Beruflich Dokumente
Kultur Dokumente
September 1996
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you
have read 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
warnings are not heeded, bodily injury or death could occur to you or other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“WARNING” as shown below.
WARNING
The message that appears under the warning, explaining the hazard, can be either written or pictorially
presented.
Operation 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
warning in this publication and on the product are therefore not all inclusive. If a tool, procedure, work
method or operating technique not specifically recommended by Caterpillar is used, you must satisfy
yourself that it is safe for you and others. You should also ensure that the product will not be damaged
or made unsafe by the operation, lubrication, maintenance or repair procedures you choose.
The information, specifications, and illustrations in this publication are on the basis of information
available at the time it was written. The specifications, torques, pressures, measurements, adjustments,
illustrations, and other items can change at any time. These changes can affect the service given to
the product. Obtain the complete and most current information before starting 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.
Oil Filter Base .......................................................... 82
Index Oil Filter Base, Disassemble & Assemble ................. 83
Oil Pan ................................................................... 131
Accessory Drive ....................................................... 23 Oil Pump ............................................................... 132
Accessory Drive, Disassemble & Assemble ............. 24 Oil Pump, Disassemble & Assemble ...................... 133
Aftercooler Housing ................................................. 75
Air Cleaner ................................................................. 5 Piston & Connecting Rod Assemblies .................... 140
Piston & Connecting Rod Assemblies, Disassemble
Bridge Dowels ....................................................... 129 & Assemble ........................................................... 142
Piston Cooling Tubes ............................................ 135
Camshaft ............................................................... 153
Camshaft Bearings ................................................ 148 Raw Water Pump .................................................... 15
Connecting Rod Bearings ...................................... 136 Raw Water Pump, Disassemble & Assemble ........... 16
Crankshaft ............................................................. 144 Rocker Shaft Assemblies & Push Rods ................. 108
Crankshaft Front Seal & Wear Sleeve .................... 149 Rocker Shaft Assemblies, Disassemble &
Crankshaft Rear Seal & Wear Sleeve ..................... 151 Assemble .............................................................. 113
Crankshaft Main Bearings ...................................... 138
Crankshaft Vibration Damper & Pulley ....................... 5 Service Meter .......................................................... 10
Cylinder Head Assembly ........................................ 123 Spacer Plate .......................................................... 126
Cylinder Liners ....................................................... 157 Sump Pump ............................................................ 12
Sump Pump, Disassemble & Assemble ................... 12
Dipstick Assembly ..................................................... 4
Tachometer Drive .................................................... 10
Electric Starting Motor ............................................. 11 Timing Gear Cover ................................................ 159
Engine Front Support ................................................ 7 Timing Gears & Plate ............................................. 155
Engine Rear Support ................................................. 7 Turbocharger ........................................................... 90
Engine Lifting Brackets .............................................. 4 Turbocharger, Disassemble & Assemble ................. 93
Engine Oil Cooler ..................................................... 85
Exhaust Manifold ................................................... 100 Valves .................................................................... 127
Expansion Tank ....................................................... 77 Valve Covers ......................................................... 107
Valve Guides ......................................................... 130
Flywheel ................................................................ 162 Valve Lifters ........................................................... 114
Flywheel Housing ................................................... 163 Valve Seat Inserts .................................................. 128
Fuel Filter Base ........................................................ 14
Fuel Injection Nozzles ............................................ 118 Water Pump .......................................................... 102
Fuel Injection Nozzle Adapters ............................... 121 Water Pump, Disassemble & Assemble ................. 104
Fuel Injection Lines .................................................. 46 Water Temperature Regulator .................................. 79
Fuel Injection Line Adapters ..................................... 47
Fuel Injection Pump Housing, Disassemble &
Assemble ................................................................ 71
WARNING
Fuel Injection Pump & Governor .............................. 49
Fuel Injection Pump & Governor Drive ..................... 30
Fuel Injection Pumps ............................................... 65 Disconnect batteries before performance of any
Fuel Injection Pumps, Disassemble & Assemble ...... 68 service work.
Fuel Priming Pump .................................................. 14
Fuel Ratio Control .................................................... 41
Fuel Ratio Control, Disassemble & Assemble .......... 42 FLUID SPILLAGE CONTAINMENT
Fuel Transfer Pump ................................................. 25
Fuel Transfer Pump, Disassemble & Assemble ........ 25 Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
Governor & Fuel Pump Drive ................................... 33 testing, adjusting and repair of the machine. Be
Governor & Fuel Pump Drive, Disassemble & prepared to collect the fluid with suitable containers
Assemble ................................................................ 37 before opening any compartment or disassembling any
Governor, Disassemble & Assemble ........................ 51 component containing fluids. Refer to "TOOLS AND
SHOP PRODUCT GUIDE, NENG2500", for tools and
Instrument Panel ........................................................ 8 supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local
Marine Gear Oil Cooler ............................................ 89 regulations and mandates.
Marine Gear Oil Cooler Core .................................... 88
5. Install three bolts (4) that hold the air cleaner to the
bracket. Tighten bolts (4) to a torque of 25 %
7 N•m (18 % 5 lb ft).
Tools Needed A
8T5255 Hydraulic Jack 1
2. Remove the bolts that hold the engine front support Typical Example
to the frame rails. Loosen the bolts that hold the
engine rear support to the frame rail.
