Turbocharger - Disassemble 318c exavator

Turbocharger - Disassemble

Disassembly Procedure

 

Start By:

1. Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove".

NOTICE : Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.

 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.

1. Place an index mark on all of the components. The marks will help to align the components during the assembly procedure.

2. Remove two bolts (1) from the oil return line. Remove bolt (2) from the oil supply line.

3. Remove oil return line (3) from the cartridge.

4. Remove oil supply line (4) from the cartridge.

5. Remove gasket (5) from the cartridge.

6. Remove gasket (6) from the turbine housing.

7. Remove the bolt and nut (7) from clamp (8). Remove clamp (8) that secures the turbine housing (9) to the cartridge (10) .

8. Separate turbine housing (9) from the cartridge (10) .

9. Remove snap ring (11) from compressor housing (12) .

10. Separate compressor housing (12) from the cartridge (10) .

Muffler - Remove and Install

Disassembly and Assembly
318C Excavator3066 Engine Supplement

Muffler - Remove and Install

Removal Procedure

1. Open hood (1) .

2.Remove nuts (2) .Note: Nuts (2) are doubled on the turbocharger.

3. Loosen clamp (3). Slide clamp (3) onto pipe (4). Remove pipe (4), clamp (3), and the gasket that is between pipe (4) and the turbocharger.

4. Disconnect drain line (5) from the bottom of the muffler.

 

5. Remove U-bolts (6). Remove muffler (7). The weight of the muffler is approximately 16 kg (35 lb).

Installation Procedure

1. Place muffler (7) in position on the brackets in the engine compartment. The weight of the muffler is approximately 16 kg (35 lb). Install U-bolts (6) .

2. Connect drain line (5) to the bottom of the muffler.

3. Install a new gasket between pipe (4) and the turbocharger. Slide clamp (3) onto pipe (4). Install pipe (4) and clamp (3) on the turbocharger. Slide clamp (3) so that the clamp is half on pipe (4) and half on the muffler. Do not tighten clamp (3) at this time.

4. Apply 4C-5599 Anti-Seize Compound to the threads of nuts (2). Install nuts (2) .Note: Nuts (2) are doubled on the turbocharger.

5. Make sure that clamp (3) is half on pipe (4) and half on the muffler. Tighten clamp (3) .

6. Close hood (1) .

Drain Line (Muffler)

Specifications
318C and 319C Excavators Machine System Specifications

Media Number -RENR6688-01

Drain Line (Muffler)

(1) Torque for fitting ... 30 ± 3 N·m (22 ± 2 lb ft)

Air Inlet Manifold (In Chassis) - Remove

Air Inlet Manifold (In Chassis) - Remove

Removal Procedure

Start By:

1. Remove the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install".
2. Remove the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove and Install".
3. Remove the air inlet heater. Refer to Disassembly and Assembly, "Air Inlet Heater - Remove and Install"

NOTICE :Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.

1. Remove bolts (1) from the bracket for the crankcase breather.

2. Remove bolt (2), the washer, and spacer (3) from the dipstick tube.

3. Remove bolts (4) and the washers.

4. Remove air inlet manifold (5) .

5. Remove gaskets (6) from the mating surfaces of the cylinder head and the air inlet manifold.

Exhaust Manifold - Remove and Install

Disassembly and Assembly
318C Excavator3066 Engine Supplement
Media Number -RENR6635-00 

Exhaust Manifold - Remove and Install

Removal Procedure

Start By:

1. Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove". 

NOTICE : Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.

1. Remove the nuts (1) and washers that secure the exhaust manifold to the cylinder head assembly. The 3066 Engine has twelve nuts and washers while the 3064 Engine has eight nuts and washers.

2. Remove exhaust manifold (2) from the cylinder head assembly.

3. Remove exhaust manifold gasket (3) that is located between exhaust manifold (2) and the cylinder head assembly.Note: The 3066 Engine has two exhaust manifold gaskets, while the 3064 Engine has one exhaust manifold gasket.
   
   

   Installation Procedure

   NOTICE : Keep all parts clean from contaminants.
   Contaminants may cause rapid wear and shortened component life.

     

   

   1. Install exhaust manifold gasket (3) between exhaust manifold (2) and the cylinder head assembly.Note: The 3066 Engine has two exhaust manifold gaskets, while the 3064 Engine has one exhaust manifold gasket.
4. Place exhaust manifold (2) in position on the cylinder head.

