CATERPIILAR'
sENR5s45-03 January 99
Sloc@ffiil@atnons 3066 Engines For Gaterp¡llar 3064 Built Machines 6LK1-UpEngine) 7JK1-UpEngine)
sENR9242-12 EXGAVATORS& 32OB LL FOREST 320i8, 32OE L, 32OB U, 32OB LU EXGAVATORS& HACI{INES Contents for Volume I (Engine, Electrical, Operation and tlaintenance) Service Manual SENR924O 4NRl-Up, SBRl-Up, 6GRl-Up' lDSl.Up' lESl.Up' 6LSl.Up' EESI-Up, gGSl-Up, 9JSl-Up' 4XWl-Up' SGWI.Up' 3tRl-UP' 4H Rl -Up, 9KR{ -Up' I G -U p' 2rII21.Up, 7ZZ1 Up 8G21.Up, AEDI-Up, BANI-Up, BBGI Up Manualforhi product.Th tems isted an be ordered eparately. This orm ists he complete erviceManualforhi Note¡ dded,he willbe will beannounced PREVIEW nd should e ordered s they temsareupdated r supplements dded,he When temsare C ontents icrofiche, EG1139F,or current ontents nd or ServiceManualContents R efer o the ServiceManual vailable.Refero numbers f hismanual. hismanual. Scction
\-,
Title
Binder Binder abel Safety C ontents ServiceManualContents Torq .re pecifcations Engine Index Tab 3066Engine ErgineSpecifications Ergine Specifications 3066Engine SystemsOperations, SystemsOperations,esting nd Adjusting 3066Engine 3066Engine 3066Engine Assembly Disassemblynd DisassemblyndAssembly Engine 3066Engine 3066 upplement nd Assembly Disassembly ndAssembly Elecfical S¡rsterns & Ope¡atoÉs Station Index Tab Electronic ontrol nd PumpElectronic Engine ndPump SystemsOperation SystemsOperation System nd Charging Starting ndCharging SystemsOPeration SystemsOPeration Electrical ystem Schemat¡c ForestMachines Electrical ystem;ForestMachines Schematic (6151-Up,JS1-Up) J S1-Up) 7721 UP Electrical ystem Schematic 8GZ1-Up,BGl-Up) 8GZ1-Up,BGl-Up) taintenance lndex Ta Operation nd Maintenance Forest achines6LS1Up 9JS1'Up) Operation nd Maintenance (721 -Up, GZ Up BANI UP Operation nd Maintenance BBGl-Up)
Form No, SENR23OO SENR9241 SENR7733 SENR9242 SENR3130 SENR,2ETO SENR5545 SENR5546 SENR5553 SENR9243 sENRil996 RENR1998 RENRlOOT SENR9258 RENR1O58 RENR3725 SENRiIET4 sEBU6975 SEBU7O79 XEBU2571
nformation,ee ee nformation. orSystems Systemsnformation, Thismanualcontains Thismanualcontains ngine, lectrical& aintenancenformation.or Note: ag RENR2982. Contents
03/09/00
CATERPILIAR'
10056692
lmportantSafety nformation Most ccidents nvolve roduct peration,aintenance epair recausec ;'. -'=-. observeasic afetyules precautions.accident often e avoided y re::a' =::'ertially hazardousituationsefore n accident ccurs. personmustbe alert o pote-: -=-=-:: person hould :-: :'-.-'y necessaryraining,k ills nd ools performhese lmproperoperation,ubrication,m aintenance r repairof this productcan be dangerous nd could result n injuryor death. Do not operate perform ny lubrication,m aintenance r repair this product unt,i yo have readand understood he operation, ubrication,maintenance nd repair nformation Safety recautions nd warnings re provided this manualand on the procjlc: ':-=:: warnings h e e d e d , o d i l y n j u r y r d e a t h o u l do c c u r o or to othe'pe's:-: hazards re dentified y the "Safety lertSymbol" WARNING" shownbelow.
meaning f thissafety lert ymbols
followed
"Signa
",:':
ollows:
Attention!BecomeAlert! YourSafety s Involved. message
appears nder hewarning xplains
ictorially resented. Operations t n i sp u b l i c a t i o n .
cause productdamage
dentified
hazard nd can "NOTICE"
s
-':^l
Caterpillar annot anticipateevery possiblecircumstance ha might involve PGri: *a n^zerd. The warnings n this publication on th productare, herefore, ot all indusite. a tool, procedure,w ork 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 s h o u l d also ensure hat the product will not be damagedor be made unsafeby th oPerabor - orication, maintenance repair procedures ha yo choose. th^+ The nformation, pecifications, llustrations publication on he:as s - -':' availablet the ime hat he publication wntten. specifications:':-=:-::: ,: l=S llustrations, othertems change t anr':-: measurements, djustments, --:-^^{^.^ = _ Jgtul v productObtain complete mos: -":--=: given affect service -: yclu orarr arry )ob. Caterpllar dealers have the most current information avai a3:
current ublication
numbers vallable,
l onter-:s'.':':-:-= S e r v i c eM a n u a C
T\OS\
JYT,
-,
Tableof Contents
Tableof Contents
i' .,'
v.
SpecifcationsSection
Specifications ection r01020901
EngineDesign
N o t e : h e r o n t n c c ' :-: ;lywheel o' :-: :froñ the ywhee - : -ron:, -:=' c y l i n d e rs
cosite
:
¡^ ^{ +t > uv ut LI /^ ,,i^,^,^/-¡ : c vtúvvru
3066Engine
SMCSCode: 1201
3064Engine
900523889
lllustration Cylinderand valve ocation (A Exhaust alves. B) lnlet valves.
