^zerd. a tool, should - orication, - t h ^ + ,: l=S - _^^{^.^ = _ J g t u l v -: T\OS\ J Y T ,

The nformation,pecifications, llustrations publication on he:as s - -':'

availablet the ime hat hepublication wntten. specifications:':-=:

measurements,

djustments,

llustrations, othertems

change t anr':-: -:::

affect service

given

productObtain complete mos: -":--

--:--yclu orarr arry )ob. Caterpllar dealers have the most current information avai a3: =:

(4)

Tableof Contents

i' .,'

(5)

SpecifcationsSection

Specifications ection

EngineDesign

SMCSCode: 1201

3064Engine

lllustration

Cylinderand valve ocation

(A Exhaust alves. B) lnlet valves.

900523889 Bore...,... ...102 4.02 nch) Stroke (5.12 nch) Displacement... ...4.3 (260 Cylinderrrangement... .. n-line Valves cylinder .,,,,...2 Firing rder ...1- -4-2 Compressionatio ...)...17.1

Fuelnjection

timing

degreeséforeopcenter

Note:Refer o the Engine nforfnation late or the performancepecificationumber.Refer o the TMI (TechnicalMarketing nformation) refer o the FuelSettingan Related nformationMicroficheor the correct imlngspecifications,

Minimumpm.,...,...

The crankshaft otations vrewed rom he flvwheelr end of the engine.Crankshaft '..*'-' rotation ....Counterclockwise

Note: he ront nc c' :-: ;-lywheel o' : :-froñ the ywhee - : --cylinders ron: , -:='

3066Engine

r01020901 cosite - ¡ ^ ^ { + t - > u v u t L I / ^ , , i ^ , ^ , ^ / - ¡ : : c v t ú v v r u lllustration

Cylinderan valve ocation

(A Exhaustvalves. B) lnletvalves )',t295223

Stroke

ñ i c n l a n o m a n t Cylinder rrangement Valves cylinder Firing rder Compressionat¡o Fuel njection timing .... c:;-=== :--'= topcenter Note:Refer o Engine -'-^'-.' or the performancepecificatro' ==':'to

(Technical arketingnfo'-a::- '-'-'to FuelSetting Relatec '-^'-z' ':rofiche

correctiming pec':e.

Minimumom... ..900 20 The crankshaftotations ' :".:: flywheel end of the engine.Cranks-=:

rotation - - -- erclockwise Note:The frontend of the e-; = . , ::osite of

lywheel nd enE'= - -' s de of engine nd ight ide ':-: :-,': are iewed from he lywheel nd of tl'e:-: No. 1 cylinder rontcylinder

nch)

a:-.390in')

In-line

. ...2

: 3-6-2-4

.. 17

(6)

lllustration 9oo53o3o7

Fuel njectionines

Tighten he uel njectlon nuts

followingorque. ...25 b

\01029754

SMCSCode: 1251,1290

lllustratlon soo53o354

Bo:s or uel njection

grten he bolts uel njectionine o the 'o,owingtorque...20 25 N'm 1B b t)

rvery alveholder

Tighten he delivery alveholder o the

followingorque.. 44 N m o 3 b ft) Bolt or lockplate

Tighten bolt or the ockplate o the

followingorque... to 5 N m 44 lb in) Bolt or fuel

Tighten he bolt or the uel ine o the ollowing torque. 10 o 13 N'm 0 ldler ubspring

Tighten he dlersubspring o the ollowing

torque. 12 b t)

l r l l a r c r h q n r i n n

Tighten he dlersubspringo the ollowing torque. ... 6 20 N'm 121o15 b t) Tighten he o the followlng

torque. 3 t 5 N'm 44ló

i01029643

SMCS Code:1254

lllustration

Seal

Fuel njection ozzle

g0O53O2B0 i01029707

Fuel njection ines

SMCSCode:1252

-t--//

rsut

/4'

Fuel niectionPump

_{Fuel njectionNozzles}

Retaineror uel njection ozzle

Tighten heretaining olt o the ollowing torque. ..,...

(7)

Specifications ection t01024279

ValveMechanism

SMCSCode:1102

3>#-o--P

n\-P

\g

lllustration

Body or fuel njection ozzle Shims

900530283

Increasinghims O.1O (.OOanch) hanges injection ressureby approximately 37 kP

(2OO si).Shims avatlablen ninesizes O.'10 (,OOanch) o 0.58 (.023 nch).

Pressure pring (7 Pressure

(B Gasket

(10) Tip or njection ozzle

(11) Retaining or uel njection ozzle Tighten ollowing torque. ...34 albfI) lllustration / I \ Q n r i n n I a n n i h r r n r l a r t e c . ' - ^ ' ^ :_{l v t l} r v v l l ü 5 1 r u r u s Free engthafter'es Maximum s3'-: Valvestem seal Diameter valves:e-lnlet alve tem, Exhaust alveste-900526366 o 5 (2.22inch) 2 degrees 7.955 : 3132 nch) 7 940 :3126inch)

stem.,,;...

