Caterpillar c32 acert мануал - Большая энциклопедия инструкций и руководств

Engine Valve Lash — Inspect/Adjust

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To prevent possible injury, do not use the starter to turn the flywheel.

Hot engine components can cause burns. Allow additional time for the engine to cool before measuring valve clearance.

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This engine uses high voltage to control the fuel injectors.

Disconnect electronic fuel injector enable circuit connector to prevent personal injury.

Do not come in contact with the fuel injector terminals while the engine is running.

Note: Valve lash is measured between the rocker arm and the valve bridge. All measurements and adjustments must be made with the engine stopped and the valves fully closed.

Valve Lash Check

An adjustment is NOT NECESSARY if the measurement of the valve lash is in the acceptable range. Check the valve lash while the engine is stopped. The range is specified in Table 1.

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Table 1

Quick Reference for Engine Valve Lash Setting C32 Engines
	Inlet Valves	Exhaust Valves
Valve Lash Setting	0.38 ± 0.08 mm (0.015 ± 0.003 inch)	0.76 ± 0.10 mm (0.030 ± 0.004 inch)
TC Compression Stroke	1-3-4-6-7-12	1-4-5-8-9-12
TC Exhaust Stroke⁽¹⁾	2-5-8-9-10-11	2-3-6-7-10-11
Firing Order	1-4-9-8-5-2-11-10-3-6-7-12⁽²⁾

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⁽¹⁾	360° from TC compression stroke
⁽²⁾	Refer to Illustration 1 in order to locate the No. 1 cylinder.

If the measurement is not within this range, then adjustment is necessary. Refer to «Valve Lash Adjustment».

Valve Lash Adjustment

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Illustration 1	g00872995
C32 engine (A) Inlet valves (B) Exhaust valves (C) Left side of the engine (D) Cylinder number (E) Front of the engine (F) Right side of the engine (G) Flywheel end of the engine

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Illustration 2	g00506544
Typical example (1) Valve adjustment locknut (2) Exhaust adjustment screw (3) Valve adjustment locknut (4) Inlet adjustment screw (5) Feeler gauge

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Table 2

Valve Lash
Valves	Thickness of Gauge
Inlet	0.38 mm (0.015 inch)
Exhaust	0.76 mm (0.030 inch)

Adjust the valve lash while the engine is stopped. Use the following procedure in order to adjust the valves:

Put the No. 1 piston at the top center position.
Note: See Testing and Adjusting, «Finding Top Center Position for the No. 1 Piston» for further details.
With No. 1 piston at the top center position of the compression stroke, an adjustment can be made to the valves.
Before any adjustments are made, lightly tap each rocker arm at the top of the adjustment screw. Use a soft mallet to ensure that the lifter roller seats against the base circle of the camshaft.
Adjust the valve lash on the inlet valves for cylinders 1, 3, 4, 6, 7, and 12.
1. Loosen valve adjustment locknut (3).
2. Place the appropriate feeler gauge (5) between the inlet rocker arm and the inlet valve bridge. Turn inlet adjustment screw (4) while valve adjustment locknut (3) is being held from turning. Adjust the valve lash until the correct specification is achieved. Refer to Table 2.
3. After each adjustment, tighten valve adjustment locknut (3) while valve adjustment screw (4) is being held from turning. Tighten to a torque of 30 ± 7 N·m (22 ± 5 lb ft). Recheck each adjustment.
Adjust the valve lash on the exhaust valves for cylinders 1, 4, 5, 8, 9, and 12.
1. Loosen valve adjustment locknut (1).
2. Place the appropriate feeler gauge (5) between the exhaust rocker arm and the exhaust valve bridge. Turn exhaust adjustment screw (2) while valve adjustment locknut (1) is being held from turning. Adjust the valve lash until the correct specification is achieved. Refer to Table 2.
3. After each adjustment, tighten valve adjustment locknut (1) while valve adjustment screw (2) is being held from turning. Tighten to a torque of 30 ± 7 N·m (22 ± 5 lb ft). Recheck each adjustment.
Remove the timing bolt, and turn the flywheel by 360 degrees in the direction of engine rotation. This action will position the No. 1 piston at the top center at the beginning of the exhaust stroke. Install the timing bolt in the flywheel.
Adjust the valve lash on the inlet valves for the following cylinders 2, 5, 8, 9, 10, and 11.
1. Loosen valve adjustment locknut (3).
2. Place the appropriate feeler gauge (5) between the inlet rocker arm and the inlet valve bridge. Turn inlet adjustment screw (4) while valve adjustment locknut (3) is being held from turning. Adjust the valve lash until the correct specification is achieved. Refer to Table 2.
3. After each adjustment, tighten valve adjustment locknut (3) while valve adjustment screw (4) is being held from turning. Tighten to a torque of 30 ± 7 N·m (22 ± 5 lb ft). Recheck each adjustment.
Adjust the valve lash on the exhaust valves for cylinders 2, 3, 6, 7, 10, and 11.
1. Loosen valve adjustment locknut (1).
2. Place the appropriate feeler gauge (5) between the exhaust rocker arm and the exhaust valve bridge. Turn exhaust adjustment screw (2) while valve adjustment locknut (1) is being held from turning. Adjust the valve lash until the correct specification is achieved. Refer to Table 2.
3. After each adjustment, tighten valve adjustment locknut (1) while valve adjustment screw (2) is being held from turning. Tighten to a torque of 30 ± 7 N·m (22 ± 5 lb ft). Recheck each adjustment.
Remove the timing bolt from the flywheel after all valve lash adjustments have been made.

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CAT
C32

Operation and
Maintenance
Manual

SEBU8219-01

June 2008

Operation and

Maintenance

Manual

C32 Power Module

MED1-Up

(Power Module)

MEG1-Up (Power Module)

