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Product: EXCAVATOR
Model: 320B EXCAVATOR 5BR
Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-
UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01550404

Troubleshooting
SMCS - 1000

Introduction
Troubleshooting can be difficult. The following pages contain a list of possible problems. In order to make a repair to a problem,
refer to the cause and refer to the correction of the problem.

The list on the following pages will provide the following information:

● Known problems

● Probable causes of known problems

● Repairs in order to correct known problems

Normally, additional repair work is needed beyond the recommendation in the list.

Remember that a problem is not normally caused by only one part. The problem's cause can be related to problems with other
parts. This list does not include all possible problems and corrections. The service technician must find the problem and the
problem's source. After the problem's source is determined, the service technician can make the necessary repairs.

Troubleshooting Problem List

1. The Engine Crankshaft Will Not Turn When The Start Switch Is On.

2. The Engine Will Not Start.

3. The Engine Is Misfiring Or The Engine Is Running Rough.

4. The Engine Stalls At Low RPM.

5. There Are Sudden Changes In Engine RPM.

6. The Engine Does Not Have Enough Power.

7. The Engine Has Too Much Vibration.

 8. The Engine Has A Loud Combustion Noise (Sound).

9. The Engine Has a Valve Train Noise (Clicking).

10. Oil Is In The Cooling System.

11. Mechanical Noise (Knock) Is In The Engine.

12. Fuel Consumption Is Too High.

13. The Engine Has A Loud Noise From The Valves Or The Valve Drive Components.

14. Little Movement Of The Rocker Arm And Too Much Valve Lash Is Present.

15. The Valve Keeper Or The Spring Is Broken.

16. Oil Is At The Exhaust.

17. Little Valve Lash Or No Valve Lash Is Present.

18. The Engine Has Early Wear.

19. Coolant Is In The Lubrication Oil.

20. Too Much Black Smoke Or Gray Smoke Is Present.

21. Too Much White Smoke Or Blue Smoke Is Present.

22. The Engine Has Low Oil Pressure.

23. The Engine Uses Too Much Lubrication Oil.

24. The Engine Coolant Is Too Hot.

25. The Starting Motor Does Not Turn.

26. The Alternator Gives No Charge.

27. The Alternator Charge Rate Is Low Or Irregular.

28. The Alternator Charge Is Too High.

29. The Alternator Has Noise.

30. The Exhaust Temperature Is Too High.

Troubleshooting Problems
Problem 1

The Engine Crankshaft Will Not Turn When The Start Switch Is On.

Probable Cause

1. Low Output From The Battery

 Check the condition of the battery. Charge the battery or replace the battery, if necessary.

2. Damaged Wires or Switches

Repair any parts or replace any parts, if necessary.

3. Damaged Starting Motor Solenoid

Install a new solenoid.

4. Damaged Starting Motor

Repair the starting motor or replace the starting motor.

5. An Internal Problem Prevents The Turning Of The Engine Crankshaft.

Disconnect the driven equipment. Remove the fuel injection nozzles if the crankshaft cannot be turned. Inspect the cylinders
for fluid while the crankshaft is being turned. If fluid in the cylinders is not the problem, the engine must be disassembled.
After you disassemble the engine, inspect the engine for other internal problems. Possible internal problems include the
following conditions:

❍ Bearing seizure

❍ Piston seizure

❍ Incorrect pistons are installed in the engine.

Problem 2

The Engine Will Not Start.

Probable Cause

1. The fuel tank is empty.

Put fuel in the fuel tank.

2. Low Quality Fuel

Remove fuel from the fuel tank. Install a new fuel filter element. Put a good grade of clean fuel in the fuel tank.

3. Dirty Fuel Filter

Install a new fuel filter.

4. Broken Fuel Lines Or Dirty Fuel Lines

Fuel lines should be cleaned or new fuel lines should be installed, if necessary.

5. The Fuel Pressure is Too Low.

Replace the fuel filter. Inspect the bypass valve for free movement. Install a new bypass valve, if necessary.

6. Air is in the Fuel System.

 Find the air leak in the fuel system and correct the leak. Remove air from the fuel system.

7. Wrong Fuel Injection Timing

Adjust the fuel injection timing, if necessary.

8. The Constant Purge Valve Stays Open. (There Is Insufficient Fuel Pressure for Starting The Engine.)

Replace the constant purge valve.

9. Slow Cranking Speed

Check condition of battery. Replace the battery, if necessary.

10. No Fuel In The Housing For The Fuel Injection Pumps

Use the priming pump in order to fill the housing for the fuel injection pumps with fuel.

11. The Fuel Has A Cloud Point That Is Higher Than The Atmospheric Temperature. (The Cloud Point Is The Temperature
That Causes Wax To Form In Fuel.)

Drain the fuel tank, the lines and the fuel injection pump housing. Change the fuel filter. Fill the tank with fuel that has the
correct cloud point.

Problem 3

The Engine Is Misfiring Or The Engine Is Running Rough.

Probable Cause

1. Low Fuel Pressure

Ensure that there is enough fuel in the fuel tank. Inspect the fuel system for leaks. Inspect the fuel line between the fuel tank
and the fuel transfer pump for bad bends. Inspect the fuel system for air. Check fuel pressure. The outlet pressure of the
fuel transfer pump at full load speed is 75 to 100 kPa (10.9 to 24.7 psi). If the fuel pressure is lower, install a new fuel filter
element. Inspect the fuel bypass valve for free movement. Install a new fuel bypass valve, if necessary.

2. Air In Fuel System

Find the air leak in the fuel system and correct the air leak. Remove the air from the fuel system.

3. Leakage Or Breakage In Fuel Line Between Fuel Injection Pump And Fuel Injection Valve

Install a new fuel line.

4. Wrong Valve Lash

Adjust the valve lash. Refer to Testing And Adjusting.

5. Worn Fuel Injection Nozzle

Run the engine at an rpm that gives the maximum misfiring or rough running. Then, loosen a fuel line nut on the fuel injection
nozzle for each cylinder one at a time. When a fuel line nut is loosened, the misfiring or rough running will increase. If
loosening a fuel line nut does not affect the misfiring or rough running, test the fuel injection nozzle for that cylinder. Install
 new parts, if necessary.

6. Wrong Fuel Injection Timing

Adjust the fuel injection timing.

7. Bent Pushrod Or Broken Pushrod

Replace the pushrod.

8. Worn Valve Seat Or Face Of Valve

A reconditioning of the cylinder head is necessary.

Problem 4

The Engine Stalls At Low RPM.

Probable Cause

1. Fuel Pressure is Low.

Ensure that enough fuel is in the fuel tank. Inspect the fuel system for leaks. Inspect the fuel line between the fuel tank and
the fuel transfer pump for bad bends. Inspect the fuel system for air. Check fuel pressure. The outlet pressure of the fuel
transfer pump at full load speed is 75 to 100 kPa (10.9 to 24.7 psi). If the fuel pressure is lower, install a new fuel filter
element. Inspect the fuel bypass valve for free movement. Install a new fuel bypass valve, if necessary.

2. Low Engine Idle RPM

Make adjustment to the governor. Ensure that the idle rpm setting matches the rpm that is listed in the Technical Marketing
Information (TMI).

3. Worn Fuel Injection Nozzle

Install a new fuel injection nozzle.

4. Wrong Valve Lash

Adjust the valve lash. Refer to the Technical Marketing Information (TMI) or refer to the Fuel Setting and Related
Information Microfiche for the correct idle rpm.

Problem 5

There Are Sudden Changes In Engine RPM.

Probable Cause

1. Air in the Fuel System

Find the air leak in the fuel system and correct the leak. Remove air from the fuel system.

2. The Linkage in The Governor Does Not Move Freely.

Clean all linkages. Clean the inside of the governor housing. Replace all damaged parts with new parts.
Problem 6

The Engine Does Not Have Enough Power.

Probable Cause

1. Low Quality Fuel

Remove fuel from the fuel tank. Install a new fuel filter element. Put a good grade of clean fuel in the fuel tank.

2. Low Fuel Pressure

Ensure that there is enough fuel in the fuel tank. Inspect the fuel system for leaks. Inspect the fuel line between the fuel tank
and the fuel transfer pump for bad bends. Inspect the fuel system for air. Check fuel pressure. The outlet pressure of the
fuel transfer pump at full load speed is 75 to 100 kPa (10.9 to 24.7 psi). If the fuel pressure is lower, install a new fuel filter
element. Inspect the fuel bypass valve for free movement. Install a new fuel bypass valve, if necessary.

3. Air in the Fuel System

Find the air leak in the fuel system. Correct the air leak. Remove air from the fuel system.

4. Leaks In Air Inlet System

Check the pressure in the air inlet manifold. Look for restrictions in the air cleaner.

5. Wrong Fuel Setting

Adjust the fuel setting, if necessary.

6. Governor Linkage

Make an adjustment in order to obtain the full travel of the linkage. Install new parts for those parts that are damaged or
damaged.

7. Wrong Valve Lash

Adjust the valve lash. Refer to Testing And Adjusting.

8. Worn Fuel Injection Nozzle

Run the engine at an rpm that gives the maximum misfiring or rough running. Then, loosen a fuel line nut on the fuel injection
nozzle for each cylinder one at a time. Tighten each fuel line nut before loosening the next fuel line nut. When a fuel line nut
is loosened, the misfiring or rough running will increase. If loosening a fuel line nut does not affect the misfiring or rough
running, test the fuel injection nozzle for the cylinder. Install new parts, if necessary.

9. Wrong Fuel Injection Timing

Adjust the fuel injection timing.

10. Carbon Deposits On Turbocharger

Inspect the turbocharger. Repair the turbocharger, if necessary.

11. Plugged Screen Of Filter On Fuel Transfer Pump

 Remove the screen. Clean the screen.

Problem 7

The Engine Has Too Much Vibration.

Probable Cause

1. A Loose Nut is Holding The Pulley.

Tighten the nut.

2. The Pulley Is Worn.

Install a new pulley.

3. The Engine Supports are Loose, Worn, or Damaged.

Tighten all mounting bolts. Install new components, if necessary.

4. The Engine Is Misfiring Or The Engine Is Running Rough.

Refer to Problem 3.

5. The Fan Blade Is Not Balanced.

Loosen the fan drive belts or remove the fan drive belts. The vibration occurred at a specific rpm. Operate the engine for a
short time at this rpm. If the vibration is not present, replace the fan assembly.

Problem 8

The Engine Has A Loud Combustion Noise (Sound).

Probable Cause

1. Low Quality Fuel

Remove fuel from the fuel tank. Install a new fuel filter element. Put a good grade of clean fuel in the fuel tank.

2. Worn Fuel Injection Nozzle

Install a new fuel injection nozzle.

3. Wrong Fuel Injection Timing

Adjust the fuel injection timing.

Problem 9

The Engine Has A Valve Train Noise (Clicking).

Probable Cause

1. Broken Valve Spring(s) or Broken Locks

 Install new parts, if necessary. Broken locks can cause the valve to slide into the cylinder. Damage can result.

2. The Bolts On The Rocker Shaft Brackets Are Loose.

Tighten the bolts to the following torque 15 ± 5 N·m (11 ± 4 lb ft).

3. Too Much Valve Lash

Adjust the valve lash. Refer to Testing And Adjusting.

4. Not Enough Lubrication

Check the lubrication in the valve compartment. There must be a strong flow of oil at engine high rpm. There must be a
small flow at low rpm. Oil passages must be clean. The oil passages that send the oil to the cylinder head are particularly
important.

Problem 10

Oil Is In The Cooling System.

Probable Cause

1. Damaged Core Of Engine Oil Cooler

Install a new core in the oil cooler.

2. Damaged Head Gasket

Install a new head gasket.

3. Obstruction in Weep Hole of Water Pump And Damaged Oil Seal in Water Pump

Free the weep hole of the water pump from obstruction. Replace the oil seal.

Problem 11

Mechanical Noise (Knock) Is In The Engine.

Probable Cause

1. Failure Of Bearing For Connecting Rod

Inspect the bearings for the connecting rods and the bearing surfaces on the crankshaft. Install new parts, if necessary.

2. Damaged Crankshaft

Replace the crankshaft.

3. Damaged Attachment

Repair components or install new components.

Problem 12

Fuel Consumption Is Too High.

Probable Cause

1. Fuel System Leaks

Replacement of parts is needed at points of leakage.

2. Fuel And Combustion Noise (Knock)

Small increases in fuel consumption may be the result of worn fuel injection nozzles, rough running or factors that cause a
loss of power. Refer to Problem 3 and refer to Problem 6.

3. Wrong Fuel Injection Timing

Adjust the fuel injection timing.

4. The Fuel Setting Is Too High.

Adjust the fuel setting. Refer to the Technical Marketing Information (TMI) or refer to the Fuel Setting and Related
Information Microfiche for the correct idle rpm.

Problem 13

The Engine Has A Loud Noise From The Valves Or From The Valve Drive Components.

Probable Cause

1. Broken Valve Spring(s)

Replace the damaged parts.

2. Broken Camshaft

Replace the damaged parts. Clean the engine thoroughly.

3. Damaged Valve Tappets

Clean the engine thoroughly. Replace the camshaft and the tappets. Look for valves that do not move freely. Adjust the
valve lash to the correct clearances.

4. Damage To Valve(s)

Replace the damaged valves and make an adjustment, if necessary.

Problem 14

Little Movement Of The Rocker Arm And Too Much Valve Lash Is Present.

Probable Cause

1. Not Enough Lubrication

Check the lubrication in the valve compartment. There must be a strong flow of oil at engine high rpm. There must be a
small flow of oil at low rpm. Oil passages must be clean. The oil passages that send the oil to the cylinder head are
particularly important.
 2. Worn Rocker Arm

If there is too much wear, install new parts or rocker arms. Make adjustment to valve lash. Refer to Testing And Adjusting.

3. The End Of The Valve Stem Is Worn.

If the end of the valve stem has too much wear, install new valves. Make adjustment to valve lash. Refer to Testing And
Adjusting.

