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Documenti di Cultura
January 2008
Specifications
C27 and C32 Engines for Caterpillar
Built Machines
5301-Up (Machine)
2211-Up (Machine)
LWA1-Up (Machine)
GEB1-Up (Machine)
TPB1-Up (Machine)
H4C1-Up (Machine)
EED1-Up (Machine)
RJG1-Up (Machine)
Z9K1-Up (Machine)
JRP1-Up (Machine)
DLS1-Up (Machine)
BTW1-Up (Machine)
JNW1-Up (Machine)
BWX1-Up (Machine)
i01658146
i02856750
Engine Design
SMCS Code: 1201
S/N: 5301-Up
S/N: 2211-Up
S/N: LWA1-Up
S/N: GEB1-Up
S/N: TPB1-Up
g01113721
Illustration 1
S/N: H4C1-Up
(A) Inlet valves
(B) Exhaust valves S/N: Z9K1-Up
Displacement ................................. 32 L (1953 cu in) When the fuel transfer pump is using diesel fuel, the
fuel transfer pump has the following specifications:
Compression ratio .............................................. 15:1
Run the pump at 2940 rpm. The full bypass pressure
Cylinder arrangement ...................... 65 degrees V12 should be the following value. ........... 716 to 786 kPa
(104 to 114 psi)
Valves per cylinder .................................................. 4
Run the pump at 840 rpm. The flow at 550 kPa
Type of combustion ............................ Direct injection (80 psi) must be 6.0 L/min (1.6 US gpm).
Valve lash measurement Run the pump at 2940 rpm. The flow at 650 kPa
(94 psi) must be 9.0 L/min (2.38 US gpm).
Inlet ................. 0.38 ± 0.08 mm (0.015 ± 0.003 inch)
Run the pump at 120 rpm with the inlet open to the
Exhaust ........... 0.76 ± 0.08 mm (0.030 ± 0.003 inch) atmosphere for 10 seconds. Block the inlet. The
pump must maintain vacuum of 30 kPa (4.5 psi)
Crankshaft rotation direction (view from the flywheel minimum in 30 seconds.
end) ............................................... Counterclockwise
Run the pump at 840 rpm with the inlet open to the
Firing order (injection atmosphere for 10 seconds. Block the inlet. The
sequence) .............. 1, 10, 9, 6, 5, 12, 11, 4, 3, 8, 7, 2 pump must maintain vacuum of 45 kPa (6.5 psi)
minimum in 30 seconds.
The no. 1 cylinder is the front cylinder on the left side
of the cylinder block. The no. 2 cylinder is the front Run the pump at 120 rpm with a blocked inlet that is
cylinder on the right side of the cylinder block. full of fuel for 30 seconds. The pump inlet must have
a suction lift of 60.9 kPa (18 In Hg) minimum.
Note: The front of the engine is opposite of the
flywheel end of the engine. The left side of the engine When the pump is viewed from the drive gear
and the right side of the engine is viewed from the end or the drive shaft, the rotation of the pump is
flywheel end of the engine. counterclockwise.
i02774897 i02774886
g01391562
Illustration 3
(1) Pressure regulating valve
(2) Weep hole
(3) Inlet port
(4) Outlet port
(A) Apply 154-9731 Thread Lock Compound to the Part No.: 260-9631
threads on the taperlock end of the stud to the S/N: GEB1-Up
following distance. ....................... 39.5 ± 0.5 mm
(1.56 ± 0.02 inch) Part No.: 260-9631
S/N: TPB1-Up
(2) Torque for the stud ..... 70 ± 15 N·m (50 ± 11 lb ft)
Part No.: 255-8001, 260-9631
S/N: H4C1-Up
i02864490
Part No.: 255-8001, 260-9631
Fuel Filter Base S/N: EED1-Up
Part No.: 260-9631
SMCS Code: 1261; 1262
S/N: RJG1-Up
Part No.: 266-9459
Part No.: 255-8001, 260-9631
S/N: LWA1-Up
S/N: Z9K1-Up
Part No.: 266-9459
Part No.: 255-8001, 260-9631
S/N: GEB1-Up
S/N: JRP1-Up
Part No.: 266-9459
Part No.: 255-8001, 260-9631
S/N: TPB1-Up
S/N: DLS1-Up
Part No.: 266-9459
Part No.: 260-9631
S/N: Z9K1-Up
S/N: BTW1-Up
Part No.: 260-9631
S/N: JNW1-Up
Part No.: 260-9631
S/N: BWX1-Up
g01426884
Illustration 5
i02792816
Part No.: 255-8001, 260-9631 Note: Refer to Testing and Adjusting, “Electronic Unit
S/N: 5301-Up Injector - Adjust” for the correct procedure for setting
the lash on the electronic unit injector.
Part No.: 255-8001, 260-9631
S/N: 2211-Up Note: Before installation of the unit injector, lubricate
Part No.: 255-8001, 260-9631 the top two O-ring seals (6) with a 50/50 mixture of
S/N: LWA1-Up clean engine oil and 8T-2998 Lubricant.