SAFETY.CAT.COM

Contents Summary of C32 Power Module Operation and
Maintenance
Manual

Page 1SEBU8219-01 June 2008 Operation and Maintenance Manual C32 Power Module MED1-Up (Power Module) MEG1-Up (Power Module) SAFETY.CAT.COM
Page 2i01658146 Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must b
Page 3SEBU8219-01 3 Table of Contents Table of Contents Setup Procedures …………………………………………. 69 Transportation Information ……………………………… 71 Foreword ……………………………………………………….. 4 Maintenance Section Safety Section R
Page 44 SEBU8219-01 Foreword Foreword Use fuel consumption or service hours to determine intervals. Calendar intervals shown (daily, annually, etc.) may be used instead of service meter intervals Literature Information if they provide more convenient schedules and approximate the indicated service meter r
Page 5SEBU8219-01 5 Foreword California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands a
Page 66 SEBU8219-01 Safety Section Safety Messages Safety Section i03085837 Safety Messages SMCS Code: 1000; 7405 g01567702 Illustration 1 C32 Generator Set
Page 7SEBU8219-01 7 Safety Section Safety Messages g01452725 Illustration 2 PM1000
Page 88 SEBU8219-01 Safety Section Safety Messages g01452776 Illustration 3 XQ1000 g01398172 Illustration 4 PM1000
Page 9SEBU8219-01 9 Safety Section Safety Messages g01452731 Illustration 5 XQ1000 Universal Warning (1) Automatic Starting (2) The universal safety message is located on each The safety message for automatic starting is located side of the generator enclosure and on each side of on each side of the enclo
Page 1010 SEBU8219-01 Safety Section Safety Messages Hot Surface (3) Lifting the Genset (4) The safety message for a hot surface is located on This safety message for lifting the genset is located each side of the radiator and on each side of the on right, left, and rear panels of the generator barrel of t
Page 11SEBU8219-01 11 Safety Section Safety Messages Hot Fluid Under Pressure (5) Electrocution (6) The safety message for hot fluid under pressure is The safety message for electrocution is located on located on top of the radiator near the radiator cap. the sides of the terminal box, on the doors of the
Page 1212 SEBU8219-01 Safety Section Additional Messages Access Door (7) i02798447 The safety message for the access door to the Additional Messages camlock panel is located on the access door to the camlock panel. SMCS Code: 1000; 7405 There are several specific messages on this machine. The exact locatio
Page 13SEBU8219-01 13 Safety Section Additional Messages g01398274 Illustration 6 C32 is shown. g01398277 Illustration 7 C32 is shown. Lifting Point(1)
Page 1414 SEBU8219-01 Safety Section General Hazard Information This message is located on both sides of the enclosure. g01398331 Illustration 10 g01398322 This is the location of a coolant drain. Illustration 8 This is the location of a lifting point. i02566298 Oil Drain(2) General Hazard Information This
Page 15SEBU8219-01 15 Safety Section General Hazard Information Engine exhaust contains products of combustion Unless other instructions are provided, perform which may be harmful to your health. Always start the the maintenance under the following conditions: engine and operate the engine in a well ventil
Page 1616 SEBU8219-01 Safety Section General Hazard Information Containing Fluid Spillage • Avoid brushing materials that contain asbestos. Care must be taken in order to ensure that fluids • Avoid grinding materials that contain asbestos. are contained during performance of inspection, maintenance, testin
Page 17SEBU8219-01 17 Safety Section Burn Prevention i02088921 i02469590 Burn Prevention Fire Prevention and Explosion SMCS Code: 1000; 4450; 7405 Prevention SMCS Code: 1000; 4450; 7405 Do not touch any part of an operating engine. Allow the engine to cool before any maintenance is performed on the engine.
Page 1818 SEBU8219-01 Safety Section Fire Prevention and Explosion Prevention Do not weld on lines or tanks that contain flammable fluids. Do not flame cut lines or tanks that contain flammable fluid. Clean any such lines or tanks thoroughly with a nonflammable solvent prior to welding or flame cutting. Wi
Page 19SEBU8219-01 19 Safety Section Crushing Prevention and Cutting Prevention Do not store ether cylinders in living areas or in the Unless other maintenance instructions are provided, engine compartment. Do not store ether cylinders never attempt adjustments while the engine is in direct sunlight or in
Page 2020 SEBU8219-01 Safety Section Engine Starting Overspeed shutdown should occur automatically. Always start the engine according to the procedure If automatic shutdown does not occur, press the that is described in the Operation and Maintenance emergency stop button in order to cut the fuel and/or Man
Page 21SEBU8219-01 21 Safety Section Electrical System i02106213 i01593543 Electrical System Generator Isolating for SMCS Code: 1000; 1400 Maintenance SMCS Code: 4450 Never disconnect any charging unit circuit or battery circuit cable from the battery when the charging unit When you service an electric pow
Page 2222 SEBU8219-01 Safety Section Generator Isolating for Maintenance 9. Determine that the generator is in a de-energized condition. Add ground straps to the conductors or terminals. During the entire work period, these ground straps must remain connected to the conductors and to the terminals.
Page 23SEBU8219-01 23 Product Information Section General Information Product Information Section General Information i02640420 Welding on Engines with Electronic Controls SMCS Code: 1000 NOTICE Proper welding procedures are necessary in order to avoid damage to the engine’s ECM, sensors, and associated co
Page 2424 SEBU8219-01 Product Information Section Model Views and Specifications Model Views and Specifications i02787919 Model View Illustrations SMCS Code: 1000; 4450 The following model views show typical features of the generator set and power module that are supported in this manual. Due to individual
Page 25SEBU8219-01 25 Product Information Section Model Views and Specifications g01392665 Illustration 22 Typical example of a C32 power module (1) Paralleling panel (6) DC light (11) Spill containment pan (2) Precleaner (7) Coolant filler access panel (12) Fuel transfer pump (3) AC light (8) Service ladd
Page 2626 SEBU8219-01 Product Information Section Model Views and Specifications g01394417 Illustration 23 Typical example of a C32 power module (1) Paralleling panel access door (5) Spare/blank port (9) Camlock panel access door (2) Air intake louver (6) Fuel onload/offload (10) Breaker panel access door
Page 27SEBU8219-01 27 Product Information Section Model Views and Specifications g01396505 Illustration 24 Rear view (1) RC panel (3) Battery charger (2) House keeping/fuel control panel (4) Distribution panel
Page 2828 SEBU8219-01 Product Information Section Model Views and Specifications g01396534 Illustration 25 Typical example of a C32 Power Module (1) Radiator (5) AC lighting (9) 4732 L (1250 US gal)Fuel tank (2) Muffler (6) DC lighting (10) Fuel transfer pump (3) Battery charger (7) Control panel (11) Main
Page 29SEBU8219-01 29 Product Information Section Model Views and Specifications g01395244 Illustration 26 Typical example of a C32 power module (1) Access door (3) External fuel connection (5) Oil drain (2) Louver (4) Radiator drain
Page 3030 SEBU8219-01 Product Information Section Model Views and Specifications g01394563 Illustration 27 Typical example of a C32 power module (1) Louver (2) Access door (3) Load cable access i02792970 Electronic Engine Features Product Description Caterpillar C32 engines are designed with electronic con
Page 31SEBU8219-01 31 Product Information Section Model Views and Specifications • System diagnostics For more information on electronic engine features, refer to the Operation and Maintenance Manual, “Features and Controls” topic (Operation Section). Engine Cooling and Lubrication The cooling system consi
Page 3232 SEBU8219-01 Product Information Section Model Views and Specifications SR4B generators are utilized in three-phase full-wave Louvers excitation and regulation. The generators are four-pole generators with four, six, ten, or twelve lead Louvers are installed in the power module in order configurat
Page 33SEBU8219-01 33 Product Information Section Model Views and Specifications The fuel transfer pump requires a specific minimum Net Positive Suction Head Available (NPSHA) to properly operate. The NPSHA can be estimated by adding the static suction head and the dynamic restrictions that are in the syst
Page 3434 SEBU8219-01 Product Information Section Product Identification Information Product Identification Engine Identification Plate (2) Information The engine identification plate is located on the right side of the engine on the oil cooler. i02793310 Setpoint of the engine altitude derate ____________
Page 35SEBU8219-01 35 Product Information Section Product Identification Information g00776690 Illustration 31 i02331504 The top level part numbers in the Parts Manual for the engine are listed with the engine arrangement Reference Information number. Occasionally, an arrangement may be slightly modified b
Page 3636 SEBU8219-01 Product Information Section Product Identification Information The performance specification can be used by Wye Configuration Diagram your Caterpillar dealer with the Technical Marketing Information system. Before the engine leaves the 6 Lead factory, the engine performance is tested.
Page 37SEBU8219-01 37 Product Information Section Product Identification Information Grounding the Frame In applications where definite measures are taken in order to prevent grounds to the load leads, an In any generator set installation, the frame of the ungrounded neutral can be used. Be sure to check g
Page 3838 SEBU8219-01 Product Information Section Product Identification Information Wye Configuration Diagrams 6 Lead g00611608 Illustration 36 12 Lead Wye Configuration — Low Voltage g00611486 Terminals T10, T11 and T12 become neutral connection when Illustration 34 the terminals are tied together. 6 Lea
Page 39SEBU8219-01 39 Product Information Section Product Identification Information 12 Lead If the neutral wire is grounded and one of the phase leads becomes grounded, the excessive current will open a load circuit breaker. The excessive current will also collapse the generator voltage. The result depend
Page 4040 SEBU8219-01 Product Information Section Product Identification Information Parallel to Utility Wye Configuration Diagrams When a Wye connected generator is going to operate 6 Lead Generators in parallel with a utility system (infinite bus) and when the secondary of the step-down transformer in th
Page 41SEBU8219-01 41 Product Information Section Product Identification Information 12 Lead Generators g00637320 Illustration 41 g00626130 Typical Parallel Wye Configuration (60 Hz, 12 Lead) Illustration 43 This is a typical high voltage connection. Typical Delta Configuration (60 Hz, 12 Lead) Delta Confi
Page 4242 SEBU8219-01 Product Information Section Product Identification Information Do not exceed the nameplate current rating for any Delta Configuration Diagrams one phase. 6 Lead Generators Wye Configuration Diagrams 6 Lead Generators g00626135 Illustration 46 Single-Phase Voltage Diagram with 6 Lead D
Page 43SEBU8219-01 43 Operation Section Lifting and Storage Operation Section Lifting the Entire Package Do NOT use the engine lifting eyes or the generator lifting eyes to lift the entire package. Lifting and Storage Lifting points (3) have been provided on the base rails of the generator set for lifting
Page 4444 SEBU8219-01 Operation Section Lifting and Storage i02147124 For more detailed information on engine storage, see Special Instruction, SEHS9031, “Storage Procedure Product Storage for Caterpillar Products”. SMCS Code: 7002 Generator Storage Short Time Storage A storage period in excess of six mont
Page 45SEBU8219-01 45 Operation Section Lifting and Storage For additional information on generator storage, consult your Caterpillar dealer for assistance.
Page 4646 SEBU8219-01 Operation Section Installation Installation Storage Short Time Storage i01856938 Generator Set Installation If the generator is not installed immediately, store the generator in a clean area. This area should also SMCS Code: 7002 have the following conditions: low humidity, stable hum
Page 47SEBU8219-01 47 Operation Section Installation • Well ventilated Protective Devices • Easily accessible for inspection and maintenance The output to the load of the generator should always be protected with an overload protection device such Do not obstruct air inlet openings. Do not obstruct as a ci
Page 4848 SEBU8219-01 Operation Section Features and Controls Features and Controls i02553580 Programmable System Parameters SMCS Code: 1900 Record your customer programmed parameters for reference. Table 3 Parameters that may be Programmed by the Customer Customer Programmed Parameters Equipment ID Engine
Page 49SEBU8219-01 49 Operation Section Features and Controls i02443021 Electronic Modular Control Panel 3 (EMCP 3) SMCS Code: 4490 Electronic Control Module (Generator Set) g01045431 Illustration 50 (1) Display screen (7) Lamp test key (13) Right key (2) AC overview key (8) Run key (14) Enter key (3) Engi
Page 5050 SEBU8219-01 Operation Section Features and Controls RUN Key (8) – Pressing the “RUN” key will start Left Key (16) – The “LEFT” key is used during the engine. setpoint adjustment. The “LEFT” key is used to select the digit that is edited during the entry of numeric AUTO Key (9) – Pressing the “AUT
Page 51SEBU8219-01 51 Operation Section Features and Controls Digital Input 2 – Digital Input 2 is used for remotely • Engine oil level starting and stopping the generator set. This input should be wired to GROUND through a switch that • Fuel level can be initiated remotely. The input can be set to activat
Page 5252 SEBU8219-01 Operation Section Features and Controls Note: Your application may not have all of these features. Pump Stop Switch (1) – The pump stop switch is optional. The pump stop switch is used to manually stop the fuel transfer pump. Fully depress the switch in order to latch the switch. The
Page 53SEBU8219-01 53 Operation Section Features and Controls Annunciator Module To acknowledge the shutdown and alarm conditions or to silence the horn, press the “Alarm Acknowledge” button that is located near the middle of the annunciator. To test the LED indicators or to test the horn when the data lin
Page 5454 SEBU8219-01 Operation Section Engine Starting Engine Starting • Do not start the engine or move any of the controls if there is a “DO NOT OPERATE” warning tag or similar warning tag attached to the start switch or i02048636 to the controls. Before Starting Engine • Ensure that the areas around th
Page 55SEBU8219-01 55 Operation Section Engine Starting Startability will be improved at temperatures below 10°C (50°F) from the use of a cylinder block coolant NOTICE heater or from other means that are used to heat Oil pressure should rise within 15 seconds after the the crankcase oil. Some engine applic
Page 5656 SEBU8219-01 Operation Section Engine Starting i01934760 5. Immediately after the stalled engine is started, disconnect the jump start cables in reverse order. Starting with Jump Start Cables Note: If there is a problem with the alternator or the battery charger, the engine will not continue to ru
Page 57SEBU8219-01 57 Operation Section Engine Operation Engine Operation i01136207 Fuel Conservation Practices i01646252 SMCS Code: 1000; 1250 Engine Operation The efficiency of the engine can affect the fuel SMCS Code: 1000 economy. Caterpillar’s design and technology in manufacturing provides maximum fu
Page 5858 SEBU8219-01 Operation Section Engine Stopping Engine Stopping i02443872 Manual Stop Procedure i02237582 SMCS Code: 1000; 7418 Emergency Stopping Note: Individual applications will have different SMCS Code: 1000; 7418 control systems. Ensure that the shutoff procedures are understood. Use the foll
Page 59SEBU8219-01 59 Operation Section Cold Weather Operation Cold Weather Operation When No. 2 diesel fuel is used the following components provide a means of minimizing problems in cold weather: i02237624 • Starting aids Fuel and the Effect from Cold Weather • Engine oil pan heaters SMCS Code: 1000; 125
Page 6060 SEBU8219-01 Operation Section Cold Weather Operation Fuel Filters Note: Heat exchanger type fuel heaters should have a bypass provision in order to prevent overheating of NOTICE the fuel in warm weather operation. Do not fill the fuel filters with fuel before installing them. The fuel would not b
Page 61SEBU8219-01 61 Operation Section Generator Operation Generator Operation i02443880 Generator Operation SMCS Code: 4450 Loading of the Generator When a generator is installed or reconnected, be sure that the total current in one phase does not exceed the nameplate rating. Each phase should carry the
Page 6262 SEBU8219-01 Operation Section Generator Operation If derating for the block load is required, refer to ISO Permanent Magnet Pilot Excited 3046 Standards or SAE J1349 Standards. Also, Generators reference Engine Data Sheet, LEKX4066, “Loading Transient Response” and Engine Data Sheet, Permanent Ma
Page 63SEBU8219-01 63 Operation Section Generator Operation Generator Options Units that operate in parallel must have the same phase rotation. There are two methods that may Space Heaters be used in order to determine if the incoming unit and the unit that is on-line have the same phase Most of the SR4B g
Page 6464 SEBU8219-01 Operation Section Generator Operation • Both generators have the same phase c. Apply the available load. The setting is correct rotation when the lights blink in unison. The only if a reactive load is available. Equalize the first condition of “Initial Start-Up” has been Kilowatts or
Page 65SEBU8219-01 65 Operation Section Generator Operation Load Division and Speed Droop (If The circulating current may be as high as 25 percent of rated amperes with cold generator sets. Equipped) Such current may not even be considered harmful. The total generator current should not exceed the Once two
Page 6666 SEBU8219-01 Operation Section Voltage Regulators Voltage Regulators The Caterpillar Digital Voltage Regulator (CDVR) is a microprocessor based voltage regulator. Control power for the CDVR is supplied from an external i02303476 source of 24 VDC. The power stage of the CDVR can be supplied from a
Page 67SEBU8219-01 67 Operation Section Voltage Regulators i01809359 Voltage Regulator Options SMCS Code: 4467 Manual Voltage Control A manual voltage control is available as an option on Caterpillar generator sets. Various specifications and certifications require manual voltage control of the generator i
Page 6868 SEBU8219-01 Operation Section Parking Recommendations Parking Recommendations i01474454 Equipment Parking SMCS Code: 1000; 7002 Power Module Operation Site The power module must be parked on a flat surface. A power module can be parked on a concrete pad or a level natural surface. It is important
Page 69SEBU8219-01 69 Operation Section Setup Procedures Setup Procedures i02732002 Setup SMCS Code: 1000; 7002 Level the Power Module Once the power module is on the site, the landing gear should be lowered in order to support the trailer. The truck should be removed from the trailer. Install the jack sta
Page 7070 SEBU8219-01 Operation Section Setup Procedures Multiple Units The switchgear in the power module controls the connection of the generator set to the electric system. The generator frame is grounded to the frame of the floor-standing switchgear. The switchgear must be connected to an earth ground
Page 71SEBU8219-01 71 Operation Section Transportation Information Transportation Information 7. After you hook up the trailer keep the trailer brakes applied. Move the tractor forward slightly. This will pull on the kingpin in order to check for a proper i01786020 interlock. Roading 8. Perform a visual ch
Page 7272 SEBU8219-01 Maintenance Section Refill Capacities Maintenance Section Table 4 Engine Oil Viscosities for Ambient Temperatures Ambient Temperature Refill Capacities Viscosity Grade Minimum Maximum SAE 0W-20 −40 °C (−40 °F) 10 °C (50 °F) i02613273 SAE 0W-30 −40 °C (−40 °F) 30 °C (86 °F) Refill Capa
Page 73SEBU8219-01 73 Maintenance Section Refill Capacities Cooling System Table 6 Coolant Service Life Coolant Recommendations Coolant Type Service Life (1) NOTICE Cat ELC Six Years Do not use a commercial coolant/antifreeze that only Cat DEAC Three Years meets the ASTM “D3306” specification. This type of
Page 7474 SEBU8219-01 Maintenance Section Maintenance Recommendations Maintenance • knowledgeable visual examination of the equipment Recommendations • the application of electrical tests i01179728 Never perform a test over the rated potential. These General Maintenance tests can damage insulation that is
Page 75SEBU8219-01 75 Maintenance Section Maintenance Recommendations i02364500 Generator Start-up Checklist SMCS Code: 4450 Table 8 GENERATOR START-UP CHECKLIST RATING INFORMATION Engine Serial Number: ___________________________________ Arrangement Number: ___________________ Generator Serial Number: ___
Page 7676 SEBU8219-01 Maintenance Section Maintenance Recommendations (Table 8, contd) GENERATOR START-UP CHECKLIST Full Load “T1” to “T2” AC “T1” to “T3” AC “T2” to “T3” AC “11” to “12” AC “11” to “13” AC “12” to “13” AC
Page 77SEBU8219-01 77 Maintenance Section Maintenance Recommendations Table 9 GENERATOR START-UP CHECKLIST (CONT.) ELECTRICAL Yes No Comments Unit properly grounded Check diodes Over current protection Over voltage protection Check for loose wiring Adjust voltage Adjust frequency MECHANICAL Data Comments B
Page 7878 SEBU8219-01 Maintenance Section Maintenance Interval Schedule i02998241 Jacket Water Heater — Check …………………………. 116 Space Heater — Check …………………………………. 121 Maintenance Interval Schedule Standby Generator Set Maintenance (Standby) Recommendations …..
Page 79SEBU8219-01 79 Maintenance Section Maintenance Interval Schedule Every 12 000 Service Hours or 6 Years Cooling System Coolant (ELC) — Change …………. 92 Overhaul Bearing — Inspect …………………………………………… 85
Page 8080 SEBU8219-01 Maintenance Section Maintenance Interval Schedule i02998237 Generator — Inspect ……………………………………… 109 Space Heater — Check …………………………………. 121 Maintenance Interval Schedule Stator Winding Temperature — Measure/Record .. 124 (Standar
Page 81SEBU8219-01 81 Maintenance Section Maintenance Interval Schedule Engine Oil and Filter — Change ……………………… 101 Engine Protective Devices — Check ……………….. 103 Fuel System Secondary Filter — Replace ………… 107 Heat Shield — Inspect/Replace ………………………
Page 8282 SEBU8219-01 Maintenance Section Air Inlet Filter — Check i02574676 1. Turn the “MAIN POWER DISCONNECT” switch to the OFF position. Remove all electrical loads. Air Inlet Filter — Check 2. The NEGATIVE “-” cable connects the NEGATIVE SMCS Code: 1051-535 “-” battery terminal to the ground plane. Di
Page 83SEBU8219-01 83 Maintenance Section Battery Electrolyte Level — Check The battery charger must not produce excessive Table 10 current during start-up. Alternatively, the charger Effects of Overcharging Batteries must be automatically disconnected for start-up. If the engine has an alternator, the cha
Page 8484 SEBU8219-01 Maintenance Section Battery or Battery Cable — Disconnect 2. Check the condition of the electrolyte with the i02023749 245-5829 Coolant Battery Tester Refractometer. Bearing (Ball) — Lubricate 3. Keep the batteries clean. (Generator) Clean the battery case with one of the following SM
Page 85SEBU8219-01 85 Maintenance Section Bearing — Inspect i02230503 5. Remove the bracket drain plug and operate the generator for one hour. This will allow the grease Bearing — Inspect to expand. The expanding grease will force the excess grease from the cavity. When the excess SMCS Code: 4471-040 greas
Page 8686 SEBU8219-01 Maintenance Section Bearing — Inspect Table 11 Bearing Bearing Part Generator Bearing Bore Bearing Bearing Rotor Shaft Outside Inside Number Frame in Bracket Shield Cavity Diameter Diameter Diameter Size mm (inch) (Type) Grease mm (inch) mm (inch) mm (inch) mL (oz) 100.000 mm 45.000 m
Page 87SEBU8219-01 87 Maintenance Section Bearing — Inspect (Table 11, contd) Bearing Bearing Part Generator Bearing Bore Bearing Bearing Rotor Shaft Outside Inside Number Frame in Bracket Shield Cavity Diameter Diameter Diameter Size mm (inch) (Type) Grease mm (inch) mm (inch) mm (inch) mL (oz) 225.000 mm
Page 8888 SEBU8219-01 Maintenance Section Bearing Temperature — Measure/Record (Table 11, contd) Bearing Bearing Part Generator Bearing Bore Bearing Bearing Rotor Shaft Outside Inside Number Frame in Bracket Shield Cavity Diameter Diameter Diameter Size mm (inch) (Type) Grease mm (inch) mm (inch) mm (inch)
Page 89SEBU8219-01 89 Maintenance Section Control Panel — Inspect Alternator Belt Adjustment Electronic Modular Control Panel 3 (EMCP 3) g01184041 Illustration 66 The Lamp Test button is located on the top right side of the electronic control module. Press and hold the Lamp Test button in order to test all
Page 9090 SEBU8219-01 Maintenance Section Cooling System Coolant (DEAC) — Change It is possible to test the LED indicators and the horn 2. Open the cooling system drain valve (if equipped). when the data link is connected and when the data If the cooling system is not equipped with a drain link is not conn
Page 91SEBU8219-01 91 Maintenance Section Cooling System Coolant (DEAC) — Change 5. Stop the engine and allow the engine to cool. 5. Stop the engine and allow the engine to cool. Loosen the cooling system filler cap slowly Loosen the cooling system filler cap slowly in order to relieve any pressure. Remove
Page 9292 SEBU8219-01 Maintenance Section Cooling System Coolant (ELC) — Change i02056152 For information regarding the disposal and the recycling of used coolant, consult your Caterpillar Cooling System Coolant (ELC) dealer or consult Caterpillar Dealer Service Tool — Change Group: SMCS Code: 1350-044-NL
Page 93SEBU8219-01 93 Maintenance Section Cooling System Coolant Extender (ELC) — Add 3. Check the coolant level. Maintain the coolant level within 13 mm (0.5 inch) below the bottom of the pipe for filling. Maintain the coolant level within Personal injury can result from hot coolant, steam 13 mm (0.5 inch
Page 9494 SEBU8219-01 Maintenance Section Cooling System Coolant Level — Check i01197583 3. Clean the cooling system filler cap and check the condition of the filler cap gaskets. Replace the Cooling System Coolant Level cooling system filler cap if the filler cap gaskets are — Check damaged. Reinstall the
Page 95SEBU8219-01 95 Maintenance Section Cooling System Coolant Sample (Level 2) — Obtain Obtain the sample of the coolant as close as possible Submit the sample for Level 2 analysis. to the recommended sampling interval. In order to receive the full effect of S·O·S analysis, you For additional informatio
Page 9696 SEBU8219-01 Maintenance Section Cooling System Water Temperature Regulator — Replace 3. Add tap water to the mixing bottle in order to bring the level up to the “10 ml” mark. Place the cap on NOTICE the bottle and shake the bottle. Excessive supplemental coolant additive concentra- tion can form
Page 97SEBU8219-01 97 Maintenance Section Crankshaft Vibration Damper — Inspect A water temperature regulator that fails in the open Visconic Damper position will cause the engine operating temperature to be too low during partial load operation. Low The visconic damper has a weight that is located engine
Page 9898 SEBU8219-01 Maintenance Section Engine — Clean i01664717 Inspecting and Replacing the Engine — Clean Secondary Air Cleaner Element (If Equipped) SMCS Code: 1000-070 NOTICE Never run the engine without an air cleaner element installed. Never run the engine with a damaged air Personal injury or dea
Page 99SEBU8219-01 99 Maintenance Section Engine Air Cleaner Service Indicator — Inspect 3. Clean the inside of the air cleaner cover and body • The red piston locks in the visible position. with a clean, dry cloth. 4. Remove the adhesive covering that covers the air Test the Service Indicator inlet for th
Page 100100 SEBU8219-01 Maintenance Section Engine Mounts — Check 2. Remove the bolts (1) and remove the breather i02108396 from the engine. Engine Oil Level — Check 3. Check the condition of the seal. Replace the seal if the seal is damaged. SMCS Code: 1348-535-FLV 4. Remove the breather element. Wash the
Page 101SEBU8219-01 101 Maintenance Section Engine Oil Sample — Obtain 2. Remove the oil filler cap and add oil, if necessary. Caterpillar recommends using the sampling valve For the correct oil to use, see this Operation in order to obtain oil samples. The quality and the and Maintenance Manual, “Refill Ca
Page 102102 SEBU8219-01 Maintenance Section Engine Oil and Filter — Change Drain the Engine Oil After the engine has been run at the normal operating temperature, stop the engine. Use one of the following methods to drain the engine crankcase oil: • If the engine is equipped with a drain valve, turn the dra
Page 103SEBU8219-01 103 Maintenance Section Engine Protective Devices — Check 3. Stop the engine and allow the oil to drain back to i02562758 the sump for a minimum of ten minutes. Engine Valve Lash — 4. Remove the oil level gauge in order to check the oil level. Maintain the oil level between the “ADD” Ins
Page 104104 SEBU8219-01 Maintenance Section Fan Drive Bearing — Lubricate i02784507 Inspect the adjustment of the lash for the fuel injector according to the Testing And Adjusting, “Fuel Injector Fan Drive Bearing — Lubricate Adjustment”. Adjust the lash for the fuel injector, if necessary. SMCS Code: 1359-
Page 105SEBU8219-01 105 Maintenance Section Fuel System Primary Filter/Water Separator — Drain 1. Turn the priming pump plunger (4) counterclockwise in order to unlock the plunger. Manually pump the plunger in order to fill the fuel lines and the fuel filters with fuel. 2. As the air is purged from the fuel
Page 106106 SEBU8219-01 Maintenance Section Fuel System Primary Filter (Water Separator) Element — Replace 2. Close drain valve(3). 2. Shut off the fuel supply. NOTICE The water separator is under suction during normal engine operation. Ensure that the drain valve is tight- ened securely to help prevent air
Page 107SEBU8219-01 107 Maintenance Section Fuel System Secondary Filter — Replace 13. Install the new filter onto the base. Tighten the filter by hand until the seal contacts the filter base. NOTICE Additionally tighten the filter by 1/3 to 1/2 rotation. Use a suitable container to catch any fuel that migh
Page 108108 SEBU8219-01 Maintenance Section Fuel Tank Water and Sediment — Drain i03071053 Some fuel tanks use supply pipes that allow water and sediment to settle below the end of the fuel Fuel Tank Water and Sediment supply pipe. Some fuel tanks use supply lines that — Drain take fuel directly from the bo
Page 109SEBU8219-01 109 Maintenance Section Generator — Inspect • Self-circulating air method • Salt • Oven method • Metal dust NOTICE • Dirt that is saturated with moisture Do not allow the winding temperature to exceed 85 °C (185.0 °F). Temperatures that are greater than 85 °C These contaminants will deve
Page 110110 SEBU8219-01 Maintenance Section Generator Load — Check Cleaning (Disassembled The power factor can be referred to as the efficiency of the load. This can be expressed as the ratio of kVA Generators) to actual kW. The power factor can be calculated by dividing kW by kVA. Power factor is expressed
Page 111SEBU8219-01 111 Maintenance Section Generator Set — Test i01473730 • The phase voltages change relative to engine speed. Generator Set — Test The generator set functional test consists of the SMCS Code: 4450-081 following steps: 1. Stop the generator. Connect the potential transformer’s high voltage
Page 112112 SEBU8219-01 Maintenance Section Generator Set Vibration — Inspect i02211917 Visually inspect all heat shields for signs of wear. Some unacceptable signs of wear are listed below. Generator Set Vibration — Inspect • Outer covering that is chafed or cracked SMCS Code: 4450-040-VI • Outer covering
Page 113SEBU8219-01 113 Maintenance Section Insulation — Test Due to extreme temperature changes, the hose will 10. Start the engine. Inspect the cooling system for heat set. Heat setting causes hose clamps to loosen. leaks. This can result in leaks. A constant torque hose clamp will help to prevent loose h
Page 114114 SEBU8219-01 Maintenance Section Insulation — Test • The generator set is installed in an enclosed area. 8. Connect the insulation tester’s BLACK lead to This area needs to be low in humidity and this area “T0”. needs to have steady temperatures. Test every twelve months (minimum). 9. For units t
Page 115SEBU8219-01 115 Maintenance Section Insulation — Test g00633226 Illustration 81
Page 116116 SEBU8219-01 Maintenance Section Jacket Water Heater — Check i01917546 The oil consumption rate (brake specific oil consumption) is measured in grams per kW/h (lb per Jacket Water Heater — Check bhp). The brake specific oil consumption (BSOC) (Standby Generator Sets (If depends on the engine load
Page 117SEBU8219-01 117 Maintenance Section Overhaul Considerations Table 17 Note: Overhaul programs vary according to the Equation For Calculating Overhaul Intervals engine application and according to the dealer that performs the overhaul. Consult your Caterpillar F/R = H dealer for specific information a
Page 118118 SEBU8219-01 Maintenance Section Overhaul Considerations Reduced engine efficiency and increased fuel • Camshaft bearings consumption translates into higher operating costs. Therefore, Caterpillar Inc. recommends repairing • Camshaft followers out-of-spec parts or replacing out-of-spec parts. Cat
Page 119SEBU8219-01 119 Maintenance Section Prelube Pump — Inspect 5. Wash the oil cooler core and the aftercooler core • Identification of contaminants with hot, soapy water. Rinse the oil cooler core and the aftercooler core thoroughly with clean water. • Identification of built up impurities (corrosion a
Page 120120 SEBU8219-01 Maintenance Section Rotating Rectifier — Check Testing a Three-Diode Rectifier Block Personal injury can result from air pressure. Personal injury can result without following prop- er procedure. When using pressure air, wear a pro- tective face shield and protective clothing. The ma
Page 121SEBU8219-01 121 Maintenance Section Space Heater — Check a. Place the red test lead on the negative “-” terminal. Place the black test lead on the following rectifier terminals: “AC1”(3), “AC2”(4), and “AC3”(5). All readings on the meter should be between 0.4 and 1.0. b. Place the black test lead on
Page 122122 SEBU8219-01 Maintenance Section Speed Sensor — Clean/Inspect g01184155 Illustration 87 1. Remove the sensor. Inspect the condition of the end of the magnet. Look for signs of wear and contaminants. 2. Clean any debris from the face of the magnet. 3. Check the tension of the sliphead. Gently exte
Page 123SEBU8219-01 123 Maintenance Section Standby Generator Set Maintenance Recommendations i01943204 Maintenance and Repair Standby Generator The maintenance that is recommended for Every Set Maintenance Week can be performed by an authorized operator. The maintenance that is recommended for the Recommen
Page 124124 SEBU8219-01 Maintenance Section Starting Motor — Inspect i02554941 i01218172 Starting Motor — Inspect Stator Lead — Check SMCS Code: 1451-040; 1453-040 SMCS Code: 4459-535 If the starting motor fails, the engine may not start in Visually inspect the following areas for cracking and an emergency
Page 125SEBU8219-01 125 Maintenance Section Turbocharger — Inspect 3. Check the compressor wheel for cleanliness. NOTICE If only the blade side of the wheel is dirty, dirt Turbocharger bearing failures can cause large quan- and/or moisture is passing through the air filtering tities of oil to enter the air
Page 126126 SEBU8219-01 Maintenance Section Varistor — Test i01494879 Test Light Varistor — Test SMCS Code: 4466-081 g00555113 Illustration 89 Test Light Refer to the test light that is shown in Illustration 89. Follow these steps in order to test the varistor: 1. Disconnect either lead of the varistor (CR7
Page 127SEBU8219-01 127 Maintenance Section Walk-Around Inspection i02591373 Excessive coolant leakage may indicate the need to replace the water pump seal. For the removal of Walk-Around Inspection water pump and the installation of water pump and/or seals, refer to the Service Manual for the engine or SMC
Page 128128 SEBU8219-01 Maintenance Section Water Pump — Inspect A visual inspection should be initially directed at Visually inspect the water pump for leaks. If any the areas that are most prone to damage and leaking is observed, replace the water pump seal deterioration. The most prone areas to damage an
Page 129SEBU8219-01 129 Maintenance Section Winding — Test Table 19 Exciter Field (Stator) (L1) – approximately 3.0 Tools Needed ohms to 6.0 ohms Part Number Part(1) Quantity Main Field (Rotor) (L3) – approximately 0.75 ohms Digital to 2.0 ohms 6V-7070 1 Multimeter Note: There should be no continuity betwee
Page 130130 SEBU8219-01 Reference Information Section Engine Ratings Reference Information i01250210 Section Engine Rating Definitions SMCS Code: 1000 Engine Ratings The ratings must be reduced in order to accommodate changes in the altitude. The ratings must be reduced according to the data for derating th
Page 131SEBU8219-01 131 Reference Information Section Engine Ratings Prime + 10% (Standby applications for a power Curtailable (Connected to a utility with a supply from a reliable utility) – This rating allows a Continuous base rating for load factors) – This load that varies up to the Prime rating. An add
Page 132132 SEBU8219-01 Reference Information Section Customer Service Customer Service Latin America, Mexico, Carribean Caterpillar Americas Co. 701 Waterford Way, Suite 200 i02097871 Miami, FL 33126-4670 USA Customer Assistance Phone: 305-476-6800 Fax: 305-476-6801 SMCS Code: 1000; 4450 Europe, Africa, an
Page 133SEBU8219-01 133 Reference Information Section Customer Service i01028392 Ordering Replacement Parts SMCS Code: 4450; 7567 When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent spec- ifications including, but not limit
Page 134134 SEBU8219-01 Reference Information Section Reference Materials Reference Materials • Maintenance log i00912149 Maintenance Records SMCS Code: 1000; 4450 Caterpillar Inc. recommends the retention of accurate maintenance records. Accurate maintenance records can be used for the following purposes:
Page 135SEBU8219-01 135 Reference Information Section Reference Materials i01176304 Maintenance Log SMCS Code: 1000; 4450 Table 20 Engine Model Customer Identifier Serial Number Arrangement Number Service Quantity Service Item Date Authorization Hours Of Fuel
Page 136136 SEBU8219-01 Reference Information Section Reference Materials i02799008 • Special Publication, SEBU6251, “Caterpillar Commercial Diesel Engine Fluids Reference Material Recommendations” SMCS Code: 1000; 4450 Coolants The following publications can be obtained from any Caterpillar dealer. • Data
Page 137SEBU8219-01 137 Reference Information Section Reference Materials • Special Publication, NEHS0526, “Service The “American Petroleum Institute Publication No. Technician Application Guide” 1509” can be obtained from the following locations: local technological society, local library, and local • Spec
Page 138138 SEBU8219-01 Reference Information Section Reference Materials i02797420 Warranty Information SMCS Code: 1000 Engines are covered by a standard one year warranty. The coverage of individual warranties may be different due to the engine application and the geographic location. The warranty is ship
Page 139SEBU8219-01 139 Reference Information Section Reference Materials i02342531 Symbols SMCS Code: 1000; 4450; 4480; 4490 g01168026 Illustration 91 The control panel and modules utilize International Graphic Symbols to identify functions. A typical list of the symbols that are used is shown above. i0120
Page 140140 SEBU8219-01 Reference Information Section Reference Materials Circulating Current – Circulating current is the flow Field – A field is a magnetic line of force that of current between two or more generators that are surrounds a conductor. This force is caused by working in parallel. Circulating
Page 141SEBU8219-01 141 Reference Information Section Reference Materials Interference – Interference is an unwanted mixture Oscillation – Oscillation is the flow of electricity that of electrical signals. Interference is usually associated periodically changes direction and/or magnitude. with electrical no
Page 142142 SEBU8219-01 Reference Information Section Reference Materials Regenerative Power – Regenerative power works Solid-State – A solid-state component is an against primary power. electrical component that has no moving parts. Reset – A reset returns a switch to a ready condition. Stator – A stator i
Page 143SEBU8219-01 143 Index Section Index A Cooling System Supplemental Coolant Additive (SCA) — Test/Add………………………………………….. 95 Additional Messages ……………………………………… 12 Add the SCA, If Necessary ………………………….. 96 After Starting E
Page 144144 SEBU8219-01 Index Section Equipment Parking ………………………………………… 68 Generator Lead Connections …………………….. 36–37 Exhaust Discharge……………………………………… 68 Grounding the Frame…………………………….. 37, 39 Power Module
Page 145SEBU8219-01 145 Index Section M R Maintenance Interval Schedule (Standard) ……….. 80 Radiator — Clean …………………………………………… 119 Maintenance Interval Schedule (Standby)…………. 78 Reference Information ……………………………………. 35 Maintenance
Page 146146 SEBU8219-01 Index Section V Varistor — Test………………………………………………. 126 Ohmmeter ……………………………………………….. 126 Test Light…………………………………………………. 126 Voltage and Frequency — Check ………………..
Page 147Product and Dealer Information Note: For product identification plate locations, see the section “Product Identification Information” in the Operation and Maintenance Manual. Delivery Date: Product Information Model: Product Identification Number: Engine Serial Number: Transmission Serial Number: Ge
Page 148©2008 Caterpillar All Rights Reserved Printed in U.S.A.

Источник

(Ocr-Read Summary of Contents of some pages of the CAT C32 Document (Main Content), UPD: 09 July 2023)

8, CAT C32 Technical CATERPILLAR – 1000 kVA Page 8 Description UTILITY POWER MODULE Revision 1.0 1 May 2006 3. CATERPILLAR ® SR4B ® 693 FRAME GENERATOR 3.1. Specifications Type: Revolving field, solid-state automatic voltage regulator. Construction: Two bearing close coupled – 693 frame 4 pole, three phase, wye connected. Insulation: Class H rated at class F. Enclosure: Drip proof IP…
5, Technical CATERPILLAR – 1000 kVA Page 5 Description UTILITY POWER MODULE Revision 1.0 1 May 2006 2.2. ADEM ® A4 Engine Controller 2.2.1. Introduction The ADEM ® A4 is an integral part of the innovative ACERT ® Technology that provides higher degree of control over a large number of combustion variables than ever before The ADEM ® A4 engine system is composed of the ADEM ® A4 ECM, control software, sensors, actuators, fuel injectors and interface to the generator…
6, CAT C32 Technical CATERPILLAR – 1000 kVA Page 6 Description UTILITY POWER MODULE Revision 1.0 1 May 2006 2 — Advanced features  Isochronous or droop speed control.  Enhanced performance from fuel injection timing and limiting.  J1939 Communications.  Adjustable monitoring of vital engine parameters.  Idle/rated speed setting.  Programmable speed acceleration ramp rate.  Adjustable cool down duration.  Data link interfaces. …
15, Technical CATERPILLAR – 1000 kVA Page 15 Description UTILITY POWER MODULE Revision 1.0 1 May 2006 V. Motor Starting 50 Hz VIII. Open Circuit Curve 50 Hz
…
21, Technical CATERPILLAR – 1000 kVA Page 21 Description UTILITY POWER MODULE Revision 1.0 1 May 2006 VIII. Air Gap Curve IX Reactive curve
…
20, Technical CATERPILLAR – 1000 kVA Page 20 Description UTILITY POWER MODULE Revision 1.0 1 May 2006 VI Open Circuit Curve 60 Hz VII. Short Circuit Curve 60 Hz
…
11, Technical CATERPILLAR – 1000 kVA Page 11 Description UTILITY POWER MODULE Revision 1.0 1 May 2006 3.5.3. CDVR ® Specifications General Specifications Voltage regulation Temp. Drift Response Time Variable Sensing Range Control Power Regulator Filtering Harmonic Tolerance Weight ±0.25% no load to full load ±1.0% for a 40° C change Maximum of 10 milliseconds 90 to 600 Volts 24 Vdc Supply (18 to 30 Vdc…
10, Technical CATERPILLAR – 1000 kVA Page 10 Description UTILITY POWER MODULE Revision 1.0 1 May 2006 3.5. Caterpillar ® Digital Voltage Regulator ® (CDVR ® ) 3.5.1. CDVR ® Description The Caterpillar ® Digital Voltage Regulator (CDVR) is a microprocessor-based control designed to provide precise voltage control, robust transient response, and generator protection with industry le…
38, Technical CATERPILLAR – 1000 kVA Page 38 Description UTILITY POWER MODULE Revision 1.0 1 May 2006 Synchronisation pulse is given if • Frequency is within given window • Phase difference is corresponding the given circuit breaker time delay Power organiser will send raise and lower pulses to the engine control panel in order to change generator frequency. Because both generator and mains voltage a…
30, Technical CATERPILLAR – 1000 kVA Page 30 Description UTILITY POWER MODULE Revision 1.0 1 May 2006 Right Side View Top View (Roof removed to show interior components, dimensions in inch)
…
37, Technical CATERPILLAR – 1000 kVA Page 37 Description UTILITY POWER MODULE Revision 1.0 1 May 2006 6.2. Controls – Power organizer Functional description The power organiser is a measuring device that in cooperates 3 phase measuring, combined with complete automatic synchronising capabilities. The module is typical suitable for generator application, but it can also be used for power measuring applications like outgoing load…
1, CAT C32 Technical CATERPILLAR – 1000 kVA Page 1 Description UTILITY POWER MODULE Revision 1.0 1 May 2006 Technical Description CATERPILLAR ® 1000 kVA POWER MODULE C32 ACERT ® TECHNOLOGY 50 / 60 Hz CONVERTIBLE SOUND ATTENUATED ISO 20 ft. CSC CERTIFIED 400 V, 50 Hz, 1000 kVA (800 EKW) 480 V, 60 Hz, 910 EKW (optional equipment shown)
…
16, Technical CATERPILLAR – 1000 kVA Page 16 Description UTILITY POWER MODULE Revision 1.0 1 May 2006 IX. Short Circuit Curve 50 Hz X. Air Gap Curve 50 Hz
…
34, Technical CATERPILLAR – 1000 kVA Page 34 Description UTILITY POWER MODULE Revision 1.0 1 May 2006 FACTORY INSTALLED STANDARD EQUIPMENT Feature s Switchgear Control s MODES of OPERATION Utility paralleling switchgear is included for automatic paralleling with a utility power source as a load management system, with provisions for standby operation feeding in an isolated load network. Modes of operation are field configurable and …
7, Technical CATERPILLAR – 1000 kVA Page 7 Description UTILITY POWER MODULE Revision 1.0 1 May 2006 ELECTRONIC SENSORS — The following sensing is available on the ADEM ® IV controller: oil pressure, fuel pressure, fuel temperature, atmospheric pressure, air inlet temperature, turbo outlet pressure, engine coolant temperature, engine speed, throttle speed, droop position, exhaust temperature, engine control switch position, oil filter pre…
23, Technical CATERPILLAR – 1000 kVA Page 23 Description UTILITY POWER MODULE Revision 1.0 1 May 2006 duplex) protocol using RS-485, which easily interfaces with existing plant systems and equipment. • Simultaneous viewing of all AC L-L voltages, all AC L-N voltages, or all AC line currents. • User-friendly, convenient, customer programmability directs the customer to logical parameter groups (Ex. AC metering, protective relaying, engine monitoring) fo…

Источник

RENR9716-02September 2008

Disassembly andAssemblyC27 and C32 Generator Sets EnginesDWB1-Up (Generator Set)SXC1-Up (Generator Set)MED1-Up (Power Module)WDR1-Up (Generator Set)

SAFETY.CAT.COM

i01658146

Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure to observebasic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardoussituations before an accident occurs. A person must be alert to potential hazards. This person should alsohave the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous andcould result in injury or death.Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread and understood the operation, lubrication, maintenance and repair information.Safety precautions and warnings are provided in this manual and on the product. If these hazard warningsare not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.The message that appears under the warning explains the hazard and can be either written or pictoriallypresented.