Bore...,.....
...102
(5.12 nch)
Stroke Displacement................
...4.3 (260
C y l i n d e rr r a n g e m e n t . . . . . . . . . . . . . . . . . Valves
4.02nch)
cylinder
Firing rder C o m p r e s s i o na t i o
Fuelnjection timing
.. n-line .,,,,.......2
.......1- -4-2 ...)......17.1
degreeséforeop center
Note:Refer o the Engine nforfnation late or the performance pecificationumber.R efer o the TMI (TechnicalM arketing nformation) refer o the FuelSettingan Related nformationMicroficheor the correct imlngspecifications, M i n i m u mp m . , . . . , . . . . . . The crankshaft otation s vrewed rom he flvwheelr '..*'-' end of the engine.Crankshaft ....Counterclockwise rotation
lllustration Cylinderan valve ocation (A Exhaustvalves. B) lnletvalves
nch)
Stroke
a:-.390in')
ñicnlanomant
In-line
Cylinder rrangement Valves
)',t295223
. .......2
cylinder
: 3-6-2-4
Firing rder
.. 17
Compression at¡o Fuel njection .... timing
c:;-=== :--'= topcenter
or the Engine -'-^'-.' Note:Refer o = = ' : ' t o p e r f o r m a n c ep e c i f i c a t r o ' '-'-'to (Technical arketingnfo'-a::':rofiche ' ^ ' z ' F u e lS e t t i n g R e l a t e c c o r r e c ti m i n g p e c ' : e . M i n i m u mo m . . . . . . . . . . . . . . . The crankshaftotations ' :".:: end of the engine.C ranks-=: rotation
..900 20 flywheel - - -- erclockwise
Note:The frontend of the e-; = . , ::osite of - -' s d e o f enE'= lywheel nd ight ide ':-: :-,': are iewed engine nd No. 1 from he l y w h e e l n d o f t l ' e : - : rontcylinder cylinder
SpecifcationsSection i01029707
Fuel njection ines
Tighten he delivery alveholder o the 44 N m f o l l o w i n go r q u e . . o3
b ft)
Bolt or lockplate
SMCSCode:1252
Tighten bolt or the ock plate o the 44 lb in) f o l l o w i n go r q u e . . . . . .. t o 5 N m Bolt or fuel Tighten he bolt or the uel ine o the ollowing 10 o 13 N'm 0 torque.
rsut -t-
-//
ldler ubspring
/4'
lllustration
Tighten he dlersubspring torque.
o the ollowing 12 b t)
lrllar crhqnrinn
9oo53o3o7
Tighten he dlersubspringo the ollowing . . . . . . . 6 2 0 N ' m 1 2 1 o1 5 b t ) torque.
F u e l n j e c t i o ni n e s Tighten he uel njectlon nuts f o l l o w i n go r q u e . .......25
Fuel niectionPump
b
Tighten he torque.
o the followlng 3 t 5 N'm
\01029754
Fuel njectionNozzles
SMCSCode: 1251,1290
44ló i01029643
SMCS Code:1254
lllustration
g0O53O2B0
Seal Fuel njection ozzle lllustratlon
soo53o354
Bo:s or uel njection grten he bolts uel njectionine o the ' o , o w i n gto r q u e . . . . . 2 0 2 5 N ' m 1B b t) rvery alveholder
Retaineror uel njection ozzle Tighten heretaining olt o the ollowing ..,...... torque.
Specifications ection
ValveMechanism
t01024279
SMCSC o d e : 1 1 0 2
3>#o--P n\-P
\g 900530283
lllustration
Body or fuel njection ozzle Shims I n c r e a s i n gh i m s O.1O (.OOan c h ) h a n g e s injection ressureby approximately 37 kP (2OO si).Shims avatlablen ninesizes (.023 nch). O . ' 1 0 (,OOan c h ) o 0 . 5 8 Pressure pring
900526366
lllustration / I \ Qnrinn I a n lnv it hl
Free engthafter' es s3'-: Maximum Valvestem seal
(B Gasket
H e i g h to t o p
(11) Retaining Tighten torque.
-l tO.30 : .012 nch)
va.:
Diameter valves:e-
njection ozzle or uel njection ozzle ollowing ......34
o5 (2.22inch) 2 degrees
lü51 rurus
(7 Pressure
(10) Tip or
(173,n"n',
r r nr rv lval r t e c . ' - ^ ' ^ :
albfI)
l n l e t a l v e tem,
7.955 : 3132 nch)
Exhaust alveste-
7 940 :3126inch) ^ - r , 3 . 1 1 0in c h )
s t e m. , , ; . . . . . . . . . . . . Minimum llowable stem........... Clearance ntake guide..0.055 0.085
='='
='^aust alve ( . 3 0 9 1n c h ) alve - --- ,¡ 0033 nch)
valve Clearance exhausi .= :'=- - -: : 0041 nch) guide 0.070 0.105 M a x i m u m l l o w a b l el e e ' a - : = : . ; i d e o r n l e t 0059 nch) valve
SpecifcationsSection lvlax allowable learance guide 0079 nch) e x ^ a . r s ta l v e . . . 0.200 Ce diameter valveguide :e diameter guide or nlet .a.: .. .13.025 13.035 m ( . 5 1 2 8 . 5 1 3 2n c h ) l-.s .z .= ....
