Beruflich Dokumente
Kultur Dokumente
SENR5545-04
October 2001
WARNING
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
pictorially presented.
Operations that may cause product damage are identified by "NOTICE" labels on the product and in
this 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 Caterpillar is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was 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 can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Caterpillar dealers have the most current information available. For a list of the most
current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.
WARNING
When replacement parts are required for this
product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent
specifications including, but not limited to, physical dimensions, type, strength and material.
Failure to heed this warning can lead to premature failures, product damage, personal injury or
death.
3
Table of Contents
Table of Contents
Specifications Section
Engine Design
Fuel Injection Lines
Fuel Injection Pump
Fuel Injection Nozzles
Lifter Group
Rocker Shaft
Valve Mechanism
Vafve Mechanism Cover
Cylinder Head
Turbocharger
Exhaust Manifold
Camshaft
Engine Oil Relief Valve
Engine Oil Pump
Engine Oil Pressure
Engine Oil Bypass Valve
Engine Oil Pan
Water Temperature Regulator
Water Pump
Cylinder Block
Crankshaft
Crankshaft Seals
Connecting Rod Bearing Journal
Main Bearing Journal
Connecting Rod
Piston and Rings
Gear Group (Front)
Flywheel
Crankshaft Pulley
Belt Tension Chart
Belt Tightener
Alternator and Regulator
Electric Starting Motor
Coolant Temperature Switch
Engine Oil Pressure Switch
Air Inlet Heater
4
5
5
6
6
7
8
9
9
10
11
12
13
14
15
15
16
16
16
17
18
20
20
21
21
23
25
26
27
27
28
28
29
29
29
29
Index Section
index
30
4
Specifications Section
Specifications Section
Engine Design
SMCSCode: 1201
3064 Engine
3066 Engine
Illustration 1
g00523889
Illustration 2
g00295223
Type
Combustion system
Bore
Stroke
Number of cylinders
Displacement
Cylinder arrangement
Type
Combustion system
Stroke
4
4.3 L (260 in3)
In-line
Number of cylinders
Displacement
In-line
2
1-5-3-6-2-4
17:1
1 -3-4-2
Firing order
Compression ratio
2
Valves per cylinder
Firing order
Direct injection
Bore
Cylinder arrangement
Valves per cylinder
Compression ratio
17:1
900 20
Minimum rpm
900 20
5
Specifications Section
Illustration 4
6
Specifications Section
SMCSCode: 1254
(8) Gasket
(9) Pin
(10) Tip for fuel injection nozzle
(11) Retaining nut for fuel injection nozzle
Tighten the nut to the following
torque
34 + 5 N-m (25 4 lb ft)
Lifter Group
Illustration 5
g00530280
SMCSCode: 1209
(1) Seal
(2) Fuel injection nozzle
(3) Retainer for fuel injection nozzle
Tighten the retaining bolt to the following
torque
22 N.m (16 lb ft)
Illustration 7
22.000 to 22.021 mm
(0.8661 to 0.8670 inch)
22.055 mm
(0.8683 inch)
7
Specifications Section
Rocker Shaft
SHCS Code: 1102
Illustration 10
Illustration 11
Valve lash adjustment
8
Specifications Section
Valve Mechanism
SMCS Code: 1102
Illustration 12
(1) Spring
30 degrees
7.940 to 7.955 mm
(0.3126 to 0.3132 inch)
7.920 to 7.940 mm
(0.3118 to 0.3126 inch)
40 degrees
Specifications Section
45 degrees
39.000 to 39.025 mm
(1.5354 to 1.5364 inch)
(16) Pushrod
Use a dial indicator in order to check all