Operations that may cause product damage are identified by “NOTICE” labels on the product and inthis publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,procedure, work method or operating technique that is not specifically recommended by Caterpillaris used, you must satisfy yourself that it is safe for you and for others. You should also ensure thatthe product will not be damaged or be made unsafe by the operation, lubrication, maintenance orrepair procedures that you choose.The information, specifications, and illustrations in this publication are on the basis of information thatwas available at the time that the publication was written. The specifications, torques, pressures,measurements, adjustments, illustrations, and other items can change at any time. These changes canaffect the service that is given to the product. Obtain the complete and most current information before youstart any job. Caterpillar dealers have the most current information available.

When replacement parts are required for thisproduct Caterpillar recommends using Caterpil-lar replacement parts or parts with equivalentspecifications including, but not limited to, phys-ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-ture failures, product damage, personal injury ordeath.

RENR9716-02 3Table of Contents

Table of Contents

Disassembly and Assembly Section

Engine — Remove …………………………………………… 4Engine — Install ………………………………………………. 6Fuel Priming Pump — Remove and Install ………….. 9Fuel Filter Base — Remove …………………………….. 10Fuel Filter Base — Install ………………………………… 10Fuel Filter and Water Separator — Remove andInstall ………………………………………………………….. 11Fuel Transfer Pump — Remove ………………………… 12Fuel Transfer Pump — Install ……………………………. 12Electronic Unit Injector — Remove ……………………. 13Electronic Unit Injector — Install ……………………….. 14Electronic Unit Injector Sleeve — Remove …………. 15Electronic Unit Injector Sleeve — Install …………….. 16Turbocharger — Remove …………………………………. 17Turbocharger — Disassemble ………………………….. 17Turbocharger — Assemble ……………………………… 18Turbocharger — Install …………………………………….. 18Exhaust Manifold — Remove and Install …………… 19Inlet and Exhaust Valve Springs — Remove andInstall …………………………………………………………. 20Inlet and Exhaust Valves — Remove and Install …. 22Inlet and Exhaust Valve Guides — Remove andInstall …………………………………………………………. 23Inlet and Exhaust Valve Seat Inserts — Remove andInstall …………………………………………………………. 24Engine Oil Filter Base — Remove …………………….. 25Engine Oil Filter Base — Disassemble ………………. 26Engine Oil Filter Base — Assemble …………………… 26Engine Oil Filter Base — Install ………………………… 27Engine Oil Cooler — Remove …………………………… 27Engine Oil Cooler — Install ………………………………. 28Engine Oil Pump — Remove ……………………………. 28Engine Oil Pump — Disassemble ……………………… 29Engine Oil Pump — Assemble ………………………….. 29Engine Oil Pump — Install ……………………………….. 30Water Pump — Remove ………………………………….. 31Water Pump — Disassemble …………………………… 31Water Pump — Assemble ……………………………….. 32Water Pump — Install ……………………………………… 33Water Temperature Regulator Housing — Remove andInstall ………………………………………………………… 33Cooling System Package (Radiator, Aftercooler, FuelCooler) — Remove ………………………………………… 35Cooling System Package (Radiator, Aftercooler, FuelCooler) — Install ……………………………………………. 36Aftercooler — Remove ……………………………………. 38Aftercooler — Install ……………………………………….. 40Radiator Core — Remove ……………………………….. 42Radiator Core — Install …………………………………… 44Engine Support (Front) — Remove and Install ……. 45Gear Group (Rear) — Remove …………………………. 46Gear Group (Rear) — Install …………………………….. 48Flywheel — Remove and Install ……………………….. 49Crankshaft Rear Seal — Remove ……………………… 50Crankshaft Rear Seal — Install …………………………. 50Flywheel Housing — Remove and Install ………….. 51

Vibration Damper and Pulley — Remove and Install………………………………………………………………….. 53Crankshaft Front Seal — Remove …………………….. 54Crankshaft Front Seal — Install ………………………… 55Gear Group (Front) — Remove ………………………… 55Gear Group (Front) — Install ……………………………. 56Housing (Front) — Remove ……………………………… 57Housing (Front) — Install …………………………………. 58Housing (Rear) — Remove ………………………………. 60Housing (Rear) — Install ………………………………….. 60Valve Mechanism Cover — Remove and Install ….. 62Valve Mechanism Cover Base — Remove andInstall …………………………………………………………. 62Rocker Arm and Shaft — Remove …………………….. 63Rocker Arm — Disassemble …………………………….. 64Rocker Arm — Assemble …………………………………. 64Rocker Arm and Shaft — Install ………………………… 65Cylinder Head — Remove ……………………………….. 66Cylinder Head — Install …………………………………… 68Camshaft — Remove ………………………………………. 71Camshaft — Install ………………………………………….. 73Camshaft Bearings — Remove …………………………. 76Camshaft Bearings — Install …………………………….. 76Engine Oil Pan — Remove and Install ………………. 78Cylinder Liner — Remove ………………………………… 79Cylinder Liner — Install ……………………………………. 79Piston Cooling Jets — Remove and Install …………. 80Pistons and Connecting Rods — Remove ………….. 81Pistons and Connecting Rods — Disassemble ……. 82Pistons and Connecting Rods — Assemble ……….. 82Pistons and Connecting Rods — Install ……………… 83Connecting Rod Bearings — Remove ……………….. 84Connecting Rod Bearings — Install …………………… 85Crankshaft Main Bearings — Remove ……………….. 86Crankshaft Main Bearings — Install …………………… 87Crankshaft — Remove …………………………………….. 88Crankshaft — Install ………………………………………… 90Bearing Clearance — Check …………………………….. 92Atmospheric Pressure Sensor — Remove andInstall …………………………………………………………. 93Camshaft Position Sensor — Remove and Install .. 93Crankshaft Position Sensor — Remove and Install .. 94Coolant Temperature Sensor — Remove andInstall …………………………………………………………. 95Engine Oil Pressure Sensor — Remove and Install………………………………………………………………….. 96Fuel Pressure Sensor — Remove and Install ……… 97Fuel Temperature Sensor — Remove and Install … 97Turbocharger Outlet Pressure Sensor — Remove andInstall …………………………………………………………. 98Inlet Air Temperature Sensor — Remove andInstall …………………………………………………………. 99Belt Guard — Remove and Install ……………………… 99Fan Guard — Remove and Install …………………… 100Fan — Remove and Install …………………………….. 101Fan Drive — Remove and Install ……………………. 102Electronic Control Module — Remove and Install .. 103Alternator — Remove and Install ……………………. 104Electric Starting Motor — Remove and Install ….. 105

Index Section

Index …………………………………………………………. 106

4 RENR9716-02Disassembly and Assembly Section

Disassembly and AssemblySection

i02747487

Engine — RemoveSMCS Code: 1000-011

Removal ProcedureTable 1

Required Tools

ToolPart

Number Part Description Qty

A 138-7573 Link Bracket 2

B 238-9586 Engine Turning Tool 1

C 1U-9200 Lever Puller Hoist 1

D 189-0411 Shackle As 2

E 6V-6146 Load Leveling Beam 1

Start By:

a. Remove the cooling package. Refer toDisassembly and Assembly, “Cooling SystemPackage (Radiator, Aftercooler, Fuel Cooler) -Remove”.

g01291159Illustration 1

1. Disconnect hose assembly (1). Disconnect cableassembly (2). Disconnect harness assemblies(3). Disconnect cable assembly (4). Disconnectharness assemblies (5).

g01291160Illustration 2

2. Disconnect harness assembly (6).

g01291161Illustration 3

3. Disconnect hose assemblies (7), (8), and (9).

g01291162Illustration 4

4. Disconnect clamp (10).

RENR9716-02 5Disassembly and Assembly Section

g01291179Illustration 5

5. Remove bolts (11). Remove bolts (12). Repeat forthe opposite side. Disconnect tube assembly (13).Repeat for the opposite side.

g01291183Illustration 6

6. Attach Tooling (A) and a suitable lifting deviceonto exhaust elbow (14). The weight of exhaustelbow (14) is approximately 34 kg (75 lb). Removeexhaust elbow (14).

g01291186Illustration 7

7. Disconnect clamp (15).

g01291225Illustration 8

8. Remove bolts (16). Remove guard (17).

g01291227Illustration 9

9. Remove bolts (18). Remove guard (19).

g01291228Illustration 10

10.Disconnect hose (20).

6 RENR9716-02Disassembly and Assembly Section

g01291232Illustration 11

g01291243Illustration 12

11. Install Tooling (B). Use Tooling (B) in order torotate the engine. Rotate the engine in order togain access to bolts (22). Remove bolts (22).Remove bolts (21).

g01376223Illustration 13

12.Use Tooling (C) in order to support generatorrotor (23).

g01291246Illustration 14

13.Attach Tooling (D) onto engine (24). Attach Tooling(E) and a suitable lifting device onto Tooling(D). The weight of engine (24) is approximately3527 kg (7775 lb).

g01291247Illustration 15

14.Remove mounting bolts (25). Remove engine(24) from the generator.

i02747534

Engine — InstallSMCS Code: 1000-012

Installation ProcedureTable 2

Required Tools

ToolPart

Number Part Description Qty

A 138-7573 Link Bracket 2

B 238-9586 Engine Turning Tool 1

C 1U-9200 Lever Puller Hoist 1

D 189-0411 Shackle As 2

E 6V-6146 Load Leveling Beam 1

RENR9716-02 7Disassembly and Assembly Section

g01291246Illustration 16

1. Attach Tooling (D) onto engine (24). Attach Tooling(E) and a suitable lifting device onto Tooling(D). The weight of engine (24) is approximately3527 kg (7775 lb). Install engine (24).

g01291247Illustration 17

2. Install mounting bolts (25).

g01291243Illustration 18

g01291232Illustration 19

3. Install bolts (21). Use Tooling (B) in order to rotatethe engine. Install bolts (22).

g01291245Illustration 20

4. Remove Tooling (C).

g01291228Illustration 21

5. Connect hose (20).

8 RENR9716-02Disassembly and Assembly Section

g01291227Illustration 22

6. Install guard (19). Install bolts (18).

g01291225Illustration 23

7. Install guard (17). Install bolts (16).

g01291186Illustration 24

8. Connect clamp (15).

g01291183Illustration 25

9. Attach Tooling (A) and a suitable lifting deviceonto exhaust elbow (14). The weight of exhaustelbow (14) is approximately 34 kg (75 lb). Installexhaust elbow (14).

g01291179Illustration 26

10.Connect tube assembly (13). Install bolts (12).Repeat for the opposite side. Install bolts (11).

g01291162Illustration 27

RENR9716-02 9Disassembly and Assembly Section

11.Connect clamp (10).

g01291161Illustration 28

12.Connect hose assemblies (7), (8), and (9).

g01291160Illustration 29

13.Connect harness assembly (6).

g01291159Illustration 30

14.Connect harness assemblies (5). Connect cableassembly (4). Connect harness assemblies (3).Connect cable assembly (2). Connect hoseassembly (1).

End By:

a. Install the cooling package. Refer to Disassemblyand Assembly, “Cooling System Package(Radiator, Aftercooler, Fuel Cooler) — Install”.

i02580978

Fuel Priming Pump — Removeand InstallSMCS Code: 1258-010

Removal Procedure

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.

Refer to Special Publication, NENG2500, “CaterpillarTools and Shop Products Guide” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01292755Illustration 31

1. Remove bolts (1).

2. Remove fuel priming pump (2) and the gasket.

10 RENR9716-02Disassembly and Assembly Section

Installation Procedure

g01292755Illustration 32

1. Position the gasket and fuel priming pump (2) onthe fuel filter base.

2. Install bolts (1).

i02580993

Fuel Filter Base — RemoveSMCS Code: 1262-011

Removal ProcedureTable 3

Required Tools

ToolPart

Number Part Description Qty

A 185-3630 Strap Wrench 1

Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

1. Turn the fuel supply to the OFF position.

g01292764Illustration 33

2. Use Tooling (A) to remove fuel filter (6) from fuelfilter base (5).

3. Disconnect harness assemblies (4).

4. Disconnect hose assembly (1) and hose assembly(2).

5. Remove bolts (3) and fuel filter base (5).

i02581008

Fuel Filter Base — InstallSMCS Code: 1262-012

Installation Procedure

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

RENR9716-02 11Disassembly and Assembly Section

g01292764Illustration 34

1. Position fuel filter base (5) on the engine. Installbolts (3).

2. Connect hose assembly (1) and hose assembly(2).

3. Connect harness assemblies (4).

4. Install fuel filter (6) on fuel filter base (5).

5. Turn the fuel supply to the ON position.

i02581074

Fuel Filter and Water Separator- Remove and InstallSMCS Code: 1261-010; 1263-010

Removal ProcedureTable 4

Required Tools

Tool Part Number Part Description Qty

A 185-3630 Strap Wrench As 1

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

1. Turn the fuel supply to the OFF position.

g01292832Illustration 35

2. Use Tooling (A) to remove the fuel filter and waterseparator (5) from base assembly (4).

3. Disconnect hose assemblies (2) and (3).

4. Remove bolts (1) and base assembly (4).

Installation Procedure

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

12 RENR9716-02Disassembly and Assembly Section

g01292832Illustration 36

1. Position base assembly (4) on the cylinder blockand install bolts (1).

2. Connect hose assemblies (2) and (3).

3. Install a new fuel filter and water separator (5) onbase assembly (4).

4. Turn the fuel supply to the ON position.

i02285574

Fuel Transfer Pump — RemoveSMCS Code: 1256-011

Removal Procedure

Refer to Special Publication, NENG2500, “CaterpillarTools and Shop Products Guide” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

1. Turn the fuel supply to the “OFF” position.

g01143748Illustration 37

2. Disconnect hose assemblies (3).

3. Remove bolts (2).

4. Remove fuel transfer pump (1) and the O-ringseal.

i02287501

Fuel Transfer Pump — InstallSMCS Code: 1256-012

Installation Procedure

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

RENR9716-02 13Disassembly and Assembly Section

g01143748Illustration 38

1. Install the O-ring seal on fuel transfer pump (1).Lubricate the O-ring seal with clean engine oil.

2. Position fuel transfer pump (1) on the engine.Install bolts (2).

3. Connect hose assemblies (3).

4. Turn the fuel supply to the “ON” position.

i02208070

Electronic Unit Injector -RemoveSMCS Code: 1290-011

Removal ProcedureTable 5

Required Tools

Tool Part Number Part Description Qty

A 5F-4764 Pry Bar 1

Start By:

a. Remove the rocker arms and the rocker arm shaft.Refer to Disassembly and Assembly, “Rocker Armand Shaft — Remove”.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01114892Illustration 39

1. Disconnect harness assembly (1).

2. Remove bridge assemblies (3).

NOTICEIf the injector hold down bolt is loose during the re-moval procedure, inspect the injector bore for wearand debris. Replace the clamp and spacer.

3. Remove bolt (4), spacer (5), and clamp (6).

4. Place an identification mark on electronic unitinjectors (2) for installation purposes. Eachelectronic unit injector must be reinstalled in theoriginal location in the cylinder head.

g01073439Illustration 40

5. Use Tooling (A) to pry beneath the base and freeelectronic unit injector (2).

6. Remove electronic unit injector (2) from thecylinder head.

14 RENR9716-02Disassembly and Assembly Section

i03143340

Electronic Unit Injector — InstallSMCS Code: 1290-012

Installation ProcedureTable 6

Required Tools

Tool Part Number Part Description Qty

B 8T-2998 Lubricant 1

1U-5718 Vacuum Pump 1

169-7372 Fluid Sampling Bottle 1C

4C-4057 Tube7.9 mm (0.31 inch) OD 1

D 4C-5552 Large Bore Brush 1

E 4C-6774 Vacuum Gun Kit 1

F 8T-7765 Surface ReconditioningPad 1

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

1. Use Tooling (C) to remove the fuel and oil fromthe cylinder. Evacuate as much fuel and oil aspossible from the cylinder before installing theelectronic unit injector. Several evacuations maybe necessary.

2. Use Tooling (D) to clean the carbon deposit fromthe inside of the electronic unit injector sleeve.Tooling (E) is available to clean loose materialfrom the bore of the electronic unit injector sleeveand the cylinder.

3. Use Tooling (F) to clean the carbon from the seatarea that is inside of the electronic unit injectorsleeve.

4. Install the O-ring seals on the electronic unitinjector. Lubricate the top two O-ring seals with a50/50 mixture of clean engine oil and Tooling (B).

g01114892Illustration 41

g01135876Illustration 42

5. When you install a new injector the E-Trimvalue must be programmed into the enginecontrol module. The injector confirmation codemay need to be programmed into the enginecontrol module. E-Trim Value (X) is a twelve digitalphanumeric code that is supplied with the datasheet that comes with the new injectors. InjectorConfirmation Code (Y) is a four digit numericcode. Both of the codes are located on the top ofelectronic unit injector (2). Use the following menuto program the E-Trim value.

• ECM Summary Screen

• Service Menu

• Calibration

• Injector Code Calibration

RENR9716-02 15Disassembly and Assembly Section

NOTICEWhen an electronic unit injector is replaced, the newelectronic injector code must be programmed into theengine’s personality module software by using the cal-ibration menu on the Electronic Service Tool. If thenew electronic injector code is not entered, the char-acteristics of the previous electronic unit injector is as-sumed.

If it is not possible to immediately reprogram the elec-tronic injector code into the personality module soft-ware, the engine will not be severely harmed. The newelectronic injector code should be reprogrammed asquickly as possible in order to optimize engine perfor-mance.

6. Position electronic unit injector (2) in the cylinderhead.

7. Install spacer (5), clamp (6), and bolt (4). Tightenthe bolt to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

8. Install bridge assemblies (3).

9. Connect harness assembly (1). Tighten the nutsto a torque of 2.5 ± 0.25 N·m (22 ± 2 lb in).

End By:

a. Install the rocker arms and the rocker arm shaft.Refer to Disassembly and Assembly, “Rocker Armand Shaft — Install”.

i02300212

Electronic Unit Injector Sleeve- RemoveSMCS Code: 1713-011

Removal ProcedureTable 7

Required Tools

ToolPart

Number Part Description Qty

A 9U-6891 Injector Tool Group 1

Start By:

a. Remove the electronic unit injectors. Refer toDisassembly and Assembly, “Electronic UnitInjector — Remove”.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

1. Drain the coolant from the cooling system into asuitable container for storage or disposal. Referto Operation and Maintenance Manual, “CoolingSystem Coolant — Change”.

g01043124Illustration 43

2. Install Tooling (A) in electronic unit injector sleeve(1).

3. Tighten the nut on Tooling (A) until the electronicunit injector sleeve is pulled free of the cylinderhead.

g01073635Illustration 44

4. Remove O-ring seals (2) and O-ring seal (3) fromelectronic unit injector sleeve (1).

16 RENR9716-02Disassembly and Assembly Section

i02287628

Electronic Unit Injector Sleeve- InstallSMCS Code: 1713-012

Installation ProcedureTable 8

Required Tools

Tool Part Number Part Description Qty

A 9U-6891 Injector Tool Group 1

9U-6862 Tapered Brush 1

9U-6863 Small Bore Brush 1

9U-7244 End Brush 1

9U-7237 Brush Extension 1

4C-5552 Large Bore Brush 1

C 4C-9507 Retaining Compound 1

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

1. Use Tooling (B) to clean the bore in the cylinderhead for the electronic unit injector sleeve.

NOTICEEnsure that the electronic unit injector sleeve and thecylinder head bore are completely free of oil, dirt, andsealant debris.

g01043165Illustration 45

2. Install new O-ring seals (2) and O-ring seal (3) onelectronic unit injector sleeve (1).

3. Apply Tooling (C) to the contact surface ofelectronic unit injector sleeve (1) on the surfacethat is Marked “X”.

Note: Do not apply Tooling (C) to the cylinder headsurfaces. Apply Tooling (C) on the electronic unitinjector sleeve only.

4. Lubricate O-ring seals (2) with clean engine oil.

g01099549Illustration 46

5. Install electronic unit injector sleeve (1) on Tooling(A). Position the electronic unit injector sleeve inthe cylinder head. Use care not to damage theO-ring seals on the electronic unit injector sleeve.Use Tooling (A) and a hammer to install theelectronic unit injector sleeve in the cylinder head.

NOTICEEnsure that the electronic unit injector sleeve isproperly seated in the cylinder head. The Tooling will»RING» when the electronic unit injector sleeve is fullyseated in the bore of the cylinder head.

6. Remove Tooling (A). Remove excess Tooling (C).

7. Fill the cooling system with coolant. Refer toOperation and Maintenance Manual, “CoolingSystem Coolant — Change”.

End By:

a. Install the electronic unit injectors. Refer toDisassembly and Assembly, “Electronic UnitInjector — Install”.

RENR9716-02 17Disassembly and Assembly Section

i02287744

Turbocharger — RemoveSMCS Code: 1052-011

Removal Procedure

Refer to Special Publication, NENG2500, “CaterpillarTools and Shop Products Guide” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

1. Drain the coolant from the cooling system into asuitable container for storage or disposal. Referto Operation and Maintenance Manual, “CoolingSystem Coolant — Change”.

g01145002Illustration 47

g01148173Illustration 48

2. Remove tube assembly (2).

3. Disconnect tube assemblies (1) and tubeassembly (4).

4. Attach a suitable lifting device to turbocharger (5).The weight of turbocharger (5) is approximately45 kg (100 lb).

5. Remove nuts (3). Remove turbocharger (5) andthe gasket.

i02287870

Turbocharger — DisassembleSMCS Code: 1052-015

Disassembly ProcedureStart By:

a. Remove the turbocharger. Refer to Disassemblyand Assembly, “Turbocharger — Remove”.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

18 RENR9716-02Disassembly and Assembly Section

g01145263Illustration 49

1. Loosen V-band clamp (2) and V-band clamp (4).

2. Separate compressor housing (1) fromturbocharger cartridge (3).

3. Separate turbine housing (5) from turbochargercartridge (3).

i02451256

Turbocharger — AssembleSMCS Code: 1052-016

Assembly Procedure

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

NOTICEThe compressor housing must remain straight withthe turbocharger cartridge during disassembly and as-sembly. Tilting may cause damage to the tips of thecompressor wheel and the compressor shaft.

g01145263Illustration 50

1. Position compressor housing (1) and turbinehousing (5) on turbocharger cartridge (3).

Note: Ensure that the mating surfaces are flush.

2. Tighten the nuts on V-band clamp (2) to a torqueof 14 ± 1 N·m (10 ± 1 lb ft). Use a soft hammer tolightly hit around the diameter of the band clamp.Tighten the nuts again to a torque of 14 ± 1 N·m(10 ± 1 lb ft).

3. Tighten the nuts on V-band clamp (4) to a torqueof 14 ± 1 N·m (10 ± 1 lb ft). Use a soft hammer tolightly hit around the diameter of the band clamp.Tighten the nuts again to a torque of 14 ± 1 N·m(10 ± 1 lb ft).

4. Ensure that the impeller spins freely.

End By:

a. Install the turbocharger. Refer to Disassembly andAssembly, “Turbocharger — Install”.

i02288273

Turbocharger — InstallSMCS Code: 1052-012

Installation ProcedureTable 9

Required Tools

Tool Part Number Part Description Qty

A 5P-3931 Anti-Seize Compound 1

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01148173Illustration 51

RENR9716-02 19Disassembly and Assembly Section

g01145002Illustration 52

1. Position the gasket on the exhaust manifold.

2. Apply Tooling (A) to the threads of the exhaustmanifold studs.

3. Attach a suitable lifting device to turbocharger (5).The weight of turbocharger (5) is approximately45 kg (100 lb). Position turbocharger (5) on theexhaust manifold.

