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3054 MOTORES Cat Especificaciones
3054 MOTORES Cat Especificaciones
g00296342
Illustration 1
Cylinder and valve location for Type 1 engines and 9RM engines
(A) Exhaust valves
(B) Inlet valves
Note: Type 1 engines can be identified in two ways. The first method refers to
Illustration 1. When the valve cover is removed, look at the cylinder head valves. Type
1 engines have two exhaust valves in a row and two inlet valves that are in a row.
The second method does not require the removal of the valve cover. Refer to the inlet
manifold and the exhaust manifold. Type 1 engines have two exhaust ports in a row and
two inlet ports that are in a row.
Type ... Four cylinder and four stroke
Combustion system ... Direct injection
Nominal Bore ... 100 mm (3.937 inch)
Stroke ... 127 mm (5.00 inch)
Capacity ... 4 liters (243 in3)
Compression Ratio ... 16:1
Number of cylinders ... 4
Arrangement of cylinders ... in-line
Firing Order ... 1, 3, 4, 2
Valve Lash
Inlet valve ... 0.20 mm (.008 inch)
Exhaust valve ... 0.45 mm (.018 inch)
When the crankshaft is viewed from the front of the engine the crankshaft rotates in the
following direction: ... Clockwise
When the camshaft is viewed from the front of the engine the camshaft rotates in the
following direction: ... Clockwise
Note: The front end of the engine is opposite the flywheel end. The left side and the
right side of the engine are viewed from the flywheel end. The No. 1 cylinder is the
front cylinder.
Type 2 Engines and 7BJ Engines
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g00296424
Illustration 2
Cylinder and valve location for Type 2 engines and 7BJ engines
(A) Exhaust valves
(B) Inlet valves
Note: Type 2 engines can be identified in two ways. The first method refers to
Illustration 2. When the valve cover is removed, look at the cylinder head valves. Type
2 engines alternate the exhaust valves and the inlet valves.
Note: Some of the Type 2 7BJ engines may look like the Type 1 engines. When the
valve cover is removed, these engines may have two exhaust valves in a row and two
inlet valves in a row. This is only a small percentage of the Type 2 7BJ engines.
The second method does not require the removal of the valve cover. Refer to the inlet
manifold and the exhaust manifold. Type 2 engines alternate the exhaust ports and the
inlet ports.
Type ... Four cylinder and four stroke
Combustion system ... Direct injection
Nominal Bore ... 100 mm (3.937 inch)
Stroke ... 127 mm (5.00 inch)
Capacity ... 4 liters (243 in3)
Compression Ratio ... 17.25:1
Number of cylinders ... 4
Arrangement of cylinders ... in-line
Firing Order ... 1, 3, 4, 2
Valve Lash
Inlet valve ... 0.20 mm (.008 inch)
Exhaust valve ... 0.45 mm (.018 inch)
When the crankshaft is viewed from the front of the engine the crankshaft rotates in the
following direction: ... Clockwise
When the camshaft is viewed from the front of the engine the camshaft rotates in the
following direction: ... Clockwise
Note: The front end of the engine is opposite the flywheel end. The left side and the
right side of the engine are viewed from the flywheel end. The No. 1 cylinder is the
front cylinder.
1 1 0
Various Fuel Injection Pumps may be equipped to the engine. Bosch, Delphi, or
Stanadyne fuel injection pumps may be equipped to the engine.
Bosch Fuel Injection Pump (EPVE)
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g00896561
Illustration 1
Note: Parts that are inside of the fuel injection pump are only serviceable by an
authorized Bosch dealer. Please consult your parts book for availability of parts on the
outside of the pump that are not related to the settings of the fuel pump and for the
possibility of remanufacturing options.
Hub nut (not shown)
Note: Do not release the hub nut from the fuel injection pump. The fuel pump hub is
positioned to the pump shaft in order to ensure that the fuel pump is in the correct
position for timing. If the hub is removed, the hub will need to be accurately positioned
to the pump shaft. Accurate positioning requires the use of special equipment by a
Caterpillar Dealer.
(1) Tighten the screw for the low idle speed adjustment to the following torque. ... 4 to
4.5 N·m (35 to 40 lb in)
(2) Tighten the fitting for the fuel return line connection to the following torque. ... 5 to
6 N·m (44 to 53 lb in)
(3) Tighten the fitting for the fuel supply connection to the following torque. ... 22 N·m
(16 lb ft)
(4) Boost control (if equipped)
(5) Tighten the high idle speed adjustment screw to the following torque. ... 4 to 4.5
N·m (35 to 40 lb in)
(6) Tighten the nuts for the high pressure fuel line connection to the following torque. ...
22 N·m (16 lb ft)
(7) Tighten the flange nuts to the following torque. ... 22 N·m (16 lb ft)
(8) Tighten the fittings for the fuel discharge lines to the following torque. ... 70.5 to
81.4 N·m (52 to 60 lb ft)
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Illustration 2
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Illustration 3
Note: Before the crankshaft is turned or the fuel injection pump is installed, move the
locking spacer (9) under the locking screw (10). Refer to position (A) that is in
Illustration 3. This position ensures that the pump drive shaft is released.
Fuel Static
Code Engine
Injection Timing
Letters on Check Piston
Pump Mark Position
Fuel Angle Displacemen
Angle Before TC
Injection (degrees) (1
t (1)
(degrees) (1) Position
Pump )
(degrees)
1.78 mm
"BK" 308 314 12
(0.070 inch)
1.78 mm
"CK" 308 314 12
(0.070 inch)
2.42 mm
"DK" 306 313 14
(0.095 inch)
2.42 mm
"EK" 308.5 315.5 14
(0.095 inch)
3.99 mm
"EK" (2)
306.5 315.5 18
(0.157 inch)
2.42 mm
"EM" 288.5 295.5 14
(0.095 inch)
1.93 mm
"FM" 289 295 12.5
(0.076 inch)
"JM" - - 6 -
"JM" (3)
- - 2 -
"JM" (4)
- - TDC -
"KC" (5)
- - TDC -
"KL" (5)
- - TDC -
"ML" (5)
- - TDC -
"PM" - - 12 -
"SK" - - 9 -
"TL" (5)
- - TDC -
VM - - 2 ATDC -
(1)
The engine must be set at the TC position on the compression stroke for the
number 1 piston. The fuel injection pump mark angle and the displacement of
the piston can be checked when the plunger for the fuel injection pump is set at
1.00 mm (0.039 inch).
