SENR9518-03 Disassembly and Assembly 3114, 3116 and 3126 Engines S/N 1ZG00001-UP from the Library of Barrington Diesel
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SENR9518-03
Disassembly and Assembly 3114, 3116 and 3126 Engines S/N 1ZG00001-UP
from the Library of Barrington Diesel Club
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
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_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01928280
Fuel Filter Base - Remove and Install SMCS - 1262-010
Removal Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
185-3630
Strap Wrench As
1
Start By: A. Remove the crankcase breather. Refer to Disassembly and Assembly, "Crankcase Breather - Remove and Install".
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.
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_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1 Typical example
g00629777
1. Use Tooling (A) to remove fuel filter (5) . 2. Disconnect tube assemblies (1) and (2) from fuel filter base (4) . 3. Remove bolts (3) from fuel filter base (4) . 4. Remove fuel filter base (4) and the gasket from the engine.
Illustration 2
g00629788
5. Remove fuel pressure relief valve (7) from fuel filter base (4), if necessary.
Installation Procedure 4
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Table 2 Required Tools Tool
Part Number
Part Description
Qty
A
185-3630
Strap Wrench As
1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 3
g00629788
1. Install fuel pressure relief valve (7) on fuel filter base (4) .
5
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 4 Typical example
g00629777
2. Inspect the condition of the gasket. Replace the gasket, if necessary. 3. Position the gasket and fuel filter base (4) on the engine. 4. Install bolts (3) that secure fuel filter base (4) on the engine. 5. Connect tube assemblies (1) and (2) to fuel filter base (4) . 6. Use Tooling (A) to install fuel filter (5) . 7. Install O-ring seal (6) on fuel filter base (4) . End By: Install the crankcase breather. Refer to Disassembly and Assembly, "Crankcase Breather - Remove and Install".
6
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01928293
Fuel Priming Pump and Primary Fuel Filter - Remove and Install SMCS - 1258-010; 1260-010
Removal Procedure 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.
7
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03 Illustration 1
g00678475
1. Disconnect tube assembly (2) from primary fuel filter base (1) .
Illustration 2
g00678476
2. Remove bolts (4) from the fuel priming pump (3) . 3. Remove fuel priming pump (3) from the primary fuel filter base.
Illustration 3
g00678479
4. Remove bolt (5) from the primary fuel filter base. 5. Remove filter element (6) and housing (7) from the primary fuel filter base.
8
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 4
g00773124
6. Remove bolts (8) from the primary fuel filter base (1) . 7. Remove primary fuel filter base (1) from the engine.
Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 5
g00773124
1. Install bolts (8) that secure primary fuel filter base (1) to the engine.
9
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 6
g00678479
2. Install filter element (6) and housing (7) to the primary filter base with bolt (5) .
Illustration 7
g00678476
3. Install bolts (4) that secure fuel priming pump (3) to the primary fuel filter base.
Illustration 8
g00678475
4. Connect tube assembly (2) to primary fuel filter base (1) .
10
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01928670
Fuel Transfer Pump - Remove SMCS - 1256-011
Removal Procedure Note: The governor and the fuel transfer pump have been removed from the engine for photographic purposes only. This procedure may be done with the governor on the engine.
Illustration 1
g00623633
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_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 2
g00623671
Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened. 1. Hold cover (1) in place and remove bolts (2) in order to release the spring beneath cover (1). Remove cover (1) .
Illustration 3
g00623686
2. Remove fitting (3) and the check valve from cover (1). Remove the filter screen (if equipped) from fitting (3) . 12
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 4
g00623687
3. Remove spring (4) and piston (5) . 4. Remove upper O-ring seal (6) .
Illustration 5
g00623714
5. Remove sleeve assembly (7). Inspect the face of lifter (8) for excessive wear. Inspect the surface of the camshaft that is inside of the governor for excessive wear or damage. 6. Remove lower O-ring seal (9) .
Illustration 6
g00623719
7. Remove fitting (10) and the check valve. 13
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Note: For information on reusability of the components in the fuel transfer pump, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8434, "3100 Governor Inspection and General Information for Mechanical Governor Groups Used in 3114, 3116, and 3126 Engines Equipped with Mechanical Unit Injectors (MUI)".
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_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01928343
Fuel Transfer Pump - Install SMCS - 1256-012
Installation Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
8T-2998
Lubricant
1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Note: For information on reusability of the components in the fuel transfer pump, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8434, "3100 Governor Inspection and General Information for Mechanical Governor Groups Used in 3114, 3116, and 3126 Engines Equipped with Mechanical Unit Injectors (MUI)".
Illustration 1
g00623719
1. Lubricate fitting (10) and the bore with clean engine oil. Install the check valve and fitting (10) . 15
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 2
g00623714
2. Inspect the condition of the O-ring seal. Replace the O-ring seal, if necessary. Install lower O-ring seal (9) . 3. Apply Tooling (A) on the face of lifter (8). Install sleeve assembly (7). Ensure that the flat on the sleeve aligns with the flat in the bore of the housing.
Illustration 3
g00623687
4. Lubricate piston (5) with clean engine oil. Install piston (5) and spring (4) .
Illustration 4
g00623686
5. Lubricate fitting (3) and the bore for the check valve with clean engine oil. Install the check valve with the sealing face toward the fitting. 16
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
6. Install the O-ring seal and fitting (3) .
Illustration 5
Illustration 6
g00623671
g00623633
Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment. 7. Place cover (1) over spring (4). Install bolts (2) in order to compress spring (4) . 17
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01928366
Fuel Shutoff Solenoid - Remove and Install SMCS - 1259-010
Removal Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
9U-5120
Spanner Wrench (1)
1
(1)
This tool is part of the 128-8822 Fuel System and Governor Tool Group .
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.
18
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
g00585831
1. Disconnect the harness assembly (2) from fuel shutoff solenoid (1) . 2. Use Tooling (A) to remove the fuel shutoff solenoid from the governor. 3. Remove the O-ring seal from the shutoff solenoid .
Installation Procedure Table 2 Required Tools Tool
Part Number
Part Description
Qty
A
9U-5120
Spanner Wrench (1)
1
(1)
This tool is part of the 128-8822 Fuel System and Governor Tool Group .
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.
19
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 2
g00585831
1. Inspect the O-ring seal on the fuel shutoff solenoid. If the O-ring seal is worn or damaged, use new parts for replacement. 2. Install the O-ring seal on the fuel shutoff solenoid. 3. Install the fuel shutoff solenoid in the governor. Use Tooling (A) and a suitable torque wrench to tighten the fuel shutoff solenoid to the following torque 30 ± 5 N·m (22 ± 4 lb ft). 4. Connect the harness assembly to the fuel shutoff solenoid.
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_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01928381
Governor - Remove SMCS - 1264-011
Removal Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
136-4149
Governor Pliers (1)
1
(1)
This tool is part of the 128-8822 Fuel System and Governor Tool Group .
Start By: A. Remove the fuel shutoff solenoid. Refer to Disassembly and Assembly, "Fuel Shutoff Solenoid - Remove and Install".
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.
21
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
g00613041
1. Disconnect the governor control cable. 2. Remove oil tube assembly (1). Remove tube assembly (2) and tube assembly for fuel ratio control (3), if equipped. Plug and cap all connections.
Illustration 2
g00613071
3. Remove clip (4) .
Illustration 3
g00655975 22
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
4. Use Tooling (A) to slide tube assembly (5) into the cylinder head.
Illustration 4
g00613149
5. Remove the clip and use Tooling (A) to remove the clevis pin (6) . Note: Clevis pin (6) must stay with the governor in order to be adjusted.
Illustration 5
g00613563
6. Remove bolts (7) and the washers that hold the governor in position.
Illustration 6
g00673182
7. Remove the governor from the engine. 23
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 7
g00673180
8. Remove O-ring seal (3) on the governor.
Illustration 8
g00672742
9. Remove the O-ring seal and tube assembly (5) from the cylinder head.
Illustration 9
g00672733
10. Remove O-ring seal (2) on the tube assembly (5) .
24
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 10
g00673178
11. Remove O-ring seal (1) from the cylinder head. Note: For more information on the governor, refer to Service Manual, SENR6454, "3114, 3116, & 3126 Engine Governors". The Service Manual, SENR6454 requires the use of a 1U-7326 Governor Calibration Bench. For information on reusability of components in the governor, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8434, "3100 Governor Inspection and General Information for Mechanical Governor Groups Used in 3114, 3116, and 3126 Engines Equipped with Mechanical Unit Injectors (MUI)".
25
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01928419
Governor - Install SMCS - 1264-012
Installation Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
136-4149
Governor Pliers (1)
1
128-8827
Pin (1)
1
Pin Pilot (1)
1
B 1U-7523 (1)
This tool is part of the 128-8822 Governor Tool Group .
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Note: For more information on the governor, refer to Service Manual, SENR6454, "3114, 3116, & 3126 Engine Governors". The Service Manual, SENR6454 requires the use of a 1U-7326 Governor Calibration Bench. For information on reusability of components in the governor, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8434, "3100 Governor Inspection and General Information for Mechanical Governor Groups Used in 3114, 3116, and 3126 Engines Equipped with Mechanical Unit Injectors (MUI)".
26
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
g00673178
1. Apply lubricant to the new O-ring seal (1). Install new O-ring seal (1) in the cylinder head.
Illustration 2
g00672733
2. Apply lubricant to the new O-ring seal (2). Install new O-ring seal (2) on the tube assembly (5) .
Illustration 3
g00672742
3. Install the O-ring seal and tube assembly (5) in the cylinder head.
27
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 4
g00673180
4. Apply lubricant to the new O-ring seal (3). Install new O-ring seal (3) on the governor.
Illustration 5
g00673182
5. Place the governor in position on the engine.
Illustration 6
g00613563
6. Install the washers and bolts (7) that hold the governor in place.
28
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 7
g00672755
7. Install clevis pin (6) in Tooling (B) .
Illustration 8
g00672752
8. Use Tooling (B) to install clevis pin (6) and the clip. 9. Check the fuel setting adjustment. Refer to Testing and Adjusting, SENR5118.
Illustration 9
g00655975
29
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
10. Use Tooling (A) to slide tube assembly (5) into the governor.
Illustration 10
g00613071
11. Install clip (4) .
Illustration 11
g00613041
12. Install oil tube assembly (1). Install tube assembly (2) and tube assembly for fuel ratio control (3), if equipped. Plug and cap all connections. 13. Install the governor control cable. End By: Install the fuel shutoff solenoid. Refer to Disassembly and Assembly, "Fuel Shutoff Solenoid - Remove and Install".
30
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01928445
Fuel Injection Control Linkage - Remove SMCS - 1298-011
Removal Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
136-4149
Governor Pliers
1
Start By: A. Remove the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod Remove".
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 1
g00613071
1. Remove clip (4). Clip (4) is located between the governor and the cylinder head. 31
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 2
g00655975
2. Use Tooling (A) to slide tube assembly (5) into the cylinder head.
Illustration 3
g00613149
3. Remove the clip and use Tooling (A) to remove the clevis pin (6). Clevis pin (6) connects the governor to the control lever of the fuel injection control linkage. Note: Clevis pin (6) must stay with the governor in order to be adjusted.
32
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 4
g00630566
4. Remove bolts (1) and remove fuel injection control linkage (2). Control lever (3) connects the fuel injection control linkage (2) to the governor. Note: For information on the inspection procedure for control lever (3), refer to Special Instruction, REHS0601, "Inspection and Modification of the 102-7459 Fuel Injection Control Linkage and the 4P-9048 Fuel Injection Control Linkage".
33
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01928573
Fuel Injection Control Linkage - Install SMCS - 1298-012
Installation Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
136-4149
Governor Pliers (1)
1
128-8827
Pin (1)
1
Pin Pilot (1)
1
B 1U-7523 C
1U-6675
Spring Compressor (1)
6
D
128-8822
Fuel System and Governor Tool Gp
1
(1)
This tool is part of the 128-8822 Governor Tool Group .
Illustration 1
g00661331
Note: For information on the inspection procedure for control lever (3), refer to Special Instruction, 34
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
REHS0601, "Inspection and Modification of the 102-7459 Fuel Injection Control Linkage and the 4P-9048 Fuel Injection Control Linkage". 1. Loosen setscrews (4) on each bracket. 2. Install fuel control linkage (2) and install bolts (1). Use the following sequence in order to tighten the bolts. 3. Tighten bracket (A) and (D) to a torque of 12 ± 3 N·m (106 ± 27 lb in). 4. Tighten brackets (B) and (C) to a torque of 12 ± 3 N·m (106 ± 27 lb in). 5. Position brackets (B) and (C) in order to allow free rotation of the fuel control rod. 6. Use a 2.5 mm (0.10 inch) wrench to tighten setscrews (4). Tighten the setscrews to a torque of 3.5 ± 0.2 N·m (31 ± 2 lb in). Do not overtighten the setscrews. Ensure that the control rod rotates freely. 7. The control rod should rotate freely when a force of 4.4 N (1 lb) or less is applied to control lever (3) .
Illustration 2
g00750163
8. Rotate the unit injectors in order to engage the injector rack bar (5) with the fuel injection control linkage (2) . Note: If the unit injectors are not installed, refer to the Disassembly and Assembly, "Unit Injector - Install". 9. Install Tooling (C) on the unit injectors and compress the springs. Note: For the procedure to install Tooling (C), refer to Tool Operating Manual, NEHS0610, "Using the 1288822 Tool Group on 3114, 3116, and 3126 Engines with Mechanical Unit Injectors (MUI)".
35
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 3
g00672755
10. Install clevis pin (6) in Tooling (B). Clevis pin (6) attaches the control lever (3) to the governor.
Illustration 4
g00672752
11. Use Tooling (B) to install clevis pin (6) and the clip. 12. Use Tooling (D) to set the unit injector synchronization. Note: For the procedure to use Tooling (D), refer to Tool Operating Manual, NEHS0610, "Using the 128-8822 Tool Group on 3114, 3116, and 3126 Engines with Mechanical Unit Injectors (MUI)". 13. Remove Tooling (C) from the unit injectors.
36
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 5
g00655975
14. Use Tooling (A) to slide tube assembly (5) into the governor.
Illustration 6
g00613071
15. Install clip (4) . End By: Install the rocker arm assemblies and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Install".
37
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i02834896
Unit Injector - Remove SMCS - 1290-011
Removal Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
5P-0302
Bar
1
Start By: A. Remove the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod 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 Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.
Note: For determining the ability to reuse a unit injector, refer to Special Instruction, SEHS9787, "Test Procedure For Caterpillar 3114, 3116 And 3126 Mechanical Unit Injectors". 38
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
Illustration 2
g00775441
g00625237
1. Remove fuel injector hold-down bolt (1) . Note: Do not pry on the injector hold-down bracket. Damage to the unit injector could occur. The unit injector has a notch on the opposite side of the rack. This notch is used for prying the unit injector loose. Some fuel injector racks move freely when the spring is not compressed. Do not move the fuel injector rack without compressing the fuel injector spring slightly. Damage may occur to the unit injector. 2. Use Tooling (A) to loosen the unit injector. Rotate the unit injector in order to disengage injector rack bar (3) from fuel injection control linkage (2) . 3. Remove the unit injector. Ensure that two O-ring seals are on the unit injector.