4. Install nuts (3) and tighten to a torque of 55 ± 9 N·m(41 ± 7 lb ft).

5. Connect tube assemblies (1) and tube assembly(4).

6. Install tube assembly (2).

7. Fill the cooling system. Refer to Operation andMaintenance Manual, “Cooling System Coolant- Change”.

i02617122

Exhaust Manifold — Removeand InstallSMCS Code: 1059-010

Removal ProcedureStart By:

a. Remove the turbocharger. Refer to Disassemblyand Assembly, “Turbocharger — Remove”.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

1. Remove the shield assemblies from the exhaustmanifolds.

g01218139Illustration 53

2. Remove locknuts (6) from exhaust manifold (7).

3. Remove spacers (2) and (3) from exhaustmanifold (7).

4. Remove exhaust manifold (7) and gaskets (1)from the cylinder head.

5. If necessary, remove clamps (4) and expansionjoints (5).

Installation ProcedureTable 10

Required Tools

Tool Part Number Part Description Qty

A 5P-3931 Anti-Seize Compound —

B 165-4638 Guide 3

g01218139Illustration 54

20 RENR9716-02Disassembly and Assembly Section

g00566145Illustration 55

1. If necessary, install expansion joints (5) andclamps (4). Tighten the clamps to a torque of8.5 ± 1.0 N·m (75 ± 9 lb in).

2. Apply Tooling (A) to the studs prior to assembly. Ifnecessary, install the studs and tighten to a torqueof 35 ± 5 N·m (26 ± 4 lb ft).

3. Position gaskets (1) and exhaust manifold (7) onthe cylinder head.

4. Install spacers (2) and (3) on exhaust manifold (7).

Note: Use Tooling (B) in at least one oversize holeper manifold section in order to align the exhaustmanifolds. Do not remove Tooling (B) until removalis required to tighten the locknuts.

5. Install locknuts (6) on exhaust manifold (7).Tighten locknuts (6) in a numerical sequence to atorque of 20 ± 3 N·m (15 ± 2 lb ft). Tighten locknuts(6) again in a numerical sequence to a torque of38 ± 5 N·m (28 ± 4 lb ft).

6. Install the shield assemblies on the exhaustmanifolds.

End By:

a. Install the turbocharger. Refer to Disassembly andAssembly, “Turbocharger — Install”.

i02300073

Inlet and Exhaust ValveSprings — Remove and InstallSMCS Code: 1108-010

Removal ProcedureTable 11

Required Tools

Tool Part Number Part Description Qty

A 9U-7241 Valve Spring Compressor 1

B 8S-2263 Spring Tester 1

Start By:

a. Remove the electronic unit injectors. Refer toDisassembly and Assembly, “Electronic UnitInjector — Remove”.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

Note: Place the piston at the top of the compressionstroke (TC). Remove the valve springs for thatcylinder. If the valves fall into the cylinder liner, thenthe cylinder head must be removed.

1. Position the No. 1 piston at the top center ofthe compression stroke. Refer to Testing andAdjusting, “Finding Top Center Position for No. 1Piston”.

g01073852Illustration 56

RENR9716-02 21Disassembly and Assembly Section

g01043625Illustration 57

Personal injury can result from being struck byparts propelled by a released spring force.

Make sure to wear all necessary protective equip-ment.

Follow the recommended procedure and use allrecommended tooling to release the spring force.

2. Install Tooling (A) in the electronic unit injectorsleeve. Secure Tooling (A) with unit injector clamp(1).

3. Tighten the full nut until valve spring keepers (3)are loose on valve (2).

4. Remove valve spring keepers (3) from the valve.

5. Carefully remove Tooling (A).

6. Remove valve rotator (4).

7. Remove outer valve spring (6) and inner valvespring (5) from the valve.

8. Remove washer (7) from the valve guide.

9. Use Tooling (B) to check the valve springs (springforce). Refer to Specifications, “Cylinder HeadValves” for additional information on the valvesprings.

Installation ProcedureTable 12

Required Tools

Tool Part Number Part Description Qty

A 9U-7241 Valve Spring Compressor 1

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

1. Lubricate the valve stems with clean engine oil.

g01043625Illustration 58

Improper assembly of parts that are spring loadedcan cause bodily injury.

To prevent possible injury, follow the establishedassembly procedure and wear protective equip-ment.

2. Ensure that washer (7) is installed on the valveguide.

3. Install inner valve spring (5) and outer valve spring(6) on valve (2).

4. Install valve rotator (4) on valve (2).

The valve spring keepers can be thrown fromthe valve when the valve spring compressor isreleased. Ensure that the valve spring keepersare properly installed on the valve stem. To helpprevent personal injury, keep away from the frontof the valve spring keepers and valve springsduring the installation of the valves.

5. Use Tooling (A) to compress inner valve spring(5) and outer valve spring (6). Install valve springkeepers (3) on valve (2). Remove unit injectorclamp (1) and Tooling (A).

22 RENR9716-02Disassembly and Assembly Section

End By:

a. Install the electronic unit injectors. Refer toDisassembly and Assembly, “Electronic UnitInjector — Install”.

i02642655

Inlet and Exhaust Valves -Remove and InstallSMCS Code: 1105-010

Removal ProcedureTable 13

Required Tools

Tool Part Number Part Description Qty

A 5S-1330 Valve SpringCompressor 1

B 8S-2263 Spring Tester 1

Start By:

a. Remove the cylinder head. Refer to Disassemblyand Assembly, “Cylinder Head — Remove”.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01015263Illustration 59

Personal injury can result from being struck byparts propelled by a released spring force.

Make sure to wear all necessary protective equip-ment.

Follow the recommended procedure and use allrecommended tooling to release the spring force.

1. Install Tooling (A) and compress the valve springs.Remove valve spring keepers (2) from valve (1).

2. Carefully remove Tooling (A) from valve (1).

3. Remove valve rotator (3).

4. Remove outer valve spring (5) and inner valvespring (4) from valve (1).

5. Remove washer (6) and valve (1) from the valveguide.

6. Use Tooling (B) to check the valve springs (springforce). Refer to Specifications, “Cylinder HeadValves” for additional information on the valvesprings.

7. Inspect the valves. Refer to Specifications,“Cylinder Head Valves” for additional informationon the inlet and exhaust valves.

RENR9716-02 23Disassembly and Assembly Section

Installation ProcedureTable 14

Required Tools

Tool Part Number Part Description Qty

A 5S-1330 Valve SpringCompressor 1

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

Note: A small amount of grease can be used to holdthe retainer locks in position during installation.

1. Lubricate the valves with clean engine oil. Installthe valves in the cylinder head.

g01015263Illustration 60

Improper assembly of parts that are spring loadedcan cause bodily injury.

To prevent possible injury, follow the establishedassembly procedure and wear protective equip-ment.

2. Install washer (6) on the valve guide.

3. Install inner valve spring (4) and outer valve spring(5) on valve (1).

4. Install valve rotator (3) on valve (1).

5. Use Tooling (A) to compress inner valve spring(4) and outer valve spring (5). Install valve springkeepers (2) on valve (1).

6. Carefully remove Tooling (A).

End By:

a. Install the cylinder head. Refer to Disassemblyand Assembly, “Cylinder Head — Install”.

i02109151

Inlet and Exhaust Valve Guides- Remove and InstallSMCS Code: 1104-010

Removal ProcedureTable 15

Required Tools

Tool Part Number Part Description Qty

A(1) 9U-6895 Valve Guide Driver 1(1) Part of 9U-7530 Engine Tool Group

Start By:

a. Remove the inlet and exhaust valves. Refer toDisassembly and Assembly, “Inlet and ExhaustValves — Remove and Install”.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

24 RENR9716-02Disassembly and Assembly Section

g01073841Illustration 61

1. Remove valve stem seal (1) from valve guide (2).

2. Use Tooling (A) and a hammer to remove thevalve guide from the cylinder head.

Installation ProcedureTable 16

Required Tools

Tool Part Number Part Description Qty

A(1) 9U-6895 Valve Guide Driver 1

B(1) 9U-6894 Guide Collar 1(1) Part of 9U-7530 Engine Tool Group

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01073842Illustration 62

1. Lubricate the bores for the valve guides with cleanengine oil.

2. Install valve guide (2) in the cylinder head withTooling (A) and Tooling (B).

Note: Tooling (B) must be used in order to install thevalve guide to the correct height.

Height to top of valve guide from cylinder headsurface ….. 35.00 ± 0.50 mm (1.378 ± 0.020 inch)

Note: For more information, refer to Specifications,“Cylinder Head Valves”.

3. Install valve stem seal (1) on the valve guide.

End By:

a. Install the inlet and exhaust valves. Refer toDisassembly and Assembly, “Inlet and ExhaustValves — Remove and Install”.

i02288478

Inlet and Exhaust Valve SeatInserts — Remove and InstallSMCS Code: 1103-010

Removal ProcedureTable 17

Required Tools

ToolPart

Number Part Description Qty

A 166-7441 Valve Seat Extractor ToolGroup

Start By:

a. Remove the inlet and exhaust valves. Refer toDisassembly and Assembly, “Inlet and ExhaustValves — Remove and Install”.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01145463Illustration 63

RENR9716-02 25Disassembly and Assembly Section

1. Use Tooling (A) to remove valve seat insert (1)from the cylinder head.

2. Clean the bores in the cylinder head for the valveseat inserts. Remove any rough areas from thebores.

Installation ProcedureTable 18

Required Tools

ToolPart

Number Part Description Qty

9U-6898 Valve Seat Driver(Exhaust)

1B(1)

9U-6897 Valve Seat Driver (Inlet) 1(1) Part of 9U-7530 Engine Tool Group

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01079028Illustration 64

1. Lower the temperature of new valve seat insert(1).

2. Use Tooling (B) to install the new valve seat insertin the cylinder head.

Note: Do not machine the prefinished valve seatinserts in order to correct the valve stem projection.An excessive valve stem projection indicates that thevalve seat insert is not seated or material was notcleaned from the bottom of the counterbore.

End By:

a. Install the inlet and exhaust valves. Refer toDisassembly and Assembly, “Inlet and ExhaustValves — Remove and Install”.

i02438648

Engine Oil Filter Base -RemoveSMCS Code: 1306-011

Removal ProcedureTable 19

Required Tools

ToolPart

Number Part Description Qty

A 185-3630 Strap Wrench As 1

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

1. Drain the engine oil into a suitable containerfor storage or disposal. Refer to Operation andMaintenance Manual, “Engine Oil and Filter -Change”.

g01218560Illustration 65

26 RENR9716-02Disassembly and Assembly Section

2. Use Tooling (A) in order to remove engine oilfilters (6).

3. Remove bolts (1), (2), (4), and (5).

4. Remove engine oil filter base (3).

i02127750

Engine Oil Filter Base -DisassembleSMCS Code: 1306-015

Disassembly ProcedureStart By:

a. Remove the engine oil filter base. Refer toDisassembly and Assembly, “Engine Oil FilterBase — Remove”.

1. Remove the O-ring seals.

g01083088Illustration 66

Personal injury can result from being struck byparts propelled by a released spring force.

Make sure to wear all necessary protective equip-ment.

Follow the recommended procedure and use allrecommended tooling to release the spring force.

2. Remove cover (4).

3. Remove springs (3) and plungers (2) from oil filterbase assembly (1).

i02127824

Engine Oil Filter Base -AssembleSMCS Code: 1306-016

Assembly Procedure

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01083088Illustration 67

Improper assembly of parts that are spring loadedcan cause bodily injury.

To prevent possible injury, follow the establishedassembly procedure and wear protective equip-ment.

1. Install plungers (2) and springs (3) in oil filter baseassembly (1).

2. Install cover (4).

3. Install the O-ring seals.

RENR9716-02 27Disassembly and Assembly Section

End By:

a. Install the engine oil filter base. Refer toDisassembly and Assembly, “Engine Oil FilterBase — Install”.

i02438813

Engine Oil Filter Base — InstallSMCS Code: 1306-012

Installation ProcedureTable 20

Required Tools

ToolPart

Number Part Description Qty

A 185-3630 Strap Wrench As 1

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01218560Illustration 68

1. Position engine oil filter base (3) on the engineoil cooler.

2. Install bolts (1), (2), (4), and (5).

3. Use Tooling (A) to install engine oil filters (6).

4. Refill the engine with engine oil. Refer to Operationand Maintenance Manual, “Engine Oil and Filter- Change”.

i02438849

Engine Oil Cooler — RemoveSMCS Code: 1378-011

Removal ProcedureStart By:

a. Remove the engine oil filter base. Refer toDisassembly and Assembly, “Engine Oil FilterBase — Remove”.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

1. Drain the coolant from the cooling system into asuitable container for storage or disposal. Referto Operation and Maintenance Manual, “CoolingSystem Coolant — Change”.

g01218689Illustration 69

2. Remove tube assembly (2).

3. Remove bonnet (1) and the gasket.

28 RENR9716-02Disassembly and Assembly Section

4. Remove engine oil cooler (3).

5. Remove the O-ring seals from engine oil cooler(3).

i02438914

Engine Oil Cooler — InstallSMCS Code: 1378-012

Installation Procedure

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01218689Illustration 70

1. Install the O-ring seals on engine oil cooler (3).

2. Lubricate the O-ring seals with clean engine oilor glycerin.

3. Install engine oil cooler (3).

4. Install the gasket and bonnet (1).

5. Install tube assembly (2).

6. Refill the cooling system with coolant. Refer toOperation and Maintenance Manual, “CoolingSystem Coolant — Change”.

End By:

a. Install the engine oil filter base. Refer toDisassembly and Assembly, “Engine Oil FilterBase — Install”.

i02439263

Engine Oil Pump — RemoveSMCS Code: 1304-011

Removal ProcedureStart By:

a. Remove the engine oil pan. Refer to Disassemblyand Assembly, “Engine Oil Pan — Remove andInstall”.

Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

g01218847Illustration 71

1. Remove tube assemblies (3) from engine oil pump(2).

2. Remove bolts (1) and engine oil pump (2).

RENR9716-02 29Disassembly and Assembly Section

i02439652

Engine Oil Pump — DisassembleSMCS Code: 1304-015

Disassembly ProcedureTable 21

Required Tools

ToolPart

Number Part Description Qty

A 1P-0510 Driver Group 1

B 1P-2320 Puller Assembly 1

Start By:

a. Remove the engine oil pump. Refer toDisassembly and Assembly, “Engine Oil Pump- Remove”.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01218982Illustration 72

Personal injury can result from being struck byparts propelled by a released spring force.

Make sure to wear all necessary protective equip-ment.

Follow the recommended procedure and use allrecommended tooling to release the spring force.

1. Remove bolt (7) and washer (6).

2. Use Tooling (B) to remove drive gear (5) frombody assembly (1). Remove the key from thepump shaft.

3. Remove bolts (4) and separate cover assembly(3) from body assembly (1).

4. Use Tooling (A) and a suitable press in order toremove the bearings from cover assembly (3).

5. Remove shaft assemblies (2).

6. Remove bolts (12) and retainer (11).

7. Remove spring (10), plunger ring (9), and plunger(8).

8. Use Tooling (A) and a suitable press in order toremove the bearings from body assembly (1).

i02439997

Engine Oil Pump — AssembleSMCS Code: 1304-016

Assembly ProcedureTable 22

Required Tools

ToolPart

Number Part Description Qty

A 1P-0510 Driver Group 1

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01218982Illustration 73

30 RENR9716-02Disassembly and Assembly Section

g01219045Illustration 74

g01219048Illustration 75

Improper assembly of parts that are spring loadedcan cause bodily injury.

To prevent possible injury, follow the establishedassembly procedure and wear protective equip-ment.

1. Use Tooling (A) to install the bearings in bodyassembly (1) until the bearings are even withthe outside surface of body assembly (1). Installthe bearings so the junctions in the bearings areAngle (X). Angle (X) is 30 ± 15 degrees from thecenter line of the bearing bores and toward theoutlet passage in the engine oil pump.

2. Install plunger (8), plunger ring (9), and spring(10).

3. Install retainer (11) and bolts (12).

4. Install shaft assemblies (2).

5. Use Tooling (A) to install the bearings in coverassembly (3) until the bearings are even withthe outside surface of cover assembly (3). Installthe bearings so the junctions in the bearings areAngle (Y). Angle (Y) is 30 ± 15 degrees from thecenter line of the bearing bores, and toward theoutlet passage. The outlet passage has a cavitybetween the bearing bores.

6. Install cover assembly (3) on body assembly (1).Install bolts (4).

7. Install the key into the pump shaft. Install drivegear (5). Install washer (6) and bolt (7). Tightenbolt (7) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

End By:

a. Install the engine oil pump. Refer to Disassemblyand Assembly, “Engine Oil Pump — Install”.

i02440080

Engine Oil Pump — InstallSMCS Code: 1304-012

Installation Procedure

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01218847Illustration 76

1. Position engine oil pump (2) and install bolts (1).

2. Install tube assemblies (3) on engine oil pump (2).

End By:

a. Install the engine oil pan. Refer to Disassemblyand Assembly, “Engine Oil Pan — Remove andInstall”.

RENR9716-02 31Disassembly and Assembly Section

i02440626

Water Pump — RemoveSMCS Code: 1361-011

Removal Procedure

Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

1. Drain the coolant from the cooling system into asuitable container for storage or disposal. Referto Operation and Maintenance Manual, “CoolingSystem Coolant — Change”.

g01219274Illustration 77

2. Remove bolts (1) and bolts (2).

3. Remove cover (3).

g01219275Illustration 78

4. Remove bolts (6) and nuts (5).

5. Remove water pump (4).

i02451192

Water Pump — DisassembleSMCS Code: 1361-015

Disassembly ProcedureTable 23

Required Tools

ToolPart

Number Part Description Qty

8S-2264 Puller Group 1

4B-3903Bolt5/16 — 18 NC by 4inch

1P-0456 Plate 1

4B-4277 Washer 2

B 1P-0510 Driver Group 1

Start By:

a. Remove the water pump. Refer to Disassemblyand Assembly, “Water Pump — Remove”.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

32 RENR9716-02Disassembly and Assembly Section

Note: The water pump seal can be replaced withoutremoving the water pump from the engine.

Note: An intermittent leakage of a small amount ofcoolant from the hole in the water pump housing isnot an indication of a water pump seal failure. Thisis required to provide lubrication for the seal. Do notreplace the water pump seal unless a large amountof leakage or a constant flow of coolant is drainingfrom the water pump housing.

g01195730Illustration 79

1. Remove adapter (15).

2. Remove bolt (9) and washer (8).

3. Use Tooling (A) to remove impeller (5) from shaft(10).

4. Remove bolt (7), washer (6), and gear (4) fromshaft (10).

5. Remove bolts (11) and retainer (13).

6. Remove O-ring seal (14) from housing (3).

7. Use a suitable press to remove shaft (10) andbearing assembly (1) from housing (3).

8. Use a suitable press to remove bearing assembly(1) from shaft (10).

9. Remove seal assembly (12) from housing (3).

10.Use Tooling (B) to remove lip seal (2) from thehousing.

i02394663

Water Pump — AssembleSMCS Code: 1361-016

Assembly ProcedureTable 24

Required Tools

ToolPart

Number Part Description Qty

B 1P-0510 Driver Group 1

C 7N-7843 Seal Installation Tool 1

D 6V-1541 Quick Cure Primer 1

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01195730Illustration 80

1. Use Tooling (B) to install lip seal (2) into thehousing.

2. Apply Tooling (D) to shaft (10). Use a suitablepress to install bearing assembly (1) on shaft (10).

3. Install shaft (10) and bearing assembly (1) inhousing (3).

4. Install O-ring seal (14) on housing (3).

5. Install retainer (13) and bolts (11).

6. Position gear (4) on shaft (10). Install washer (6)and bolt (7).

RENR9716-02 33Disassembly and Assembly Section

7. Use Tooling (C) to install seal assembly (12) ontoshaft (10) until the stationary cup is fully seatedinto housing (3).

8. Install impeller (5) on shaft (10). Install washer(8) and bolt (9). Tighten bolt (9) to a torque of39 ± 3 N·m (29 ± 2 lb ft).

9. Install adapter (15).

End By:

a. Install the water pump. Refer to Disassembly andAssembly, “Water Pump — Install”.

i02440675

Water Pump — InstallSMCS Code: 1361-012

Installation Procedure

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01219275Illustration 81

1. Position water pump (4) in the front housing.

2. Install nuts (5) and bolts (6).

g01219274Illustration 82

3. Position cover (3) on the water pump.

4. Install bolts (2) and bolts (1).

5. Fill the cooling system. Refer to Operation andMaintenance Manual, “Cooling System Coolant- Change”.

i02440754

Water Temperature RegulatorHousing — Remove and InstallSMCS Code: 1393-010

Removal Procedure1. Drain the coolant from the cooling system into asuitable container for storage or disposal until thecoolant is below the level of the water temperatureregulator housing. Refer to Operation andMaintenance Manual, “Cooling System Coolant- Change”.

34 RENR9716-02Disassembly and Assembly Section

g01219336Illustration 83

2. Disconnect hose assembly (1) and elbow (3).

3. Remove bolts (2) and bolts (4). Remove watertemperature regulator housing (5).

g01223744Illustration 84

4. Remove O-ring seals (6) and water temperatureregulators (7) from water temperature regulatorhousing (5).

5. If necessary, remove the lip seals.

Installation ProcedureTable 25

Required Tools

ToolPart

Number Part Description Qty

A 221-8647 Seal Installer Gp 1

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

1. If necessary, use Tooling (A) to install the lip seals.

g01223744Illustration 85

2. Install water temperature regulators (7) and O-ringseals (6) in water temperature regulator housing(5).

g01219336Illustration 86

3. Position water temperature regulator housing (5)on the engine. Install bolts (4) and bolts (2).

4. Connect elbow (3) and hose assembly (1).

5. Fill the cooling system. Refer to Operation andMaintenance Manual, “Cooling System Coolant- Change”.

RENR9716-02 35Disassembly and Assembly Section

i02576096

Cooling System Package(Radiator, Aftercooler, FuelCooler) — RemoveSMCS Code: 1063-011; 1353-011; 1712-011

Removal ProcedureTable 26

Required Tools

Tool PartNumber Part Description Qty

A 189-0410 Shackle As 2

Start By:

a. Remove the fan. Refer to Disassembly andAssembly, “Fan — Remove and Install”.

Refer to Special Publication, NENG2500, “CaterpillarTools and Shop Products Guide” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

1. Drain the coolant from the cooling system intoa suitable container for storage or for disposal.Refer to Operation and Maintenance Manual,“Cooling System Coolant (ELC) — Change”.

g01290908Illustration 87

2. Remove clamp (1). Repeat for the opposite side.

g01290915Illustration 88

3. Disconnect bottom aftercooler tube (2).

g01290916Illustration 89

4. Disconnect top radiator hose (3).

g01290917Illustration 90

5. Disconnect top aftercooler tube (4).

36 RENR9716-02Disassembly and Assembly Section

g01290930Illustration 91

6. Disconnect bottom radiator hose (5). Disconnectbottom aftercooler tube (6).

g01290934Illustration 92

7. Disconnect hose assembly (8) from fuel cooler (7).

g01290939Illustration 93

8. Disconnect hose assembly (9) from fuel cooler (7).

g01290940Illustration 94

9. Attach Tooling (A) and a suitable lifting deviceonto cooling package (10). The weight of coolingpackage (10) is approximately 544 kg (1200 lb).

g01290941Illustration 95

10.Remove bolts (11). Repeat for the opposite side.Remove cooling package (10).

i02576308

Cooling System Package(Radiator, Aftercooler, FuelCooler) — InstallSMCS Code: 1063-012; 1353-012; 1712-012

Installation ProcedureTable 27

Required Tools

Tool Part Number Part Description Qty

A 189-0410 Shackle As 2

RENR9716-02 37Disassembly and Assembly Section

Refer to Special Publication, NENG2500, “CaterpillarTools and Shop Products Guide” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

g01290940Illustration 96

1. Attach Tooling (A) and a suitable lifting deviceonto cooling package (10). The weight of coolingpackage (10) is approximately 544 kg (1200 lb).

g01290941Illustration 97

2. Install cooling package (10). Install bolts (11).Repeat for the opposite side.

g01290939Illustration 98

3. Connect hose assembly (9) onto fuel cooler (7).

g01290934Illustration 99

4. Connect hose assembly (8) onto fuel cooler (7).

g01290930Illustration 100

5. Connect bottom aftercooler tube (6). Connectbottom radiator hose (5).

38 RENR9716-02Disassembly and Assembly Section

g01290917Illustration 101

6. Connect top aftercooler tube (4).

g01290916Illustration 102

7. Connect top radiator hose (3).

g01290915Illustration 103

8. Connect bottom aftercooler tube (2).

g01290908Illustration 104

9. Install clamp (1). Repeat for the opposite side.

10. Fill the cooling system with coolant. Refer toOperation and Maintenance Manual, “CoolingSystem Coolant (ELC) — Change”.

End By:

a. Install the fan. Refer to Disassembly andAssembly, “Fan — Remove and Install”.

i02584900

Aftercooler — RemoveSMCS Code: 1063-011

Removal ProcedureTable 28

Required Tools

Tool Part Number Part Description Qty

A 189-0410 Shackle As 2

Start By:

a. Remove the fan. Refer to Disassembly andAssembly, “Fan — Remove and Install”.