(2)
The information plate on the fuel injection pump is stamped "J609".
(3)
"AD70229" and "AD702230" only
(4)
"AD80643" only
(5)
The cold start advance (KSB) must be energized before the timing is set.
Note: Later Bosch Fuel Injection Pumps use a pin to time the pump.
Stanadyne Fuel Injection Pump (DB2 or DB4)
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g00788020
Illustration 4
Note: Parts that are inside of the fuel injection pump are only serviceable by an
authorized Stanadyne dealer. Please consult your parts book for availability of parts on
the outside of the pump that are not related to the settings of the fuel pump and for the
possibility of remanufacturing options.
Hub nut (not shown)
Note: Do not release the hub nut from the fuel injection pump. The fuel pump hub is
positioned to the pump shaft in order to ensure that the fuel pump is in the correct
position for timing. If the hub is removed, the hub will need to be accurately positioned
to the pump shaft. Accurate positioning requires the use of special equipment by a
Caterpillar Dealer.
(1) Electrical connection for the stop solenoid
(2) Tighten the fitting for the fuel return line connection to the following torque. ... 5 to
6 N·m (44 to 53 lb in)
(3) Tighten the high idle speed adjustment screw to the following torque. ... 4 to 4.5
N·m (35 to 40 lb in)
(4) Tighten the screw for the low idle speed adjustment to the following torque. ... 4 to
4.5 N·m (35 to 40 lb in)
(5) Tighten the flange nuts to the following torque. ... 22 N·m (16 lb ft)
(6) Adjustment screw for advance timing
(7) Tighten the fittings for the fuel discharge to the following torque. ... 70.5 to 81.4
N·m (52 to 60 lb ft)
(8) Tighten the nuts for the high pressure fuel injection line to the following torque. ...
22 N·m (16 lb ft)
(9) Tighten the nut for the end cap to the following torque. ... 22 N·m (16 lb ft)
NOTICE
The No. 1 cylinder must be at the top center position on the
compression stroke before the fuel injection pump is installed. If the
crankshaft needs to be rotated, the fuel injection pump must be
mounted temporarily or the loose gear could cause damage to the front
housing.
"CL" (1)
- 247.5
"LM" (2)
288.5 295
"MM" (3)
288.5 295
"ZM" (4)
282 287
"ZM" (5)
282 289
(1)
The fuel injection pump is timed with a pin.
(2)
The fuel injection pump is coded "2643U211" or "2643U213".
(3)
The fuel injection pump is coded "2643U214".
(4)
The values are for the fuel injection pumps with a serial number up to
"7665964".
(5)
The values are for the fuel injection pump with a serial number that includes
"7665965". The values are also for the fuel injection pumps with serial numbers
that are higher than "7665965".
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g00788005
Illustration 5
Note: Parts that are inside of the fuel injection pump are only serviceable by an
authorized Delphi dealer. Please consult your parts book for availability of parts on the
outside of the pump that are not related to the settings of the fuel pump and for the
possibility of remanufacturing options.
(1) Hub nut
Note: Do not release the hub nut from the fuel injection pump. The fuel pump hub is
positioned to the pump shaft in order to ensure that the fuel pump is in the correct
position for timing. If the hub is removed, the hub will need to be accurately positioned
to the pump shaft. Accurate positioning requires the use of special equipment by a
Caterpillar Dealer.
(2) O-ring
(3) Locking spacer
The drive shaft of the fuel injection pump must not be turned without the spacer in
position under the locking screw (4) .
(4) Tighten the locking screw to the following torque. ... 10 N·m (7 lb ft)
The locking screw prevents the rotation of the drive shaft.
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g00292837
Illustration 6
Before the crankshaft is turned or the fuel injection pump is installed, move the locking
spacer (3) under the locking screw (4). Refer to position (A) that is in Illustration 6. This
position ensures that the pump drive shaft is released.
(5) Tighten the fitting for the fuel return line connection to the following torque. ... 5 to
6 N·m (44 to 53 lb in)
(6) Tighten the adjustment screw for low idle to the following torque. ... 4 to 4.5 N·m
(35 to 40 lb in)
(7) Tighten the adjustment screw for high idle to the following torque. ... 4 to 4.5 N·m
(35 to 40 lb in)
(8) Electrical connection for the stop solenoid
(9) Tighten the fitting for the fuel supply connection to the following torque. ... 22 N·m
(16 lb ft)
(10) Tighten the nuts for the fuel line to the following torque. ... 22 N·m (16 lb ft)
(11) Tighten the flange nuts to the following torque. ... 22 N·m (16 lb ft)
(12) Electrical connection for cold starting aid
(13) Tighten the fittings for the fuel discharge lines to the following torque. ... 70.5 to
81.4 N·m (52 to 60 lb ft)
Engine Check
Code that is on the Fuel Injection Pump
Angle (degrees)
Fuel Injection Pump Mark Angle (degrees)
"LK" (1)
328 337.5
"MK" (2)
325 336
(1)
"YA31257" only
(2)
"YA50532" only
Table 4
"BC" 336.5
"CC" 338.5
"DC" 337.5
"EC" 337.5
"FC" 335.5
"GC" 337
"PC" 339
"RC" 339
"SC" 341
"XL" 22
Note: Later Delphi Fuel Injection Pumps are timed with a pin.