^ - r , 3 . 1 1 0inch)

Minimum llowable ='=' ='^aust alve stem... (.3091nch) Clearance ntake alve

guide..0.055 0.085 - --- ,¡ 0033 nch) Clearance exhausi .= :'=- valve

guide 0.070 0.105 - - -: : 0041 nch) Maximum llowablelee'a-:= :.;ide or nlet

valve 0059 nch)

(173,n"n',

Heighto top va.: -l tO.30 : .012 nch)

(8)

SpecifcationsSection lvlax allowable learance guide

ex^a.rstalve... 0.200 0079 nch) Ce diameter valveguide

:e diameter guide or nlet

.a.: .. .13.025 13.035 m (.5128 .5132nch) l-.s diameter guide exhaust

.z .= . 13.025 13.035 m (.5128 .5132nch) diameter f guide or new nlet

.... 8.010 o 8.035 .3154o.3163 nch) ñiameter f ouide exhaust

: = 8.010 o 8.025 (.3154o 3159 nch) ^.'', _{inside iameter ouide or nlet}

A ñ O m m i n n h \

. . . . u . v w l l l r l l l l ¡ v ¡ 1 , /

'.'i' _{inside iameter ouide or exhaust}

8.12 rm .320nch)

- o c c n f l i n

c thicknessor rnlet nd exhaust

.: .:-i 2 13 mm (,084 nch) ',' - ---n allowablealve ip hicknessor inlet :-: :xlaust valves ..1.20 (.047 nch)

¡ = oÍ valve ace...,. 30 degrees

tr¡usira: - 900526884

l=c:^ of bore n head orvalveseat

-se': , .9,5 0.1 (.374 ..004 nch) C^a':fer inlet alve... ...40 egrees Note: depthof the chamfer f the nlet alve s 2.38= C 10 mm (.094 .004 nch).

(10) C^amfer f exhaust alve ..45 degrees Note:Tn depth of the chamferof the exhaust alve

t 0.'10 (.079 .004 nch).

(11)Valve eatbore or n|et..46.000 46.025 (1.8110o 1 8120 nch) ('12)Valveseat bore or exhaust 39.000 o 39.025 (1.5354 1.5364nch) lllustration 900527479 (13)W¡dth f valve eat... 1 ¡ 0.25 (.055 .010 nch) Note:The maximum ermissible idthof the valve seat 1.BO m (.071 nch).

(14) Valve eatangle 30 degrees (15) Dimensionrom op of closedvalve face of

n o t ñ

Exhaustalve... ...0.50 0.25 (.020 .010 nch) Inlet a|ve....0.400.25 (.016 .010 nch) Note: maximum ermissibleepth s 1.10 (.043 nch).

lllustration 0

(16) Pushrod

(9)

Specifications ection

a dial ndicator order o check

pushrodsor runout.Replace pushrod f the runout xceeds he ollowing alue. ....

(.016 nch)

t01023644

lllustration 2 900526256

Align he oilholes n roc<?'='^ : -shing with he holesn he'c:-.' .'-',vhen rocker bushing ¿:=: 900526252 ^"'-tl J : / -lllustration 3

Positionhe rocker haftbrac.e = bolts.

Long bolt

Tighten bolt torque.

Shortbolt

Tighten shortbolt o :^e':

torque.

..,.15

(6 Rocker haftbracket

900526257 ñ ^ r r n l r n ^ tBlbft) 1 1 + A l h f t \

ValveRocker

SMCSCode: 1123 lllustration 1 Rocker rm bushing

Bore n rockerarm bushing or

shaft... ...0.011 20.094 m (.7878o .791 inch) (2 Rockerar shaft Diameter f rocker rm shaft... 19.966 19.984 7861 o .7868 nch) Clearance rockerarm bushing

shaft.,...0.027o 0.128 (.0011 .0050nch) Replace rockerarm bushing f repair imit of 0.15 (.006 nch) been eached.Replace th rockerar bushingand the rockerarm shaft

(10)

ValveMechanism over

SMCSCode:1107 l ¡ l u s l r a : :

-,a,::over

lllustratlon Valve as adjustment 900526261

Tur^ ^: crankshaft ntil he timingmarkon the c'e'-=- oulley aligned ith pointer

:=ar houslng order o adjust he valve :::^ the No, 1 inlet alveand the o e/-. .:- .Ave nushrods_{- - - ^ . ^ ^ t , ^ .} be in tension

^ . ^ ^

exhaustalve ash ...0.25 (.010 nch)

t01023202

900525829

the valve covernuts o the followinq 3to5Nm(26to44 lbin)

CylinderHead

SMCSCode: 1100

lllustrat¡on 6

Cylinder

a straightedge d feelergauge o check the cylinder ead orwarpage,

ol"l' _:"n :u'l n":33¿%li'?.'d#,?