39
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i02834915
Unit Injector - Install SMCS - 1290-012
Installation Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
B
4C-5553
Injector Seat Cleaning Brush
1
C
173-1530
Injector Seating Tool
1
D
143-2099
Unit Injector Tool Group (Sleeve Replacement)
1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Note: For determining the ability to reuse a unit injector, refer to Special Instruction, SEHS9787, "Test Procedure For Caterpillar 3114, 3116 And 3126 Mechanical Unit Injectors". 1. Inspect the unit injector sleeve for pitting and for carbon tracking. Used unit injector sleeves do not need to be reamed unless the seated area is pitted or eroded. If the seated area has excessive carbon deposits, the used unit injector sleeves need to be reamed. Refer to Tool Operating Manual, NEHS0675, "Using the 143-2099 Sleeve Replacement Tool Group on 3114, 3116, and 3126 Engines". Use Tooling (D) to ream injector sleeves. 2. Inspect the condition of the O-ring seals on the unit injector. Replace the seals, if necessary. 3. Lubricate the O-ring seals with clean engine oil.
40
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
g00775441
4. Position the unit injector in the cylinder head and rotate the unit injector in order to engage injector rack bar (3) with fuel injection control linkage (2) . Push down on the unit injector and ensure that the unit injector is properly seated in the cylinder head. Note: Do not use fuel injector hold-down bolt (1) to pull the unit injector into the cylinder head. 5. Install a new fuel injector hold-down bolt (1) in the hold-down bracket for the unit injector. Tighten fuel injector hold-down bolt (1) to a torque of 12 ± 3 N·m (106 ± 27 lb in). Note: Do not overtighten fuel injector hold-down bolt (1) . Excessive torque may cause damage to the unit injector and the unit injector may seize. 6. Refer to the Tool Operating Manual, NEHS0738, "Using the 173-1530 Injector Seating Tool Group on 3114, 3116, and 3126 MUI or 3126 HEUI 2-Valve Engines" for the remaining steps on installing the unit injector. End By: a. Install the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod Install". b. Synchronize the unit injectors. Refer to Testing and Adjusting, "Unit Injector Synchronization - Adjust".
41
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01928597
Unit Injector Sleeve - Remove SMCS - 1713-011
Removal Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
143-2099
Unit Injector Tool Group
1
Start By: A. Remove the unit injector. Refer to Disassembly and Assembly, "Unit Injector - 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.
42
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
g00627676
1. Use Tooling (A) to remove unit injector sleeve (1) from the cylinder head. Refer to Tool Operating Manual, NEHS0675, "Using the 143-2099 Sleeve Replacement Tool Group on 3114, 3116, and 3126 Engines" for the correct procedure.
43
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01928606
Unit Injector Sleeve - Install SMCS - 1713-012
Installation Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
143-2099
Unit Injector Tool Group
1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
44
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
g00627676
1. Inspect the condition of the existing sleeve and ream out the existing sleeve, if necessary. When you are replacing the existing injector sleeve, use a new brass sleeve. It is not necessary to ream the new brass sleeves. Use Tooling (A) to install unit injector sleeve (1) into the cylinder head. Refer to Tool Operating Manual, NEHS0675, "Using the 143-2099 Sleeve Replacement Tool Group on 3114, 3116, and 3126 Engines" for the correct procedure. End By: Install the unit injector. Refer to Disassembly and Assembly, "Unit Injector - Install".
45
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01928645
Turbocharger - Remove SMCS - 1052-011
Removal Procedure 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.
Note: For information on the reusability of components of the turbocharger, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8018, "Turbochargers". For information on the salvage of components of the turbocharger, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8071, "Procedures to Salvage Turbocharger Components".
46
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
g00617515
Illustration 2
g00617565
1. Disconnect oil supply tube assembly (5) from turbocharger (6) . 2. Remove bolts (1) and disconnect oil drain tube assembly (2) from turbocharger (6) . 3. Remove bolts (3) . 4. Remove locknuts (4) . 5. Remove turbocharger (6) and the gasket from the exhaust manifold. Note: Place index marks on the turbocharger cartridge and the housing. 6. Remove the end housing from the cartridge. Note: The wastegate is part of the turbine housing and the wastegate is preset at the factory. The wastegate is nonserviceable.
47
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01928659
Turbocharger - Install SMCS - 1052-012
Installation Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
5P-3931
Anti-Seize Compound
1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Note: For information on the reusability of components of the turbocharger, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8018, "Turbochargers". For information on the salvage of components of the turbocharger, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8071, "Procedures to Salvage Turbocharger Components". 1. Inspect the turbocharger gasket for wear or damage. If the turbocharger gasket is worn or damaged, use a new part for replacement. 2. Apply Tooling (A) on the threads of the mounting studs for the turbocharger.
48
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
g00617565
3. Position the turbocharger gasket and turbocharger (6) on the exhaust manifold. Install nuts (4) and tighten nuts (4) to a torque of 54 ± 5 N·m (40 ± 4 lb ft).
Illustration 2
g00617515
4. Inspect the gaskets for oil supply tube assembly (5) and oil drain tube assembly (2). If the gaskets are worn or damaged, use a new part for replacement. 5. Position oil drain tube assembly (2) and the gasket on turbocharger (6). Install bolts (1) on the turbocharger and install bolts (3) on the cylinder block. 6. Install the gasket for oil supply tube assembly (5) and connect oil supply tube assembly (5) to turbocharger (6) .
49
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01928788
Exhaust Manifold - Remove and Install SMCS - 1059-010
Removal Procedure Start By: A. Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove".
Illustration 1 Typical example
g00652578
1. Remove bolts (1), exhaust manifold (2), locks and the gaskets from the cylinder head assembly. 2. If the engine is equipped with a three-piece exhaust manifold, disassemble exhaust manifold (2) into three pieces. 3. Remove mounting studs (3) from exhaust manifold (2), if necessary.
Installation Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
5P-3931
Anti-Seize Compound
1 50
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
B
2P-2333
High Temperature Sealer
Illustration 2 Typical example
1
g00652578
1. Apply Tooling (A) to the threads of mounting studs (3) . 2. Install mounting studs (3). Tighten mounting studs (3) to a torque of 35 ± 5 N·m (26 ± 4 lb ft). 3. If the engine is equipped with a three-piece exhaust manifold, apply a thin coat of Tooling (B) to the male ends of exhaust manifold (2). Coat the inside of the female ends of exhaust manifold (2) with clean engine oil. Assemble exhaust manifold (2) and remove the excess sealant from the joints. 4. Install new exhaust manifold gaskets. 5. Apply Tooling (A) to the threads of bolts (1). Position the gaskets and exhaust manifold (2) on the cylinder head assembly. Install locks and bolts (1) .
Illustration 3 Typical example of a three-piece exhaust manifold
g00617739
51
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 4 Exhaust manifold for a Four cylinder engine
g00641026
Illustration 5 Water cooled exhaust manifold
g00641092
6. Tighten bolts (1) in a numerical sequence to a torque of 4 ± 1 N·m (35 ± 9 lb in). 7. Tighten bolts (1) in a numerical sequence to a torque of 45 ± 5 N·m (33 ± 4 lb ft).
52
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 6 Typical example of locking tabs
g00675760
8. Bend the locking tabs (4) over the flat of each bolt head. End By: Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Install".
53
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01328419
Inlet Manifold - Remove SMCS - 1058-011
Removal Procedure Start By: A. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install".
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. Disconnect air inlet piping from the turbocharger to the aftercooler, if necessary.
54
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
g00629952
2. Remove bolts (1) and disconnect air inlet heater solenoid (3) . 3. Remove air inlet elbows (2) from air inlet manifold (5) . 4. Remove bolts (4) from air inlet manifold (5) . 5. Remove air inlet manifold (5) and the gasket.
55
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01414226
Inlet Manifold - Install SMCS - 1058-012
Installation Procedure 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.
56
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03 Illustration 1
g00675794
1. Install a new gasket (6) on the cylinder head.
Illustration 2
g00629952
2. Position the air inlet manifold (5) on the engine. 3. Install bolts (4). Tighten the bolts to a torque of 28 ± 7 N·m (21 ± 5 lb ft). 4. Install air inlet elbows (2) on air inlet manifold (5) . 5. Install bolts (1) and connect air inlet heater solenoid (3) . End By: Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover Remove and Install".
57
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01943334
Inlet and Exhaust Valves - Remove and Install SMCS - 1105-010
Removal Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
5S-1330
Valve Spring Compressor
1
Start By: A. Remove the cylinder head assembly. Refer to Disassembly and Assembly, "Cylinder Head - Remove".
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Note: For information on the reusability of the inlet valves, the exhaust valves and the springs, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8002, "Valves, Valve Springs, Valve Rotators, and Locks", Guideline For Reusable Parts And Salvage Operations, SEBF8034, "Valve and Valve Spring Specifications", and Guideline For Reusable Parts And Salvage Operations, SEBF8162, "Specifications to Measure and Salvage Cylinder Head Assemblies and Related Components".
58
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
g01011225
Note: The following components of the exhaust valves are different from the components of the inlet valves: spring retainer (2), valve spring (3) and valve (5).
Illustration 2
g01011269
1. Use Tooling (A) to compress valve spring (3). Remove retainer lock (1) . 2. Remove Tooling (A) . 3. Remove spring retainer (2). Remove valve spring (3) . 4. Remove valve seal (4) and valve (5) . 5. Repeat Steps 1 through 4 in order to remove the remaining inlet valves and exhaust valves.
Installation Procedure 59
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Table 2 Required Tools Tool
Part Number
Part Description
Qty
A
5S-1330
Valve Spring Compressor
1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Note: For information on the reusability of the inlet valves, the exhaust valves and the springs, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8002, "Valves, Valve Springs, Valve Rotators, and Locks", Guideline For Reusable Parts And Salvage Operations, SEBF8034, "Valve and Valve Spring Specifications", and Guideline For Reusable Parts And Salvage Operations, SEBF8162, "Specifications to Measure and Salvage Cylinder Head Assemblies and Related Components".
Illustration 3
g01011225
1. Lubricate valve (5) with clean engine oil. Install valve (5) in the cylinder head assembly. Install new valve seal (4) against the valve guide. 2. Place the following items on the valve stem: valve spring (3) and spring retainer (2) .
60
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
The valve keepers can be thrown from the valve when the valve spring compressor is released. Ensure that the valve keepers are properly installed on the valve stem. To help prevent personal injury, keep away from the front of the valve keepers and valve springs during the installation of the valves. Note: A small amount of grease can be used to hold retainer locks (1) in position during installation.
Illustration 4
g01011269
3. Use Tooling (A) to compress valve spring (3). Install retainer lock (1) . 4. Repeat Steps 1 through 3 in order to install the remaining inlet valves and exhaust valves. End By: Install the cylinder head assembly. Refer to Disassembly and Assembly, "Cylinder Head - Install".
61
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01961680
Inlet and Exhaust Valve Guides - Remove and Install SMCS - 1104-010
Removal Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
1U-7793
Valve Guide Driver (1)
1
(1)
Part of 1U-6685 Valve Guide Tool Kit
Start By: A. Remove the inlet and exhaust valves. Refer to Disassembly and Assembly, "Inlet and Exhaust Valves - Remove and Install".
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Note: For information on the reusability of the valve guides, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8218, "Specifications for Cylinder Head Asseblies 3114, 3116, and 3126 Engines" and Guideline For Reusable Parts And Salvage Operations, SEBF8162, "Procedure to Measure and Salvage Cylinder Head Assemblies and Related Components".
62
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1 Typical example
g00745735
1. Use Tooling (A) to remove the inlet valve guides from the cylinder head assembly. Use Tooling (A) to remove the exhaust valve guides from the cylinder head assembly.
Installation Procedure Table 2 Required Tools Tool
Part Number
Part Description
Qty
A
1U-7793
Valve Guide Driver (1)
1
B
1U-7792
Guide Collar (1)
1
C
9U-6895
Valve Guide Driver
1
D
149-4008
Guide Collar
1
(1)
Part of 1U-6685 Valve Guide Tool Kit
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Note: For information on the reusability of the valve guides, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8218, "Specifications for Cylinder Head Assemblies 3114, 3116, and 3126 Engines" and Guideline For Reusable Parts And Salvage Operations, SEBF8162, "Procedure to Measure and Salvage Cylinder Head Assemblies and Related Components".
63
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 2 Typical example
g00745782
1. Position inlet valve guide (1) and tap on the top of inlet valve guide (1). This is done in order to start inlet valve guide (1) into the cylinder head assembly. 2. Use Tooling (A) and Tooling (B) to install inlet valve guide (1). Install inlet valve guides (1) until tooling (B) contacts the cylinder head.
Illustration 3 Typical example
g00745672
3. Position exhaust valve guide (2) and tap on the top of exhaust valve guide (2). This is done in order to start the exhaust valve guide into the cylinder head assembly. Note: Some of the early engines have inlet valves and exhaust valves that are identical in size. Use the same specifications and the same tools for both valves. Proceed to Step 4 if the valves are not the same size. 4. Use Tooling (C) and Tooling (D) to install exhaust valve guide (2). Install inlet valve guides (2) until tooling (D) contacts the cylinder head. 64
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
End By: Install the inlet and exhaust valves. Refer to Disassembly and Assembly, "Inlet and Exhaust Valves Remove and Install".
65
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01929146
Inlet and Exhaust Valve Seat Inserts - Remove and Install SMCS - 1103-010
Removal Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A (1)
6V-4194
Valve Seat Extractor
1
B (1)
165-5647
Valve Seat Extractor
1
C (1)
6V-4804
Handle
1
D (1)
6V-4192
Threaded Shaft
1
E (1)
6V-4199
Lifting Bracket
1
(1)
Part of the 166-7441 Valve Seat Extractor Tool
Start By: A. Remove the inlet and exhaust valves. Refer to Disassembly and Assembly, "Inlet and Exhaust Valves - Remove and Install".
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Note: For information on the reusability of the valve seats, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8218, "Specifications for Cylinder Head Assemblies 3114, 3116, and 3126 Engines".
66
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
Illustration 2
g00615519
g00656459
Note: Replace Tooling (A) with Tooling (B) for the removal of the inlet valve seat insert. 1. Install Tooling (A) in the exhaust valve seat insert. 2. Install Tooling (C) and Tooling (D) in Tooling (A). Hand tighten Tooling (D). Tooling (A) will expand below the edge of valve seat insert (1) .
67
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 3
g00656462
3. Install Tooling (E) on the cylinder head under Tooling (C). Hold Tooling (D) while you turn Tooling (C). Remove valve seat insert (1) .
Installation Procedure Table 2 Required Tools Tool
Part Number
Part Description
Qty
F
1U-6685
Guide and Insert Tool Group
1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Note: For information on the reusability of the valve seats, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8218, "Specifications for Cylinder Head Assemblies 3114, 3116, and 3126 Engines". 1. Cool the valve seat inserts for easier installation.