RENR9716-02 39Disassembly and Assembly Section

Refer to Special Publication, NENG2500, “CaterpillarTools and Shop Products Guide” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

1. Drain the coolant from the cooling system intoa suitable container for storage or for disposal.Refer to Operation and Maintenance Manual,“Cooling System Coolant (ELC) — Change”.

g01290908Illustration 105

2. Remove clamp (1). Repeat for the opposite side.

g01290915Illustration 106

3. Disconnect bottom aftercooler tube (2).

g01290916Illustration 107

4. Disconnect top radiator hose (3).

g01290917Illustration 108

5. Disconnect top aftercooler tube (4).

g01290930Illustration 109

6. Disconnect bottom radiator hose (5). Disconnectbottom aftercooler tube (6).

40 RENR9716-02Disassembly and Assembly Section

g01290934Illustration 110

7. Disconnect hose assembly (8) from fuel cooler (7).

g01290939Illustration 111

8. Disconnect hose assembly (9) from fuel cooler (7).

g01294215Illustration 112

9. Remove bolts (10). Remove bolt (11).

g01294232Illustration 113

10.Attach Tooling (A) and a suitable lifting deviceonto aftercooler (12). The weight of aftercooler(12) is approximately 227 kg (500 lb).

g01294234Illustration 114

11.Remove bolt (13). Remove bolts (14) and bolts(15) from aftercooler (12).

12.Repeat Step 9 through Step 11 for the oppositeside.

13.Remove aftercooler (12).

i02585968

Aftercooler — InstallSMCS Code: 1063-012

Installation ProcedureTable 29

Required Tools

Tool Part Number PartDescription Qty

A 189-0410 Shackle As 2

RENR9716-02 41Disassembly and Assembly Section

g01294232Illustration 115

1. Attach Tooling (A) and a suitable lifting device ontoaftercooler (12). The weight of aftercooler (12) isapproximately 227 kg (500 lb). Install aftercooler(12).

g01294234Illustration 116

2. Install bolts (14) and bolts (15) into aftercooler(12). Install bolt (13).

g01294215Illustration 117

3. Install bolt (11). Install bolts (10).

4. Repeat Step 2 and Step 3 for the opposite side.

g01290939Illustration 118

5. Connect hose assembly (9) onto fuel cooler (7).

g01290934Illustration 119

6. Connect hose assembly (8) onto fuel cooler (7).

g01290930Illustration 120

7. Connect bottom aftercooler tube (6). Connectbottom radiator hose (5).

42 RENR9716-02Disassembly and Assembly Section

g01290917Illustration 121

8. Connect top aftercooler tube (4).

g01290916Illustration 122

9. Connect top radiator hose (3).

g01290915Illustration 123

10.Connect bottom aftercooler tube (2).

g01290908Illustration 124

11. Install clamp (1). Repeat for the opposite side.

12. Fill the cooling system with coolant. Refer toOperation and Maintenance Manual, “CoolingSystem Coolant (ELC) — Change”.

End By:

a. Install the fan. Refer to Disassembly andAssembly, “Fan — Remove and Install”.

i02581106

Radiator Core — RemoveSMCS Code: 1353-011; 1353-011-KO

Removal ProcedureTable 30

Required Tools

Tool PartNumber Part Description Qty

A 138-7575 Link Bracket 2

Start By:

a. Remove the aftercooler. Refer to Disassemblyand Assembly, “Aftercooler — Remove”.

RENR9716-02 43Disassembly and Assembly Section

Refer to Special Publication, NENG2500, “CaterpillarTools and Shop Products Guide” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

g01292911Illustration 125

1. Remove the upper and the lower radiator guards(1).

g01292912Illustration 126

2. Attach Tooling (A) and a suitable lifting device ontoradiator top tank (2). The weight of the radiator isapproximately 227 kg (500 lb).

g01294577Illustration 127

3. Remove the upper and the lower braces (3).

g01294578Illustration 128

4. Remove bolts (4) and remove bolts (5).

g01294579Illustration 129

5. Remove bolts (6).

44 RENR9716-02Disassembly and Assembly Section

g01294580Illustration 130

6. Remove bolts (7). Remove bolts (8). Removesupport (9).

7. Repeat Steps 4 through 6 for the opposite side.

g01294602Illustration 131

8. Remove bolts (11). Repeat for the opposite side.Remove radiator (10).

i02585957

Radiator Core — InstallSMCS Code: 1353-012-KO; 1353-012

Installation ProcedureTable 31

Required Tools

Tool PartNumber Part Description Qty

A 138-7575 Link Bracket 2

g01292912Illustration 132

1. Attach Tooling (A) and a suitable lifting device ontoradiator top tank (2). The weight of the radiator isapproximately 227 kg (500 lb).

g01294602Illustration 133

2. Install radiator (10). Install bolts (11). Repeat forthe opposite side.

g01294580Illustration 134

3. Install support (9). Install bolts (8). Install bolts (7).

RENR9716-02 45Disassembly and Assembly Section

g01294579Illustration 135

4. Install bolts (6).

g01294578Illustration 136

5. Install bolts (4) and bolts (5).

6. Repeat Steps 3 through 5 for the opposite side.

g01294577Illustration 137

7. Install the upper and the lower braces (3).

g01292911Illustration 138

8. Install the upper and the lower radiator guards (1).

End By:

a. Install the aftercooler. Refer to Disassembly andAssembly, “Aftercooler — Install”.

i02444868

Engine Support (Front) -Remove and InstallSMCS Code: 1154-010-FR

Removal Procedure (Type 1)Start By:

a. Remove the vibration damper and the pulley.Refer to Disassembly and Assembly, “VibrationDamper and Pulley — Remove and Install”.

1. Support the front of the engine.

g01221659Illustration 139

2. Remove bolts (1).

3. Remove engine support (2).

46 RENR9716-02Disassembly and Assembly Section

Installation Procedure (Type 1)

g01221659Illustration 140

1. Position engine support (2) on the engine.

2. Install bolts (1).

End By:

a. Install the vibration damper and the pulley. Referto Disassembly and Assembly, “Vibration Damperand Pulley — Remove and Install”.

Removal Procedure (Type 2)Start By:

a. Remove the vibration damper and the pulley.Refer to Disassembly and Assembly, “VibrationDamper and Pulley — Remove and Install”.

1. Support the front of the engine.

g01221663Illustration 141

2. Remove bolts (3).

3. Use a suitable lifting device to remove enginesupport (4). The weight of engine support (4) isapproximately 35 kg (77 lb).

Installation Procedure (Type 2)

g01221663Illustration 142

1. Use a suitable lifting device to position enginesupport (4) on the engine. The weight of enginesupport (4) is approximately 35 kg (77 lb).

2. Install bolts (3).

End By:

a. Install the vibration damper and the pulley. Referto Disassembly and Assembly, “Vibration Damperand Pulley — Remove and Install”.

i02440962

Gear Group (Rear) — RemoveSMCS Code: 1206-011; 1212-011

Removal ProcedureTable 32

Required Tools

ToolPart

Number Part Description Qty

A 1P-0510 Driver Group 1

Start By:

a. Remove the flywheel housing. Refer toDisassembly and Assembly, “Flywheel Housing- Remove and Install”.

RENR9716-02 47Disassembly and Assembly Section

Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01219485Illustration 143

1. Remove bolts (10), thrust plate (11), and gearassembly (9).

2. Use Tooling (A) and a suitable press to removethe bearing from gear assembly (9).

3. Remove bolts (8), gear assembly (6), and shaftassembly (7).

4. Use Tooling (A) and a suitable press to removethe bearing from gear assembly (6).

5. Remove bolts (2), gear assembly (1), and shaftassembly (3).

6. Use Tooling (A) and a suitable press to removethe bearing from gear assembly (1).

7. Remove gear assembly (12).

8. Remove bolts (5) and gear assemblies (4).

g01219500Illustration 144

9. Remove bolts (16) and shaft assembly (17).

10.Remove bolts (13), thrust plates (14), and adapterassemblies (15).

11.Use bolt (13) in order to remove the sealingplates. Remove the O-ring seals.

48 RENR9716-02Disassembly and Assembly Section

i02442469

Gear Group (Rear) — InstallSMCS Code: 1206-012; 1212-012

Installation ProcedureTable 33

Required Tools

ToolPart

Number Part Description Qty

A 1P-0510 Driver Group 1

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

Note: Apply clean engine oil to the bearings and theshaft assemblies prior to installation on the engine.

g01219500Illustration 145

1. Install the O-ring seals and the sealing plates onthe cylinder head.

2. Install adapter assemblies (15), thrust plates (14),and bolts (13).

3. Position shaft assembly (17) and install bolts (16).

g01220275Illustration 146

g01151468Illustration 147

4. Refer to Testing and Adjusting, “Rear Gear Group- Time” for additional information.

Note: Align the Timing Marks on gear assemblies (4)with the Timing Marks on the rear housing and alignthe dowels on gear assemblies (4) with the adapterassemblies.

5. Position gear assemblies (4) and install bolts (5).

6. Install gear assembly (12).

7. Use Tooling (A) and a suitable press to install thebearing in gear assembly (1). Install the bearing toa depth of 2.6 ± 0.5 mm (0.10 ± 0.02 inch).

RENR9716-02 49Disassembly and Assembly Section

8. Install shaft assembly (3), gear assembly (1), andbolts (2).

9. Use Tooling (A) and a suitable press to install thebearing in gear assembly (6). Install the bearing toa depth of 2.6 ± 0.5 mm (0.10 ± 0.02 inch).

10. Install shaft assembly (7), gear assembly (6), andbolts (8).

11.Use Tooling (A) and a suitable press to install thebearing in gear assembly (9). Install the bearing toa depth of 2.5 ± 0.5 mm (0.10 ± 0.02 inch).

Note: Align the Timing Mark on gear assembly (9)with the Timing Mark on gear assembly (12).

12. Install gear assembly (9), thrust plate (11), andbolts (10).

13. Tighten the bolts on gear assemblies (4) to atorque of 240 ± 40 N·m (177 ± 30 lb ft). Tightenthe bolts in the following sequence: 1, 4, 2, 5, 3,6, 1, 4.

End By:

a. Install the flywheel housing. Refer to Disassemblyand Assembly, “Flywheel Housing — Remove andInstall”.

i02752668

Flywheel — Remove and InstallSMCS Code: 1156-010

Removal ProcedureTable 34

Required Tools

ToolPart

Number Part Description Qty

A — Guide Stud5/8 — 18 UNF by 11 inch 2

g01220437Illustration 148

g01220438Illustration 149

1. Remove two bolts (1). Install Tooling (A) in thecrankshaft.

2. Remove remaining bolts (1). Slide flywheel (2)away from the engine on Tooling (A).

3. Attach a suitable lifting device to flywheel (2). Theweight of flywheel (2) is approximately 130 kg(285 lb). Remove flywheel (2).

4. If necessary, use a hammer and a punch in orderto remove ring gear (3) from flywheel (2).

Installation ProcedureTable 35

Required Tools

ToolPart

Number Part Description Qty

A — Guide Stud5/8 — 18 UNF by 11 inch 2

B 6V-4876 Lubricant —

g01220438Illustration 150

50 RENR9716-02Disassembly and Assembly Section

g01220437Illustration 151

Note: Ring gear (3) must be installed with thechamfered side of the teeth upward. The chamferedside of the gear teeth will be facing toward the startingmotor when the flywheel is installed.

1. Raise the temperature of ring gear (3). Install ringgear (3) on flywheel (2).

2. Install Tooling (A) in the crankshaft.

3. Attach a suitable lifting device to flywheel (2). Theweight of flywheel (2) is approximately 130 kg(285 lb). Position flywheel (2) on the crankshaft.

4. Apply Tooling (B) to the threads of bolts (1).

5. Install bolts (1). Remove Tooling (A). Installremaining bolts (1).

6. Tighten bolts (1) to a torque of 100 ± 5 N·m(75 ± 4 lb ft). Turn the bolts for an additional 180 ±5 degrees.

7. Check the flywheel runout. Refer to Testing andAdjusting, “Flywheel — Inspect”.

i02442878

Crankshaft Rear Seal — RemoveSMCS Code: 1161-011

Removal ProcedureTable 36

Required Tools

ToolPart

Number Part Description Qty

A 1U-7600 Slide Hammer Puller 1

Start By:

a. Remove the flywheel. Refer to Disassembly andAssembly, “Flywheel — Remove and Install”.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01220531Illustration 152

1. Use Tooling (A) or a punch and hammer in orderto puncture three or more holes in crankshaft rearseal (1).

2. Use Tooling (A) to remove crankshaft rear seal (1)and crankshaft wear sleeve (2).

i02442921

Crankshaft Rear Seal — InstallSMCS Code: 1161-012

Installation ProcedureTable 37

Required Tools

ToolPart

Number Part Description Qty

249-2937(1) Seal Locator As 1

5P-7310(1) Bolt 3

9S-8858(1) Nut (Seal Installer) 1

6V-6143(1) Seal Installer 1

5P-1733(2) Seal Locator As 1

5P-7309(2) Bolt 3

9S-8858(2) Nut (Seal Installer) 1

6V-6142(2) Seal Installer 1(1) Large crankshaft gear(2) Small crankshaft gear

RENR9716-02 51Disassembly and Assembly Section

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01220558Illustration 153

1. Clean the outside diameter of the crankshaft.

Note: Install the crankshaft rear seal with the arrowthat shows the direction of crankshaft rotation towardthe rear of the engine.

2. Use Tooling (B) to install crankshaft wear sleeve(2) and crankshaft rear seal (1) as a unit.

End By:

a. Install the flywheel. Refer to Disassembly andAssembly, “Flywheel — Remove and Install”.

i02752908

Flywheel Housing — Removeand InstallSMCS Code: 1157-010

Removal ProcedureTable 38

Required Tools

ToolPart

Number Part Description Qty

A 138-7574 Link Bracket 2

B — Guide Stud1/2 — 13 NC by 7 inch 2

Start By:

a. Remove the crankshaft rear seal. Refer toDisassembly and Assembly, “Crankshaft RearSeal — Remove”.

b. Remove the electric starting motor. Refer toDisassembly and Assembly, “Electric StartingMotor — Remove and Install”.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01220951Illustration 154

1. Disconnect hose assemblies (1) from flywheelhousing (2).

2. Disconnect fuel filter base (5) from flywheelhousing (2). Reposition fuel filter base (5) and thehose assemblies.

3. Remove two bolts (4) and install Tooling (B).

4. Attach Tooling (A) and a suitable lifting deviceto flywheel housing (2). The weight of flywheelhousing (2) is approximately 110 kg (245 lb).

5. Remove remaining bolts (4), bolts (6), and bolts(3). Remove flywheel housing (2) and the gasketfrom the rear housing.

52 RENR9716-02Disassembly and Assembly Section

Installation ProcedureTable 39

Required Tools

ToolPart

Number Part Description Qty

A 138-7574 Link Bracket 2

B — Guide Stud1/2 — 13 NC by 7 inch 2

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01220951Illustration 155

g01221009Illustration 156

1. Install Tooling (B) in the cylinder block.

2. Attach Tooling (A) and a suitable lifting deviceto flywheel housing (2). The weight of flywheelhousing (2) is approximately 110 kg (245 lb).

3. Position the gasket and flywheel housing (2) onthe rear housing. Install bolts (3), bolts (6), andbolts (4).

4. Remove Tooling (B) and install remaining bolts (4).

5. Tighten the bolts, as follows:

a. In a numerical sequence, tighten Bolt 1 throughBolt 2 to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

b. In a numerical sequence, tighten Bolt 3through Bolt 10 to a torque of 135 ± 20 N·m(100 ± 15 lb ft).

c. In a numerical sequence, tighten Bolt 11through Bolt 36 to a torque of 47 ± 9 N·m(35 ± 7 lb ft).

6. Reposition fuel filter base (5) and the hoseassemblies. Connect fuel filter base (5) to flywheelhousing (2).

7. Connect hose assemblies (1) to flywheel housing(2).

RENR9716-02 53Disassembly and Assembly Section

End By:

a. Install the electric starting motor. Refer toDisassembly and Assembly, “Electric StartingMotor — Remove and Install”.

b. Install the crankshaft rear seal. Refer toDisassembly and Assembly, “Crankshaft RearSeal — Install”.

i02443805

Vibration Damper and Pulley -Remove and InstallSMCS Code: 1205-010

Removal ProcedureTable 40

Required Tools

ToolPart

Number Part Description Qty

A — Guide Stud1/2 — 13 NC by 5 inch 2

g01221066Illustration 157

g01221078Illustration 158

1. Remove V-belt (1) from the engine.

2. Remove two bolts (2) and install Tooling (A).

3. Remove remaining bolts (2) and pulley (3).

4. Slide vibration damper (4) along Tooling (A).

5. Attach a suitable lifting device onto vibrationdamper (4). The weight of vibration damper (4)is approximately 34 kg (75 lb). Remove vibrationdamper (4) from the adapter.

Installation ProcedureTable 41

Required Tools

ToolPart

Number Part Description Qty

A — Guide Stud1/2 — 13 NC by 5 inch 2

g01221078Illustration 159

54 RENR9716-02Disassembly and Assembly Section

g01221066Illustration 160

1. Install Tooling (A) in the adapter.

2. Attach a suitable lifting device onto vibrationdamper (4). The weight of vibration damper (4)is approximately 34 kg (75 lb). Position vibrationdamper (4) on the adapter.

3. Install pulley (3) and bolts (2).

4. Remove Tooling (A). Install remaining bolts (2).Tighten bolts (2) to a torque of 135 ± 20 N·m(100 ± 15 lb ft).

5. Install V-belt (1) on the engine.

i02444403

Crankshaft Front Seal -RemoveSMCS Code: 1160-011

Removal ProcedureTable 42

Required Tools

ToolPart

Number Part Description Qty

A 1U-7600 Slide Hammer Puller 1

Start By:

a. Remove the crankshaft vibration damper andpulley. Refer to Disassembly and Assembly,“Vibration Damper and Pulley — Remove andInstall”.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01221272Illustration 161

1. Remove bolts (1) and adapter (2).

g01221276Illustration 162

2. Use Tooling (A) or a punch and hammer in orderto puncture three or more holes in crankshaft frontseal (4).

3. Use Tooling (A) to remove crankshaft front seal(4).

4. If necessary, use Tooling (A) or a punch andhammer in order to puncture three or more holesin crankshaft wear sleeve (3). Use Tooling (A) toremove crankshaft wear sleeve (3).

RENR9716-02 55Disassembly and Assembly Section

i02444556

Crankshaft Front Seal — InstallSMCS Code: 1160-012

Installation ProcedureTable 43

Required Tools

ToolPart

Number Part Description Qty

5P-1733 Seal Locator 1

5P-1737 Bolt 3

9S-8858 Nut (Seal Installer) 1B

6V-6142 Seal Installer 1

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

1. Clean the outside diameter of the crankshaft.

g01221389Illustration 163

2. Use Tooling (B) to install crankshaft front seal (4)and crankshaft wear sleeve (3) as a unit.

Note: Install the crankshaft front seal with the arrowthat shows the direction of crankshaft rotation towardthe front of the engine.

g01221272Illustration 164

3. Install adapter (2) and bolts (1).

End By:

a. Install the crankshaft vibration damper and pulley.Refer to Disassembly and Assembly, “VibrationDamper and Pulley — Remove and Install”.

i02292422

Gear Group (Front) — RemoveSMCS Code: 1206-011

Removal ProcedureStart By:

a. Remove the front housing. Refer to Disassemblyand Assembly, “Housing (Front) — Remove”.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

56 RENR9716-02Disassembly and Assembly Section

g01147593Illustration 165

1. Remove bolts (5) and gear assembly (4).

2. Remove bolts (3) and plate (2). Remove gearassembly (1).

g01147620Illustration 166

3. Remove bolts (6) and shaft (7).

i02691256

Gear Group (Front) — InstallSMCS Code: 1206-012

Installation Procedure

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01147620Illustration 167

1. Apply clean engine oil to shaft (7), the bearingbore, and the thrust faces prior to installation.Install shaft (7) and bolts (6). Tighten bolts (6) to atorque of 55 ± 10 N·m (41 ± 7 lb ft).

g01147593Illustration 168

2. Position gear assembly (1) on the shaft. Installplate (2) and bolts (3).

3. Install gear assembly (4) and bolts (5).

End By:

a. Install the front housing. Refer to Disassembly andAssembly, “Housing (Front) — Install”.

RENR9716-02 57Disassembly and Assembly Section

i02445219

Housing (Front) — RemoveSMCS Code: 1151-011

Removal ProcedureStart By:

a. Remove the water temperature regulator housing.Refer to Disassembly and Assembly, “WaterTemperature Regulator Housing — Remove andInstall”.

b. Remove the water pump. Refer to Disassemblyand Assembly, “Water Pump — Remove”.

c. Remove the crankshaft front seal. Refer toDisassembly and Assembly, “Crankshaft FrontSeal — Remove”.

d. Remove the front engine support. Refer toDisassembly and Assembly, “Engine Support(Front) — Remove and Install”.

e. Remove the alternator. Refer to Disassembly andAssembly, “Alternator — Remove and Install”.

f. Remove the crankshaft position sensor. Refer toDisassembly and Assembly, “Crankshaft PositionSensor — Remove and Install”.

g. Remove the camshaft position sensor. Refer toDisassembly and Assembly, “Camshaft PositionSensor — Remove and Install”.

Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01221893Illustration 169

1. Disconnect hose assemblies (2) from fronthousing (4).

2. Remove covers (1).

3. Remove alternator bracket (3) from front housing(4).

g01221941Illustration 170

4. Remove bolts (5) and dampers (6).

58 RENR9716-02Disassembly and Assembly Section

g01221953Illustration 171

5. Disconnect bracket (7) and elbows (8).

g01221955Illustration 172

6. Remove adapters (9).

7. Attach a suitable lifting device to front housing (4).The weight of front housing (4) is approximately70 kg (155 lb).

8. Remove bolts (10) and bolts (11).

9. Remove front housing (4) and the gasket.

i02445708

Housing (Front) — InstallSMCS Code: 1151-012

Installation ProcedureTable 44

Required Tools

ToolPart

Number Part Description Qty

A 4C-9612 Silicone Sealant 1

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01221955Illustration 173

1. Apply Tooling (A) to the bottom of front housing(4) at the junction of the cylinder block and theengine oil pan.

2. Attach a suitable lifting device to front housing (4).The weight of front housing (4) is approximately70 kg (155 lb). Position the gasket and fronthousing (4) on the dowel pins on the cylinderblock.

3. Install bolts (10) and bolts (11).

4. Trim the gasket between the front housing and thecylinder block even with the bottom of the fronthousing.

5. Install adapters (9).

RENR9716-02 59Disassembly and Assembly Section

g01221953Illustration 174

6. Connect elbows (8) and bracket (7).

g01221941Illustration 175

g01151441Illustration 176

7. Install dampers (6) and bolts (5).

8. Tighten the bolts to a torque of 240 ± 40 N·m(177 ± 30 lb ft). Tighten the bolts in the followingsequence: 1, 4, 2, 5, 3, 6, 1, 4.

g01221893Illustration 177

9. Install alternator bracket (3) on front housing (4).

10. Install covers (1).

11.Connect hose assemblies (2) to front housing (4).

End By:

a. Install the camshaft position sensor. Refer toDisassembly and Assembly, “Camshaft PositionSensor — Remove and Install”.

b. Install the crankshaft position sensor. Refer toDisassembly and Assembly, “Crankshaft PositionSensor — Remove and Install”.

c. Install the alternator. Refer to Disassembly andAssembly, “Alternator — Remove and Install”.

d. Install the front engine support. Refer toDisassembly and Assembly, “Engine Support(Front) — Remove and Install”.

e. Install the crankshaft front seal. Refer toDisassembly and Assembly, “Crankshaft FrontSeal — Install”.

f. Install the water pump. Refer to Disassembly andAssembly, “Water Pump — Install”.

g. Install the water temperature regulator housing.Refer to Disassembly and Assembly, “WaterTemperature Regulator Housing — Remove andInstall”.

60 RENR9716-02Disassembly and Assembly Section

i02290579

Housing (Rear) — RemoveSMCS Code: 1157-011

Removal ProcedureStart By:

a. Remove the rear gear group. Refer to Disassemblyand Assembly, “Gear Group (Rear) — Remove”.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

1. Remove the bolts that hold the engine oil pan tothe rear housing.

g01147132Illustration 178

g01147138Illustration 179

2. Disconnect hose assembly (1).

3. Remove bolts (2).

4. Attach a suitable lifting device to rear housing (4).The weight of rear housing (4) is approximately84 kg (185 lb).

5. Remove bolts (3).

6. Remove rear housing (4) and the gasket.

i02291566

Housing (Rear) — InstallSMCS Code: 1157-012

Installation ProcedureTable 45

Required Tools

ToolPart

Number Part Description Qty

A 4C-9612 Silicone Sealant 1

RENR9716-02 61Disassembly and Assembly Section

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

1. Apply Tooling (A) to the bottom of the rear housingat the junction of the cylinder block and the engineoil pan.

g01147138Illustration 180

g01147149Illustration 181

2. Attach a suitable lifting device to rear housing (4).The weight of rear housing (4) is approximately84 kg (185 lb).

3. Position the gasket on rear housing (4).

4. Position rear housing (4) on the cylinder block.Install bolts (3). Tighten bolts (3) in a numericalsequence to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

5. Trim the gasket between the rear housing and thecylinder block even with the bottom of the rearhousing.

62 RENR9716-02Disassembly and Assembly Section

g01147132Illustration 182

6. Install bolts (2).

7. Connect hose assembly (1).

8. Install the bolts that hold the engine oil pan to therear housing.

9. Tighten all the bolts that hold the engine oil panevenly in order to raise the engine oil pan intoposition.

End By:

a. Install the rear gear group. Refer to Disassemblyand Assembly, “Gear Group (Rear) — Install”.

i02293132

Valve Mechanism Cover -Remove and InstallSMCS Code: 1107-010

Removal Procedure

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01147941Illustration 183

1. Remove bolts (1) and valve mechanism covers(2).

Installation Procedure

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01147941Illustration 184

1. Position valve mechanism covers (2) on the valvemechanism cover base. Install bolts (1).

i02293148

Valve Mechanism Cover Base -Remove and InstallSMCS Code: 1120-010

Removal ProcedureStart By:

a. Remove the valve mechanism cover. Refer toDisassembly and Assembly, “Valve MechanismCover — Remove and Install”.