Resurfacehe cylinder ead f the warpage exceeds he ollowing mount ....0.20 m

(.008 nch) Gasket hickness f cylinder

head...1.700.10 (.070 .004 nch) Thickness head...95.000,10

(3.740 .004 nch) Minimumhickness f cvlinder ead .94.70

(3.728nch) Note: repair imitof the contact urface f the gasket repair imit cylinder lock surfaces 0.20 (.008 nch).

lllustration 7

Numerical equenceof bolts or 3064 Eng¡ne

141025762

944527524

aBttagr

(11)

lllustration 8

Numerical equenceof bolts or 3066 Engine

900527527

cleanengrne il on the hreads f the cylinder headbolts. nstallhe bolts tighten he bolts the appropriate umerical equenceo the following torque. ...1185 N'm 4lb ft) i01030322

Turbocharger

SMCSGode:1052

lllustration20 Turbine haft

Place dial ndlcato'o-shaft.Move he comPress:' axialdirection orderto play.... .057 o 0.103 Note:The urbochargerr-s: :: the urbocharqer :-::' the end play s beyond

900530560 :' :ne urbine n ^ t ^ , , E ñ ^ P r a y . L r r u .0041 nch) . = .embJed nd -.:':learances - : : ^ S ,

,ri

^-Y

900530558 (4 lllustration Compressorwheel Turbinewheel Turbine ousing Compressor ousing Cartridge ousing

Note: Mark the orieniation f the compressor housing, he cartridge ousing nd the turbine housing efore isassembly.

lllustration 1

(7 Lock plates

Position plates

followingorque. the bolts

(12)

Specif cations Section i01 29608

ExhaustManifold

SMCSCode: 1059 l' s'.'a::^ 22 r- -: -:-srng (3 an Cartridge ousing 900530562

:-rbinehousing with he cartridge

-s:'a:3,^ 23 900530564

^ ; - n ,

5P-3931Anti-Seizeompoundo the :--.¿:s of the clamp.Tighten clamp

:,',.g torque. t 1 N'm

Tac : a-: ightly round he circumference. Tig^::- : amp o the ollowing

torc-? 1 N'm lb n)

Nuts or urbocharger

Tighten he nuts or he urbochargero the foilowingorque.

Studs or urbocharger

Tightenhe studs or he urbocharger followlngorque. 12 N'm Studs or exhaustmanifold

Tighten studs he exhaustmanifold followingorque. 12.5

Nuts or exhaustmanifold

Tighten nuts or heexhaustmanifold

followingorque. b ft)

ü!-'*"

900530254 lllustration24

(13)

Camshaft

SMCSCode: 1210

í^f\, )

\ \ \ \ l v '

f) ,v)

lllustrat¡on25

Camshaft

Maximum ermissibleemperaturef the gear for nstallationn thecamshaft 315'C(600'F) Note:Do not use a torch.

Diameters f camshaftournals Table Number of Journal for 3064 Engine Number of Journal i for 3066 Engine Standard Diameter 53.94 to 53.96mm (2.123 2.124 nch) 900527937 53.90mm (2.122nch) lllustration26 Note: Camshaftobe ift Specified amshaft Exhaustobe... Inlet obe

Serviceimit or obe ift :'- = Serviceimit or obe ift o' Note:Replacehe cams'¿:

obe ift s reached. Camshaft heigi:: Basecircle 1. Measure he camshafi Measurehe basecircie Subtract basecirc :-=-from he eight s'---difference actua ca-:-:

900527952 2891 nch) ^-(2633inch) .6.844 (.2695nch) 6.189 (.2437 nch) ::-. ce limit or '--^:inStep2 Step1. The lift 52.94 to 52.96 (2.084 2.085 nch)

(1 Th serviceimit s the maximumimension the serv¡ce limit s the minimum imensionha specifiedor part.