( 1 1 ) V a l v e e a tb o r e o r n | e t . . 4 6 . 0 0 0 4 6 . 0 2 5 ( 1 . 8 1 1 0o 1 8 1 2 0 n c h ) ('12)Valveseat bore or exhaust
39.000 o 39.025 ( 1 . 5 3 5 4 1 . 5 3 6 4n c h )
diameter guide exhaust . 13.025 13.035 m (.5128 .5132nch) diameter f guide or new nlet . 3 1 5 4o . 3 1 6 3 n c h ) 8.010o8.035
ñiameter f ouide exhaust (.3154o 3159 nch) : = 8.010 o 8.025 ^.'', inside iameter ouide or nlet ....
'.'i'
A u . vñwO lm l lm rll
innh\
ll¡v¡1,/
inside iameter ouide orexhaust
8.12 rm .320nch)
-occ
( 1 3 )W¡dth f v a l v e e a t . . . . . . .
nf lin
c thicknessor rnlet nd exhaust .: .:-i 2 13mm(,084 nch) ',' - ---n allowable alve ip hicknessor inlet (.047 nch) ..1.20 :-: :xlaust valves ¡ = oÍvalveace.........,.
lllustration
30degrees
900527479
1 ¡ 0.25 (.055 .010 nch)
Note:The maximum ermissible idthof the valve s e a t 1.BO m ( . 0 7 1 n c h ) . (14) Valve eatangle
30 degrees
(15) Dimensionrom op of closedvalve face of notñ
E x h a u s ta l v e . . . . . Inlet a|ve....0.400.25
......0.50 0.25 (.020 .010 nch) (.016 .010 nch)
m a x i m u m e r m i s s i b l ee p t h s 1 . 1 0 Note: (.043 nch).
900526884
tr¡usira: -
l=c:^ of bore n head orvalveseat -se': , (.374 ..004 nch) .9,5 0.1 C^a':fer
inlet alve...
......40 egrees
Note: depthof the chamfer f the nlet alve s 2 . 3 8= C 1 0 m m ( . 0 9 4 . 0 0 4 n c h ) . (10) C^amfer f exhaust alve
..45 degrees
Note:Tn depth of the chamferof the exhaust alve t 0.'10 (.079 .004 nch).
lllustration 0
(16)Pushrod
gOA52749A
Specifications ection a dial ndicator order o check pushrods or runout.R eplace pushrod f the runout xceeds he ollowing alue. .... (.016 nch)
ValveRocker
t01023644
SMCSCode: 1123
900526256
lllustration 2
A l i g n h e o i l h o l e s n r o c < ? '= ' ^ : - s h i n g w i t h h e h o l e sn h e ' c : - . ' . ' - ' , v h e n rocker bushing ¿:=: ^"'-
tl
900526252
lllustration 1
Rocker rmbushing Bore n rockerarm bushing or . . . . . . .0 . 0 1 1 2 0 . 0 9 4 m shaft........... ( . 7 8 7 8o . 7 9 1 i n c h ) (2 Rockerar
shaft
Diameter f rocker rm shaft...
19.966 19.984 7861 o .7868 nch)
Clearance rockerarm bushing ( . 0 0 1 1 . 0 0 5 0n c h ) s h a f t . , .. . . . 0 . 0 2 7o 0 . 1 2 8 Replace rockerarm bushing f repair imit (.006 nch) of 0.15 been eached.R eplace th rockerar bushingand the rockerarm shaft
I?:::3': "tit
J:-/-
of he ocker rmbushinsasbeen
900526257
lllustration 3
Positionhe rocker haftbrac.e = bolts.
ñ^r rnlrn^
Long bolt Tighten torque.
bolt
tBlbft)
Shortbolt Tighten
torque.
shortbolt o :^e':
..,.15
(6 Rocker haftbracket
11 + A lh ft\
SpecifcationsSection 141025762
CylinderHead
SMCS Code: 1100
900526261
lllustratlon Valve as adjustment
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 / - . . : - . Av e n u s h r o d s be in tension - --^.^^t,^.
^.^^
e x h a u s ta l v e a s h . . .0 . 2 5
(.010 nch)
ValveMechanism over
t01023202
SMCSC o d e :1 1 0 7
944527524
lllustrat¡on 6
Cylinder a straightedge d feelergauge o check the cylinder ead or warpage,
ol"l' _:" n :u'l n":33¿%li'?.'d#,?
Resurfacehe cylinder ead f the warpage ....0.20 m exceeds he ollowing mount (.008 nch)
Gasket hickness f cylinder (.070 .004 nch) h e a d . . . . . . . . . . . . 1 . 700. 1 0 Thickness
h e a d . . . . . . . . . . . 9 5 . 000, 1 0 (3.740 .004 nch)
Minimumhickness f cvlinder ead .94.70 ( 3 . 7 2 8n c h ) repair imitof the contact urface f the Note: gasket repair imit cylinder lock ( . 0 0 8 nch). s u r f a c es 0 . 2 0
900525829
l¡luslra::-
,a,::over the valve cover nuts o the followinq 3to5Nm(26to44 lbin)
aBttagr 15. 11€-$
¡úFoZ 5(!-Q)1s
lllustration 7 Numerical equenceof bolts or 3064 Eng¡ne
.¡
SpecifcationsSection
¡o rC-Ot f9-O6 lllustration 8 Numerical equenceof bolts or 3066 Engine
tt¡
900527527
cleanengrne il on the hreads f the cylinder tighten he bolts headbolts. nstallhe bolts the appropriate umerical equenceo the following 4lb ft) . . . . . . . . 1 1 85 N ' m torque.