4. Too Much Valve Lash

Adjust the valve lash. Refer to the Testing and Adjusting.

5. Worn Pushrods

If the pushrods have too much wear, install new pushrods. Make adjustment to valve lash. Refer to Testing And Adjusting.

6. Worn Tappets

Install new tappet assemblies if the tappet assemblies are worn too much. Adjust the valve lash. Refer to Testing And
Adjusting.

7. Worn Lobes on Camshaft

Check valve lash. Check for free movement of valves or bent valve stems. Install new components, if necessary. Make
adjustment to valve lash. Refer to Testing And Adjusting.

8. The Bolts For The Rocker Arm Bracket Are Loose.

Tighten the bolts to the following torque 15 ± 5 N·m (11 ± 4 lb ft).

Problem 15

The Valve Keeper Or The Spring Is Broken.

Probable Cause

1. Damaged Valve Keepers

Locks with damage can cause the valve to fall into the cylinder. This will cause severe damage.

2. Damage To Valve Spring(s)

Install the new valve spring(s).

Problem 16

Oil Is At The Exhaust.

Probable Cause

1. Too Much Oil In The Valve Compartment

Be sure that the plugs are installed in the ends of the rocker arm shaft.
 2. Worn Valve Guides

Reconditioning of the cylinder head is required.

3. Worn Piston Rings

Inspect piston rings and install new parts, as required.

4. Damaged Seal In Turbocharger

Recondition the turbocharger.

5. Plugged Air Cleaner Element

Replace the air cleaner element.

Problem 17

Little Valve Lash Or No Valve Lash Is Present.

Probable Cause

1. Worn Valve Seat Or Worn Valve Face

Reconditioning of the cylinder head is required. Make adjustment to valve lash. Refer to Testing And Adjusting.

Problem 18

The Engine Has Early Wear.

Probable Cause

1. Dirt In Lubrication Oil

Remove dirty lubrication oil. Install a new oil filter element. Put clean oil in the engine.

2. Air Inlet Leaks

Inspect all gaskets and connections. Make repairs if leaks are found.

3. Fuel Leakage Into Lubrication Oil

This will cause high fuel consumption and low engine oil pressure. Make repairs if leaks are found. Install new parts, as
required.

Problem 19

Coolant Is In The Lubrication Oil.

Probable Cause

1. Failure Of Engine Oil Cooler Core

Install a new core for the damaged engine oil cooler.

 2. Failure Of The Cylinder Head Gasket

Install a new cylinder head gasket. Tighten the bolts that hold the cylinder head. Refer to the Specifications module.

3. Cracked Cylinder Head Or Damaged Cylinder Head

Install a new cylinder head.

4. Cracked Cylinder Block Or Damaged Cylinder Block

Install a new cylinder block.

5. Failure Of Front Cover Gasket

Install a new front cover gasket.

6. Obstruction In Weep Hole Of Water Pump And Damaged Water Seal Of Water Pump

Free the weep hole of the water pump of the obstruction. Replace the water seal.

Problem 20

Too Much Black Smoke Or Gray Smoke Is Present.

Probable Cause

1. Not Enough Air For Combustion

Check the air cleaner for restrictions. The maximum pressure of the air cleaner is the following amount 7.5 kPa (30 inch of
water).

2. Damaged Fuel Injection Nozzle(s)

Install new fuel injection nozzle(s).

3. Wrong Fuel Injection Timing

Make adjustment to timing.

Problem 21

Too Much White Smoke Or Blue Smoke Is Present.

Probable Cause

1. Too Much Lubrication Oil In Engine

Remove extra oil. Find the source of the extra oil. Put the correct amount of oil in engine.

2. The Engine Is Misfiring Or The Engine Is Running Rough.

Refer to Problem 3.

3. Wrong Fuel Injection Timing

 Adjust the timing.

4. Worn Valve Guides

Reconditioning of the cylinder head is required.

5. Worn Piston Rings

Install new parts, if necessary.

6. Failure Of Turbocharger Oil Seal

Check the air inlet pipe for oil. Repair the turbocharger, if necessary.

Problem 22

The Engine Has Low Oil Pressure.

Probable Cause

1. Damaged Oil Pressure Gauge

Install new gauge.

2. Dirty Engine Oil Filter Or Engine Oil Cooler

Check the operation of the bypass valve for the filter. Install new engine oil filter elements, if necessary. Clean the engine oil
cooler core or install a new engine oil cooler core. Remove dirty oil from the engine. Put clean oil in the engine.

3. Diesel Fuel In Lubrication Oil

Find the source of the leakage of the diesel fuel into the lubrication oil. Make repairs, as required. Remove the lubrication
oil that has been contaminated with diesel fuel. Install new oil filters. Put clean oil in the engine.

4. Too Much Clearance Between Rocker Arm Shaft And Rocker Arms

Check lubrication in valve compartments. Install new parts, if necessary.

5. Damaged Oil Pump Suction Pipe

Replacement of oil pump suction pipe is required.

6. Improper Operation Of Pressure Relief Valve For Oil Pump

Clean the valve and the housing. Install new parts, if necessary.

7. Damaged Oil Pump

Repair the oil pump or replace the oil pump, if necessary.

8. Too Much Clearance Between Crankshaft And Crankshaft Bearings

Inspect the crankshaft bearings and make replacement, as required.

9. Too Much Clearance Between Camshaft And Camshaft Bearings

 Inspect the camshaft and the camshaft bearings. Replace the camshaft and the camshaft bearings, if necessary.

10. Too Much Bearing Clearance For Idler Gear

Inspect the bearings and make replacement, as required.

11. Orifices For Piston Cooling Jets Are Not Installed.

Install the orifices for the piston cooling jet.

Problem 23

The Engine Uses Too Much Lubrication Oil.

Probable Cause

1. Too Much Lubrication Oil In Engine

Remove the extra oil. Find the source of the extra oil. Put the correct amount of oil in the engine.

2. Oil Leaks

Find all oil leaks. Make repairs, as needed.

3. High Oil Temperature

Check operation of oil cooler. Install new parts, if necessary. Clean the oil cooler cores.

4. Too Much Oil To Inlet Valve Guides

Refer to Problem 16.

5. Worn Valve Guides

Refer to Problem 16.

6. Worn Piston Rings

Install new parts, if necessary.

7. Failure Of Turbocharger Oil Seal

Inspect the turbocharger. Repair the turbocharger, if necessary.

Problem 24

The Engine Coolant Is Too Hot.

Probable Cause

1. Restricted Flow Of Air Through the Radiator Or Restricted Flow Of Coolant Through the Radiator

Remove all of the flow restrictions.

 2. Low Coolant Level

Add coolant to the cooling system.

3. Damaged Pressure Cap

Check operation of the pressure cap. Install a new pressure cap, if necessary.

4. Combustion Gases In Coolant

Find the source of the leakage of combustion gases into the cooling system. Make repairs, as needed.

5. Damaged Water Temperature Regulators Or Temperature Gauge

Check water temperature regulators for correct operation. Check the water temperature gauge for correct operation.
Install new parts, if necessary.

6. Damaged Water Pump

Install a new water pump.

7. Too Much Load On The System

Reduce the load on the system.

8. Wrong Fuel Injection Timing

Adjust the fuel injection timing.

9. Loose Drive Belts

Adjust the drive belts.

10. The Antifreeze Concentration Is Too High.

A 50 percent antifreeze concentration is acceptable for most applications.

Problem 25

The Starting Motor Does Not Turn.

Probable Cause

1. Low Output From The Battery

Check the condition of the battery. Charge or replace the battery, if necessary.

2. Damaged Wires Or Switches

Repair the wires or the switches or replace the wires or the switches, if necessary.

3. Damaged Starting Motor Solenoid

Install a new starting motor solenoid.

 4. Damaged Starting Motor

Repair the starting motor or replace the starting motor.

Problem 26

The Alternator Gives No Charge.

Probable Cause

1. Loose Drive Belt For The Alternator

Adjust the drive belt in order to obtain the correct tension.

2. Damaged Charging, Ground Return Circuit Or Battery Connections

Inspect all cables and connections. All connections should be cleaned and tightened. Replace all damaged parts.

3. Damaged Brushes In Alternator

Install new brushes.

4. Damaged Rotor (Field Coil)

Install a new rotor.

Problem 27

The Alternator Charge Rate Is Low Or The Alternator Charge Rate Is Not Regular.

Probable Cause

1. Loose Drive Belt For The Alternator

Adjust the drive belt in order to obtain the correct tension.

2. Damaged Charging, Ground Return Circuit Or Battery Connections

Inspect all cables and connections. All connections should be cleaned and tightened. Replace all damaged parts.

3. Damaged Alternator Regulator

Repair the alternator regulator or replace the alternator regulator.

4. Damaged Brushes In Alternator

Install new brushes.

5. Damaged Rectifier Diodes

Replace the damaged rectifier diode.

6. Damaged Rotor (Field Coil)

Install a new rotor.

Problem 28

The Alternator Charge Is Too High.

Probable Cause

1. Loose Connections On The Alternator Or The Alternator Regulator

Tighten all connections to the alternator or the alternator regulator.

2. Damaged Alternator Regulator

Install a new alternator regulator.

Problem 29

The Alternator Has Noise.

Probable Cause

1. Drive Belt For The Alternator That Is Worn Or Damaged

Install a new drive belt for the alternator.

2. Loose Alternator Drive Pulley

Check the groove in the pulley for a key that holds the pulley in place. If the groove is worn, install a new pulley. Tighten
the pulley nut according to Specifications.

3. Misaligned Drive Belt And Drive Pulley For The Alternator

Align the drive belt and the drive pulley.

4. Worn Alternator Bearings

Install new bearings in the alternator.

5. Bent Rotor Shaft on Armature

Replace the rotor shaft.

6. Shorted Rectifiers In The Alternator

Replace the diode assembly.

Problem 30

The Exhaust Temperature Is Too High.

Probable Cause

1. Restriction At The Air Inlet System Or The Exhaust System

Remove the restriction.

 2. Wrong Fuel Injection Timing

Adjust the fuel injection timing.

3. Leak In Air Inlet System

Check the pressure in the air inlet system. Find the leaks. Correct the leaks.

4. Leak In Exhaust System

Find the leak in the exhaust system. Correct the leak in the exhaust system.

Copyright 1993 - 2009 Caterpillar Inc. Mon Jul 20 2009 08:41:01 GMT-0300 (SA Eastern Standard Time)
All Rights Reserved.
Private Network For SIS Licensees.
 Shutdown SIS

Previous Screen

Product: EXCAVATOR
Model: 320B EXCAVATOR 5BR
Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-
UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01550929

Fuel System - Inspect

SMCS - 1250-040

A problem with the components that send fuel to the engine can cause low fuel pressure. This can decrease engine performance.

1. Check the fuel level in the fuel tank. Ensure that the vent in the fuel cap is not filled with dirt.

2. Check all fuel lines for fuel leakage. The fuel lines must be free from restrictions and faulty bends. Verify that the fuel return
line is not collapsed.

3. Install a new fuel filter.

4. Cut the old filter open with the 175-7546 Oil Filter Cutter. Inspect the filter for excess contamination. Determine the source
of the contamination. Make the necessary repairs.

5. Service the primary fuel filter (if equipped).

6. Operate the hand priming pump (if equipped). If uneven resistance is felt, test for air in the fuel. Refer to Testing and
Adjusting, "Air in Fuel - Test" for more information.

7. Remove any air that may be in the fuel system. Refer to Testing and Adjusting, "Fuel System - Prime".

Copyright 1993 - 2009 Caterpillar Inc.

Mon Jul 20 2009 08:41:57 GMT-0300 (SA Eastern Standard Time)
All Rights Reserved.
Private Network For SIS Licensees.
 Shutdown SIS

Previous Screen

Product: EXCAVATOR
Model: 320B EXCAVATOR 5BR
Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-
UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i02488066

Air in Fuel - Test

SMCS - 1280-081

Table 1

Required Tools

Part Number Part Description Qty

2P-8278 Tube As (Sight Gauge) 1

This procedure checks for air in the fuel system. This procedure also assists in finding the source of the air.

1. Examine the fuel system for leaks. Ensure that the fuel line fittings are properly tightened. Check the fuel level in the fuel
tank. Air can enter the fuel system on the suction side between the fuel transfer pump and the fuel tank.

Work carefully around an engine that is running. Engine parts that are
hot, or parts that are moving, can cause personal injury.

2. Install a 2P-8278 Tube As (Sight Gauge) in the fuel return line. When possible, install the sight gauge in a straight section of
the fuel line that is at least 304.8 mm (12 inches) long. Do not install the sight gauge near the following devices that create
turbulence:

❍ Elbows

❍ Relief valves

❍ Check valves

Observe the fuel flow during engine cranking. Look for air bubbles in the fuel. If there is no fuel that is present in the sight
gauge, prime the fuel system. Refer to Testing and Adjusting, "Fuel System - Prime" for more information. If the engine
starts, check for air in the fuel at varying engine speeds. When possible, operate the engine under the conditions which have
been suspect.
 Illustration 1 g00578151
2P-8278 Tube As (Sight Gauge)

(1) A steady stream of small bubbles with a diameter of approximately 1.60 mm (0.063 inch) is an acceptable amount of air in the fuel.

(2) Bubbles with a diameter of approximately 6.35 mm (0.250 inch) are also acceptable if there is two seconds to three seconds intervals
between bubbles.

(3) Excessive air bubbles in the fuel are not acceptable.

3. If excessive air is seen in the sight gauge in the fuel return line, install a second sight gauge at the inlet to the fuel transfer
pump. If a second sight gauge is not available, move the sight gauge from the fuel return line and install the sight gauge at the
inlet to the fuel transfer pump. Observe the fuel flow during engine cranking. Look for air bubbles in the fuel. If there is no
fuel that is present in the sight gauge, prime the fuel system. Refer to Testing and Adjusting, "Fuel System - Prime" for more
information. If the engine starts, check for air in the fuel at varying engine speeds.

