卡特320d发动机c6.4(中文资料)

1、 PAGE PAGE 55C4.2andC6.4EnginesforCaterpillarBuiltMachinesEngineDesignSMCS 1201排气门进气门102 mm (4.02 inch)冲程 . 130 mm (5.12 inch)排放 . 6.4 L (389 cu in) 4发动机气门间隙进气 . 0.25 mm (0.010 inch)排气 . 0.40 mm (0.016 inch)1-5-3-6-2-4转的方向从飞轮往发动机直视曲轴旋转方向逆时针1燃油喷油油路检查，维修和服务指示，可能会导致人身伤害或死亡。(1)41 5 Nm (30 4 lb ft)(2) 12

2、17.0 1.7 Nm (150 15 lb in)(3) 49 1 Nm (80 9 lb in) (4)8.5 0.5 Nm (75 4 lb in)(5)25.0 to 27.5 Nm (220 to 245 lb in) (6) 434 4 Nm (300 35 lb in)(7) 615 2 Nm (130 18 lb in)(8) 225.0 to 27.5 Nm (220 to 245 lb in)燃油喷油泵1)70 5 Nm (50 4 lb ft)(2) 260 6 Nm (44 4 lb ft) (3)15 2 Nm (11 1 lb ft)使用以下步骤去拎紧螺丝:螺丝拧紧

3、到 5 Nm (45 lb in).2. 拧螺丝角度到 18.8 1.0 度.3. 最后螺丝扭矩 12 2 Nm (105 18 lb in).安装之前, 用干净的机油去润滑这三个密封.(6)40 3 Nm (30 2 lb ft) (7)123Nm(10527lbin)(8)9 1 Nm (80 9 lb in) (22 1 lb ft)使用下面步骤去拎 4 颗螺丝:5 Nm (45 lb in).19.9 1.0 degrees.3.12 2 Nm (105 18 lb in).(11)接头扭矩 . 25.02.5Nm(182lbft)(12)接头扭矩 . 25.02.5Nm(182lbf

4、t)(13)接头扭矩 . 25.02.5Nm(182lbft)(14)接头扭矩 . 25.02.5Nm(182lbft)喷油嘴夹具O 型密封圈(1) 这个螺丝扭矩 . 293 Nm (212 lb ft)燃油滤芯座(1)32 3 Nm (285 27 lb in) (2)8.81.0Nm(809lbin)摇臂轴Bore in rocker arm bushing for shaft . 24.949 to 24.975 mm (0.9822to 0.9833 inch)armshaft.24.915to24.928mm(0.9809to0.9814inch)Clearance of rocke

5、r arm bushing and shaftMinimum . 0.021 mm (0.0008 inch)Maximum . 0.060 mm (0.0024 inch)Align the oil holes in rocker arm bushing (4) with the oil holes in the rocker arm when therocker arm bushing is replaced.Torque for six bolts . 18 2 Nm (13 1 lb ft)Torque for six bolts . 18 2 Nm (13 1 lb ft)Torqu

6、e for bolt . 74 5 Nm (55 4 lb ft)Turn the crankshaft until the timing mark on the crankshaft pulley is aligned with the pointer on the timing gear housing in order to adjustthe valve lash. Both the No. 1 inlet valve and the No. 1 exhaust valvepushrods must not be in tension against the rocker arms.I

7、nlet valve lash . 0.25 mm (0.010 inch) Exhaustvalvelash.0.40mm(0.016inch)Valve Mechanism CoverTorque for 25 bolts . 18 2 Nm (160 18 lb in)Torque for 18 bolts . 17 2 Nm (150 18 lb in)Torquefor eight bolts . 8.8 1.0 Nm (80 9 lb in)CylinderHeadValvesDiameter of the valve headInlet . 34.5 mm (1.36 inch)

8、Exhaust . 27.5 mm (1.08 inch)Diameter of the valve stemInlet valve . 6.6 mm (0.26 inch) Exhaustvalve.6.6mm(0.26inch)Length of the valveInlet valve . 144.0 mm (5.67 inch) Exhaustvalve.144.0mm(5.67inch)Width of the valve seatInlet . 1.0 mm (0.039 inch)Exhaust . 1.2 mm (0.047 inch)Angle of valve seat f

9、aceInlet . 30 degrees Exhaust.45degreesCylinder Head(1) Dimension for the cylinder headUse a straightedge and a feeler gauge to check the cylinder head forwarpage.Flatness of the cylinder head over total span . 0.05 mm (0.002inch)Resurfacethecylinderheadifthewarpageexceedsthefollowingvalue. . 0.20 m