68
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 4
g01003799
2. Turn Tooling (F) upside-down and use Tooling (F) and a press to install the valve seat inserts in the cylinder head assembly. 3. After the valve seat inserts are installed, grind the inserts to the final specification. Refer to Guideline for Reusable Parts and Salvage Operation, SEBF8218, "Specifications for Cylinder Head Assemblies 3114, 3116, and 3126 Engines" for the specifications. End By: Install the inlet valves and exhaust valves. Refer to Disassembly and Assembly, "Inlet and Exhaust Valves Remove and Install".
69
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01929163
Engine Oil Filter Base - Remove SMCS - 1306-011
Removal Procedure Table 1 Required Tools Tool
Part Number
A
185-3630
Part Description Strap Wrench
Qty 1
Start By: A. 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.
70
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
g01009468
1. Use Tooling (A) to remove engine oil filter (3) . 2. Disconnect the tube assembly for the turbocharger inlet (1) from the engine oil filter base (4) . 3. Remove bolts (2) and the washers that hold engine oil filter base (4) to the cylinder block. 4. Remove engine oil filter base (4) and the gasket.
71
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01929612
Engine Oil Filter Base - Disassemble SMCS - 1306-015
Disassembly Procedure Start By: A. Remove the engine oil filter base. Refer to Disassembly and Assembly, "Engine Oil Filter Base - Remove".
Illustration 1
g01011623
Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. 1. Remove plugs (1) and (3) from oil filter base (2) .
72
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 2
g01011627
2. Remove springs (4) and valves (6). Remove O-ring seals (5) from plugs (1) and (3). Inspect the parts for wear or damage. If the parts are worn or damaged, use new parts for replacement.
73
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01929615
Engine Oil Filter Base - Assemble SMCS - 1306-016
Assembly Procedure
Illustration 1
g01011627
1. Install O-ring seals (5) onto plugs (1) and (3). Install valves (6) and springs (4) .
Illustration 2
g01011623
74
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment. 2. Install plugs (1) and (3) onto oil filter base (2) . End By: Install the engine oil filter base. Refer to Disassembly and Assembly, "Engine Oil Filter Base - Install".
75
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i02376426
Engine Oil Filter Base - Install SMCS - 1306-012
Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 1
g01009468
76
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 2
Illustration 3
g01185803
g00676791
1. Position the gasket and engine oil filter base (4) on the cylinder block. 2. Install the washers and bolts (2) that hold engine oil filter base (4) to the cylinder block. Tighten the bolts according to the following procedure: a. Tighten Bolt (1) through Bolt (15) in a numerical sequence to a torque of 15 N·m (11 lb ft). b. Tighten Bolt (1) through Bolt (15) in a numerical sequence to a torque of 28 N·m (21 lb ft). 3. Apply lubricant to new O-ring seal (5) . Install O-ring seal (5) in the fitting on the engine oil filter base. 4. Connect tube assembly (1) to engine oil filter base (4) . Note: Never install an oil filter with a wrench. Follow the instructions on the oil filter. 5. Put a coat of fresh oil on the O-ring seal for the engine oil filter. Install engine oil filter (3) on engine oil filter base (4) by hand. 6. After the O-ring seal contacts engine oil filter base (4) , turn engine oil filter (3) for 3/4 of a turn. End By: Install the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Install".
77
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01943853
Engine Oil Filter Bypass Valve - Remove and Install SMCS - 1308-010-BV
Removal Procedure 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.
78
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03 Illustration 1
g00630032
Illustration 2
g00629985
Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. 1. Remove plug (1) and the O-ring seal from the engine oil filter base. 2. Remove valve spring (2) and bypass valve (3) from the engine oil filter base.
Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 3
g00630032
79
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 4
g00629985
Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment. 1. Inspect the condition of the O-ring seal. Replace the seal, if necessary. 2. Install bypass valve (3) and valve spring (2) in the engine oil filter base. 3. Install plug (1) in the engine oil filter base.
80
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01944039
Engine Oil Cooler Bypass Valve - Remove and Install SMCS - 1314-010
Removal Procedure 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.
81
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03 Illustration 1
g00629979
Illustration 2
g00629985
Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. 1. Remove plug (1) and the O-ring seal from the engine oil cooler. 2. Remove valve spring (2) and bypass valve (3) from the engine oil cooler.
Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 3
g00629985
82
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 4
g00629979
Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment. 1. Inspect the condition of the O-ring seal. Replace the seal, if necessary. 2. Install bypass valve (3) and valve spring (2) in the engine oil cooler. 3. Install plug (1) in the engine oil cooler.
83
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01929226
Engine Oil Cooler - Remove SMCS - 1378-011
Removal Procedure Start By: A. Remove the engine oil filter base. Refer to Disassembly and Assembly, "Engine Oil Filter Base - 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.
Note: For information on the reusability of the engine oil cooler, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8077, "Engine Oil Coolers".
84
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
g00677082
1. Remove engine oil cooler (1) and the gasket.
Illustration 2
g00677084
2. Remove O-ring seals (2) .
85
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01929231
Engine Oil Cooler - Install SMCS - 1378-012
Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Note: For information on the reusability of the engine oil cooler, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8077, "Engine Oil Coolers".
Illustration 1
g00677084
1. Install new O-ring seals (2) .
86
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 2
g00677107
2. Install new gasket (3) on the engine oil cooler (1) .
Illustration 3
g00677082
Note: Installation can be simplified by the use of guide bolts. 3. Install the gasket and engine oil cooler (1) . End By: Install the engine oil filter base. Refer to Disassembly and Assembly, "Engine Oil Filter Base - Install".
87
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01929340
Engine Oil Pump - Remove SMCS - 1304-011
Removal Procedure Start By: A. Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".
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.
Note: For information on the reusability of the engine oil pump, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8167, "Reconditioning Procedures 3114 and 3116 Engines".
88
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
g00894501
1. Remove bolts (1) and bolt (2) . 2. Remove engine oil pump (3) . 3. Remove the O-ring seal that is located between the cylinder block and the outlet elbow.
89
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01944046
Engine Oil Pump - Disassemble SMCS - 1304-015
Disassembly Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
1P-0510
Driver Gp
1
B
1P-2320
Combination Puller
1
Start By: A. Remove the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - 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.
Note: For information on the reusability of the engine oil pump, refer to Guideline For Reusable Parts And Salvage 90
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Operations, SEBF8167, "Reconditioning Procedures 3114 and 3116 Engines".
Illustration 1
g00614664
1. Remove the bolts from tube assembly for the pickup of oil (2), and the gasket from the engine oil pump. Remove the bolt and outlet elbow (1) from the engine oil pump.
Illustration 2
g00614677
2. Remove bolt (3), washer (4), and idler gear (5) from the engine oil pump.
Illustration 3
g00614683
3. Use Tooling (A) and a suitable press in order to remove the bearing from idler gear (5) . 4. Remove shaft (6) of engine oil pump from oil pump body assembly (7) . 91
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
5. Use Tooling (B) to remove drive gear (8) .
Illustration 4
g00614689
6. Remove bolts (10). Separate oil pump body (9) from oil pump body assembly (7) .
Illustration 5
g00614694
NOTICE Before removing the drive shaft from the pump housing, be sure that no burrs exist on the drive shaft. If the drive shaft has burrs on it, the bores in the pump housing may be scratched.
7. Remove shaft assembly (11) and shaft assembly (12) from oil pump body (9) .
92
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 6
g00824021
Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened. 8. Remove the following items from oil pump body assembly (7) : the bolt and the washer, spring (14) and oil pressure relief plunger (13)
93
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01944064
Engine Oil Pump - Assemble SMCS - 1304-016
Assembly Procedure Table 1 Required Tools Tool
Part Number
A
1P-0510
Part Description Driver Gp
Qty 1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Note: For information on the reusability of the engine oil pump, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8167, "Reconditioning Procedures 3114 and 3116 Engines". 1. Ensure that all of the parts of the engine oil pump are thoroughly clean prior to assembly. Note: Lubricate all internal parts of the engine oil pump with clean engine oil.
Illustration 1
g00824021
94
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment. 2. Install oil pressure relief plunger (13) and spring (14) in oil pump body assembly (7). Install the washer and the bolt.
Illustration 2
g00614694
Illustration 3
g00614689
3. Install shaft assembly (12) in oil pump body (9) . 4. Install shaft assembly (11) in oil pump body (9) . 5. Position oil pump body (9) on oil pump body assembly (7) and install bolts (10) .
95
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 4
g00614683
6. Press drive gear (8) on shaft assembly (11) until drive gear (8) is flush with the end of shaft assembly (11) . 7. Install oil pump shaft (6). Install the bearing in idler gear (5) with Tooling (A). Install the bearing so the distance between the hub bolt face of idler gear (5) and the bearing is 0.75 ± 0.25 mm (0.030 ± 0.010 inch).
Illustration 5
g00614677
8. Install idler gear (5) on oil pump shaft (6). Install washer (4) and bolt (3). Tighten bolt (3) to 70 ± 15 N·m (52 ± 11 lb ft).
Illustration 6
g00614664
9. Check the condition of the gasket that is used in tube assembly for the pickup of oil (2). If the gasket is damaged, replace the gasket. Install the gasket and tube assembly for the pickup of oil (2) . 10. Check the condition of the O-ring seal that is used in outlet elbow (1). If the O-ring seal is damaged, replace the 96
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
O-ring seal. Install the O-ring seal and outlet elbow (1) . End By: Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Install".
97
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01981031
Engine Oil Pump - Install SMCS - 1304-012
Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Note: Ensure that the mounting surfaces for the engine oil pump are thoroughly clean.
Illustration 1
g01029320
98
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
1. Install the O-ring seal. Position engine oil pump (3) on the cylinder block. 2. Install bolts (1) and bolt (2) . End By: Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".
99
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01929373
Water Pump - Remove SMCS - 1361-011
Removal procedure 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.
Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand. Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns. 100
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes.
1. Drain the coolant from the cooling system into a suitable container for storage or for disposal. 2. Use hole (4) to remove tension from the V-belt.
Illustration 1
g01004978
3. Loosen bolts (3) and (6) on idler pulley assembly (7) . Note: For information on the reusability of idler pulley assembly (7), refer to Guideline For Reusable Parts And Salvage Operations, SEBF8046, "Cast Iron and Steel Pulleys". 4. Remove water pump V-belt (5) . 5. Loosen hose clamps (1). Disconnect the hose assembly between the water pump and the water temperature regulator housing. 6. Remove bolts (2) that hold the water pump to the front of the engine. Carefully remove the water pump and two O-ring seals from the front of the engine.
101
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01929375
Water Pump - Disassemble SMCS - 1361-015
Disassembly Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
1P-0510
Driver Group
1
B
1P-0520
Driver Group
1
Start By: A. Remove the water pump. Refer to Disassembly and Assembly, "Water Pump - Remove".
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.
102
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
g00614231
1. Remove O-ring seals (1) from the rear cover of the water pump. Remove bolts (2) and the washers. Remove the rear cover and the gasket.
Illustration 2
g00614234
2. Position the water pump in a press. Use spacer plates to level the water pump. 3. Push the shaft and pulley (3) out of impeller (4) with a suitable drive plate from Tooling (A) and a press. Remove the impeller. Note: For information on the reusability of pulley (3), refer to Guideline For Reusable Parts And Salvage Operations, SEBF8046, "Cast Iron and Steel Pulleys". Note: The new 7E-0321 Pump Impeller, 153-9123 Impeller and a 109-5324 Impeller can be removed with a bolt. Insert a bolt 0.75inch into the thread insert of the impeller. Turn the bolt inward toward the shaft. Twist and pull the impeller out of the pump.
103
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03 Illustration 3
g00614238
Note: Do not allow the shaft and the pulley to fall to the floor when the shaft and the pulley are removed. 4. Continue to push the shaft and pulley (3) out of seal (5) and the water pump housing.
Illustration 4
g00614253
5. Remove seal (5) from the water pump housing with the handle from Tooling (B) and a press.
Illustration 5
g00614261
6. Remove the shaft and the bearing from pulley (3) with a press.
104
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01929381
Water Pump - Assemble SMCS - 1361-016
Assembly Procedure Table 1 Required Tools Tool
Part Number
C
5P-9722
Part Description Seal Driver
Qty 1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 1
g00614283
1. Install the shaft and the bearing into pulley (3) with a press. Install the shaft until the shaft is flush with the end of pulley (3) . 2. Press the shaft, the bearing, and pulley (3) as a unit into the water pump housing. The distance between the front of pulley (3) and the machined surface of the water pump housing must be 103.8 ± 0.3 mm (4.09 ± 0.01 inch). 105
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Note: For information on the reusability of pulley (3), refer to Guideline For Reusable Parts And Salvage Operations, SEBF8046, "Cast Iron and Steel Pulleys".
Illustration 2
g01004707
3. Install seal (5) in the water pump housing with Tooling (C) .
Illustration 3
g00614288
106
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
4. Install impeller (4) on the shaft of the water pump with a press. Install the impeller until the distance between the impeller and the machined surface of the water pump is 0.75 ± 0.25 mm (0.030 ± 0.010 inch).
Illustration 4
g00614231
5. Install a new gasket between the rear cover of the water pump and the water pump housing. Position the gasket and the cover on the water pump housing. Install bolts (2) and the washers. 6. Install new O-ring seals (1) in the rear cover. End By: Install the water pump. Refer to Disassembly and Assembly, "Water Pump - Install".
107
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01929434
Water Pump - Install SMCS - 1361-012
Installation procedure 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.
Illustration 1
g01004978
108
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
1. Install new O-ring seals in the cover of the water pump. Position the water pump on the front of the engine. Install bolts (2) . 2. Connect the hose assembly between the water pump and the water temperature regulator housing. Tighten hose clamps (1) that hold the hose in position. 3. Position V-belt (5) on the idler pulley assembly (7) . Note: For information on the reusability of idler pulley assembly (7), refer to Guideline For Reusable Parts And Salvage Operations, SEBF8046, "Cast Iron and Steel Pulleys". 4. Adjust the tension on the water pump V-belt (5) . 5. Use hole (4) to apply tension to the V-belt. Refer to Specifications, "Belt Tensioner Chart" for the correct tension on the belt. 6. Fill the cooling system to the correct level. Refer to the Operation and Maintenance Manual, "Refill Capacities" topic for the correct fluid and the correct filling procedure.
109
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01929437
Water Temperature Regulator Housing - Remove and Install SMCS - 1393-010
Removal Procedure 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. Drain the coolant from the cooling system into a suitable container for storage or disposal.
110
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
g00747272
2. Loosen clamp (3) . 3. Remove bolts (2) . 4. Remove water temperature regulator housing (1) and the gasket from the cylinder head.
Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 2
g00747272
1. Install a new gasket and water temperature regulator housing (1) on the cylinder head. 2. Install bolts (2) . 3. Tighten clamp (3) . 4. Fill the cooling system with coolant to the correct level. Refer to the Operation and Maintenance Manual for the correct procedure.
111
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01929442
Water Temperature Regulator - Remove and Install SMCS - 1355-010
Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
1. Drain the coolant from the cooling system into a suitable container for storage or disposal.
Illustration 1 Typical Example
g00623238
2. Remove bolts (1) . 3. Remove pipe assembly for the water outlet (2) and remove the gasket from the water temperature regulator housing.