If excessive air is not seen at the inlet to the fuel transfer pump, the air is entering the system after the fuel transfer pump.
Refer to the Testing and Adjusting, "Fuel System - Prime".

If excessive air is seen at the inlet to the fuel transfer pump, air is entering through the suction side of the fuel system.

To avoid personal injury, always wear eye and face protection when using
pressurized air.

NOTICE
 To avoid damage, do not use more than 55 kPa (8 psi) to pressurize the
fuel tank.

4. Pressurize the fuel tank to 35 kPa (5 psi). Do not use more than 55 kPa (8 psi) in order to avoid damage to the fuel tank.
Check for leaks in the fuel lines between the fuel tank and the fuel transfer pump. Repair any leaks that are found. Check
the fuel pressure in order to ensure that the fuel transfer pump is operating properly. For information about checking the fuel
pressure, see Testing and Adjusting, "Fuel System Pressure - Test".

5. If the source of the air is not found, disconnect the supply line from the fuel tank and connect an external fuel supply to the
inlet of the fuel transfer pump. If this corrects the problem, repair the fuel tank or the stand pipe in the fuel tank.

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Product: EXCAVATOR
Model: 320B EXCAVATOR 5BR
Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-
UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i02928119

Engine Speed - Check

SMCS - 1000

Table 1

Tools Needed

Part Number Part Name Quantity

9U-7400 Multitach Tool Gp 1

OR

9U-7401 Multitach Tool Gp (1) 1

6V-4950 Speed Pickup 1

(1) Part of 9U-7400 Multitach Tool Gp

Illustration 1 g00286276
9U-7400 Multitach Tool Gp
The 9U-7400 Multitach Tool Gp can measure engine rpm from a magnetic pickup on the flywheel housing. The 9U-7400
Multitach Tool Gp also has the ability to measure engine rpm from visual engine parts in rotation.

Note: Refer to Special Instruction, NEHS0605 for the operating instructions of the 9U-7400 Multitach Tool Gp and the
instructions for the test procedure.

The 6V-4950 Speed Pickup is another diagnostic tool accessory that can be used with the 9U-7401 Multitach Tool Gp . The 6V-
4950 Speed Pickup can be used on single wall fuel injection lines that are 6 mm (0.25 inch). With these tools, engine speed can
be measured quickly with an accuracy of ± 1 rpm.

Note: Refer to Special Instruction, SEHS8029 for the operating instructions of the 6V-4950 Speed Pickup .

For the maximum engine operating speed (rpm), refer to Operation and Maintenance Manual, "Emissions Certification Film".

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Product: EXCAVATOR
Model: 320B EXCAVATOR 5BR
Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-
UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i03469360

Finding Top Center Position for No. 1 Piston

SMCS - 1105-531

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

Table 1

Required Tools

Callout Part Number Description Quantity

A 299-9126 Crankshaft Turning Tool 1

1. Remove the valve mechanism cover from the engine.

Illustration 1 g01420177
(A) 299-9126 Crankshaft Turning Tool
2. Install Tooling (A) on the engine's flywheel housing. Use Tooling (A) in order to rotate the engine. Refer to Illustration 1.

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

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

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

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

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

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

Illustration 2 g01811376
(1) Pointer

(2) Pulley

(3) Top center mark

 Illustration 3 g01830733
(1) Pointer

(2) Pulley

(3) Top center mark

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

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Product: EXCAVATOR
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Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-
UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i02646340

Fuel Injection Nozzle - Test

SMCS - 1254-081

Perform the following procedures in order to determine if a fuel injection nozzle does not work correctly.

Table 1

Required Tools

Part Number Part Name Qty

5P-4150 Nozzle Testing Group 1

5P-7448 Adapter 1

6V-2170 Tube As 1

8S-2270 Fuel Collector 1

1U-8857 Extension Tube 1

6V-6068 Calibration Fluid 1

8S-2245 Injector Cleaning Tool Gp 1

Illustration 1 g01328160
Fuel injection nozzle assembly

(1) Holder assembly

(2) Shim

(3) Pressure spring

(4) Pressure pin

(5) Gasket

(6) Pin

(7) Fuel injection nozzle

(8) Retaining nut

1. Start the engine and run the engine at low idle.

2. Loosen the nut for fuel supply line at each fuel injection nozzle. Listen for the low idle to decrease at each cylinder. Also,
listen for the low idle to become rough at each cylinder.
 3. The fuel injection nozzle may be damaged if the items that follow occur:

❍ Engine rpm does not decrease.

❍ The engine continues to run properly.

Remove the fuel injection nozzle from the engine cylinder head for additional testing.

Note: If leakage at the nut for fuel supply line occurs, make sure that the fuel supply line and the nut for the fuel supply line
are correctly aligned with the inlet connection of the fuel injection nozzle. Do not tighten the nut for the fuel supply line on
the high pressure fuel line more than the recommended torque. If the nut is tightened more, the fuel line may become
restricted or the threads of the fuel injection nozzle and the nut may be damaged.

Cleaning Of Fuel Injection Nozzles

Personal injury can result from improper handling of chemicals.

Make sure you use all the necessary protective equipment required to do
the job.

Make sure that you read and understand all directions and hazards
described on the labels and material safety data sheet of any product used
to clean the components.

Observe all safety precautions recommended by the chemical

manufacturer for handling, storage, and disposal of cleaning agents.

NOTICE
Do not use a steel brush or wire wheel to clean the nozzle body or the
nozzle tip. Use of these tools can cause a small reduction of orifice size,
and this will cause a large reduction in engine horsepower. Too much use
of a wire brush will also remove the coating that is on the fuel injection
nozzle for protection.
Illustration 2 g00570038
Remove carbon with the 8S-2258 Brass Wire Brush which is included in the 8S-2245 Injector Cleaning Tool Gp .

Before the fuel injection nozzle can be tested, remove all loose carbon around the tip of the fuel injection nozzle. Use the 8S-2245
Injector Cleaning Tool Gp to clean the fuel injection nozzle. Refer to Special Instruction , SEHS8627, "Use of 8S-2245 injection
Nozzle Cleaning Tool Group"for more information.

1. Remove retaining nut (8) from the holder assembly (1) . Remove the tip assembly of fuel injection nozzle (7) . Wash the
needle valve and the body.

Note: Do not mix the needle valve and bodies of different nozzles. The components of the nozzle tip assembly are a
precise fit. The components must not be exchanged with other components. Do not touch the sliding surfaces of the needle
valve.

2. Wash tip assembly of fuel injection nozzle (7) in clean kerosene. After washing, assemble the needle valve and the body in
clean fuel.

3. Tighten retaining nut (8) to a torque of 30 to 39 N·m (22 to 29 lb ft).

4. Replace the nozzle tip if the discharge pattern is still unacceptable.

Note: Extra care should be used in handling the fuel injection nozzle in order to prevent damage to the nozzle tip. A scratch or a
burr could cause needle leakage or spray distortion. Dirt that is in the orifices of the nozzle tip can damage engine components.
Dirt can also cause spray distortion.

Fuel Injection Lines

Fuel from the fuel injection pump goes to the fuel injection nozzle through the fuel injection lines. When the fuel injection lines are
disconnected or removed, always put caps or plugs on the ends of the lines in order to keep dirt out of the lines. Ensure that all of
the line clamps and all of the vibration dampers are installed in the original locations when the fuel injection lines are installed.

Note: Fuel injection lines can leak if the fuel injection lines are bent or damaged. Fuel injection lines can also leak if the fuel
injection lines are rubbing. Leakage of fuel can also cause a fire. Replace any lines which have damage or leaks that can not be
corrected when the nuts are tightened to the correct torque.

Note: Ensure that the fuel injection line clamps are installed in the correct location. Incorrectly installed clamps may allow the fuel
injection lines to vibrate. Incorrectly installed clamps may allow the fuel injection lines to become damaged. The damaged lines
may leak. Leakage of fuel can cause a fire.

All nuts that hold a fuel injection line to the fuel injection nozzle or to the fuel injection pump must be tightened to the correct
torque. If the nut is loose, fuel will leak from the connection. If the nut is too tight, the inside diameter of the fuel line will become
smaller. This causes a restriction to the flow of fuel in the fuel line. Use a torque wrench to tighten the nuts of the fuel injection lines
to a torque of 26.5 to 32.4 N·m (20 to 24 lb ft).

Pressure Test

Ensure that you wear eye protection at all times during testing. When fuel
injection nozzles are tested, test fluids travel through the orifices of the
nozzle tip with high pressure. Under this amount of pressure, the test fluid
can pierce the skin and cause serious injury to the operator. Always keep
the tip of the fuel injection nozzle pointed away from the operator and into
the fuel collector and extension.

NOTICE
Do not use dirty test fluids when you test fuel injection nozzles. Also, do
not test fuel injection nozzles unless you have the correct service
tools.The use of dirty test fluids and the use of incorrect service tools will
result in damage to fuel injection nozzles.
Illustration 3 g01328191
Pressure test the fuel injection nozzle by using 5P-4150 Nozzle Testing Group .

(9) 5P-7448 Adapter

(10) Fuel injection nozzle

(11) 5P-4721 Tube

(12) 1U-8857 Extension Tube

(13) 8S-2270 Fuel Collector

(14) 8T-5313 Filter

Note: This procedure is a test of the first opening pressure of the fuel injection nozzle. The test for the second opening pressure of
the fuel injection nozzle can not be performed with this procedure. A test of the second opening pressure requires the disassembly
of the fuel injection nozzle and the use of special shims. Disassembly of the fuel injection nozzles may invalidate the standards for
emissions of the engine.

1. Connect fuel injection nozzle (10) to the tooling that is shown in Illustration 3.

The spray from the fuel injection nozzle must be directed into 1U-8857 Extension Tube (12) and 8S-2270 Fuel Collector
(13) .

Refer to the table in the Specifications Module, "Fuel Injection Nozzles" topic for the correct pressure settings. If the
opening pressure is not within the range of the setting which is given in the table, the fuel injection nozzle must be replaced.

Use clean 6V-6068 Calibration Fluid when the fuel injection nozzles are tested. The calibration fluid is similar to SAE J-967
(ISO 4113) oil.
 2. Close the gauge protector valve. Close the shutoff valve. Open the pump isolator valve. Flush the fuel injection nozzle by
operating the nozzle tester. Operate the nozzle tester for 10 to 15 strokes at a rate of approximately sixty strokes per
minute.

3. Open the gauge protector valve. Slowly increase the pressure until the valve in the fuel injection nozzle opens. Note the
highest pressure indication on the dial indicator before the pointer moves to 0 kPa (0 psi). This highest pressure indication is
the opening pressure of the fuel injection nozzle. The opening pressure will happen when valve needle rises from the nozzle
seat.

Refer to Specifications Module, "Fuel Injection Nozzles" for correct pressure settings. If the opening pressure is not within
the range of the setting that is given in the table, the fuel injection nozzle must be replaced.

Back Leakage Test

1. Connect fuel injection nozzle (10) to the tooling that is shown in Illustration 3.

Position the fuel injection nozzle so that the direction of the fuel spray is into 1U-8857 Extension (12) and 8S-2270 Fuel
Collector (13) .

2. Pump the pressure to about 1957 kPa (284 psi) below the opening pressure of the fuel injection nozzle. Refer to the
Specifications Module, "Fuel Injection Nozzles" topic for the correct setting of the opening pressure. Release the handle.
When the pressure begins to decrease, note the time that is required for the pressure to decrease to approximately 0 kPa
(0 psi). If the fuel injection nozzle is not damaged, the time will not be less than 5 seconds or more than 45 seconds.

If the time that is required for the pressure to decrease to 0 kPa (0 psi) is less than 5 seconds, too much fuel is leaking
around the valve needle. Replace the fuel injection nozzle.
 Illustration 4 g00570047
Leakage test after ten seconds

(A) Acceptable

(B) Unacceptable

3. Look for any leakage from the pressure faces of the holder and the retaining nut of the fuel injection nozzle. If leakage is
visible, make sure that the components are tightened to the correct torque.

If leakage continues to occur, unscrew the retaining nut from the body. Inspect the threaded surfaces for foreign particles
and damage. If the faces are clean and undamaged, test the fuel injection nozzle. Repeat Steps 1 and 2.

Fuel Injector Nozzle And Seat Test

1. Connect fuel injection nozzle (10) to the tooling that is shown in Illustration 3.

Position fuel injection nozzle so that the direction of the fuel spray is into 1U-8857 Extension Tube (12) and 8S-2270 Fuel
Collector (13) .

2. Pump the pressure of the nozzle tester to approximately 1957 kPa (284 psi) below the opening pressure of the fuel
injection nozzle. Fuel should not collect on the tip of the fuel injection nozzle in a sufficient quantity in order to drip from the
tip for at least ten seconds. A light dampness is acceptable.

If the results of the tests are not acceptable, replace the fuel injection nozzle.

Test The Spray Pattern

Ensure that you wear eye protection at all times during testing. When fuel
injection nozzles are tested, test fluids travel through the orifices of the
nozzle tip with high pressure. Under this amount of pressure, the test fluid
can pierce the skin and cause serious injury to the operator. Always keep
the tip of the fuel injection nozzle pointed away from the operator and into
the fuel collector and extension.

The pressure adjustment must be correct before the spray pattern is tested.
Illustration 5 g00322083

Correct Spray Pattern For Fuel Injector Nozzles

1. Connect fuel injection nozzle (10) to tooling that is shown in Illustration 3.

Position the fuel injection nozzle so that the direction of fuel spray is into 1U-8857 Extension Tube (12) and 8S-2270 Fuel
Collector (13) .

2. Close the gauge protector valve and the shutoff valve. Open the pump isolator valve.

3. Quickly pump the nozzle tester and look at the spray pattern when the fluid begins to flow through the orifices of the fuel
injection nozzle.

The spray, which flows from all of the orifices, must have the same pattern. A difference in the nozzle spray patterns
indicates that fuel injection nozzle is damaged. Refer to the correct spray pattern in Illustration 5.