10、m (0.008 inch)Gasketthicknessofcylinderhead.1.700.05mm(0.0670.002inch)limitofthecontactsurfaceofthegasketandtherepairlimit of the cylinder block surface is 0.20 mm (0.008 inch).Note: Put clean engine oil on the threads of the cylinder head bolts.1throughbolt26inthenumericalsequencethatisshownin Illu

11、stration 2 to 137 5 Nm (100 4 lb ft).Exhaust ManifoldTorque for 13 nuts . 18 2 Nm (13 1 lb ft)Camshafttemperatureofthecamshaftgearforinstallationon the camshaft . 250 C (482 F)NOTICEDonotuseatorchtoheatthegear.Atorchcanunevenlyheatthegearcausingwarpage.Thehardnessofthegearmayalsobechangedwiththeuseo

12、fatorch.Diameters of camshaft journalsTable 1Table 1NumberofJournalStandardDiameterServiceLimit (1)1, 2, 353.94to53.96mm(2.124to2.124inch)53.90mm(2.122inch)452.94to52.96mm(2.084to2.085inch)52.90mm(2.083inch)( 1 ) The service limit is the maximum dimension or the service limit is the minimum dimensio

13、n that is specified for a part. Replace the part if theservice limit is reached.Torque for two bolts . 12 2 Nm (105 18 lb in)Usethefollowingprocedureinordertodeterminethecamshaftlobelift:Measure the camshaft lobe height (C) .Measure the base circle (D) .Subtract the base circle measurement in Step 2

14、 from the camshaft lobe height in Step 1. The difference is the actual camshaft lobelift (B) .Specified camshaft lobe liftExhaust lobe . 7.463 mm (0.2938 inch)Inlet lobe . 6.154 mm (0.2423 inch)Servicelimitforlobeliftforexhaust.6.963mm(0.2741inch)Servicelimitforlobeliftforinlet.5.654mm(0.2226inch)No

15、te: Replace the camshaft if the service limit for the lobe lift isreached.Note: Use a dial indicator and blocks in order to determine the runoutofthecamshaft.Takeonehalfofthedialindicatorreadingastherunout.Maximum permissible runout for camshaft . 0.04 mm (0.002 inch)Measure the camshaft bearing wit

16、h a dial indicator. Subtract the diameter of the camshaft journal in order to give bearing clearances. to Table 4for theclearance betweenthe camshaft journalsand thebushings.Table 2Table 2NumberofJournalStandardDiameterRepairLimit (2)1, 2, 30.04to0.09mm(0.002to0.004inch)0.15mm(0.006inch)40.040to0.11

17、9mm(0.0016to0.0047inch)0.15mm(0.006inch)( 2 ) The repair limit is the maximum dimension or the repair limit is the minimum dimensionthatisspecifiedforapart.Repairthepartiftherepairlimitisreached.Engine Oil Pump1)Drivengearassembly(2)DrivegearassemblySpindleNOTICEBefore operation, thepumpmustbelubric

18、ated withcleanengineoilandthepumpmustturnfreelybyhandordamagetopartscanbetheresult.Note: Theminimumacceptableoilpressureatlowidleis98kPa(14psi).to 220 C (356 to428 F) and support the end of the drive gear shaft in order to install the oil pump gear. Press the oil pump gear until the oil pump gear is

19、 flush with the end ofthe shaft.NOTICEDonotuseatorchtoheatthegear.Atorchcanunevenlyheatthegearcausingwarpage.Thehardnessofthegearmayalsobechangedwiththeuseofatorch.The backlash between the oil pump gear (3) and the idler gear (4) is thefollowing. . 0.100 to 0.190 mm (0.0039 to 0.0075 inch)Note: Repl

20、acethe gearsif thebacklash exceeds0.35 mm(0.014 inch).Note:Theoilpumpgearandthedrivegearassemblyarenotserviceableif the oil pump gear is removed.Housing for oil pump gearMaximum distance between the oil pump gear assembly and the oil pumphousingDistance above the housing . 0.020 mm (0.0008 inch)Dist

21、ancebelowthehousing.0.034mm(0.0013inch)Note: Theservicelimitoftheoilpumpgearassemblyis0.150mm(0.0059inch) below the oil pump housing.Note:Measuretheclearancebetweentheoilpumpgearsandtheoilpumphousing with a feeler gauge.Clearance between the oil pump gears and the oil pump housing . 0.050to 0.098 mm

22、 (0.0020 to 0.0039 inch)Note:Theservicelimitoftheoilpumpgearassemblyis0.10mm(0.004inch).Measure the inside diameters of the bores of the shafts in the cover (8)and the oil pump housing (7) . Measure the bores of the shafts. The andthe oil pump housing andcover .0.04 to 0.07 mm (0.002 to 0.003 inch)N