SENR9936-06 7
Specifications Section
(1) Torque for cap nut .. 2.50 ± 0.25 N·m (22 ± 2 lb in) Part No.: 223-6408, 249-8717
S/N: 2211-Up
(2) Torque for nut ............ 100 ± 10 N·m (75 ± 7 lb ft)
Part No.: 223-6408, 249-8717
(A) Adjust the unit injector height from the timing seat S/N: LWA1-Up
to the following distance. ............. 78.0 ± 0.2 mm
Part No.: 223-6408
(3.07 ± 0.01 inch)
S/N: GEB1-Up
Use the following procedure to tighten the bolt (3) Part No.: 223-6408
for clamp (5): S/N: TPB1-Up
1. Tighten the bolt for the clamp to 55 ± 10 N·m Part No.: 223-6408, 249-8717
(41 ± 7 lb ft). S/N: H4C1-Up
2. Loosen the bolt for the clamp until the bolt is finger Part No.: 223-6408, 249-8717
tight. S/N: EED1-Up
Part No.: 223-6408
3. Tighten the bolt for the clamp again to 55 ± 10 N·m S/N: RJG1-Up
(41 ± 7 lb ft).
Part No.: 223-6408, 249-8717
S/N: Z9K1-Up
i02796857
Part No.: 223-6408, 249-8717
Electronic Unit Injector Rocker S/N: JRP1-Up
Arm Part No.: 223-6408, 249-8717
SMCS Code: 1123 S/N: DLS1-Up
g01397096
Illustration 7
Typical example
(1) Location of bearing joint
i02864507
g01075720
Illustration 8
Electronic Unit Injector Wiring Typical example
(1) Engine harness assembly and connector seal
SMCS Code: 1290
Part No.: 223-6408, 249-8717
S/N: 5301-Up
8 SENR9936-06
Specifications Section
Note: Install the flat part of the connector seal against Note: Refer to Testing and Adjusting, “Engine Valve
the connector surface. The curved part of the seal Lash - Inspect/Adjust” for the correct procedure on
must be installed so that the seal is against the valve setting the engine valve lash.
mechanism cover base.
(5) Location for checking the valve lash
(2) Torque for the 24 retainer nuts that are on the 12
cap assemblies ..... 2.50 ± 0.25 N·m (22 ± 2 lb in) Inlet valves ................................. 0.38 ± 0.08 mm
(0.015 ± 0.003 inch)
Note: Orient connectors so wires are not contacting Exhaust valves .......................... 0.76 ± 0.08 mm
metal surfaces. (0.030 ± 0.003 inch)
i02897419
Valve Mechanism
SMCS Code: 1102
Part No.: 260-9631
g01404154
Illustration 10
Left side of engine
g01442728
Illustration 9
(1) Rocker arm
(4) Camshaft Illustration 11
g01404155
(6) Valve bridge
Right side of engine
(2) Torque for the adjustment screw
locknut ........................... 30 ± 7 N·m (22 ± 5 lb ft)
Note: Tighten the bolts for the rocker arm group in the Diameter of a new rocker arm shaft
sequence 9, 10, 8, 11, 9, 10. Refer to Illustration 12. ........ 40.000 ± 0.010 mm (1.5748 ± 0.0004 inch)
Bore in a new bearing for rocker arm
(7) Torque for bolts ........ 109 ± 15 N·m (80 ± 11 lb ft) shaft ..................................... 40.065 ± 0.015 mm
(1.5774 ± 0.0006 inch)
Maximum dimension for the bore in a worn
i02794903
bearing for rocker arm shaft ............. 40.193 mm
Valve Mechanism (1.5824 inch)
SMCS Code: 1102 Note: Refer to Testing and Adjusting, “Engine Valve
Lash - Inspect/Adjust” for the correct procedure on
Part No.: 255-8001 setting the engine valve lash.
S/N: 5301-Up
(5) Location for checking the valve lash
Part No.: 255-8001
S/N: 2211-Up Inlet valves ................................. 0.38 ± 0.08 mm
(0.015 ± 0.003 inch)
Part No.: 255-8001 Exhaust valves .......................... 0.76 ± 0.08 mm
S/N: LWA1-Up (0.030 ± 0.003 inch)
Part No.: 255-8001
S/N: H4C1-Up
Part No.: 255-8001
S/N: EED1-Up
Part No.: 255-8001
S/N: Z9K1-Up
Part No.: 255-8001
S/N: JRP1-Up
Part No.: 255-8001
S/N: DLS1-Up
g01400357
Illustration 14
Left side of engine
g01400358
Illustration 15
Right side of engine
g01246863
Illustration 13 (7) Torque for bolts ........ 109 ± 15 N·m (80 ± 11 lb ft)
(1) Rocker arm
(4) Camshaft
(6) Valve bridge
g01415562
Illustration 17
View of area D
Inlet valve seat insert
g01415536
Illustration 16
(1) Exhaust valve
(2) Inlet valve
Quantity .......................................................... 24
Length under test force ... 60.14 mm (2.368 inch)
Test force .................... 150 ± 12 N (33.7 ± 2.7 lb)
Approximate free length after test ...... 71.70 mm
(2.823 inch)
Outside diameter ............ 25.17 mm (0.991 inch)
i02846910
Cylinder Head
SMCS Code: 1100
Part No.: 284-8895
g01423291
Illustration 20
Bolt tightening sequence
12 SENR9936-06
Specifications Section
The bolts that are marked “X” are 216 mm (8.5 inch)
long.
2. Torque for bolt 1 through bolt 26 in a numerical Note: Lubricate the bores for the cup plugs with
sequence to 450 ± 15 N·m (330 ± 11 lb ft) 6V-6640 Sealant prior to installing the cup plugs.