3. Install the nuts (1) and the washers that secure the exhaust manifold to the cylinder head assembly. The 3066 Engine has twelve nuts and washers while the 3064 Engine has eight nuts and washers.

4. Tighten exhaust manifold nuts (1) to a torque of 18 ± 4 N·m (13 ± 3 lb ft).

End By: Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Install".

 

Air Inlet Heater - Remove and Install

Disassembly and Assembly
318C Excavator3066 Engine Supplement

Media Number -RENR6635-00

Air Inlet Heater - Remove and Install

SMCS - 1090-010

Removal Procedure

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NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.

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1. Open the engine hood. Lock the engine hood in the OPEN position.

2. Remove rubber boot (1) from the electrical connector.

3. Remove nut (2) in order to disconnect electrical wire (3) from the air inlet heater.

4. Loosen hose clamp (4) in order to disconnect the air hose from the air inlet elbow.

5. Remove bolts (5) and the washers from the air inlet manifold.Note: Ground wire (6) will be disconnected when the bolt is removed.

6. Remove air inlet elbow (7) .

7. Remove air inlet heater (8) .

8. Remove gasket (9) from the air inlet heater.

Installation Procedure

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NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.----------------------------------------------------------------------------

Note: Gaskets and seals should always be replaced. A used gasket may not have the same sealing properties as a new gasket.

1. Install wire mesh filter (10) .

 

2. Install gasket (9) on the air inlet heater.

3. Install air inlet heater (8) .

4. Install air inlet elbow (7) .

Note: Make sure that ground wire (6) is connected when the bolt is installed.

5. Install bolts (5) in the air inlet manifold.

6. Tighten bolts (5) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).

7. Connect the air inlet hose to the air inlet elbow. Tighten hose clamp (4) .

8. Connect electrical wire (3) to the air inlet heater. Install nut (2) .

9. Install rubber boot (1) on the electrical connector.

10. Close the engine hood.

Finding Top Center Position for No. 1 Piston

Finding Top Center Position for No. 1 Piston

Note: Refer to the Disassembly and Assembly for your machine for the removal of components.

Table 1

Required Tools
Callout	Part Number	Description	Quantity
A	299-9126	Crankshaft Turning Tool	1

1. Remove the valve mechanism cover from the engine.

 

2. Install Tooling (A) on the engine's flywheel housing. Use Tooling (A) in order to rotate the engine. Refer to Illustration 1.

3. Rotate the crankshaft clockwise when you face the front of the engine. Rotate the crankshaft until the pushrod for the inlet valve of the rear cylinder begins to tighten.

4. Rotate the crankshaft further by 1/8 of a turn in a clockwise direction. Insert a suitable lever between the rocker arm and the valve spring cap of the No. 1 inlet valve. Open the inlet valve. Put a spacer that is approximately 5 mm (0.2 inch) thick between the valve stem and the rocker arm.

5. Slowly rotate the crankshaft in a counterclockwise direction until the piston makes contact with the open valve. Make a temporary mark on the damper or the pulley. The temporary make must align accurately with the tip of the pointer.

6. Rotate the crankshaft in a clockwise direction by one or two degrees. Remove the spacer that is between the valve stem and the rocker arm. Rotate the crankshaft by 1/4 of a turn in a counterclockwise direction. Put a spacer that is approximately 5 mm (0.2 inch) thick between the valve stem and the rocker lever of the No. 1 inlet valve.

7. Slowly rotate the crankshaft clockwise until the piston makes contact with the open valve. Make another temporary mark on the damper or the pulley. The temporary mark must align accurately with the tip of the pointer.

8. Make a temporary mark at the center point between the two marks on the damper or the pulley. Remove the other two marks. Rotate the crankshaft by 1/8 of a turn in a counterclockwise direction. Remove the spacer between the valve stem and the rocker arm.

(1) Pointer
(2) Pulley

(3) Top center mark 

(1) Pointer (2) Pulley (3) Top center mark

9. Slowly rotate the crankshaft in a clockwise direction until the mark on the damper of the pulley (2), which was made in Step 8, aligns with the tip of the pointer (1). The No. 1 piston is now at the top center on the compression stroke. Refer to Illustration 2 and Illustration 3.

