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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