3. Again torque the bolt 1 through bolt 26 in (B) The cup plugs are measured from the face of the
a numerical sequence to 450 ± 15 N·m cylinder head to the top edge of the plug. Depth
(330 ± 11 lb ft). of installation .............................. 1.25 ± 0.25 mm
(0.049 ± 0.010 inch)
4. Torque for bolt 27 through bolt 39 in a numerical
sequence to 45 ± 7 N·m (33 ± 5 lb ft) NOTICE
Camshaft bearings must be installed into their correct
Note: Install the taperlock studs so that the letter “Y” position. Failure to do so will result in engine damage.
is showing.
g01419268
Illustration 23
g01419264
Illustration 21
(41) Oil gallery
(42) Camshaft bearing
(43) Oil holes
(44) Typical location for cup plug
SENR9936-06 13
Specifications Section
g01423293 g01427660
Illustration 24 Illustration 25
Top view of engine
The installation depth of the camshaft bearings (42)
is very important. Install the camshaft bearings to the
following depths:
(D) ..................... 8.0 ± 0.5 mm (0.31 ± 0.02 inch)
(E) ................. 227.5 ± 0.5 mm (8.96 ± 0.02 inch)
(F) ................ 411.7 ± 0.5 mm (16.21 ± 0.02 inch)
(G) .............. 595.8 ± 0.5 mm (23.46 ± 0.02 inch)
(H) ............... 780.0 ± 0.5 mm (30.71 ± 0.02 inch)
(J) ............... 964.1 ± 0.5 mm (37.96 ± 0.02 inch)
(K) .............. 1140.3 ± 0.5 mm (44.89 ± 0.02 inch)
i02857841
NOTICE
g01431037
Do not disassemble the Variable Valve Actuator. Illustration 27
There are no components of the Variable Valve Tightening sequence for the rocker arm shaft
Actuator that are serviceable. If the Variable Valve Left side view
Actuator is disassembled, the warranty will be void.
14 SENR9936-06
Specifications Section
g01428104
Illustration 29
Left side view of engine
g01427680
Illustration 28
Right side view of engine
g01428087
Illustration 30
Right side view of engine
Tightening sequence for the valve actuator group
SENR9936-06 15
Specifications Section
g01436074 g01427354
Illustration 31 Illustration 32
Left side view of engine Typical example
Tightening sequence for the valve actuator group
Note: The lash setting for the exhaust valve to rocker
Use the following procedure to tighten the valve arm must be completed before the lash setting of the
actuator group: compression brake. Refer to Testing and Adjusting,
“Engine Valve Lash - Inspect/Adjust” for procedural
1. In order to install the valve actuator group for the information.
compression brake to the cylinder head, place the
housing over the mounting studs. Finger tighten (14) Lash setting for compression
the mounting stud nuts and the mounting bolt. brake ......... 0.76 ± 0.08 mm (0.030 ± 0.003 inch)
2. Tighten the nuts, the bolt and flange nuts of each (15) Torque for locknut ........ 15 ± 3 N·m (11 ± 2 lb ft)
valve actuator group in the sequence 9, 12, 8, 10,
7, 13, 11, 9 to standard torque. Refer to Illustration Reference: Refer to Testing and Adjusting,
30 and Illustration 31. “Compression Brake Lash - Adjust” for procedural
information that is related to the adjustment of the
3. Again tighten the nuts, the bolt and flange nuts of compression brake.
each valve actuator group in the sequence 9, 12,
8, 10, 7, 13, 11, 9 to standard torque.
16 SENR9936-06
Specifications Section
i02884389
Turbocharger
SMCS Code: 1052
Part No.: 290-4621
S/N: 5301-Up
Part No.: 290-4621
S/N: 2211-Up
Part No.: 290-4621
S/N: H4C1-Up
Part No.: 277-8418
S/N: EED1-Up
Part No.: 217-6570
S/N: RJG1-Up
Part No.: 277-8419
S/N: JRP1-Up
Part No.: 277-8418
S/N: DLS1-Up
g01436068
Illustration 33
Typical example
Front view
(3) Spacer
g01436065
Illustration 34
Typical example
i02844244
Turbocharger
SMCS Code: 1052
Part No.: 217-5689
S/N: RJG1-Up
Part No.: 217-5689
S/N: BTW1-Up
Part No.: 217-5689
S/N: BWX1-Up
g01434386
Illustration 35
Front view of engine
SENR9936-06 19
Specifications Section
g01434384
Illustration 36
Top view of engine
Note: The oil supply and the oil drain holes should
be in the vertical position with respect to the engine
when the turbocharger group (1) is attached to the
exhaust manifold.
i02884391
Turbocharger
SMCS Code: 1052
Part No.: 245-9774
S/N: LWA1-Up
Part No.: 245-9774
S/N: Z9K1-Up
g01436070
Illustration 37
Front view
(3) Spacer
i02884396
Turbocharger
SMCS Code: 1052
Part No.: 294-9711
S/N: JNW1-Up
g01436069
Illustration 38
g01436082
Illustration 39
(4) Torque for the compressor clamp Rear view
assembly .............. 13.5 ± 1.0 N·m (120 ± 9 lb in)
(1) Apply 4C-5599 Anti-Seize Compound to the
Use the following procedure to tighten the turbine threads of the eight bolts before assembly.
clamp assembly (5):
(2) Torque for the eight locknuts ............. 55 ± 9 N·m
1. Tighten the turbine clamp assembly to 18.1 N·m (41 ± 7 lb ft)
(160 lb in).
g01436083
Illustration 40
i02844349
Turbocharger
SMCS Code: 1052
Part No.: 292-8580
S/N: GEB1-Up
Part No.: 292-8580
S/N: TPB1-Up
g01436071
Illustration 41
Front view
g01435716
Illustration 42
Turbocharger group
Note: The oil supply and the oil drain holes should
be in the vertical position with respect to the engine
when the turbocharger group is attached to the
exhaust manifold.