23、ote: Replacethe oilpump gearassembly, thecover, orthe oilpump housingiftheclearanceexceedstheservicelimitof0.15mm(0.006inch).Note: Replacethe drivegear anddrivengear asan assembly.Idler gear bushingInsidediameterofidlergearbushing.25.000to25.021mm(0.9842 to 0.9851 inch)Maximum diameter of idler gear

24、 bushing for oil pump . 25.059 mm(0.9866 inch)SpindleDiameterofspindle.24.939to24.960mm(0.9818to0.9827inch)Minimumdiameterofspindleforoilpump.24.901mm(0.9804inch)(9) Torque for bolts . 35 6 Nm (26 4 lb ft)Engine Oil Bypass ValveTorque for nut . 44 5 Nm (32 4 lb ft)Torque for relief valve assembly .

25、49 5 Nm (36 4 lb ft)Thevalveopensatthefollowingpressure35050kPa(517psi)Engine Oil PanTorque for the bolt . 32 3 Nm (24 2 lb ft)Torque for 38 bolts . 18 2 Nm (13 1 lb ft)Torque for the valve . 49 5 Nm (36 4 lb ft)Torque for the plug . 83 10 Nm (60 7 lb ft)Note:Apply154-9731 ThreadLockCompoundtothethr

26、eadsofthebolts.Torque for four bolts . 30.0 1.5 Nm (22 1 lb ft)Water Temperature RegulatorStart to open temperature of the water temperature regulator . 71 2 C (160 4 F)Thevalveliftsmorethan10mm(0.4inch)atthefollowingtemperature85 C (185 F)Water Pump(2) ShaftThepressfitbetweentheshaftandtheflange(3)

27、.0.035to0.065mm (0.0014 to 0.0026 inch)The press fit between the shaft and the impeller (1) . 0.022 to0.062 mm (0.0009 to 0.0024 inch)Note: Flush the face of the impeller and the face of shaft.(4) Torque for the bolts . 32 3 Nm (24 2 lb ft)Cylinder Block(1) Measure the amount of the warpage of the c

28、ylinder block with a straightedge and feeler gauge. Maximum allowable clearance . 0.05 mm(0.002 inch)Repair limit . 0.20 mm (0.008 inch)Resurface the top of the block if the repair limit is reached.Measure the amount of the warpage of the cylinder block with a straightedge and feeler gauge. Maximum

29、allowable clearance . 0.05 mm(0.002 inch)Repair limit . 0.20 mm (0.008 inch)Resurface the top of the block if the repair limit is reached.Table 1TolerancesofCylinderSleevesStandardatAssemblyRepairLimitService(1)Limit(2)InsideDiameterOut ofRoundN/AN/ATaperN/ATable 1TolerancesofCylinderSleevesStandard

30、atAssemblyRepairLimitService(1)Limit(2)InsideDiameterOut ofRoundN/AN/ATaperN/AN/Amiddle andthe bottom of the cylinder liner. RefertoTable 2 fortolerancesof the cylinder liner.102.010 to 102.045 mm102.200 mm102.700 mm(4.0161 to 4.0175 inch)(4.0236 inch)(4.0433 inch)0.010mm(0.0004inch)0.015mm(0.0006in

31、ch)( 1 ) The repair limit is the maximum dimension or the repair limit is the minimum dimension that is specified for a part. Repair a part if the repair limit is reached.( 2 ) The service limit is the maximum dimension or the service limit is the minimumdimension that is specified for a part. Repla

32、ce the part if the service limitis reached.Bore the cylinder to the specified oversize dimension if the inside the repairlimitbuttheinsidediameterdoesnotreachthe service limit. Refer to Table 3.Honethelinerto+0.25mm(+0.010inch)or+0.50mm(+0.020inch)oversize. Hone the liner to an accuracy within 0.010

33、 to 0.045 mm (0.0004 to 0.0018inch).Determine the oversize dimension that is necessary in order to clean upthe cylinder if any liner has uneven wear.Replace all cylinder liners thatare in excess of the servicelimit.Note: Refinishalllinerstothesame oversize dimension. Usea ridgereamer in order to cut

34、 the ridgeof the cylinder if the lineris in goodTable 2OversizeTable 2OversizeBoreCylinderBoreSize0.250 mm (0.0100 inch)102.260102.295mmmm(4.0260(4.0274inch)inch)0.500 mm (0.0197 inch)102.510102.545mmmm(4.0358(4.0372inch)inch)Service limit of cylinder liner . 102.700 mm (4.0433 inch) Note: Replace a