Turbocharger ,ri
i01030322
900530560
lllustration 20
Turbine haft :' :ne urbine n
Place dial ndlcato'oshaft.Move he comPress:' axialdirection orderto play.... .057o0.103
SMCSGode:1052
Note:The urbochargerr-s: :: :-::' the urbocharqer the end play s beyond
^ t ^ , , LE rñr ^u Pray.
.0041nch) . = .embJednd -.:':learances -:
:^S,
^-Y
lllustration
900530558
Compressorw heel Turbinewheel Turbine ousing (4 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 plates Position followingorque.
the bolts
Specif cations Section i01 29608
ExhaustManifold SMCSCode: 1059
l' s'.'a::^ 22 r- -: -:-srng (3 an Cartridge ousing
:-rbinehousing
900530562 ü!-'*"
with he cartridge lllustration24
900530254
Nuts or urbocharger Tighten he nuts or he urbochargero the foilowingorque. Studs or urbocharger Tighten he studs or he urbocharger 12 N'm followlngorque. Studs or exhaustm anifold
-s:'a:3,^ 23
900530564
^;-n,
5 P - 3 9 3 1A n t i - S e i z eo m p o u n do the :--.¿:s of the clamp.Tighten clamp t 1 N'm :,',.g torque. ightly round he circumference. Tac : a-: o the ollowing Tig^::- : amp lb n) 1 N'm torc-?
he exhaustm anifold Tighten studs 12.5 followingorque. Nuts or exhaustm anifold Tighten nuts or he exhaustm anifold b ft) followingorque.
Camshaft SMCSCode: 1210
í^f\, ) \\ \\l v'
f) ,v)
,\T,i
\iN
900527952
lllustration26
Note: 900527937
lllustrat¡on25
Camshaftobe ift Specified amshaft
Camshaft Maximum ermissibleemperaturef the gear for nstallationn the camshaft 315'C (600'F) Note:Do not use a torch. Diameters f camshaftournals
E x h a u s to b e . . . . . . Inlet obe Serviceimit or obe ift
2891 nch) ^-(2633inch) :'- =
Serviceimit or obe ift o'
Table
Number Number of Journal of Journal for 3064 i for 3066 Engine Engine
N o t e :R e p l a c eh e c a m s ' ¿ : obe ift s reached.
Standard Diameter 53.94 to 53.96mm 53.90mm (2.123 (2.122nch) 2.124 nch) 52.94 to 52.96 52.90 (2.083 nch) (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
Camshaft
.6.844 ( . 2 6 9 5n c h ) 6.189 (.2437 nch) ::-. ce limitor
heigi::
Basecircle 1. Measure he camshafi Measurehe basecircie '--^:inStep2 Subtract basecirc :-=Step1 . T h e s'--eight from he difference actuaca-:-: lift
Standard Diameter Clearance between camshaft journalsan bushings
Repair Limit(1)
oo,l3J¡0,3 .do7,""n1
,0.15 (.006nch)
(1 The reoair imit 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.
900528061
lLluSl'álrOn
Note: :::='-
a dial ndicator nd blocks n order o one half runout f the camshaft. indicator eading the runout.
r
--^h^{+ - = 5r tdlt
' , ' r x . n u mp e r m i s s i b l eu n o u t ... .0 0 2 0 :a-shaft
(.0008nch)
ghten he camshaft runout s ess (.0020nch) 0 050 c w i n ga m o u n t . the camshaft runout s more han (.0020 nch) 0.050 :,,,,lng mount.
900529304
lllustration
Install he dial indicatorn order o determine play gear p | a y . . . . 0 . . 1o0 0 . 2 5
( 0 0 4 o . O 1 0n c h )
hrustplate f the end playexceeds Replace o l l o w i n gm o u n t ,. . . . . . . . 0 . 3 0 ( . 0 ' 1 2n c h ) (.191nch) T h r u s t l a t e h i c k n e s s . . , . .4.. 8 5
i
(-\r
-]l_,o 900528067
lllustral,cr ¡R,
i:-cn:fi
l_raarinn
Meas-'e camshaftearing a dial ndicator. camshafto urnal Suc:rac: diameter nrne'
oive l-rearino learances.Refer o Table
900529307
lllustration30
(10) Tappet orediameter Tappet
diameter.....22.000 o 22.021 (.8661 .8670 nch)
M a x i m u ma p p e t
d i a m e t e r. . . . .2 2 . 0 5 5 (.8683nch)
Clearance f tappet b o r e . . .0 . 0 3 5 o 0 . 0 8 6
r'{: ( . 0 0 . 1 4o . 0 0 3 4 n c h )
Note:Replace he tappet the clearance s exceeoeo. i01030986
Engine Valve
PressureRelief
NOTICE Beforeoperation,he pump n!s: :: :ubricated th cleanengineoil and the pump -,si turn reely handor damage partscan 5e :-= result. N o t e : h em i n i m u m c c e c : a 3 - : - : s s ! r e psi). idle s 1OO P Driven
assembly
Drivegear assembly
SMCSCode: 1315 /"\
f.\¡l ^r rmn
^a.r
ldlergearassembly backlash etweer -= - : -^.: gear
t h e i c i l e ro c e r s t h e
amount.