Qéptacé thé part i{ the se.vice limit is

reached-Thrust late

Tighten bolt o the ollowing

torque.

b

52.90 (2.083 nch) ,\T,i

(14)

Standard

Diameter Repair Limit(1)

Clearance between camshaft journalsan

bushings

(1 The reoairimit s the maximum imension r the repair im¡t s the minimumdimension hat is specified or part. Repair he part f the repair imit s reached.

oo,l3J¡0,3

_,0.15

.do7,""n1

(.006nch)

lLluSl'álrOn 900528061

Note: a dial ndicator nd blocks n order o :::='- runout f the camshaft. one half

r indicator eading the runout. - - ^ h ^ { +

- = 5 r t d l t

','rx.numpermissibleunout

:a-shaft ... .0 020 (.0008nch) ghten he camshaft runouts ess

cwingamount. 0 050 (.0020nch) the camshaft runouts more han :,,,,lng mount. 0.050 (.0020 nch)

lllustral,cr

¡ R , i : - c n : f i l _ r a a r i n n

900528067

Meas-'e camshaftearing a dial ndicator.

Suc:rac: diameter

camshaftournal

nrne' oive l-rearino learances.Refer o Table

lllustration

Install he dial gear play

900529304

indicatorn order o determine p|ay....0..10o 0.25 (004 o.O10nch) Replace hrustplate f the end playexceeds ollowingmount,...0.30 (.0'12nch) Thrust late hickness..,....4.85 (.191 nch)

-]l_,o

lllustration30 900529307 (10) Tappet orediameter Tappet diameter...22.000 o 22.021 (.8661 .8670 nch) Maximumappet diameter...22.055 (.8683nch) i

(-\r

(15)

Clearance f tappet r'{: bore...0.035 o 0.086 (.00.14o .0034 nch) Note:Replace he tappet the clearance s

exceeoeo. i01030986

Engine

PressureRelief

Valve

SMCSCode: 1315 NOTICE

Beforeoperation,he pump n!s: :: :ubricated th cleanengineoil and the pump -,si turn reely handor damage partscan 5e :-= result. Note: heminimum ccec:a3 - :-:ss!re idle s 1OO P psi).

Driven assembly Drivegearassembly

/ " \ f . \ ¡ l ^ r r m n ^ a . r

ldlergearassembly

backlash etweer -= - : -^.: gear

t he i ci lerocer s the :,,,

amount. - --:oO190mm - - ::. I 0075 nch) Note:Replace gears :-= :: -. :s^ exceeds 0.35 (.014 nch)

Spindle

Note: he pumpgeer ,: gear assembly re not servicea: ' . . 3imo gear removed.

lllustration 3

pumpgear

Note:Do no sea torch,

900530644 lllustration31 Oi pressure eliefvalve 900530799 1r

!..

.: 14

Remove he oil pressure eliefvalve from the cylinder lock.Check he valveand the valveseat

abnormal ontactpatterns.nspect he spring for weakness r damage.Replace he oil pressure reliefvalve, f necessary.

Relief alve pening ressure...343 20 kPa psi)

01 30415

Engine Pump

SMCS ode: 30

(16)

SpecifcationsSection Heat he oil pump gear to 180' to 220'C

(356" o 428"F) nd support he end of the drive gear snaft order o installhe oil pump gear. Press he oil pumpgearuntil he oil pumpgear f ushwith end of the shaft.

llirs:'at¡on 34

r e i n ¡ f n r n i l n r_{:, -.} _{rJmp gear}

900530697

'.ieasurethe difference engthof the assembry pumpgearand hedepth

:^e o,rpumphousing.

I earance 0.020 o -0.034 0008 00'13 nch) Note:Replacehe oil pump gearassembly

crea'a.ceexceeds he serviceimit -0.150 CC59 ch).

Meas-'e he clearance etweenhe oil pump gears anc :^e orlpumphousing feeler auge.

t - ^ - . ^ ^ ^ ^

0.050o 0.098

(.0020 .0039nch)

Note: Rep\aoe the oil pump gear assembly th

clea'a^ce exceeds the serv¡ce limit -0.150

0C59 nch).

Measure nsidediameters f the bores the shafts the cover and the oll pump housing Measurehe boresof the shafts. The clearance etween hegearshafts nd

pumphousing cover.... .04 o 0.07 002 o .003 nch) Note:Replace he oil pumpgearassembly,

cover, r the oil pump housing the clearance exceeds he serviceimitof 0.15 (.006 nch). Note:Replace he drivegearand drivengear assemory.

lllustration36

dlergearbushing Inside iameter idler

900530704

bushing 25.000 o 25.021 (.9843 .9851 nch) Maximum iameter f idlergearbushing

pump... ...25.059 (.9866nch) Splndle Drameter f spindle 24.939 o 24.960 (.9818 .9827 nch) lllustration35 Cover 900530702

(17)

SpecificationsSection

Engine Pressure

SMCS Code:1924 Table Engine gi P¡sss¡r¡g(t) Oi Pressuret 1500 om

Minimum iameter f spindle or

pump...,... .,...24.901 (.9804nch) 01 31038 Openingpressure bypass = =

Engine

SMCSCode:1302

l t 98 kPat psi) i01030410 19 o 392 kPa (2 to 57 psi)

Oi Pressure iflls{e) 98 kPa (1 psi) (l The oil emperature us be 60'to 70"C(140'to 158"F) (2 Engine dle s 900 r 20 rpm.

i01030990

Engine BypassValve

SMCS Code: .1306

90053080

Note: oil bypassvalve s mounted nside along he railof the oil pan.