1. Put Tooling (A) in position under the flywheel
3. Use the hoist or and raise the front of the engine. housing to support the rear of the engine. Loosen
The weight of the front of the engine is the bolts that hold the engine front support to the
approximately 998 kg (2200 lb). frame rail.
4. Remove eight bolts (1), and remove engine front 2. Remove the bolts that hold the engine rear support
support (2). The weight of the engine front support to the frame rail, and raise the engine approximately
is approximately 32 kg (70 lb). 6.35 mm (.250 in) with Tooling (A). The weight of
the rear of the engine is approximately 624 kg
NOTE: The following steps are for installation of the (1375 lb).
engine front support.
3. Remove bolts (1) that hold the engine rear support
5. Put engine front support (2) in position on the to the flywheel housing, and remove the engine rear
engine, and install eight bolts (1). support.
6. Lower the engine to the frame rails, and install the NOTE: The following steps are for installation of the
bolts that hold the engine front support to the frame engine rear supports.
rails. Tighten the bolts in the engine rear support.
4. Put the engine rear supports in position on the
flywheel housing, and install bolts (1).
1. Put instrument panel (1) in position on the 5. Put the line and clips (5) in position on the
aftercooler housing, and install the spacers and aftercooler housing, and install the bolts.
bolts.
6. Turn the fuel supply to the “ON” position.
Typical Example
a. install service meter 4. Install wires in the correct location on the starting
motor.
1. Disconnect oil lines (3) and (4). Cap and plug all 1. Remove pipe assembly (2) from the sump pump.
openings immediately.
2. Remove the three bolts, cover assembly (1) and the
2. Remove three bolts (2) that hold the sump pump to gasket from the sump pump.
the bracket, and remove sump pump (1).
4. Remove nut (4), packing (6) and shaft (5) from cover
(7).
End By:
4. Put the gasket and fuel priming pump in position on 1. Use Tool (A) to remove filter assembly (1).
the fuel filter base, and install two bolts (2).
8. Install a new filter assembly (1) on the fuel filter 2. Remove bolts (2), elbows (1) and the gaskets from
base. Follow the installation instructions on the filter the raw water pump.
assembly. See the Operation & Maintenance
Manual.
End By:
Tools Needed A B C
1P1855 Pliers 1
1P1861 Pliers 1
9S9152 Bearing Puller 1
Start By:
13. Use Tool (B) and remove ring (19) from the
10. Remove cam (15) and ceramic seal (16) (part of housing.
the seal assembly) from body assembly (3).
Tools Needed A B C D E
1P510 Driver Group 1
9S9152 Bearing Puller 1
1P1861 Pliers 1
1P1855 Pliers 1
1U6684 Compressor 1
7. Put clean engine oil on seal (6) and install the seal
on the shaft as shown.
4. Use a press and install shaft (3) and the bearings in 8. Put plate (8) in position in body assembly (7) as
housing (2). shown.
5. Use Tool (C) and install ring (5) in the housing. 9. Make an alignment of the dowel (10) in body
assembly (7) with cam (9). Install cam (9) in body
assembly (7).
12. Put clean engine oil in the seal bore of the body
assembly and install ceramic seal (11), polished
surface toward the impeller. If the face of the seal
is damaged (marked, scratched) a replacement
must be made.
15. Use Tool (D) and install ring (15) on the shaft that
holds the seal assembly in place.
17. Put clean engine oil on seal (16) and install on the
shaft.
19. Make sure all impeller blades are bent in the same End By:
direction and in the correct direction of rotation.
a. install raw water pump
20. Use Tool (E) and install impeller assembly (17) in
the body assembly.
1. Remove bolts (1), plate (2) that hold the gear to the
bearing.
3. Install cover (5) and the bolts that hold the gear in
the bearing.
End By:
Remove & Install Fuel Transfer 4. Put the O-ring seal in position on the fuel transfer
Pump 1256-010 pump. Put clean engine oil on the O-ring seal.
FLUID SPILLAGE CONTAINMENT 5. Put fuel transfer pump (2) in position, and install
bolts (1).
Care must be taken to ensure that fluids are contained 6. Remove the caps from the fuel lines, and connect
during performance of inspection, maintenance, fuel lines (3) to the fuel transfer pump.
testing, adjusting and repair of the machine. Be
prepared to collect the fluid with suitable containers 7. Turn the fuel supply to the “ON” position.
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND 8. Prime the fuel system. See the Operation &
SHOP PRODUCT GUIDE, NENG2500", for tools and Maintenance Manual for the proper procedure.
supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local NOTE: For more detailed information regarding the
regulations and mandates. fuel transfer pump, see the topic “Fuel Transfer Pump”
in the Specifications Manual.
1. Turn the fuel supply to the “OFF” position.
9. Remove seal (14) from guide (15). 12. Remove seal (19) from cover (18).
10. Remove ring (16) from tappet (17) and the tappet
from guide (15).
End By:
3. Remove the bolts that hold cover (4) to the ring,
and remove the cover.
a. install fuel transfer pump
Tools Needed A B
6V4186 Timing Pin 1
9S9082 Engine Turning Tool 1
1. Remove the plug from the timing pin hole, and put
Tool (A) in the timing pin hole.
11. Put O-ring seals (7) on cover (6). Put clean engine
oil on the O-ring seals.
12. Install cover (6) on the ring, and install the bolts
that hold it.
Tools Needed A B
6V4186 Timing Pin 1
9S9082 Engine Turning Tool 1
1. Remove the plug from the timing pin hole in the fuel
injection pump housing, and install Tool (A) in the
timing pin hole.