1
1 0
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g00308903
Illustration 1
Pressure Settings for the Fuel Injection Nozzles for the Type 1 Engines and 9RM
Engines
"HU"
22291 kPa (3233 psi)
"HV"
25331 kPa (3674 psi)
"HZ"
22291 kPa (3233 psi)
"JA"
25331 kPa (3674 psi)
"JB"
25331 kPa (3674 psi)
"JE"
22291 kPa (3233 psi)
"JF"
25331 kPa (3674 psi)
"JG"
23304 kPa (3380 psi)
"JH"
25331 kPa (3674 psi)
"JJ"
25331 kPa (3674 psi)
"JK"
22291 kPa (3233 psi)
"JL"
25331 kPa (3674 psi)
"JR"
25331 kPa (3674 psi)
"JS"
25331 kPa (3674 psi)
"JT"
25331 kPa (3674 psi)
"JU"
22291 kPa (3233 psi)
"JY"
25331 kPa (3674 psi)
"NJ"
22291 kPa (3233 psi)
"NK"
22801 kPa (3307 psi)
"NL"
22801 kPa (3307 psi)
"NM"
23304 kPa (3380 psi)
"NN"
23304 kPa (3380 psi)
"NP"
22291 kPa (3233 psi)
"NR"
23304 kPa (3380 psi)
"NS"
25331 kPa (3674 psi)
"NT"
23304 kPa (3380 psi)
"NU"
22291 kPa (3233 psi)
"NV"
22291 kPa (3233 psi)
"NW"
22291 kPa (3233 psi)
"RD"
25028 kPa (3630 psi)
"RE"
25028 kPa (3630 psi)
"RF"
25028 kPa (3630 psi)
"RH"
25028 kPa (3630 psi)
"RK"
26903 kPa (3902 psi)
"RM"
25028 kPa (3630 psi)
"RN"
25028 kPa (3630 psi)
"RP"
25028 kPa (3630 psi)
"RR"
25028 kPa (3630 psi)
"RS"
25028 kPa (3630 psi)
"RT"
25028 kPa (3630 psi)
"RU"
25028 kPa (3630 psi)
"RV"
25028 kPa (3630 psi)
(1)
The code letters are stamped on the side of the fuel injector body. The code letters are located below
the connection for the nut of the high pressure fuel line.
Note: Ensure that the new fuel injection nozzles have the same identification code as
the nozzles which were originally installed in the cylinder head.
Leakage in 10 seconds ... 0 drops
Type 2 Engines and 7BJ Engines
Note: For a complete description of Type 1 and Type 2 engines, refer to the
Specifications Module, "Engine Design" for more information.
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g00293085
Illustration 2
Pressure Settings for the Fuel Injection Nozzles for the Type 2 Engines and 7BJ
Engines
"KB"
30406 kPa (4410 psi)
"KC"
28979 kPa (4203 psi)
"KD"
29385 kPa (4262 psi)
"KE"
29385 kPa (4262 psi)
"KF"
29385 kPa (4262 psi)
"KG"
29385 kPa (4262 psi)
"KH"
29392 kPa (4263 psi)
"KJ"
25338 kPa (3675 psi)
"KK"
30406 kPa (4410 psi)
"KL"
30406 kPa (4410 psi)
"KM"
30406 kPa (4410 psi)
"KN"
29385 kPa (4262 psi)
"KP"
29385 kPa (4262 psi)
"KR"
29392 kPa (4263 psi)
"KT"
29392 kPa (4263 psi)
"KS"
29392 kPa (4263 psi)
"KU"
29385 kPa (4262 psi)
"KV"
25338 kPa (3675 psi)
"KW"
29385 kPa (4262 psi)
"NX"
29385 kPa (4262 psi)
"NY"
29392 kPa (4263 psi)
"NZ"
29392 kPa (4263 psi)
"PA"
29392 kPa (4263 psi)
"PB"
29392 kPa (4263 psi)
"PC"
29385 kPa (4262 psi)
"PD"
27862 kPa (4041 psi)
"PE"
28372 kPa (4115 psi)
"RZ"
25338 kPa (3675 psi)
"SA"
25338 kPa (3675 psi)
"SB"
25338 kPa (3675 psi)
"SC"
25338 kPa (3675 psi)
(1)
The code letters are stamped on the side of the fuel injector body. The code letters are located below
the connection for the nut of the high pressure fuel line.
Note: Ensure that the new fuel injection nozzles have the same identification code as
the nozzles which were originally installed in the cylinder head.
Leakage in 10 seconds ... 0 drops
1 1 0
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Illustration 1 g00293216
Typical example of the fuel transfer pump
Method of drive ... Camshaft
Output pressure during the first ten seconds of cranking:
Normal pressure ... 42 to 70 kPa (6 to 10 psi)
Minimum pressure ... 30 kPa (4.4 psi)
The engine may be equipped with four mounting bolts or four mounting studs with nuts.
Tighten to the following torque: ... 22 N·m (16 lb ft)
Apply 4C-4030 Thread Lock Compound to the first three threads of the mounting bolts
or the mounting studs.
Refer to the Systems Operation, Testing and Adjusting Module, "Fuel System Pressure -
Test" topic in order to test the operation of the fuel transfer pump.
Note: When the fuel transfer pump is installed on the engine, ensure that the camshaft is
on minimum lobe lift and that the bolts are evenly tightened. Failure to follow this
procedure can cause the following conditions: loss of maximum engine power and
damage to the fuel transfer pump.
1 1 0
Rocker Shaft
SMCS - 1102
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Illustration 1
1 0
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Illustration 1
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Illustration 1
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Illustration 2
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Illustration 3
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Illustration 4
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Illustration 5
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Illustration 6
1 0
Cylinder Head
SMCS - 1100
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Illustration 1
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Illustration 2
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Illustration 3
Positions for measuring the bow of the cylinder head (typical example)
Maximum permissible amount of bow (curve of cylinder head)
Naturally aspirated engines
A ... 0.08 mm (.003 inch)
B ... 0.15 mm (.006 inch)
C ... 0.15 mm (.006 inch)
Turbocharged engines
A ... 0.13 mm (.005 inch)
B ... 0.25 mm (.010 inch)
C ... 0.25 mm (.010 inch)
Tighten the bolts of the inlet manifold (not shown) to the following torque: ... 44 N·m
(32 lb ft)
Tighten exhaust manifold nuts (not shown) to the following torque:
Plated ... 44 N·m (32 lb ft)
Plain ... 50 N·m (37 lb ft)
Type 2 Engines and 7BJ Engines
Note: For a complete description of Type 1 and Type 2 engines, refer to the
Specifications Module, "Engine Design" for more information.