RENR9716-02 63Disassembly and Assembly Section

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01147965Illustration 185

1. Remove tube assemblies (1).

2. Disconnect harness assemblies (5) and harnessassembly (2).

3. Remove bolts (4).

4. Remove valve mechanism cover base (3) and theseal from the cylinder head.

Installation Procedure

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01147965Illustration 186

1. Install the seal on valve mechanism cover base(3).

2. Position valve mechanism cover base (3) on thecylinder head and install bolts (4).

3. Position harness assemblies (5) on the electronicunit injectors. Tighten the cap nuts to a torque of1.70 ± 0.25 N·m (15 ± 2 lb in).

4. Connect harness assembly (2).

5. Install tube assemblies (1).

End By:

a. Install the valve mechanism cover. Refer toDisassembly and Assembly, “Valve MechanismCover — Remove and Install”.

i02293245

Rocker Arm and Shaft -RemoveSMCS Code: 1102-011

Removal ProcedureTable 46

Required Tools

ToolPart

Number Part Description Qty

A 124-2946 Lifting Bracket 1

64 RENR9716-02Disassembly and Assembly Section

Start By:

a. Remove the valve mechanism cover. Refer toDisassembly and Assembly, “Valve MechanismCover — Remove and Install”.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01148045Illustration 187

1. Remove bolts (2).

2. Use Tooling (A) to remove rocker arm shaftassembly (4), valve rocker arms (3), and electronicunit injector rocker arms (1) as a unit.

i02451112

Rocker Arm — DisassembleSMCS Code: 1123-015

Disassembly ProcedureStart By:

a. Remove the rocker arms and the rocker shaft.Refer to Disassembly and Assembly, “Rocker Armand Shaft — Remove”.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01047557Illustration 188

1. Remove valve rocker arms (11) and electronic unitinjector rocker arm (3) from rocker shaft assembly(4).

2. Remove jam nut (7) from adjustment screw (8).

3. Remove adjustment screw (8) from valve rockerarms (11).

4. Remove button (10) from adjustment screw (8).Remove O-ring seal (9) from the adjustmentscrew.

5. Remove jam nut (2) from unit injector adjustmentscrew (1).

6. Remove unit injector adjustment screw (1) fromelectronic unit injector rocker arm (3).

7. Remove button (6) from unit injector adjustmentscrew (1). Remove O-ring seal (5) from the unitinjector adjustment screw.

i02451120

Rocker Arm — AssembleSMCS Code: 1123-016

Assembly Procedure

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

RENR9716-02 65Disassembly and Assembly Section

g01047557Illustration 189

Note: Do not reuse the O-ring seal on the adjustmentscrew if the button is removed from the adjustmentscrew.

1. Install O-ring seal (9) in button (10).

2. Use a soft hammer to seat button (10) onadjustment screw (8).

3. Install adjustment screw (8) in valve rocker arms(11). Install jam nut (7) on the adjustment screw.

4. Install O-ring seal (5) in button (6).

5. Use a soft hammer to seat button (6) on unitinjector adjustment screw (1).

6. Install unit injector adjustment screw (1) inelectronic unit injector rocker arm (3). Install jamnut (2) on the unit injector adjustment screw.

7. Lubricate rocker shaft assembly (4) with cleanengine oil.

8. Install valve rocker arms (11) and electronic unitinjector rocker arm (3) on rocker shaft assembly(4).

End By:

a. Install the rocker arms and the rocker shaft. Referto Disassembly and Assembly, “Rocker Arm andShaft — Install”.

i03203773

Rocker Arm and Shaft — InstallSMCS Code: 1102-012

Installation ProcedureTable 47

Required Tools

ToolPart

Number Part Description Qty

A 124-2946 Lifting Bracket 1

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01148045Illustration 190

g01325993Illustration 191

66 RENR9716-02Disassembly and Assembly Section

1. Position rocker arm shaft assembly (4), valverocker arms (3), and electronic unit injector rockerarms (1) as a unit with Tooling (A) on the cylinderhead.

2. Install bolts (2) and tighten to a torque of50 ± 5 N·m (37 ± 4 lb ft) plus 45 ± 5 degree turn.Tighten the bolts in the following sequence: 2, 3,4, 1.

3. Adjust the valve lash for the inlet valves and theexhaust valves. Refer to Testing and Adjusting,“Engine Valve Lash — Inspect/Adjust”.

4. Adjust the electronic unit injectors. Refer to Testingand Adjusting, “Electronic Unit Injector — Adjust”.

End By:

a. Install the valve mechanism cover. Refer toDisassembly and Assembly, “Valve MechanismCover — Remove and Install”.

i02446003

Cylinder Head — RemoveSMCS Code: 1100-011

Removal ProcedureTable 48

Required Tools

ToolPart

Number Part Description Qty

A 138-7573 Link Bracket 3

B 1U-9200 Lever Puller Hoist 1

Start By:

a. Remove the electronic unit injectors. Refer toDisassembly and Assembly, “Electronic UnitInjector — Remove”.

b. Remove the valve mechanism cover base. Referto Disassembly and Assembly, “Valve MechanismCover Base — Remove and Install”.

c. Remove the fuel transfer pump. Refer toDisassembly and Assembly, “Fuel Transfer Pump- Remove”.

Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

NOTICEDo not turn the crankshaft or the camshaft while thecamshaft gear is removed. If the rear gear group isnot correctly timed during installation, interference canoccur between the pistons and the valves, resulting indamage to the engine.

1. Drain the coolant from the cooling system into asuitable container for storage or disposal. Referto Operation and Maintenance Manual, “CoolingSystem Coolant — Change”.

g01222228Illustration 192

2. Remove cover (1).

RENR9716-02 67Disassembly and Assembly Section

g01222230Illustration 193

3. Remove bolts (2) and gear (3).

g01222233Illustration 194

4. Remove bolts (4), thrust plate (5), and adapterassembly (6).

g01222234Illustration 195

5. Use bolt (4) in order to remove sealing plate (7).Remove the O-ring seals.

g01148246Illustration 196

6. Remove elbow (8). Disconnect hose assembly (9).

g01148489Illustration 197

7. Remove elbow (11) and cover (10).

8. Disconnect harness assembly (12) and harnessassembly (13).

9. Remove bracket (14).

g01148492Illustration 198

68 RENR9716-02Disassembly and Assembly Section

10.Remove bolts (15) and damper (16).

g01148516Illustration 199

11.Remove bolts (17). Remove sealing plate (18)and adapter assembly (19).

g01148522Illustration 200

12.Disconnect clip assembly (22) from the cylinderhead. Remove tube assemblies (21).

13.Remove bracket (20).

14.Disconnect tube assembly (23) and remove tubeassembly (24).

g01148568Illustration 201

15.Attach Tooling (A) and a suitable lifting device tocylinder head (25). Attach Tooling (B) to the sideof cylinder head (25) that is near the turbocharger.The weight of cylinder head (25) is approximately365 kg (800 lb).

16.Remove bolts (26) and bolts (27).

17.Remove cylinder head (25). Remove the gaskets,O-ring seals, and the spacer plate.

i02446286

Cylinder Head — InstallSMCS Code: 1100-012

Installation ProcedureTable 49

Required Tools

Tool Part Number Part Description Qty

A 138-7573 Link Bracket 3

B 1U-9200 Lever Puller Hoist 1

C 4c-5593 Anti-Seize Compound 1

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01148568Illustration 202

RENR9716-02 69Disassembly and Assembly Section

g01148791Illustration 203

1. Install the gaskets, O-ring seals, and the spacerplate on the engine.

2. Attach Tooling (A) and a suitable lifting device tocylinder head (25). Attach Tooling (B) to the sideof cylinder head (25) that is near the turbocharger.The weight of cylinder head (25) is approximately365 kg (800 lb).

3. Position cylinder head (25) on the dowel pins inthe cylinder block.

Note: Apply Tooling (C) to the bolt threads andboth sides of the washers. Tighten the bolts in thefollowing step sequence:

4. Install bolts (26) and bolts (27) according to thefollowing procedure.

a. In a numerical sequence, tighten Bolt (1)through Bolt (26) to a torque of 270 ± 15 N·m(199 ± 11 lb ft).

b. In a numerical sequence, tighten Bolt (1)through Bolt (26) to a torque of 450 ± 15 N·m(332 ± 11 lb ft).

c. In a numerical sequence, again tighten Bolt (1)through Bolt (26) to a torque of 450 ± 15 N·m(332 ± 11 lb ft).

d. In a numerical sequence, tighten Bolt (27)through Bolt (39) to a torque of 45 ± 7 N·m(33 ± 5 lb ft).

g01148522Illustration 204

5. Connect tube assembly (23) and install tubeassembly (24).

6. Install bracket (20).

7. Connect clip assembly (22). Install tubeassemblies (21).

g01148516Illustration 205

70 RENR9716-02Disassembly and Assembly Section

8. Install adapter assembly (19) and sealing plate(18). Install bolts (17).

g01148492Illustration 206

g01151441Illustration 207

9. Install damper (16) and bolts (15).

10. Tighten the bolts to a torque of 240 ± 40 N·m(177 ± 30 lb ft). Tighten the bolts in the followingsequence: 1, 4, 2, 5, 3, 6, 1, 4.

g01148489Illustration 208

11. Install bracket (14).

12.Connect harness assembly (13) and harnessassembly (12).

13. Install cover (10) and elbow (11).

g01148246Illustration 209

14.Connect hose assembly (9). Install elbow (8).

g01222314Illustration 210

15. Install new O-ring seals and sealing plate (7).

g01222233Illustration 211

16. Install adapter assembly (6), thrust plate (5), andbolts (4).

RENR9716-02 71Disassembly and Assembly Section

g01222230Illustration 212

g01151468Illustration 213

17. Install gear (3) and bolts (2).

18. Tighten the bolts to a torque of 240 ± 40 N·m(177 ± 30 lb ft). Tighten the bolts in the followingsequence: 1, 4, 2, 5, 3, 6, 1, 4.

g01222228Illustration 214

19. Install cover (1).

20. Fill the cooling system. Refer to Operation andMaintenance Manual, “Cooling System Coolant- Change”.

End By:

a. Install the fuel transfer pump. Refer to Disassemblyand Assembly, “Fuel Transfer Pump — Install”.

b. Install the valve mechanism cover base. Refer toDisassembly and Assembly, “Valve MechanismCover Base — Remove and Install”.

c. Install the electronic unit injectors. Refer toDisassembly and Assembly, “Electronic UnitInjector — Install”.

i02446397

Camshaft — RemoveSMCS Code: 1210-011

Removal ProcedureTable 50

Required Tools

Tool Part Number Part Description Qty

A 177-8001 Pilot Sleeve 2

B 249-2936 Adapter 1

C274-7932(1)

or274-7933(2)

Guide 1

(1) Front Removal(2) Rear Removal

Start By:

a. Remove the rocker arms and the rocker shafts.Refer to Disassembly and Assembly, “Rocker Armand Shaft — Remove”.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

NOTICECare must be used when removing or installing thecamshaft. Do not damage the finshed surfaces of thecamshaft or the camshaft bearings.

72 RENR9716-02Disassembly and Assembly Section

1. Drain the coolant from the cooling system into asuitable container for storage or disposal. Referto Operation and Maintenance Manual, “CoolingSystem Coolant — Change”.

g01222228Illustration 215

2. Remove cover (1).

g01222230Illustration 216

3. Remove bolts (2) and gear (3).

g01222233Illustration 217

4. Remove bolts (4), thrust plate (5), and adapterassembly (6).

g01222234Illustration 218

5. Use bolt (4) in order to remove sealing plate (7).Remove the O-ring seals.

g01160256Illustration 219

6. Remove elbow (9) and cover (8).

g01160259Illustration 220

7. Remove bolts (10) and damper (11).

RENR9716-02 73Disassembly and Assembly Section

g01160261Illustration 221

8. Remove bolts (12). Remove sealing plate (13) andadapter assembly (14).

g01160265Illustration 222

10. Install Tooling (A) and Tooling (B) on the rear ofcamshaft (15). Install Tooling (A) on the front ofcamshaft (15).

11. Install Tooling (C) on the front housing or therear housing. Tooling (C) is used to support thecamshaft.

Note: It is necessary to install Tooling (A) and Tooling(B) on the camshaft. Tooling (A) and Tooling (B) willsupport the camshaft as the camshaft is moved outof the cylinder head and into Tooling (C). Align thecamshaft with the bore of Tooling (C).

Note: Avoid lifting the camshaft. The camshaft shouldrest on Tooling (A) and Tooling (B). Lifting of thecamshaft can cause misalignment as the camshaftis removed, resulting in damage to the camshaftbearings.

12.Carefully slide the camshaft out of the cylinderhead for removal. Use two technicians to removethe camshaft. Keep the camshaft level while thecamshaft is being removed from the cylinderhead. The weight of the camshaft is approximately35 kg (77 lb).

Note: Rotate the camshaft during removal. This willprevent the camshaft from binding in the camshaftbearings.

i02446568

Camshaft — InstallSMCS Code: 1210-012

Installation ProcedureTable 51

Required Tools

ToolPart

Number Part Description Qty

A 177-8001 Pilot Sleeve 2

B 249-2936 Adapter 1

C274-7932(1)

or274-7933(2)

Guide 1

D 8T-2998 Lubricant 1(1) Front Removal(2) Rear Removal

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

NOTICECare must be used when removing or installing thecamshaft. Do not damage the finshed surfaces of thecamshaft or the camshaft bearings.

1. Ensure that the camshaft and camshaft bearingsare thoroughly clean. Lubricate the camshaftlobes with a 50/50 mixture of Tooling (D) and cleanengine oil. Apply a thin coat of clean engine oil onthe camshaft bearings.

74 RENR9716-02Disassembly and Assembly Section

g01160265Illustration 223

2. Install Tooling (A) and Tooling (B) on the rear ofcamshaft (15). Install Tooling (A) on the front ofcamshaft (15).

3. Install Tooling (C) on the front housing or therear housing. Tooling (C) is used to support thecamshaft.

4. Use two technicians to install the camshaft. UseTooling (C) to assist in aligning the camshaftwith the camshaft bearings. Carefully slidethe camshaft into the cylinder head. Keep thecamshaft level while the camshaft is beinginstalled in the cylinder head. The weight of thecamshaft is approximately 35 kg (77 lb).

Note: Rotate the camshaft during installation. Thiswill prevent the camshaft from binding in the camshaftbearings.

5. Remove Tooling (A) and Tooling (B) from thecamshaft.

g01160261Illustration 224

6. Install adapter assembly (14) and sealing plate(13). Install bolts (12).

g01160259Illustration 225

g01151441Illustration 226

7. Install damper (11) and bolts (10).

8. Tighten the bolts to a torque of 240 ± 40 N·m(177 ± 30 lb ft). Tighten the bolts in the followingsequence: 1, 4, 2, 5, 3, 6, 1, 4.

g01160256Illustration 227

9. Install cover (8) and elbow (9).

RENR9716-02 75Disassembly and Assembly Section

g01222314Illustration 228

10. Install new O-ring seals and sealing plate (7).

g01222233Illustration 229

11. Install adapter assembly (6), thrust plate (5), andbolts (4).

g01222230Illustration 230

g01151468Illustration 231

12. Install gear (3) and bolts (2).

13. Tighten the bolts to a torque of 240 ± 40 N·m(177 ± 30 lb ft). Tighten the bolts in the followingsequence: 1, 4, 2, 5, 3, 6, 1, 4.

g01222228Illustration 232

14. Install cover (1).

15. Fill the cooling system. Refer to Operation andMaintenance Manual, “Cooling System Coolant- Change”.

End By:

a. Install the rocker arms and the rocker shafts.Refer to Disassembly and Assembly, “RockerArms and Shaft — Install”.

76 RENR9716-02Disassembly and Assembly Section

i02451045

Camshaft Bearings — RemoveSMCS Code: 1211-011

Removal ProcedureTable 52

Required Tools

Tool Part Number Part Description Qty

A 8S-2241 Camshaft Bearing ToolGroup 1

9U-7222 Camshaft Bearing Pilot 1B

8M-8778 Taperlock Stud1/2 — 13 by 1 9/16 inch 1

C 9U-7210 Puller Plate 1

Start By:

a. Remove the camshaft. Refer to Disassembly andAssembly, “Camshaft — Remove”.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01159745Illustration 233

1. Remove the No. 7 camshaft bearing (rear). Workfrom the rear of the engine to the front of theengine.

2. Install the small end of Tooling (B) in camshaftbearing (1).

3. Position Tooling (C) over Tooling (A). InstallTooling (A) through the cylinder head on Tooling(B).

Note: Tooling (C) is installed on the outside of thecylinder head. Tooling (C) is required in order toremove all the camshaft bearings from the cylinderhead.

4. Use Tooling (A) to remove camshaft bearing (1)from the cylinder head.

5. Remove Tooling (B) from Tooling (A) and removethe camshaft bearing.

i02451063

Camshaft Bearings — InstallSMCS Code: 1211-012

Installation ProcedureTable 53

Required Tools

Tool Part Number Part Description Qty

A 8S-2241 Camshaft Bearing ToolGroup 1

9U-7222 Camshaft Bearing Pilot 1B

8M-8778 Taperlock Stud1/2 — 13 by 1 9/16 inch 1

C 9U-7210 Puller Plate 1

D 9U-7223 Alignment Bushing 1

9U-7213 Backup Plate 1E

0S-1621 Bolt1/2 — 13 by 1 inch 1

F 9U-7214 Spacer Plate 1

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01159754Illustration 234

RENR9716-02 77Disassembly and Assembly Section

1. Install the No. 7 camshaft bearing (rear), asfollows:

a. Insert the large end of Tooling (B) into the No.7 camshaft bore.

b. Position Tooling (C) over Tooling (A). InstallTooling (A) through the cylinder head onTooling (B).

c. Position camshaft bearing (1) on Tooling (B).Install Tooling (E) on Tooling (B).

Note: Refer to Specifications, “Cylinder Head” forappropriate information for the orientation of thecamshaft bearings in the cylinder head.

d. Use Tooling (A) in order to pull camshaftbearing (1) into the camshaft bore.

Note: When the chamfer of Tooling (E) contacts theface of the camshaft bore, the camshaft bearing isproperly installed.

g01159756Illustration 235

2. Install the No. 6 through No. 2 camshaft bearings,as follows:

a. Insert the large end of Tooling (B) into thecamshaft bore.

Note: Use Tooling (D) to align Tooling (A) and Tooling(B) with the camshaft bearing bores. Install Tooling(D) in the inside diameter of any installed camshaftbearing between Tooling (A) and Tooling (B).

b. Install Tooling (A) on Tooling (B). Positioncamshaft bearing (1) on Tooling (B). InstallTooling (E) on Tooling (B).

Note: Refer to Specifications, “Cylinder Head” forappropriate information for the location and theorientation of the camshaft bearings in the cylinderhead.

c. Use Tooling (A) in order to pull camshaftbearing (1) into the camshaft bore.

Note: When the chamfer of Tooling (E) contacts theface of the camshaft bore, the camshaft bearing isproperly installed.

g01159758Illustration 236

3. Install the No. 1 camshaft bearing (front), asfollows:

a. Insert the large end of Tooling (B) into the No.1 camshaft bore. Assemble Tooling (A) andTooling (D) on Tooling (B).

b. Position camshaft bearing (1) on Tooling (B).Install Tooling (E) and Tooling (F) on Tooling(B).

Note: Refer to Specifications, “Cylinder Head” forappropriate information for the location and theorientation of the camshaft bearings in the cylinderhead.

Note: Tooling (F) is used to seat the No. 1 camshaftbearing to the correct depth in the camshaft bore.

c. Use Tooling (A) in order to pull the No. 1camshaft bearing into the No. 1 camshaft bore.When the chamfer of Tooling (E) contactsthe face of the camshaft bore, the camshaftbearing is properly installed.

End By:

a. Install the camshaft. Refer to Disassembly andAssembly, “Camshaft — Install”.

78 RENR9716-02Disassembly and Assembly Section

i02447352

Engine Oil Pan — Remove andInstallSMCS Code: 1302-010

Removal ProcedureTable 54

Required Tools

ToolPart

Number Part Description Qty

A 1U-7505 Hydraulic Jack 1

Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

1. Drain the engine oil into a suitable containerfor storage or disposal. Refer to Operation andMaintenance Manual, “Engine Oil and Filter -Change”.

g01222524Illustration 237

2. Remove tube assemblies (1) from engine oil pan(3).

3. Use Tooling (A) to support engine oil pan (3). Theweight of engine oil pan (3) is approximately 25 kg(55 lb).

4. Remove bolts (2). Remove engine oil pan (3) andthe gasket.

Installation ProcedureTable 55

Required Tools

ToolPart

Number Part Description Qty

A 1U-7505 Hydraulic Jack 1

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01222524Illustration 238

1. Use Tooling (A) to support engine oil pan (3). Theweight of engine oil pan (3) is approximately 25 kg(55 lb).

2. Position the gasket and engine oil pan (3) on theengine. Install bolts (2).

Note: If the oil drain plugs were removed, install theoil drain plugs. Tighten the oil drain plugs to a torqueof 80 ± 10 N·m (59 ± 7 lb ft).

3. Install tube assemblies (1) on engine oil pan (3).

4. Fill the engine with engine oil to the correct level.Refer to Operation and Maintenance Manual,“Engine Oil and Filter — Change”.

RENR9716-02 79Disassembly and Assembly Section

i02294951

Cylinder Liner — RemoveSMCS Code: 1216-011

Removal ProcedureTable 56

Required Tools

Tool Part Number Part Description Qty

A 5P-8665(1) Cylinder Liner Puller Gp 1(1) The 6V-9448 Cylinder Pack Puller is an optional Tool forremoving the cylinder liner.

Start By:

a. Remove the pistons and connecting rods. Referto Disassembly and Assembly, “Pistons andConnecting Rods — Remove”.

Refer to Special Publication, NENG2500, “CaterpillarTools and Shop Products Guide” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01149417Illustration 239

1. Use Tooling (A) to remove cylinder liner (1).

2. Remove liner seals (3) and filler band (2) fromcylinder liner (1).

i02294960

Cylinder Liner — InstallSMCS Code: 1216-012

Installation ProcedureTable 57

Required Tools

Tool Part Number Part Description Qty

B 2P-8260 Cylinder Liner Installer 1

C 5P-3975 Rubber Lubricant 1

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

1. Check the cylinder liner projection. Refer toTesting and Adjusting, “Cylinder Liner Projection- Inspect”.

80 RENR9716-02Disassembly and Assembly Section

g01149469Illustration 240

2. Install liner seals (3) on cylinder liner (1).

3. Apply Tooling (C) on the cylinder block liner boresurfaces and liner seals (3).

4. Dip filler band (2) in clean engine oil for amoment. Install the filler band on the cylinder linerimmediately.

5. Use Tooling (B) to install cylinder liner (1) in thecylinder block. Ensure that any marks in relationto the cylinder liner projection are in alignment.

End By:

a. Install the pistons and connecting rods. Referto Disassembly and Assembly, “Pistons andConnecting Rods — Install”.

i02295020

Piston Cooling Jets — Removeand InstallSMCS Code: 1331-010

Removal ProcedureTable 58

Required Tools

ToolPart

Number Part Description Qty

A 9S-9082 Engine Turning Tool 1

Start By:

a. Remove the engine oil pump. Refer toDisassembly and Assembly, “Engine Oil Pump- Remove”.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01149484Illustration 241

1. Use Tooling (A) to rotate the crankshaft in order togain access to the piston cooling jet.

2. Remove bolt (1) and piston cooling jet (2).

Installation ProcedureTable 59

Required Tools

ToolPart

Number Part Description Qty

A 9S-9082 Engine Turning Tool 1

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

RENR9716-02 81Disassembly and Assembly Section

g01149484Illustration 242

1. Use Tooling (A) to rotate the crankshaft in order togain access to the piston cooling jet.

2. Position piston cooling jet (2) in the cylinder block.Install bolt (1). Tighten the bolt to a torque of25 ± 6 N·m (18 ± 4 lb ft).

End By:

a. Install the engine oil pump. Refer to Disassemblyand Assembly, “Engine Oil Pump — Install”.

i02295112

Pistons and Connecting Rods- RemoveSMCS Code: 1225-011

Removal ProcedureTable 60

Required Tools

Tool Part Number Part Description Qty

A 9S-9082 Engine Turning Tool 1

Start By:

a. Remove the cylinder head. Refer to Disassemblyand Assembly, “Cylinder Head — Remove”.

b. Remove the piston cooling jets. Refer toDisassembly and Assembly, “Piston Cooling Jets- Remove and Install”.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01149594Illustration 243

1. Use Tooling (A) to rotate the crankshaft until thepiston is at the bottom center.

2. Remove the carbon ridge from the top insidesurface of the cylinder liner.

3. Inspect the connecting rod and connecting rod capfor the proper identification mark. The connectingrod and the connecting rod cap should have anetched number on the side. The number shouldmatch the cylinder number. Mark the connectingrod and the connecting rod cap, if necessary.

Note: Do not stamp the connecting rod assembly.Stamping or punching the connecting rod assemblycould cause the connecting rod to fracture.