6. Put two O-ring seals (8) in position on governor and 12. Put the gasket and cover (9) in position on the
fuel pump drive (7). timing gear cover, and install the nuts.
WARNING
3. Remove ring (4) and the carrier from ring (5). 6. Remove ring (4) from carrier (3).
8. Place ring (13) and two springs (14) in position on 11. Install seals (18) on body (7).
retainer (15).
End By:
9. Place ring (16) and the carrier in position on ring
(13). Make sure that the small spring fits over the a. install governor and fuel pump drive
end of the spool in the carrier assembly.
Care must be taken to ensure that fluids are contained 5. Put fuel ratio control in position on the governor.
during performance of inspection, maintenance, Make sure the flange on the end of the fuel ratio
testing, adjusting and repair of the machine. Be control is behind the groove (slot) in the lever.
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any 6. Install the two bolts that hold the fuel ratio control to
component containing fluids. Refer to "TOOLS AND the governor.
SHOP PRODUCT GUIDE, NENG2500", for tools and
supplies suitable to collect and contain fluids in 7. Install tube (1).
Caterpillar machines. Dispose fluids according to local
regulations and mandates.
NOTE: See the Systems Operation Testing &
Adjusting Manual for the adjustment of the fuel ratio
control.
Tools Needed A B
FT1820 Fixture Assembly 1
1P1855 Retaining Ring Pliers 1
Start By:
WARNING
5. Remove spring (9), washer (7), and diaphragm (10) 8. Remove piston assembly (20) from the housing.
from retainer (8). Remove retainer (8) from housing
(11).
9. Use Tooling (B), and remove snap ring (21) and the
wave washers from valve assembly (22). Remove
6. Remove nut (16) from extension (15), and remove piston assembly (23) from the valve assembly.
the extension from retainer (8). Remove valve (12),
spring (13) and O-ring seal (14) from the extension. 10. Remove seal (24) from piston (23).
7. Put O-ring seal (12) on extension (13). Put spring 11. Hold retainer (14) in position, and install cover (21)
(11) and valve (10) in position on the extension. on the housing. Install the bolts that hold the
cover, and tighten them to a torque of 9 % 3 N•m
8. Lubricate O-ring seal (12) with clean engine oil. (81 ± 27 lb in).
Install extension (13) in retainer (14). Install nut (15).
Tools Needed A B
5P0144 Fuel Line Socket 1
5P5195 Fuel Line Wrench 1
Start By:
NOTICE
Do not let the tops of the fuel nozzles turn when the
fuel lines are loosened. The nozzles will be damaged
if the top of the nozzles turn in the body.
Tools Needed A
5P5195 Fuel Line Wrench 1
5P0144 Fuel Line Socket 1
1. Remove fuel line (2). Remove fuel line (1) from the
fuel injection pump. Cap and plug all openings
immediately.
4. Install two lines (4) on the engine. Install fuel line (4)
to the fuel injection pump.
End By:
Tools Needed A B C
FT1251 Pump Housing Stand 1
6V2163 Clamp Assembly - Spring Compressor 1
1P1855 Pliers 1
Start By:
2. Remove the two bolts and clamps, and remove 6. Remove locknut (6) and low idle adjustment screw
service meter (2). (7) from cover (4).
3. Remove the bolts that hold the rear governor 7. Remove seal (5) from the cover.
housing in place, and remove rear governor housing
(1) and the gasket from the front governor housing.
13. Use needle nose pliers (22), and remove the shaft.
Remove spacer (19), lever (20) and spacer (21)
from the rear governor housing.
10. Remove the rings, pins (13), stop (14) and two
plates (12) from the shaft assembly.
14. Remove lever (24) and spring (23) from lever (20).
15. Remove the nuts and set screws from the lever if
necessary.
11. Remove dowel (16), pin (17) and spring (15) from
the shaft assembly.
16. Release spring (26) from the notch in the rear 20. Remove cover (31), and remove the high idle
governor housing. Remove snap ring (25), and screw.
remove shaft (27) from the housing. Remove lever
(28) and spring (26). 21. If necessary, remove the remaining three covers.
17. Remove two lip seals (29) from the rear governor 22. Remove two bolts (34), housing (35) and the
housing. gasket from the fuel injection pump housing.
24. Remove two bolts and block (38) from housing 28. Remove the three bolts and governor servo (42)
(35). from the fuel injection pump housing.
31. Remove pin (51) and lever (54) from the cylinder.
35. Remove ring (57) and dashpot assembly (58) from
the governor shaft.
38. Remove seat (59) and spring (62) from shield (61).
40. Remove ring (68), races (69) and bearing (67) from
the riser. 44. Remove races (76) and (78) and bearing (77) from
the fuel injection pump housing.
Tools Needed A B C D
FT-1251 Pump Housing Stand 1
1P-1855 Snap Ring Pliers 1
6V-2163 Clamp Assembly Spring Compressor 1
1P-0510 Driver Group 1
2. Install race (3), bearing (2) and race (1) on the end
of the camshaft in the fuel injection pump housing.
7. Install race (10), bearing (12), race (9) and ring (11)
on riser (13).
NOTICE
Make sure the flyweight toes are under the bearing
race.
9. Install spool (18) and ring (19) on seat (17), and use
Tool (B) to install ring (20) to hold them in place.