i02841625
Exhaust Manifold
SMCS Code: 1059
Part No.: 295-0647
S/N: 5301-Up
Part No.: 295-0647
S/N: 2211-Up
Part No.: 259-6926
S/N: EED1-Up
Part No.: 253-2633, 259-6926
S/N: JRP1-Up
Part No.: 259-6926
S/N: DLS1-Up
Part No.: 253-2633, 259-6926, 291-3026
S/N: BTW1-Up
Part No.: 253-2633, 259-6926, 291-3026
S/N: BWX1-Up
g01417453
Illustration 43
Typical example
SENR9936-06 25
Specifications Section
g01417476
Illustration 44
Exhaust manifold
Tightening sequence for the exhaust manifold
i02843153
Exhaust Manifold
SMCS Code: 1059
Part No.: 217-6686
S/N: EED1-Up
Part No.: 217-6686
S/N: RJG1-Up
Part No.: 217-6686
S/N: BTW1-Up
Part No.: 217-6686
S/N: BWX1-Up
g01417760
Illustration 45
Front view
g01417778
Illustration 46
Exhaust manifold
Tightening sequence for the exhaust manifold
i02866063
Exhaust Manifold
SMCS Code: 1059
Part No.: 251-1088
S/N: LWA1-Up
Part No.: 251-1088
S/N: H4C1-Up
Part No.: 251-1088
S/N: Z9K1-Up
g01427800
Illustration 47
Front view
(1) Install the 12 gaskets so that the “MANIFOLD Note: Use a centering tool in at least one oversize
SIDE” marking faces away from the cylinder hole per exhaust manifold section in order to align
head. the exhaust manifolds. Do not remove the centering
tool until removal is required to tighten the locknuts.
(2) Torque for the two taperlock studs ..... 35 ± 5 N·m
(26 ± 4 lb ft) Use the following procedure to tighten locknut 4
through locknut 15:
(3) Torque for the eight clamps ........... 8.5 ± 1.0 N·m
(75 ± 9 lb in) Note: Apply 4C-5599 Anti-Seize Compound to the
threads of the 24 locknuts.
SENR9936-06 29
Specifications Section
i02843234
Exhaust Manifold
SMCS Code: 1059
Part No.: 283-1004
S/N: JNW1-Up
g01417806
Illustration 48
Orientation of clamps from front view of engine
Tightening sequence for the exhaust manifold
(C) Orientation for the four clamps ... 78 ± 2 degrees Note: Use a centering tool in at least one oversize
hole per exhaust manifold section in order to align
(D) Orientation for the four clamps ... 90 ± 2 degrees the exhaust manifolds. Do not remove the centering
tools until removal is required to tighten the locknuts.
(13) Torque for the eight clamps ......... 8.5 ± 1.0 N·m
(75 ± 9 lb in) Use the following procedure to tighten the locknuts:
30 SENR9936-06
Specifications Section
i02843368
Exhaust Manifold
SMCS Code: 1059
Part No.: 272-2953
S/N: GEB1-Up
Part No.: 272-2953
S/N: TPB1-Up Illustration 50
g01417902
i02840165
Illustration 49
g01432982 Camshaft
Front view
SMCS Code: 1210
Part No.: 260-9307
S/N: 5301-Up
Part No.: 260-9307
S/N: 2211-Up
Part No.: 260-9307
S/N: LWA1-Up
SENR9936-06 31
Specifications Section
Part No.: 260-9307 (1) The end of the camshaft that is marked “F” must
S/N: GEB1-Up be placed at the front of the engine. Lubricate the
camshaft bearings, the journals, and the lobes
Part No.: 260-9307 with a 50/50 mixture of 8T-2998 Lubricant and
S/N: TPB1-Up clean engine oil.
Part No.: 260-9307
S/N: H4C1-Up
Part No.: 260-9306
S/N: EED1-Up
Part No.: 260-9306
S/N: RJG1-Up
Part No.: 260-9307
S/N: Z9K1-Up
Part No.: 260-9307
S/N: JRP1-Up
Part No.: 260-9306
g01416694
S/N: DLS1-Up Illustration 52
(2) Exhaust lobe
Part No.: 260-9306 (3) Injector lobe
S/N: BTW1-Up (4) Inlet lobe
g01416960
Illustration 53
g01419688
Illustration 54
(1) Oil filter base assembly
(2) Fluid sampling valve
(3) Oil supply line (unfiltered oil)
(5) Oil cooler bypass valves
(6) Oil return line (filtered oil)
(4) Lightly lubricate the bore and the O-ring seals for
the cooler bypass tube with clean engine oil.
i02848619
g01419678
Illustration 55
g01432945
Illustration 56
Left side view of engine
34 SENR9936-06
Specifications Section
i02847457
g01420429
Illustration 58
Section C-C
SENR9936-06 35
Specifications Section
g01419620
Illustration 60
Oil pump body
Illustration 59
g01419619 (F) Installation depth for sleeve bearing
.................. 0.30 ± 0.25 mm (0.012 ± 0.010 inch)
(A) Diameters of the shafts
Oil pump drive shaft for the pump drive shaft
assembly ............................. 22.217 ± 0.005 mm
(0.8747 ± 0.0002 inch)
Oil pump drive shaft for the idler shaft
assembly ............................. 22.217 ± 0.005 mm
(0.8747 ± 0.0002 inch)
i02857697
g01422622
Illustration 62
g01423433
Illustration 64
g01423414
Illustration 63
g01423468
Illustration 65
38 SENR9936-06
Specifications Section
i02865988
i02865980
g01427688
Illustration 67
Typical example
Right side view
i02855050
g01422063
Illustration 68
Typical example
Right side view
Use the following procedure to tighten the bolts for 1. Tighten the bolts in the numerical sequence to
the oil pan: 47 ± 9 N·m (35 ± 7 lb ft).