4. Remove bolts (1) and connecting rod bearing cap(2).

g01149595Illustration 244

5. Remove piston (3) and the connecting rod fromthe cylinder liner.

82 RENR9716-02Disassembly and Assembly Section

i02447789

Pistons and Connecting Rods- DisassembleSMCS Code: 1225-015

Disassembly ProcedureTable 61

Required Tools

ToolPart

Number Part Description Qty

A 6V-6192 Pliers 1

B 7B-7974 Piston Ring Expander Gp 1

Start By:

a. Remove the pistons and connecting rods. Referto Disassembly and Assembly, “Pistons andConnecting Rods — Remove”.

Note: Mark the components of each piston andconnecting rod assembly. The components must bereinstalled in the original location. Do not interchangecomponents.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01222629Illustration 245

1. Remove lower connecting rod bearing (9) fromconnecting rod bearing cap (10).

2. Remove upper connecting rod bearing (8) fromconnecting rod (6).

3. Use Tooling (A) to remove pin retainers (5) frompiston body assembly (4).

4. Remove connecting rod pin (7) and connectingrod (6) from the piston body assembly.

5. Use Tooling (B) to remove top piston ring (1),intermediate piston ring (2), and oil control pistonring (3) from the piston body assembly.

i02447828

Pistons and Connecting Rods- AssembleSMCS Code: 1225-016

Assembly ProcedureTable 62

Required Tools

ToolPart

Number Part Description Qty

A 6V-6192 Pliers 1

B 7B-7974 Piston Ring Expander Gp 1

Note: Prior to removal from the engine, the pistonsand connecting rod assemblies were marked.The components must be reassembled together.The components must be installed in the originallocation in the engine. Do not interchange any of thecomponents.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

RENR9716-02 83Disassembly and Assembly Section

g01222629Illustration 246

1. Position the spring for the oil control piston ring inthe oil ring groove in the piston body assembly.

2. Position oil control piston ring (3) over the spring.Position the oil control piston ring so that the gapis 180 degrees from the joint in the spring. Installthe oil control piston ring on the piston with Tooling(B).

3. Use Tooling (B) to install intermediate piston ring(2) with the side that has the identification “UP-2”toward the top of the piston.

4. Use Tooling (B) to install top piston ring (1) withthe side that has the identification “UP-1” towardthe top of the piston.

5. Position top piston ring (1), intermediate pistonring (2), and oil control piston ring (3) so the gapsare 120 degrees from each other.

6. Check the clearance between the ends of toppiston ring (1), intermediate piston ring (2), andoil control piston ring (3). Refer to Specifications,“Pistons And Rings”.

7. Position piston body assembly (4) on connectingrod (6). Apply clean engine oil to connecting rodpin (7) and install the connecting rod pin. Installpin retainers (5) with Tooling (A).

8. Install upper connecting rod bearing (8) inconnecting rod (6).

Note: Ensure that the bearing locking tab is locatedin the notch of the connecting rod.

9. Install lower connecting rod bearing (9) inconnecting rod bearing cap (10).

Note: Ensure that the bearing locking tab is locatedin the notch of the connecting rod bearing cap.

10.Ensure that the dowels are installed in theconnecting rod bearing cap.

End By:

a. Install the pistons and connecting rods. Referto Disassembly and Assembly, “Pistons andConnecting Rods — Install”.

i02630922

Pistons and Connecting Rods- InstallSMCS Code: 1225-012

Installation ProcedureTable 63

Required Tools

Tool PartNumber Part Description Qty

A 9S-9082 Engine Turning Tool 1

B 200-3914 Piston Ring Compressor 1

C 8T-3052 Degree Wheel 1

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

Note: Install the connecting rod bearings drywhen clearance checks are performed. Refer toDisassembly and Assembly, “Bearing Clearance -Check”. Apply clean engine oil on the connecting rodbearings for final assembly.

1. Apply clean engine oil to the cylinder liner bore, tothe piston rings, and to the outer surface of thepiston.

Note: Ensure that the connecting rod and pistons areinstalled in the correct cylinder.

84 RENR9716-02Disassembly and Assembly Section

g01149650Illustration 247

2. Use Tooling (A) to rotate the crankshaft until theconnecting rod journal is at the bottom center.

3. Use Tooling (B) to install piston (3) and theconnecting rod in the cylinder liner.

Note: Install the connecting rod so that the bearingtab is located on the opposite side of the pistoncooling jet.

4. Install the upper connecting rod bearing in theconnecting rod.

Note: Ensure that the connecting rod bearing isinstalled so that the bearing tab fits into the notch inthe connecting rod.

5. Pull the connecting rod onto the crankshaft journal.

6. Install the lower connecting rod bearing in theconnecting rod bearing cap.

Note: Ensure that the connecting rod bearing isinstalled so that the bearing tab fits into the notch inthe connecting rod.

g01149651Illustration 248

7. Position connecting rod bearing cap (2) on theconnecting rod.

Note: Ensure that the number on the side of theconnecting rod bearing cap is on the same side asthe number on the connecting rod. The bearing tabsof the connecting rod bearing cap and the connectingrod are located on the side opposite of the pistoncooling jet.

8. Lubricate the threads of bolts (1) with clean engineoil. Install the bolts.

9. Tighten bolts (1), as follows:

a. Tighten Bolt (A) and Bolt (C) to a torque of70 ± 4 N·m (52 ± 3 lb ft).

b. Tighten Bolt (B) and Bolt (D) to a torque of70 ± 4 N·m (52 ± 3 lb ft).

c. Turn Bolt (B) and Bolt (D) for an additional 60 ±5 degrees (1/6 turn).

Note: If Tooling (C) is not used, place an index markon each bolt.

d. Tighten Bolt (A) and Bolt (C) again to a torqueof 70 ± 4 N·m (52 ± 3 lb ft).

e. Turn Bolt (A) and Bolt (C) for an additional 60 ±5 degrees (1/6 turn).

Note: If Tooling (C) is not used, place an index markon each bolt.

f. Rotate the crankshaft in order to ensure thatthe crankshaft turns freely.

End By:

a. Install the piston cooling jets. Refer to Disassemblyand Assembly, “Piston Cooling Jets — Removeand Install”.

b. Install the cylinder head. Refer to Disassemblyand Assembly, “Cylinder Head — Install”.

i02295567

Connecting Rod Bearings -RemoveSMCS Code: 1219-011

Removal ProcedureTable 64

Required Tools

ToolPart

Number Part Description Qty

A 9S-9082 Engine Turning Tool 1

RENR9716-02 85Disassembly and Assembly Section

Start By:

a. Remove the engine oil pump. Refer toDisassembly and Assembly, “Engine Oil Pump- Remove”.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01149594Illustration 249

1. Use Tooling (A) to rotate the crankshaft until theconnecting rod is at the bottom center.

2. Inspect the connecting rod and connecting rod capfor the proper identification mark. The connectingrod and the connecting rod cap should have anetched number on the side. The number shouldmatch the cylinder number. Mark the connectingrod and the connecting rod cap, if necessary.

Note: Do not stamp the connecting rod assembly.Stamping or punching the connecting rod assemblycould cause the connecting rod to fracture.

3. Remove bolts (1) and connecting rod bearing cap(2) from the connecting rod.

4. Remove the lower half of the connecting rodbearing from the connecting rod bearing cap.

5. Push the connecting rod away from the crankshaft.Remove the upper half of the connecting rodbearing from the connecting rod.

i02295910

Connecting Rod Bearings -InstallSMCS Code: 1219-012

Installation ProcedureTable 65

Required Tools

ToolPart

Number Part Description Qty

A 9S-9082 Engine Turning Tool 1

B 8T-3052 Degree Wheel 1

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g00998730Illustration 250

1. Use Tooling (A) to rotate the crankshaft until theconnecting rod journal is at the bottom center.

2. Install a new lower half connecting rod bearing (3)in connecting rod bearing cap (2).

Note: Ensure that bearing locking tab (4) is locatedin the notch of the connecting rod bearing cap.

3. Install a new upper half connecting rod bearing inthe connecting rod.

Note: Ensure that the bearing locking tab is locatedin the notch of the connecting rod.

86 RENR9716-02Disassembly and Assembly Section

4. Pull the connecting rod onto the crankshaft.

g01149651Illustration 251

5. Position connecting rod bearing cap (2) on theconnecting rod.

6. Lubricate the threads of bolts (1) with clean engineoil. Install the bolts.

7. Tighten bolts (1), as follows:

a. Tighten Bolt (A) and Bolt (C) to a torque of70 ± 4 N·m (52 ± 3 lb ft).

b. Tighten Bolt (B) and Bolt (D) to a torque of70 ± 4 N·m (52 ± 3 lb ft).

c. Turn Bolt (B) and Bolt (D) for an additional 60 ±5 degrees (1/6 turn).

Note: If Tooling (B) is not used, place an index markon each bolt.

d. Tighten Bolt (A) and Bolt (C) again to a torqueof 70 ± 4 N·m (52 ± 3 lb ft).

e. Tighten Bolt (A) and Bolt (C) for an additional60 ± 5 degrees (1/6 turn).

Note: If Tooling (B) is not used, place an index markon each bolt.

f. Rotate the crankshaft in order to ensure thatthe crankshaft turns freely.

End By:

a. Install the engine oil pump. Refer to Disassemblyand Assembly, “Engine Oil Pump — Install”.

i02296017

Crankshaft Main Bearings -RemoveSMCS Code: 1203-011

Removal ProcedureTable 66

Required Tools

ToolPart

Number Part Description Qty

A 2P-5518 Bearing Tool 1

Start By:

a. Remove the engine oil pump. Refer toDisassembly and Assembly, “Engine Oil Pump- Remove”.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

1. Check the main bearing caps for identification ofthe location and check the direction of the mainbearing caps in relation to the cylinder block. Themain bearing caps must be installed in the originallocation and the original direction.

g01149949Illustration 252

2. Remove bolts (1) and bolts (3) from No. 2 throughNo. 6 main bearing caps (2).

Note: Remove No. 1 and No. 7 main bearing caps(2) after No. 2 through No. 6 main bearing caps havebeen installed.

RENR9716-02 87Disassembly and Assembly Section

g01149952Illustration 253

3. Install Tooling (A) in the oil hole of the crankshaft.Carefully rotate the crankshaft in order to removeupper main bearing (4) from the cylinder block.

Note: Push the upper main bearing from the oppositeside of the bearing tab with Tooling (A). If thecrankshaft is turned in the wrong direction, the tab onthe bearing will be pushed between the crankshaftand the bearing area of the cylinder block. This canresult in damage to the cylinder block and/or thecrankshaft.

4. Remove the thrust plates from each side of theNo. 4 main bearing.

5. Remove the lower halves of the main bearingsfrom the main bearing caps.

i02296049

Crankshaft Main Bearings -InstallSMCS Code: 1203-012

Installation ProcedureTable 67

Required Tools

Tool Part Number Part Description Qty

A 2P-5518 Bearing Tool 1

B 8T-5096 Dial Indicator 1

C 8T-3052 Degree Wheel 1

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

Note: Install the main bearings dry when clearancechecks are performed. Refer to Disassembly andAssembly, “Bearing Clearance — Check”. Apply cleanengine oil on the main bearings for final assembly.

Note: Ensure that the main bearings are installedso that bearing tabs fit into the notch in the cylinderblock. The upper halves of the main bearings havethe oil groove and the oil hole.

g01149952Illustration 254

1. Position new upper main bearing (4) on thecrankshaft. Insert the end of the upper mainbearing that does not have the tab into the cylinderblock. Install Tooling (A) in the oil hole of thecrankshaft. Carefully rotate the crankshaft in orderto push the upper main bearing into the cylinderblock.

Note: Push the upper main bearing from the side ofthe bearing tab with Tooling (A). If the crankshaft isturned in the wrong direction, the tab on the bearingwill be pushed between the crankshaft and thebearing area of the cylinder block. This can result indamage to the cylinder block and/or the crankshaft.

2. Install the thrust plates on each side of the No. 4main bearing.

Note: Install the thrust plates with the words “BlockSide” toward the cylinder block.

3. Install the lower halves of the crankshaft mainbearings in the main bearing caps.

Note: Ensure that the main bearings are installed sothat bearing tabs fit into the notch in the main bearingcaps.

88 RENR9716-02Disassembly and Assembly Section

g01149987Illustration 255

4. Position main bearing caps (2) on the crankshaft.

Note: Ensure that the numbers on the main bearingcaps match the numbers on the cylinder block. Alsoensure that the “FRONT” on the main bearing cap isinstalled toward the front of the cylinder block.

5. Lubricate the threads of bolts (1) and bolts (3) withclean engine oil. Install the bolts.

6. Tighten bolts (1) and bolts (3) for the main bearingcaps, as follows:

a. Tighten Bolt (A) to a torque of 258 ± 14 N·m(190 ± 10 lb ft).

Note: Bolt (A) is on the bearing tab side of the mainbearing cap.

b. Tighten Bolt (B) to a torque of 258 ± 14 N·m(190 ± 10 lb ft).

Note: Bolt (B) is on the opposite side of the bearingtab of the main bearing cap.

c. Tighten Bolt (B) for an additional 120 ± 5degrees (2 flats).

Note: If Tooling (C) is not used, place an index markon the bolt and the main bearing cap.

d. Tighten Bolt (A) for an additional 120 ± 5degrees (2 flats).

Note: If Tooling (C) is not used, place an index markon the bolt and the main bearing cap.

e. Tighten Bolt (D) to a torque of 80 ± 10 N·m(59 ± 7 lb ft).

Note: Bolt (D) is on the opposite side of the bearingtab of the main bearing cap.

f. Tighten Bolt (C) to a torque of 80 ± 10 N·m(59 ± 7 lb ft).

Note: Bolt (C) is on the bearing tab side of the mainbearing cap.

g. Rotate the crankshaft in order to ensure thatthe crankshaft turns freely.

7. Use Tooling (B) to check the crankshaft end play.Ensure that Tooling (B) is against a machinedsurface. The end play is controlled by the thrustplates of No. 4 main bearing (center).

Crankshaft end play (new thrustplates) …… 0.10 to 0.60 mm (0.004 to 0.024 inch)

End By:

a. Install the engine oil pump. Refer to Disassemblyand Assembly, “Engine Oil Pump — Install”.

i02296738

Crankshaft — RemoveSMCS Code: 1202-011

Removal ProcedureTable 68

Required Tools

ToolPart

Number Part Description Qty

A 138-7574 Link Bracket 2

1H-3110 Bearing Puller 1

8B-7560 Step Plate 1

9U-6600 Hand Hydraulic Pump 1

1H-3108 Push-Puller Leg 2

1H-3107 Bearing Puller 1

3H-0468 Puller Plate 5

3H-0465 Push-Puller Plate 2

1P-0820 Hydraulic Puller 1

5B-0637 Nut 1

8S-6586 Forcing Screw 1

5P-0944 Dowel Puller Group 1C

5P-0939 Dowel Extractor 1

Start By:

a. Remove the front housing. Refer to Disassemblyand Assembly, “Housing (Front) — Remove”.

b. Remove the rear housing. Refer to Disassemblyand Assembly, “Housing (Rear) — Remove”.

RENR9716-02 89Disassembly and Assembly Section

c. Remove the piston cooling jets. Refer toDisassembly and Assembly, “Piston Cooling Jets- Remove and Install”.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

1. Check the main bearing caps for identification forthe location and the direction in the cylinder block.The identification marks on the main bearing capsmust be installed in the same direction prior toremoval.

2. Check the connecting rod and the connecting rodbearing caps for identification and the location inthe cylinder block.

g01150281Illustration 256

3. Remove bolts (1). Remove connecting rod bearingcaps (2).

g01150289Illustration 257

4. Remove bolts (3) and bolts (5). Remove mainbearing caps (4).

5. Install Tooling (A) and a suitable lifting deviceon each end of crankshaft (6). The weight ofcrankshaft (6) is approximately 188 kg (415 lb).

6. Remove crankshaft (6) from the cylinder block.

7. Remove the thrust plates from each side of theNo. 4 main bearing.

8. Remove the lower main bearings from mainbearing caps (4). Remove the upper mainbearings from the cylinder block.

g01150282Illustration 258

9. Use Tooling (B) to remove crankshaft gear (7)from crankshaft (6).

g01150284Illustration 259

10. If necessary, use Tooling (C) to remove dowel (8)and dowel (9) from crankshaft (6).

90 RENR9716-02Disassembly and Assembly Section

i02296800

Crankshaft — InstallSMCS Code: 1202-012

Installation ProcedureTable 69

Required Tools

ToolPart

Number Part Description Qty

A 138-7574 Link Bracket 2

D 8T-5096 Dial Indicator 1

E 8T-3052 Degree Wheel 1

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01150312Illustration 260

1. Install dowel (8) in the crankshaft.

Protrusion of dowel (8) from the crankshaftface …………………………………. 8.4 mm (0.33 inch)

2. Install dowel (9) in the crankshaft.

Protrusion of dowel (9) from the crankshaft………………………. 4.1 ± 0.5 mm (0.16 ± 0.02 inch)

3. Install crankshaft gear (7) on the crankshaft withthe keyway in alignment with dowel (9). TimingMark “V” of the gear should face away fromcrankshaft (6).

4. Install the upper halves of the main bearings inthe cylinder block.

Note: Ensure that the main bearings are installed sothat the bearing tabs fit into the notch in the cylinderblock. The upper halves of the main bearings havethe oil groove and the oil hole.

g01150344Illustration 261

5. Install Tooling (A) and a suitable lifting deviceon each end of crankshaft (6). The weight ofcrankshaft (6) is approximately 188 kg (415 lb).

6. Install crankshaft (6) with Timing Mark “V” on thecrankshaft gear in alignment with Timing Mark “V”on the cluster gear.

7. Install the thrust plates on each side of the No. 4main bearing.

Note: Install the thrust plates with the words “BlockSide” toward the cylinder block.

8. Install the lower halves of the crankshaft mainbearings in the main bearing caps.

Note: Ensure that the main bearings are installedso that the bearing tabs fit into the notch in the mainbearing cap.

9. Position main bearing caps (4) on the crankshaft.

10. Lubricate the threads of bolts (3) and bolts (5)with clean engine oil. Install the bolts.

11. Tighten bolts (3) and bolts (5) for the main bearingcaps, as follows:

a. Tighten Bolt (A) to a torque of 258 ± 14 N·m(190 ± 10 lb ft).

Note: Bolt (A) is on the bearing tab side of the mainbearing cap.

b. Tighten Bolt (B) to a torque of 258 ± 14 N·m(190 ± 10 lb ft).

RENR9716-02 91Disassembly and Assembly Section

Note: Bolt (B) is on the opposite side of the bearingtab of the main bearing cap.

c. Tighten Bolt (B) for an additional 120 ± 5degrees (2 flats).

Note: If Tooling (E) is not used, place an index markon the bolt and the main bearing cap.

d. Tighten Bolt (A) for an additional 120 ± 5degrees (2 flats).

Note: If Tooling (E) is not used, place an index markon the bolt and the main bearing cap.

e. Tighten Bolt (D) to a torque of 80 ± 10 N·m(59 ± 7 lb ft).

Note: Bolt (D) is on the opposite side of the bearingtab of the main bearing cap.

f. Tighten Bolt (C) to a torque of 80 ± 10 N·m(59 ± 7 lb ft).

Note: Bolt (C) is on the bearing tab side of the mainbearing cap.

g. Rotate the crankshaft in order to ensure thatthe crankshaft turns freely.

12.Use Tooling (D) to check the crankshaft end play.Ensure that Tooling (D) is against a machinedsurface. The end play is controlled by the thrustplates of No. 4 main bearing (center).

Crankshaft end play (new thrustplates) …… 0.10 to 0.60 mm (0.004 to 0.024 inch)

g01150364Illustration 262

13.Position the connecting rod against thecrankshaft. Install connecting rod bearing cap (2)on the connecting rod.

14. Lubricate the threads of bolts (1) with cleanengine oil. Install the bolts.

15. Tighten bolts (1), as follows:

a. Tighten Bolt (A) and Bolt (C) to a torque of70 ± 4 N·m (52 ± 3 lb ft).

b. Tighten Bolt (B) and Bolt (D) to a torque of70 ± 4 N·m (52 ± 3 lb ft).

c. Turn Bolt (B) and Bolt (D) for an additional 60 ±5 degrees (1/6 turn).

Note: If Tooling (E) is not used, place an index markon each bolt and connecting rod cap.

d. Tighten Bolt (A) and Bolt (C) again to a torqueof 70 ± 4 N·m (52 ± 3 lb ft).

e. Turn Bolt (A) and Bolt (C) for an additional 60 ±5 degrees (1/6 turn).

Note: If Tooling (E) is not used, place an index markon each bolt and connecting rod cap.

f. Rotate the crankshaft in order to ensure thatthe crankshaft turns freely.

End By:

a. Install the piston cooling jets. Refer to Disassemblyand Assembly, “Piston Cooling Jets — Removeand Install”.

b. Install the rear housing. Refer to Disassembly andAssembly, “Housing (Rear) — Install”.

c. Install the front housing. Refer to Disassembly andAssembly, “Housing (Front) — Install”.

92 RENR9716-02Disassembly and Assembly Section

i02717761

Bearing Clearance — CheckSMCS Code: 1203-535; 1219-535

Measurement ProcedureTable 70

Required Tools

ToolPart

Number Part Description Qty

198-9142 Plastic Gauge (Green)0.025 to 0.076 mm(0.001 to 0.003 inch)

198-9143 Plastic Gauge (Red)0.051 to 0.152 mm(0.002 to 0.006 inch)

198-9144 Plastic Gauge (Blue)0.102 to 0.229 mm(0.004 to 0.009 inch)

198-9145 Plastic Gauge (Yellow)0.230 to 0.510 mm(0.009 to 0.020 inch)

Note: Plastic gauge may not be necessary when theengine is in the chassis.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

Note: Caterpillar does not recommend the checkingof the actual bearing clearances particularly onsmall engines. This is because of the possibility ofobtaining inaccurate results and the possibility ofdamaging the bearing or the journal surfaces. EachCaterpillar engine bearing is quality checked forspecific wall thickness.

Note: The measurements should be withinspecifications and the correct bearings shouldbe used. If the crankshaft journals and the boresfor the block and the rods were measured duringdisassembly, no further checks are necessary.However, if the technician still wants to measure thebearing clearances, Tooling (A) is an acceptablemethod. Tooling (A) is less accurate on journals withsmall diameters if clearances are less than 0.10 mm(0.004 inch).

NOTICELead wire, shim stock or a dial bore gauge can dam-age the bearing surfaces.

The technician must be very careful to use Tooling (A)correctly. The following points must be remembered:

• Ensure that the backs of the bearings and thebores are clean and dry.

• Ensure that the bearing locking tabs are properlyseated in the tab grooves.

• The crankshaft must be free of oil at the contactpoints of Tooling (A).

1. Put a piece of Tooling (A) on the crown of thebearing that is in the cap.

Note: Do not allow Tooling (A) to extend over theedge of the bearing.

2. Use the correct torque-turn specifications in orderto install the bearing cap. Do not use an impactwrench. Be careful not to dislodge the bearingwhen the cap is installed.

Note: Do not turn the crankshaft when Tooling (A)is installed.

3. Carefully remove the cap, but do not removeTooling (A). Measure the width of Tooling (A)while Tooling (A) is in the bearing cap or on thecrankshaft journal. Refer to Illustration 263.

g01152855Illustration 263

Typical Example

4. Remove all of Tooling (A) before you install thebearing cap.

RENR9716-02 93Disassembly and Assembly Section

Note: When Tooling (A) is used, the readings cansometimes be unclear. For example, all parts ofTooling (A) are not the same width. Measure themajor width in order to ensure that the parts arewithin the specification range. Refer to SpecificationsManual, “Connecting Rod Bearing Journal” andSpecifications Manual, “Main Bearing Journal” for thecorrect clearances.

i02449735

Atmospheric Pressure Sensor- Remove and InstallSMCS Code: 1923-010

Removal Procedure

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01222887Illustration 264

1. Disconnect harness assembly (2).

2. Remove atmospheric pressure sensor (1) fromthe adapter on the cylinder block.

3. Remove the O-ring seal from atmosphericpressure sensor (1).

Installation Procedure

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01222887Illustration 265

1. Install a new O-ring seal on atmospheric pressuresensor (1).

2. Install atmospheric pressure sensor (1) andtighten to a torque of 10 ± 2 N·m (90 ± 18 lb in).

3. Connect harness assembly (2).

i02297743

Camshaft Position Sensor -Remove and InstallSMCS Code: 1912-010

Removal Procedure

Refer to Special Publication, NENG2500, “CaterpillarTools and Shop Products Guide” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

94 RENR9716-02Disassembly and Assembly Section

g01150693Illustration 266

1. Disconnect harness assembly (3).

2. Remove bolt (1) and camshaft position sensor (2).

3. Remove the O-ring seal from camshaft positionsensor (2).

Installation Procedure

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01150693Illustration 267

1. Install a new O-ring seal on camshaft positionsensor (2). Lubricate the O-ring seal with cleanengine oil.

2. Position camshaft position sensor (2) in the fronthousing and install bolt (1). Tighten bolt (1) to atorque of 28 ± 7 N·m (21 ± 5 lb ft).