32. Install insulator (51). Tighten the insulator to a NOTE: Steps 36-38 are only for governors equipped
torque of 4.5 % 0.5 N•m (40.00 % 4.40 lb in). with a manual shutoff.
33. Use Tool (D), and install lip seal (50) with the lip 35. Put clip (57) in position on shaft (56), and install
toward the inside. Put clean engine oil on the lip of shaft (56) into the rear governor housing through
the seal. spring (55) and lever (54). Put the key in the lever
in alignment with the keyway in the shaft.
44. Install bolt (75) into lever (76) through the notch in
shaft assembly (67).
End By:
49. Put the seat, two wave washers, one flat washer
and spring (81) in position on the guide in the rear
governor housing.
a. remove fuel injection lines 6. Carefully and slowly lift the handle to release the
spring force. Remove the tooling.
b. disassemble governor *
8. Remove seal (3) and fuel pump (4) from the fuel
pump housing.
1. Remove the plug, and move the rack until Tool (A)
can be installed to hold the rack in the center
position. The rack must be in the center position to
remove the fuel injection pump. 9. Remove spacers (5) from the pump housing.
WARNING
Tools Needed A B
6V7870 Fixture Group * 1
8T5116 Pliers 1
*See SMHS8378 for tool usage.
Start By:
10. After each fuel pump has been installed, follow the FLUID SPILLAGE CONTAINMENT
steps below to check total rack travel to make
sure each pump has been installed correctly. Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
a. Remove Tool (A) from the fuel pump housing. testing, adjusting and repair of the machine. Be
prepared to collect the fluid with suitable containers
b. Install Tooling (D) on the fuel pump housing as before opening any compartment or disassembling any
shown. component containing fluids. Refer to "TOOLS AND
SHOP PRODUCT GUIDE, NENG2500", for tools and
c. Move rack (7) in and out of the fuel pump housing supplies suitable to collect and contain fluids in
to measure total rack travel. Total rack travel must Caterpillar machines. Dispose fluids according to local
be approximately 19.7 mm (.78 in). If this regulations and mandates.
measurement is not obtained, center the rack,
install Tool (A), and remove and install the fuel
pump again.
NOTICE
End By: Be careful when the injection pumps are disassem-
bled. Do not damage the surfaces of the plungers,
a. assemble governor barrels and bonnets. Any scratches will cause leakage
inside the fuel injection pump. The plunger and barrel
b. install fuel injection lines for each pump are made as a set. Do not put the
plunger of one pump in the barrel of another pump. If
one part has wear, install a complete new pump
assembly. Be careful when the plunger is put into the
bore of the barrel.
End By:
1. Put spring (2) and valve (5) in barrel (1).
a. install fuel injection pumps
2. Put bonnet (4), barrel (1) and ring (3) in position on
Tool (A).
4. Use Tool (B), and lower ring (3) on to the barrel and
the bonnet to hold them together.
Start By:
a. disassemble governor
2. Remove six lifters (2) from the fuel pump housing.
b. remove fuel injection pumps Put identification marks on the lifters for installation
purposes.
FLUID SPILLAGE CONTAINMENT
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
SHOP PRODUCT GUIDE, NENG2500", for tools and
supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local
regulations and mandates.
Tools Needed A B C
6V4824 Drive 1
6V4825 Plate 1
1P0510 Driver Group 1
8S2241 Camshaft Bearing Installation And 1
Removal Group
10. Install ring (8), races (10) and bearing (9) on the
camshaft.
Start By:
NOTICE
The rack must slide freely in the rack bearings after 2. Remove tube (1). Cap and plug all openings
installation. immediately.
End By:
b. assemble governor
Tools Needed A
6V2156 Link Brackets 2
4. Remove five bolts and washers (3) that hold air inlet
pipe (4) to the aftercooler housing. Move the air inlet
pipe away from the aftercooler housing.
End By:
a. install fuel filter base 3. Remove tube (3). Cap and plug all openings
immediately.
Tools Needed A
6V2156 Link Brackets 2
Tools Needed A
1P0510 Driver Group 1
Tools Needed A
2P8250 Strap Wrench 1
10. Install the bolt that holds clip (9) to the expansion
tank.
11. Install the gasket, and connect adapter (10) to the 1. Remove filter assembly (1) with Tool (A).
cover assembly.
3. Remove the two bolts that hold tube (4) to the 4. Put clean oil on the gasket on filter assembly (5),
cylinder block. and install the filter assembly on the oil filter base.
Tighten the filter assembly 3/4 of a turn after the
4. Remove the bolts that hold oil filter base (2) to the gasket makes contact with the oil filter base.
cylinder block, and remove the oil filter base and
tube (4) as an assembly. Cap or plug all openings
immediately.
Disassemble Oil Filter Base 1306-015
Start By:
Install Oil Filter Base 1306-012
a. remove oil filter base
1. Put oil filter base (2) and tube (3) in position on the
cylinder block as an assembly, and install four bolts
(1) to hold the oil filter base to the cylinder block.
4. Remove the cover that holds spring (4) and plunger 2. Put 9S-3263 Thread Lock on the tapered threads
(5) in the oil filter base. of stud (4), and install the stud in oil filter base (3).
Tighten the stud to a torque of 83 % 13 N•m
5. Remove the spring and plunger from oil filter base (62 % 10 lb ft).
(1).
3. Put O-ring seal (5) on tube (6), and install the tube
in the oil filter base.
End By:
2. Remove the bolts that hold tube (1) to the oil filter
base and bypass valve body, and remove the tube.