:,,,
- --:oO190mm - - ::. I 0075 nch)
N o t e :R e p l a c e g e a r s : - = : : - . : s ^ e x c e e d s (.014 nch) 0.35 Spindle lllustration31 Oi pressure eliefvalve
900530799
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.
N o t e : h e p u m pg e e r assembly re not servicea: ' removed.
,: gear . . 3imo gear
R e l i e f a l v e p e n i n g r e s s u r e. . . . . 3 4 3 2 0 k P a psi)
Engine
Pump
01 30415
SMCS ode: 30
1r
!..
lllustration 3
.:
pumpgear
14
Note:Do no sea torch, lllustration32
900530573
900530644
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 install he oil pump gear. Press he oil pump gear until he oil pump gear f ushwith end of the shaft.
lllustration35
900530702
Cover Measure nsidediameters f the bores the shafts the cover and the oll pump housing Measurehe boresof the shafts. The clearance etween he gear shafts nd p u m ph o u s i n g c o v e r . . . . . 0 4 o 0 . 0 7 002 o .003 nch) 900530697
llirs:'at¡on 34 r e i n :¡ , f n- r. n i l rnJr m p
gear
'.ieasurethe difference engthof the p u m pg e a ra n d h ed e p t h assembry : ^ e o , rp u m ph o u s i n g . 0.020 o -0.034 I earance 00'13 nch) 0008
Note:Replace he oil pump gear assembly, cover, r the oil pump housing the clearance (.006 nch). exceeds he serviceimitof 0.15 Note:Replace he drivegearand drivengear assemory.
Note:Replace he oil pump gear assembly crea'a.ceexceeds he service imit -0.150 CC59 c h ) . Meas-'e he clearance etween he oil pump gears feeler auge. a n c : ^ e o r lp u m p h o u s i n g t- ^-.^^^^
0.050 o 0.098 (.0020 .0039nch)
th Note: Rep\aoe the oil pump gear assembly -0.150 clea'a^ce exceeds the serv¡ce limit
0C59 nch).
lllustration36
900530704
d l e rg e a rb u s h i n g Inside iameter idler bushing
25.000 o 25.021 (.9843 .9851 nch)
Maximum iameter f idlergear bushing pump...... . . . . . . . . . 2 5 . 0 5 9 ( . 9 8 6 6n c h ) Splndle Drameter f spindle
24.939 o 24.960 (.9818 .9827 nch)
SpecificationsSection Minimum iameter f spindle or pump...,... . , . . . . . . . 2 4 . 9 0 1 ( . 9 8 0 4n c h )
Engine
01 31038
Pressure
SMCS Code:1924
Openingpressure bypass = =
l
t 98 kPa psi) t i01030410
Engine SMCSCode:1302
Table
Engine gi P¡sss¡r¡g(t)
Oi Pressuret 1500 om
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.
Engine
BypassValve
i01030990
SMCS Code: .1306
900530566
lllustration38 /r \ r.
ar;l ^^^ \ J i l Pd
h^t+^ uL)rJ
Tighten he oil torque.
bc .-. -
d r a i np l u g Tighten
foliowing 4 lb ft) 01 33378
WaterT emperatureegulator SMCSCode: 1355
il' ii,
8010 WaterTemperature
Regulator 90053080
Note: oil bypassvalve s mounted nside along he railof the oil pan. ('1)Valve eat Check he valve and the valve seat or abnormal contact patterns.
water emperature t h e f o l l o w i n g t e m p e l a tu l e valve iftsmore followingemperature,
:':'-: o open - - , ( 1 6 0 '+ 4 ' F ) -:r) at the 85"C 185"F)
8020 WaterTemperature
Regulator
Spring
water emperature a::- :':": :c open the ollowingemperature. 32"C 180'F)
Inspect he spring or weakness r damage. Free engthof spring (3.29 nch) 83.5
valve iftsmore han 10 following emperature
at the 36'C (204'F)
SpecifcationsSection
WaterPump
i01031
Th press it between he waterpump shaftan th ollowing rmpeller (.0013 .0026 nch) amount. 0.032 o 0.065
SMCSCode: 1361
CylinderBlock
tO1a2B288
SMCS Gode: .1201
lllustrat¡on 900530877
lllLs:'at¡on
-oeller 'aces -sn.
mpeller nd he waterpump shaft
ange -i'e of the mpellero the distance rom he housings the ollowing .',are' (.826 .854 nch) a'nount.. 21.00 o 21.70
Cylinder lock Measurehe amount f the warpage f the eeler cylinder iockwith straightedge gauge.Maximum llowable (.002 nch) .......,. clearance R e p a i ri m i t . . . . . .
g00530BZB
V/a:e'pump shaft T^ cress it between he water pump shaft nd ange is the ollowing 0.035 o 0.065 an:oint. (.0014 .0026nch)
.........0.20 (.008 nch)
Resurfacehe op of the block f the repair imit s reached.
lllustration lllustrat¡on
900529444
Cylinder leeve
900529446
SpecifcationsSection nsidediameter f the cylinder leeve Measure parallel the crankshaft. easure he that s in a insidedrameter f the cylinder leeve perpendicularosition o the crankshaft. easure op, he middleand the bottom f the cylinder sleeve.Refer o Table4 for tolerances f the cylinder leeves. Table
Tolerances of Cylinder Sleeves
i--_!-_
tandard Standard
n^--¡Repair
Limit{l)
A""lirory Inside Diameter
c^n,¡^^ Service
Limit€)
102.010 102.700 102.200 102.045 4.0161 mm 4.0236 mm (4.0433 inch) inch) 4.0175 inch)
0.010
Out of Round
(.0004 nch)
Taper
0.015 (.0006 nch)
N/A N/A
N/A N/A
Cylinder leeve
Replace cylinder lee.=: limit
--'l
'iil
1l
Replace cylinder leeves service imit.