35、ll cylinder liners that exceed the service limit. Usethefollowingprocedureinordertoreplacethecylinderliners.Set up a boring machine on the cylinder block. Align the boring machine with the center of the bottom of the cylinder liner withthe least worn area.Bore the liner until the thickness is 0.50 m

36、m (0.020 inch).Remove the remainder of the liner. Be careful not to damage thecylinder block.Installanewliner.Alignthelinerwiththetopofthecylinderblock.The bore of the cylinder must be 102.000 to 102.035 mm (4.0157 to4.0171 inch).Diameter for the main bearing bores . 95.000 mm (3.7402 inch)Maximum d

37、iameter of the main bearing bores . 95.022 mm (3.7410 inch)New height of deck from centerline of crankshaft to deck . 307.00 0.05mm (12.086 0.002 inch)Minimum height from the centerline of crankshaft to deck . 306.70 mm(12.075 inch)CrankshaftCrankshaft main bearing journalSupport the crankshaft in a

38、 set of vee blocks. Measure the runoutjournal.Maximumrunout.0.040.10mm(0.002 0.004 inch)(3) Crankshaft end play . 0.100 0.246 mm (0.0039 0.0097 inch)Note: The maximumrepair limit is0.300 mm (0.0118inch).Replace the standard thrust plates if the end play exceeds the standardclearance. Three oversizet

39、hrust plates areavailable as replacementsif the end play still exceeds the maximum limit. Generally, the rear journal is likely to be worn more rapidly than the front journal. If necessary,replacetherearthrustplate.RefertoTable2foroversizethrustplates.Plateorrear)orrear)0.15 mm (0.00633.15 mm (1.305

40、33.30 mm (1.3110.039 mm (0.0015inch)inch)inch)inch)0.30 mm (0.01233.30 mm (1.31133.45 mm (1.3170.039 mm (0.0015inch)inch)inch)inch)0.45 mm (0.01833.45 mm (1.31733.60 mm (1.3230.039 mm (0.0015inch)inch)inch)inch)Table 1DimensionsforGrindingofCrankshaftOversizeThrustPlatesOversizeThrustOversize(frontO

41、versize(frontToleranceTorqueforTable 1DimensionsforGrindingofCrankshaftOversizeThrustPlatesOversizeThrustOversize(frontOversize(frontToleranceThe maximum temperature for installing the crankshaft gear is thefollowing value. . 250 C (482 F)ConnectingRodBearingJournalOriginal size journalUndersize jou

42、rnal64.945to64.965mm(2.5569to2.5577inch)0.25 mm (0.010 inch)64.695to64.715mm(2.5470to2.5478inch)Undersize journal0.50 mm (0.020 inch)64.445to64.465mm(2.5372to2.5380inch)Undersize journal0.75 mm (0.030 inch)64.195to64.215mm(2.5274to2.5281inch)ConnectingRodConnectingRodBearingJournalAn undersized bear

43、ing is required if the clearance between the connectingrod journal and the bearing is in excess of the service limit of 0.200mm (0.0079 inch). If the crankshaft is worn excessively, or if the crankshaft is uneven, an undersized bearing is required. If an undersizedbearingisrequired, grindthecranksha

44、ft toadimensionlistedinTable2.Note:Theallowabletoleranceforrodbearingjournalsthatareoutofround is 0.010 mm (0.0004 inch). The maximum repair limit is 0.030 mm (0.0012 inch). If the repair limit is exceeded, regrind the bearing journals to the specified dimension.Main Bearing JournalMainbearingcapDia

45、lindicatorProcedure to measure the bore of main bearing journalPut the main bearing caps in position in the cylinder block. Apply cleanengineoilonthemainbearingbolts.Installthemainbearingboltsandtightenthemainbearingboltstoatorqueof1375Nm (100 4 lb ft).bearingboreswithadialindicator.Subtractthecrank

46、shaftjournalfromtheinsidediameterofthemainbearinginordertodeterminethebearingclearanceonthemainjournal. Clearance between the crankshaft journal and the main bearing is 0.050 to 0.118 mm (0.0020 to 0.0047 inch).Note: Replace thebearings orrefinish thecrankshaft tothe next undersize bearing if the ma

47、in bearing clearance exceeds 0.20 mm (0.008inch).Note:Theallowabletoleranceformainbearingjournalsthatareoutofround is 0.010 mm (0.0004 inch). The maximum repair limit is 0.030 mm (0.0012 inch). If the repair limit is exceeded, regrind the bearing journals to the specified dimension.(1)Mainbearingcap