Systems Operation- Basic Engine

Systems Operation
3064 and 3066 Engines for Caterpillar Built Machines 

Basic Engine

SMCS - 1200

Cylinder Block, Cylinder Liners, and Cylinder Head

The cylinder block has cylinders which are arranged in-line. The crankshaft of the four cylinder engine has five main bearings and the crankshaft of the six cylinder engine has seven main bearings. The thrust bearings on the main bearing journals control the end play of the crankshaft.
A cylinder sleeve is available as a replacement. Replace the cylinder sleeve if a sleeve is worn or if a sleeve is worn in excess of the service limit. Set up a boring bar on the cylinder block. Bore the cylinder sleeve to 0.5 mm (0.02 inch) of the original thickness. Remove the remainder of the cylinder sleeve with a hammer and punch. Install the cylinder sleeve in the bore of the block with the appropriate tooling. Bore the sleeve and hone the sleeve to a diameter of 102.00 to 102.04 mm (4.016 to 4.017 inch).
A cylinder head gasket is used between the plate and the head in order to seal combustion gases, water, and oil.
The engine has a cast cylinder head. An inlet valve and an exhaust valve for each cylinder are controlled by a pushrod valve system.

Pistons, Rings, and Connecting Rods

The cast aluminum piston has three rings: two compression rings and one oil control piston ring. All rings are located above the bore of the piston pin. The two compression rings sit in a cast iron insert.
The oil control piston ring is a standard type and the oil ring is spring loaded. Oil returns to the crankcase through holes in the groove of the oil control piston ring.
The direct injection piston has a full skirt. The direct injection piston uses a special shape on the top surface in order to help combustion efficiency.
The full floating piston pin is retained by two snap rings. The two snap rings fit in grooves in the pin bore.
Piston cooling jets are located on the main webs of the cylinder block. The piston cooling jets direct oil in order to cool the piston components and the cylinder walls. The piston cooling jets also direct oil in order to lubricate the piston components and the cylinder walls.

Crankshaft

The crankshaft changes the combustion forces in the cylinder into usable rotating torque in order to power the machine. Vibration is caused by impacts from combustion along the crankshaft. The vibration forces are minimized by the use of a vibration damper. The vibration damper is located on the front of the crankshaft.
A gear at the front of the crankshaft drives the timing gears. The gear also drives the oil pump.
Pressurized oil is supplied to all bearing surfaces through drilled holes in the crankshaft.
Lip type seals are used on both the front of the crankshaft and the rear of the crankshaft.

Camshaft

The engine has a single camshaft. The camshaft is driven at the front end. Bearings support the camshaft. As the camshaft turns, the camshaft lobes move the valve system components. The valve system components move the cylinder valves. The camshaft gear must be timed to the crankshaft gear. The relationship between the lobes and the camshaft gear causes the valves in each cylinder to open at the correct time. The relationship between the lobes and the camshaft gear also causes the valves in each cylinder to close at the correct time.

Air Cleaner - Remove and Install 318C Excavator3066 Engine

Disassembly and Assembly
318C Excavator3066 Engine Supplement
Media Number -RENR6635-00

    Air Cleaner - Remove and Install

Removal Procedure

 

1. Remove four bolts (2) and the washers in order to remove cover (1) 

  

2. Open the access door (3) on the front left side of the machine

  

3. Unlatch four clamps (4) and remove the air cleaner cover (5) .

  

4. Remove O-ring seal (6) from cover (5) .

5. Remove valve (7) from cover (5) .

 

6. Remove the primary filter element (9) and secondary filter element (10) from the air cleaner housing (8) .

 

7. Disconnect electrical connection (11) from the air cleaner housing (8) 

8. Loosen hose clamp (13) and disconnect air inlet hose (12) .

9. Remove four bolts (14) and washers that hold the air cleaner housing into position.
10. Remove air cleaner housing (8)

11. Loosen fitting in order to remove indicator assembly (15) .

Testing and Adjusting - air systeme

Testing and Adjusting
3064 and 3066 Engines for Caterpillar Built Machines

Air Inlet and Exhaust System - Inspect


There will be a reduction in the horsepower and in the efficiency of the engine if there is a restriction in the air inlet system or in the exhaust system.

Note: A restriction is a negative pressure difference measurement between the atmosphere and the air that has gone through the air cleaner.

