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Product: TELEHANDLER
Model: TH103 TELEHANDLER 3PN
Configuration: TH103 Telehandler 3PN00001-02026 (MACHINE) POWERED BY 3054 Engine
Disassembly and Assembly
3054 Engine for Caterpillar Built Machines
Media Number -SENR6241-13 Publication Date -01/08/2008 Date Updated -04/08/2008
i01054405
Valve Mechanism Cover - Remove and Install
SMCS - 1107-010
Removal Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop
Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Note: The engines are equipped with either an aluminum valve cover or with a composite valve
cover. The aluminum valve cover has a seal that fits between the valve cover and the inlet
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manifold. The composite valve cover has a seal that is permanently fixed to the side of the valve
cover.
Illustration 1 g00547002
Typical example
Illustration 2 g00547003
Aluminum valve cover
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Illustration 3 g00547004
Composite valve cover
1. Loosen hose clamp (1) .
2. Disconnect breather hose (2) .
3. Remove three nuts (3), steel washers (6), and sealing washers (8) .
Note: When you remove nuts (3), ensure that the nuts on the rocker arm bracket are not
loosened.
Note: Current production engines have an additional shim washer (7) .
4. Remove valve cover (4), gasket (10), and seal (5) .
5. Remove seal (9) for the oil filler cap.
Installation Procedure
Note: The engines are equipped with either an aluminum valve cover or with a composite valve
cover. The aluminum valve cover has a seal that fits between the valve cover and the inlet
manifold. The composite valve cover has a seal that is permanently fixed to the side of the valve
cover.
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Illustration 4 g00547002
Typical example
Illustration 5 g00547003
Aluminum valve cover
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Illustration 6 g00547004
Composite valve cover
1. Inspect the condition of the gaskets and the seals. Replace the gaskets and the seals, if
necessary.
2. Install seal (9) for the oil filler cap, if necessary.
3. Apply 8T-9022 Silicone Gasket to gasket (10) .
Note: Ensure that the flat face of the gasket is toward the valve cover.
4. Install gasket (10), seal (5), and valve cover (4) .
5. Lubricate three nuts (3) with clean engine oil.
6. Install three nuts (3), steel washers (6), and sealing washers (8) .
Note: When you install three nuts (3) without shim washers (7), tighten the nuts to a torque
of 20 N·m (15 lb ft). Do not overtighten the nuts.
Note: When you install three nuts (3) with shim washers (7), tighten the nuts to a torque of
30 N·m (22 lb ft). Do not overtighten the nuts.
7. Connect breather hose (2) .
8. Tighten hose clamp (1) .
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Product: TELEHANDLER
Model: TH103 TELEHANDLER 3PN
Configuration: TH103 Telehandler 3PN00001-02026 (MACHINE) POWERED BY 3054 Engine
Disassembly and Assembly
3054 Engine for Caterpillar Built Machines
Media Number -SENR6241-13 Publication Date -01/08/2008 Date Updated -04/08/2008
i01761173
Rocker Shaft and Pushrod - Remove
SMCS - 1102-011; 1208-011
Removal Procedure
Start By:
a. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve
Mechanism Cover - Remove and Install".
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Illustration 1 g00635152
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Typical example
Note: It is not necessary to remove the oil supply tube in order to remove the rocker shaft
assembly and the pushrods.
1. Remove nuts (1) and bolt (2) from the rocker shaft assembly. Begin with the end brackets
and move toward the center.
2. Remove rocker shaft assembly (3).
3. Remove the oil seal from the oil supply passage in the cylinder head.
Illustration 2 g00635153
Typical example
4. Remove pushrods (4). Place an identification mark on the pushrods for installation.
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Product: TELEHANDLER
Model: TH103 TELEHANDLER 3PN
Configuration: TH103 Telehandler 3PN00001-02026 (MACHINE) POWERED BY 3054 Engine
Disassembly and Assembly
3054 Engine for Caterpillar Built Machines
Media Number -SENR6241-13 Publication Date -01/08/2008 Date Updated -04/08/2008
i01667090
Rocker Shaft - Disassemble
SMCS - 1102-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-0510 Driver Group 1
Start By:
A. Remove the rocker shaft assembly. Refer to Disassembly and Assembly, "Rocker Shaft and
Pushrod - Remove".
Illustration 1 g00550061
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1. Use a screwdriver or a similar tool to remove retaining ring (1) from both ends of the rocker
shaft assembly.
Illustration 2 g00550062
(1) Retaining ring
(2) Washer on the end of the rocker shaft
(3) Rocker arm assembly
(4) Rocker shaft bracket
(5) Spring on the rocker shaft
(6) Washer
(7) Rocker shaft
(8) Bolt
(9) Oil supply connection
(10) Rocker arm bushing
2. Remove the rocker arms and the rocker shaft brackets from the rocker shaft assembly.
Note: Place an identification mark on each of the components for the proper order for
installation.
3. Check the clearance between rocker arm assembly (3) and rocker shaft (7). Replace rocker
arm bushing (10) if the clearance is larger than 0.13 mm (0.005 inch). Use Tool (A) and a
suitable press in order to remove rocker arm bushing (10) from rocker arm assembly (3), if
necessary.
4. Remove rocker shaft bracket (4) from rocker shaft (7) .
5. Remove springs (5), washer (6), bolt (8) and oil supply connection (9) from rocker shaft
(7) .