pushrods for runout. Replace the pushrod if the
runout exceeds the following value
0.40 mm
(0.016 inch)
Illustration 14
Illustration 16
1.40 0.20 mm
(0.055 0.008 inch)
30 degrees
0.50 0.25 mm
(0.020 0.010 inch)
Inlet valve
0.40 0.25 mm
(0.016 0.010 inch)
Cylinder Head
SMCSCode: 1100
Illustration 17
Illustration 15
10
Specifications Section
Turbocharger
SMCS Code: 1052
95.00 0.10 mm
(3.740 0.004 inch)
Illustration 20
g00530558
Illustration 19
Numerical sequence of bolts for 3066 Engine
11
Specifications Section
Illustration 24
g00530564
(8) Clamp
Apply 5P-3931 Anti-Seize Compound to the
threads of the clamp. Tighten the clamp to the
following torque
4 1 N-m (35 9 lb in)
Illustration 22
900530561
Exhaust Manifold
SMCS Code: 1059
Illustration 23
900530562
Illustration 25
900530254
12
Specifications Section
Camshaft
SMCSCode: 1210
Illustration 27
g00527952
6.844 mm
(0.2695 inch)
6.189 mm
(0.2437 inch)
Illustration 26
Table 1
Number
of Journal
for 3064
Engine
1, 2
Number
of Journal
for 3066
Engine
Standard
Diameter
1, 2, 3
53.94 to
53.96 mm
(2.123 to
2.124 inch)
53.90 mm
(2.122 inch)
52.94 to
52.96 mm
(2.084 to
2.085 inch)
52.90 mm
(2.083 inch)
Service
Limit(1)
(1) The service limit is the maximum dimension or the service limit
is the minimum dimension that is specified for a part. Replace
the part if the service limit is reached.
Illustration 28
13
Specifications Section
(7) Camshaft
0.10 to 0.25 mm
(0.004 to 0.010 inch)
Illustration 29
Illustration 31
Standard
Diameter
Clearance
between
camshaft
journals and
bushings
Repair Limit(1)
0.04 to 0.09 mm
(0.002 to
0.004 inch)
0.15 mm
(0.006 inch)
(1) The repair limit is the maximum dimension or the repair limit is
the minimum dimension that is specified for a part. Repair the
part if the repair limit is reached.
Illustration 30
343 20 kPa
(50 3 psi)
Tighten the engine oil relief valve to the following
torque
49 + 5 N-m (36 4 lb ft)
14
Specifications Section
Illustration 32
NOTICE
Before operation, the pump must be lubricated with
clean engine oil and the pump must turn freely by hand
or damage to parts can be the result.
Note: The minimum acceptable oil pressure at low
idle is 100 kPa(15 psi).
(1) Driven gear assembly
(2) Drive gear assembly
(3) Oil pump gear
Note: Do not use a torch.
Heat the oil pump gear to 180 to 220C
(356 to 428F) and support the end of the drive
gear shaft in order to install the oil pump gear. Press
the oil pump gear until the oil pump gear is flush
with the end of the shaft.
(4) Idler gear assembly
The backlash between the oil pump
gear and the idler gear is the following
amount
0.100 to 0.190 mm
(0.0039 to 0.0075 inch)
Note: Replace the gears if the backlash exceeds
0.35 mm (0.014 inch).
(5) Spindle
Note: The oil pump gear and the drive gear
assembly are not serviceable if the oil pump gear
is removed.
Illustration 33
0.050 to 0.098 mm
(0.0020 to 0.0039 inch)
15
Specifications Section
(7) Cover
(10) Bolts
Tighten the bolts (10) for the oil pump cover (7)
to the following torque
35 6 N-m
(26 4 lb ft)
Illustration 35
24.939 to 24.960 mm
(0.9818 to 0.9827 inch)
Illustration 36
16
Specifications Section
Water Pump
SMCS Code: 1361
2
Illustration 38
Illustration 39
g00530566
(1) Impeller
The faces of the impeller and the water pump shaft
are flush.