48、BoltsMainbearingMainbearingjournal(3) Torque for bolts . 137 5 Nm (100 4 lb ft)inch)0.25Undersizemm (0.010 inch)2.602to2.615mm (0.1024inch)to0.10300.50Undersizemm (0.020 inch)2.727to2.740mm (0.1074inch)to0.10790.75Undersizemm (0.030 inch)2.852to2.865mm (0.1123inch)to0.1128Table 1ThicknessforCranksha

49、ftMainBearingSizeofCrankshaftMainBearingJournalTable 1ThicknessforCrankshaftMainBearingSizeofCrankshaftMainBearingJournalBearingThicknessOriginal size journal2.477 to 2.490 mm (0.0975 to 0.0980Undersize journal89.95to89.97mm(3.541to3.542inch)0.25 mm (0.010 inch)89.70to89.72mm(3.531to3.532inch)Unders

50、ize journal0.50 mm (0.020 inch)89.45to89.47mm(3.521to3.522inch)Undersize journal0.75 mm (0.030 inch)89.20to89.22mm(3.512to3.513inch)Table 2MainBearingJournalOriginal size journal(1)( 1 ) Regrindthemainbearingjournalstothenextundersizedimensioniftherepairlimitof89.85mmTable 2MainBearingJournalOrigina

51、l size journal(1)Connecting RodMatching marks that are used to align the cap to the connecting rodThe upper oil hole is 40 degrees above the horizontal centerline.The lower oil hole is 30 degrees below the horizontal centerline.The end of the piston pin bearing is 30 degrees below the lower oilhole.

52、Bore of piston pin bearing . 34.020 to 34.045 mm (1.3394 to 1.3404inch) the piston pinis 0.023to 0.054 mm (0.0009 to 0.0021 inch).Note: Aclearanceforthepistonpintothepistonpinbearingover0.080mm (0.0031 inch) is excessive. Replace the piston pin or replace the bearing if the clearance is excessive.No

53、te:Beforeassembly,putcleanengineoilontheboltthreadsandallsurfaces that make contact between the bolt and connecting rod caps.Torque for nuts . 103 5 Nm (75 4 lb ft)Note: Measure the bores of each of the connecting rods and record thedimension of the bores.rod.64.000mmto64.019mm(2.5197inchto2.5204inc

54、h)Useafeelergaugetomeasuretheendplay.Endplayoftheconnectingrod should be within 0.15 to 0.35 mm (0.006 to 0.014 inch).Note:Replacetheconnectingrodiftheendplayexceeds0.50mm(0.020inch).Assemblethepiston(4)andconnectingrods.Ensurethatthemarkings(5)onthepistonandthemarks(1)ontheconnectingrodareonthesame

55、side.Installthepistonassemblywiththemarks(1)ontheconnectingrodtowardthe camshaft (6) .Use the following procedure to measure the height of each piston abovethecylinderblock.Ifclearancesarenotintheacceptablerange,inspectthe components for wear or damage.Determinethetopcenterpositionofthepistonwithadi

56、alindicator assembly.Install the dial indicator assembly on the top of the block. Setthe needle of the dial indicator to zero.Measure projection (F) at three places on the top of the piston.Take an average of the three measurements in order to determine theprojection. Subtract the projection from th

57、e installed thicknessof the cylinder head gasket in order to determine the clearance between the top of the piston and the cylinder head.Installedthicknessofthecylinderheadgasket.1.700.10mm(0.067 0.004 inch)Piston projection . 0.55 to 1.15 mm (0.022 to 0.045 inch)Piston and RingsPiston diameterEach

58、piston has markings (1) which are stamped on top of the piston. Themarkings are used to align the piston assembly to the camshaft side of the cylinder block. 2 gives thedimensions forpistonsthat are standard.Table 2 alsogives the dimensions for pistons that are oversize.Note:Measurethepistondiameter

59、alongtheperpendicularofthepistonpin bore.DimensionsDimensionsforPistonDiametersBoreSizeStandardatAssemblyServiceLimit (1)Standard mm (4.0124 101.730mm(4.0051to 4.0136 inch)inch)Oversize0.25mm(0.010 inch) mm (4.0222 101.980mm(4.0150to 4.0234 inch)inch)Oversize0.50mm(0.020 inch) mm (4.0321 102.230mm(4

60、.0248to 4.0333 inch)inch)( 1 ) Apistonwhichexceedsthislimitmustbereplaced.DiameterofpistonpinboreDiameterofpistonpin.33.991to33.997mm(1.3382to1.3385inch)Measure the piston pin bore diameter. Subtract the piston pin diameterfromtheborediameter.Theclearancebetweentheboreandpistonpin.0.005 to 0.021 mm