SENR9936-06 41
Specifications Section
2. Again tighten the bolts in the numerical sequence (3) After assembly, trim off excess gasket material
to 47 ± 9 N·m (35 ± 7 lb ft). from outside of assembled joint.
i02857775
g01433353
Illustration 70
42 SENR9936-06
Specifications Section
i02799191
g01056598
Illustration 72
Typical example
(1) Seal
i02798334
Water Pump
SMCS Code: 1361
Illustration 71
g01433751 Part No.: 230-4172
S/N: 5301-Up
Note: Lubricate the threads of the drain plug lightly Part No.: 230-4172
with clean engine oil before assembly. S/N: 2211-Up
(2) Torque for the drain plug .................. 70 ± 10 N·m Part No.: 230-4172
(50 ± 7 lb ft) S/N: LWA1-Up
Part No.: 230-4172
S/N: GEB1-Up
SENR9936-06 43
Specifications Section
g01403680
Illustration 75
Right side of the engine
g01443593
Illustration 74
Front of the engine
(F) Extension of dowels from the rear face of the
cylinder block and from the front face of the
Note: Apply 6V-6640 Sealant to the pipe threads cylinder block .. 19.0 ± 0.5 mm (0.75 ± 0.02 inch)
of stud (1). Tighten the stud with the coated pipe
Note: The main bearing caps (7) must be installed
threads into the cylinder block.
with the identifying marks toward the front of the
(4) Torque for three taperlock studs ........ 35 ± 5 N·m engine. The number of the main bearing cap (7) must
also match the cast number on the left side of each
(26 ± 4 lb ft)
main bearing saddle.
Note: The top face of the cylinder block, both sides
Use the following procedure to install the main
of plate gasket (3) and bottom surface of spacer plate
(2) must be free of fuel, oil, water, gasket adhesives, bearing caps:
assembly compounds and any other contaminants
during assembly.
1. Apply clean engine oil on the threads of the main (J) The distance from the centerline of the crankshaft
bearing cap bolts (8). Loosely install the main bearing bore to the bottom of the cylinder block
bearing cap bolts (8). .............. 165.10 ± 0.10 mm (6.500 ± 0.004 inch)
5. Put a mark on each main bearing cap bolt (8) and Part No.: 197-9322
each main bearing cap (7). See Illustration 76. S/N: DLS1-Up
Part No.: 197-9322
6. Tighten the main bearing cap bolts (8) that are S/N: BTW1-Up
placed opposite the main bearing tab side of the
main bearing cap (7) from the mark by angle (G) Part No.: 197-9322
of 120 ± 5 degrees. S/N: JNW1-Up
7. Tighten the main bearing cap bolts (8) that are Part No.: 197-9322
placed on the main bearing tab side of the main S/N: BWX1-Up
bearing cap (7) from the mark by angle (G) of 120
± 5 degrees.
g01392812
Illustration 78
(1) Filler band
(B) Flange
Thickness .............................. 8.890 ± 0.020 mm
(0.3500 ± 0.0008 inch)
Minimum thickness ....... 8.870 mm (0.3492 inch)
(H) The distance from the centerline of the 2. Dip the filler band completely in clean engine oil.
crankshaft bearing bore to the top of the cylinder
block ... 419.10 ± 0.15 mm (16.500 ± 0.006 inch)
46 SENR9936-06
Specifications Section
3. Immediately install the filler band in the groove Thickness of flange on cylinder
that is under the cylinder liner flange. liner ........... 8.89 ± 0.02 mm (0.350 ± 0.001 inch)
Minimum thickness ....... 8.870 mm (0.3492 inch)
4. Install the cylinder liner into the cylinder block
before the expansion of the filler band. Use the following procedure to install the cylinder
liner:
Note: Refer to Guideline For Reusable Parts and
Salvage Operations, SEBF8068, “Cylinder Liners” for 1. Apply liquid soap on the cylinder block liner bore
more information. Also, refer to Reuse And Salvage surfaces and the rubber seals that are on the
Guidelines, SEBF8049, “Visual Inspection of the lower end of the cylinder liner.
Piston” for more information.
2. Dip the filler band (2) completely in clean engine
oil.
i02801040
g01399536
Illustration 79
i02801044
Crankshaft
SMCS Code: 1202
Part No.: 224-3250
S/N: 5301-Up
Part No.: 224-3250
S/N: 2211-Up
Part No.: 224-3250
S/N: LWA1-Up
Part No.: 224-3250
S/N: GEB1-Up
Part No.: 224-3250
S/N: TPB1-Up
Part No.: 224-3250
S/N: H4C1-Up
Part No.: 225-6052
S/N: EED1-Up
Part No.: 225-6052
S/N: RJG1-Up
Part No.: 224-3250
S/N: Z9K1-Up
Part No.: 224-3250
S/N: JRP1-Up
Part No.: 225-6052
S/N: DLS1-Up
Part No.: 225-6052
S/N: BTW1-Up
Part No.: 225-6052
S/N: JNW1-Up
Part No.: 225-6052
S/N: BWX1-Up
g01399550
Illustration 80
Typical example
(3) Main journal (4) Rod journal
Note: Thrust plates (1) are used on the center main Note: The seal and the sleeve can not be used if the
bearing only. seal and the sleeve have been separated.