Cap or plug all openings immediately.
WARNING
7. Install the clip that holds the engine oil cooler to the 11. Install the clip that holds the bonnet to the engine
flange. oil cooler.
8. Install the O-ring seals on adapter (9), and install the 12. Put the O-ring seal in place on tube (11), and
adapter in bonnet (8). install the tube in the bypass valve body.
13. Put the gasket on the oil filter base, and connect
tube (11).
14. Fill the cooling system to the correct level. See the
Operation & Maintenance Manual.
15. Check oil level in the engine. See the Operation &
Maintenance Manual.
3. Remove water lines (3) and (4). 7. Fasten a hoist to the turbocharger. Remove four
nuts (11), and remove turbocharger (10) and the
gasket from the exhaust manifold. The weight of the
turbocharger is 39 kg (86 lb).
1. Put gasket (1) in position on the exhaust manifold. 6. Put the gasket and elbow (5) in place on the
aftercooler housing, and install the bolts.
2. Put 5P-3931 Anti-Seize Compound on studs (3).
Tools Needed A B C D E F G
9S6363 Turbocharger Fixture Group 1
9S6343 Fixture Group 1
5S9566 T-Wrench 1
FT168 Fixture Adapter 1
1P1861 Snap Ring Pliers 1
1P0074 Slide Hammer 1
2P2312 Leg 3
FT0745 Modified Pliers 1
NOTICE
When the nut is loosened, do not put a side force on
the shaft.
WARNING
12. Remove bearing (18), sleeve (17) and the ring from
the cartridge housing. 14. Turn the cartridge assembly over. Use Tool (G),
and remove ring (21). Remove bearing (22) from
the cartridge housing, and put a short dye mark
on the top of the bearing.
Tools Needed A B C D E
FT0745 Modified Pliers 1
1P1861 Pliers 1
9S6363 Fixture Assembly 1
8T5096 Dial Test Indicator Group 1
9S6363 Turbocharger Fixture Group 1
a. remove turbocharger
End By:
a. install turbocharger 1. Remove bolts (1), and disconnect flange (2) from
the exhaust manifold.
4. Remove six bolts (3), and remove pipe (5) from the
engine.
6. Remove the gaskets from the cylinder head. 5. Tighten the nuts in the number sequence shown to
a torque of 38 % 5 N•m (28 % 4 lb ft).
Typical Example
2. Make sure the seal is in position on elbow (1). 8. Install tube (7) on the engine.
7. Remove two nuts (9) and five bolts (8) that hold the
water pump to the timing gear plate, and remove
water pump (7).
8. Remove the O-ring seal from the front of the water 4. Put the O-ring seal in position on the rear of the
pump. water pump.
Tools Needed A B C
8S-2264 Puller Group 1
4B-3903 Bolt 5/16-18 NC X 102mm (4 in) Long 2
1P-0456 Plate 1
4B-4277 Washer 2
1P-0510 Driver Group 1
2W-9102 Seal Installation Tool 1
Start By:
7. Make sure the O-ring seal is in place on adapter (6). a. remove water pump
8. Install the gaskets on the water pump and elbow FLUID SPILLAGE CONTAINMENT
(5).
Care must be taken to ensure that fluids are contained
9. Put bonnet (7) in position on the adapter, and install during performance of inspection, maintenance,
the bolts that hold the bonnet to the water pump testing, adjusting and repair of the machine. Be
and elbow (5). prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
10. Install the clip that holds the bonnet to the oil component containing fluids. Refer to "TOOLS AND
cooler. SHOP PRODUCT GUIDE, NENG2500", for tools and
supplies suitable to collect and contain fluids in
11. Fill the cooling system to the correct level. See the Caterpillar machines. Dispose fluids according to local
Operation & Maintenance Manual. regulations and mandates.
2. Remove bolt (1) and washer (2). Use Tool (A) to 6. Use a press to remove shaft (13) from the gear.
remove impeller (6) from shaft (13). Remove bearing (9), spacer (10), and bearing (11)
from the shaft.
3. Remove spring and seal (5) from the shaft.
7. Remove lip seal (8) from the housing.
4. Remove four bolts (16) from retainer (12) that hold
the shaft assembly to the pump housing. Remove 8. Turn the housing over, and remove ceramic ring
O-ring seal (18) from housing (7). (20) and seal (19) from the housing.
10. Install bearing (9), spacer (10), and bearing (11) on 16. Separate spring from seal (5). Use hand pressure
shaft (13). and Tool (C) to install the seal on the shaft of gear
and shaft assembly (17). Push the seal on the
11. Put retainer (12) and gear (17) on the shaft shaft until the seal faces make light contact. Install
assembly. Install retainer (14) and bolt (15) on the the spring on the shaft.
shaft.
17. Put impeller (6) in position on the shaft. Install
12. Use Tool (B) to install lip seal (8) in housing (7). washer (2) and bolt (1) that hold the impeller.
Install seal with the lip toward the inside of the Tighten the bolt to a torque of 39 % 3 N•m (29 %
housing. Put a small amount of clean engine oil on 2 lb ft).
the lip of the seal.
18. Install the O-ring seal on the outside diameter of
13. Install a new O-ring seal (18) on the housing. adapter (4). Put a small amount of clean SAE 30
oil on the O-ring seal.
14. Put gear and shaft assembly (17) in position in the
housing. Install bolts (16) that hold retainer (12) to 19. Install O-ring seal (3) on the adapter.
the housing.