Note: Be sure that the gauge protector valve is closed before fuel injection nozzle is removed from the nozzle tester.
Closing the gauge protector valve will prevent damage to the pressure gauge.

Installation Of Fuel Injection Nozzles

 Illustration 6 g01328217
Typical example of fuel injection nozzle

(1) Retainer for fuel injection nozzle

(2) Fuel injection nozzle

(3) Seat washer

1. When a fuel injection nozzle is removed from the cylinder head, replace the following components:

❍ Retainer for fuel injection nozzle (1)

❍ Fuel injection nozzle (2)

❍ Seat washer (3)

Ensure that seat washer is 2.0 mm (0.08 inch) thick.

Ensure that all mating surfaces are clean.

Note: Ensure that all old gaskets are removed and that the new gasket is undamaged. If an old gasket remains in the recess
of the cylinder head for fuel injection nozzle, the depth of the nozzle into the precombustion chamber will be incorrect.

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Product: EXCAVATOR
Model: 320B EXCAVATOR 5BR
Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-
UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i02959108

Fuel Injection Timing - Check

SMCS - 1251-036

Illustration 1 g01471339
Timing Gears

(1) Idler gear

(2) Camshaft gear

(3) Fuel injection pump drive gear

(4) Crankshaft gear

1. Improper fuel injection timing can cause poor engine performance. The engine timing gears have a reference mark on each
gear. The No. 1 cylinder is at the top center position when the two numbers on the fuel injection pump gear, the camshaft
gear and the crankshaft gear straddle a tooth on the idler gear. The fuel injection pump drive gear turns the camshaft of the
fuel pump. Rotating the fuel pump relative to the pump gear changes the fuel injection timing.

Note: This engine is not timed with a pin and this engine has an idler gear with an odd number of teeth. Do not rotate the
engine if the fuel injection pump is removed. If you rotate the engine, the engine should be timed by Step 7. The gears must
be aligned by using the timing marks once the front housing is removed. Mark the teeth with a paint stick. Reinstall the fuel
injection pump by meshing the marked teeth.

Illustration 2 g00569342
Fuel Injection Pump Timing Mark

(1) Timing marks

(2) Timing marks

2. Timing marks (1) and (2) on the fuel injection pump indicate the pump position relative to the timing gear. Each mark on the
scale represents a change in timing of six degrees.
 Illustration 3 g00569356
Adjusting Fuel Injection Pump Timing

(X) Direction of advancing timing

(Y) Direction of retarding timing

3. Loosen the retaining bolts. Rotating the fuel pump toward the engine retards injection timing while rotating the fuel pump
away from the engine advances injection timing.

4. To check the fuel injection timing, disconnect the fuel injection line from the fuel injection pump. Loosen the clamp and
remove the delivery valve holder. Remove the valve spring and the stopper from the delivery valve holder. Replace only the
delivery valve holder. Install a new fuel line to the delivery valve holder.

5. Turn the crankshaft until the No. 1 piston is approximately 60 degrees BTC on the compression stroke.

Note: Check the valve lash with the No. 1 cylinder at the top center position. This ensures that the cylinder is on the
compression stroke and that the cylinder is not on the exhaust stroke.
 Illustration 4 g00565561
Crankshaft Pulley Timing Marks

6. The crankshaft pulley contains a scale that has a range of 0 degrees to 40 degrees. Each mark on the scale represents a 5
degree crankshaft rotation.

NOTICE
Use a suitable container to catch any fuel that might spill. Clean up any
spilled fuel immediately.

Illustration 5 g00836673
Checking for fuel flow (6 cylinder engine)

(3) Fuel priming pump

 7. Operate the fuel priming pump. Rotate the engine crankshaft until the fuel stops flowing. Read the number of the timing
mark on the crankshaft pulley that is indicated. The fuel timing advance should be 8 degrees BTC or the fuel timing advance
should be 20 degrees BTC for the 3064 Engine. The fuel timing advance should be 10 degrees BTC or the fuel timing
advance should be 16 degrees BTC for the 3066 Engine. Refer to the Engine Information Plate on the valve cover for fuel
injection timing. Refer to the Technical Marketing Information (TMI) for other technical data. To correct the fuel injection
timing, rotate the fuel pump. Refer to Step 3.

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Product: EXCAVATOR
Model: 320B EXCAVATOR 5BR
Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-
UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i02281170

Fuel Quality - Test

SMCS - 1280-081

Table 1

Required Tools

Part Number Part Description Qty

5P-2712 Thermometer/Hydrometer 1

This test checks for problems regarding fuel quality. Refer to Diesel Fuels and Your Engine, SEBD0717 for additional details.

Use the following procedure to test for problems regarding fuel quality:

1. Determine if water and/or contaminants are present in the fuel. Check the water separator (if equipped). If a water
separator is not present, proceed to Step 2. Drain the water separator, if necessary. A full fuel tank minimizes the potential
for overnight condensation.

Note: A water separator can appear to be full of fuel when the water separator is actually full of water.

2. Determine if contaminants are present in the fuel. Remove a sample of fuel from the bottom of the fuel tank. Visually inspect
the fuel sample for contaminants. The color of the fuel is not necessarily an indication of fuel quality. However, fuel that is
black, brown, and/or similar to sludge can be an indication of the growth of bacteria or oil contamination. In cold
temperatures, cloudy fuel indicates that the fuel may not be suitable for operating conditions. The following methods can be
used to prevent wax from clogging the fuel filter:

❍ Fuel heaters

❍ Blending fuel with additives

❍ Utilizing fuel with a low cloud point such as kerosene

Refer to Operation and Maintenance Manual, "Fuel Recommendations" for more information.

3. Check fuel API with a 5P-2712 Thermometer/Hydrometer for low power complaints. The acceptable range of the fuel
API is 30 to 45 when the API is measured at 15 °C (60 °F), but there is a significant difference in energy within this range.
 Table 2

Fuel Density (API) (1) Correction Factors

API at
Correction Factor
16 °C (60 °F)

32.0 0.987

35.0 1.000

40.0 1.022

45.0 1.044
(1) The measured fuel API rating and the corresponding temperature must be corrected to 16 °C (60 °F) before selecting a fuel correction
factor. Use the chart for the fuel density correction factor in order to determine the fuel API rating at 16 °C (60 °F).

Note: A correction factor that is greater than 1.000 may be the cause of low power and/or poor fuel consumption.

4. If fuel quality is still suspected as a possible cause to problems regarding engine performance, disconnect the fuel inlet line,
and temporarily operate the engine from a separate source of fuel that is known to be good. This will determine if the
problem is caused by fuel quality. If fuel quality is determined to be the problem, drain the fuel system and replace the fuel
filters. Engine performance can be affected by the following characteristics:

❍ Cetane number of the fuel

❍ Air in the fuel

❍ Other fuel characteristics

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Product: EXCAVATOR
Model: 320B EXCAVATOR 5BR
Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-
UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01562475

Fuel System - Prime

SMCS - 1258-548

Illustration 1 g00569115
Removing Air From The Fuel System

(1) Plug

(2) Overflow valve

(3) Priming Pump

Use the following procedures to prime the fuel system.

1. Loosen the screw cap on the priming pump (3) .

2. Open plug (1) on the fuel filter while you operate the priming pump.

3. Continue to operate priming pump (3) until no air bubbles remain in the fuel that is flowing from plug (1) .
 4. Close plug (1) .

Open the overflow valve (2) of the fuel injection pump. Continue to operate the priming pump (3) until no air bubbles are in the
fuel that is flowing from the overflow valve of fuel injection pump.

NOTICE
Do not crank the engine continuously for more than 30 seconds. Allow
the starting motor to cool for two minutes before cranking the engine
again.

Start the engine. The fuel injection system is now primed.

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Product: EXCAVATOR
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Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-
UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01562501

Fuel System Pressure - Test

SMCS - 1250-081; 1256-081

When the engine is operating at full load speed, the fuel transfer pump moves the fuel through the following components at 76 to
245 kPa (11.0 to 35.5 psi):

● Fuel filter

● Fuel injection pump housing

Use the following steps to check the fuel pressure of the fuel transfer pump.

1. Disconnect the fuel line from the filter at the inlet of the fuel injection pump housing.

2. Install a tee at the inlet and connect the fuel line to the tee.

3. Connect a pressure gauge to the tee and start the engine.

If the fuel pressure is not above 76 kPa (11.0 psi) perform the following steps.

1. Stop the engine.

2. Replace the fuel filter.

3. Ensure that the inlet screen on the fuel transfer pump is not plugged or damaged.

4. Ensure that the fuel lines are not plugged or damaged.

5. Ensure that the fuel hoses are not plugged or damaged.

6. Start the engine and again check the fuel pressure.

If the fuel pressure is below 76 kPa (11.0 psi) the fuel transfer pump is faulty.

Perform one of the following items if the fuel transfer pump is faulty:

● Repair the fuel transfer pump.

● Replace the fuel transfer pump.

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Product: EXCAVATOR
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Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-
UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i02956328

Gear Group (Front) - Time

SMCS - 1206-531

Note: When the timing gear case is not installed, do not turn the crankshaft gear.

Illustration 1 g01471339
(1) Timing marks for the idler gear

(2) Timing mark for the camshaft gear

(3) Timing marks for the fuel injection pump drive gear

(4) Timing mark for the crankshaft gear

1. Ensure that the No. 1 piston is at top center on the intake stroke. Refer to Illustration 1.

2. Make sure that the marks on the gears are in alignment.

Note: The idler gear has an odd number of teeth. The position that is shown in Illustration 1 may never be obtained. When
the No. 1 piston is at top center on the intake stroke, each of the other gears will have the two numbers that are straddling
a tooth on the idler gear.

3. Install the dial gauge so that the dial gauge contacts the flat surface of the camshaft gear.

4. Measure the backlash between the camshaft gear and the idler gear. The backlash between the camshaft gear and the idler
gear should be 0.03 ± 0.17 mm (0.001 ± 0.007 inch).

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Product: EXCAVATOR
Model: 320B EXCAVATOR 5BR
Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-
UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i02956328

Gear Group (Front) - Time

SMCS - 1206-531

Note: When the timing gear case is not installed, do not turn the crankshaft gear.

Illustration 1 g01471339
(1) Timing marks for the idler gear

(2) Timing mark for the camshaft gear

(3) Timing marks for the fuel injection pump drive gear

(4) Timing mark for the crankshaft gear

1. Ensure that the No. 1 piston is at top center on the intake stroke. Refer to Illustration 1.

2. Make sure that the marks on the gears are in alignment.

Note: The idler gear has an odd number of teeth. The position that is shown in Illustration 1 may never be obtained. When
the No. 1 piston is at top center on the intake stroke, each of the other gears will have the two numbers that are straddling
a tooth on the idler gear.

3. Install the dial gauge so that the dial gauge contacts the flat surface of the camshaft gear.

4. Measure the backlash between the camshaft gear and the idler gear. The backlash between the camshaft gear and the idler
gear should be 0.03 ± 0.17 mm (0.001 ± 0.007 inch).

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Product: EXCAVATOR
Model: 320B EXCAVATOR 5BR
Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-
UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01968624

Governor - Adjust - In-line Fuel Pump

SMCS - 1264-025

High Idle and Low Idle can be checked in-chassis. Low Idle may be adjusted in-chassis. High Idle should only be adjusted on a
bench.

Note: The adjustment screw for High Idle is sealed at the factory in order to prevent tampering. High Idle will vary on different
machines due to parasitic loads or due to slight differences in the control spring of the governor. The Full Load Set Point is critical.
Attempting to adjust High Idle in-chassis may result in values that are out of the specification for the Full Load Set Point RPM,
which is not acceptable. On some engines, the adjustment screws for High Idle and Full Load Set Point are sealed at the factory
in order to prevent tampering. When you remove the seals, be careful not to damage the adjustment screw. A service kit is
available to reseal the governors.

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Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-
UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01562415

Low Idle RPM - Adjust

SMCS - 1250-025

Note: Refer to Special Instruction, NEHS0605 for the operating instructions of the 9U-7400 Multitach Tool Group and the
instructions for the test procedure.

Illustration 1 g00569479
Points of Adjustment on Governor

(1) Set screw of governor

 (2) Control lever

(3) Low idle set screw

(4) Idler subspring

(5) Bolt for stopping at full load

(6) Stop lever

Note: For any adjustments, ensure that the coolant and oil temperature are above 70 °C (158 °F).

1. Operate the starting motor in order to crank the engine.

2. At approximately 150 rpm, the engine will begin to start and the engine will pick up speed. Immediately after the engine is
running, move the control lever (2) in order to hold the engine rpm between 800 and 1000 rpm.

3. When the engine is running at a steady rpm, move the control lever (2) to the low idle position.

Illustration 2 g00569487
Adjusting Low Idle

(2) Control lever

(3) Low idle set screw (if equipped)

4. Hold control lever (2) at the position needed for no load minimum rpm, and set low idle set screw (3) (if equipped). Low
idle is 900 ± 20 rpm.
 5. Turning the low idle set screw (3) clockwise raises the idle rpm.

Illustration 3 g00569488
Adjusting The Idler Subspring

(4) Idler subspring

6. If the engine rpm tends to fluctuate, turn idler subspring (4) clockwise. Allow the idler subspring to come into slight contact
with the tension lever. The engine rpm will rise slightly and the engine rpm will stop fluctuating when the idler subspring is
exerting some force upon the tension lever.

Note: Tightening the idler subspring adjusting screw is likely to cause the engine to overspeed when the load is dumped
during heavy-duty operation. Tighten the idler subspring slowly until the unstable condition is eliminated.

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Product: EXCAVATOR
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Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-
UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i03561404

High Idle RPM - Adjust

SMCS - 1250-025

Note: Refer to Special Instruction, NEHS0605 for the operating instructions of the 9U-7400 Multitach Tool Group and the
instructions for the test procedure.

Illustration 1 g00569534
Adjustment of Governor Setting

(1) Set screw

(2) Control lever

 1. Hold control lever (2) at the position of maximum rpm while you apply a full load to the engine. Refer to the machine's
Testing and Adjusting manual for the High Idle value.