(A) Thickness of new thrust plate .... 5.74 ± 0.04 mm Note: The sleeve must be flush with the front face of
(0.226 ± 0.002 inch) the crankshaft within 0.13 mm (0.005 inch).
i02287333 i02866012
g01144821
Illustration 82
The seal driver should not contact the seal within the
following diameter. ....................... 177.80 ± 0.25 mm
g01427717
(7.000 ± 0.010 inch) Illustration 83
(1) Damper adapter
(2) Rear crankshaft seal (2) Damper
Install the rear seal to the following distance from the (3) Torque for 12 bolts .. 135 ± 20 N·m (100 ± 15 lb ft)
end of the crankshaft. .......................... 1.5 ± 0.5 mm
(0.06 ± 0.02 inch)
The seal driver should not contact the seal within the
following diameter. ....................... 177.80 ± 0.25 mm
(7.000 ± 0.010 inch)
i02866018 i02856619
g01427740
Illustration 84
(1) Damper
(2) Damper adapter
i02866033 i02866067
g01427778
Illustration 87
(1) Dampers
(3) Damper adapter
g01427752
Illustration 86
(1) Damper adapter
(2) Dampers
i02776231 i02776201
Table 3
Part No.: 319-6714
S/N: LWA1-Up
Main Bearing Bore
Part No.: 319-6714
Original Size of the Bore 129.891 ± 0.013 mm
(5.1138 ± 0.0005 inch)
S/N: GEB1-Up
In the Block
Oversize Bore 0.63 mm 130.526 ± 0.013 mm Part No.: 319-6714
(0.025 inch) (5.1388 ± 0.0005 inch) S/N: TPB1-Up
Part No.: 319-6714
S/N: H4C1-Up
Part No.: 213-4836
S/N: EED1-Up
Part No.: 213-4836
S/N: RJG1-Up
Part No.: 319-6714
S/N: Z9K1-Up
Part No.: 239-6144
S/N: JRP1-Up
Part No.: 213-4836
S/N: DLS1-Up
Part No.: 213-4836
S/N: BTW1-Up
Part No.: 213-4836
S/N: JNW1-Up
Part No.: 213-4836
S/N: BWX1-Up
g01318414
Illustration 88
Tightening sequence, and index mark for torque-turn process
(1),(2),(3),(4) Bolts for rod cap
54 SENR9936-06
Specifications Section
g01399634 g01401199
Illustration 90 Illustration 91
(7) Oil jet tube assembly
Note: The bearing joint must be located within area
(E) along the horizontal centerline of the piston pin (8) Torque for the special bolt of oil jet tube
bore. assembly ....................... 25 ± 6 N·m (18 ± 4 lb ft)
Note: The bore of bearing for piston pin must be Piston and Rings
machined after installation into the connecting rod.
SMCS Code: 1214; 1215
(G) Outside diameter of bearing for piston Part No.: 213-4836
pin before installation into the connecting S/N: EED1-Up
rod .. 64.717 ± 0.013 mm (2.5479 ± 0.0005 inch)
Part No.: 213-4836
(H) Dimensions for piston pin S/N: RJG1-Up
Bore diameter of bearing for the piston pin after Part No.: 213-4836
machining ............................ 60.035 ± 0.008 mm S/N: DLS1-Up
(2.3636 ± 0.0003 inch)
Part No.: 213-4836
Diameter of piston pin .......... 59.975 ± 0.005 mm S/N: BTW1-Up
(2.3612 ± 0.0002 inch)
Part No.: 213-4836
Note: Apply heat to the connecting rod prior to S/N: JNW1-Up
installation of bearing for piston pin. Do not use a
Part No.: 213-4836
torch to heat the connecting rod.
S/N: BWX1-Up
(J) Maximum length for heating the connecting
rod during the installation of bearing for piston
pin ............................................ 95 mm (3.7 inch)
g01391600
Illustration 92
The 1U-6431 Piston Ring Groove Gauge Gp is Clearance between groove and oil control piston
used for measuring the ring grooves in keystone ring .......................................... 0.05 mm (0.002 inch)
style pistons. Refer to the Special Instruction that is
supplied with the piston ring groove gauge group. When a new piston ring is installed in a cylinder liner
with a bore of 137.16 mm (5.400 inch), the clearance
The 5P-3519 Piston Ring Groove Gauge Gp is between the ends of the piston ring is the following
available for checking the ring grooves with straight value: .............. 0.55 ± 0.15 mm (0.022 ± 0.006 inch)
sides. Refer to the Guideline for Reusable Parts for
instructions on the piston ring groove gauge group. Increase in the clearance between the ends of the
piston ring for each 0.03 mm (0.001 inch) increase in
Note: Lubricate the entire piston in zone (A) with the cylinder liner bore ............. 0.08 mm (0.003 inch)
clean engine oil prior to assembly into the cylinder
block. Note: After the piston rings have been installed,
rotate the piston rings so that the end gaps are 120
degrees from each other.
Top Piston Ring (1)
Install the piston ring with the side marked “UP-1” Piston Pin Bore (4)
toward the top of the piston. The red stripe faces to
the right of the piston ring end gap. Note: Thoroughly lubricate the piston pin with clean
engine oil before the piston is inserted into the piston
When a new piston ring is installed in a cylinder liner and the rod assembly.
with a bore of 137.16 mm (5.400 inch), the clearance
between the ends of the piston ring is the following Diameter of the bore in the finished bearing that
value: .............. 0.40 ± 0.10 mm (0.016 ± 0.004 inch) is installed into the piston skirt for the piston
pin .. 60.0925 ± 0.0075 mm (2.36584 ± 0.00030 inch)
Increase in the clearance between the ends of the
piston ring for each 0.03 mm (0.001 inch) increase in Diameter of the new piston pin .. 59.975 ± 0.005 mm
the cylinder liner bore ............. 0.08 mm (0.003 inch) (2.3612 ± 0.0002 inch)
Part No.: 319-6714 Increase in clearance between the ends of the piston
S/N: LWA1-Up rings for each 0.030 mm (0.0012 inch) increase in the
cylinder liner bore ................... 0.08 mm (0.003 inch)
Part No.: 319-6714
S/N: GEB1-Up
Intermediate Piston Ring (2)
Part No.: 319-6714
S/N: TPB1-Up Install the piston ring with the side marked “UP-2”
toward the top of the piston. The white colored stripes
Part No.: 319-6714 face to the right of the piston ring end gap.