('1)Valve eat

Check he valveand the valve seat or abnormal contactpatterns.

Spring

Inspect he spring or weakness r damage. Free engthof spring 83.5 (3.29 nch)

lllustration38 / r \ a r ; l ^ ^ ^ _r. _\Jil h ^ t + ^ Pd uL)rJ Tighten he oil bc .. -torque. drainplug Tighten 900530566 foliowing 4 lb ft) 01 33378

il'

ii,

WaterTemperatureegulator

SMCSCode: 1355

8010 WaterTemperature

Regulator

water emperature :':'-: o open thefollowingtempelatule - -, (160'+ 4'F)

valve iftsmore -:r) at the followingemperature, 85"C 185"F)

8020 WaterTemperature

Regulator

water emperature a::- :':": :c open the ollowingemperature. 32"C 180'F)

valve iftsmore han 10 at the following emperature 36'C(204'F)

(18)

SpecifcationsSection i 0 1 0 3 1

WaterPump

SMCSCode: 1361 lllLs:'at¡on -oeller 900530877

'aces _{mpeller nd he waterpumpshaft} -sn.

ange

-i'e distancerom he of the mpellero the .',are' housings the ollowing

a'nount.. 21.00 o 21.70 (.826 .854 nch)

Th press it between he waterpump shaftan th rmpeller ollowing

amount. 0.032 o 0.065 (.0013 .0026 nch)

tO1a2B288

lllustrat¡on g00530BZB

V/a:e'pumpshaft

T^ cress it between he waterpump shaft nd ange is the ollowing

an:oint. 0.035 o 0.065 (.0014 .0026nch)

CylinderBlock

SMCSGode: .1201 lllustrat¡on Cylinder lock 900529444

Measurehe amount f the warpage f the cylinder iockwith straightedge eeler gauge.Maximum llowable

clearance ...,. (.002 nch) Repairimit... ...0.20 (.008 nch) Resurfacehe op of the block f the repair imit s reached.

lllustration

Cylinder leeve

(19)

Measure nsidediameter f thecylinder leeve that parallel the crankshaft. easure he insidedrameter f the cylinder leeve s in a perpendicularositiono the crankshaft. easure

op, he middleand the bottom f the cylinder sleeve.Refer o Table4 for tolerances f the cylinder leeves. Table Inside Diameter Out of Round 102.010 102.045 4.0161mm 4.0236102.200 inch) 102.700 mm (4.0433 inch) lllustration43 Cylinder leeve Serviceimit f cyi;nc=' Replace cylinder lee.=: limit 900529534 . 102.700mm 0433 nch) - ¡ + h ^ ^ ^ " , , i ^ ^ - : : U t l l U J ú l V I U V 4.0175 inch) 0.010 _N/A (.0004 nch)

Taper _{(.0006 nch)}0.015 N/A N/A

(1 Th repair imit s the maximum imension the repair imit s th m¡nimum imension hat is specified or part. Repair part f the repair imit s reached.

(2 The service ¡m¡t s the maximumdimension the service limit s the minimumdimension hat ¡s specified or part. Replace he part if the service imit s reached.

Bore he cylinder o the specified versize

dimension nsidedtametereaches repair limitbut the insidediameter not reach he service imit.Refer o Table5.

Hone he sleeve +0.25 inch) +0.50 (+.020 nch)oversize. one he sleeve o a accuracywithin0.010 o 0.045 (.0004 .0018 nch).

Determinehe oversize imension s necessary order o cleanup the cylinder

unevenwear.

Replace cylinder leeves n excess service imit.

Note:Refinish ll sleeves o the sameoversize dimensron. se ridge reamer n order

ridge the cylinder f the sleeve s i good condition. one he cvlinder ore.

Table lllustration44 Cylinder leeves following rocec-': cylinder leeves. 1. Set a boringmacn Align boringmacr,^e

bottomof the cylinder Bore he sleeveuntil - (.020 nch).