The air flow through a used air cleaner element or through a plugged air cleaner element must not have a restriction of more than the following amount: 7.5 kPa (30 inch of water)

The air flow through a new air cleaner element must not have a restriction of more than the following amount: 3.7 kPa (15 inch of water)

Note: Back pressure of the exhaust is the pressure difference that is measured between the pipe at the end of the turbocharger discharge and the atmosphere.

The back pressure from the exhaust must not be more than the following amount: 10.0 kPa (40 inch of water) 4

Turbocharger - Inspect

SMCS - 1052-040

Check the turbocharger under the following conditions:

    Every 7200 hours of usage
    Any unusual noises from the turbocharger
    Any unusual vibrations in the turbocharger

A quick check of a turbocharger bearing's condition can be made without the disassembly of the turbocharger. Follow this procedure for this quick check:

    Remove the piping from the turbocharger.

    Inspect the following components:
        Turbocharger compressor wheel
        Turbocharger turbine wheel
        Compressor cover

    Rotate the assembly of the turbocharger compressor wheel and the turbocharger turbine wheel by hand. Take extra care to feel for any excess end play and for radial clearance.The assembly of the turbocharger compressor wheel and the turbocharger turbine wheel should rotate freely without any rubbing and without any binding.
    If the turbocharger turbine wheel rubs against the compressor cover or the turbine wheel rubs against the turbine housing, the turbocharger needs replacement or repair. For replacement, use a turbocharger that is new, reconditioned, or rebuilt.

    Inlet Manifold Pressure - Test
 
    SMCS - 1058-081
    Inlet Manifold Pressure
    Normal inlet manifold pressure with high exhaust temperature can be caused by blockage in the fins of the aftercooler core assembly. Clean the fins of the aftercooler core assembly.
    Low inlet manifold pressure and high exhaust manifold temperature can be caused by any of the following conditions:
    Plugged air cleaner - Clean the air cleaner, as required. Replace the air cleaner, as required.
    Blockage in the air lines - Blockage in the air lines between the air cleaner and the turbocharger must be removed.
    Aftercooler core leakage - A leak in the aftercooler core should be repaired.
    Leakage of the induction system - Any leakage from the pressure side of the induction system should be repaired.
    Inlet manifold leak - An inlet manifold leak can be caused by any one of the following problems:
    Loose fittings and loose plugs
    Missing fittings and missing plugs
    Damaged fittings and damaged plugs
    The inlet manifold to cylinder head gaskets

Check all of these items, if necessary.

                       

318C EXCAVATOR BTG

318C EXCAVATOR BTG

Service Repair Information (Systems Operation, Testing and Adjusting, Troubleshooting, Specifications, Disassembly and Assembly) 

1-AIR INLET AND EXHAUST SYSTEM  

1-1 systems Operation

3064 and 3066 Engines for Caterpillar Built Machines - SENR5546

Air Inlet and Exhaust System

SMCS - 1050

 

Air Inlet and Exhaust System Schematic

(1) Exhaust manifold
(2) Inlet manifold
(3) Engine cylinder
(4) Air inlet heater
(5) Turbocharger compressor wheel
(6) Turbocharger turbine wheel
(7) Air inlet
(8) Exhaust outlet

(9) Turbocharger 

The components of the air inlet and the components of the exhaust system control the quality of available air for combustion. The components of the air inlet and the components of the exhaust system also control the amount of available air for combustion. The air inlet and the exhaust system consist of the following components:

• Air cleaner
• Inlet manifold
• Cylinder head
• Valves
• Valve components
• Exhaust manifold
• Turbocharger

Turbocharger compressor wheel (5) pulls clean inlet air from the air cleaner through air inlet (7). The rotation of turbocharger compressor wheel (5) causes compression of the air and the rotation of the turbocharger compressor wheel forces the air through inlet manifold (2) to the inlet valves in the cylinder head. The inlet valves control the air flow into each engine cylinder.
There is one inlet and one exhaust valve for each cylinder. Refer to "Valves and Valve System Components". The inlet valves open when the piston moves down on the inlet stroke. Compressed air from inlet manifold (2) is pulled into engine cylinder (3). The inlet valve closes. The piston starts to move up on the compression stroke. When the piston is near the top of the compression stroke, fuel is injected into the engine cylinder. The fuel mixes with the air and combustion begins. The force of combustion pushes the piston downward. The piston is pushed downward on the power stroke. The piston moves up again on the exhaust stroke. The exhaust valve opens and the exhaust gases are pushed through the exhaust port into exhaust manifold (1). After the piston makes the exhaust stroke, the exhaust valve closes and the cycle starts again. The cycle consists of the following items: inlet, compression, power and exhaust.
Exhaust gases from exhaust manifold (1) go into the turbine side of turbocharger (9) and the exhaust gases cause turbocharger turbine wheel (6) to turn. Turbocharger turbine wheel (6) and turbocharger compressor wheel (5) are connected to the same shaft. The exhaust gases travel through the exhaust outlet (8). The exhaust gases travel through the exhaust system.

