Caterpillar 3054E Engines Repair Service Manual
Caterpillar 3054E Engines Repair Service Manual
Complete All Inclusive Technical Manual with electrical wiring diagrams for Caterpillar 3054E Engines, with workshop information to maintain, diagnose, repair, and rebuild like professional mechanics (Specifications, Systems Operation, Tests & Adjusting, Repair, Disassembly and Assembly, Troubleshooting).
3054E Industrial Engine & 3054E Engine for Caterpillar Built Machines workshop technical service manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 1,451 pages
File Format: PDF (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English
RENR2409 - Specifications (3054E Engine for Caterpillar Built Machines).pdf
RENR2410 - Systems Operation (3054E Engines for Caterpillar Built Machines).pdf
RENR2410 - Testing & Adjusting (3054E Engines for Caterpillar Built Machines).pdf
RENR2411 - Disassembly and Assembly (3054E Engine for Caterpillar Built Machines).pdf
RENR2417 - Troubleshooting (3054E and 3056E Industrial Engines and Engines for Caterpillar Built Machines).pdf
RENR7567 - Specifications (3054E Industrial Engine).pdf
RENR7568 - Systems Operation (3054E Industrial Engine).pdf
RENR7568 - Testing & Adjusting (3054E Industrial Engine).pdf
RENR7569 - Disassembly and Assembly (3054E Industrial Engine).pdf
RENR7570 - Schematic (3054E Industrial Engine Electrical System).pdf
TABLE OF CONTENTS
RENR2409 - Specifications (3054E Engine for Caterpillar Built Machines)............1
Engine Design............3
Fuel Injection Lines............5
Fuel Injection Pump............6
Fuel Injection Nozzles............8
Fuel Transfer Pump............9
Lifter Group............11
Rocker Shaft............12
Valve Mechanism Cover............14
Cylinder Head Valves............15
Cylinder Head............20
Turbocharger............23
Exhaust Manifold............25
Camshaft............26
Engine Oil Filter............30
Engine Oil Pump............32
Engine Oil Pressure............39
Engine Oil Bypass Valve............40
Engine Oil Pan............44
Crankcase Breather............49
Water Temperature Regulator............51
Water Pump............53
Cylinder Block............54
Crankshaft - Steel Crankshaft............57
Crankshaft Seals............61
Connecting Rod Bearing Journal - Steel Crankshaft............63
Main Bearing Journal - Steel Crankshaft............66
Connecting Rod - For Use With Steel Crankshaft............69
Piston and Rings............74
Piston Cooling Jet............77
Balancer - If Equipped............79
Front Housing and Covers............80
Gear Group (Front)............82
Flywheel............86
Flywheel Housing............88
Crankshaft Pulley............89
Fan Drive............90
Engine Lifting Bracket............92
Alternator and Regulator............93
Electric Starting Motor............95
Coolant Temperature Sensor............97
Engine Oil Pressure Sensor............99
Boost Pressure Sensor............101
Inlet Manifold Temperature Sensor............103
Speed_Timing Sensor............105
Electronic Control Module............107
Glow Plugs............109
RENR2410 - Systems Operation (3054E Engines for Caterpillar Built Machines)............110
Introduction............111
Basic Engine............115
Air Inlet and Exhaust System............124
Cooling System............130
Lubrication System............132
Electrical System............135
Fuel Injection............139
Electronic Control System............154
Power Sources............161
Glossary of Electronic Control Terms............167
RENR2410 - Testing & Adjusting (3054E Engines for Caterpillar Built Machines)............172
Fuel System - Inspect............174
Air in Fuel - Test............176
Engine Speed - Check............180
Finding Top Center Position for No. 1 Piston............183
Fuel Injection Nozzle - Test............186
Fuel Injection Timing - Check............192
Fuel Quality - Test............195
Fuel System - Prime............198
Fuel System Pressure - Test............200
Air Inlet and Exhaust System - Inspect............203
Turbocharger - Inspect............207
Exhaust Temperature - Test............213
Engine Crankcase Pressure (Blowby) - Test............215
Compression - Test............217
Engine Valve Lash - Inspect_Adjust............219
Valve Depth - Inspect............223
Valve Guide - Inspect............226
Engine Oil Pressure - Test............228
Engine Oil Pump - Inspect............233
Excessive Bearing Wear - Inspect............237
Excessive Engine Oil Consumption - Inspect............239
Increased Engine Oil Temperature - Inspect............241
Cooling System - Check............242