112
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 2
g00745103
4. Remove water temperature regulator (3) from the water temperature regulator housing.
Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 3
g00745103
1. Install water temperature regulator (3) in the water temperature regulator housing.
113
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03 Illustration 4
g00623238
2. Install a new gasket, and pipe assembly for the outlet (2) on the water temperature regulator housing. 3. Install bolts (1) . 4. Fill the cooling system with coolant to the correct level. Refer to the Operation and Maintenance Manual for the correct procedure.
114
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01929472
Aftercooler - Remove SMCS - 1063-011
Removal Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
8T-0292
Bolt
2
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.
At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. 115
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand. Remove the fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury. Note: Put identification marks on all hose assemblies, on all wires, and on all tube assemblies for installation purposes. Plug all hose assemblies and tube assemblies. This helps to prevent fluid loss and this helps to keep contaminants from entering the system. 1. Drain the coolant from the cooling system into a suitable container for storage or disposal.
Illustration 1
g00508835
Illustration 2
g00508837
2. Remove bolts (2). Remove exhaust elbow (1) and exhaust pipe assembly (3) .
116
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 3
g00746355
3. Loosen clamp (4) . 4. Disconnect coupling (5) .
Illustration 4
g00746356
5. Loosen clamps (6) and (7) . 6. Remove two top bolts (8) and install Tooling (A). Remove remaining bolts (8). Remove aftercooler (10) . 7. Remove gasket (9) from aftercooler (10) .
117
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01929554
Aftercooler - Install SMCS - 1063-012
Installation Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
4C-9502
Gasket Sealant
1
B
5P-3931
Anti-Seize Compound
1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Note: Use a new gasket in order to install the aftercooler.
118
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
g00746356
Note: Apply Tooling (A) to the threads of the bottom bolts before installation. 1. Install gasket (9) on the engine. Install aftercooler (10). Install bolts (8) . 2. Tighten clamp (6) and tighten clamp (7) .
Illustration 2
g00746355
3. Tighten clamp (4). 4. Connect coupling (5) .
119
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 3
g00508837
Illustration 4
g00508835
Note: Apply Tooling (B) to the threads of the exhaust elbow bolts. 5. Install exhaust elbow (1) and exhaust pipe (3). Install bolts (2) . 6. Fill the cooling system. Refer to Operation and Maintenance Manual, SEBU7098, "Cooling System Level Check" for the correct procedure.
120
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01929596
Engine Lifting Bracket - Remove and Install SMCS - 1122-010
Removal Procedure
Illustration 1
g00623010
1. Remove bolts (2) and the washers. 2. Remove engine lifting bracket (1) from the front of the engine.
Illustration 2
g00623016
3. Remove bolts (4) and the washers. 121
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
4. Remove engine lifting bracket (3) from the rear of the engine.
Installation Procedure
Illustration 3
g00623016
1. Position engine lifting bracket (3) on the rear of the engine. 2. Install the washers and bolts (4) .
Illustration 4
g00623010
3. Position engine lifting bracket (1) on the front of the engine. 4. Install the washers and bolts (2) .
122
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01929610
Flywheel - Remove SMCS - 1156-011
Removal Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
138-7573
Link Bracket
2
B
-
Guide Bolt (M16 x 2 by 4 inch)
1
Note: For information on the reusability of the flywheel on 3116 engines, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8207, "Flywheel Specifications for 3116 Engines". 1. Support the engine with blocks or a suitable lifting device. 2. Install Tooling (A) on the flywheel. Fasten a suitable lifting device to the flywheel.
3. Remove top bolt (1) and the washers. Install Tooling (B). Remove remaining bolts (1) and the washers. 4. Remove flywheel (2) from Tooling (B). The weight of flywheel (2) is approximately 23 kg (50 lb). 5. Inspect the flywheel ring gear. Replace the ring gear, if necessary. Place the flywheel on a wood block. Use a 123
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
hammer and a punch in order to remove the flywheel ring gear.
124
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01944113
Flywheel - Install SMCS - 1156-012
Installation Procedure Table 1 Required Tools Tool
Part Number
A
138-7573
B
-
C
9S-3263
Part Description
Qty
Link Bracket
2
Guide Bolt (M16 x 2 by 4 inch)
1
Thread Lock Compound
1
Note: For information on the reusability of the flywheel on 3116 engines, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8207, "Flywheel Specifications for 3116 Engines". Note: Drill and tap the new flywheel ring gear if the outer bolt holes of the flywheel are used. Use the flywheel as a template and drill twelve holes to a diameter of 8.2 mm (0.32 inch). Thread the holes with a tap. 1. Raise the temperature of the flywheel ring gear to a maximum temperature of 204 °C (400 °F). Do not use a torch to heat the flywheel ring gear. Install the flywheel ring gear on the flywheel. Position the flywheel ring gear with the part number toward the crankshaft. Allow the flywheel ring gear to cool. Use a soft hammer in order to seat the flywheel ring gear against the shoulder of the flywheel.
Illustration 1
g00613482
125
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
2. Install Tooling (A) on flywheel (2). Fasten a suitable lifting device to flywheel (2) . 3. Place flywheel (2) in the original position on Tooling (B). Align the arrows on flywheel (2) and the crankshaft. 4. Apply Tooling (C) to the threads of bolts (1) . 5. Install bolts (1) and the washers. Remove Tooling (B) and install remaining bolt (1) and the washer. Tighten the bolts evenly to a torque of 120 ± 20 N·m (90 ± 15 lb ft). 6. Check the flywheel runout. Refer to Testing and Adjusting, "Basic Block" for the correct procedure.
126
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01980554
Crankshaft Rear Seal - Remove SMCS - 1161-011
Removal Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
1U-8145
Drill Bit
1
B
1U-7600
Slide Hammer Puller Gp
1
C
4C-4869
Distorter Ring
1
D
5P-7312
Seal Distorter
1
Start By: A. Remove the flywheel. Refer to Disassembly and Assembly, "Flywheel - Remove".
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
1. Use Tooling (A) to drill three evenly spaced holes in the crankshaft rear seal.
127
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
g00989088
2. Carefully remove crankshaft rear seal (1) by alternating the position of Tooling (B) from hole to hole. This will allow crankshaft rear seal (1) to be removed evenly without damage to the rear flange surface of the crankshaft. Note: New engines from the factory do not have a wear sleeve. Engines with seals that have been replaced will be equipped with a wear sleeve. If the crankshaft of the engine is equipped with a wear sleeve, refer to Disassembly and Assembly, "Crankshaft Wear Sleeve (Rear) - Remove" in order to remove the wear sleeve. 3. Use Tooling (C) and Tooling (D) to remove the wear sleeve (if equipped).
128
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01980581
Crankshaft Rear Seal - Install SMCS - 1161-012
Installation Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
E
1U-7598
Seal Installer Gp
1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Note: Replacement rear seals are supplied with a wear sleeve. This wear sleeve must be installed with the rear seal. New engines from the factory do not have a wear sleeve. Do not install the rear seal if any of the following conditions exist:
The crankshaft rear seal has been separated from the wear sleeve.
The rear seal group appears to be damaged.
The crankshaft rear seal has been lubricated. The seal is designed to be installed dry.
1. Ensure that the rear of the crankshaft is thoroughly clean and dry prior to the installation of the crankshaft rear seal.
129
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1 Typical example
g01026625
2. Use Tooling (E) to install crankshaft rear seal (1) . End By: Install the flywheel. Refer to Disassembly and Assembly, "Flywheel - Install".
130
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01987820
Crankshaft Rear Seal Carrier - Remove and Install SMCS - 1161-010-C3
Removal Procedure Start By: A. Remove the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing - Remove and Install".
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
131
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
g01027007
1. Remove bolts (1) . 2. Remove rear seal carrier (2) .
Installation Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
138-8440
Component Cleaner
B
169-5464
Quick Cure Primer
C
1U-8846
Gasket Sealant
D
9S-3263
Thread Lock Compound
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
132
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Illustration 2
g01027007
1. Clean the joint face of rear seal carrier (2) and the cylinder block with Tooling (A) . 2. Apply Tooling (B) to the joint face of rear seal carrier (2). Allow the primer to air dry for three to five minutes. Note: Tooling (C) is used on the joint face of rear seal carrier (2). Do not allow the sealant to get into the oil passage in the mounting face of the cylinder block. 3. Apply Tooling (C) to the joint face of rear seal carrier (2). Spread the sealant uniformly. Rear seal carrier (2) must be installed within ten minutes of application of the sealant. 4. Position rear seal carrier (2) on the dowels in the rear of the cylinder block. 5. Apply Tooling (D) on the threads of bolts (1). Install bolts (1) that hold rear seal carrier (2) to the cylinder block. End By: Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing - Remove and Install".
133
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01929753
Flywheel Housing - Remove and Install SMCS - 1157-010 S/N - 1NJ1-UP S/N - 1SK1-UP S/N - 1ZG1-UP S/N - 1ZJ1-UP S/N - 2MR1-UP S/N - 2SG1-UP S/N - 4KG1-UP S/N - 4PG1-UP S/N - 5EN1-UP S/N - 5JG1-UP S/N - 6AF1-UP S/N - 6MK1-UP S/N - 6MS1-UP S/N - 6SR1-UP S/N - 8NM1-UP S/N - 9ZR1-UP S/N - CKK1-UP
Removal Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty 134
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
A
138-7573
Link Bracket
2
Start By: A. Remove the flywheel. Refer to Disassembly and Assembly, "Flywheel - 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.
Illustration 1
g01011885
1. Fasten Tooling (A) and a suitable lifting device to flywheel housing (1) . 2. Remove bolts (2) and bolt (3) that fastens flywheel housing (1) to the cylinder block. 3. Remove flywheel housing (1). The weight of flywheel housing (1) is approximately 32 kg (70 lb).
Installation Procedure Table 2 Required Tools 135
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Tool
Part Number
Part Description
Qty
A
138-7573
Link Bracket
2
B
1U-8846
Gasket Sealant
1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 2 g00740507 Correct installation of O-ring seal (3). Do not install the O-ring seal in location (4) .
Note: On wet flywheel housings that have rear seal carriers, ensure that the 8C-3091 O-Ring Seal is installed properly. Improper installation will result in leakage of torque converter oil between the flywheel housing and the cylinder block. Note: Ensure that the mating surface of the flywheel housing and the mounting face of the cylinder block are thoroughly clean. 1. Apply Tooling (B) to the entire mounting face of the flywheel housing prior to installation.
136
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 3
g01011885
2. Fasten Tooling (A) and a suitable lifting device to flywheel housing (1). Position flywheel housing (1) on the cylinder block. The weight of flywheel housing (1) is approximately 32 kg (70 lb). 3. Install bolts (2) and bolt (3) that fastens flywheel housing (1) to the cylinder block. Refer to the Specification, "Flywheel Housing" for the torque specification. 4. Remove Tooling (A) and the hoist from flywheel housing (1) . 5. Check the flywheel housing runout. Refer to the Systems Operation/Testing and Adjusting, "Flywheel and Flywheel Housing". End By: Install the flywheel. Refer to Disassembly and Assembly, "Flywheel - Install".
137
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01929931
Vibration Damper and Pulley - Remove and Install SMCS - 1205-010
Removal Procedure 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.
Illustration 1
g00691836
138
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
1. Remove bolts (2), crankshaft vibration damper (3), and spacers from the crankshaft pulley. Note: For information on the reusability of the vibration damper on 3114 and 3116 engines, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8220, "Specifications for Damper Inspection 3114 and 3116 Engines". 2. Loosen the tension on water pump drive belt (1). Remove the belt from the crankshaft pulley.
Illustration 2
g00691831
3. Remove bolts (4) and the washers. 4. Remove crankshaft pulley (5) . Note: For information on the reusability of the crankshaft pulley, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8046, "Cast Iron and Steel Pulleys".
Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 3
g00691831
1. Position crankshaft pulley (5) on the crankshaft. Install bolts (4) and tighten the bolts to a torque of 160 ± 30 N·m (118 ± 22 lb ft). 139
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Note: For information on the reusability of the crankshaft pulley, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8046, "Cast Iron and Steel Pulleys".
Illustration 4
g00691836
2. Install water pump drive belt (1) . Note: Check the alignment marks on the rubber vibration dampers for proper alignment. The rubber vibration damper should be replaced if the rubber vibration damper is out of alignment. Refer to Specifications, "Vibration Damper". 3. Install spacers and crankshaft vibration damper (3). Tighten bolts (2) to a torque of 55 ± 10 N·m (40 ± 7 lb ft). Note: For information on the reusability of the vibration damper on 3114 and 3116 engines, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8220, "Specifications for Damper Inspection 3114 and 3116 Engines". 4. Adjust the tension of water pump drive belt (1). Refer to the Specifications Module, "Belt Tension Chart". Also, refer to the Operation and Maintenance Manual, "Belt - Inspect".
140
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01982085
Crankshaft Front Seal - Remove SMCS - 1160-011
Removal Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
1U-7600
Slide Hammer Puller
1
B
1U-8145
Drill Bit
1
Start By: A. Remove the vibration damper and the pulley. Refer to Disassembly and Assembly, "Vibration Damper and Pulley - Remove and Install".
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
141
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
g00989224
1. Use Tooling (B) and carefully drill three evenly spaced holes in crankshaft front seal (1) . 2. Alternate between the drilled holes and use Tooling (A) to remove crankshaft front seal (1) .
142
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01982092
Crankshaft Front Seal - Install SMCS - 1160-012
Installation Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
C
1U-7430
Front Seal Installer
1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
143
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
g00989228
1. Use Tooling (C) to install crankshaft front seal (1) . Note: The crankshaft seal is designed to be installed dry. End By: Install the vibration damper and the pulley. Refer to Disassembly and Assembly, "Vibration Damper and Pulley - Remove and Install".
144
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01176651
Front Cover - Remove SMCS - 1166-011
Removal Procedure
Illustration 1
g00629709
Note: It is not necessary to remove the vibration damper and the crankshaft pulley in order to remove the front cover. 1. Remove bolts (1) from front cover (2) . 2. Remove front cover (2) and the gasket from the front of the engine.
145
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01437510
Front Cover - Install SMCS - 1166-012
Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 1
g00752906
1. Install a new gasket (3) on the front cover (2) .
146
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 2
g00629709
2. Install the gasket and front cover (2) on the front of the engine. 3. Install bolts (1) in front cover (2) .
147
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01929983
Gear Group (Front) - Remove SMCS - 1206-011
Removal Procedure Table 1 Required Tools Tool
Part Number
A
1P-0520
Part Description Driver Gp
Qty 1
Start By: A. Remove the crankshaft vibration damper. Refer to Disassembly and Assembly, "Vibration Damper and Pulley Remove and Install". B. Remove the crankshaft front seal. Refer to Disassembly and Assembly, "Crankshaft Front Seal - Remove". C. Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove". D. Remove the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove". Note: For information on reusability of the camshaft idler gear, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8045, "Timing Gears for All Engines". 1. Place the engine at the Top Center position. The timing marks should be in line with the crankshaft gear.