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g00295370
Illustration 4
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Illustration 5
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Illustration 6
Positions for measuring the bow of the cylinder head (typical example)
Maximum permissible amount of bow (curve of the cylinder head)
A ... 0.08 mm (.003 inch)
B ... 0.15 mm (.006 inch)
C ... 0.15 mm (.006 inch)
Tighten the bolts for the inlet manifold (not shown) to the following torque: ... 44 N·m
(32 lb ft)
Tighten the nuts for the exhaust manifold (not shown) to the following torque:
Plated ... 44 N·m (32 lb ft)
Plain ... 50 N·m (37 lb ft)
1 1 0
Turbocharger
SMCS - 1052
Turbocharger
Ver imagen
g00295466
Illustration 1
(1) Put oil on the threads of the nut and put oil on the seat face.
Tighten the impeller nut to the following torque: ... 2 to 2.3 N·m (18 to 20 lb in)
Tighten the nut again to the following value: ... 110 degrees
Note: Do not bend or add stress to the shaft when the nut is tightened.
(2) Tighten the bolts, which hold the back plate, to the following torque: ... 8.5 to 10.2
N·m (75 to 90 lb in)
(3) Put 5P-3931 Anti-Seize Compound on the threads. Tighten the bolts, which hold the
compressor housing to the center section, to the following torque: ... 15.3 to 18.7 N·m
(12 to 14 lb ft)
(4) Put 5P-3931 Anti-Seize Compound on the threads. Tighten the bolts, which hold the
turbine housing to the center section, to the following torque: ... 18.6 to 20.4 N·m (14 to
15 lb ft)
(5) Turbine wheel assembly
Minimum journal outside diameter ... 10.152 mm (.3997 inch)
Ring groove diameter (minimum) ... 14.401 mm (.5670 inch)
Ring groove width (maximum) ... 1.740 mm (.0685 inch)
Hub outside diameter (minimum) ... 17.323 mm (.6820 inch)
(6) End play for shaft
Minimum permissible end play ... .03 mm (.001 inch)
Maximum permissible end play ... .10 mm (.004 inch)
(7) Compressor wheel
Bore inside diameter (maximum) ... 6.353 mm (.2501 inch)
(8) Backplate assembly
Seal inside diameter (maximum) ... 12.713 mm (.5005 inch)
Flatness from the backplate to the mating surface of the center housing is within
the following value: ... .013 mm (.0005 inch)
(9) Thrust collar
Thickness (maximum) ... 18.339 mm (0.7220 inch)
Bore inside diameter (maximum) ... 6.363 mm (.2505 inch)
Thrust bearing groove width (maximum) ... 4.440 mm (.1748 inch)
Thrust bearing groove diameter (minimum) ... 9.398 mm (.3700 inch)
Piston ring groove width (maximum) ... 1.659 mm (.0653 inch)
(10) Thrust bearing
Thickness (minimum) ... 4.359 mm (0.1716 inch)
Bore inside diameter (maximum) ... 10.922 mm (.4300 inch)
(11) Radial play (side to side movement) for shaft
Minimum permissible radial play (side to side movement) ... .08 mm (.003 inch)
Maximum permissible radial play (side to side movement) ... .15 mm (.0059
inch)
(12) Center housing
Bearing inside diameter (maximum) ... 15.806 mm (.6223 inch)
Seal inside diameter (maximum) ... 17.805 mm (.7010 inch)
Put 5P-3931 Anti-Seize Compound on the threads. Tighten the bolts, which hold the
turbocharger to the manifold (not shown), to the following torque: ... 55 ± 5 N·m (40 ± 4
lb ft)
Air Inlet Heater
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g00298861
Illustration 2
Exhaust Manifold
SMCS - 1059
g00559857
Illustration 1
1 0
Muffler
SMCS - 1062
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g00295475
Illustration 1
(1) Tighten the nuts to the following torque. ... 30 ± 7 N·m (22 ± 5 lb ft)
(2) Tighten the bolts and the nuts to the following torque. ... 55 ± 10 N·m (41 ± 7 lb ft
Camshaft
SMCS - 1210
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g00618583
Illustration 1
End play of a new camshaft ... 0.10 to 0.41 mm (0.004 to 0.016 inch)
Maximum permissible end play of a worn camshaft ... 0.53 mm (0.021 inch)
(1) Locating pin
(2) Camshaft thrust washer
Thickness of thrust washer ... 5.49 to 5.54 mm (0.216 to 0.218 inch)
Cylinder block recess depth for thrust washer ... 5.46 to 5.54 mm (0.215 to 0.218
inch)
Relationship of thrust washer to cylinder block front face ... -0.05 to +0.08 mm
(-0.002 to +0.003 inch)
(3) Woodruff key
(4) Diameter of camshaft journals
Table 1
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g00295323
Illustration 2
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Illustration 1
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Illustration 1
The relief valve for the engine oil pressure should open at the following pressure
setting:
Engines that are not equipped with piston cooling jets ... 340 to 395 kPa (49 to
57 psi)
Engines that are equipped with piston cooling jets ... 415 to 470 kPa (60 to 68
psi)
Engines that are equipped with counter balancer ... 523 kPa (76 psi)
(1) Spring
Length under test force ... 59.8 mm (2.35 inch)
Length under test force for engines that are equipped with counter balancer ...
42.7 mm (1.681 inch)
Test force ... 15.9 to 23.1 N (3.6 to 5.2 lb)
Test force with engines that are equipped with counter balancer ... 34 to 38 N
(7.6 to 8.5 lb)
(2) Outside diameter of plunger ... 18.16 to 18.18 mm (.715 to .716 inch)
Outside diameter of plunger with engines that are equipped with counter balancer ...
15.95 to 15.98 mm (.628 to .629 inch)
Clearance of plunger in bore ... 0.06 to 0.11 mm (.002 to .004 inch)
Clearance of plunger in bore with engines that are equipped with counter balancer ...