2. Position set screw (1) at the High Idle position. Tighten the locknut.

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Product: EXCAVATOR
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Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-
UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i02591129

Air Inlet and Exhaust System - Inspect

SMCS - 1050-040

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

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

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

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

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

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

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Model: 320B EXCAVATOR 5BR
Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-
UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01562530

Turbocharger - Inspect
SMCS - 1052-040

Check the turbocharger under the following conditions:

● Every 7200 hours of usage

● Any unusual noises from the turbocharger

● Any unusual vibrations in the turbocharger

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

1. Remove the piping from the turbocharger.

2. Inspect the following components:

❍ Turbocharger compressor wheel

❍ Turbocharger turbine wheel

❍ Compressor cover

3. Rotate the assembly of the turbocharger compressor wheel and the turbocharger turbine wheel by hand. Take extra care to
feel for any excess end play and for radial clearance.

The assembly of the turbocharger compressor wheel and the turbocharger turbine wheel should rotate freely without any
rubbing and without any binding.

If the turbocharger turbine wheel rubs against the compressor cover or the turbine wheel rubs against the turbine housing,
the turbocharger needs replacement or repair. For replacement, use a turbocharger that is new, reconditioned, or rebuilt.

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Product: EXCAVATOR
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Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-
UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01885055

Inlet Manifold Pressure - Test

SMCS - 1058-081

Inlet Manifold Pressure

Normal inlet manifold pressure with high exhaust temperature can be caused by blockage in the fins of the aftercooler core
assembly. Clean the fins of the aftercooler core assembly.

Low inlet manifold pressure and high exhaust manifold temperature can be caused by any of the following conditions:

Plugged air cleaner - Clean the air cleaner, as required. Replace the air cleaner, as required.

Blockage in the air lines - Blockage in the air lines between the air cleaner and the turbocharger must be removed.

Aftercooler core leakage - A leak in the aftercooler core should be repaired.

Leakage of the induction system - Any leakage from the pressure side of the induction system should be repaired.

Inlet manifold leak - An inlet manifold leak can be caused by any one of the following problems:

● Loose fittings and loose plugs

● Missing fittings and missing plugs

● Damaged fittings and damaged plugs

● The inlet manifold to cylinder head gaskets

Check all of these items, if necessary.

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Product: EXCAVATOR
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Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-
UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01562563

Exhaust Temperature - Test

SMCS - 1088-081

Table 1

Tools Needed

Part Number Part Description Qty

164-3310 Infrared Thermometer 1

Use the 164-3310 Infrared Thermometer to check the exhaust temperature.

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UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01562575

Engine Crankcase Pressure (Blowby) - Test

SMCS - 1215; 1317

Table 1

Tools Needed

Part Number Part Description Qty

8T-2700 Blowby/Air Flow Indicator 1

Pistons or rings that have damage can be the cause of too much pressure in the crankcase. This condition may cause the engine to
run rough. There will be more than the normal amount of fumes (blowby) rising from the crankcase breather. This crankcase
pressure can also cause the element for the crankcase breather to have a restriction in a very short time. This crankcase pressure
can also be the cause of any oil leakage at the gaskets and at the seals. These areas would not normally have leakage. Other
sources of blowby include worn valve guides and seal leakage of the turbocharger.

Illustration 1 g00286269
8T-2700 Blowby/Air Flow Indicator
The 8T-2700 Blowby/Air Flow Indicator checks the amount of blowby. Refer to Special Instructions, SEHS8712 for more
information on using this tool.

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Product: EXCAVATOR
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Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-
UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01967378

Compression - Test
SMCS - 1215

Table 1

Tools Needed

Part Number Part Name Qty

9U-6274 Compression Test Tool Gp 1

The following conditions can affect the results of the cylinder compression test:

● Battery

● Condition of the starter motor

● Ambient conditions

● Quality of the compression gauge

Illustration 1 g00564993
Checking compression of engine

1. Remove the fuel injection nozzle from the cylinder in order to measure the compression for that cylinder.

2. Connect a compression gauge to the cylinder.

3. Disconnect the fuel shutoff solenoid or hold the governor stop lever in the engine stop position.

4. Operate the starter motor and record the pressure on the compression gauge.

5. Repeat for each cylinder.

Note: Compression tests should only be used to compare pressures between cylinders of an engine. If one or more
cylinders vary more than 350 kPa (51 psi) then those cylinders may be damaged.

Note: The cylinder compression test should not be the only test for determining the condition of an engine.

Table 2

Standard at Assembly Repair Limit

Compression Pressure (1)

2940 kPa (427 psi) 2650 kPa (384 psi)
(1) The compression pressure is taken at 300 rpm.

6. Repair procedures must be taken if the compression is lower than the repair limit.
 NOTICE
Be sure to measure the compression on all of the cylinders. If all of the
cylinders are not checked an improper diagnosis may result. The
compression pressure will vary with the change in engine rpm. It is
necessary to keep the engine rpm constant for all cylinders when you are
taking a compression reading.

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Product: EXCAVATOR
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UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01906072

Engine Valve Lash - Inspect/Adjust

SMCS - 1102-025

Be sure the engine cannot be started while this maintenance is being

performed. To prevent possible injury, do not use the starting motor to
turn the flywheel.

Hot engine components can cause burns. Allow additional time for the
engine to cool before measuring/adjusting engine valve lash clearance.

The valve lash is measured between the top of the cap of the valve stem and the rocker arm. The valve lash is measured with a
feeler gauge.

Valve Lash Setting with Stopped Engine (Cold)

Inlet and Exhaust Valve ... 0.25 mm (0.010 inch)

Use the following procedure to check and make adjustments to the valve lash:

1. Remove the valve covers.

 Illustration 1 g00565561
Finding The Location of Top Center

2. Turn the crankshaft in a counterclockwise direction until the No. 1 piston is at the top center on the compression stroke.
The rotation of the crankshaft is viewed from the rear of the engine. The alignment mark on the pulley assembly will be in
alignment with the timing pointer.

Note: The crankshaft may be turned by using a socket wrench on the bolt in the crankshaft pulley. The crankshaft may also
be turned by turning the alternator. This will turn the belt and this will turn the crankshaft pulley.

Note: Refer to the Engine Supplement, Disassembly and Assembly for your specific machine for additional information.

Illustration 2 g00526261
Valve Lash

3. 3064 Engine: Adjust the valve lash on the inlet valves for cylinders 1 and 2. Adjust the valve lash on the exhaust valves for
 cylinders 1 and 3.

3066 Engine: Adjust the valve lash on the inlet valves for cylinders 1, 2, and 4. Adjust the valve lash on the exhaust valves
for cylinders 1, 3, and 5.

4. Turn the flywheel for 360 degrees in the direction of engine rotation. The No. 4 piston (four cylinder) and the No. 6 piston
(six cylinder) will be at the top center (TC) on the compression stroke.

5. 3064 Engine: Adjust the valve lash on the inlet valves for cylinders 3 and 4. Adjust the valve lash on the exhaust valves for
cylinders 2 and 4.

3066 Engine: Adjust the valve lash on the inlet valves for cylinders 3, 5, and 6. Adjust the valve lash on the exhaust valves
for cylinders 2, 4, and 6.

6. Hold the adjustment screw and tighten the locknut after the adjustment is complete.

Adjusting the valve lash several times in a short period indicates wear in a different part of the engine. Find the problem and make
any necessary repairs in order to prevent more damage to the engine.

Rapid wear of the camshaft and tappets can occur if insufficient valve lash is not corrected. Insufficient valve lash can also be an
indication of faulty valve seats. The following items are reasons for faulty seats of the valves: faulty fuel injection nozzles,
restrictions to the air inlet, dirty air filters, incorrect fuel setting and overloading the engine.

Broken valve stems, broken pushrods, or broken spring retainers can be caused by insufficient valve lash that is not corrected. A
fast increase in valve lash can be an indication of any of the following items:

● Worn camshaft and tappets

● Worn rocker arms

● Bent pushrods

● Loose adjustment screws for valve lash

● Broken socket on the upper end of pushrod

Fuel in the lubrication oil may be a possible cause of rapid wear of the camshaft and the tappets. Dirty lubrication oil may also be
a possible cause of rapid wear of the camshaft and tappets.

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Product: EXCAVATOR
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Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-
UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01562607

Valve Guide - Inspect

SMCS - 1104-040

Use the following items in order to remove valve guides and install valve guides:

● 9U-6137 Guide Collar

● 1U-7793 Guide Driver

The counterbore in the driver bushing installs the guide to the correct height. Install the guide in the head. Use a 1P-7451 Valve
Guide Honing Group in order to make a finished bore in the valve. Refer to Special Instruction, SMHS7526, "Use of 1P-7451
Valve Guide Honing Group" for more information on the proper procedure. Grind the valves after the new valve guides are
installed.

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Product: EXCAVATOR
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Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-
UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01562753

Engine Oil Pressure - Test

SMCS - 1304-081

Table 1

Tools Needed

Part Number Part Name Qty

1U-5470 Engine Pressure Group 1

An oil pressure gauge that has a defect can indicate low oil pressure.

The 1U-5470 Engine Pressure Group can be used to check engine oil pressure.

Illustration 1 g00296486
1U-5470 Engine Pressure Group

The 1U-5470 Engine Pressure Group has a gauge that measures the oil pressure in the engine. Refer to Special Instruction,
SEHS8907 for more information on using the 1U-5470 Engine Pressure Group. The information is included in the tool group.
 1. Ensure that the engine is filled to the correct oil level.

2. Connect the 1U-5470 Engine Pressure Group to a pressure tap location for engine oil.

3. Operate the engine. Allow the engine to obtain normal operating temperature.

4. Keep the oil temperature constant with the engine at the rated rpm. Read the pressure gauge.

5. Refer to Table 2 in order to determine if the engine oil pressure is in tolerance.

Table 2

Oil Pressure (1)

Oil Pressure at 1500 rpm

196 to 392 kPa (28 to 57 psi)

Oil Pressure at Idle (2)

83 to 98 kPa (12 to 14 psi)
(1) The oil temperature must be 60° to 70°C (140° to 158°F).
(2) Idle rpm is 900 ± 20 rpm.

Find the cause of the problem and correct the problem if the results of the test do not fall within the pressure range in Table 2.
Engine failure or a reduction in engine life can be the result if engine operation is continued with oil pressure outside this range.

Note: A record of engine oil pressure at regular intervals can be used as an indication of possible problems of the engine. A
record of engine oil pressure at regular intervals can also be used as an indication of possible damage to the engine. The engine
should be inspected and the problem should be corrected if there is a sudden increase or a sudden decrease of 70 kPa (10 psi) in
oil pressure.

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Product: EXCAVATOR
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UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01574562

Engine Oil Pump - Inspect

SMCS - 1304-040

If any part of the oil pump is worn enough in order to affect performance of the oil pump, the oil pump must be replaced.

Perform the following procedures in order to inspect the oil pump. Refer to Specifications, "Engine Oil Pump" for clearances and
torques.

1. Remove the cover for the engine oil pump. Refer to the Disassembly and Assembly, "Engine Oil Pump - Remove".

2. Clean all of the parts. Look for cracks in the metal or other damage.

Illustration 1 g00530573
Engine oil pump

(1) Driven gear assembly

(2) Drive gear assembly

(3) Oil pump gear

(4) Idler gear assembly

(5) Spindle

NOTICE
Before operation, the pump must be lubricated with clean engine oil and
the pump must turn freely by hand or damage to parts can be the result.

Note: The minimum acceptable oil pressure at low idle is 100 kPa (15 psi).

Measure the backlash between the oil pump gear and the idler gear.

Note: Replace the gears if the backlash exceeds 0.35 mm (0.014 inch).

Note: The oil pump gear and the drive gear assembly are not serviceable if the oil pump gear is removed.

Illustration 2 g00530644
(3) Oil pump gear

Note: Do not use a torch.

Heat the oil pump gear to 180° to 220°C (356° to 428°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 flush with the end of the shaft.
Illustration 3 g00530697
(6) Housing for oil pump gear

Measure the difference in the length of the assembly for the oil pump gear. Measure the depth in the oil pump housing.

Note: Replace the oil pump gear assembly if the clearance exceeds the service limit of 0.150 mm (0.0059 inch).

Measure the clearance between the oil pump gears and the oil pump housing with a feeler gauge.

Note: Replace the oil pump gear assembly if the clearance exceeds the service limit of 0.100 mm (0.0039 inch).
Illustration 4 g00530702
(6) Housing for oil pump gear

(7) Cover

Measure the inside diameters of the bores of the shafts in the cover (7) and the oil pump housing (6). Measure the bores of the
shafts.

Note: Replace the oil pump gear assembly, the cover, or the oil pump housing if the clearance exceeds the service limit of 0.150
mm (0.0059 inch).

Note: Replace the drive gear and driven gear as an assembly.

Illustration 5 g00835890
(5) Spindle

(8) Idler gear bushing

Measure the inside diameter of the idler gear bushing.

Measure the diameter of the spindle.

Clean the surface of the oil pump cover (7). Install the cover to the oil pump housing (6). Install bolts for the oil pump cover.

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Product: EXCAVATOR
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Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-
UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01126690

Excessive Bearing Wear - Inspect

SMCS - 1203-040; 1211-040; 1219-040

When some components of the engine show bearing wear in a short time, the cause can be a restriction in an oil passage.

An engine oil pressure indicator may show that there is enough oil pressure, but a component is worn due to a lack of lubrication.
In such a case, look at the passage for the oil supply to the component. A restriction in an oil supply passage will not allow enough
lubrication to reach a component. This will result in early wear.

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Product: EXCAVATOR
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UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i03314492

Excessive Engine Oil Consumption - Inspect

SMCS - 1348-040

Engine Oil Leaks on the Outside of the Engine

Check for leakage at the seals at each end of the crankshaft. Look for leakage at the gasket for the engine oil pan and all
lubrication system connections. Look for any engine oil that may be leaking from the crankcase breather. This can be caused by
combustion gas leakage around the pistons. A dirty crankcase breather will cause high pressure in the crankcase. A dirty
crankcase breather will cause the gaskets and the seals to leak.