148
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
g01005265
2. Identify the type of idler gear on the engine. Remove bolts (1) that hold the idler gear to the block. Remove plate (7) .
Illustration 2
g00677884
3. Identify the location of timing marks (4) and (5) on the camshaft idler gear. Identify the location of timing mark (6) on the crankshaft drive gear. 4. Remove idler shaft (3) and camshaft idler gear (2). Separate idler gear (2) from idler shaft (3) and remove the sleeve bearing from the camshaft idler gear. 5. Use Tooling (A) and a press to remove the bearing.
149
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01930002
Gear Group (Front) - Install SMCS - 1206-012
Installation Procedure Table 1 Required Tools Tool
Part Number
A
1P-0520
Part Description Driver Gp
Qty 1
Note: For information on reusability of the camshaft idler gear, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8045, "Timing Gears for All Engines".
150
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1 Type 1
g00643979
1. Use Tooling (A) and a suitable press to install the sleeve bearing in the camshaft idler gear. 2. Install the bearing sleeve to a depth of 0.40 ± 0.25 mm (0.016 ± 0.010 inch) below the front face of the gear. 3. Place the idler shaft (3) on the cylinder block. Install bolts (1) that hold the idler shaft to the cylinder block. Tighten the bolts to a torque of 70 ± 15 N·m (51 ± 11 lb ft). 4. Install camshaft idler gear (2) on idler shaft (3). The timing marks should face outward. 5. Align the timing marks on camshaft idler gear (2) with the timing marks on the crankshaft drive gear.
151
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 2 Type 2
g00644057
1. Use Tooling (A) and a suitable press and install the sleeve bearing in the camshaft idler gear. 2. Install plate (4) on the back of idler shaft (3). Position idler gear assembly on the cylinder block. Install bolts that hold the idler gear to the engine block. Tighten the bolts to a torque of 70 ± 15 N·m (51 ± 11 lb ft). 3. Install camshaft idler gear (2) on idler shaft (3). The timing marks should face outward. 4. Align the timing marks on camshaft idler gear (2) with the timing marks on the crankshaft drive gear.
152
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 3 Type 3
g00644128
1. Position idler shaft (3) on the cylinder block. Install the shortest bolt in the recessed hole in idler shaft (3). This bolt will hold the shaft in position on the cylinder block. 2. Install camshaft idler gear (2) on idler shaft (3). The timing marks should face outward. 3. Align the timing marks on idler gear (2) with the timing marks on the camshaft drive gear. 4. Position plate (4) over the gear and install the remaining bolts (1). Tighten bolts (1) to a torque of 70 ± 15 N·m (51 ± 11 lb ft). End By: a. b. c. d.
Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Install". Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Install". Install the crankshaft front seal. Refer to Disassembly and Assembly, "Crankshaft Front Seal - Install". Install the crankshaft vibration damper and pulley. Refer to Disassembly and Assembly, "Vibration Damper and Pulley -Remove and Install".
153
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01944129
Housing (Front) - Remove SMCS - 1151-011
Removal Procedure Start By: A. Remove the crankshaft vibration damper. Refer to Disassembly and Assembly, "Vibration Damper and Pulley Remove and Install". B. Remove the crankshaft front seal. Refer to Disassembly and Assembly, "Crankshaft Front Seal - Remove". C. Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove".
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. Remove any external components, if equipped. 2. Support the front of the engine.
154
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
g01011903
3. Remove bolts (2) and remove front engine support. 4. Remove bolts (1) and belt tightener (3) .
Illustration 2
g01011906
5. Remove bolts (5) that fasten front housing (4) to the cylinder block and to the engine oil pan. Remove front housing (4). Clean the sealant from front housing (4) and the cylinder block.
155
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01944143
Housing (Front) - Install SMCS - 1151-012
Installation Procedure Table 1 Required Tools Tools
Part Number
Part Description
Qty
A
138-8440
Component Cleaner
1
B
169-5464
Quick Cure Primer
1
C
1U-8846
Gasket Sealant
1
156
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
g01011906
1. Clean the joint face on front housing (4) with Tooling (A) . 2. Apply Tooling (B) to the joint face. Allow the primer to dry for at least three to five minutes. Note: Do not allow Tooling (C) to seal the main oil passage on front housing (4) . 3. Apply Tooling (C) to the joint face. Spread the sealant uniformly. The front housing must be installed within ten minutes of applying the sealant. 4. Position the front housing on the cylinder block. 5. Install bolts (5) that fasten the front housing to the cylinder block and the engine oil pan.
Illustration 2
g01011903
6. Position belt tightener (3) and install bolts (1) . 157
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
7. Position the front engine support and install bolts (2) . 8. Install any external components, if equipped. End By: a. Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Install". b. Install the crankshaft front seal. Refer to Disassembly and Assembly, "Crankshaft Front Seal - Install". c. Install the crankshaft vibration damper. Refer to Disassembly and Assembly, "Vibration Damper and Pulley Remove and Install".
158
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01176330
Crankcase Breather - Remove and Install SMCS - 1317-010
Removal Procedure
Illustration 1
g00629572
1. Remove bolt (4) and the clip from the engine block. 2. Loosen clamp (2) and remove the hose from crankcase breather (3) . 3. Remove bolt (1) and remove crankcase breather (3) from the fuel filter base.
Installation Procedure
159
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03 Illustration 2
g00629572
1. Inspect the filter in crankcase breather (3). Replace the filter, if necessary. 2. Position crankcase breather (3) on the fuel filter base and install bolt (1). Tighten the bolt to a torque of 7 ± 2 N·m (62 ± 18 lb in). 3. Install the hose on crankcase breather (3) and tighten clamp (2) . 4. Install the clip and bolt (4) on the hose.
160
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01930088
Valve Mechanism Cover - Remove and Install SMCS - 1107-010
Removal Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
138-8440
Component Cleaner
1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
161
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
g00886209
1. Remove engine oil filler cap (if equipped). 2. Remove bolts (1) and washers (2) from valve mechanism cover (3) . 3. Remove valve mechanism cover (3) and gasket (4) . 4. Clean valve mechanism cover (3) with Tooling (A) .
Installation Procedure Table 2 Required Tools Tool
Part Number
Part Description
Qty
B
154-8874
Adhesive Kit
1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
162
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 2
g00886209
Note: For later valve cover gaskets which have a rubber bead on one side, no adhesive is required. The gasket is designed to be installed dry. 1. Apply adhesive to valve mechanism cover (3) with Tooling (B) . 2. Install new gasket (4) and valve mechanism cover (3) . 3. Install washers (2) and bolts (1) .
Illustration 3
g00611545
Tightening sequence for the engine valve covers
163
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03 (A) Rear (B) Front
4. Tighten the bolts in sequence to a torque of 12 ± 3 N·m (106 ± 27 lb in). 5. Install engine oil filler cap (if equipped).
164
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01930098
Rocker Shaft and Pushrod - Remove SMCS - 1102-011; 1208-011
Removal Procedure Start By: A. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install".
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Note: For information on reusability of components of the rocker shaft, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8267, "Rocker Arms and Rocker Arm Shafts for 3114 and 3116 Engines".
Illustration 1
g00629575
1. Loosen all rocker arm adjustment screws (3) . 2. Remove bolts (1) from the rocker shaft assembly (2) . 3. Remove rocker shaft assembly (2) from the cylinder head. 165
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
4. Repeat the procedure for each rocker shaft assembly. 5. Remove the pushrods.
166
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01930098
Rocker Shaft and Pushrod - Remove SMCS - 1102-011; 1208-011
Removal Procedure Start By: A. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install".
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Note: For information on reusability of components of the rocker shaft, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8267, "Rocker Arms and Rocker Arm Shafts for 3114 and 3116 Engines".
Illustration 1
g00629575
1. Loosen all rocker arm adjustment screws (3) . 2. Remove bolts (1) from the rocker shaft assembly (2) . 3. Remove rocker shaft assembly (2) from the cylinder head. 167
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
4. Repeat the procedure for each rocker shaft assembly. 5. Remove the pushrods.
168
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01930194
Rocker Shaft - Assemble SMCS - 1102-016
Assembly Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Note: For information on reusability of components of the rocker shaft, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8267, "Rocker Arms and Rocker Arm Shafts for 3114 and 3116 Engines".
Illustration 1
g00630277
1. Install button (6) and the retaining ring, if necessary. 2. Place clean engine oil on a new bearing (5) prior to installation. 3. Ensure that the oil hole in bearing (5) is aligned with the oil hole in the rocker arm. Hone the bearing, if necessary. Refer to the Specifications Module for the correct dimensions.
169
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Illustration 2
g00629612
4. Lubricate rocker shaft assembly (4) with clean engine oil. 5. Install valve rocker arms (2) and unit injector rocker arm (3) on rocker shaft assembly (4) . 6. Install support bracket (1) on rocker shaft assembly (4) . End By: Install the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod Install".
170
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i02736495
Rocker Shaft and Pushrod - Install SMCS - 1102-012; 1208-012
Installation Procedure Table 1 Required Tools Tool
Part Number
A
146-2597
Part Description Pushrod Holder
Qty 1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Note: For information on reusability of components of the rocker shaft, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8267, "Rocker Arms and Rocker Arm Shafts for 3114 and 3116 Engines". 1. Install the pushrods in the engine. The base of the pushrod should be in the seat of the pushrod lifter. 2. Install Tooling (A) .
Illustration 1
g00629575
171
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
3. Position rocker shaft assembly (2) in the engine. Line up the pushrods with the rocker arms. 4. Install bolts (1) in rocker shaft assembly (2) . Tighten the bolts to a torque of 28 ± 7 N·m (21 ± 5 lb ft). 5. Remove Tooling (A) from the pushrods. 6. Adjust the valve lash on all of the adjustment screws. Refer to Testing and Adjusting, "Engine Valve Lash Inspect/Adjust". 7. Repeat the procedure for the remaining rocker shaft assemblies. End By: Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover Remove and Install".
172
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01935828
Cylinder Head - Remove SMCS - 1100-011
Removal Procedure Start By: A. Remove the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install". B. Remove the governor. Refer to Disassembly and Assembly, "Governor - Remove". C. Remove the fuel control linkage. Refer to Disassembly and Assembly, "Fuel Injection Control Linkage Remove". D. Remove the unit injectors. Refer to Disassembly and Assembly, "Unit Injector - Remove". E. Remove the water temperature regulator housing. Refer to Disassembly and Assembly, "Water Temperature Regulator Housing - Remove and Install". F. Remove the inlet manifold. Refer to Disassembly and Assembly, "Inlet Manifold - Remove". G. Remove the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install".
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.
Note: For information on the reusability of the cylinder head, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8218, "Specifications for Cylinder Head Assemblies 3114, 3116, and 3126 Engines" and Guideline For Reusable Parts And Salvage Operations, SEBF8162, "Procedure to Measure and Salvage Cylinder Head 173
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Assemblies and Related Components".
Illustration 1 Typical example
g01007597
1. Attach a suitable lifting device to the cylinder head.
Illustration 2
g00654709
2. Remove bolts (1) and (2) that hold the cylinder head to the cylinder block. Carefully remove the cylinder head from the cylinder block. The cylinder head for the 3116 engine weighs approximately 85 kg (187 lb).
174
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 3
g00611342
3. Remove cylinder head gasket (3) .
175
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01930413
Lifter Group - Remove and Install SMCS - 1209-010
Removal Procedure Start By: A. Remove the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod 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.
Note: For information on reusability of components of the lifter group, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8264, "Camshaft Roller Followers Used in 3114 and 3116 Engines" and Guideline For Reusable Parts And Salvage Operations, SEBF8067, "Slipper Followers and Camshaft Roller Followers".
176
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
g00747310
1. Remove bolts (1) from cover (2) . 2. Carefully remove cover (2) and the gasket. Note: It may be necessary to remove the governor in order to remove the cover at the front of the engine.
Illustration 2
g00629677
3. Remove bolts (4), lifter shaft (5), and lifters (3) from cover (2) .
Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Note: For information on reusability of components of the lifter group, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8264, "Camshaft Roller Followers Used in 3114 and 3116 Engines" and Guideline For Reusable Parts And Salvage Operations, SEBF8067, "Slipper Followers and Camshaft Roller Followers".
177
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 3
g00629677
1. Position lifters (3) and lifter shaft (5) on cover (2). Install bolts (4) .
Illustration 4
g00747310
2. Position the gasket and cover (2) on the engine. 3. Install bolts (1) in cover (2) . End By: Install the rocker shaft and the pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod Install".
178
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01930426
Camshaft - Remove SMCS - 1210-011
Removal Procedure Start By: A. Remove the governor. Refer to Disassembly and Assembly, "Governor - Remove". B. Remove the side covers. Refer to Disassembly and Assembly, "Lifter Group - Remove and Install". C. Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - 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.
Note: For information on reusability of the camshaft, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8097, "Camshaft Measurement", Guideline For Reusable Parts And Salvage Operations, SEBF8146, "Visual Inspection of Camshafts", and Guideline For Reusable Parts And Salvage Operations, SEBF8251, "Specifications for Measurement of Camshafts in 3114/3116 Engines". For information on reusability of the camshaft gear, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8045, "Timing Gears for All Engines". Note: The air compressor was removed in order to accommodate the engine repair stand. Note: It is not necessary to remove the cylinder head for removal of the camshaft. 179
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
1. Turn the crankshaft to top center compression stroke for the No. 1 piston. Install the timing bolt in the flywheel. This is for timing during installation.
Illustration 1 Typical example
g01007643
2. Ensure that timing mark (1) on the camshaft gear is aligned with timing mark (2) on the idler gear.
Illustration 2
g01007645
3. Remove bolts (4) and camshaft retainer plate (6) . 4. Remove camshaft gear (5) and camshaft (3) from the cylinder block.
180
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01930093
Camshaft - Install SMCS - 1210-012 S/N - 1NJ1-UP S/N - 1SK1-UP S/N - 1ZG1-UP S/N - 1ZJ1-UP S/N - 2MR1-UP S/N - 2SG1-UP S/N - 4KG1-UP S/N - 4PG1-UP S/N - 5EN1-UP S/N - 5JG1-UP S/N - 6AF1-UP S/N - 6MK1-UP S/N - 6MS1-UP S/N - 6SR1-UP S/N - 8NM1-UP S/N - 9ZR1-UP S/N - CKK1-UP
Installation Procedure NOTICE Keep all parts clean from contaminants. 181
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Contaminants may cause rapid wear and shortened component life.
Note: For information on reusability of the camshaft, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8097, "Camshaft Measurement", Guideline For Reusable Parts And Salvage Operations, SEBF8146, "Visual Inspection of Camshafts", and Guideline For Reusable Parts And Salvage Operations, SEBF8251, "Specifications for Measurement of Camshafts in 3114/3116 Engines". For information on reusability of the camshaft gear, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8045, "Timing Gears for All Engines". 1. Lubricate the camshaft and the camshaft bearings with clean engine oil.
Illustration 1
g00654762
2. Carefully install camshaft (4) and camshaft gear (1) in the engine.
NOTICE When installing the camshaft, make sure the number one cylinder is at top center of the compression stroke with the timing bolt installed in the flywheel. The camshaft timing is very important. The timing mark on the camshaft drive gear must line up with the timing mark on the idler gear. Refer to the Specifications Manual for more information.