0.02 to 0.08 mm (.0008 to .0031 inch)
(3) Diameter of the bore in the valve housing ... 18.24 to 18.27 mm (.718 to .719 inch)
Diameter of the bore in the valve housing with engines that are equipped with counter
balancer ... 16.00 to 16.03 mm (.630 to .631 inch)
(4) Tighten the bolt to the following torque: ... 44 ± 5 N·m (32 ± 4 lb ft)
1
1 0
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Illustration 1
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Illustration 2
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Illustration 3
The minimum oil pressure at low idle with an ambient temperature of 18 to 20 °C (64 to
68 °F) is the following value: ... 62 kPa (9 psi)
The minimum oil pressure at high idle and at normal operating temperature is the
following value:
Turbocharged engine ... 280 kPa (40 psi)
Tighten the oil pressure switch, which is located on the left side of the engine block, to
the following torque: ... 7 to 12 N·m (62 to 107 lb in)
1 1
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g00877006
Illustration 1
1 0
Water Pump
SMCS - 1361
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Illustration 1 g00295544
(1) Outside diameter of shaft for drive gear ... 15.91 to 15.92 mm (.626 to .627 inch)
(2) Diameter of bore of drive gear ... 15.86 to 15.88 mm (.624 to .625 inch)
Interference fit of drive gear on shaft ... 0.03 to 0.06 mm (.001 to .002 inch)
(3) Diameter of bore of impeller ... 15.87 to 15.89 mm (.625 to .626 inch)
Outside diameter of shaft for impeller ... 15.91 to 15.92 mm (.626 to .627 inch)
Interference fit of impeller on shaft ... 0.02 to 0.05 mm (.001 to .002 inch)
(4) Diameter of bearing ... 29.990 to 30.000 mm (1.1807 to 1.1811 inch)
Diameter of bore for bearing ... 29.960 to 29.980 mm (1.1795 to 1.1803 inch)
Interference fit of bearing in pump body ... 0.010 to 0.040 mm (.0004 to .0016 inch)
(5) The water pump must be assembled in order to correctly measure the distance from
the impeller boss to the front face of the pump body. Distance ... 8.1 to 8.5 mm (.32 to .
34 inch)
(6) The water pump must be assembled in order to correctly measure the distance of the
gear from the rear face of the pump body. Distance ... 0.6 to 2.6 mm (.02 to .10 inch)
Type 2 Engines and 7BJ Engines
Note: For a complete description of Type 1 and Type 2 engines, refer to the
Specifications Module, "Engine Design" for more information.
Note: The water pump for Type 2 engines and 7BJ engines is not serviceable. Contact
your Caterpillar dealer for more replacement information.
1 1
Cylinder Block
SMCS - 1201
Ver imagen
g00892504
Illustration 1
Typical example
(1) Cylinder liner
Outside diameter of cylinder liner ... 104.25 to 104.28 mm (4.105 to 4.106 inch)
Inside diameter of cylinder liner ... 100.00 to 100.03 mm (3.937 to 3.938 inch)
Maximum permissible wear of cylinder liner bore ... 0.25 mm (0.010 inch)
Interference fit of cylinder liner in cylinder block ... 0.03 to 0.08 mm (0.001 to
0.003 inch)
Flange thickness of cylinder liner ... 3.81 to 3.86 mm (0.150 to 0.152 inch)
The projection of the liner flange can be 0.10 mm (0.004 inch) above to 0.10 mm (0.004
inch) below the top face of the cylinder block.
(2) Plug with baffle plates (if equipped)
Orientation of baffle plates to the vertical plane ... +/- 5 degrees
Depth of plug from face of cylinder block ... 3 mm (0.12 inch)
(3) Cylinder block
Diameter of the bore for the cylinder liner ... 104.20 to 104.23 mm (4.103 to
4.104 inch)
Depth of the recess for the cylinder liner flange ... 3.81 to 3.91 mm (0.150 to
0.154 inch)
Diameter of the recess for the cylinder liner flange ... 107.82 to 107.95 mm
(4.245 to 4.250 inch)
(4) Tighten the bolts that fasten the housing for the crankshaft rear seal to the cylinder
block to the following torque. ... 22 N·m (16 lb ft)
(5) Tighten the bolts that fasten the housing for the crankshaft rear seal to the bridge to
the following torque.
M6 ... 13 N·m (10 lb ft)
M8 ... 22 N·m (16 lb ft)
(6) Bridge bolt
Use the following procedure in order to install the bridge bolts.
1. Use a straight edge in order to ensure that the bridge is aligned with the front
face of the cylinder block.
2. Evenly tighten the bridge bolts to a torque of 16 N·m (12 lb ft).
3. When the bridge is installed on the cylinder block, apply a thin bead of 8T-9013
Silicone Sealant into the groove at each end of the bridge.
(7) Main bearing cap bolts
Use the following procedure in order to install the main bearing cap bolts.
1. Apply clean engine oil to the threads of the main bearing cap bolts.
2. Put the main bearing caps in the correct position that is indicated by a number on
the top of the main bearing cap. Install the main bearing caps with the locating
tabs in correct alignment with the recess in the cylinder block.
3. Evenly tighten the main bearing cap bolts to a torque of 265 N·m (195 lb ft).
(8) Bore in the cylinder block for the main bearings ... 80.416 to 80.442 mm (3.1660 to
3.1670 inch)
(9) Camshaft bearing
Inside diameter of the camshaft bearing for the number 1 camshaft journal ...
50.79 to 50.85 mm (2.000 to 2.002 inch)
Bore diameter in the cylinder block for the number 1 camshaft bearing ... 55.56
to 55.59 mm (2.187 to 2.189 inch)
Bore diameter in the cylinder block for the number 2 camshaft journal ... 50.55
to 50.60 mm (1.990 to 1.992 inch)
Bore diameter in the cylinder block for the number 3 camshaft journal ... 50.04
to 50.09 mm (1.970 to 1.972 inch)
Total height of cylinder block between the top and the bottom faces. ... 441.12 to 441.33
mm (17.367 to 17.375 inch)
Piston Cooling Jets (If Equipped)
Ver imagen
g00631670
Illustration 2
(1) Tighten the piston cooling jets to the following torque. ... 27 N·m (20 lb ft)
(2) Diameter of rod ... 1.70 mm (0.067 inch)
(3) Cylinder block
Note: Ensure that the piston cooling jet is positioned correctly on the dowel in the
cylinder block (not shown).