Turbocharger

Left side view of the 3066 Engine

(1) Turbocharger (2) Exhaust manifold 

Turbocharger (1) is installed on the center of the exhaust manifold (2). All of the exhaust gases from the engine travel through turbocharger (1). The compressor side of turbocharger (1) is connected to the elbow of the air heater of the inlet manifold by a rubber hose. 

Turbocharger


(3) Air inlet
(4) Compressor housing
(5) Compressor wheel
(6) Bearing
(7) Oil inlet port
(8) Bearing
(9) Turbine housing
(10) Turbine wheel
(11) Exhaust outlet
(12) Oil outlet port
(13) Exhaust inlet 

The exhaust gases travel into the turbine housing (9) through exhaust inlet (13). The exhaust gases push the blades of turbocharger turbine wheel (10). Turbocharger turbine wheel (10) and turbocharger compressor wheel (5) have the same shaft.
Clean air from the air cleaners is pulled through the air inlet (3) of the compressor housing by the rotation of the turbocharger compressor wheel (5). The inlet air is compressed by the movement of the blades of the compressor. The compression allows the engine to burn more air and fuel during combustion. The result is greater power for the engine.
More fuel is injected into the cylinders when the load on the engine increases. More exhaust gases are produced and turbocharger turbine wheel (10) and turbocharger compressor wheel (5) of the turbocharger turn faster. More air is forced into the engine as turbocharger compressor wheel (5) turns faster. The engine burns more fuel with greater efficiency because of the increased air flow. More engine power is the result.
The maximum rpm of the turbocharger is controlled by the fuel setting, the high idle speed setting, and the height above sea level of the engine.

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NOTICE

If the fuel setting is higher than given in the TMI (Technical Marketing Information), there can be damage to engine or turbocharger parts. Damage will result when increased heat and/or friction due to the higher engine output goes beyond the engine cooling and lubrication systems abilities. A mechanic that has the proper training is the only one to make the adjustment of fuel setting and high idle rpm setting.

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The fuel setting adjustment is performed at the factory for a specific engine application. The governor housing is sealed in order to prevent changes in the adjustment of the fuel. The governor housing is also sealed in order to prevent changes of the high idle speed setting.
Bearing (6) and bearing (8) of the turbocharger use engine oil under high pressure for lubrication. The oil passes through the oil inlet port (7). The oil then travels through the passages in the center section for the lubrication of the bearings. Oil from the turbocharger travels through the oil outlet port (12) in the bottom of the center suction. The oil then travels back to the engine lubrication system. 

Valves and Valve System Components

The valves and the valve system components control the flow of inlet air into the cylinder during engine operation. The valves and the valve system components also control the flow of exhaust gases out of the cylinder during engine operation.

Valve System Components

(1) Rocker arm
(2) Valve retainer
(3) Valve cap
(4) Adjusting screw
(5) Pushrod
(6) Valve spring
(7) Valve guide (8) Valve 

The inlet and exhaust valves are opened and the inlet and exhaust valves are closed by the movement of the following components: crankshaft, camshaft, tappets, pushrods, rocker arms and valve springs. Rotation of the crankshaft causes rotation of the camshaft. The camshaft gear is timed to a gear on the front of the crankshaft. The camshaft gear is also driven by the gear on the front of the crankshaft. The rotation of the camshaft causes the lobes to rotate. The rotation of the lobes of the camshaft cause the tappets to move. The movement causes pushrod (5) to move rocker arm (1). Movement of rocker arm (1) causes the inlet and exhaust valves to open according to the firing order (injection sequence) of the engine. Valve spring (6) for each valve makes the valve return to the closed position. The valve spring also holds the valve closed.  

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