Illustration 2
g00677700
182
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03 Typical example
3. Ensure that timing mark (5) on the camshaft gear is aligned with timing mark (6) on the idler gear. 4. Install camshaft retainer plate (2) and bolts (3) . End By: a. Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Install". b. Install the side cover. Refer to Disassembly and Assembly, "Lifter Group - Remove and Install". c. Install the Unit Injector Hydraulic Pump. Refer to Disassembly and Assembly, "Unit Injector Hydraulic Pump Install". d. Install the Rocker Shaft and Pushrods. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod Install".
183
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01171077
Camshaft Gear - Remove and Install SMCS - 1210-010-GE
Removal Procedure Start By: A. Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove". Note: For information on reusability of the camshaft gear, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8045, "Timing Gears for All Engines". 1. Wrap the camshaft with a protective covering in order to prevent damage to the camshaft.
Illustration 1
g00611152
NOTICE Do not allow the camshaft to fall to the floor when pressing it from the drive gear. Also make sure that the camshaft lobes do not catch on the press plates.
2. Place the camshaft and camshaft gear (1) in a suitable press. Press the camshaft from camshaft gear (1) .
Installation Procedure 184
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Note: For information on reusability of the camshaft gear, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8045, "Timing Gears for All Engines".
Illustration 2
g00611152
1. Heat the camshaft gear to a maximum temperature of 315 °C (600 °F). 2. Align the key in the camshaft with the groove (keyway) in the camshaft gear. 3. Install the camshaft gear on the end of the camshaft. End By: Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Install".
185
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i02183087
Camshaft Bearings - Remove and Install SMCS - 1211-010
Removal Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
8S-2241
Camshaft Bearing Tool Group
1
Start By: A. Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - 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.
Note: Note the oil hole orientation in each camshaft bearing prior to removal for assembly purposes. 1. Use Tooling (A) to remove the camshaft bearings from the cylinder block. 186
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Installation Procedure Table 2 Required Tools Tool
Part Number
Part Description
Qty
A
8S-2241
Camshaft Bearing Tool Group
1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 1
g01104577
187
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 2
g01104579
1. Use Tooling (A) to install all of the camshaft bearings except for the front bearing. Orient oil hole (1) in each bearing so that oil hole (1) is located at the top of the bore. 2. Use Tooling (A) to install the front camshaft bearing. Align oil hole (1) in the front camshaft bearing with the oil hole in the cylinder block. Locate joint (2) in the front camshaft bearing in the proper position. End By: Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Install".
188
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01572486
Engine Oil Pan - Remove and Install SMCS - 1302-010 S/N - 1NJ1-UP S/N - 1ZG1-UP S/N - 2MR1-UP S/N - 2SG1-UP S/N - 2WG1-UP S/N - 4PG1-UP S/N - 5EF1-UP S/N - 5EN1-UP S/N - 5JG1-UP S/N - 6AF1-UP S/N - 6MS1-UP S/N - 9ZR1-UP S/N - CKK1-UP
Removal Procedure 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 189
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
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.
Illustration 1
g00596538
Note: Drain engine oil into a suitable container for disposal. 1. Remove bolts (1) and the washers that hold engine oil pan (2) to the cylinder block. 2. Remove engine oil pan (2) and the gasket. Use a rubber mallet to tap lightly on engine oil pan (2) if it is necessary. Note: Do not pry on the engine oil pan.
Installation Procedure 1. Clean the mating surfaces of the engine oil pan and the cylinder block. Note: Do not put liquid gasket material on the oil pan gasket or on the gasket surface of the engine oil pan. 2. Put the gasket and the engine oil pan (2) in position on the cylinder block. Install bolts (1) and washers.
190
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 2 Typical drawing (6 cylinder engine)
g00596576
3. Tighten four bolts (3). Start with bolt (4) and tighten the remaining bolts in a counterclockwise sequence. 4. Tighten bolts to a torque of 31 ± 3 N·m (23 ± 2 lb ft). 5. Fill the crankcase with engine oil to the proper level. Refer to Operation and Maintenance Manual, "Refill Capacities".
191
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01930590
Engine Balancer Shaft - Remove and Install Removal Procedure Start By: A. Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".
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.
Note: The Balancer shafts are used on the 3114 Engines.
192
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Illustration 1 314 engine
g00596194
1. Remove oil tube assembly (1) . 2. Remove bolts (2) and the washers that hold the balancer group in position. 3. Remove the balancer group and the engine oil pump as a unit.
Installation Procedure
Illustration 2
g00596364
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
1. Turn the engine in the counterclockwise direction and place the number one piston at the top center (TC) of the compression stroke. Install the timing bolt in the flywheel housing. 2. Align the timing marks on the balancer gears (3) with oil holes (4) in the engine oil pump. Position the balancer group in the cylinder block. Install the washers and bolts (2) . 193
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 3
g00596194
3. Check the condition of the O-ring seals in oil tube assembly (1). Replace the O-ring seal, if necessary. 4. Remove the timing bolt from the flywheel housing. End By: Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove and Install".
194
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01411264
Piston Cooling Jets - Remove and Install SMCS - 1331-010
Removal Procedure Start By: A. Remove the engine balancer shaft on the 3114 engines only. Refer to Disassembly and Assembly, "Engine Balancer Shaft - Remove and Install". B. Remove the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Remove".
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.
195
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
g00642470
1. Remove bolt (1) and piston cooling jet (2) . 2. Remove the remainder of the piston cooling jets.
Installation Procedure
Illustration 2
g00642470
NOTICE Ensure that the piston cooling jet is seated properly prior to tightening the bolt.
1. Position piston cooling jet (2) in the cylinder block. 2. Ensure that the piston cooling jet is seated properly and install bolt (1) that holds the piston cooling jet in position. 196
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
NOTICE Hold piston cooling jet in position when the mounting bolt is tightened. If the cooling tube is not held in position, the cooling tube may bend or the cooling tube may break.
3. Install the remainder of the piston cooling jets. End By: a. Install the engine balancer shaft on the 3114 engine. Refer to Disassembly and Assembly, " Engine Balancer Shaft - Remove and Install". b. Install the oil pump. Refer to Disassembly and Assembly, " Engine Oil Pump - Install".
197
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01580049
Pistons and Connecting Rods - Remove SMCS - 1225-011
Removal Procedure Start By: A. Remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Remove". B. Remove the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Remove". C. Remove the piston cooling jets. Refer to Disassembly and Assembly, "Piston Cooling Jets - Remove and Install".
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Note: For information on reusability of the pistons, refer to the following list.
Guideline For Reusable Parts And Salvage Operations, SEBF8049, "Pistons"
Guideline For Reusable Parts And Salvage Operations, SEBF8228, "Procedure to Clean and Inspect One and Two-Piece Pistons in 3114/3116 Engines"
Guideline For Reusable Parts And Salvage Operations, SEBF8290, "Visual Inspection of Two-Piece Pistons"
Note: For information on reusability of the connecting rods, refer to the following list.
Guideline For Reusable Parts And Salvage Operations, SEBF8206, "Specifications for Connecting Rods on 3116 Engines"
Guideline For Reusable Parts And Salvage Operations, SEBF8063, "Visual Inspection of Connecting Rods"
Guideline For Reusable Parts And Salvage Operations, SEBF8064, "Salvage of Non-Serrated Connecting Rods"
Note: For information on reusability of the piston pins, refer to the following list.
Guideline For Reusable Parts And Salvage Operations, SEBF8051, "Piston Pins and Retaining Rings"
Guideline For Reusable Parts And Salvage Operations, SEBF8303, "Procedure to Inspect Piston Pins" 198
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Note: For information on reusability of the rod eye bushing, refer to the following list.
Guideline For Reusable Parts And Salvage Operations, SEBF8242, "Verification of Connecting Rod Eye Bushing Retention Using 5P-8639 Connecting Rod Bushing Press Group"
Guideline For Reusable Parts And Salvage Operations, SEBF8274, "Using Rod Eye Bushing Installation and Removal Tools"
Note: For information on reusability of the cylinder block and salvage procedures, refer to the following list.
Guideline For Reusable Parts And Salvage Operations, SEBF8192, "Specifications and Salvage for Cylinder Blocks on 3114, 3116, 3126 Engines"
Guideline For Reusable Parts And Salvage Operations, SEBF8261, "Installing a 7C-6208 Cylinder Sleeve in 3114, 3116 Engines and a 107-7604 Cylinder Sleeve in 3126 Engines"
Special Instruction, GMG00981, "Using 1P-3537 Dial Bore Gauge Group to Check Cylinder Bore Size"
Special Instruction, SMHS7606, " Use of 1P-4000 Line Boring Tool Group"
Special Instruction, SEHS8841, " Using the Ironstitch Procedure for Casting Salvage"
Special Instruction, SEHS8919, "Salvage Weld Procedure for Cast Iron Cylinder Blocks"
Guideline For Reusable Parts And Salvage Operations, SEBF8076, "Specifications to Salvage Cylinder Block Contact Surfaces"
Special Instruction, SEHS8869, "Cylinder Block Salvage Procedure Using Belzona Ceramic R Metal"
Illustration 1
g00610269
1. Inspect the connecting rod and connecting rod cap (2) for the proper identification mark. The connecting rod and connecting rod cap (2) should have an etched number on the side that is toward the right side of the engine. The number should match the cylinder number. Mark the connecting rod and connecting rod cap (2), if necessary.
199
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Illustration 2
g00610272
2. Remove connecting rod cap nuts (1), bolts (5), and connecting rod cap (2) . 3. Remove the lower half of bearing (4) from connecting rod cap (2) .
NOTICE Install short pieces of rubber hose over both connecting rod bolts in order to protect the crankshaft from the threaded portion of the connecting rod bolts.
Illustration 3
g00610272
4. Push the piston and connecting rod away from the crankshaft. Remove the upper half of connecting rod bearing (4) from connecting rod (3) . 5. Remove the piston and connecting rod (3) from the cylinder block. 6. Repeat Steps 1 through 5 for the remaining pistons and connecting rods. 200
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01983492
Pistons and Connecting Rods - Disassemble SMCS - 1225-015
Disassembly Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
1U-6683
Ring Expander
1
B
1P-1861
Retaining Ring Pliers
1
Start By: A. Remove the pistons and the connecting rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Remove".
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
201
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
g00988677
1. Use Tooling (B) to remove retaining ring (2). Remove piston pin (4) and separate piston (1) from connecting rod (3) .
202
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03 Illustration 2
g00988681
2. Use Tooling (A) to remove piston rings (5) .
203
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01930637
Pistons and Connecting Rods - Assemble SMCS - 1225-016
Assembly Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
1U-6683
Ring Expander
1
B
1P-1861
Retaining Ring Pliers
1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
NOTICE Verify correct assembly of the pistons and the connecting rods. Ensure that the etched numbers on the rod and the rod cap are in the correct positions. The etched number on the rod and the rod cap correspond to the cylinder in which it should be installed.
Note: For information on reusability of the pistons, refer to the following list.
Guideline For Reusable Parts And Salvage Operations, SEBF8049, "Pistons"
Guideline For Reusable Parts And Salvage Operations, SEBF8228, "Procedure to Clean and Inspect One and Two-Piece Pistons in 3114/3116 Engines"
Guideline For Reusable Parts And Salvage Operations, SEBF8290, "Visual Inspection of Two-Piece Pistons"
Tool Operating Manual, NEHS0775, "Using the 186-0137 Pston Ring Gauge on Steel Crown, Two-Piece Pistons used in 3126 Engines" 204
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Note: For information on reusability of the connecting rods, refer to the following list.
Guideline For Reusable Parts And Salvage Operations, SEBF8206, "Specificatios for ConnectingRods on 3116 Engines"
Guideline For Reusable Parts And Salvage Operations, SEBF8063, "Visual Inspection of Connecting Rods"
Guideline For Reusable Parts And Salvage Operations, SEBF8064, "Salvage of Non-Serrated Connecting Rods"
Note: For information on reusability of the piston pins, refer to the following list.
Guideline For Reusable Parts And Salvage Operations, SEBF8051, "Piston Pins and Retaining Rings"
Guideline For Reusable Parts And Salvage Operations, SEBF8303, "Procedure to Inspect Piston Pins"
Note: For information on reusability of the rod eye bushing, refer to the following list.
Guideline For Reusable Parts And Salvage Operations, SEBF8242, "Verification of Connecting Rod Eye Bushing Retention Using 5P-8639 Connecting Rod Bushing Press Group"
Guideline For Reusable Parts And Salvage Operations, SEBF8274, "Using Rod Eye Bushing Installation and Removal Tools"
Illustration 1
g00610428
1. Check the clearance between the ends of piston rings (5). Refer to the Specifications Manual, "Pistons and Rings". Note: The oil ring must be installed over the spring with the end gap 180 degrees from the oil ring spring joint. 2. Install the oil control piston ring with Tooling (A). The ends of the spring should be rotated 180 degrees from the ring end gap. 3. Install the intermediate piston ring with the side marked "UP-2" toward the top of the piston. Use Tooling (A) in order to install the ring. 4. Install the top piston ring with the side marked "UP-1" toward the top of the piston. Use Tooling (A) in order to install the ring.
205
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 2
g00610498
5. Replace rod bearing (6) by pressing a new bearing into the connecting rod. Refer to Special Instruction, SEHS7295 for the correct tooling and the correct installation procedure.
Illustration 3 One piece piston
g00641764
206
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 4
g00610503
6. This piston is a two-piece assembly. This piston consists of piston crown (7) and piston skirt (8). Inspect bearing (9) in the piston crown (7). The piston crown must be replaced if the piston crown is worn or damaged. Bearing (9) is nonserviceable.
Illustration 5
g00678083
7. Position piston (1) on connecting rod (3). Coat piston pin (4) with clean engine oil and install piston pin (4) .
Illustration 6
g00678081
8. Use Tooling (B) to install the retaining ring.
207
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 7
g00610426
9. Ensure that retainer rings (2) are in the grooves of piston (1) . End By: Install the pistons and the connecting rods. Refer to Disassembly and Assembly, "Piston and Connecting Rods - Install".
208
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Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i03478580
Pistons and Connecting Rods - Install SMCS - 1225-012
Installation Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
187-1462
Piston Ring Compressor
(1)
1
173-5529
Piston Ring Compressor
(2)
1
4C-5593
Anti-Seize Compound
A B (1)
Used for 3114 and 3116 Engines
(2)
Used for 3126 Engines
1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Note: For information on reusability of the pistons, refer to the following list.
Guideline For Reusable Parts And Salvage Operations, SEBF8049, "Pistons"
Guideline For Reusable Parts And Salvage Operations, SEBF8290, "Visual Inspection of Two-Piece Pistons"
Tool Operating Manual, NEHS0775, "Using the 186-0190 Piston Ring Gauge on Steel Crown, Two-Piece Pistons used in 3126 and 3126B Engines"
Note: For information on reusability of the connecting rods, refer to the following list.