Cooling System - Inspect............244
Cooling System - Test............246
Engine Oil Cooler - Inspect............254
Water Temperature Regulator - Test............256
Piston Ring Groove - Inspect............258
Connecting Rod - Inspect............261
Connecting Rod Bearings - Inspect............264
Main Bearings - Inspect............265
Cylinder Block - Inspect............266
Cylinder Head - Inspect............268
Piston Height - Inspect............272
Flywheel - Inspect............276
Flywheel Housing - Inspect............279
Gear Group - Inspect............283
Alternator - Test............285
Battery - Test............288
Electric Starting System - Test............290
Glow Plugs - Test............295
RENR2411 - Disassembly and Assembly (3054E Engine for Caterpillar Built Machines)............298
Fuel Priming Pump and Fuel Filter Base - Remove and Install............301
Fuel Injection Lines - Remove and Install............304
Fuel Injection Nozzles - Remove............309
Fuel Injection Nozzles - Install............311
Fuel Injection Pump - Remove............313
Fuel Injection Pump - Install............317
Turbocharger - Remove............322
Turbocharger - Install............325
Exhaust Manifold - Remove and Install............328
Inlet and Exhaust Valve Springs - Remove and Install............330
Inlet and Exhaust Valves - Remove and Install............335
Inlet and Exhaust Valve Guides - Remove and Install............342
Inlet and Exhaust Valve Seat Inserts - Remove and Install............345
Engine Oil Filter Base - Remove and Install............349
Engine Oil Cooler - Remove............354
Engine Oil Cooler - Install............356
Engine Oil Relief Valve - Remove and Install - Engine without Balancer Group............358
Engine Oil Pump - Remove - Engines Without a Balancer............361
Engine Oil Pump - Install - Engines Without a Balancer............364
Water Pump - Remove and Install............367
Water Temperature Regulator - Remove and Install............371
Flywheel - Remove............374
Flywheel - Install............377
Crankshaft Rear Seal - Remove............380
Crankshaft Rear Seal - Install............382
Crankshaft Wear Sleeve (Rear) - Remove............385
Crankshaft Wear Sleeve (Rear) - Install............387
Flywheel Housing - Remove and Install............389
Crankshaft Pulley - Remove and Install............393
Crankshaft Front Seal - Remove............395
Crankshaft Front Seal - Install............397
Front Cover - Remove and Install............400
Idler Gear - Remove and Install............402
Housing (Front) - Remove............409
Housing (Front) - Install............412
Accessory Drive - Remove and Install............416
Crankcase Breather - Remove and Install............420
Valve Mechanism Cover - Remove and Install............423
Rocker Shaft and Pushrod - Remove............426
Rocker Shaft - Disassemble............428
Rocker Shaft - Assemble............430
Rocker Shaft and Pushrod - Install............432
Cylinder Head - Remove............434
Cylinder Head - Install............437
Lifter Group - Remove and Install............442
Camshaft - Remove and Install............444
Camshaft Gear - Remove and Install............446
Camshaft Bearings - Remove and Install............449
Engine Oil Pan - Remove and Install............452
Piston Cooling Jets - Remove and Install............457
Pistons and Connecting Rods - Remove............459
Pistons and Connecting Rods - Disassemble............461
Pistons and Connecting Rods - Assemble............464
Pistons and Connecting Rods - Install............468
Connecting Rod Bearings - Remove............471
Connecting Rod Bearings - Install............473
Crankshaft Main Bearings - Remove............476
Crankshaft Main Bearings - Install............479
Crankshaft - Remove............484
Crankshaft - Install............488
Crankshaft Timing Ring - Remove and Install............495
Crankshaft Gear - Remove and Install............498
Bearing Clearance - Check............501
Coolant Temperature Sensor - Remove and Install............504
Engine Oil Pressure Sensor - Remove and Install............507
Speed_Timing Sensor - Remove and Install............510
Boost Pressure Sensor - Remove and Install............512
Inlet Air Temperature Sensor - Remove and Install............514
Glow Plugs - Remove and Install............516
V-Belts - Remove and Install............519
Fan - Remove and Install............521
Fan Drive - Remove and Install............524
Electronic Control Module - Remove and Install............526
Voltage Load Protection Module - Remove and Install............528
Alternator - Remove............530