20. Put adapter (4) in position on the housing.
NOTICE
Avoid contaminating the seal faces with grease or oil.
Also, avoid stretching the rubber seal during installa-
tion.
1. Loosen clamps (1), and disconnect the hose from 2. Put valve cover (1) in position on the valve cover
the breather cap. base. Install the bolts that hold the valve cover in
place. Tighten the bolts to a torque of 18 % 3 N•m
(13 % 2 lb ft).
88249P3*
Tools Needed A B
5P0144 Socket 1
5P5195 Fuel Line Wrench 1
Start By:
NOTICE
To prevent damage to the fuel injection nozzle, hold
adapter assembly (5) in position at the top of injection
nozzle (6) when fuel line nut (7) is loosened or tight-
ened.
Tools Needed A B
5P5195 Fuel Line Wrench 1
5P0144 Socket 1
NOTICE
Do not let the tops of the fuel nozzles turn when the
fuel lines are tightened. The nozzles will be damaged
if the top of the nozzles turns in the body.
End By:
NOTE: The center bracket does not have a pin. 4. Install rocker arm (4) on each end of the shaft.
Install washers (5) as needed to get an assembled
4. Remove bracket (3), rocker arm (4) and spring (5). clearance of .03 to 1.40 mm (.012 to .055 in) at
each end of the shaft. Install the retainer on each
end of the shaft.
End By:
Tools Needed A B C D E
5P0144 Socket 1
5P5195 Fuel Line Socket 1
FT1322 Lever Assembly 1
9S9082 Engine Turning Pinion 1
5P7433 Valve Lifter Tool Group 1
Start By: NOTE: If necessary, use Tooling (D) to turn the engine
so the valves do not make contact with the pistons
a. remove valve covers when the valves are opened with Tool (C) to remove
the push rods.
NOTICE
Do not let the tops of the fuel nozzles turn when the
fuel lines are loosened. The nozzles will be damaged
if the top of the nozzles turns in the body.
1. Loosen the fuel injection line nut at the nozzle end 5. Remove the inlet valve lifter with Tooling (E) as
with Tool (A) and a 5P-0328 Crow Foot Wrench follows:
(7/8 in).
a. Install 5P-2685 Nut (3) and 5P-6601 Collet (4)
2. Loosen the fuel line nut at the fuel injection line on 5P-2408 Outer Handle Assembly (5).
adapter with Tool (B). Remove inner fuel injection
lines (1). Install caps and plugs on all fuel line b. Install 5P-6599 Inner Handle Assembly (6) in
openings to keep dirt out of the fuel system. 5P-2408 Outer Handle Assembly (5).
NOTICE
When a valve lifter is removed, a new guide spring
must be installed.
NOTICE
If necessary, use Tool (C) to turn the engine so the
valves do not make contact with the pistons when the
valves are opened with Tool (B) to install the push
rods.
5. Turn the rocker arms up, and use Tool (B) to install
b. Put the exhaust valve lifter in the valve lifter bore push rods (9).
of the cylinder block. Install 5P-6599 Inner
Handle Assembly (7) in the 5P-2408 Outer
Handle Assembly , and push the exhaust valve
lifter from Tooling (A).
End By:
Start By:
2. Remove seal (2) from fuel injection line (1) if
a. remove valve covers necessary.
FLUID SPILLAGE CONTAINMENT
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
testing, adjusting and repair of the machine. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
SHOP PRODUCT GUIDE, NENG2500", for tools and
supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local
regulations and mandates.
NOTICE
Do not let the tops of the fuel nozzles turn when the
fuel lines are loosened. The nozzles will be damaged
if the top of the nozzles turn in the body.
1. Use Tooling (A), and remove inner fuel injection lines 4. Remove the fuel injection nozzles with Tooling (B)
(1). Install caps and plugs on all fuel injection line as follows:
openings to keep dirt out of the fuel system.
a. Install 6V-6983 Adapter (6) and 6V-4152
Screw (7) into nozzle assembly (5).
Tools Needed A B C D
6V4979 Carbon Stop Seal Tool 1
5P0144 Socket 1
5P5195 Fuel Line Wrench 1
8S2245 Cleaning Tool Group 1
6V4089 Reamer * 1
*Part of 6V7020 Nozzle Puller Group.
NOTICE
A replacement of compression seal washer (11) and of
carbon dam seal (12) must be made each time the fuel
nozzle is removed. Be sure that the replacement com-
pression seal washer (11) is the same color code and
part number as the original compression seal washer.
If the wrong thickness washer is used, engine damage
could occur. See the topic “Fuel Injection Nozzle And
Adapter” in the Specifications Manual for more
detailed information. 1. Install compression seal washer (1), and use Tool
(A) to install carbon dam seal (2) on the fuel injection
nozzle.
3. Use Tool (D) to clean adapter bore (3) for the fuel
injection nozzle. Use an open end wrench or a tap
driver to turn Tool (D).
End By:
Tools Needed A B
FT1887 Compressor Plate Group 1
5P0125 Precombustion Chamber Wrench 1
Start By:
c. remove fuel injection nozzles b. Install stud (2) and nut (3). Tighten the nut.
NOTICE c. Install plate (4), washer (5) and nut (6). Tighten the
Be sure that the piston is at Top Center (TC) so that nut until the locks are free.
the valves will be held in position when the springs are
removed. d. Remove locks (7), and remove the nut, washer and
plate from the stud. Remove the stud and adapter
plate from the fuel injection nozzle adapter.