Guideline For Reusable Parts And Salvage Operations, SEBF8063, "Visual Inspection of Connecting Rods"
Guideline For Reusable Parts And Salvage Operations, SEBF8064, "Salvage of Non-Serrated Connecting Rods" 209
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Note: For information on reusability of the piston pins, refer to the following list.
Guideline For Reusable Parts And Salvage Operations, SEBF8051, "Piston Pins and Retaining Rings"
Guideline For Reusable Parts And Salvage Operations, SEBF8303, "Procedure to Inspect Piston Pins"
Note: For information on reusability of the rod eye bushing, refer to the following list.
Guideline For Reusable Parts And Salvage Operations, SEBF8242, "Verification of Connecting Rod Eye Bushing Retention Using 5P-8639 Connecting Rod Bushing Press Group"
Guideline For Reusable Parts And Salvage Operations, SEBF8274, "Using Rod Eye Bushing Installation and Removal Tools"
Illustration 1
g00678193
1. Install the bolts (5) and the upper half of connecting rod bearing (4) . Ensure that the bearing tab engages with the slot in connecting rod (3) .
Illustration 2
g00678195
2. Install the lower half of connecting rod bearing (4) . Ensure that the bearing tab engages with the slot in connecting rod cap (2) . 3. Place clean engine oil on the following items: the pistons, the piston rings, the cylinder bore, the upper half of the connecting rod bearing and the lower half of the connecting rod bearing.
NOTICE 210
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Install short pieces of rubber hose over both connecting rod bolts in order to protect the crankshaft from the threaded portion of the connecting rod bolts.
Illustration 3
g00746584
4. Install short pieces of rubber hose (6) over both connecting rod bolts.
Illustration 4
g00634923
Note: Each piston ring end gap must be positioned 120 degrees from each other. 5. Install Tooling (A) in order to compress the piston rings. 6. With the number one crankshaft throw at the bottom center, install the piston and connecting rod in the engine. Ensure that the proper piston and connecting rod are in the corresponding cylinder with the bearing retainer notch toward the right side of the engine. Note: The etched number on the connecting rod must be on the right side of the engine in the corresponding cylinder. 7. Line up the piston and the connecting rod with the crankshaft. Use a soft hammer and tap the piston into the cylinder bore until Tooling (A) comes off of the piston. 8. Use a soft hammer in order to tap the piston into the cylinder bore while you guide the connecting rod onto the crankshaft. 9. Remove the hoses that were installed in Step 4 from the connecting rod bolts.
211
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 5
g00678200
10. Install connecting rod bearing cap (2) on the connecting rod (3) . Ensure that the number on connecting rod bearing cap (2) matches the number on the connecting rod (3) . Ensure that the numbers are on the same side. 11. Lubricate connecting rod cap bolts with Tooling (B) .
Illustration 6
g00610272
NOTICE Loose connecting rod nuts can result in the separation of the rod cap and result in major engine damage.
Note: Later connecting rods will have bolts in place of the bolts and nuts. 12. Install connecting rod cap nuts (1) . Tighten nuts (1) to the torque that is specified in Table 2. Table 2 Torque Specifications Machined Connecting
Tighten nuts (1) to a torque of 54 ± 7 N·m (40 ± 5 lb ft) plus an additional 60 ± 212
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Rods
5 degrees.
Fractured Connecting Rods
Tighten nuts (1) to a torque of 70 ± 5 N·m (52 ± 4 lb ft) plus an additional 120 ± 5 degrees.
13. Repeat Steps 1 through 12 for the remaining pistons and connecting rods. End By: a. Install the piston cooling jets. Refer to Disassembly and Assembly, "Piston Cooling Jets - Remove and Install". b. Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Install". c. Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".
213
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01931297
Crankshaft Main Bearings - Remove SMCS - 1203-011
Removal Procedure Table 1 Required Tools Tool
Part Number
A
2P-5518
Part Description Bearing Tool
Qty 1
Start By: A. Remove the engine balancer shaft on 3114 engines. Refer to Disassembly and Assembly, "Engine Balancer Shaft - Remove and Install". B. Remove the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Remove".
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 1
g00610152
214
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
1. Remove bolts (1) that hold crankshaft main bearing cap (2). Remove crankshaft main bearing cap (2) . 2. Remove the lower half of the crankshaft main bearing from crankshaft main bearing cap (2) .
Illustration 2
g00516920
NOTICE If the crankshaft is turned in the wrong direction, the tab of the crankshaft main bearing will be pushed between the crankshaft and the cylinder block. this can cause damage to either or both the crankshaft and the cylinder block.
Note: Some crankshaft main bearing journals do not have an oil hole. Place a thin piece of soft material that will not damage the journal against the end of the bearing. Ensure that the material is on the opposite side of the bearing tab. Hit the bearing with the soft material until the bearing tab is free from the bearing tab groove in the cylinder block. 3. Use the following steps in order to remove the upper half of crankshaft main bearings: a. Turn the crankshaft until Tooling (A) can be installed in the crankshaft journal. Install Tooling (A) . b. Turn the crankshaft in order to remove the upper half of the crankshaft main bearing. In order to get the tab out first, the crankshaft must be turned in the correct direction. c. Check the condition of the crankshaft main bearings. Refer to the Guideline For Reusable Parts And Salvage Operations, SEBF8009, "Main and Connecting Rod Bearings" and Special Publication, SEBD0531, "Engine Bearings and Crankshafts".
215
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01931316
Crankshaft Main Bearings - Install SMCS - 1203-012
Installation Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
2P-5518
Bearing Tool
1
B
8T-5096
Dial Indicator Group
1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Note: For information on the reusability of the crankshaft main bearings, refer to the Guideline For Reusable Parts And Salvage Operations, SEBF8009, "Main and Connecting Rod Bearings". Note: Place clean engine oil on the crankshaft main bearings prior to assembly. Ensure that the tabs on the back side of the crankshaft main bearings fit in the grooves of the crankshaft main bearing caps and the cylinder block.
216
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03 Illustration 1
g00516920
1. Use Tooling (A) and install the upper halves of the crankshaft main bearings in the cylinder block. Do not put oil on the back of the crankshaft main bearing.
Illustration 2
g00610152
2. Install the lower halves of the crankshaft main bearings in crankshaft main bearing caps (2). Do not put oil on the back of the crankshaft main bearing.
Illustration 3 Six cylinder engine with oil grooves in the cylinder block
g00639559
217
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 4 Six cylinder engine with no oil grooves in the cylinder block
g00639623
NOTICE Crankshaft main bearing caps should be installed with the part number toward the right side of the engine. Crankshaft main bearing caps are to be identified by stamped numbers 1 through 7 located on the bottom surface. The thrust plate is used on the number 6 crankshaft main bearing only.
3. Oil grooves are machined in the saddles of the cylinder blocks of all 3114 engines and earlier 3116 engines. No oil grooves are machined in the saddles of the cylinder block on later 3116 engines and all 3126 engines. 4. Install the bearing caps with the sequence number to the right. A six cylinder engine has an order of 1 through 7 (front to rear). A four cylinder engine has an order of 1 through 5 (front to rear). Place crankshaft main bearing caps (2) in position on the cylinder block. Place clean engine oil or Molylube on the bolt threads and the washer face. Install bolts (1) . 5. Tighten bolts (1) to a torque of 54 ± 7 N·m (40 ± 5 lb ft). Tighten each bolt (1) for an additional 90 ± 5 degrees (1/4 turn).
Illustration 5
g00517003
6. Check the end play of the crankshaft with Tooling (B). The end play must be 0.07 mm (0.003 inch) to 0.32 mm 218
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
(0.013 inch). End By: a. Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump - Install". b. Install the engine balancer shaft on 3114 engines. Refer to Disassembly and Assembly, "Engine Balancer Shaft - Remove and Install".
219
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01935937
Crankshaft - Remove SMCS - 1202-011
Removal Procedure Start By: A. Remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Remove". B. Remove the crankshaft seal carrier. Refer to Disassembly and Assembly, "Crankshaft Rear Seal Carrier Remove and Install". C. Remove the front gear group. Refer to Disassembly and Assembly, "Gear Group (Front) - Remove". D. Remove the piston and the connecting rods. Refer to Disassembly and Assembly, "Piston and Connecting Rods-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.
Note: For information on reusability of the crankshaft, refer to the following list.
Guideline For Reusable Parts And Salvage Operations, SEBF8041, "Crankshaft Measurement"
Guideline For Reusable Parts And Salvage Operations, SEBF8054, "Procedure to Measure and Straighten Bent Crankshafts" 220
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Guideline For Reusable Parts And Salvage Operations, SEBF8094, "Procedure to Grind Crankshafts"
Guideline For Reusable Parts And Salvage Operations, SEBF8043, "Visual Inspection of Crankshafts"
Guideline For Reusable Parts And Salvage Operations, SEBF8039, "Inspection of Crankshafts for Cracks"
Guideline For Reusable Parts And Salvage Operations, SEBF8042, "Procedure to Polish Crankshafts"
Note: For information on reusability of the crankshaft main bearings, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8009, "Main and Connecting Rod Bearings". Note: For information on reusability of the cylinder block and salvage procedures, refer to the following list.
Guideline For Reusable Parts And Salvage Operations, SEBF8192, "Specifications and Salvage for Cylinder Blocks on 3114, 3116, and 3126 Engines"
Guideline For Reusable Parts And Salvage Operations, SEBF8261, "Installing a 7C-6208 Cylinder Sleeve in 3114, 3116 Engines and a 107-7604 Cylinder Sleeve in 3126 Engines"
Special Instruction, SEHS8869, "Cylinder Block Salvage Procedure Using Belzona Ceramic R Metal"
Special Instruction, GMG00981, "Using 1P-3537 Dial Bore Gauge Group to Check Cylinder Bore Size"
Special Instruction, SMHS7606, " Use of 1P-4000 Line Boring Tool Group"
Special Instruction, SEHS8841, " Using the Ironstitch Procedure for Casting Salvage"
Special Instruction, SEHS8919, "Salvage Weld Procedure for Cast Iron Cylinder Blocks"
Guideline For Reusable Parts And Salvage Operations, SEBF8076, "Specifications to Salvage Cylinder Block Contact Surfaces"
Illustration 1
g00625767
Note: The weight of the crankshaft for the 3114 Engine is 37 kg (82 lb). The weight of the crankshaft for 3116 and 3126 Engines is 62 kg (137 lb). 1. Use a suitable lifting device. Remove bolts (2), the washers and main bearing caps (3). Carefully remove crankshaft (1) from the cylinder block.
221
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 2
g00625782
2. Remove upper main bearing (4) from the cylinder block. 3. Remove the main bearings from the main bearing caps.
222
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01931442
Crankshaft Wear Sleeve (Rear) - Remove - If Equipped SMCS - 1161-011-ZV
Removal Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
4C-4869
Distorter Ring
1
B
5P-7312
Seal Distorter
1
Start By: A. Remove the crankshaft rear seal. Refer to Disassembly and Assembly, "Crankshaft Rear Seal - Remove".
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 1
g00614029
223
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Note: Wear sleeves are not installed at the factory. The wear sleeve is included with the replacement rear seal. 1. Install Tooling (A) in the bore of the crankshaft rear sleeve. 2. Install Tooling (B) between Tooling (A) and the crankshaft wear sleeve. Turn Tooling (B) until the edge of Tooling (B) makes a crease in the crankshaft wear sleeve. Make a crease in the crankshaft wear sleeve at two other locations around the crankshaft wear sleeve until the crankshaft wear sleeve is loose. 3. Remove Tooling (B), Tooling (A), and the crankshaft wear sleeve from the end of the crankshaft.
224
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01929732
Crankshaft Wear Sleeve (Rear) - Install SMCS - 1161-012-ZV
Installation Procedure Table 1 Required Tools Tool
Part Number
C (1)
132-8772
Seal Locator
1
D (1)
1U-7596
Bolt
2
E (1)
1U-7597
Sleeve Ring
1
F (1)
1U-7594
Seal Installer
1
G (1)
9S-8858
Nut
1
(1)
Part Description
Qty
Part of the 1U-7598 Seal Installer
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
1. Ensure that the rear of the crankshaft is thoroughly clean and dry prior to the installation of the crankshaft rear seal.
225
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
g01003875
2. Fasten Tooling (C) to the rear of the crankshaft with Tooling (D). Hand tighten Tooling (D) . 3. Position the crankshaft rear seal and crankshaft rear sleeve (1) on Tooling (C). Position Tooling (E) on Tooling (C) .
Illustration 2 Typical example
g01003866
4. Position Tooling (F) over Tooling (C) and Tooling (E). Install Tooling (G). Tighten Tooling (G) in order to install the crankshaft rear seal and the crankshaft wear sleeve. 5. Remove Tooling (G), Tooling (F), and Tooling (E). Turn over Tooling (E). Install Tooling (E), Tooling (F), and Tooling (G). Tighten Tooling (G) in order to complete the installation of the crankshaft rear seal and the crankshaft wear sleeve. 6. Remove Tooling (G) and Tooling (F). Check Tooling (E) and Tooling (C). The faces of Tooling (E) and Tooling (C) will be flush if the crankshaft rear seal and the crankshaft wear sleeve are properly installed. Refer to the Specifications module for more information. 7. Remove Tooling (E), Tool (E), and Tooling (C) . End By: Install the flywheel. Refer to Disassembly and Assembly, "Flywheel - Install".
226
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01931335
Crankshaft - Install SMCS - 1202-012
Installation Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
8T-5096
Dial Indicator Group
1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
NOTICE Ensure that the crankshaft main bearing tabs engage with the grooves in the block and the crankshaft main bearing cap.
Note: For information on reusability of the crankshaft, refer to the following list.
Guideline For Reusable Parts And Salvage Operations, SEBF8041, "Crankshaft Measurement"
Guideline For Reusable Parts And Salvage Operations, SEBF8054, "Procedure to Measure and Straighten Bent Crankshafts"
Guideline For Reusable Parts And Salvage Operations, SEBF8094, "Procedure to Grind Crankshafts"
Guideline For Reusable Parts And Salvage Operations, SEBF8043, "Visual Inspection of Crankshafts"
Guideline For Reusable Parts And Salvage Operations, SEBF8039, "Inspection of Crankshafts for Cracks"
Guideline For Reusable Parts And Salvage Operations, SEBF8042, "Procedure to Polish Crankshafts" 227
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Note: For information on reusability of the cylinder block and salvage procedures, refer to the following list.
Guideline For Reusable Parts And Salvage Operations, SEBF8192, "Specifications and Salvage for Cylinder Blocks on 3114, 3116, and 3126 Engines"
Guideline For Reusable Parts And Salvage Operations, SEBF8261, "Installing a 7C-6208 Cylinder Sleeve in 3114, 3116 Engines and a 107-7604 Cylinder Sleeve in 3126 Engines"
Special Instruction, SEHS8869, "Cylinder Block Salvage Procedure Using Belzona Ceramic R Metal"
Special Instruction, GMG00981, "Using 1P-3537 Dial Bore Gauge Group to Check Cylinder Bore Size"
Special Instruction, SMHS7606, " Use of 1P-4000 Line Boring Tool Group"
Special Instruction, SEHS8841, " Using the Ironstitch Procedure for Casting Salvage"
Special Instruction, SEHS8919, "Salvage Weld Procedure for Cast Iron Cylinder Blocks"
Guideline For Reusable Parts And Salvage Operations, SEBF8076, "Specifications to Salvage Cylinder Block Contact Surfaces"
1. Check the condition of the crankshaft main bearings. Refer to the Guideline For Reusable Parts And Salvage Operations, SEBF8009, "Main and Connecting Rod Bearings" and Special Publication, SEBD0531, "Engine Bearings and Crankshafts". Note: The number four main bearing in 3114 Engines is the thrust bearing. The number six main bearing in the six cylinder engines is the thrust bearing. 2. Clean the bearing surfaces in the cylinder block for the main bearings.