Remove remainder not o damage cyllnc:' Install sleeve. lig^

the cylinder lock. The bore of the cylinder

102.000 102.035 N/A

-\

,^¡: -\//

--'l -<t

ba

?*

--*$z

| : ,

'iil

1l

900529962 l:- .f,repalr ne = n d e r b l o c k . :enter .re lessworn

=== 0.50

==.e, careful

==. with he op

Tolerances of Cylinder Sleeves

i - - _ ! - _

Standardtandard n^--¡- _Repair c^n,¡^^_Service

A""lirory

Limit{l)

Limit€)

OversizeBore CylinderBore Size

250mm0100nch)J3273:5ilili:339?liil

0.500 (.0197 nch) 102.510_{102.545mm (4.0372 nch)}(4.0358nch)

(20)

'-"'":l"i

."zuü8ro

_{*o o 68 m}

(3.5441to .5460nch) diameter f the mainbearing

...90.150 (3.5492nch) of deck centerline f crankshaft

307.00 0.05 .002 nch) reight rom he centerline crankshaft

306.70 (12.075nch)

i01023233

Pu sealanton the contactsurfacebetween he slinger nd the crankshaft. cleanengineoil on the surface f therearsealassembly

Distancerom earsealassembly crankshaft (.24 nch) r01022388

ConnectingRod Bearing

Journal

SMCSCode: 1219;1225

Connecting Rod Bearing Journal

Original ize ournal(l) _{(2.3600 o 2.3608 nch)}59.945 o 59.965mm

Undersizeournal 0.25 (.010 nch) (2.3502 2.3510 nch)59.695 o 59.715 Undersizeournal 0.50 (.020 nch) (2.3404 2.3411 nch)59.445 o 59.465mm Undersizeournal 0.75 (.030 nch) (2.3305o 2.3313 nch)59.195o 59.215

(1 Regrind he connecting od ournals o the next undersize dimensionf the repair ¡mit f 59.980mm (2.3614nch) s exceeded.

The clearance etween new bearing d a journals the ollowingalue... .035 0.100

0014 .0039 nch) An undersized earing s required clearance betweenhe connecting ournal nd he bearing

excessof the service imit 0 200 mm (.0079nch). f thecrankshafts wornexcessively, if the crankshafts uneven, n undersized earing is required,f an undersized earing s required, grind crankshafto a dimensionisted n Table Note: allowableoleranceor rod bearing journals hat are out of round s 0.010

(.0004 nch). maximum epair imit s 0.030 (.0012nch). epairimit s exceeded,egrind the bearingournalso the specified imension.

< - ^ a / = : 2 ' Note r

CrankshaftSeals

SMCSCode:1160: 161 -Si'3i l' 45 = . - - - - ^ ^ l

=:='seaf ssembly

Nóter -: .oar eeat assembly and the

900525904

slinger are

Note 'earsealassembly nd the slrnger re

^ , , ^ i + : - : = - i J d u t i l t ,

sealassembly

tearsealassembly hould flushwith :e' after nstallation.

l:-:act surfacebetween he sltnqer nd

. ^ A ^ f + _ t d l t

(21)

20 Specificationsection

MainBearing ournal

SMCSCode:1203

mainDea' : =: : n r ¡ l i n | o r h l n ¡ ¡ = u - = h o r r i n n h n J t c , - r - : i i n h i o n t h o r r z torque. - / ? \ ñ i e l i n d i n ¡ i n r f \ ^ ^ ^ , , , ^ + h ^ - ^ f v f u c l ¡ u t v I I r d indicator.uorra:: : crankshaftourna the mainbearing .'=. U g O l l l I U U I V O I O l U g v

Clearance etweer c'a'. :' 0earrng Note:Replacehe bear : s :' nextunde's'ze =2" -clearance xceeos Table fordirrei^s,ors' --:= Note: heallowableoie'a-:: ior¡rnals r t .:,-: (.0004nch) Themaxir--0012 nch). he epa' bearingournalso :^e s:-: Note: maxlmum en':: iournai -0.90

crankshaftf the cranxs?a-. thisspecification

\01022652

lllustration46

Crankshaft ainbearingournal

90052534i

Measurehe mainbearingournal. he diameter the crankshaft ainbearingournal given Table

Table

Main Bearing ournal

Original iz ournal(t) _{(3.541 o 3.542 nch)}89.95 o 89.97 mm

Undersizeournal

0.75 mm (.030 nch) (3.512 o 3.513 nch)89.20 to 89.22 mm

Begrind he main bearing ournals o the ne xt undersize dimension f the repair imit of 89.85 mm (3.537 nch) s exceeded.

lllustration48 Typicalexample

(4 Crankshaft

Support he crankshai = -Measure unout i-:-. journal. aximumuno-: Note:Replace he cranksna reoair imitof 0.050 900525380 blocks. Centef .0.020 0008 nch) exceeds lllustration47 Mainbearing ap

¿.:{ln:

= following t4lbft) a dial : ameter -'re - ^ a l '^aland main -:o011Bmm c 0047 nch) a a ¿ a a l ' ^ A ^ 1 + E U t A t l n Jt t d t L Deaflng -:-r Referto d t - . ' -.' cearing --- nm s0030mm - - - . - ^ ^ . ^ ^ , ; ^ A : - : : J ü u , r ú g I t t u . - - * ^ ñ ^ i ^ ^ I J ¡ U ¡ I , crankshaft aCe he : 'n DeyOnO Undersizeournal 0.25 (.010 nch) (3.531 3.532 nch)89.70 to 89.72 mm 89.45 o 89.47 mm (3.521 o 3.522 nch) 900525373

(22)

Note:The maximum epair imit s 0.300 (.01 nch).

