Engine 3066 - Disassembly and Assembly(Supplemental Information)

CATERPILLAR

RENR3813-01 December 2000

Supplemental Information

3 2 0 C Excavator Supplement for 3 0 6 6 Engine APA1-Up (Machine) ANB1-Up (Machine) BCB1-Up (Machine) BDB1-Up (Machine) BGB1-Up (Machine) AMC1-Up (Machine) BBC1 -Up (Machine) BDC1-Up (Machine) CC01-Up (Machine) ALF1-Up (Machine) BEF1-Up (Machine) AKH1-Up (Machine) BKK1-Up (Machine) CLM1-Up (Machine) BER1 -Up (Machine) BPR1-Up (Machine) ALX1-Up (Machine) BRX1-Up (Machine) CLZ1-Up (Machine)

Important Safety Information Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. 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 to other persons. The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER", "WARNING" or "CAUTION". The Safety Alert "WARNING" label is shown below.

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 Excavator Supplement for 3066 Engine Table of Contents

Table of Contents Disassembly and Assembly Section Hydraulic System Pressure - Release 4 Alternator - Remove and Install 6 Electric Starting Motor - Remove and Install 8 Governor Control Motor - Remove and Install 9 Fuel Priming Pump - Remove andjnstall 12 Fuel Filter (Primary) and Fuel Filter Base - Remove and Install 13 Water Separator-Remove and Install 14 Engine Oil Level Gauge (Dipstick) - Remove and Install 16 Engine Oil Filter and Oil Filter Base - Remove and Install 17 Engine Oil Filter Base - Disassemble 19 Engine Oil Filter Base - Assemble 21 Engine Oil Cooler - Remove and Install 23 Hydraulic Oil Cooler - Remove 25 Hydraulic Oil Cooler - Install 27 Air Cleaner - Remove and Install 30 Air Inlet Manifold - Remove 33 Air Inlet Manifold - Install 35 Air Inlet Heater - Remove and Install 36 Muffler - Remove and Install 38 Exhaust Manifold - Remove and Install 40 Turbocharger - Remove 41 Turbocharger - Install 43 Water Temperature Regulator - Remove and Install 45 Fuel Injection Lines - Remove and Install 47 Fuel Injection Pump - Remove 51 Fuel Injection Pump - Install 54 Fuel Injection Nozzles - Remove 56 Fuel Injection Nozzles - Install 57 Valve Mechanism Cover - Remove and Install 57 Rocker Shaft and Push Rod - Remove 60 Rocker Shaft and Push Rod - Install 61 Cylinder Head - Remove 61 Cylinder Head - Install 63 Radiator- Remove 64 Radiator- Install 67 V-Belts - Remove and Install 69 Fan - Remove and Install 70 Water Pump - Remove 72 Water Pump - Disassemble 73 Water Pump - Assemble 74 Water Pump - Install 75 Water Outlet Manifold - Remove 76 Water Outlet Manifold - Install 77 Crankshaft Pulley - Remove and Install 78 Housing (Front) - Remove 80 Housing (Front) - Install 82 Crankshaft Front Seal - Remove 85 Crankshaft Front Seal - Install 86 Oil Pan - Remove and Install 87 Refrigerant Compressor - Remove and Install 91 Refrigerant Condenser - Remove and Install 94 Hood - Remove and Install 97 Engine and Main Hydraulic Pump - Remove 99

Engine and Main Hydraulic Pump - Install 109 Flywheel and Ring Gear - Remove and Install ..119 Crankshaft Rear Seal - Remove 121 Crankshaft Rear Seal - Install 122

Index Section Index

124

WARNING Accidental machine starting can cause injury or death to personnel working on the machine. To avoid accidental machine starting, turn the battery disconnect switch to the OFF position and remove the key. If the machine is not equipped with a battery disconnect switch, disconnect the battery cables from the battery and tape the battery clamps. Place a do not operate tag at the battery disconnect switch location to inform personnel that the machine is being worked on.

4 Excavator Supplement for 3066 Engine Disassembly and Assembly Section

Disassembly and Assembly Section Hydraulic System Pressure Release SMCS Code: 3000-553-PX; 4250-553-PX; 4300-553-PX; 5050-553-PX

Pressure Release Procedure The release of hydraulic pressure in an hydraulic circuit is required before service is performed to that hydraulic circuit. Release the pressure in the following hydraulic circuits before any hydraulic lines are disconnected from that hydraulic circuit or hydraulic components are removed.

NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. Perform the following Steps in order to release the hydraulic pressure from a single hydraulic circuit of the main hydraulic system. 1. Position the machine on level ground.

• Boom hydraulic circuit • Stick hydraulic circuit • Bucket hydraulic circuit • Swing hydraulic circuit • Travel hydraulic circuit • Attachment hydraulic circuits (if equipped) • Pilot hydraulic circuit • Return hydraulic circuit Illustration 1

Release Of Hydraulic Pressure From A Single Hydraulic Circuit WARNING Personal injury can result from hydraulic oil pressure and hot oil.

2. Fully retract the stick cylinder rod. Adjust the position of the bucket so that the bucket is parallel to the ground. Lower the boom until the bucket is flat on the ground. Refer to Illustration 1. 3. Shut off the engine.

Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.

4. Turn the engine start switch to the ON position without starting the engine.

Make sure all of the attachments have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

6. Move only the joysticks or the pedals of the hydraulic circuit that requires service to the FULL STROKE positions. This will release the high pressure only in that single hydraulic circuit. This will also release any pressure that might be present in the pilot hydraulic circuit.

5. Place the hydraulic activation control lever in the UNLOCKED position.

5 Excavator Supplement for 3066 Engine Disassembly and Assembly Section Note: If the desired hydraulic circuit that requires service requires the activation of a switch for operation, activate the necessary switches for the operation of the hydraulic circuit.

Perform the following Steps in order to release the hydraulic pressure from multiple hydraulic circuits of the main hydraulic system. 1. Position the machine on level ground.

7. Place the hydraulic activation control lever in the LOCKED position. 8. Turn the engine start switch to the OFF position. 9. Slowly loosen the filler plug onThe hydraulic tank and release the pressure from the hydraulic tank. Leave the filler plug loose for a minimum of 45 seconds. This will release the pressure that may be present in the return hydraulic circuit. 10. Tighten the filler plug on the hydraulic tank to the specified torque. 11. The pressure in the single hydraulic circuit that requires service is now released and lines and components can be disconnected or removed from that hydraulic circuit.

Release Of Hydraulic Pressure From Multiple Hydraulic Circuits WARNING

Illustration 2

2. Fully retract the stick cylinder rod. Adjust the position of the bucket so that the bucket is parallel to the ground. Lower the boom until the bucket is flat on the ground. Refer to Illustration 2. 3. Shut off the engine.

Personal injury can result from hydraulic oil pressure and hot oil.

4. Turn the engine start switch to the ON position without starting the engine.

Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system.

5. Place the hydraulic activation control lever in the UNLOCKED position.

Make sure all of the attachments have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

6. Move only the joysticks or the pedals of the hydraulic circuit that requires service to the FULL STROKE positions. This will release the high pressure only in that hydraulic circuit. This will also release any pressure that might be present in the pilot hydraulic circuit. Note: If the hydraulic circuit that requires service requires the activation of a switch for operation, activate the necessary switches for the operation of the hydraulic circuit. 7. Place the hydraulic activation control lever in the LOCKED position. 8. Start the engine. 9. Place the hydraulic activation control lever in the UNLOCKED position. Do not move any joysticks or pedals from the NEUTRAL position during this step. Do not activate any switches during this Step. 10. Return the hydraulic activation control lever to the LOCKED position. 11. Shut off the engine.

6 Excavator Supplement for 3066 Engine Disassembly and Assembly Section

12. Repeat Steps 4 through 11 for each additional hydraulic circuit that requires service. 13. After releasing the hydraulic pressure in each of the desired hydraulic circuits, place the hydraulic activation control lever in the LOCKED position. 14. Turn the engine start switch to the OFF position. 15. Slowly loosen the filler plug on the hydraulic tank and release the pressure. Leave the filler plug loose for a minimum of 45 seconds. This will release the pressure that may be present in the return hydraulic circuit. 16. Tighten the filler plug on the hydraulic tank to the specified torque. 17. The pressure in the multiple hydraulic circuits that require service is now released and lines and components can be disconnected or removed from those hydraulic circuits.