s necessary
n excess
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
OversizeBore
CylinderBore Size
250mm0100nch)J3273:5ilili:339? liil 0.500
(.0197 nch)
102.510 (4.0358nch) 102.545mm (4.0372 nch)
102.700mm 0433 nch) -¡ ::U
-
,^¡: -
-\
+h^ ^^",,i^^ tl lU Júl V IUV
-\//
ba
--*$z
Bore he cylinder o the specified versize nsidedtametereaches repair dimension not reach he limitbut the insidediameter service imit.Refer o Table5.
Determinehe oversize imension order o cleanup the cylinder unevenwear.
.
S e r v i c ei m i t f c y i ; n c = '
(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.
inch) Hone he sleeve +0.25 (+.020 nch)oversize. one he +0.50 sleeve o a accuracywithin0.010 o 0.045 (.0004 .0018nch).
900529534
lllustration43
|
?*
:,
900529962
lllustration44 Cylinder leeves
following rocec-': cylinder leeves.
l:- .f, repalr ne
1 . S e t a b o r i n gm a c n A l i g n b o r i n gm a c r , ^ e bottomof the cylinder
=
Bore he sleeveuntil (.020 nch).
-
nderbl ock. :enter .re lessworn
=== 0.50 careful
Remove remainder not o damage cyllnc:'
==.e,
sleeve. lig^ Install the cylinder lock.
==. with he op
The bore of the cylinder 102.000 102.035
nch).
SpecifcationsSection
'-"'":l"i
."zuü8ro *o o 68 m ( 3 . 5 4 4 1 t o . 5 4 6 0n c h )
diameter f the mainbearing . . . . . . . 9 0 . 1 5 0 ( 3 . 5 4 9 2n c h ) of deck centerline f crankshaft .002 nch) 307.00 0.05 reight rom he centerline crankshaft 3 0 6 . 7 0 ( 1 2 . 0 7 5n c h )
CrankshaftS eals
i01023233
Pu sealanton the contactsurfacebetween he slinger nd the crankshaft. cleanengineoil on the surface f therearsealassembly Distancerom earsealassembly crankshaft
(.24 nch)
ConnectingRod Bearing Journal
r01022388
SMCSCode: 1219;1225 Connecting Rod Bearing Journal
S M C SC o d e :1 1 6 0 : 1 6 1
Original ize ournal(l)
59.945 o 59.965mm (2.3600 o 2.3608 nch)
Undersizeournal (.010 nch) 0.25
59.695 o 59.715 (2.3502 2.3510 nch)
Undersize ournal (.020 nch) 0.50 Undersize ournal (.030 nch) 0.75
59.445 o 59.465 mm (2.3404 2.3411 nch) 5 9 . 1 9 5o 5 9 . 2 1 5 (2.3305 o 2.3313 nch)
(1 Regrind he connecting od ournals o the next undersize dimensionf the repair ¡mit f 59.980mm (2.3614 nch) s exceeded.
The clearance etween new bearing d a j o u r n a ls t h e o l l o w i n ga l u e .. . . . . 0 3 5 0 . 1 0 0 0014 .0039 nch)
900525904
45
-Si'3i l' =.---
-^^l
=:='seaf ssembly -:
N óter
.oar eeat assembly
and the s l i n g e r a r e
-^a/
<
'ear sealassembly nd the slrnger re
Note :-:
=-
iJ
=:2'
Note r
^,,^i+ d ut ilt,
sealassembly
tearsealassembly hould :e' after nstallation.
flushwith
l:-:act surfacebetween he sltnqer nd _
.
^A^f+ tdlt
clearance An undersized earing s required betweenhe connecting ournal nd he bearing excessof the service imit 0 200 mm (.0079 nch). f the crankshafts 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 maximum epair imit s 0.030 (.0004 nch). ( . 0 0 1 2n c h ) . e p a i r i m i t s e x c e e d e d ,e g r i n d the bearing ournals o the specified imension.
20 Specificationsection
MainBearing ournal
\01022652
m a i nD e a '
nr¡lin|or
SMCSCode:1203
horrinn
hnJtc
iinhion
tho rrz
ñiel
=
,- r-:
torque. /?\
¿.:{ln:
: =: :
=u-
hln¡¡
= following t4lbft)
-
indin¡inr
f\ ^^^, ,,^ fvfucl¡utv
+h^
a dial
-^ IIrd
i n d i c a t o r .u o r r a : : : crankshaftourna t h e m a i nb e a r i n g . ' = . UgOl
ll IU
UIVOI
Ol
Ug
: ameter -'re - ^ a l
v
'^aland main -:o011Bmm c 0047 nch)
Clearance etweer c'a'. :' 0earrng
90052534i
lllustration46
Crankshaft ainbearing ournal Measurehe mainbearing ournal. he diameter the crankshaft ainbearing ournal given Table Table
Main Bearing ournal Original iz ournal(t)
89.95 o 89.97 mm (3.541 o 3.542 nch)
Undersizeournal (.010 nch) 0.25
89.70 to 89.72 mm (3.531 3.532 nch)
Note:Replace he bear : s :' n e x tu n d e ' s ' z e = 2 " clearance xceeos T a b l e f o r d i r r e i ^ s , o r s' - - : =
a E
a¿aal'^A^1+ U t A t l n Jt t d t L
Deaflng -:-r Referto dt-.