Engine Oil Leaks into the Combustion Area of the Cylinders

Engine oil that is leaking into the combustion area of the cylinders can be the cause of blue smoke. There are several possible
ways for engine oil to leak into the combustion area of the cylinders:

● Leaks between worn valve guides and valve stems

● Worn components or damaged components (pistons, piston rings, or dirty return holes for the engine oil)

● Incorrect installation of the compression ring and/or the intermediate ring

● Leaks past the seal rings in the turbocharger shaft

● Overfilling of the crankcase

● Wrong oil level gauge or guide tube

● Sustained operation at light loads

Excessive consumption of engine oil can also result if engine oil with the wrong viscosity is used. Engine oil with a thin viscosity can
be caused by fuel leakage into the crankcase or by increased engine temperature.

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Product: EXCAVATOR
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Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-
UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i02286625

Increased Engine Oil Temperature - Inspect

SMCS - 1348-040

When the engine is at operating temperature and the engine is using SAE 10W30 or SAE 15W40 oil, the maximum oil
temperature should be 110 °C (230 °F). This is the temperature of the oil after passing through the oil cooler.

If the oil temperature is high, then check for a restriction in the oil passages of the oil cooler. A restriction in the oil cooler will not
cause low oil pressure in the engine.

Determine if the oil cooler bypass valve is held in the open position. This condition will allow the oil to pass through the valve
instead of the oil cooler. The oil temperature will increase.

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Product: EXCAVATOR
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Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-
UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01371296

Cooling System - Check - Overheating

SMCS - 1350-535

Above normal coolant temperatures can be caused by many conditions. Use the following procedure to determine the cause of
above normal coolant temperatures:

Personal injury can result from escaping fluid under pressure.

If a pressure indication is shown on the indicator, push the release valve in

order to relieve pressure before removing any hose from the radiator.

1. Check the coolant level in the cooling system. If the coolant level is too low, air will get into the cooling system. Air in the
cooling system will cause a reduction in coolant flow and bubbles in the coolant. Air bubbles will keep coolant away from
the engine parts, which will prevent the transfer of heat to the coolant. Low coolant level is caused by leaks or incorrectly
filling the radiator.

2. Check the mixture of antifreeze and water. The mixture should be approximately 50 percent water and 50 percent
antifreeze with 3 to 6 percent coolant conditioner. If the coolant mixture is incorrect, drain the system. Put the correct
mixture of water, antifreeze and coolant conditioner in the cooling system.

3. Check for air in the cooling system. Air can enter the cooling system in different ways. The most common causes of air in
the cooling system are not filling the cooling system correctly and combustion gas leakage into the cooling system.
Combustion gas can get into the system through inside cracks, a damaged cylinder head, or a damaged cylinder head
gasket. Air in the cooling system causes a reduction in coolant flow and bubbles in the coolant. Air bubbles keep coolant
away from the engine parts, which prevents the transfer of heat to the coolant.

4. Check the sending unit. In some conditions, the temperature sensor in the engine sends signals to a sending unit. The
sending unit converts these signals to an electrical impulse which is used by a mounted gauge. If the sending unit
malfunctions, the gauge can show an incorrect reading. Also if the electric wire breaks or if the electric wire shorts out, the
gauge can show an incorrect reading.

5. Check the radiator.

a. Check the radiator for a restriction to coolant flow. Check the radiator for debris, dirt, or deposits on the inside of
the radiator core. Debris, dirt, or deposits will restrict the flow of coolant through the radiator.
 b. Check for debris or damage between the fins of the radiator core. Debris between the fins of the radiator core
restricts air flow through the radiator core. Refer to Testing and Adjusting, "Cooling System - Inspect".

6. Check the filler cap. A pressure drop in the radiator can cause the boiling point to be lower. This can cause the cooling
system to boil. Refer to Testing and Adjusting, "Cooling System - Test".

7. Check the fan and/or the fan shroud. The fan shroud must be the proper size and the fan shroud must be positioned
correctly.

8. Check for loose drive belts.

a. A loose fan drive belt will cause a reduction in the air flow across the radiator. Check the fan drive belt for proper
belt tension. Adjust the tension of the fan drive belt, if necessary. Refer to the Testing and Adjusting Section, "Belt
Tension Chart".

b. A loose water pump drive belt will cause a reduction in coolant flow through the radiator. Check the water pump
drive belt for proper belt tension. Adjust the water pump drive belt's tension, if necessary. Refer to the Testing and
Adjusting Section, "Belt Tension Chart".

9. Check the cooling system hoses and clamps. Damaged hoses with leaks can normally be seen. Hoses that have no visual
leaks can soften during operation. The soft areas of the hose can become kinked or crushed during operation. These areas
of the hose can cause a restriction in the coolant flow. Hoses become soft and/or get cracks after a period of time. The
inside of a hose can deteriorate, and the loose particles of the hose can cause a restriction of the coolant flow.

10. Check for a restriction in the air inlet system. A restriction of the air that is coming into the engine can cause high cylinder
temperatures. High cylinder temperatures require higher than normal temperatures in the cooling system.

11. Check for a restriction in the exhaust system. A restriction of the air that is coming out of the engine can cause high cylinder
temperatures.

a. Make a visual inspection of the exhaust system.

b. Check for damage to exhaust piping or for a damaged muffler. If no damage is found, check the exhaust system for a
restriction.

12. Check the shunt line. The shunt line must be submerged in the expansion tank. A restriction of the shunt line from the
radiator top tank to the engine water pump inlet will cause a reduction in water pump efficiency. A reduction in water pump
efficiency will result in low coolant flow and overheating.

13. Check the water temperature regulator. A water temperature regulator that does not open, or a water temperature
regulator that only opens part of the way can cause overheating. Refer to Testing and Adjusting, "Water Temperature
Regulator - Test".

14. Check the water pump. A water pump with a damaged impeller does not pump enough coolant for correct engine cooling.
Remove the water pump and check for damage to the impeller.

15. Check the air flow through the engine compartment. The air flow through the radiator comes out of the engine
compartment. Ensure that the filters, air conditioner, and similar items are not installed in a way that prevents the free flow
of air through the engine compartment.

16. Consider high outside temperatures. When outside temperatures are too high for the rating of the cooling system, there is
not enough of a temperature difference between the outside air and coolant temperatures.

17. Consider high altitude operation. The cooling capacity of the cooling system goes down as the engine is operated at higher
altitudes. A pressurized cooling system that is large enough to keep the coolant from boiling must be used.
18. The engine may be running in the lug condition. When the load that is applied to the engine is too large, the engine will run in
the lug condition. When the engine is running in the lug condition, engine rpm does not increase with an increase of fuel. This
lower engine rpm causes a reduction in air flow through the radiator. This lower engine rpm also causes a reduction in
coolant flow through the system. This combination of less air and less coolant flow during high input of fuel will cause above
normal heating.

19. Timing of the engine which is incorrect may also cause overheating of the engine. Late timing creates more heat in the
engine. Early timing creates less heat in the engine.

Note: If the timing of the engine is incorrect, the exhaust valves may be burned and damage to the exhaust manifold may
occur.

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Product: EXCAVATOR
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Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-
UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01300404

Cooling System - Inspect

SMCS - 1350-040

Cooling systems that are not regularly inspected are the cause for increased engine temperatures. Make a visual inspection of the
cooling system before any tests are performed.

Personal injury can result from escaping fluid under pressure.

If a pressure indication is shown on the indicator, push the release valve in

order to relieve pressure before removing any hose from the radiator.

1. Check the coolant level in the cooling system.

2. Look for leaks in the system.

Note: A small amount of coolant leakage across the surface of the water pump seals is normal. This leakage is required in
order to provide lubrication for this type of seal. A hole is provided in the water pump housing in order to allow this
coolant/seal lubricant to drain from the pump housing. Intermittent leakage of small amounts of coolant from this hole is not
an indication of water pump seal failure.

3. Make sure that air flow through the radiator does not have a restriction. Look for bent core fins between the folded cores
of the radiator. Also, look for debris between the folded cores of the radiator.

4. Inspect the drive belts for the fan.

5. Check for damage to the fan blades.

6. Look for air or combustion gas in the cooling system.

7. Inspect the filler cap, and check the surface that seals the filler cap. This surface must be clean.

8. Look for large amounts of dirt in the radiator core. Look for large amounts of dirt on the engine. Remove the dirt from the
radiator core and the engine.

9. Fan shrouds that are loose or missing cause poor air flow for cooling.
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Product: EXCAVATOR
Model: 320B EXCAVATOR 5BR
Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-
UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i02765190

Cooling System - Test

SMCS - 1350-040; 1350-081

This engine has a pressure type cooling system. A pressure type cooling system has two advantages:

● The pressure type cooling system can operate safely at a higher temperature than the boiling point of water at a range of
atmospheric pressures.

● The pressure type cooling system prevents cavitation in the water pump.

Cavitation is the sudden generation of low pressure bubbles in liquids by mechanical forces. The generation of an air or steam
pocket is more difficult in a pressure type cooling system.

Regular inspections of the cooling system should be made in order to identify problems before damage can occur. Visually inspect
the cooling system before tests are made with the test equipment.

Remember that temperature and pressure work together. When a diagnosis is made of a cooling system problem, temperature
and pressure must be checked. Cooling system pressure will have an effect on the cooling system temperature. For an example,
refer to Illustration 1. This will show the effect of pressure on the boiling point (steam) of water. This will also show the effect of
height above sea level.
Illustration 1 g00313203
Cooling system pressure at specific altitudes and boiling points of water

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 filler cap slowly to relieve pressure only when engine is stopped
and radiator cap is cool enough to touch with your bare hand.

Cooling System Conditioner contains alkali. Avoid contact with skin and
eyes.

The coolant level must be to the correct level in order to check the coolant system. The engine must be cold and the engine must
not be running.

After the engine is cool, loosen the pressure cap in order to relieve the pressure out of the cooling system. Then remove the
pressure cap.

The level of the coolant should not be more than 13 mm (0.5 inch) from the bottom of the filler pipe. If the cooling system is
equipped with a sight glass, the coolant should be to the proper level in the sight glass.
Illustration 2 g01328289
Test location for water temperature

(1) Plug

Test Tools For The Cooling System

Table 1

Required Tools

Part Number Part Name Qty

4C-6500 Digital Thermometer 1

285-0910 Multi-Tool Gp 1

9U-7400 Multitach Tool Gp 1

9S-8140 Pressurizing Pump 1

245-5829 Coolant/Battery Tester Gp 1

Making contact with a running engine can cause burns from hot parts and
can cause injury from rotating parts.

When working on an engine that is running, avoid contact with hot parts
and rotating parts.
Illustration 3 g00286267
4C-6500 Digital Thermometer

The 4C-6500 Digital Thermometer is used in the diagnosis of problems that cause overheating or overcooling in the engine. This
tool can be used to check the temperature in several areas of the cooling system. The testing procedure is in Tool Operating
Manual, NEHS0554.

Illustration 4 g01311364
285-0910 Multi-Tool Gp
Illustration 5 g00313263

The 285-0910 Multi-Tool Gp is used to check the air flow through the radiator core.

Illustration 6 g00286276
9U-7400 Multitach Tool Group

The 9U-7400 Multitach Tool Gp is used to measure the fan speed. Refer to Operating Manual, NEHS0605, " 9U-7400
Multitach Tool Gp " for the testing procedure.

Illustration 7 g00286369
9S-8140 Pressurizing Pump

The 9S-8140 Pressurizing Pump is used to test the filler caps. This pressurizing pump is also used to pressure test the cooling
system for leaks.
Illustration 8 g00439083
245-5829 Coolant/Battery Tester Gp

Check the coolant frequently in cold weather for the proper glycol concentration. Use the 245-5829 Coolant/Battery Tester Gp in
order to ensure adequate freeze protection. The testers are identical except for the temperature scale. The testers give immediate,
accurate readings. The testers can be used for coolants that contain ethylene or propylene glycol.

Making the Correct Antifreeze Mixtures

Do not add pure antifreeze to the cooling system in order to adjust the concentration of antifreeze. The pure antifreeze increases
the concentration of antifreeze in the cooling system. The increased concentration increases the concentration of dissolved solids
and undissolved chemical inhibitors in the cooling system.

Add an antifreeze and water mixture in the concentration which provides the desired freeze protection. Use the following chart in
order to determine the correct concentration of antifreeze in water to use.

Table 2

Antifreeze Concentrations For Freeze Protection

Temperature Concentration

Protection to
30% antifreeze and 70% water
−15 °C (5 °F)

Protection to
40% antifreeze and 60% water
−23 °C (−9 °F)

Protection to
50% antifreeze and 50% water
−37 °C (−35 °F)

Protection to
60% antifreeze and 40% water
−51 °C (−60 °F)

Checking the Filler Cap

 Table 3

Required Tools

Part Number Part Name Qty

9S-8140 Pressurizing Pump 1

One cause for a pressure loss in the cooling system can be a faulty seal on the radiator pressure cap.

Illustration 9 g01328299
Typical schematic of filler cap

(1) Sealing surface between the pressure cap and the radiator

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 filler cap slowly to relieve pressure only when engine is stopped
and radiator cap is cool enough to touch with your bare hand.

Cooling System Conditioner contains alkali. Avoid contact with skin and
eyes.

To check for the amount of pressure that opens the filler cap, use the following procedure:

1. After the engine cools, carefully loosen the filler cap. Slowly release the pressure from the cooling system. Then, remove the
filler cap.

2. Inspect the pressure cap carefully. Look for damage to the seal. Look for damage to the surface that seals. Remove any
 debris on the cap, the seal, or the sealing surface.

Carefully inspect the filler cap. Look for any damage to the seals and to the sealing surface. Inspect the following
components for any foreign substances:

❍ Filler cap

❍ Seal

❍ Surface for seal

Remove any deposits that are found on these items, and remove any material that is found on these items.