1. Remove the valve cover bases.
Tools Needed A B
5P0125 Precombustion Chamber Wrench 1
FT1887 Compressor Plate Group 1
4. Remove bolts (4) and (5) that hold the cylinder head
assembly to the cylinder block.
a. Tighten bolts 1 through 14 in number sequence 5. Install the valve cover bases and the inner fuel lines.
to a torque of 270 % 25 N•m (200 % 20 lb ft). See the topic “Install Rocker Shaft Assemblies &
Push Rods”.
b. Tighten bolts 1 through 14 in number sequence
to a torque of 470 % 20 N•m (345 % 15 lb ft).
NOTICE
Do not cause damage to the dowels.
NOTICE
Both surfaces of the spacer plate, top of cylinder
block and both sides of the spacer plate gasket must
be clean and dry. Gasket adhesives or other sub-
stances must not be used on these surfaces.
End By:
Tools Needed A B
5S1330 Pneumatic Valve Spring Compressor 1
8S2263 Valve Spring Tester 1
Start By:
Tools Needed A
5S1330 Pneumatic Valve Spring Compressor 1
WARNING
Tools Needed A
9S3095 Handle Assembly 1
9S3081 Extractor Inlet 1
9S3086 Extractor Exhaust 1
Start By:
a. remove valves
2. Use Tool (A) to compress the spring.
WARNING
5. Do Steps 1 through 4 again for the remainder of the 1. Use Tooling (A) to remove the valve seat inserts.
valves.
2. Clean and remove the burrs from the valve seat
End By: bore.
End By:
a. install valves
Tools Needed A
7S8859 Driver 1
Start By:
a. remove valves
End By:
a. install valves
End By: 1. Remove the magnetic drain plug and drain the oil
from the oil pan into a suitable container for storage
a. install valves or disposal.
Tools Needed A B
1P2321 Puller Assembly 1
1P0458 Plate * 1
1P0510 Driver Group 1
*Part of 1P-0510 Driver Group.
Start By:
2. Use Tooling (A), and remove drive gear (1) from the
shaft. Remove the key from the shaft.
Tools Needed A
1P0510 Driver Group 1
2. Install idler gear (1) and drive gear (3) in the oil
pump body. Put clean engine oil on the bearings
and the gears.
Tools Needed A B
9S-9082 Engine Turning Tool 1
5P-8709 Piston Cooling Jet Alignment Tool Group 1
Start By:
End By:
Tools Needed A
Plastigage *
Start By:
1. Check the connecting rods and caps for their NOTE: Install the bearings dry when the clearance
identification and location. checks are made. Put clean engine oil on the bearings
for final assembly.
NOTICE
Be sure the tabs in the back of bearings are in the tab
grooves of the connecting rod and cap. The service-
man must be very careful to use Plastigage, Tool (A)
correctly. The following points must be remembered.
End By:
Start By:
NOTICE
If the crankshaft is turned in the wrong direction, the
tab of the bearing will be pushed between the crank-
shaft and cylinder block. This can cause damage to
either or both.
NOTICE
Do not use an impact wrench to tighten the bolts the
additional 120 % 5 degrees (1/3 turn) when the bear-
ing clearance is being checked.
End By:
End By:
Install Pistons & Connecting Rod
Assemblies 1225-012 a. Install piston cooling tubes
Tools Needed A B C
1P1858 Retaining Ring Pliers 1
7M3978 Piston Ring Expander 1
5P8639 Press Group 1
8F0024 Hose Assembly 1
1P2375 Coupler Assembly 1
1P2376 Coupler Assembly 1
5P9725 Cylinder Group 1
5P8651 Spacer 1
5P8649 Adapter 1
5P8650 Adapter 1
Start By:
WARNING
a. remove pistons and connecting rod assemblies
Piston rings (5) may break apart during removal
from the pistons. If the rings are to be removed,
wear eye protection to prevent possible personal
injury from flying parts.
13. Install the first (top) piston ring with the side that
has the identification “UP-1” toward the top of the
piston. Use Tool (B) to install the ring.
End By:
Tools Needed A B
1H-3110 Bearing Puller Attachment 1
8B-7560 Step Plate 1
6U-6600 Hand Pump (Or Electric) 1
1H-3108 Leg 2
1H-3107 Puller Assembly 1
3H-0468 Plates 5
3H-0465 Nuts 2
1P-0820 Hydraulic Puller Group 1 2. Install one of the bolts from the front pulley in each
5B-0637 Nut 1 end of the crankshaft.
8S-6586 Screw 1
3. Fasten a hoist to crankshaft (3), and remove
5P-0944 Dowel Puller Group 1
crankshaft (3) from the block. The weight of the
5P-0939 Extractor 1 crankshaft is 159 kg (350 lb).
12. Remove the main bearing caps. Remove a. install pistons and connecting rod assemblies
Plastigage (B) from the caps. Check the width of
Plastigage (B) to find the bearing clearance. The b. install flywheel housing
bearing clearance must be 0.091 to 0.185 mm
(.0036 to .0073 in) with new bearings. Maximum c. install timing gear cover
clearance with used bearings is 0.25 mm
(.010 in).