S/N: H4C1-Up
Part No.: 319-6714 When a new piston ring is installed in a cylinder
S/N: Z9K1-Up liner with a bore of 145 mm (5.7 inch), the clearance
between the ends of the piston ring is the following
Part No.: 239-6144 value: ...... 0.600 ± 0.125 mm (0.0236 ± 0.0049 inch)
S/N: JRP1-Up
Increase in clearance between the ends of the piston
ring for each 0.030 mm (0.0012 inch) increase in the
cylinder liner bore ................... 0.08 mm (0.003 inch)
i02801103
Housing (Front)
SMCS Code: 1151
Part No.: 238-9862
g01399843
Illustration 95
g01399842
Illustration 94
g01399846
Illustration 96
View A-A
(6) Cylinder block
i02801118
Housing (Rear)
SMCS Code: 1157
Part No.: 233-2462
S/N: 5301-Up
Part No.: 233-2462 g01399863
Illustration 97
S/N: 2211-Up
Left side view of engine
60 SENR9936-06
Specifications Section
g01399869
Illustration 99
Rear view
g01399864
Illustration 98 i02801133
View A-A
(3) Cylinder block
Gear Group (Front)
SMCS Code: 1206
(2) Apply a continuous bead of 230-6262 Sealant
immediately prior to assembling the rear housing. Part No.: 235-0993
After assembly of the rear housing, remove any S/N: 5301-Up
excess sealant from the flange with a straight
edge. Part No.: 235-0993
S/N: 2211-Up
(4) Apply 230-6262 Sealant to the T-shaped joints
immediately prior to the installation of the gasket Part No.: 235-0993
for the pan. The application of the sealant should S/N: LWA1-Up
cover the entire width of the T-shaped joints, as Part No.: 235-7134
shown. S/N: GEB1-Up
SENR9936-06 61
Specifications Section
Part No.: 235-0993 (2) Torque for the 12 bolts of the camshaft
S/N: JNW1-Up gear ....................... 240 ± 40 N·m (175 ± 30 lb ft)
Part No.: 235-0993 (4) Lubricate the shaft, the bearing bore, and the
S/N: BWX1-Up thrust faces of the idler gear assembly with clean
engine oil.
g01399922
Illustration 102
Section A-A
g01399881 (8) Lubricate the drive idler shaft with clean engine
Illustration 100
(1) Damper group oil.
(3) Gear assembly
(5) Crankshaft gear Note: Install the thrust plate with the oil groove side
(6) Gear toward the idler gear assembly.
i02866666
(3) With the no. 1 piston in the top dead center (TDC)
position, align the timing marks. The mark on the
camshaft gear assembly must be in alignment
with the drilled timing marks in the rear housing.
(5) With the no. 1 piston in the top dead center (TDC)
position, align the timing marks. The mark on the
idler gear assembly (4) must be in alignment with
the mark on the crankshaft gear assembly.
i02867504
g01428031
Illustration 105
Typical example
Section A-A
g01428029
Illustration 106
Typical example
Section B-B
g01428402
Illustration 108
Tightening sequence
(6) With the no. 1 piston in the top dead center (TDC)
position, align the timing marks. The mark on the
idler gear assembly (5) must be in alignment with
the mark on the crankshaft gear assembly (7).
i02866758
g01428401
Illustration 110
Section B-B
g01428074
Illustration 111
Rear view of engine
66 SENR9936-06
Specifications Section
g01428072
Illustration 112
Tightening sequence
(6) With the no. 1 piston in the top dead center (TDC)
position, align the timing marks. The mark on the
idler gear assembly (5) must be in alignment with
the mark on the crankshaft gear assembly.
i02899682
g01443779
Illustration 115
(2) Lubricate the shaft, the bearing bore, and the (11) Lubricate the shaft, the bearing bore, and the
thrust faces of the camshaft gear assembly with thrust faces of the cranshaft gear assembly with
clean engine oil. clean engine oil.
g01400787
Illustration 117
Section A-A
(10) With the number one piston in the top dead Part No.: 231-6377
center position, align the timing marks. The mark S/N: JNW1-Up
on the idler gear must be in alignment with the Part No.: 224-3167
mark on the crankshaft gear. S/N: BWX1-Up
SENR9936-06 69
Specifications Section
i02900830
Flywheel
SMCS Code: 1156
Part No.: 273-2713, 273-2715, 273-2716,
273-7293
S/N: JRP1-Up
g01450105
Illustration 119
Typical example
i02857727 i02857899
g01249502 g01423950
Illustration 120 Illustration 121
(1) Gear Rear view of engine
g01427297
Illustration 123
Section A-A
(37) The seal driver must not contact the seal within
the following diameter. ........... 177.80 ± 0.25 mm
(7.000 ± 0.010 inch)
i02884495
Flywheel Housing
SMCS Code: 1157
Part No.: 245-9775
S/N: 5301-Up
Part No.: 245-9775
S/N: 2211-Up
Part No.: 245-9775
S/N: LWA1-Up
Part No.: 245-9775
S/N: H4C1-Up
Part No.: 245-9775
S/N: Z9K1-Up
Part No.: 259-3123
S/N: JRP1-Up
Part No.: 217-5685
S/N: BTW1-Up
Part No.: 217-5685
S/N: BWX1-Up
g01424823
Illustration 125
Typical example
Right side view of the engine
g01436141
Illustration 126
Section A-A
(37) The seal driver must not contact the seal within
the following diameter. ........... 177.80 ± 0.25 mm Illustration 127
g01435183
(7.000 ± 0.010 inch) Rear view of engine
g01435182
Illustration 129
Section A-A
1. For bolt (1) and bolt (2), use 3/8-16 X 6 1/4 inch
bolts. Torque the bolt (1) and bolt (2 ) in the
numerical sequence that is shown in Illustration
127 to 55 ± 10 N·m (41 ± 7 lb ft).