(2) Flange
(3) The distance from the face of the impeller
to the water pump housing is the following
amount
21.00 to 21.70 mm
(0.826 to 0.854 inch)
Illustration 40
17
Specifications Section
J01576112
Standard at
Assembly
Repair
Limit(1)
Service
Limit(2)
Inside
Diameter
102.010 to
102.045
mm
(4.0161 to
4.0175 inch)
102.200
mm (4.0236
inch)
102.700
mm (4.0433
inch)
Out of
Round
0.010 mm
(0.0004
inch)
N/A
N/A
Taper
0.015 mm
(0.0006
inch)
N/A
N/A
Cylinder Block
SMCSCode: 1201
(1) The repair limit is the maximum dimension or the repair limit
is the minimum dimension that is specified for a part. Repair a
part if the repair limit is reached.
(2) The service limit is the maximum dimension or the service limit
is the minimum dimension that is specified for a part. Replace
the part if the service limit is reached.
Illustration 41
^00529444
Illustration 42
Oversize Bore
900529446
18
Specifications Section
g00529534
Crankshaft
SMCSCode: 1202
102.700 mm
(4.0433 inch)
900525341
Illustration 45
g00529962
Cylinder liner
89.95 to 89.97 mm
(3.541 to 3.542 inch)
Undersize journal
0.25 mm (0.010 inch)
89.70 to 89.72 mm
(3.531 to 3.532 inch)
Undersize journal
0.50 mm (0.020 inch)
89.45 to 89.47 mm
(3.521 to 3.522 inch)
Undersize journal
0.75 mm (0.030 inch)
89.20 to 89.22 mm
(3.512 to 3.513 inch)
19
Specifications Section
Illustration 46
Illustration 48
(2) Crankshaft
0.100 to 0.264 mm
(0.0039 to 0.0104 inch)
Oversize
(front or
rear)
Oversize
(front or
rear)
Tolerance
+0.15 mm
(+.006 inch)
33.15 mm
(1.305 inch)
33.30 mm
(1.311 inch)
+0.039 mm
(+0.0015
inch)
+0.30 mm
(+0.012
inch)
33.30 mm
(1.311 inch)
33.45 mm
(1.317 inch)
+0.039 mm
(+0.0015
inch)
+0.45 mm
(+0.018
inch)
33.45 mm
(1.317 inch)
33.60 mm
(1.323 inch)
+0.039 mm
(+0.0015
inch)
20
Specifications Section
i01576124
Crankshaft Seals
i01576126
59.945 to 59.965 mm
(2.3600 to 2.3608 inch)
Undersize journal
0.25 mm (0.010 inch)
59.695 to 59.715 mm
(2.3502 to 2.3510 inch)
Undersize journal
0.50 mm (0.020 inch)
59.445 to 59.465 mm
(2.3404 to 2.3411 inch)
Undersize journal
0.75 mm (0.030 inch)
59.195 to 59.215 mm
(2.3305 to 2.3313 inch)
g00525904
21
Specifications Section
Connecting Rod
SMCSCode: 1218
Illustration 52
22
Specifications Section
Illustration 53
g00525l94
Illustration 54
34.020 to 34.045 mm
(1.3394 to 1.3404 inch)
Illustration 56
(6) Piston
(7) Markings on piston
Assemble the piston and connecting rods. Ensure
that the markings on the piston (7) and the marks
on the connecting rod (1) are on the same side.