Replace standardhrust lates f the end play exceeds standard learance. hreeoversize thrustplates available replacementsf the

playstillexceeds maximumimit.Generally, rear ournal ikely o be wornmore apidly han

ront ournal. necessary,eplace rear hrust plate.Refer Table for oversizehrustplates.

Table

Dimensions for Grinding of Crankshaft Oversize Thrust Plates

lllustration49

Width crankshaft bearing

900525383 Oversize Thrust Plate Oversize (front or rear) Oversize (front Tolerance or rear)

journal

...33.000

o 33.039

(1.2992 .3007nch)

+0.15mm 33.15 (+.006nch) (1.305 nch) (1.311nch) +0.039mm (+.0015 inch) +0.039mm +0.30mm (+.012nch) (1.31 nch) (1.317nch)33.30mm 33.45mm (+.0015_inch) +0.45mm 33.45 (+.018nch) (1.317nch) (1.323nch)33.60mm +0.039 (+.0015 inch)

Tighten reta¡ning of the crankshaft ulley ollowlngorque....,. N m (363 4 lb

tO1022446

900525387

Connecting

SMCSGode:1218

lllustration50

Put hemainbearing thrust lates n the block nstallhe crankshaft. clean engine il on the bolt hreadsTighten he bolts to the ollowingorque. 137 5 (101 4lbft) q00525099 9005254 lllustration 2

Matcning arks

marks reused

connectrng

lllustrahon

(7) lv'leas:rehe crankshaft olay.

0.'100o 0.264 0039 .0104nch)

ryfr

(23)

22

Specifications ection

Connecting bolts

Before ssembly, c ea- =- cil on the bolt hreads nd allsurla:=- *aKe contact betweenhe bolt co-- =-' caps. Tighten connec:'a'-= followlng torque. il:-: .--z6t4lbft) Measurehe bores '

er:-rods and record -:-. 1 n n a ^ t r n ne bores.

lllustration53 9005251

upper hole s 40 degreesabove he horizontal enterline.

The ower hole s 30 degreesbelow he horizontal enterline,

The end of the piston in bearing s 30 degrees below he ower hole.

illu$raüon 54

(2 Boreof pistonpi

bearing 34.020 o 34.045mm (1.3394 '1.3404inch) The clearancebetween he piston pin bearing

piston 0.023 o 0.054 (.0009 .0021 nch).

Note:A clearance or he pistonpi to the pistonpi bearing ver0.010 (.0004 nch) s excessive. Replace he piston pin or replace he bearing th clearance excessive. lllustration 55 Connecting feeler auge -::: play.... o 0 3: 9005251 play. , - : : o 0 1 4 n c h ) Note:Replacehe conne:. : a n ñ n t q \ / exceeds .50 \

V/

Cl:---'

'l I lllustration 56 Piston Markings n 900525201

Assemble piston cc--=:' ':ds. Ensure that he markings n thep,s::- :-: the marks on heconnecting ate.---= =:'ne ide.

(24)

Specifcations ection

Plstonprojection ..0.55 1.15 (.0221o.045nch) \a1421241

Piston

Rings

SMCSCode: 1214,1215 lllustrat¡on57 90o525206

Install piston ssembly ith hemarks the connectingod oward he camshaft

lllustration

(9 Piston

900525250

following rocedure measure he helghtof eachpistonabove cylinder lock. clearances n theacceptableange, nspect

components wear damage.

Determine centerposition f the piston with dial ndicator ssemblY.

2- inetalt he dia.t indicator assembly on the top of

the block. needle of the d¡al indicator

zero.

3. Measureprojection 9) at threeplaceson th top of th piston.Takean average th threemeasurementsn order o determine projection. ubtract he projection rom the installedhickness f the cylinder gasket n order o determine clearance etween

of the piston cylinder ead. Installedhickness f thecylinoer

gasket ..110 t .070 .004 nch)

Eachpiston markings hich stamped of the piston. markings used al¡gn plstonassembly camshaft of the cylinder lock,

Piston iameter

Table gives dimensions prstons standard, able9 alsogives dimensions pistons oversize.

Note:Measure pistondiameter long perpendicular piston bore.