Use the following procedure in order to ensure the correct alignment of the piston
cooling jet.
1. Insert rod (2) into the end of the piston cooling jet. Rod (2) should protrude out
of the top of the cylinder block.
2. Use the following dimensions to locate the center point of diameter (C) .
Dimension (A) ... 33 mm (1.3 inch)
Dimension (B) ... 21 mm (0.8 inch)
Diameter (C) ... 14 mm (0.6 inch)
Note: Dimension (A) and dimension (B) are tangent to the cylinder bore.
3. Position rod (2) within diameter (C) .
1 1 0
Crankshaft
SMCS - 1201
/sisw eb/sisw eb/m /sisw eb/mediase
Ver imagen
g00295557
Illustration 1
If the bearing journal has been ground beyond this size, then
regrind the bearing journals to the next undersize journal. 63.43 mm (2.497 inch)
Undersize Journal
0.25 mm (0.010 inch) 63.22 to 63.24 mm
(2.489 to 2.490 inch)
Undersize Journal
0.51 mm (0.020 inch) 62.96 to 62.98 mm
(2.479 to 2.480 inch)
Undersize Journal
0.76 mm (0.030 inch) 62.71 to 62.73 mm
(2.469 to 2.470 inch)
Connecting rod bearings are available for remachined journals with the following
undersize dimensions:
Undersize ... 0.25 (0.010)
Undersize ... 0.51 (0.020)
Undersize ... 0.76 (0.030)
(7) Dimensions of main journals which are the standard, original size
Width of front journal ... 36.93 to 37.69 mm (1.454 to 1.484 inch)
Width of center journal ... 44.15 to 44.22 mm (1.738 to 1.741 inch)
Width of all other journals ... 39.24 to 39.35 mm (1.545 to 1.549 inch)
Measure the main bearing journals on the crankshaft. See the following chart for
dimensions.
Table 2
If the bearing journal has been ground beyond this size, then
regrind the bearing journals to the next undersize journal. 76.12 mm (2.996 inch)
Original Size Journal
76.16 to 76.18 mm
(2.998 to 2.999 inch)
Undersize Journal
0.25 mm (0.010 inch) 75.91 to 75.93 mm
(2.988 to 2.989 inch)
Undersize Journal
0.51 mm (0.020 inch) 75.65 to 75.67 mm
(2.978 to 2.979 inch)
Undersize Journal
0.76 mm (0.030 inch) 75.40 to 75.42 mm
(2.968 to 2.969 inch)
Tighten the bolts for the main bearing journal to the following torque: ... 265 N·m (195
lb ft)
Main bearings are available for remachined journals with the following undersize
dimensions:
Undersize ... 0.25 (0.010)
Undersize ... 0.51 (0.020)
Undersize ... 0.76 (0.030)
Tighten the retaining bolts of the crankshaft pulley (not shown) to the following
torque: ... 115 N·m (85 lb ft)
Apply 9S-3263 Thread Lock Compound to the bolts of the crankshaft damper. Tighten
the bolts (not shown) to the following torque:
M8 bolts ... 35 N·m (26 lb ft)
M12 bolts ... 75 N·m (55 lb ft)
Tighten the bolts that fasten the rear oil seal housing to the cylinder block (not shown)
to the following torque: ... 22 N·m (16 lb ft)
Tighten the bolts that fasten the rear oil seal housing to the bridge (not shown) to the
following torque:
M6 ... 13 N·m (10 lb ft)
M8 ... 18 N·m (13 lb ft)
1 1 0
Crankshaft Seals
Ver imagen
g00664588
Illustration 1
The front oil seal (2) is normally installed to a depth of 7.00 ± 0.25 mm (0.2756 ±
0.0098 inch) (A) from the face of the front oil seal housing (6). The oil seal may cause
wear on the hub of crankshaft pulley (3). This wear may allow oil leakage past the oil
seal. If this situation occurs, the front oil seal can be installed to a depth of 9.3 mm (0.37
inch) from the face of the front oil seal housing.
If a wear sleeve (4) is installed, the front oil seal is installed to a depth of 9.30 mm
(0.366 inch) from the face of the front oil seal housing. When the wear sleeve is
installed, the flange of the wear sleeve does not require removal. If a wear sleeve is
installed, a new front oil seal must be installed.
(5) Tighten three bolts for the crankshaft pulley to the following torque. ... 115 N·m (85
lb ft)
Crankshaft Rear Seal
Ver imagen
g00317365
Illustration 2
0
Connecting Rod
SMCS - 1218
Note: For a complete description of Type 1 and Type 2 engines, refer to the
Specifications Module, "Engine Design" for more information.
Ver imagen
g00295602
Illustration 1
Turbocharged Engines
(1) Inside diameter of rod for bearing ... 42.07 to 42.09 mm (1.656 to 1.657 inch)
(2) Outside diameter of bearing for piston pin ... 42.160 to 42.190 mm (1.6600 to
1.6613 inch)
Inside diameter of bearing for piston pin after reaming ... 38.120 to 38.140 mm (1.5008
to 1.5015 inch)
Clearance between small end bearing and piston pin ... 0.020 to 0.043 mm (.0008 to .
