Caterpillar cat 3054 industrial engine (prefix 6 fk) service repair manual (6fk00001 and up)

Service Repair Manual
Models
3054 Industrial Engine

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Product: INDUSTRIAL ENGINE
Model: 3054 INDUSTRIAL ENGINE 6FK
Configuration: 3054 Industrial Engine 6FK00001-UP
Disassembly and Assembly
3054 and 3056 Industrial and Generator Set Engines
Media Number -SENR5547-04 Publication Date -01/02/2004 Date Updated -25/02/2004
i01092432
Engine Oil Pump - Remove
SMCS - 1304-011
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-1855 Retaining Ring Pliers 1
Start By:
A. Remove the front housing. Refer to Disassembly and Assembly, "Housing (Front) -
Remove".
Note: The engine oil pump is mounted on the No. 1 crankshaft main bearing cap. The engine oil
pump can be removed without removing the front housing if the No. 1 crankshaft main bearing
cap is removed. Use a 9U-6282 Torque Wrench Extension in order to remove the No. 1 crankshaft
main bearing cap. The engine oil pump is then removed from the No. 1 crankshaft main bearing
cap.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE
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2019/10/30https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sis...

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 g00552238
1. Remove two bolts (1) from suction pipe (3) .
2. Remove bolt (2) from the mounting bracket.
3. Remove the strainer, suction pipe (3), and the gasket.
4. Remove the engine oil relief valve. Refer to Disassembly and Assembly, "Engine Oil Relief
Valve - Remove".
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5. Use Tool (A) to remove retaining ring (4) .
6. Remove idler gear (5) from the gear drive of the engine oil pump. Inspect the shaft of the
idler gear for wear or damage. Use the following steps if the shaft needs to be replaced.
a. Use a suitable press in order to remove the shaft for the idler gear from a 3054
Engine.
Idler gear shaft
(A) 8.3 mm (0.33 inch)
(B) 20.0 mm (0.79 inch)
(C) 1.0 mm (0.04 inch)
(D) 16.25 ± 0.15 mm (0.640 ± 0.006 inch)
(E) The bore has a diameter of 6.9 mm (0.27 inch). The bore has a depth of 22.0 mm (0.87 inch). The
hole is for a 5/16-24 UNF and an 18 millimeter thread.
(F) 36.0 mm (1.42 inch)
(G) The bore has a diameter of 6.55 ± 0.05 mm (0.258 ± 0.002 inch). The bore must be countersunk
9.0 millimeters.
(H) 31.75 mm (1.250 inch)
(I) 15.9 mm (0.63 inch)
b. The shaft for the idler gear on a 3056 Engine is retained with a pin. Make a drill guide
with the dimensions listed above in order to remove the pin.
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c. Place drill guide (1) into position on the opposite side of pin (2) on the main bearing
cap.
Note: Ensure that the countersink in the guide faces outward. Also ensure that the
edge of the guide is aligned with the front edge of the main bearing cap. Use a 5/16
inch UNF (4) and a flat washer (3) to retain the guide.
d. Drill a hole with a 6.4 mm (0.25 inch) diameter in the main bearing cap. The hole
should be 47.0 mm (1.85 inch) deep.
e. Remove drill guide (1) .
f. Use a suitable drift to drive pin (2) from the main bearing cap.
g. Press the shaft for the idler gear out of the main bearing cap.
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7. Remove three bolts (6) that hold engine oil pump (7) on the front of the engine.
8. Remove engine oil pump (7) .
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed Oct 30 14:11:19 UTC+0800 2019
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i01092600
Engine Oil Pump - Install
SMCS - 1304-012
Installation Procedure
Table 1
Required Tools
A 1P-1855 Retaining Ring Pliers 1
NOTICE
NOTICE
If any of the parts on the engine oil pump are worn or damaged, the
entire pump must be replaced.
Note: If the No. 1 crankshaft main bearing cap was removed, install the No. 1 crankshaft main
bearing cap with the engine oil pump. Tighten the bolts for the No. 1 crankshaft main bearing cap
to a torque of 265 ± 40 N·m (195 ± 30 lb ft).
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1. If the shaft for the idler gear on the engine oil pump of a 3054 Engine was removed, remove
the old sealant. Apply a fresh layer of Loctite 603 to the bore in the main bearing cap and
use a suitable press to install the shaft.
2. If the shaft for the idler gear on the engine oil pump of a 3056 Engine was removed, use the
following steps to install the shaft.
Note: If the shaft on the 3056 Engine was not originally installed with a pin, the pin must be
installed.
a. Ensure that the bore in the main bearing cap is clean and that the main bearing cap
has no burrs. Apply Loctite 603 to the bore and use a suitable press to install the shaft.
Note: Ensure that the shaft is at 90 degrees to the main bearing cap.
b. Use the original hole for the pin in the main bearing cap. Drill the hole to a new
diameter of 6.35 mm (0.250 inch). The depth of the hole is 9.5 mm (0.37 inch).
c. Install new pin (2) into the main bearing cap and the shaft. Remove the excess Loctite
603.
d. Remove bolt (4), flat washer (3), and drill guide (1) .
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3. Fill engine oil pump (7) with clean engine oil. Install engine oil pump (7) on the engine.
4. Install three bolts (6). Tighten the bolts to a torque of 22 N·m (16 lb ft).
5. Install idler gear (5) .
6. Use Tool (A) to install retaining ring (4) on idler gear (5) .
Note: After you install the engine oil pump and the idler gear, ensure that there is a
minimum of 0.08 mm (0.003 inch) backlash between the gear on the engine oil pump and
the idler gear.
7. Install the engine oil relief valve. Refer to Disassembly and Assembly, "Engine Oil Relief
Valve - Install".
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8. Install the strainer, suction pipe (3), and the gasket.
9. Install bolt (2) on the mounting bracket. Tighten the bolt to a torque of 22 N·m (16 lb ft).
10. Install two bolts (1) in suction pipe (3). Tighten the bolts to a torque of 22 N·m (16 lb ft).
End By: Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) -
Install".
Wed Oct 30 14:12:15 UTC+0800 2019
4/4(W)w