Alternator - Install............532
Electric Starting Motor - Remove and Install............534
RENR2417 - Troubleshooting (3054E and 3056E Industrial Engines and Engines for Caterpillar Built Machines)............538
System Overview............542
Glossary............547
Electronic Service Tools............553
Indicator Lamps............559
Replacing the ECM............563
Self-Diagnostics............566
Sensors and Electrical Connectors............567
Engine Wiring Information............572
Programming Parameters............581
Factory Passwords............582
Flash Programming............584
System Configuration Parameters............586
Alternator Noise - Noisy Operation............588
Alternator Will Not Charge - Charging Problem............590
Battery............591
Can Not Reach Top Engine RPM............593
Coolant in Engine Oil............596
Coolant Temperature Is Too High............598
ECM Will Not Accept Factory Passwords............601
ECM Will Not Communicate with Other Systems or Display Modules............603
Electronic Service Tool Will Not Communicate with ECM............604
Engine Cranks but Will Not Start............606
Engine Has Early Wear............610
Engine Misfires; Runs Rough or Is Unstable............612
Engine Oil in Cooling System............616
Engine Stalls at Low RPM............618
Engine Vibration............620
Engine Will Not Crank............622
Excessive Black Smoke............625
Excessive Engine Oil Consumption............628
Excessive Valve Lash............631
Excessive White Smoke............633
Intake Air Temperature Is Too High............636
Intermittent Engine Shutdown............638
Intermittent Low Power or Power Cutout............641
Low Engine Oil Pressure............644
Low Power_Poor or No Response to Throttle............647
Mechanical Noise (Knock) in Engine............652
Noise Coming from Cylinder............654
Diagnostic Code Cross Reference............655
CID 0041 FMI 03............658
CID 0041 FMI 04............659
CID 0091 FMI 02............660
CID 0091 FMI 03............662
CID 0091 FMI 04............664
CID 0091 FMI 08............666
CID 0091 FMI 12............668
CID 0100 FMI 03............669
CID 0100 FMI 04............670
CID 0100 FMI 10............671
CID 0102 FMI 03............673
CID 0102 FMI 04............674
CID 0102 FMI 10............675
CID 0105 FMI 03............676
CID 0105 FMI 04............677
CID 0110 FMI 03............678
CID 0110 FMI 04............679
CID 0174 FMI 02............680
CID 0247 FMI 09............682
CID 0253 FMI 02............683
CID 0262 FMI 03............684
CID 0262 FMI 04............685
CID 0320 FMI 02............686
CID 0320 FMI 11............687
CID 0342 FMI 02............688
CID 0774 FMI 02............689
CID 0774 FMI 03............691
CID 0774 FMI 04............693
CID 0774 FMI 08............695
CID 0774 FMI 12............697
CID 1627 FMI 03............699
CID 1684 FMI 00............700
CID 1684 FMI 02............702
CID 1684 FMI 03............704
CID 1684 FMI 04............706
CID 1684 FMI 05............707
CID 1684 FMI 07............708
CID 1684 FMI 08............709
CID 1684 FMI 09............712
CID 1684 FMI 10............714
CID 1684 FMI 11............716
CID 1684 FMI 12............718
CID 1684 FMI 14............720
CID 1743 FMI 02............722
CID 1894 FMI 02............723
CID 1895 FMI 02............724
Event Codes............725
E015 High Engine Coolant Temperature Derate............726
E016 High Engine Coolant Temperature Shutdown............727
E017 High Engine Coolant Temperature Warning............728
E025 High Inlet Air Temperature Derate............729
E027 High Inlet Air Temperature Warning............730
E040 Low Engine Oil Pressure Shutdown............732
E054 High Fuel Temperature Derate............733
E056 High Fuel Temperature Warning............735
E100 Low Engine Oil Pressure Warning............737
E190 Engine Overspeed Warning............740
5 Volt Engine Pressure Sensor Supply Circuit - Test............741
Air Inlet Heater Circuit - Test............749
Analog Throttle Position Sensor Circuit - Test............757
CAN Data Link Circuit - Test............767
Data Link Circuit - Test............780
Digital Throttle Position Sensor Circuit - Test............793
Electrical Connectors - Inspect............805
Electrical Power Supply Circuit - Test............817
Engine Pressure Sensor Open or Short Circuit - Test............824
Engine Temperature Sensor Open or Short Circuit - Test............835
Fuel Injection Pump Circuit - Test............843
Indicator Lamp Circuit - Test............859
Mode Selection Circuit - Test............865