3. Install the pressure cap on the 9S-8140 Pressurizing Pump .

4. Observe the exact pressure that opens the filler cap.

5. Compare the pressure to the pressure rating that is found on the top of the filler cap.

6. If the filler cap is damaged, replace the filler cap.

Testing The Radiator And Cooling System For Leaks

Table 4

Required Tools

Part Number Part Name Qty

9S-8140 Pressurizing Pump 1

Use the following procedure to test the radiator and the cooling system for leaks.

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 filler cap slowly to relieve pressure only when engine is stopped
and radiator cap is cool enough to touch with your bare hand.

Cooling System Conditioner contains alkali. Avoid contact with skin and
eyes.

1. When the engine has cooled, loosen the filler cap to the first stop. Allow the pressure to release from the cooling system.
Then remove the filler cap.

2. Make sure that the coolant covers the top of the radiator core.

3. Put the 9S-8140 Pressurizing Pump onto the radiator.

 4. Use the pressurizing pump to increase the pressure to an amount of 20 kPa (3 psi) more than the operating pressure of the
filler cap.

5. Check the radiator for leakage on the outside.

6. Check all connections and hoses of the cooling system for leaks.

The radiator and the cooling system do not have leakage if all of the following conditions exist:

❍ You do NOT observe any leakage after five minutes.

❍ The dial indicator remains constant beyond five minutes.

The inside of the cooling system has leakage only if the following conditions exist:

❍ The reading on the gauge goes down.

❍ You do NOT observe any outside leakage.

Make any repairs, as required.

Cooling System Conditioner

Supplemental cooling system additive contains alkali. To prevent personal

injury, do not drink, avoid contact with the skin and eyes.

NOTICE
All water is corrosive at engine operating temperature. The cooling
system should be protected with a 3% to 6% concentration of cooling
system conditioner at all times.

Caterpillar does not recommend the use of cooling system solutions that
are intended to stop leaks.

Use of these products may result in excessive internal deposits that could
reduce the engine's heat transfer characteristics.

Caterpillar Cooling System Conditioner can be used with an antifreeze or without an antifreeze of ethylene glycol base in the
coolant.

When the conditioner is added to the coolant, the cooling system must be flushed and the cooling system must be cleaned.

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Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-
UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i02878004

Engine Oil Cooler - Inspect

SMCS - 1378-040

Illustration 1 g01432449
(1) Element

(2) Gaskets

(3) Oil cooler cover

Check the element (1) for cracks or other defects. If the element is damaged replace the element. Replace all gaskets (2) and
check the oil cooler cover (3) for cracks. If the oil cooler cover is damaged, replace the cover.

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UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01666401

Water Temperature Regulator - Test

SMCS - 1355-081-ON ; 1355-081

Personal injury can result from escaping fluid under pressure.

If a pressure indication is shown on the indicator, push the release valve in

order to relieve pressure before removing any hose from the radiator.

1. Remove the water temperature regulator from the engine.

2. Heat water in a pan until the temperature of the water is equal to the fully open temperature of the water temperature
regulator. Refer to Specifications, "Water Temperature Regulator" for the fully open temperature of the water temperature
regulator. Stir the water in the pan. This will distribute the temperature throughout the pan.

3. Hang the water temperature regulator in the pan of water. The water temperature regulator must be below the surface of
the water. The water temperature regulator must be away from the sides and the bottom of the pan.

4. Keep the water at the correct temperature for ten minutes.

5. After ten minutes, remove the water temperature regulator. Immediately measure the opening of the water temperature
regulator. Refer to Specifications, "Water Temperature Regulator" for the minimum opening distance of the water
temperature regulator at the fully open temperature.

If the distance is less than the amount listed in the manual, replace the water temperature regulator.

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UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i02707320

Piston Ring Groove - Inspect

SMCS - 1214-040

Table 1

Required Tools

Part Number Part Name Qty

8H-8581 Feeler Gauge 1

Inspect the Piston and the Piston Rings

1. Check the piston for wear and other damage.

2. Check that the piston rings are free to move in the grooves and that the rings are not broken.

Inspect the Clearance of the Piston Ring

1. Remove the piston rings and clean the grooves and the piston rings.
 Illustration 1 g01284934
(1) Feeler gauge

(2) Piston ring

(3) Piston grooves

2. Fit new piston rings (2) in the piston grooves (3) .

3. Check the clearance for the piston ring by placing the 8H-8581 Feeler Gauge (1) between piston groove (3) and the top of
piston ring (2) . Refer to Specifications, "Piston and Rings" for the dimensions.

Note: Some pistons have a tapered top groove and the piston ring is wedged. The clearance for the top piston ring cannot
be checked by the above method when this occurs.

Inspect the Piston Ring End Gap

 Illustration 2 g01358235
(1) Piston ring

(2) Cylinder ring ridge

(3) Feeler gauge

1. Clean all carbon from the top of the cylinder bores.

2. Place each piston ring (1) in the cylinder bore just below the cylinder ring ridge (2) .

3. Use the 8H-8581 Feeler Gauge (3) to measure piston ring end gap. Refer to Specifications, "Piston and Rings" for the
dimensions.

Note: The coil spring must be removed from the oil control ring before the gap of the oil control ring is measured.

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Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01764002

Connecting Rod - Inspect

SMCS - 1218-040

Note: The bolts on the connecting rod are installed in the connecting rod by a special process. The bolts should not be rotated or
removed. If the bolts are rotated or removed, the connecting rod and the bolts will be damaged.

These procedures determine the following characteristics of the connecting rod.

● Length of the connecting rod

● Distortion of the connecting rod

● Parallel alignment of the bores of the connecting rod

Note: If the connecting rod or the bearing for the piston pin is replaced, a new piston must also be installed. A new piston is
required in order to ensure that the height of the piston above the cylinder block is correct.

Length of a Connecting Rod

CRL is the connecting rod length. The length of the connecting rod is given in Table 1 for each length grade of connecting rod.

In order to ensure that the piston height above the cylinder block is correct, six length grades of connecting rods are used in
production. The length grade is identified by a letter or a color which is marked on the side of the connecting rod. The longest
grade is marked with the letter "A". The shortest grade is marked with the letter "F". The difference in each length grade is 0.03
mm (0.001 inch).

The length grade of a connecting rod is determined in the factory by machining an eccentric hole in a semi-finished piston pin
bushing.

If the connecting rod must be replaced, a new connecting rod assembly must be purchased and installed. The length grade of the
new connecting rod must be specified. The new connecting rod contains a new piston pin bearing. The piston pin bearing is
reamed to the correct bore. Refer to Table 1.

Replace Only the Piston or the Bearing for the Piston Pin

This procedure is applicable when the original connecting rod is used with the following components: piston and piston pin
bearing.
 1. Remove the bearing for the piston pin, which was installed in the factory, from the connecting rod. Install a new bushing in
the connecting rod. If necessary, ream the new bearing in order to obtain the correct clearance between the piston pin and
the bearing.

Refer to Specifications, "Piston and Rings" for dimensions of bearings and piston pins.

2. Install a new piston, if necessary. The new piston will be the "Std" height grade. Also, a new piston pin may be required.

Refer to Specifications, "Piston and Rings" for specifications of pistons and piston rings.

3. Measure the height of the piston above the cylinder block in order to ensure the correct piston height.

If the height of the piston is incorrect, a new connecting rod must be installed. If the piston height is too high, a shorter
connecting rod is required. If the piston height is too low, a longer connecting rod is required. Refer to Table 1.

Replacing the Connecting Rod and Piston

This procedure determines the length of the connecting rod. The length of the connecting rod must be known so that the correct
length of a replacement for the connecting rod can be purchased.

Determine the length grade of the connecting rod by one of the following characteristics:

● Length grade letter

● Measuring the length

If the letter for the length grade is used in order to determine the length grade, refer to Table 1. If the length of the connecting rod
must be measured in order to determine the length grade, refer to Illustration 1.

Table 1

Length grades of the connecting rod

Length grade that is used in Length Grade that is used for Length Of The Connecting Rod
Production Replacement (CRL)

"A" and "B" "B" 132.05 to 132.08 mm (5.199 to 5.200

inch)

"C" and "D" "D" 131.99 to 132.02 mm (5.196 to 5.198

inch)

"E" and "F" "F" 131.93 to 131.96 mm (5.194 to 5.195

inch)

If the mark for the length grade cannot be observed on the connecting rod, perform the following procedure in order to measure
the length of the connecting rod ("CRL").
 Illustration 1 g00396379
(1) Measuring pins

(2) Connecting rod

1. Use the following tools that are provided by the customer in order to measure the distances for the connecting rod (2)
which are specified in Illustration 1:

❍ Appropriate gauges for measuring distance

❍ Measuring pins (1)

2. Ensure that the measuring pins (1) are parallel. If the measuring pins are not parallel, refer to "Distortion of a Connecting
Rod". This will determine if the distortion is within the tolerance.

Measure "CRL". Compare the "CRL" that is measured to the "CRL" that is given in Table 1. The length grade of the
connecting rod is determined by this "CRL".

Distortion of a Connecting Rod

Illustration 2 g00720855
(A) 127 mm (5.0 inch)

(B) The allowable tolerance for parallelism between center lines is ± 0.25 mm (± 0.010 inch).

(1) Measuring pins

(2) Connecting rod

1. Use the following tools that are provided by the customer in order to measure the distances for the connecting rod (2)
which are specified in Illustration 2:

❍ Appropriate gauges for measuring distance

❍ Measuring pins (1)

2. Measure the connecting rod for distortion between the bores.

The bores for the crankshaft bearing and the bearing for the piston pin must be square and parallel with each other within
the required limits. When the bearings for the connecting rod are removed, the limits for parallelism and for squareness are
0.25 mm (0.010 inch) . The limits are measured at a distance of 127 mm (5.0 inch) (A) from each side of the connecting
rod.

Inspect the Bearing and Piston Pin for Wear

Note: The bolts on the connecting rod are installed in the connecting rod by a special process. The bolts should not be rotated or
removed. If the bolts are rotated or removed, the connecting rod and the bolts will be damaged.

1. Inspect the bearing for the piston pin and the piston pin for wear.

2. Measure the clearance of the piston pin in the bearing for the piston pin.

Refer to Specifications, "Connecting Rod" for dimensions.

If the bearing or the piston pin are not within tolerances, the component must be replaced. If the clearance between the bearing
and piston pin is not within the tolerance, one or both components must be replaced.
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Product: EXCAVATOR
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Configuration: 320B & 320B L TRACK-TYPE EXCAVATORS 5BR00001-
UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01366183

Connecting Rod Bearings - Inspect

SMCS - 1219-040

Illustration 1 g00720890

Inspect the connecting rod bearings for peeling, melting, seizure or poor contact. If the connecting rod bearings are worn or if the
connecting rod bearings are damaged, replace the connecting rod bearings.

1. Measure the clearance between the connecting rod bearing and the crankshaft journal.

2. Measure the connecting rod bearings at positions (1) and (2) in directions (A) and (B). Refer to the Specifications Module,
"Connecting Rod" topic for information on the tolerances.

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UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01366224

Main Bearings - Inspect

SMCS - 1203-040

Illustration 1 g00720890

Inspect the main bearings for peeling, melting, seizure or poor contact. If the main bearings are worn or if the main bearings are
damaged, replace the main bearings.

1. Measure the clearance between the main bearings and the crankshaft journal.

2. Measure the main bearings at positions (1) and (2) in directions (A) and (B). Refer to the Specifications Module, "Cylinder
block" topic for information on the tolerances.

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UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01309662

Cylinder Block - Inspect

SMCS - 1201-040

Table 1

Required Tools

Part Number Part Name Qty

1P-3537 Dial Bore Gauge Group 1

Illustration 1 g00285686

Inspect the top of the cylinder block for cracks and warpage. Refer to the Specifications Module, "Cylinder Block" topic for the
tolerances.

Inspect each cylinder bore. There should be no scoring, rust or corrosion. Use a 1P-3537 Dial Bore Gauge Group in order to
measure each cylinder bore. Each cylinder bore should be measured at the top, middle and bottom. Refer to Special Instruction,
GMG00981 for the instructions that are needed to use the dial bore gauge.
If the cylinder bores are out of the service limit, the cylinder block must be bored oversize. Refer to the Specifications Module,
"Cylinder Block" topic for the tolerances.

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UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01652707

Cylinder Head - Inspect

SMCS - 1100-040

Table 1

Required Tools

Part Number Part Name Quantity

8S - 6691 Cylinder Head Repair Stand 1

1U - 7234 Feeler Gauge 1

Illustration 1 g00876723
Bolt tightening sequence

1. Remove the cylinder head bolts in the reverse sequence that is shown in Illustration 1. A 14 mm extended socket is
required in order to remove the bolts which are numbered 12 through 15. Remove the cylinder head from the engine.
2. Clean the cylinder head thoroughly. Make sure that the contact surfaces of the cylinder head and the cylinder block are
clean, smooth and flat.

3. Inspect the bottom surface of the cylinder head for pitting, corrosion, and cracks. Inspect the area around the valve seat
inserts and the holes for the fuel injection nozzles.

Illustration 2 g00876690
(1) Cylinder head

(2) Cylinder head repair stand

4. Put the cylinder head (1) on the 8S-6691 Cylinder Head Stand Set (2) .

Illustration 3 g00876693
 (3) Straight edge

(4) Feeler gauge

Illustration 4 g00859749
Positions for measuring the flatness of the cylinder head

Typical example

5. Measure the cylinder head for flatness. Measure the flatness with a straight edge (3) and with a feeler gauge (4) .

❍ Measure the cylinder head from point (A) to the opposite end.

❍ Measure the cylinder head from point (B) to the opposite end.

❍ Measure the cylinder head from point (C) to the opposite end.

Refer to the Specifications, "Cylinder Head" for the requirements of flatness.