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i01644325
Water Pump - Remove
SMCS - 1361-011
Removal Procedure
NOTICE
NOTICE
containing fluids.
1. Drain the coolant from the cooling system into a suitable container for storage or disposal.
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Typical example
2. Remove eight bolts (1) and two nuts (2) that fasten the water pump to the front housing.
3. Tap water pump (3) with a soft hammer in order to loosen water pump (3) .
4. Remove water pump (3) and the gasket.
Wed Oct 30 14:13:10 UTC+0800 2019
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i01052998
Water Pump - Disassemble
SMCS - 1361-015
Disassembly Procedure
Table 1
Required Tools
A
6V-3009 Crossbar 1
5H-9976 Screw 1
9S-9152 Bearing Puller 1
7X-0290 Bolt 2
Start By:
A. Remove the water pump. Refer to Disassembly and Assembly, "Water Pump - Remove".
NOTICE
NOTICE
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containing fluids.
1. Remove six bolts (1) from cover (2). Remove cover (2) and the gasket.
2. Remove O-ring seal (3) from the rear of the water pump housing.
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3. Install Tool (A). Remove gear (4) .
4. Use a suitable lever in order to remove seal (5) .
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5. Use a suitable press to remove shaft (6), seal (7), and impeller (8) from housing (9) .
Wed Oct 30 14:14:06 UTC+0800 2019
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i01053681
Water Pump - Assemble
SMCS - 1361-016
Assembly Procedure
NOTICE
1. Clean the inside of the pump body. Ensure that the bearing bore and the counterbore for the
water seal are particularly clean.
2. Apply 4C-9507 Retaining Compound to the outer surface of the bearing. Keep the
compound away from the ends of the bearing.
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3. Support the gear end of the water pump body.
4. Place the bearing and shaft (6) square in the pump body. Ensure that the shortest end of
shaft (6) is in housing (9) .
5. Use a suitable press and a suitable adapter that will apply force to the bearing. The adapter
should not apply force to the shaft. Press the bearing onto the shaft until the end of the
bearing is level with the bottom of the counterbore for the water seal.
Note: Remove the excess compound from the end of the bearing.
6. Install seal (7) on the rear of water pump housing.
NOTICE
Ensure that the water seal is not contaminated by oil or grease. Hold
the seal only by the edge of the flange. Do not damage the ring of green
sealant that is applied to the body of the water seal behind the flange.
7. Hold water seal (5) by the edge of the flange. Push the seal onto shaft (6) until the seal is
against the chamfer of the counterbore. Only apply force to the outer flange of the seal.
Note: Ensure that the wide end of the seal is toward the bearing and that the seal is square
with the counterbore.
8. Continue to apply force and hold water seal (5) for ten seconds. This ensures that the seal
will remain in place.
9. Hold the pump with the gear end of the shaft on a suitable support. Use a flat bar in order to
press impeller (8) onto shaft (6) to a depth of 8.30 ± 0.20 mm (0.320 ± 0.010 inch). After
installation, ensure that the impeller will turn freely.
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Note: Apply 4C-9507 Retaining Compound to impeller (8) if the original impeller is used.
Remove excess compound after assembly.
10. Lubricate oil seal (3) with clean engine oil. Install oil seal (3) with the flat surface toward
the bearing. Press oil seal (3) into the body with a suitable adapter until the rear of the seal is
level with the end of the pump.
11. Continue to apply force and hold oil seal (3) in position for ten seconds. This ensures that
the seal will remain in place.
12. Press gear (4) onto shaft (6) at a distance of 1.60 ± 1.00 mm (0.015 ± 0.005 inch) .
Note: Apply 4C-9507 Retaining Compound to gear (4) if the original gear is used. Remove
excess compound after assembly.
13. Install a new gasket and cover (2) on the pump body.
14. Install six bolts (1) in cover (2). Tighten the bolts to a torque of 9 N·m (80 lb in).
End By: Install the water pump. Refer to Disassembly and Assembly, "Water Pump - Install".
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i01644338
Water Pump - Install
SMCS - 1361-012
Installation Procedure
NOTICE
1. Inspect the condition of the gasket. Replace the gaskets, if necessary.
Typical example
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2. Install the gasket and water pump (3) to the front housing.
3. Install eight bolts (1) and install two nuts (2) that fasten the water pump (3) to the front
housing.
4. Fill the cooling system. If the engine uses diesel engine antifreeze/coolant, refer to
Operation and Maintenance Manual, "Cooling System Coolant (DEAC) - Change". If the
engine uses extended life coolant, refer to Operation and Maintenance Manual, "Cooling
System Coolant (ELC) - Change".
Wed Oct 30 14:15:57 UTC+0800 2019
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Caterpillar cat 3054 industrial engine (prefix 6 fk) service repair manual (6fk00001 and up)

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