Illustration 1
g00678393
3. Install the upper main bearings (4) in the cylinder block. Ensure that the tab on the back side of the bearing engages with the groove in the cylinder block. Apply clean engine oil on the upper main bearing. Do not put engine oil on the back side of the bearing surfaces.
228
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 2 Typical example
g00610100
4. Put clean engine oil on the journals of the crankshaft bearing. Fasten lifting straps and a hoist to crankshaft (1). Carefully install the crankshaft in the cylinder block. 5. Clean the bearing surface of the main bearing caps.
Illustration 3
g00678394
6. Install the lower main bearings (5) in the crankshaft main bearing caps (3). Ensure that the tab on the back side of the bearing engages with the groove in the main bearing cap. Apply clean engine oil on the lower main bearing. Do not put engine oil on the back side of the bearing surfaces. 7. Install crankshaft main bearing caps with the part numbers toward the right hand side of the cylinder block. Ensure that crankshaft main bearing caps have numbers 1 through 7. The numbers should start at the front of the engine. Place clean engine oil or Molylube on the bolt threads and the washers. Note: When the bolts for the rear main bearing cap are tightened, slide the main bearing cap as far forward as possible until the cap is against the bolts. Hold the main bearing cap in this position and tighten the bolts.
229
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 4 Typical example
g00609985
8. Install bolts (2) and the washers for main bearing caps (3). Tighten bolts (2) to a torque of 54 ± 7 N·m (40 ± 5 lb ft). 9. Turn bolts (2) for an additional 90 ± 5 degrees (1/4 turn).
Illustration 5 Typical example
g00610119
10. Check the end play of crankshaft (1) with Tooling (A). The end play must be 0.07 mm (0.003 inch) to 0.32 mm (0.013 inch). End By: a. Install the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods Install". b. Install the front gear group. Refer to Disassembly and Assembly, "Gear Group (Front) - Install". c. Install the crankshaft seal carrier. Refer to Disassembly and Assembly, "Crankshaft Rear Seal Carrier- Remove and Install". d. Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".
230
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03 Shutdown SIS
Previous Screen Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01944203
Crankshaft Gear - Remove and Install SMCS - 1204-010-GE
Removal Procedure Start By: A. Remove the front gear group. Refer to Disassembly and Assembly, "Gear Group (Front) - Remove".
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Note: For information on reusability of the camshaft gear, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8045, "Timing Gears for All Engines". 1. Place alignment marks on the crankshaft gear and on the crankshaft. The alignment marks will ensure that the camshaft gear is aligned properly during installation.
Illustration 1
g00630476
2. Heat crankshaft gear (1). Remove crankshaft gear (1) from crankshaft (2) .
Installation Procedure 231
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Note: For information on reusability of the camshaft gear, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8045, "Timing Gears for All Engines".
Illustration 2
g00630476
1. Heat crankshaft gear (1) to a maximum temperature of 204 °C (400 °F) for no longer than 1 hour for installation. 2. Align the timing marks on the crankshaft and on crankshaft gear (1). Install crankshaft gear (1) on crankshaft (2) . Note: Ensure that crankshaft gear (1) is flush against the shoulder of crankshaft. If the gear is not flush damage to the gear may occur. End By: Install the front gear group. Refer to Disassembly and Assembly, "Gear Group (Front) - Install".
232
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i02717761
Bearing Clearance - Check SMCS - 1203-535; 1219-535 S/N - 1SK1-UP S/N - 1ZG1-UP S/N - 1ZJ1-UP S/N - 2MR1-UP S/N - 2SG1-UP S/N - 2WG1-UP S/N - 4KG1-UP S/N - 4PG1-UP S/N - 5EF1-UP S/N - 5EN1-UP S/N - 5JG1-UP S/N - 6AF1-UP S/N - 6MK1-UP S/N - 6MS1-UP S/N - 6SR1-UP S/N - 8NM1-UP S/N - 9ZR1-UP S/N - CKK1-UP
Measurement Procedure Table 1 Required Tools 233
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Tool
Part Number
Part Description
Qty
198-9142
Plastic Gauge (Green) 0.025 to 0.076 mm (0.001 to 0.003 inch)
1
198-9143
Plastic Gauge (Red) 0.051 to 0.152 mm (0.002 to 0.006 inch)
1
198-9144
Plastic Gauge (Blue) 0.102 to 0.229 mm (0.004 to 0.009 inch)
1
198-9145
Plastic Gauge (Yellow) 0.230 to 0.510 mm (0.009 to 0.020 inch)
1
A
Note: Plastic gauge may not be necessary when the engine is in the chassis.
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Note: Caterpillar does not recommend the checking of the actual bearing clearances particularly on small engines. This is because of the possibility of obtaining inaccurate results and the possibility of damaging the bearing or the journal surfaces. Each Caterpillar engine bearing is quality checked for specific wall thickness. Note: The measurements should be within specifications and the correct bearings should be used. If the crankshaft journals and the bores for the block and the rods were measured during disassembly, no further checks are necessary. However, if the technician still wants to measure the bearing clearances, Tooling (A) is an acceptable method. Tooling (A) is less accurate on journals with small diameters if clearances are less than 0.10 mm (0.004 inch).
NOTICE Lead wire, shim stock or a dial bore gauge can damage the bearing surfaces.
The technician must be very careful to use Tooling (A) correctly. The following points must be remembered:
Ensure that the backs of the bearings and the bores are clean and dry.
Ensure that the bearing locking tabs are properly seated in the tab grooves.
The crankshaft must be free of oil at the contact points of Tooling (A) .
1. Put a piece of Tooling (A) on the crown of the bearing that is in the cap. Note: Do not allow Tooling (A) to extend over the edge of the bearing. 2. Use the correct torque-turn specifications in order to install the bearing cap. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed. Note: Do not turn the crankshaft when Tooling (A) is installed. 234
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
3. Carefully remove the cap, but do not remove Tooling (A) . Measure the width of Tooling (A) while Tooling (A) is in the bearing cap or on the crankshaft journal. Refer to Illustration 1.
Illustration 1 Typical Example
g01152855
4. Remove all of Tooling (A) before you install the bearing cap. Note: When Tooling (A) is used, the readings can sometimes be unclear. For example, all parts of Tooling (A) are not the same width. Measure the major width in order to ensure that the parts are within the specification range. Refer to Specifications Manual, "Connecting Rod Bearing Journal" and Specifications Manual, "Main Bearing Journal" for the correct clearances.
235
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01931368
Engine Oil Pressure Sensor - Remove and Install SMCS - 1924-010
Removal Procedure 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.
At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the filler cap is cool enough to touch with the bare hand. Remove the filler cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury. Note: Put identification on all hose assemblies, wires, and tube assemblies for installation purposes. Install a cap or plug on all hose assemblies and tube assemblies in order to prevent foreign material from entering the system. Note: Drain all fluids into a suitable container for storage or disposal.
236
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1
g00678580
1. Disconnect harness assembly (2) at the clip.
Illustration 2
g00678582
2. Remove oil pressure sensor (1) and O-ring seal (3) .
Installation Procedure
Illustration 3
g00678582
1. Install a new O-ring seal (3) on oil pressure sensor (1). Install oil pressure sensor (1) .
237
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Illustration 4
g00678580
2. Connect harness assembly (2) at the clip. Note: Refer to the Operation and Maintenance Manual for all fluid capacities and the proper filling procedures.
238
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Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01200681
Ether Atomizer - Remove and Install SMCS - 1456-010
Removal Procedure
Illustration 1
g00642608
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
1. Remove ether atomizer (1) from the top of the air inlet manifold.
Installation Procedure
239
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 2
g00642608
Note: Install the ether atomizer so that the direction of the spray is parallel to the air inlet heater, If equipped. The ether atomizer has an indicator in order to show the direction of the spray. Note: The ether atomizer has two ports that are separated by 180 degrees. The two ports must be aimed parallel to the length of the block. 1. Install ether atomizer (1). The minimum torque for the ether atomizer is 2.8 N·m (25 lb in).
240
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01930316
Belt Tensioner - Remove and Install SMCS - 1358-010
Removal Procedure
Illustration 1
g01011962
1. Use a breaker bar to release the tension on belt tensioner (1). Remove the drive belt. 2. Remove bolt (2) and belt tensioner (1) .
Installation Procedure
241
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 2
g01011962
1. Position belt tensioner (1) on the cylinder block. Install bolt (2) . 2. Install the drive belt. Use a breaker bar to release tension on belt tensioner (1) .
242
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01930317
Belt Tightener - Remove SMCS - 1358-011
Removal Procedure
Illustration 1
g00619355
1. Remove bolts (1) that hold water pump belt tightener (3) to the timing gear housing. 2. Remove V-belt (2) from the pulley of water pump belt tightener (3). Remove water pump belt tightener (3) .
243
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01930280
Belt Tightener - Install SMCS - 1358-012
Installation Procedure
Illustration 1
g00619355
1. Position water pump belt tightener (3) and install V-belt (2) on the pulley of water pump belt tightener (3) . 2. Install bolts (1) that hold water pump belt tightener (3) to the timing gear housing. 3. Adjust the tension of V-belt (2). Refer to Operation and Maintenance Manual, "Belt Tension Chart".
244
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01930386
Alternator - Remove and Install SMCS - 1405-010
Removal Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
168-0383
Circuit Breaker Bar
1
Illustration 1 Typical Example
g00609523
Note: Release the tension on the belt at the belt tightener, if the engine is not equipped with a belt tensioner. 1. Use Tooling (A) to release the tension on belt tensioner (5) . 2. Remove drive belt (4) from the drive pulley on alternator (3) . 3. Place an index mark on the wires of harness assembly (1) that are connected to the alternator. Disconnect harness assembly (1) from the alternator. 4. Remove bolts (2) . 5. Remove alternator (3) from the mounting bracket. 245
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Installation Procedure Table 2 Required Tools Tool
Part Number
Part Description
Qty
A
168-0383
Circuit Breaker Bar
1
Illustration 2 Typical example
g00609523
1. Position alternator (3) on the mounting bracket. Install bolts (2) . 2. Use Tooling (A) to install drive belt (4) on the drive pulley of the alternator. Note: Adjust the tension on the drive belt if the engine is not equipped with a belt tensioner. Refer to the Operation and Maintenance Manual for the correct adjusting procedure. 3. Connect harness assembly (1) to the alternator. Use the index marks to correctly connect the harness assembly. Tighten the mounting bolt for the ground wire to a torque of 6.2 ± 0.6 N·m (54 ± 5 lb in). Tighten the mounting bolt for the battery wire to a torque of 11.3 ± 2.3 N·m (100 ± 20 lb in).
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_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i03904991
Electric Starting Motor - Remove and Install SMCS - 1453-010
Removal Procedure
Personal injury can result from failure to disconnect the battery. First, disconnect the negative battery cable. Then, disconnect the positive battery cable. A positive power lead can cause sparks if the battery is not disconnected. Sparks can possibly result in battery explosion or fire.
Illustration 1
g02146813
1. Disconnect cable strap (1) . 2. Place an index mark on all of the harness assemblies. Disconnect the harness assemblies from electric starting motor (2) . 3. Fasten a suitable lifting device to electric starting motor (4). The weight of electric starting motor (4) is approximately 35 kg (77 lb). 4. Remove bolts (3) . 247
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
5. Remove electric starting motor (4) and the gasket from the flywheel housing.
Installation Procedure 1. Install electric starting motor (4) in reverse order.
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_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01931416
Air Compressor - Remove and Install SMCS - 1803-010
Removal Procedure
Do not disconnect the air lines until the air pressure in the system is at zero. If hose is disconnected under pressure it can cause personal injury.
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. Remove the air pressure from the air tank and drain the coolant from the cooling system.
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_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 1 Typical example
g00484206
2. Disconnect hose assemblies (1), (2) and (9) from the air compressor. Remove tube assembly (4) from the air compressor. 3. Remove bolt (5) and the washer. Remove clamp (7) from tube assembly for the breather. Move the tube assembly for the breather aside. 4. Remove bolts (3) and the washers that hold the air compressor to the timing gear housing. 5. Remove bolts (6) and remove air compressor (8) and the gasket from the engine.
Installation Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
4C-4030
Thread Lock Compound
1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Note: Check the condition of the gaskets and O-ring seals. If gaskets or O-ring seals are damaged, use new parts for replacement.
250
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Illustration 2 Typical example
g00484206
1. Use bolts (3) and the washers to install air compressor (8). Apply Tooling (A) to the threads of bolts (6). Torque bolts (6) to 160 ± 30 N·m (118 ± 22 lb ft). 2. Install clamp (7) for the tube assembly for the breather with bolt (5) and the washer. 3. Install tube assembly (4) and connect hose assemblies (9), (2) and (1) to air compressor (8) .
251
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
Product: INDUSTRIAL ENGINE Model: 3114 INDUSTRIAL ENGINE 1ZG Configuration: 3114 INDUSTRIAL ENGINE 1ZG00001-UP
Disassembly and Assembly 3114, 3116 and 3126 Engines Media Number -SENR9518-03
Publication Date -01/09/2005
Date Updated -03/10/2005 i01931465
Air Compressor Drive Gear - Install SMCS - 1803-012-GE
Installation Procedure Table 1 Required Tools Tool
Part Number
Part Description
Qty
A
132-5451
Holding Fixture
1
B
138-8440
Component Cleaner
1
NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.
Illustration 1 Typical example
g00609907
1. Use Tooling (B) in order to clean the inside diameter of air compressor drive gear (4) and the outside diameter of the drive shaft for the air compressor. 252
_____________________________________________________________________________________________________ 3114 INDUSTRIAL ENGINE 1ZG00001-UP Disassembly and Assembly SENR9518-03
2. Lubricate washer (3) and the threads on the drive shaft with clean engine oil. 3. Mount air compressor (1) in a bench vise.
NOTICE A loose air compressor drive gear can lead to immediate loss of hydraulic power to vehicle systems
4. Install Tooling (B) . 5. Install air compressor drive gear (4) on the air compressor crankshaft. 6. Install washer (3) and nut (2) . 7. Tighten nut (2) to a torque of 170 ± 15 N·m (125 ± 11 lb ft). 8. Use a soft faced hammer and tap the air compressor drive gear. Again tighten the nut to a torque of 170 ± 15 N·m (125 ± 11 lb ft). End By: Install the air compressor. Refer to Disassembly and Assembly, "Air Compressor - Remove and Install".
from the Library of Barrington Diesel Club
253