Set Speed Circuit - Test............872
Speed_Timing Sensor Circuit - Test............881
Throttle Switch Circuit - Test............887
RENR7567 - Specifications (3054E Industrial Engine)............895
Engine Design............897
Fuel Injection Lines............899
Fuel Injection Pump............900
Fuel Injection Nozzles............902
Fuel Transfer Pump............903
Lifter Group............905
Rocker Shaft............906
Valve Mechanism Cover............908
Cylinder Head Valves............909
Cylinder Head............914
Turbocharger............917
Exhaust Manifold............919
Camshaft............920
Engine Oil Filter............924
Engine Oil Pump............926
Engine Oil Pressure............933
Engine Oil Bypass Valve............934
Engine Oil Pan............938
Crankcase Breather............943
Water Temperature Regulator............945
Water Pump............947
Cylinder Block............948
Crankshaft - Spheroidal Graphite Iron (SGI) Crankshaft............951
Crankshaft - Steel Crankshaft............953
Crankshaft Seals............957
Connecting Rod Bearing Journal - Spheroidal Graphite Iron Crankshaft............959
Connecting Rod Bearing Journal - Steel Crankshaft............960
Main Bearing Journal - Spheroidal Graphite Iron (SGI) Crankshaft............963
Main Bearing Journal - Steel Crankshaft............964
Connecting Rod - For Use With Spheroidal Graphite Iron (SGI) Crankshaft............967
Connecting Rod - For Use With Steel Crankshaft............971
Piston and Rings............976
Piston Cooling Jet............979
Balancer - If Equipped............981
Front Housing and Covers............982
Gear Group (Front)............984
Flywheel............988
Flywheel Housing............990
Crankshaft Pulley............991
Fan Drive............992
Engine Lifting Bracket............994
Alternator and Regulator............995
Electric Starting Motor............997
Coolant Temperature Sensor............999
Engine Oil Pressure Sensor............1001
Boost Pressure Sensor............1003
Inlet Manifold Temperature Sensor............1005
Speed_Timing Sensor............1007
Electronic Control Module............1009
Glow Plugs............1011
RENR7568 - Systems Operation (3054E Industrial Engine)............1012
Introduction............1013
Basic Engine............1016
Air Inlet and Exhaust System............1025
Cooling System............1031
Lubrication System............1033
Electrical System............1035
Fuel Injection............1038
Electronic Control System............1052
Power Sources............1059
Glossary of Electronic Control Terms............1064
RENR7568 - Testing & Adjusting (3054E Industrial Engine)............1068
Fuel System - Inspect............1070
Air in Fuel - Test............1071
Engine Speed - Check............1074
Finding Top Center Position for No. 1 Piston............1076
Fuel Injection Nozzle - Test............1078
Fuel Injection Timing - Check............1083
Fuel Quality - Test............1086
Fuel System - Prime............1088
Fuel System Pressure - Test............1090
Air Inlet and Exhaust System - Inspect............1092
Turbocharger - Inspect............1093
Exhaust Temperature - Test............1099
Engine Crankcase Pressure (Blowby) - Test............1100
Compression - Test............1102
Engine Valve Lash - Inspect_Adjust............1104
Valve Depth - Inspect............1107
Valve Guide - Inspect............1110
Engine Oil Pressure - Test............1112
Engine Oil Pump - Inspect............1117
Excessive Bearing Wear - Inspect............1121
Excessive Engine Oil Consumption - Inspect............1122
Increased Engine Oil Temperature - Inspect............1123
Cooling System - Check............1124
Cooling System - Inspect............1126
Cooling System - Test............1128
Engine Oil Cooler - Inspect............1136
Water Temperature Regulator - Test............1138
Piston Ring Groove - Inspect............1140
Connecting Rod - Inspect............1143
Connecting Rod Bearings - Inspect............1145
Main Bearings - Inspect............1146
Cylinder Block - Inspect............1147
Cylinder Head - Inspect............1148
Piston Height - Inspect............1152
Flywheel - Inspect............1155
Flywheel Housing - Inspect............1158
Gear Group - Inspect............1162
Alternator - Test............1163
Battery - Test............1165
Electric Starting System - Test............1166
Glow Plugs - Test............1170
RENR7569 - Disassembly and Assembly (3054E Industrial Engine)............1172
Fuel Priming Pump and Fuel Filter Base - Remove and Install............1175
Fuel Injection Nozzle Cover - Remove and Install............1178