0017 inch)
(3) Distance between center of piston pin and center of crankshaft bearing ... 219.05 to
219.10 mm (8.624 to 8.626 inch)
(4) Bearings are available for remachined journals of the crankshaft which have the
following undersize dimensions:
0.25 mm (.010 inch)
0.51 mm (.020 inch)
0.76 mm (.030 inch)
Shell thickness ... 1.835 to 1.844 mm (.0723 to .0726 inch)
Width of connecting rod bearing ... 31.55 to 31.88 mm (1.240 to 1.255 inch)
Bearing clearance ... 0.030 to 0.081 mm (.0012 to .0032 inch)
(5) Inside diameter of rod for bearing ... 67.210 to 67.220 mm (2.6460 to 2.6465 inch)
(6) Connecting rod cap with nuts and bolts
Tighten the nuts for the connecting rod to the following torque: ... 125 N·m (92 lb ft)
Connecting rod cap with bolts only
Tighten the bolts for the connecting rod to the following torque: ... 155 N·m (114 lb ft)
Note: If piston cooling jets are installed, the piston and the connecting rod assembly
must be turned when the piston and rod assembly are installed. Turning the piston and
connecting rod assembly will prevent the connecting rod from hitting and damaging the
piston cooling jet. When the connecting rod has passed the piston cooling jet, turn the
connecting rod until the arrow or "Front" mark on the top of the piston is toward the
front of the engine.
Type 2 Engines and 7BJ Engines
Note: For a complete description of Type 1 and Type 2 engines, refer to the
Specifications Module, "Engine Design" for more information.
The piston height is controlled by the length of the connecting rod. Connecting rods are
supplied in six grades of length. The different grades of length are manufactured by
machining the hole in the piston pin bearing in an off-center position. The different
grades of length are created by the following method:
Machining the center of the hole in the piston pin
Machining the center of the hole in the bearing
If the connecting rod is replaced, ensure that the same grade of
length as the original connecting rod is used.
However, if the crankshaft or the cylinder block is replaced, the required grade of length
of the connecting rods may change.
A correct grade of length of a connecting rod can be ordered for replacement. The
connecting rod includes the piston pin bearing. The piston pin bearing is machined in
order to create the correct grade of length. The piston pin is installed in the connecting
rod at the factory. Table 2 provides the specifications for the grade of length.
Note: The length of the connecting rod is determined by the following method: The
bearing for the crankshaft journal must be removed and the piston pin must be installed.
The original grade of length of the connecting rod is determined when the original
piston pin is installed.
Connecting rods are color coded. The color code is a reference for the length (Y) of the
connecting rod. Refer to Table 2 for the different lengths of connecting rods.
Ver imagen
g00915056
Illustration 2
Table 1
Grade of
Color Length of the Connecting Rod
Length
Orange
"G" 165.682 to 165.715 mm (6.5229 to 6.5247
inch)
If a piston pin bearing requires replacement but the connecting rod does not require
replacement, a new piston pin bearing can be ordered. This bearing is partially finished.
The hole in the bearing must be machined off-center to the correct distance in order to
create a connecting rod assembly that is the correct grade of length.
Refer to the Testing and Adjusting manual for the following procedures:
Determine the length of the connecting rod.
Determine the distortion of a connecting rod.
Replace the piston pin bearing.
Turbocharged Engines
Ver imagen
g00295602
Illustration 3
Connecting Rod And Bearings
(1) Inside diameter of rod for bearing ... 43.01 to 43.04 mm (1.693 to 1.694 inch)
(2) Outside diameter of bearing for piston pin ... 43.11 to 43.15 mm (1.697 to 1.699
inch)
Inside diameter of bearing for piston pin after reaming ... 39.723 to 39.738 mm (1.5639
to 1.5645 inch)
Clearance between small end bearing and piston pin ... 0.023 to 0.044 mm (.0009 to .
0017 inch)
(3) Distance between center of piston pin and center of crankshaft bearing ... 219.05 to
219.10 mm (8.624 to 8.626 inch)
(4) Bearing for connecting rod journal
Shell thickness ... 1.835 to 1.844 mm (.0723 to .0726 inch)
Width of connecting rod bearing ... 31.55 to 31.88 mm (1.240 to 1.255 inch)
Bearing clearance ... 0.030 to 0.081 mm (.0012 to .0032 inch)
(5) Inside diameter of rod for bearing ... 67.210 to 67.220 mm (2.6460 to 2.6465 inch)
(6) Connecting rod cap with nuts and bolts
Tighten the nuts for the connecting rod to the following torque: ... 125 N·m (92 lb ft)
Connecting rod cap with bolts only
Tighten the bolts for the connecting rod to the following torque: ... 155 N·m (114 lb ft)
Note: If piston cooling jets are installed, the piston and the connecting rod assembly
must be turned when the piston and rod assembly are installed. Turning the piston and
connecting rod assembly will prevent the connecting rod from hitting and damaging the
piston cooling jet. When the connecting rod has passed the piston cooling jet, turn the
connecting rod until the arrow or "Front" mark on top of the piston is toward the front
of the engine.
Ver imagen
g01064497
Illustration 4
Ver imagen
g01064498
Illustration 5
(9) Diameter of the bore for the piston pin ... 43.01 to 43.04 mm (1.693 to 1.694 inch)
(10) Distance between bearing centers ... 219.05 to 219.10 mm (8.624 to 8.626 inch)
(11) DPiston and Rings
Ver imagen
g00295711
Illustration 1
Turbocharged Engines
(1) Shape of groove in piston for top ring ... Taper
Shape of top ring ... Taper
Clearance between the ends of top ring in a cylinder liner without any wear ... 0.35 to
0.75 mm (.014 to .030 inch)
(2) Width of groove in piston for intermediate ring ... 2.56 to 2.58 mm (.101 to .102
inch)
Thickness of intermediate ring ... 2.48 to 2.49 mm (.097 to .098 inch)
Clearance between groove and intermediate ring ... 0.07 to 0.11 mm (.003 to .004 inch)
Clearance between the ends of an intermediate ring in a cylinder liner without any
wear ... 0.30 to 0.76 mm (.012 to .030 inch)
(3) Width of groove in piston for oil control ring ... 4.040 to 4.060 mm (.1591 to .1598
inch)
Thickness of oil control ring ... 3.98 to 3.99 mm (.156 to .157 inch)
Clearance between groove and oil control ring ... 0.05 to 0.08 mm (.002 to .003 inch)
Clearance between the ends of an oil control ring in a cylinder liner without any wear ...
0.38 to 0.84 mm (.015 to .033 inch)
(4) Diameter of new piston pin ... 38.095 to 38.100 mm (1.4998 to 1.5000 inch)
Bore for piston pin ... 38.103 to 38.109 mm (1.5000 to 1.5004 inch)
Piston Height
Ver imagen
g00891532
Illustration 2
Quadram piston
There are two different designs for the crown of the piston. One design is the Quadram
piston. There is only one grade of piston for the replacement of a Quadram piston.