Illustration 4 Top view of the alternator

1. Remove the nut and the washer behind rubber boot (2). Disconnect the wire behind the rubber boot. 2. Remove electrical connection (4) from the alternator (1).

i01341250

Alternator - Remove and Install SMCSCode: 1405-010

Removal Procedure

3. Disconnect electrical connection (3). 4. Remove bolt (5) and the washer in order to disconnect the ground wires from alternator (1). 5. Remove bolt (6), the washer, and the spacer in order to remove the wiring harness from alternator (1).

Start By: a. Deactivate the electrical system. Refer to Operation and Maintenance Manual, "Battery Disconnect Switch" in order to deactivate the electrical system. b. Remove the V-Belts. Refer to Disassembly and Assembly, "V-Belts - Remove and Install" in this manual.

j 2 inn

Illustration 5 The radiator is removed for photographic purposes.

6. Remove bolt (7) and the washer from the alternator. 7. Remove bolt (8), the washer, and the spacer from the alternator. Illustration 3 Rear view of the alternator

7 Excavator Supplement for 3066 Engine Disassembly and Assembly Section 3. Install the spacer, the washer, and bolt (8) to the alternator. 4. Install the washer and bolt (7) to the alternator.

Illustration 6 Rear view of the alternator

8i Support alternator (1). Remove bolt (9), the washer, and the spacer from alternator (1). 9. Remove alternator (1) from the machine.

Installation Procedure

Illustration 9 Rear view of the alternator

5. Install the wiring harness to alternator (1). Install the spacer, the washer, and bolt (6) to alternator (1).

Illustration 7 Illustration 10

1. Install alternator (1) to the machine.

Top view of the alternator

2. Install the spacer, the washer, and bolt (9)

6. Connect two ground wires to alternator (1). Install the washer and bolt (5). 7. Connect electrical connection (3). 8. Install electrical connection (4) to alternator (1). 9. Connect the wire that is behind rubber boot (2). Install the washer and the nut that is located behind rubber boot (2). End By: a. Install the V-Belts. Refer to Disassembly and Assembly, "V-Belts - Remove and Install" in this manual.

Illustration 8 The radiator is removed for photographic purposes.

b. Activate the electrical system. Refer to Operation and Maintenance Manual, "Battery Disconnect Switch" in order to activate the electrical system.

8 Excavator Supplement for 3066 Engine Disassembly and Assembly Section io-1341994

Electric Starting Motor Remove and Install

2. R e m o v e nut (2) a n d the washer. D i s c o n n e c t

battery cables (3).

SMCS Code: 1453-010

Removal Procedure Start By: a. Deactivate the electrical system. Refer to Operation and Maintenance Manual, "Battery Disconnect Switch" in order to deactivate the electrical system. b. Remove the hood. Refer to Disassembly and Assembly, "Hood - Remove and Install" in this manual. Note: Put identification marks on all wires prior to the removal of the electric starting motor.

Illustration 13

3. Remove bolt (5) and the washer. Disconnect grounding strap (4).

Illustration 14 Illustration 11

1. Remove rubber boot (1). Slide the rubber boot down the battery cable in order to access the nut under the rubber boot.

Illustration 12

4. Remove nuts (6). Remove electrical starting motor (7).

Installation Procedure

Illustration 15

1. Install electrical starting motor (7) in the flywheel housing. Install nuts (6).

9 Excavator Supplement for 3066 Engine Disassembly and Assembly Section End By: a. Install the hood. Refer to Disassembly and Assembly, "Hood - Remove and Install" in this manual. b. Activate the electrical system. Refer to Operation and Maintenance Manual, "Battery Disconnect Switch" in order to activate the electrical system.

Illustration 16

2. Connect grounding strap (4). Install the washer and bolt (5). Tighten the bolt to a torque of 3.5 ± 1.0 N-m (31 ± 9 lb in).

Illustration 17

3. Connect battery cables (3). Install the washer and nut (2). Tighten the nut to a torque of 1 1 + 1 N-m (97 + 9 lb in).

Governor Control Motor Remove and Install SMCSCode: 1716-011; 1716-012

Removal Procedure

Illustration 19

1. Remove two bolts (3) and the washers from the hinge. 2. Remove three bolts (1) and the washers in order to remove access panel (2).

Illustration 18

4. Install rubber boot (1) over nut (2).

Illustration 20

3. Remove three bolts (5) and the washers in order to remove access panel (4). 4. Open the engine hood.