N o t e : h e a l l o w a b l eo i e ' a - : : ' - . ' c e a r i n g ior¡rnals r t .:,-: --- nm ( . 0 0 0 4 n c h ) T h em a x i r - s0030mm --.-^^ .^^,;^A 0012 nch). he epa' : -::Jüu, rúgIttu . * ^ ñ ^ i ^ ^ b e a r i n go u r n a l so :^e s:-: IJ¡U¡ I, Note: maxlmum en':: iournai -0.90 crankshaftf the cranxs?a-. thisspecification
:
crankshaft aCe he 'n DeyOnO
89.45 o 89.47 mm (3.521 o 3.522 nch) Undersizeournal 0.75 mm (.030 nch)
89.20 to 89.22 mm (3.512 o 3.513 nch)
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
900525380
(4 Crankshaft Support he crankshai = unout i-:-. Measure j o u r n a l . a x i m u mu n o - : lllustration 47
Mainbearing ap
900525373
Note:Replace he cranksna reoair imitof 0.050
blocks. Centef .0.020 0008 nch) exceeds
Note:The maximum epair imit s 0.300 (.01 nch). Replace standard hrust lates f the end play exceeds standard learance. hreeoversize thrustplates available replacementsf the play stillexceeds maximumimit.G enerally, rear ournal ikely o be wornmore apidly han ront ournal. necessary,e place rear hrust plate.Refer Table for oversizehrustplates. Table Dimensions for Grinding of Crankshaft Oversize Thrust Plates 900525383
lllustration 49
Width crankshaft
journal
bearing
o 33.039 .......33.000 (1.2992 .3007nch)
ryfr
Oversize Thrust Plate
Oversize (front or rear)
Oversize (front or rear)
Tolerance +0.039mm (+.0015 inch)
33.15 +0.15mm (+.006 nch) (1.305 nch) (1.311nch)
+0.039mm +0.30mm 33.30mm 33.45mm (+.0015 (+.012nch) ( 1 . 3 1 n c h ) ( 1 . 3 1 7n c h ) inch)
33.60mm 33.45 +0.45mm ( + . 0 1 8n c h ) ( 1 . 3 1 7n c h ) (1.323nch)
+0.039 (+.0015 inch)
Tighten reta¡ning of the crankshaft ulley N m (363 4 lb o l l o w l n go r q u e . . . . , . tO1022446
900525387
lllustration50
thrust lates n the Put he mainbearing nstallhe crankshaft. clean block engine il on the bolt hreadsTighten he bolts 137 5 to the ollowingorque. (101 4lbft)
Connecting SMCSG o d e : 1 2 1 8
lllustration 2
q00525099
Matcning arks 9005254
lllustrahon
(7) lv'leas:rehe crankshaft 0 . ' 1 0 0o 0 . 2 6 4
olay. 0039
.0104nch)
marks reused align connectrng
to the
22 Specifications ection bolts
Connecting
Before ssembly, c ea- =cil on the * a Ke contact b o l t h r e a d s n d a l ls u r l a : = co--=-' b e t w e e nh e b o l t caps. Tighten connec:'a'-= followlng il:-: .--z6t4lbft) torque. M e a s u r eh e b o r e s ' e r : -:-. rods and record
lllustration 53
1nna^trnn
e bores.
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.
9005251
lllustration 55
Connecting
f e e l e r a u g e -::: play.... o 0 3:
N o t e :R e p l a c eh e c o n n e : . exceeds .50
play. , -: :o 014 nch) :
anñ
ntq\/
'l I
\
V/ 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 (.0004 nch) s excessive. bearing ver0.010 Replace he piston pin or replace he bearing th clearance excessive.
lllustration 56
Cl:---' 900525201
Piston Markings n ':ds. Ensure cc--=:' Assemble piston :-: themarks that he m a r k i n g s n t h e p,s::ate.---= =:'ne ide. o n h ec o n n e c t i n g
Specifc ations ection ..0.55 1.15 ( . 0 2 2 1 o . 0 4 5n c h )
Plstonprojection
Piston
Rings
\a1421241
SMCSCode: 1214,1215
lllustrat¡on57
90o525206
Install piston ssembly ith he marks the connecting od oward he camshaft
900524461
lllustration59
Markings piston lllustration
900525250
(9 Piston following rocedure measure he helghtof each pistonabove cylinder lock. n the acceptable ange, nspect clearances components wear damage. centerposition f the piston Determine with dial ndicator ssemblY. 2- inetalt he dia.t indicator assembly on the top of needle of the d¡al indicator the block.
zero.
3. Measureprojection 9) at three places on th top of th piston.Takean average th threemeasurementsn order o determine projection. ubtract he projection rom the gasket n installedhickness f the cylinder order o determine clearance etween cylinder ead. of the piston Installedhickness f the cylinoer .070 .004 nch) ..110 t gasket
stamped markings hich Each piston markings used al¡gn of the piston. of the camshaft plstonassembly cylinder lock, Piston iameter dimensions prstons Table gives dimensions standard, able9 also gives oversize. pistons Note:Measure perpendicular
pistondiameter long piston bore.