3. Connect harness assembly (3).

i02297803

Crankshaft Position Sensor -Remove and InstallSMCS Code: 1912-010

Removal Procedure

Refer to Special Publication, NENG2500, “CaterpillarTools and Shop Products Guide” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01150731Illustration 268

1. Disconnect harness assembly (1).

2. Remove bolt (3) and crankshaft position sensor(2).

3. Remove the O-ring seal from crankshaft positionsensor (2).

RENR9716-02 95Disassembly and Assembly Section

Installation Procedure

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01150731Illustration 269

1. Install a new O-ring seal on crankshaft positionsensor (2). Lubricate the O-ring seal with cleanengine oil.

2. Install crankshaft position sensor (2) in the fronthousing. Install bolt (3). Tighten bolt (3) to a torqueof 28 ± 7 N·m (21 ± 5 lb ft).

3. Connect harness assembly (1).

i02449857

Coolant Temperature Sensor -Remove and InstallSMCS Code: 1906-010

Removal Procedure

Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

1. Drain the coolant from the cooling system to alevel below the coolant temperature sensor into asuitable container for storage or disposal. Referto Operation and Maintenance Manual, “CoolingSystem Coolant — Change”.

g01222981Illustration 270

2. Disconnect harness assembly (1).

3. Remove coolant temperature sensor (2).

4. Remove the O-ring seal from coolant temperaturesensor (2).

Installation Procedure

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01222981Illustration 271

96 RENR9716-02Disassembly and Assembly Section

1. Install a new O-ring seal on coolant temperaturesensor (2).

2. Install coolant temperature sensor (2) and tightento a torque of 20 ± 5 N·m (15 ± 4 lb ft).

3. Connect harness assembly (1).

4. Fill the cooling system with coolant. Refer toOperation and Maintenance Manual, “CoolingSystem Coolant — Change”.

i02298137

Engine Oil Pressure Sensor -Remove and InstallSMCS Code: 1924-010

Removal Procedure

Refer to Special Publication, NENG2500, “CaterpillarTools and Shop Products Guide” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01150948Illustration 272

1. Disconnect harness assembly (2).

2. Remove engine oil pressure sensor (1) from theadapter on the cylinder block.

3. Remove the O-ring seal from engine oil pressuresensor (1).

Installation Procedure

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01150948Illustration 273

1. Install a new O-ring seal on engine oil pressuresensor (1).

2. Install engine oil pressure sensor (1) and tightento a torque of 10 ± 2 N·m (89 ± 18 lb in).

3. Connect harness assembly (2).

RENR9716-02 97Disassembly and Assembly Section

i02581037

Fuel Pressure Sensor -Remove and InstallSMCS Code: 7414-010

Removal Procedure

Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

1. Turn the fuel supply valve to the OFF position.

g01292812Illustration 274

2. Disconnect harness assembly (1).

3. Remove fuel pressure sensor (2) from the fuelfilter base.

4. Remove the O-ring seal from fuel pressure sensor(2).

Installation Procedure

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01292812Illustration 275

1. Install a new O-ring seal on fuel pressure sensor(2).

2. Install fuel pressure sensor (2). Tighten fuelpressure sensor (2) to a torque of 10 ± 2 N·m(90 ± 18 lb in).

3. Connect harness assembly (1).

4. Turn the fuel supply valve to the ON position.

i02581061

Fuel Temperature Sensor -Remove and InstallSMCS Code: 1922-010

Removal Procedure

Refer to Special Publication, NENG2500, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

98 RENR9716-02Disassembly and Assembly Section

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

1. Turn the fuel supply valve to the OFF position.

g01292826Illustration 276

2. Disconnect harness assembly (1).

3. Remove fuel temperature sensor (2) from the fuelfilter base.

4. Remove the O-ring seal from fuel temperaturesensor (2).

Installation Procedure

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01292826Illustration 277

1. Install a new O-ring seal on fuel temperaturesensor (2).

2. Install fuel temperature sensor (2). Tighten fueltemperature sensor (2) to a torque of 20 ± 5 N·m(15 ± 4 lb ft).

3. Connect harness assembly (1).

4. Turn the fuel supply valve to the ON position.

i02449930

Turbocharger Outlet PressureSensor — Remove and InstallSMCS Code: 1917-010

Removal Procedure

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01223056Illustration 278

1. Disconnect harness assembly (1).

2. Remove turbocharger outlet pressure sensor (2)from the inlet manifold.

3. Remove the O-ring seal from turbocharger outletpressure sensor (2).

Installation Procedure

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

RENR9716-02 99Disassembly and Assembly Section

g01223056Illustration 279

1. Install a new O-ring seal on turbocharger outletpressure sensor (2).

2. Install turbocharger outlet pressure sensor (2) andtighten to a torque of 10 ± 2 N·m (90 ± 18 lb in).

3. Connect harness assembly (1).

i02449945

Inlet Air Temperature Sensor -Remove and InstallSMCS Code: 1921-010

Removal Procedure

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01223082Illustration 280

1. Disconnect harness assembly (1).

2. Remove inlet air temperature sensor (2) from theinlet manifold.

3. Remove the O-ring seal from inlet air temperaturesensor (2).

Installation Procedure

NOTICEKeep all parts clean from contaminants.

Contaminants may cause rapid wear and shortenedcomponent life.

g01223082Illustration 281

1. Install a new O-ring seal on inlet air temperaturesensor (2).

2. Install inlet air temperature sensor (2) and tightento a torque of 20 ± 5 N·m (15± 4 lb ft).

3. Connect harness assembly (1).

i02574366

Belt Guard — Remove andInstallSMCS Code: 1357-010-GD

Removal Procedure

g01289708Illustration 282

100 RENR9716-02Disassembly and Assembly Section

1. Remove bolts (1). Repeat for the opposite side.Remove bottom belt guard (2).

g01289709Illustration 283

2. Remove bolt (3). Repeat for the opposite side.Remove upper belt guard (4).

Installation Procedure

g01289709Illustration 284

1. Install upper belt guard (4). Install bolt (3). Repeatfor the opposite side.

g01289708Illustration 285

2. Install lower belt guard (2). Install bolts (1). Repeatfor the opposite side.

i02755046

Fan Guard — Remove and InstallSMCS Code: 1360-010

Removal Procedure

g01289778Illustration 286

1. Remove bolts (1). Remove lower fan guard (2).

g01379587Illustration 287

2. Remove bolts (3). Remove upper fan guard (4).

Installation Procedure

g01379587Illustration 288

1. Install upper fan guard (4). Install bolts (3).

RENR9716-02 101Disassembly and Assembly Section

g01289778Illustration 289

2. Install lower fan guard (2). Install bolts (1).

i02755088

Fan — Remove and InstallSMCS Code: 1356-010

Removal ProcedureTable 71

Required Tools

ToolPart

Number Part Description Qty

A 140-7742 Sleeve 1

Start By:

a. Remove the fan guard. Refer to Disassembly andAssembly, “Fan Guard — Remove and Install”.

g01289730Illustration 290

1. Attach Tooling (A) and a suitable lifting deviceonto fan (1). The weight of fan (1) is approximately45 kg (100 lb).

g01289733Illustration 291

2. Remove bolts (2). Remove fan (1).

Installation ProcedureTable 72

Required Tools

ToolPart

Number Part Description Qty

A 140-7742 Sleeve 1

g01289733Illustration 292

1. Attach Tooling (A) and a suitable lifting deviceonto fan (1). The weight of fan (1) is approximately45 kg (100 lb). Install fan (1). Install bolts (2).

102 RENR9716-02Disassembly and Assembly Section

g01289730Illustration 293

2. Remove Tooling (A) and the suitable lifting devicefrom fan (1).

End By:

a. Install the fan guard. Refer to Disassembly andAssembly, “Fan Guard — Remove and Install”.

i02574047

Fan Drive — Remove and InstallSMCS Code: 1359-010; 1386-010

Removal ProcedureStart By:

a. Remove the fan. Refer to Disassembly andAssembly, “Fan — Remove and Install”.

b. Remove the belt guard. Refer to Disassembly andAssembly, “Belt Guard — Remove and Install”.

1. Remove the belts. Refer to Operationand Maintenance Manual, “Belts -Inspect/Adjust/Replace”.

g01289585Illustration 294

2. Loosen bolts (1). Loosen locknut (2).

g01289589Illustration 295

3. Attach a suitable lifting device onto fan drive (3).The weight of fan drive (3) is approximately 45 kg(100 lb). Remove bolts (1). Remove fan drive (3).

RENR9716-02 103Disassembly and Assembly Section

Installation Procedure

g01289589Illustration 296

1. Attach a suitable lifting device onto fan drive (3).The weight of fan drive (3) is approximately 45 kg(100 lb). Install fan drive (3). Install bolts (1).

g01289585Illustration 297

2. Install the belts. Refer to Operationand Maintenance Manual, “Belts -Inspect/Adjust/Replace”.

3. Tighten bolts (1). Tighten locknut (2).

End By:

a. Install the belt guard. Refer to Disassembly andAssembly, “Belt Guard — Remove and Install”.

b. Install the fan. Refer to Disassembly andAssembly, “Fan — Remove and Install”.

i02417465

Electronic Control Module -Remove and InstallSMCS Code: 1901-010

Removal Procedure1. Turn the battery disconnect switch to the “OFF”position.

2. Disconnect the negative battery terminal at thebattery.

g01208278Illustration 298

3. Loosen allen head screw (1). Disconnect theharness assembly from electronic control module(5).

4. Disconnect hose assemblies (2) and (4).

5. Remove bolts (6). Remove electronic controlmodule (5) and ground strap (3).

6. Remove washers (7) and isolation mounts (8)from electronic control module (5).

104 RENR9716-02Disassembly and Assembly Section

Installation Procedure

g01208278Illustration 299

1. Position isolation mounts (8) on electronic controlmodule (5). Position the spacers, washers (7),ground strap (3), and electronic control module (5)on the support assemblies. Install bolts (6).

2. Connect hose assemblies (4) and (2).

3. Connect the harness assembly to electroniccontrol module (5). Tighten allen head screw (1)to a torque of 6 ± 1 N·m (53 ± 9 lb in).

4. Connect the negative battery terminal at thebattery.

5. Turn the battery disconnect switch to the “ON”position.

i02450170

Alternator — Remove and InstallSMCS Code: 1405-010

Removal Procedure1. Turn the battery disconnect switch to the OFFposition.

g01223195Illustration 300

2. Remove V-belt (1) from alternator (3).

3. Disconnect the harness assemblies fromalternator (3).

4. Remove bolt (2) and bolt (4).

5. Remove alternator (3) from the mounting group.

Installation Procedure

g01223195Illustration 301

1. Position alternator (3) on the mounting group.

2. Install bolt (4) and bolt (2).

3. Connect the harness assemblies to alternator (3).Refer to Specifications, “Alternator and Regulator”.

4. Install V-belt (1) on alternator (3).

5. Adjust the tension on the V-belt. Refer toOperation and Maintenance Manual, “Belt -Inspect/Adjust/Replace”.

6. Turn the battery disconnect switch to the ONposition.

RENR9716-02 105Disassembly and Assembly Section

i02419387

Electric Starting Motor -Remove and InstallSMCS Code: 1453-010

Removal Procedure

Personal injury can result from failure to discon-nect the battery.

First, disconnect the negative battery cable. Then,disconnect the positive battery cable.

A positive power lead can cause sparks if the bat-tery is not disconnected. Sparks can possibly re-sult in battery explosion or fire.

1. Turn the battery disconnect switch to the “OFF”position.

g01208927Illustration 302

2. Place an index mark on all of the harnessassemblies. Disconnect the harness assembliesfrom electric starting motor (1).

3. Fasten a suitable lifting device to electric startingmotor (1). The weight of electric starting motor (1)is approximately 37 kg (80 lb).

4. Remove bolts (2).

5. Remove electric starting motor (1) and the gasketfrom the flywheel housing.

Installation Procedure

g01208927Illustration 303

1. Fasten a suitable lifting device to electric startingmotor (1). The weight of electric starting motor (1)is approximately 37 kg (80 lb).

2. Position the gasket and electric starting motor (1)in the flywheel housing. Install bolts (2).

3. Connect the harness assemblies to electricstarting motor (1). Refer to Specifications, “ElectricStarting Motor”.

4. Turn the battery disconnect switch to the “ON”position.

106 RENR9716-02Index Section

Index

Aftercooler — Install…………………………………………. 40Installation Procedure …………………………………. 40

Aftercooler — Remove……………………………………… 38Removal Procedure ……………………………………. 38

Alternator — Remove and Install ……………………… 104Installation Procedure ……………………………….. 104Removal Procedure ………………………………….. 104

Atmospheric Pressure Sensor — Remove andInstall …………………………………………………………. 93Installation Procedure …………………………………. 93Removal Procedure ……………………………………. 93

Bearing Clearance — Check …………………………….. 92Measurement Procedure …………………………….. 92

Belt Guard — Remove and Install ……………………… 99Installation Procedure ……………………………….. 100Removal Procedure ……………………………………. 99

Camshaft — Install…………………………………………… 73Installation Procedure …………………………………. 73

Camshaft — Remove……………………………………….. 71Removal Procedure ……………………………………. 71

Camshaft Bearings — Install …………………………….. 76Installation Procedure …………………………………. 76

Camshaft Bearings — Remove …………………………. 76Removal Procedure ……………………………………. 76

Camshaft Position Sensor — Remove and Install … 93Installation Procedure …………………………………. 94Removal Procedure ……………………………………. 93

Connecting Rod Bearings — Install ……………………. 85Installation Procedure …………………………………. 85

Connecting Rod Bearings — Remove………………… 84Removal Procedure ……………………………………. 84

Coolant Temperature Sensor — Remove andInstall …………………………………………………………. 95Installation Procedure …………………………………. 95Removal Procedure ……………………………………. 95

Cooling System Package (Radiator, Aftercooler, FuelCooler) — Install ……………………………………………. 36Installation Procedure …………………………………. 36

Cooling System Package (Radiator, Aftercooler, FuelCooler) — Remove ………………………………………… 35Removal Procedure ……………………………………. 35

Crankshaft — Install…………………………………………. 90Installation Procedure …………………………………. 90

Crankshaft — Remove……………………………………… 88Removal Procedure ……………………………………. 88

Crankshaft Front Seal — Install …………………………. 55Installation Procedure …………………………………. 55

Crankshaft Front Seal — Remove……………………… 54Removal Procedure ……………………………………. 54

Crankshaft Main Bearings — Install……………………. 87Installation Procedure …………………………………. 87

Crankshaft Main Bearings — Remove………………… 86Removal Procedure ……………………………………. 86

Crankshaft Position Sensor — Remove and Install.. 94Installation Procedure …………………………………. 95Removal Procedure ……………………………………. 94

Crankshaft Rear Seal — Install………………………….. 50Installation Procedure …………………………………. 50

Crankshaft Rear Seal — Remove………………………. 50Removal Procedure ……………………………………. 50

Cylinder Head — Install ……………………………………. 68Installation Procedure …………………………………. 68

Cylinder Head — Remove ………………………………… 66Removal Procedure ……………………………………. 66

Cylinder Liner — Install…………………………………….. 79Installation Procedure …………………………………. 79

Cylinder Liner — Remove…………………………………. 79Removal Procedure ……………………………………. 79

Disassembly and Assembly Section…………………… 4

Electric Starting Motor — Remove and Install ……. 105Installation Procedure ……………………………….. 105Removal Procedure ………………………………….. 105

Electronic Control Module — Remove and Install.. 103Installation Procedure ……………………………….. 104Removal Procedure ………………………………….. 103

Electronic Unit Injector — Install ………………………… 14Installation Procedure …………………………………. 14

Electronic Unit Injector — Remove …………………….. 13Removal Procedure ……………………………………. 13

Electronic Unit Injector Sleeve — Install ……………… 16Installation Procedure …………………………………. 16

Electronic Unit Injector Sleeve — Remove ………….. 15Removal Procedure ……………………………………. 15

Engine — Install………………………………………………… 6Installation Procedure …………………………………… 6

Engine — Remove…………………………………………….. 4Removal Procedure ……………………………………… 4

Engine Oil Cooler — Install……………………………….. 28Installation Procedure …………………………………. 28

Engine Oil Cooler — Remove……………………………. 27Removal Procedure ……………………………………. 27

Engine Oil Filter Base — Assemble……………………. 26Assembly Procedure…………………………………… 26

Engine Oil Filter Base — Disassemble ……………….. 26Disassembly Procedure ………………………………. 26

Engine Oil Filter Base — Install …………………………. 27Installation Procedure …………………………………. 27

Engine Oil Filter Base — Remove ……………………… 25Removal Procedure ……………………………………. 25

RENR9716-02 107Index Section

Engine Oil Pan — Remove and Install………………… 78Installation Procedure …………………………………. 78Removal Procedure ……………………………………. 78

Engine Oil Pressure Sensor — Remove and Install.. 96Installation Procedure …………………………………. 96Removal Procedure ……………………………………. 96

Engine Oil Pump — Assemble…………………………… 29Assembly Procedure…………………………………… 29

Engine Oil Pump — Disassemble………………………. 29Disassembly Procedure ………………………………. 29

Engine Oil Pump — Install ………………………………… 30Installation Procedure …………………………………. 30

Engine Oil Pump — Remove…………………………….. 28Removal Procedure ……………………………………. 28

Engine Support (Front) — Remove and Install …….. 45Installation Procedure (Type 1) …………………….. 46Installation Procedure (Type 2) …………………….. 46Removal Procedure (Type 1) ……………………….. 45Removal Procedure (Type 2) ……………………….. 46

Exhaust Manifold — Remove and Install …………….. 19Installation Procedure …………………………………. 19Removal Procedure ……………………………………. 19

Fan — Remove and Install ……………………………… 101Installation Procedure ……………………………….. 101Removal Procedure ………………………………….. 101

Fan Drive — Remove and Install ……………………… 102Installation Procedure ……………………………….. 103Removal Procedure ………………………………….. 102

Fan Guard — Remove and Install ……………………. 100Installation Procedure ……………………………….. 100Removal Procedure ………………………………….. 100

Flywheel — Remove and Install ………………………… 49Installation Procedure …………………………………. 49Removal Procedure ……………………………………. 49

Flywheel Housing — Remove and Install ……………. 51Installation Procedure …………………………………. 52Removal Procedure ……………………………………. 51

Fuel Filter and Water Separator — Remove andInstall ………………………………………………………….. 11Installation Procedure ………………………………….. 11Removal Procedure …………………………………….. 11

Fuel Filter Base — Install………………………………….. 10Installation Procedure …………………………………. 10

Fuel Filter Base — Remove………………………………. 10Removal Procedure ……………………………………. 10

Fuel Pressure Sensor — Remove and Install………. 97Installation Procedure …………………………………. 97Removal Procedure ……………………………………. 97

Fuel Priming Pump — Remove and Install ……………. 9Installation Procedure …………………………………. 10Removal Procedure ……………………………………… 9

Fuel Temperature Sensor — Remove and Install …. 97Installation Procedure …………………………………. 98Removal Procedure ……………………………………. 97

Fuel Transfer Pump — Install ……………………………. 12Installation Procedure …………………………………. 12

Fuel Transfer Pump — Remove ………………………… 12Removal Procedure ……………………………………. 12

Gear Group (Front) — Install …………………………….. 56Installation Procedure …………………………………. 56

Gear Group (Front) — Remove …………………………. 55Removal Procedure ……………………………………. 55

Gear Group (Rear) — Install……………………………… 48Installation Procedure …………………………………. 48

Gear Group (Rear) — Remove………………………….. 46Removal Procedure ……………………………………. 46

Housing (Front) — Install ………………………………….. 58Installation Procedure …………………………………. 58

Housing (Front) — Remove………………………………. 57Removal Procedure ……………………………………. 57

Housing (Rear) — Install…………………………………… 60Installation Procedure …………………………………. 60

Housing (Rear) — Remove……………………………….. 60Removal Procedure ……………………………………. 60

Important Safety Information …………………………….. 2Inlet Air Temperature Sensor — Remove andInstall …………………………………………………………. 99Installation Procedure …………………………………. 99Removal Procedure ……………………………………. 99

Inlet and Exhaust Valve Guides — Remove andInstall …………………………………………………………. 23Installation Procedure …………………………………. 24Removal Procedure ……………………………………. 23

Inlet and Exhaust Valve Seat Inserts — Remove andInstall …………………………………………………………. 24Installation Procedure …………………………………. 25Removal Procedure ……………………………………. 24

Inlet and Exhaust Valve Springs — Remove andInstall …………………………………………………………. 20Installation Procedure …………………………………. 21Removal Procedure ……………………………………. 20

Inlet and Exhaust Valves — Remove and Install ….. 22Installation Procedure …………………………………. 23Removal Procedure ……………………………………. 22

Piston Cooling Jets — Remove and Install………….. 80Installation Procedure …………………………………. 80Removal Procedure ……………………………………. 80

Pistons and Connecting Rods — Assemble ………… 82Assembly Procedure…………………………………… 82

Pistons and Connecting Rods — Disassemble ……. 82Disassembly Procedure ………………………………. 82

Pistons and Connecting Rods — Install………………. 83Installation Procedure …………………………………. 83

Pistons and Connecting Rods — Remove…………… 81Removal Procedure ……………………………………. 81

Radiator Core — Install…………………………………….. 44Installation Procedure …………………………………. 44

Radiator Core — Remove…………………………………. 42Removal Procedure ……………………………………. 42

Rocker Arm — Assemble………………………………….. 64Assembly Procedure…………………………………… 64

Rocker Arm — Disassemble……………………………… 64Disassembly Procedure ………………………………. 64

Rocker Arm and Shaft — Install…………………………. 65Installation Procedure …………………………………. 65

Rocker Arm and Shaft — Remove……………………… 63Removal Procedure ……………………………………. 63

Table of Contents…………………………………………….. 3Turbocharger — Assemble ……………………………….. 18Assembly Procedure…………………………………… 18

Turbocharger — Disassemble …………………………… 17Disassembly Procedure ………………………………. 17

Turbocharger — Install …………………………………….. 18Installation Procedure …………………………………. 18

Turbocharger — Remove …………………………………. 17Removal Procedure ……………………………………. 17

Turbocharger Outlet Pressure Sensor — Remove andInstall …………………………………………………………. 98Installation Procedure …………………………………. 98Removal Procedure ……………………………………. 98

Valve Mechanism Cover — Remove and Install …… 62Installation Procedure …………………………………. 62Removal Procedure ……………………………………. 62

Valve Mechanism Cover Base — Remove andInstall …………………………………………………………. 62Installation Procedure …………………………………. 63Removal Procedure ……………………………………. 62

Vibration Damper and Pulley — Remove andInstall …………………………………………………………. 53Installation Procedure …………………………………. 53Removal Procedure ……………………………………. 53

Water Pump — Assemble…………………………………. 32Assembly Procedure…………………………………… 32

Water Pump — Disassemble…………………………….. 31Disassembly Procedure ………………………………. 31

Water Pump — Install ………………………………………. 33Installation Procedure …………………………………. 33

Water Pump — Remove …………………………………… 31Removal Procedure ……………………………………. 31

Water Temperature Regulator Housing — Remove andInstall …………………………………………………………. 33Installation Procedure …………………………………. 34Removal Procedure ……………………………………. 33

Cat, Caterpillar, their respective logos, “Caterpillar Yellow” and the Power edgetrade dress, as well as corporate and product identity used herein, are trademarksof Caterpillar and may not be used without permission.

Printed in U.S.A.

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Catalog excerpts

standard ENGINE equipment • Air cleaner/fumes disposal system • Electronic governor MARINE PROPULSION engine • A4 Electronic Control Unit • Electronic diagnostics and fault logging • Engine and transmission monitoring • Sea water aftercooler • Titanium plate heat exchanger with expansion tank • Gear-driven jacket water and sea water pumps • Watercooled exhaust manifold and turbocharger • MEUI fuel system • Fuel priming and transfer pump • Shallow sump oil pan • Oil filter, dipstick, and oil filler (RH or LH service) • Crankcase breather • Adjustable front support Image shown may not reflect actual engine DIMENSIONS Front Right Side • EPA Tier 3 Recreational/IMO II compliant • 32.16 L displacement • 2300 rpm rated engine speed • 145 mm (5.71 in) bore x 162 mm (6.38 in) stroke • Turbocharged and aftercooled aspiration • Electronically governed • Heat exchanger cooled • Refill capacity – ooling system: 79 L (20.9 gal) C – Lube oil system: 85.2 L (22.5 gal) • 4V electronic protection system 2 • AE No. 0 flywheel and flywheel housing, S 136 flywheel teeth • ounterclockwise rotation from flywheel end C • 250-hour oil change interval • Caterpillar Diesel Engine Oil 10W30 or 15W40 Note: Do not use these dimensions for installation design. See general dimension drawings for detail.

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MARINE PROPULSION engine MARINE ENGINE PERFORMANCE Prop Demand Maximum Power BSFC lb/hp-hr Torque lb-ft Torque lb-ft Prop Demand RATING DEFINITIONS AND CONDITIONS E Rating (High Performance) Typical applications: For vessels operating at rated load and rated speed up to 8% of the time, or 1/2 hour out of 6, (up to 30% load factor). Typical applications could include but are not limited to vessels such as pleasure craft, harbor patrol boats, harbor master boats, some fishing or patrol boats. Typical operation ranges from 250 to 1000 hours per year. CAT, CATERPILLAR, their respective logos,…

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Valve Lash Check

Valve Lash Adjustment

Contents Summary of C32 Power Module Operation and Maintenance Manual

Catalog excerpts

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Contents Summary of C32 Power Module Operation and
Maintenance
Manual