Grade of piston for service ... L
Height of a Quadram piston above the top face of the cylinder block ... 0.14 to 0.36 mm
(0.005 to 0.014 inch)
Ver imagen
g00891548
Illustration 3
Fastram piston
The other style of piston is the Fastram piston. The piston height above the top face of
the cylinder block is controlled by different grades of height of the piston. Identification
of the height grade is by the letter that is stamped on the top of each piston. The height
grade can be checked by measuring from the center of the piston pin to the top of the
piston. The difference between each grade of height is 0.045 mm (0.0018 inch). Table 1
provides the specifications for the grade of height for a Fastram piston.
Table 1
A (1)
70.334 mm (2.7690 G
inch)
B (1)
70.289 mm (2.7673 H
inch)
C (1)
J
70.244 mm (2.7655
inch)
D (1)
70.199 mm (2.7637 K
inch)
E (1)
70.154 mm (2.7620 L
inch)
F 70.391 mm (2.7713 -
inch)
G 70.345 mm (2.7695 -
inch)
H 70.299 mm (2.7677 -
inch)
J 70.253 mm (2.7659 -
inch)
K 70.207 mm (2.7640 -
inch)
L 70.161 mm (2.7622 -
inch)
(1)
Earlier engines
Height of a Fastram piston above the top face of the cylinder block ... 0.38 to 0.50 mm
(0.015 to 0.020 inch)
Type 2 Engines and 7BJ Engines
Note: For a complete description of Type 1 and Type 2 engines, refer to the
Specifications Module, "Engine Design" for more information.
Ver imagen
g00500921
Illustration 4
Note: The word "Front" or an arrow which is marked on the piston crown must be
toward the front of the engine. If the piston crown is not marked, put the narrowest side
of the piston crater toward the side of the engine with the fuel injection pump. The
shortest distance between the edge of the piston crater and the edge of the piston is the
narrowest side of the piston crater.
Note: Be sure that the ring end gaps of all the piston rings have 120 degrees spacing
from each other.
Note: Refer to Systems Operation, "General Information" for the location of the serial
number.
Turbocharged Engines
(1) Top piston ring
Shape of groove in piston for top ring ... Taper
Clearance between the ends of the top ring in a cylinder liner without
any wear ... 0.28 to 0.63 mm (.011 to .025 inch)
Note: Install the word "TOP" toward the top of the piston. New top rings have a red
identification mark which must be on the left of the ring gap when the intermediate ring
is installed on an upright piston.
(2) Intermediate ring
Width of groove in piston for intermediate ring ... 2.56 to 2.58 mm
(0.101 to 0.102 inch)
Note: Install the word "TOP" toward the top of the piston. New intermediate rings have
a green identification mark which must be on the left of the ring gap when the
intermediate ring is installed on an upright piston.
(3) Oil control ring
Width of groove in piston for oil control ring ... 3.54 to 3.56 mm (.139
to .140 inch)
Thickness of oil control ring ... 3.47 to 3.49 mm (.136 to .137 inch)
Clearance between groove and oil control ring ... 0.05 to 0.09 mm
(.002 to .004 inch)
Note: A pin is used in order to hold both ends of the spring of the oil control ring in
position. The ends of the spring of the oil control ring must be 180 degrees opposite the
end gap of the oil control ring.
(4) Diameter of new piston pin ... 39.694 to 39.700 mm (1.5628 to 1.5630 inch)
Bore for piston pin ... 39.703 to 39.709 mm (1.5631 to 1.5633 inch)
Piston height above cylinder block (not shown) ... 0.36 to 0.50 mm ( .014 to .020 inch)
1 1 0
iameter for the bore for the connecting rod bearing ... 67.21 to 67.22 mm (2.6460 to
2.6465 inch)
Housing (Front)
SMCS - 1151
g00753583
Illustration 1
Ver imagen
g00753612
Illustration 2
Ver imagen
g00295804
Illustration 1
Ver imagen
g00295950
Illustration 1
(1) Tighten the bolts of the flywheel housing to the following torque:
The M10 bolts for the cast iron flywheel housing ... 44 N·m (32 lb ft)
The M12 bolts that are stamped "8.8" for the cast iron flywheel
housing ... 75 N·m (55 lb ft)
The M10 bolts that are stamped "10.9" for the cast iron flywheel
housing ... 63 N·m (46 lb ft)
The M12 bolts that are stamped "10.9" for the cast iron flywheel
housing ... 115 N·m (85 lb ft)
The M10 bolts that are for the aluminum flywheel housing ... 70 N·m
(52 lb ft)
(2) The maximum temperature for heating the flywheel ring gear for installation ... 250
°C (482 °F)
(3) Tighten flywheel bolts to the following torque: ... 105 N·m (77 lb ft)
Flywheel Housing Runout
Face Runout
Ver imagen
g00295952
Illustration 2
Bore Runout
Ver imagen
g00295954
Illustration 3
Face Runout
Ver imagen
g00295955
Illustration 4
Ver imagen
g00295956
Illustration 5
SMCS - 1453
Ver imagen
g00295928
Illustration 1
Ver imagen
g00295930
Illustration 2
End view of the starting motor which shows the electrical connections
No load conditions at 25 °C (77 °F)
Rpm of shaft ... 7000 minimum
(1) Tighten the battery terminal nut to the following torque: ... 24 to 32 N·m (18 to 24 lb
ft)
(2) Tighten the nut for the switch terminal to the following torque: ... 1.0 to 1.3 N·m (9
to 12 lb in)
Tension of the spring for the motor brush ... 8.34 to 11.00 N (1.9 to 2.5 lb)
Minimum resistance of the starter cable at 200 °C (392 °F) and at 12 volts ... 0.0017
ohms
Start Relays
9G-4368 Relay
Ver imagen
g00731492
Illustration 3
069-5466 Relay
Ver imagen
g00295932
Illustration 4
1 1 5