23
Specifications Section
Illustration 57
Illustration 59
Illustration 58
0.55 to 1.15 mm
(0.022 to 0.045 inch)
24
Specifications Section
Table 9
Standard at
Assembly
Service LimiK(1)
Standard
101.915 to
101.945 mm
(4.0124 to
40136 inch)
101.730 mm
(4.0051 inch)
Oversize
0.25 mm
(0.010 inch)
102.165 to
102.195 mm
(4.0222 to
4.0234 inch)
101.980 mm
(4.0150 inch)
Oversize
0.50 mm
(0.020 inch)
102.415 to
102.445 mm
(4.0321 to
4.0333 inch)
102.230 mm
(4.0248 inch)
Illustration 61
g00524467
Illustration 60
33.993 to 34.000 mm
(1.3383 to 1.3385 inch )
25
Specifications Section
Illustration 63
g00524492
Piston
Rings
Width of
Ring
Side
Clearance
of Ring
Groove
No. 1
Compression
Ring
3.00 mm
(0.118
inch)
0.080 to
0.120 mm
(0.0031 to
0.0047 inch)
0.200 mm
(0.0080
inch)
No. 2
Compression
Ring
2.00 mm
(0.080
inch)
0.080 to
0.120 mm
(0.0031 to
0.0050 inch)
0.150 mm
(0.0060
inch)
Oil Control
Ring
4.00 mm
(0.157
inch)
0.025 to
0.065 mm
(0.0010 to
0.0026 inch)
0.150 mm
(0.0060
inch)
Service
Limit (1)
(1) The piston must be replaced if the piston rings exceed these
clearances.
Illustration 64
g00527858
26
Specifications Section
Illustration 65
g00527864
Table 11
Item
Standard at
Assembly
Service Limit(1)
Backlash of idler
gear
0.03 to 0.17 mm
(0.001 to
0.007 inch)
0.25 mm
(0.010 inch)
0.05 to 0.20 mm
(0.002 to
0.008 inch)
0.35 mm
(0.014 inch)
Clearance
between idler
gear bushing
and shaft
0.009 to 0.080
mm (0.0004 to
0.0031 inch)
0.100 mm
(0.0039 inch)
900527912
Illustration 67
Illustration 66
900819139
Flywheel
SMCSCode: 1156
Illustration 68
(1) Flywheel
g00529633
27
Specifications Section
Crankshaft Pulley
SMCSCode: 1205
0.15 mm
(0.006 inch)
Illustration 70
g00529634
127
Note: Do not use the belt tension chart for belts with
tensioners that are spring loaded.
28
Specifications Section
Table 12
Width of Belt
3/8
1/2
BT-33-97
BT-33-97
Measure the tension of the belt that is farthest from the engine.
(1) Initial Belt Tension refers to a new belt.
(2)Used Belt Tension refers to a belt that has been in operation for 30 minutes or more at the rated speed.
i01574161
i01574185
Belt Tightener
S M C S C o d e : 1358
S M C S C o d e : 1405; 1 4 1 0
Illustration 71
goossosos
(1) Bolt.
illustration 72
g00530887
negative ground
either direction
5000 rpm
28.0 .5 V
50 A
29
Specifications Section
SMCSCode: 1453
74
Engrie coolant temperature switch
SMCSCode: 1924
85 A
Voltage
23 V
30
Index Section
Index
L
A
Air Inlet Heater
Alternator and Regulator
29
28
Lifter Group
M
B
Main Bearing Journal
Belt Tension Chart
Belt Tightener
21
27
28
P
Piston and Rings
C
Camshaft
Connecting Rod
Connecting Rod Bearing Journal
Coolant Temperature Switch
Crankshaft
Crankshaft Pulley
Crankshaft Seals
Cylinder Block
Cylinder Head
12
21
20
29
18
27
20
17
9
29
4
4
4
15
16
15
29
14
13
11
26
5
6
5
G
Gear Group (Front)
25
I
Important Safety Information
Rocker Shaft
S
Specifications Section
Table of Contents
Turbocharger
3
10
V
Valve Mechanism
Valve Mechanism Cover
8
9
W
Water Pump
Water Temperature Regulator
F
Flywheel
Fuel Injection Lines
Fuel Injection Nozzles
Fuel Injection Pump
E
Electric Starting Motor
Engine Design
3064 Engine
3066 Engine
Engine Oil Bypass Valve
Engine Oil Pan
Engine Oil Pressure
Engine Oil Pressure Switch
Engine Oil Pump
Engine Oil Relief Valve
Exhaust Manifold
23
16
16