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UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01582547

Piston Height - Inspect

SMCS - 1214-040

If the height of the piston above the cylinder block is not within the tolerance that is given in the Specifications Module, "Piston and
Rings", the piston and the bearing for the piston pin must be replaced. If any of the following components are replaced or
remachined, the piston height above the cylinder block must be measured:

● Crankshaft

● Cylinder head

● Connecting rod

● Bearing for the piston pin

● Piston

The correct piston height must be maintained in order to ensure that the engine conforms to the standards for emissions.

Note: The top of the piston should not be machined. If the original piston is installed, be sure that the original piston is assembled
to the correct connecting rod and installed in the original cylinder.

Six grades of length of connecting rods determine the piston height above the cylinder block. The grade of length of a connecting
rod is identified by a letter or a color. The letter or the color is marked on the side of the connecting rod. Refer to Testing and
Adjusting, "Connecting Rod - Inspect" and Specifications, "Connecting Rod" for additional information.
Illustration 1 g00323908
8T-0455 Liner Projection Tool Group

(1) 1P-2403 Dial indicator

(2) 1P-2402 Gauge body

(3) 1P-5507 Gauge block

1. Use the 8T-0455 Liner Projection Tool Group in order to measure the piston height above the cylinder block. Use the
gauge block (3) to zero the dial indicator (1) on the face of the cylinder block.

2. Position the gauge block (3) on the cylinder block. Rotate the crankshaft until the piston is at the approximate top center.
Ensure that the flame ring of the cylinder liner does not interfere with the gauge block or the dial indicator.
 Illustration 2 g00326383
Measurement of the piston height

(1) 1P-2403 Dial indicator

(2) 1P-2402 Gauge body

3. Position the gauge body (2) and dial indicator (1) in order to measure the piston height above the cylinder block. Slowly
rotate the crankshaft in order to determine when the piston is at the highest position. Record this dimension. Compare this
dimension with the dimensions that are given in Specifications, "Piston and Rings".

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UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i02646947

Flywheel - Inspect
SMCS - 1156-040

Face Runout (Axial Eccentricity) of the Flywheel

Table 1

Required Tools

Part Number Part Name Qty

8T-5096 Dial Indicator Gp 1

 Illustration 1 g00295955
Checking face runout of the flywheel

1. Refer to Illustration 1 and install the dial indicator. Always put a force on the crankshaft in the same direction before the dial
indicator is read. This will remove any crankshaft end clearance.

2. Set the dial indicator to read 0.0 mm (0.00 inch).

3. Turn the flywheel at intervals of 25 mm (1.00 inch) along the outer circumference of the flywheel face, and record
measurements at each point.

4. The difference between two consecutive measurements must not be more than 0.03 mm (0.001 inch), which is the
maximum permissible flywheel face runout.

Flywheel Runout
Note: The flywheel housing must be removed in order to perform this runout check.
Illustration 2 g00295956
Checking flywheel runout

1. Refer to Illustration 2 and install the dial indicator.

2. Set the dial indicator to read 0.00 mm (0.000 inch).

3. Turn the flywheel at intervals of 90 degrees and read the dial indicator.

4. Calculate the difference between the lowest measurement and the highest measurement of the four locations. This difference
must not be greater than 0.30 mm (0.012 inch). This dimension is the maximum permissible distance for the outside
diameter runout of the flywheel.

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UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i02488286

Flywheel Housing - Inspect

SMCS - 1157-040

Table 1

Required Tools

Part Number Part Name Qty

8T-5096 Dial Indicator Gp 1

Face Runout (Axial Eccentricity) of the Flywheel Housing

Illustration 1 g00285931
8T-5096 Dial Indicator Gp

1. Fasten a dial indicator to the flywheel so the anvil of the dial indicator will contact the face of the flywheel housing.
 2. Put a force on the crankshaft toward the rear before the dial indicator is read at each point.

Illustration 2 g00285932
Checking face runout of the flywheel housing

3. Turn the flywheel while the dial indicator is set at 0.0 mm (0.00 inch) at location (A) . Read the dial indicator at locations
(B) , (C) and (D) .

4. The difference between the lower measurements and the higher measurements that are performed at all four points must not
be more than 0.20 mm (0.008 inch) for an "SAE 5" flywheel housing. The difference between the lower measurements and
the higher measurements that are performed at all four points must not be more than 0.23 mm (0.009 inch) for an "SAE 4"
flywheel housing. These measurements are the maximum permissible face runout (axial eccentricity) of the flywheel
housings.

Bore Runout (Radial Eccentricity) of the Flywheel Housing

 Illustration 3 g00285934
8T-5096 Dial Indicator

1. Fasten a dial indicator to the flywheel so the anvil of the dial indicator will contact the bore of the flywheel housing.

Illustration 4 g00285932
Checking bore runout of the flywheel housing

2. Turn the flywheel while the dial indicator is set at 0.0 mm (0.00 inch) at location (A) . Read the dial indicator at locations
(B) , (C) and (D) .

3. The difference between the lower measurements and the higher measurements that are performed at all four points must not
be more than 0.20 mm (0.008 inch) for an "SAE 5" flywheel housing. The difference between the lower measurements and
the higher measurements that are performed at all four points must not be more than 0.23 mm (0.009 inch) for an "SAE 4"
flywheel housing. These measurements are the maximum permissible bore runout (radial eccentricity) of the flywheel
housings.

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UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i02686950

Alternator - Test
SMCS - 1405-081

Table 1

Required Tools

Part Number Part Name Qty

237-5130 Digital Multimeter 1

225-8266 Ammeter Tool Gp 1

1. Put the positive lead "+" of the multimeter on the "Bat" terminal of the alternator. Put the negative "-" lead on the ground
terminal or on the frame of the alternator. Put the ammeter around the positive output wire of the alternator.

2. Turn off all electrical accessories. Turn off the fuel to the engine. Crank the engine for 30 seconds. Wait for two minutes in
order to cool the starting motor. If the electrical system appears to operate correctly, crank the engine again for 30
seconds.

Note: Cranking the engine for 30 seconds partially discharges the batteries in order to do a charging test. If the battery has
a low charge, do not perform this step. Jump start the engine or charge the battery before the engine is started.

3. Start the engine and run the engine at full throttle.

4. Check the output current of the alternator. The initial charging current should be equal to the minimum full load current or
greater than the minimum full load current. Refer to Specifications, "Alternator and Regulator" for the correct minimum full
load current.

Table 2

Fault Conditions And Possible Causes

Current At Start-up The Voltage Is Below The Voltage Is Within Specifications The Voltage Is
Specifications After 10 Minutes. After 10 Minutes. Above Specifications
After 10 Minutes.

Less than the Replace the alternator. Check the Turn on all accessories. If the voltage -
specifications circuit of the ignition switch. decreases below the specifications,
 replace the alternator.

Decreases after Replace the alternator. The alternator and the battery match Replace the
matching the specifications. Turn on all alternator.
specifications accessories in order to verify that the
voltage stays within specifications.

The voltage Follow the procedures that are in The alternator operates within the Replace the
consistently exceeds the Tool Operating Manual, specifications. Follow the alternator. Inspect
specifications. SEHS7633 in order to test the procedures in the Tool Operating the battery for
battery. Test the alternator again. Manual, SEHS7633 in order to test damage.
the battery.

5. After approximately ten minutes of operating the engine at full throttle, the output voltage of the alternator should be 14.0 ±
0.5 volts. Refer to the Fault Conditions And Possible Causes in Table 3.

6. After ten minutes of engine operation, the charging current should decrease to approximately 10 amperes. The actual length
of time for the charging current to decrease to 10 amperes depends on the following conditions:

❍ The battery charge

❍ The ambient temperature

❍ The rpm of the engine

Refer to the Fault Conditions And Possible Causes in Table 3.

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UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01344679

Battery - Test
SMCS - 1401-081

Personal injury can result from battery fumes or explosion.

Batteries give off flammable fumes that can explode. Electrolyte is an acid
and can cause personal injury if it contacts the skin or eyes.

Prevent sparks near the batteries. Sparks could cause vapors to explode.
Do not allow jumper cable ends to contact each other or the engine.
Improper jumper cable connections can cause an explosion.

Always wear protective glasses when working with batteries.

The battery circuit is an electrical load on the charging unit. The load is variable because of the condition of the charge in the
battery. The alternator may be damaged during operation if the circuit is broken between the battery and the alternator. The
damage can occur when the load on the battery suddenly stops. The loss of the load on the battery causes a sudden increase in
the voltage. This high voltage can damage the charging unit, the regulator, and other electrical components.

The 4C-4911 Battery Load Tester is used to load test a battery that does not hold a charge.

Refer to the Tool Operating Manual, SEHS9249 for instructions on the use of the 4C-4911 Battery Load Tester. Refer to Special
Instruction, SEHS7633 for the correct procedures and specifications for testing batteries.

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UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01450647

Belt Tension Chart

SMCS - 1357

Note: Do not use the belt tension chart for belts with tensioners that are spring loaded.

Table 1

Belt Tension Chart

Borroughs Gauge Numbers

Gauge Reading
Size of Belt
Width of Belt
Used Belt Tension (2) Number of the Selected
Initial Belt Tension (1)
Gauge

3/8 10.72 mm (0.422 445 ± 22 N (100 ± 5 400 ± 22 N (90 ± 5 lb) BT-33-97

inch) lb)

1/2 13.89 mm (0.547 534 ± 22 N (120 ± 5 400 ± 44 N (90 ± 10 BT-33-97

Inch) lb) lb)

Measure the tension of the belt that is farthest from the engine.
(1) Initial Belt Tension refers to a new belt.
(2) Used Belt Tension refers to a belt that has been in operation for 30 minutes or more at the rated speed.

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UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01461457

Charging System - Test

SMCS - 1406-081

The condition of charge in the battery at each regular inspection will show if the charging system is operating correctly. An
adjustment is necessary when the battery is constantly in a low condition of charge or a large amount of water is needed. There
are no adjustments on maintenance free batteries. A large amount of water would be more than one ounce of water per cell per
week or per every 100 service hours.

When it is possible, make a test of the charging unit and voltage regulator on the engine, and use wiring and components that are a
permanent part of the system. Off-engine testing or bench testing will give a test of the charging unit and voltage regulator
operation. This testing will give an indication of needed repair. After repairs are made, perform a test in order to prove that the
units have been repaired to the original condition of operation.

Alternator Regulator
The charging rate of the alternator should be checked when an alternator is charging the battery too much or not charging the
battery enough.

Alternator output should be 28 ± 1 volt on a 24 volt system and 14 ± 0.5 volt on a 12 volt system. No adjustment can be made in
order to change the rate of charge on the alternator regulators. If the rate of charge is not correct, a replacement of the regulator is
necessary. For individual alternator output, refer to Specification, "Alternator and Regulator".

See Special Instruction, REHS0354, "Charging System Troubleshooting" for the correct procedures to use to test the charging
system. This publication also contains the specifications to use when you test the charging system.

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UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01964005

Electric Starting System - Test

SMCS - 1450-081

Use the multimeter in the DCV range to find starting system components which do not function.

Move the start control switch in order to activate the starting solenoids. The starting solenoid's operation can be heard as the
pinion of the starting motor is engaged with the ring gear on the engine flywheel.

If a solenoid for a starting motor will not operate, it is possible that the current from the battery did not reach the solenoid. Fasten
one lead of the multimeter to the connection (terminal) for the battery cable on the solenoid. Connect the other lead to a good
ground. A zero reading indicates that there is a broken circuit from the battery. More testing is necessary when there is a voltage
reading on the multimeter.

The solenoid operation also closes the electric circuit to the motor. Connect one lead of the multimeter to the solenoid connection
(terminal) that is fastened to the motor. Connect the other lead to a good ground. Activate the starting solenoid and look at the
multimeter. A voltage reading of the battery shows that the problem is in the motor. The motor must be removed for further
testing. A zero reading on the multimeter shows that the solenoid contacts do not close. This indicates the need for repair to the
solenoid, or to the clearance for the starter motor pinion.

Perform a test. Fasten one multimeter lead to the connection (terminal) for the small wire at the solenoid and fasten the other lead
to the ground. Look at the multimeter and activate the starting solenoid. A voltage reading shows that the problem is in the
solenoid. A zero reading indicates that the problem is in the start switch or the wires for the start switch.

Fasten one multimeter lead to the start switch at the connection (terminal) for the wire from the battery. Fasten the other lead to a
good ground. A zero reading indicates a broken circuit from the battery. Check of the circuit breaker and wiring. If there is a
voltage reading, the problem is in the start switch or in the wires for the start switch.

Starting motors that operate too slowly can have an overload due to excessive friction in the engine that is being started. Slow
operation of the starting motors can also be caused by a short circuit, loose connections, and/or dirt in the motor.

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UP (MACHINE) POWERED BY 3066 ENGINE

Testing and Adjusting

3064 and 3066 Engines for Caterpillar Built Machines
Media Number -SENR5546-12 Publication Date -01/05/2008 Date Updated -30/05/2008

i01571498

Pinion Clearance - Adjust

SMCS - 1454-025

Gap of Pinion

Illustration 1 g00570128
Check the gap of the pinion.

(1) "S" terminal

(2) "M" terminal

Note: Do not continue to test for more than 20 seconds in order to prevent the windings on the magnetic switch from overheating.

1. Connect the electric starting motor to a 24 volt battery, as shown. The pinion will shift into the cranking position and the
pinion will start turning slowly. Disconnect the lead of the jumper from the "M" terminal of the starting motor. The pinion will
remain in the cranking position.

Illustration 2 g00835755
Pinion clearance

(3) Packing

(4) Pinion clearance

2. Push the pinion toward the armature and measure the amount of movement (gap) of the pinion.
 Illustration 3 g00835760
Pinion clearance

(4) Pinion clearance

3. Add the packing or remove the packing on the magnetic switch in order to adjust the gap of the pinion. Adding the packing
will decrease the gap.

Table 1

Standard At Assembly

Gap of Pinion
0.5 to 2.0 mm (0.020 to 0.079 inch)

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