Start By:
a. remove camshaft
1. Use Tooling (A) to install the camshaft bearings in
b. remove flywheel housing the cylinder block.
c. remove pistons and connecting rod assemblies 2. All camshaft bearings must be installed so that the
holes in the bearings are 90 % 15 degrees from
d. remove timing gears and plate the oil holes in the cylinder block. Make sure the
bearing joint position is above the oil holes.
Tools Needed A B C
1U7600 Puller Group 1
5P7312 Distorter 1
5P7314 Ring 1
B82546P2*
NOTICE
The crankshaft front seal and wear sleeve come as a
set and must be installed as a set. If a replacement of
the seal is to be made, a replacement of the wear
sleeve must also be made.
Tools Needed A
5P1733 Locator 1
5P1737 Bolt 3
9S8858 Nut 1
6V6142 Installer 1
a. remove flywheel
d. Put wear sleeve (2) and seal (6) as a unit in
position on locator (1). FLUID SPILLAGE CONTAINMENT
e. Put installer (4) in position on locator (1).
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
f. Put clean engine oil on the face of nut (5) and its
testing, adjusting and repair of the machine. Be
contact area on installer (4). Install nut (5) on
prepared to collect the fluid with suitable containers
locator (1).
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
g. Tighten nut (5) until the inside surface of installer
SHOP PRODUCT GUIDE, NENG2500", for tools and
(4) comes in contact with locator (1).
supplies suitable to collect and contain fluids in
Caterpillar machines. Dispose fluids according to local
h. Remove Tooling (A) from the crankshaft seal and
regulations and mandates.
wear sleeve. Tooling (A) will install the seal and
wear sleeve to the correct depth on the
crankshaft.
End By:
B82546P2*
Tools Needed A
5P1733 Locator 1
5P1737 Bolt 3
6V6143 Installer 1
9S8858 Nut 1
Start By:
b. Install locator (1) and the bolts on crankshaft (3). FLUID SPILLAGE CONTAINMENT
c. The seal and wear sleeve must be installed dry. Care must be taken to ensure that fluids are contained
Make sure the seal is installed with the part during performance of inspection, maintenance,
number and the arrows showing crankshaft testing, adjusting and repair of the machine. Be
rotation toward the outside. prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any
component containing fluids. Refer to "TOOLS AND
NOTICE SHOP PRODUCT GUIDE, NENG2500", for tools and
The front and rear seals and wear sleeves have differ- supplies suitable to collect and contain fluids in
ent spiral grooves in the seal. Because of this type of Caterpillar machines. Dispose fluids according to local
design, the rear seal group for an engine is different regulations and mandates.
from the front seal group. If a seal group is installed on
the wrong side of the engine, oil can actually be taken 1. Turn the engine to top center compression stroke
out of the engine instead of moving the oil back into for the No. 1 piston.
the engine.
f. Put clean engine oil on the face of nut (5) and its
contact area on installer (4). Install nut (5) on
locator (1).
End By:
a. install flywheel
4. Remove two bolts (4) and retainer (5) that hold the
camshaft to the cylinder block.
Tools Needed A B
1P2321 Puller Assembly 1
1P0474 Plate * 1
1P0510 Driver Group 1
*Part of 1P-0510 Driver Group.
6. Install idler gear (3) on its shaft. Be sure the “V” Start By:
mark on idler gear (3) is in alignment with the “V”
mark on the crankshaft gear. The “K” marks on the a. remove timing gear cover
camshaft gear can be seen at the edge of the idler
gear. b. remove fuel injection pump housing and governor
7. Install plate (4) and the bolts that hold the idler gear 1. Remove four bolts (2), plate (3) and idler gear (1).
in place.
End By:
Tools Needed A
5P8665 Cylinder Liner Puller 1
Start By:
a. remove pistons
NOTE: Set the gear on the front face (the face with
the timing marks). Drive the bearing from the rear face
toward the front face of the gear. Install the bearing to
a depth of 1.5 % 0.5 mm (.06 % .02 in) below the
rear face of the idler gear.
End By:
Tools Needed A B C
7H-3598 Bolt 6*
8F-1484 Washer (Steel) 6*
7K-1977 Washer (Fiber) 6*
8T-0455 Liner Projection Tool Group 1
2P-8260 Liner Installation Group 1
End By:
b. install pistons
3406C Marine Engine 159 Disassembly & Assembly
3. Remove the bolts that hold tube assembly (3) to the 6. Remove bolts (6) that hold the accessory drive
timing gear cover, and remove the tube from the cover to the timing gear cover.
aftercooler elbow.
7. Remove two bolts (7) that hold the fuel injection
pump to the timing gear cover.
8. Remove two bolts (8) that hold the timing gear plate
to the timing gear cover.
1. Put O-ring seal (1) in position on the dowel in the 7. Put the hose and clamp (4) in position on the timing
timing gear plate. gear cover, and install the nut that holds them in
place.
Tools Needed A
FT0120 Lifting Bracket 1
End By:
g. install water pump 2. Remove bolts (2) that hold the flywheel to the
crankshaft, and remove the flywheel. The weight of
the flywheel is 59 kg (130 lb).
Tools Needed A
5P9736 Link Bracket 1
Start By:
a. remove turbocharger
b. remove electric starting motor 2. Install Tool (A) on the flywheel housing, and fasten a
hoist as shown.
c. remove sump pump (if so equipped)
3. Remove the bolts (3) that hold the flywheel housing
d. remove oil pan to the cylinder block.
e. remove crankshaft rear seal and wear sleeve 4. Remove the flywheel housing from the cylinder
block.
End By:
e. install turbocharger