900524461 lllustration59

(25)

Specifcations ection

Crankshaft

Note:Ensure hat he marks the iminggears alignment.

lllustration65 ldlergear 2)

900527864

Install dial ndicator nd rotate idlergear back forth order measure acklash. Replace he dlergear backlash xceeds service imit.Refer o Table

Table11

0.100 (.0039nch)

(1 Replace he idlergear f the service imit s exceeded

lllustration66 ldlergearbolt lllustration 7 / ? \ r ^ ^ i ! ^ : i ^ - ^ + ^ ' ^ . _{: : : .} _{_} \ / , / i l t > r L r g L j r d r r E r u r / Q \ l r i l a r n o e r c h a f \ v / , v ' v ' Replace bushing : :=- - idler bushing : -:-1 the service imit.Reter c '

i r ^ ^ ^ , , , ^ + A ^ f a o l o r a c ' r ^ a Q c j ; ' ' t r f l a r a a a r h r l ' ' . " . - - ' -r v -r u -r v u q -r J -' :',afWith ;^ten ,.r-:,.35N'm rb t) j00527912 - t , . , ^ ¡ n t F . n - = i v v E v t I L ¡ - - - { + ^ . / ^ ^ ^ ^ ^ : d t L E ^ u g v u ) 0r028537

Flywheel

SMCSCode: 1156 lr, ii ili

l'

lllustration68Flywheel Place he lywheeln a s-'-=:: indicator order o meas-'='-= f ywheel. Standardat assembly .. ', == 900529633 | t ^ ^ ^ , . 1 : ^ l '.iness ..0 15 mm / ñO A i n n h \ \ . v v v Í r v r r / 0.03 0.17 (.001 .007 nch) 0.05.to^0.20 _0.35mm

ártrtil?., ('br+ncn)

clearance _{o.oogo o.ogo}

?:'-Y":il95j mm.ooo4

_{s"-1'-o!:llls .ooit ncn¡}

and Snan

(26)

SpecifcationsSection Repairimit f flywheel...0.50 (,020 nch)

Note:Refrnish flywheelf the repair imit s exceeded

lllustration69 q00529634

Measure runout n lywheelace with dial ndicator. aximumace unout. . 0.15

(.006 nch) Repairimit face unout...0.50 (.020 nch) Note:Refinish flywheel repair imit s

exceeoeo.

permissibleemperature ringgear nstallatlonn the lywheel ithout sing

rorcn.,,..,.... . .. 150"C 302'F) Note:The ringgear pressed n the lywheel. Tighten lywheel olts o the ollowing

torque t t 4 lb Number f teeth lywheel gear...127

Apply pressure o each beltmidway between he pulleysn order inspect he belt ension. djust the bolt or healternatorf the ensions incorrect. Properan belt ensions approximately

following eflection. .12.0 (.50 nch) r01053076

BeltTensioner

SMCSCode: 1358 q005461 lllustration70 Bolt.

(27)

28 SpecifcationsSection i01031047

o,o.,r.,f

BeltTensioner

SMCSGode:1358

Alternator

SMCSCode: 1405 900530808 _{lllustration72} alternatorulre.' Tighten or te z'.'' followingorque. Polarity Rotation Speed or esting rPm)

Output oltage

Rated utPut..

900530887 :- ey l- to b =;ative round : :rer direction . 5000 rP .28.0 lllustration71

Bolt

Apply pressure o each belt midwaybetween he pulleys n order inspect belt ension. djust ifre Oott or th alternatorf the tension incorrect

Proper an belt ension approximately

(28)

SpecifcationsSection 31378

ElectricStartingMotor

SMCSCode: 1453 lllustration 3

Terminal

900530889

Tightenhe ermrnal uts o the ollowing

torque. ...11 1 N'm 9 tb n) The rotation s viewed rom he drive end of the electnc tartingmotor.Rotation f electric tarting motor...,... clockwise No loadconditions

Speed rpm)... 3300 pm minlmum Maximum urrent draw)

(29)

lndexSection

lndex

Alternator .-'.' 8 MainBearing

Beft ensioner...

27,28

Camshaft .'.'.' Connectingod ... ..."' Connecting Bearing ournal ...'.. Crankshafteals ... ..." Cylinder1ock... '...'."17 Cylinder ... ...'...'

Electric tarting otor... '."'.-....".29 Engine esign .'-...'.'.'...'.4

3064Engine '..'.'.".'...'....4 3066Engine '-.-.'."...'..'.'-4 Engine Bypass alve ..." .-...16 fngine ... engine Pressure ... fngine Pressure elief alve .-.'.'.'14 fngine PumP '.".""'...14 Exhaust anifold .'..'.'...11

Flywheel '.."..26 Fuel njectionines ".'...5 Fuel njection ozzles ."..."....'...'...'.. Fuel njection ...'.5