SENR9936-06 75
Specifications Section
i02883207
Flywheel Housing
SMCS Code: 1157
Part No.: 294-9164
S/N: JNW1-Up
g01435175
Illustration 131
Right side view of engine
g01435176
Illustration 132
Section A-A
(37) The seal driver must not contact the seal within
the following diameter. ........... 177.80 ± 0.25 mm
(7.000 ± 0.010 inch)
i02858265
Flywheel Housing
SMCS Code: 1157
Part No.: 216-0822
S/N: GEB1-Up
Part No.: 216-0822
S/N: TPB1-Up
g01424195
Illustration 133
Rear view of engine
Note: The front face of the flywheel housing group 3. For bolt (10) through bolt (15), use 3/8-16 X 4
and the rear face of the rear housing must be free of inch bolts. For bolt (16) through bolt (26), use
oil, fuel, water, assembly compounds and any other 3/8-16 X 3 inch bolts. For bolt (27) through bolt
contaminants during assembly. The gasket for the (42), use 3/8-16 X 5 1/4 inch bolts. Torque the bolt
flywheel housing group must be free of contaminants (10) through bolt (42) in the numerical sequence
during assembly. that is shown in Illustration 133 to 47 ± 9 N·m
(35 ± 7 lb ft).
Use the following procedure to tighten the bolts for
the flywheel housing group:
i02845077
g01089060
Illustration 135
g01391967
Illustration 136
(1) Connector
With an increase in flow (force), the switch opens at (1) Final installation torque for the temperature
the following value: .......................... 0.362 ± 0.029 N sensor ............................ 20 ± 5 N·m (15 ± 4 lb ft)
(0.0814 ± 0.0065 lb)
Output type ................................................... Passive
With a decrease in flow (force), the switch closes at
the following minimum value: ..... 0.303 N (0.0681 lb) Operating temperature ........................ −40 to 150 °C
(−40 to 302 °F)
Note: When the switch is installed in the engine
cooling system, there is not enough force from the
flow of coolant at engine cranking speed in order to
activate the switch. When the engine is running at
low idle, the flow of coolant has enough force in order
to activate the switch.
i02839267
g01089060
Illustration 138
SENR9936-06 81
Specifications Section
g01089060
Illustration 139
i02853439
g01421159
Illustration 141
i02853437 i02665532
g01275664
Illustration 142
g01155331
Illustration 143
(1) Final installation torque for the pressure sensor
group .......................... 10 ± 2 N·m (90 ± 18 lb in) Note: Prior to installing the pressure sensor group
onto the engine, apply 5P-3413 Pipe Sealant to the
Operating voltage ............................... 5.0 ± 0.5 VDC first three threads of the pressure sensor group.
Operating temperature ........................ −40 to 125 °C (1) Final installation torque for the pressure sensor
(−40 to 257 °F) group .......................... 10 ± 2 N·m (90 ± 18 lb in)
i02845092 i02666631
g01190345
Illustration 145
Illustration 144
g01068621 Operating voltage ........................... 5.00 ± 0.25 VDC
i02879859 i02845102
g01154731
Illustration 146
i02854065 i02854115
g01391967
Illustration 148
Operating temperature ........................ −40 to 150 °C (1) Final installation torque for the pressure sensor
(−40 to 302 °F)
group .......................... 10 ± 2 N·m (90 ± 18 lb in)
g01154731
Illustration 150
i02857202
Speed/Timing Sensor
SMCS Code: 1907; 1912
88 SENR9936-06
Specifications Section
g01423342
Illustration 152
(2) Speed sensor
(3) Bracket
Index
A I
C
M
Camshaft ............................................................... 31
Compression Brake ............................................... 13 Main Bearing Journal............................................. 52
Connecting Rod..................................................... 53 Mass Air Flow Sensor...................................... 82–83
Connecting Rod Bearing Journal........................... 52
Coolant Flow Switch .............................................. 79
Coolant Temperature Sensor........................... 78–79 P
Crankshaft ............................................................ 47
Crankshaft Seals ................................................... 49 Piston and Rings ............................................. 55, 57
Cylinder Block........................................................ 43 Intermediate Piston Ring (2) ........................ 56–57
Cylinder Head......................................................... 11 Oil Control Piston Ring (3) ........................... 56–57
Cylinder Head Valves ............................................ 10 Piston Pin Bore (4)....................................... 56, 58
Cylinder Liner .................................................. 45–46 Top Piston Ring (1) ...................................... 56–57
E S
Housing (Front)...................................................... 58
Housing (Rear) ...................................................... 59
90 SENR9936-06
Index Section
SENR9936-06 91
Index Section
©2008 Caterpillar
All Rights Reserved Printed in U.S.A.