Fuel Injection Lines - Remove and Install............1180
Fuel Injection Nozzles - Remove............1185
Fuel Injection Nozzles - Install............1187
Fuel Injection Pump - Remove............1189
Fuel Injection Pump - Install............1193
Turbocharger - Remove............1198
Turbocharger - Install............1201
Exhaust Manifold - Remove and Install............1204
Inlet and Exhaust Valve Springs - Remove and Install............1206
Inlet and Exhaust Valves - Remove and Install............1211
Inlet and Exhaust Valve Guides - Remove and Install............1218
Inlet and Exhaust Valve Seat Inserts - Remove and Install............1221
Engine Oil Filter Base - Remove and Install............1225
Engine Oil Cooler - Remove............1230
Engine Oil Cooler - Install............1232
Engine Oil Relief Valve - Remove and Install - Engine with Balancer Group............1234
Engine Oil Relief Valve - Remove and Install - Engine without Balancer Group............1237
Engine Oil Pump - Remove - Engines Without a Balancer............1240
Engine Oil Pump - Install - Engines Without a Balancer............1243
Water Pump - Remove and Install............1246
Water Temperature Regulator - Remove and Install............1250
Flywheel - Remove............1253
Flywheel - Install............1256
Crankshaft Rear Seal - Remove............1259
Crankshaft Rear Seal - Install............1261
Crankshaft Wear Sleeve (Rear) - Remove............1264
Crankshaft Wear Sleeve (Rear) - Install............1266
Flywheel Housing - Remove and Install............1268
Crankshaft Pulley - Remove and Install............1272
Crankshaft Front Seal - Remove............1274
Crankshaft Front Seal - Install............1276
Crankshaft Wear Sleeve (Front) - Remove............1279
Crankshaft Wear Sleeve (Front) - Install............1281
Front Cover - Remove and Install............1283
Idler Gear (Front) - Remove............1285
Idler Gear (Front) - Disassemble............1289
Idler Gear (Front) - Assemble............1291
Idler Gear (Front) - Install............1294
Housing (Front) - Remove............1300
Housing (Front) - Install............1303
Accessory Drive - Remove and Install............1307
Crankcase Breather - Remove and Install............1311
Valve Mechanism Cover - Remove and Install............1314
Rocker Shaft and Pushrod - Remove............1317
Rocker Shaft - Disassemble............1319
Rocker Shaft - Assemble............1321
Rocker Shaft and Pushrod - Install............1323
Cylinder Head - Remove............1325
Cylinder Head - Install............1329
Lifter Group - Remove and Install............1334
Camshaft - Remove and Install............1336
Camshaft Gear - Remove and Install............1338
Camshaft Bearings - Remove and Install............1341
Engine Oil Pan - Remove and Install............1344
Balancer Group - Remove - If Equipped............1349
Balancer Group - Install - If Equipped............1352
Piston Cooling Jets - Remove and Install............1356
Pistons and Connecting Rods - Remove............1358
Pistons and Connecting Rods - Disassemble............1360
Pistons and Connecting Rods - Assemble............1363
Pistons and Connecting Rods - Install............1367
Connecting Rod Bearings - Remove............1370
Connecting Rod Bearings - Install............1372
Crankshaft Main Bearings - Remove and Install - Crankshaft in Position............1375
Crankshaft - Remove............1383
Crankshaft - Install............1387
Crankshaft Timing Ring - Remove and Install............1394
Crankshaft Gear - Remove and Install............1397
Bearing Clearance - Check............1400
Coolant Temperature Sensor - Remove and Install............1403
Engine Oil Pressure Sensor - Remove and Install............1406
Speed_Timing Sensor - Remove and Install............1409
Boost Pressure Sensor - Remove and Install............1411
Inlet Air Temperature Sensor - Remove and Install............1413
Glow Plugs - Remove and Install............1415
V-Belts - Remove and Install............1418
Fan - Remove and Install............1420
Fan Drive - Remove and Install............1423
Alternator - Remove............1425
Alternator - Install............1427
Electronic Control Module - Remove and Install............1429
Voltage Load Protection Module - Remove and Install............1431
Electric Starting Motor - Remove and Install............1433
Air Compressor - Remove and Install............1437
Air Compressor Idler Gear - Remove and Install............1441
RENR7570 - Schematic (3054E Industrial Engine Electrical System)............1445
Collage............1445
Main............1454