Specifc ations ection ir^^^,,,^
Crankshaft Note:Ensure hat he marks alignment.
the iminggears
900527864
lllustration 65 ldlergear 2)
Install dial ndicator nd rotate idlergear forth order measure acklash. back backlash xceeds Replace he dlergear service imit.Refer o Table Table11
0.03 0 . 1 7 (.001 .007 nch) 0.05.to^0.20 lr, ii
ili
ártrtil?.,
clearance
o.oog o o.ogo
mm .ooo4 ?:'-Y":il95j s"-1'-o!:llls .ooit ncn¡ and Snan
0.35mm
('br+ncn)
-' :',afWith ;^ten ,.r-:,.35N'm rb t)
+A^
faolor ac' r^a Qcj;' 'trflaraaar r v r u r v u q r h r l ' ' . " .J- -
-'
--
j00527912
lllustration 7 /?\ \/,/
r^^i!^ ilt>rLrg
/ Q\
lrilar
\ v / , v ' v '
:i^-^+^' Ljrdr rErur
noe
^.
:::.
_
r c h af
: :=- Replace bushing : ' -:-1 idler bushing the service imit.Reter c
-t,.,^¡n tF.n - =ivvEvt I L¡ ---{+ ^./^^^^^ : dtL E^ugvu)
0r028537
Flywheel SMCSC o d e : 1 1 5 6
0.100 (.0039nch)
(1 Replace he idlergear f the service imit s exceeded
lllustration 68
l'
900529633
Flywheel lllustration66
ldlergear bolt
90052791
P l a c e h e l y w h e e l n a s - ' - = : : ' . i n e| st ^s^ ^ , . 1 : ^ l indicator order o meas-'='-= f ywheel. ..0 15 mm Standardat assembly .. ', == / ñO A iÍ nr nv rh \r / \.vvv
SpecifcationsSection R e p a i ri m i t f f l y w h e e l .. . . . 0 . 5 0 Note:Refrnish exceeded
(,020 nch)
flywheelf the repair imit s
SMCSCode: 1358
q00529634
lllustration69
lllustration70
lywheelace with Measure runout n d i a l n d i c a t o r . a x i m u ma c e u n o u t . . 0 . 1 5 (.006 nch) R e p a i r i m i t f a c e u n o u t . . . . .0 . 5 0 Note:Refinish exceeoeo.
flywheel
(.020 nch)
repair imit s
ring gear permissibleemperature nstallatlonn the lywheel ithout sing . .. 150"C 302'F) rorcn.,,..,.... Note:The ringgear Tighten torque
BeltTensioner
pressed n the lywheel.
lywheel olts o the ollowing t 4 lb t
N u m b e r f teeth
r01053076
lywheel
g e a r . . . . . .. . 1 2 7
q005461
Bolt. Apply pressure o each belt midway between he pulleys n order inspect he belt ension. djust the bolt or he alternatorf the ension s incorrect. Proper an belt ension s approximately .12.0 (.50 nch) following eflection.
28 Specif cationsSection
BeltTensioner
i01031047
Alternator SMCS Code: 1405
SMCSGode: 1358
lllustration71
o,o.,r.,f
900530808
Bolt Apply pressure o each belt midway between he pulleys n order inspect belt ension. djust ifre Oott or th alternator f the tension incorrect Proper an belt ension approximately (.50 nch) .....120 followingeflection.
900530887
lllustration72
a l t e r n a t o ru l r e . ' or te z'.'' Tighten f o l l o w i n go r q u e .
:- ey l- to
b
Polarity
=;ative round
Rotation
: :rer direction
Speed or esting rPm)
Output oltage Rated utPut..
. 5000 rP .28.0
SpecifcationsSection
ElectricStartingMotor
31378
SMCSCode: 1453
lllustration 3
900530889
Terminal Tighten he 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.R otation f electric tarting motor...,..... clockwise No loadconditions S p e e d rpm)...
3300 pm minlmum
Maximum urrent draw) Voltage
...............23\/
lndexSection
lndex Alternator
.-'.' 8
Beft ensioner................
27,28
Piston
........'......'
Rings
.'.'.' Camshaft ..................."' C o n n e c t i n g od .......... ...'.. Connecting Bearing ournal ....................." ........ C r a n k s h a f te a l s '...'."17 C y l i n d e r1 o c k . . . . . . . . . .....'...' ........ Cylinder V a l v eR o c k e r E l e c t r i c t a r t i n g otor......... Engine esign 3 0 6 4E n g i n e 3 0 6 6E n g i n e E n g i n e B y p a s s a l v e ......" fngine engine Pressure Pressure elief alve fngine fngine PumP Exhaust anifold
Flywheel F u e l n j e c t i o ni n e s Fuel njection ozzles Fuel njection
GearGroup Front)........
lmportantafetynformation.
M a i nB e a r i n g
'."'.-....".29 .'-.....'.'.'...'.4 '..'.'.".'...'....4 '-.-.'."...'..'.'-4 .-........16 ................ ........ .-.'.'.'14 '.".""'...14 .'..'.'.....11
'.."..26 ".'.......5 ."..."....'...'.....'.. ........'.5
.....................25
"--.-.--....'.2
20
............
.'....',..",.....8
.......'.."'..'..17 ........ Water ' .'............... Water emperatureegulator ::-lator....'....... -801ÓWater emperatur: =:-lator.'....""" -8020Water emperature