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Product: TELEHANDLER
Model: TH103 TELEHANDLER 3PN
Configuration: TH103 Telehandler 3PN00001-02026 (MACHINE) POWERED BY 3054 Engine
Disassembly and Assembly
3054 Engine for Caterpillar Built Machines
Media Number -SENR6241-13 Publication Date -01/08/2008 Date Updated -04/08/2008
i01667093
Rocker Shaft - Assemble
SMCS - 1102-016
Assembly Procedure
1. Lubricate all of the components with clean engine oil.
Illustration 1 g00550062
(1) Retaining ring
(2) Washer on the end of the rocker shaft
(3) Rocker arm assembly
(4) Rocker shaft bracket
(5) Spring on the rocker shaft
(6) Washer
(7) Rocker shaft
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(8) Bolt
(9) Oil supply connection
(10) Rocker arm bushing
2. Install oil supply connection (9) and bolt (8) on rocker shaft (7) .
Note: Ensure that the bolt and the connection are correctly positioned on the rocker shaft.
Note: Ensure that all of the oil holes in the rocker shaft and in the rocker arms are not
plugged before you begin the assembly procedure.
3. Install rocker arm bushing (10) in rocker arm assembly (3) with a suitable press. Ream the
bushing to a clearance of 0.06 ± 0.03 mm (0.0024 ± 0.0012 inch), if necessary.
4. Install each of the components in the correct order onto rocker shaft (7). See Illustration 1.
Illustration 2 g00550061
5. Install retaining ring (1).
End By: Install the rocker shaft assembly. Refer to Disassembly and Assembly, "Rocker Shaft
and Pushrod - Install".
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Product: TELEHANDLER
Model: TH103 TELEHANDLER 3PN
Configuration: TH103 Telehandler 3PN00001-02026 (MACHINE) POWERED BY 3054 Engine
Disassembly and Assembly
3054 Engine for Caterpillar Built Machines
Media Number -SENR6241-13 Publication Date -01/08/2008 Date Updated -04/08/2008
i01749382
Rocker Shaft and Pushrod - Install
SMCS - 1102-012; 1208-012
Installation Procedure
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Illustration 1 g00635153
Typical example
1. Install pushrods (4).
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Note: Ensure that the pushrods are installed in the original location and that the pushrods
are seated in the valve lifters correctly.
2. Install a new oil seal in the oil supply hole in the cylinder head.
Illustration 2 g00635152
Typical example
3. Put rocker shaft assembly (3) in position on the cylinder head. Make sure that the
connection for the oil supply is installed correctly into the oil seal.
Note: Ensure that the adjustment screws are properly seated in the ends of pushrods (4).
Note: It may be necessary to loosen the adjustment screws on each rocker arm. This will
help prevent a bent valve or a bent pushrod during the installation of the rocker shaft.
4. Lubricate nuts (1) and bolt (2) with clean engine oil.
5. Install nuts (1) and bolt (2).
6. Alternately tighten the nuts and the bolt. Start from the center and work toward the outside.
Tighten the nuts and the bolt on an aluminum bracket to a torque of 40 N·m (30 lb ft).
Tighten the nuts and the bolt on a cast iron or a steel bracket to a torque of 75 N·m
(55 lb ft).
7. Adjust the inlet valve lash to 0.20 mm (0.008 inch) and adjust the exhaust valve lash to
0.45 mm (0.018 inch). Refer to Testing and Adjusting, "Air Inlet and Exhaust System" for
more information on adjusting the valve lash.
End By:
a. Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism
Cover - Remove and Install".
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Product: TELEHANDLER
Model: TH103 TELEHANDLER 3PN
Configuration: TH103 Telehandler 3PN00001-02026 (MACHINE) POWERED BY 3054 Engine
Disassembly and Assembly
3054 Engine for Caterpillar Built Machines
Media Number -SENR6241-13 Publication Date -01/08/2008 Date Updated -04/08/2008
i01645897
Cylinder Head - Remove
SMCS - 1100-011
Removal Procedure
Start By:
A. Disconnect the electrical connections at the battery.
B. Drain the coolant system. If the engine uses Diesel Engine Antifreeze/Coolant (DEAC),
refer to Operation and Maintenance Manual, "Cooling System Coolant (DEAC) - Change".
If the engine uses Extended Life Coolant (ELC), refer to Operation and Maintenance
Manual, "Cooling System Coolant (ELC) - Change".
C. Remove the air inlet manifold. Refer to Disassembly and Assembly, "Air Inlet Manifold -
Remove".
D. Remove the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold -
Remove and Install".
E. Remove the fuel injection nozzles. Refer to Disassembly and Assembly, "Fuel Injection
Nozzles - Remove".
F. Remove the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base -
Remove and Install".
G. Remove the water outlet manifold. Refer to Disassembly and Assembly, "Water Outlet
Manifold - Remove".
H. Remove the rocker shaft assembly and the pushrods. Refer to Disassembly and Assembly,
"Rocker Arm and Shaft - Remove".
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Illustration 1 g00550160
Typical example
Illustration 2 g00550162
1. Gradually loosen 22 cylinder head bolts (1) in the reverse order that is shown in Illustration
2. This will help prevent distortion of the cylinder head.
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Illustration 3 g00550163
Typical example
2. Attach a suitable lifting device to cylinder head (2). Carefully lift cylinder head (2) off the
engine block. The weight of the cylinder head is 41 kg (90 lb).
NOTICE
Place the cylinder head on a surface that will not scratch the face of the
cylinder head.
Illustration 4 g00550165
3. Remove cylinder head gasket (3) .
4. Note the location of dowels (4) on each end of the cylinder block. Dowels (4) hold cylinder
head gasket (3) in place while cylinder head (2) is installed.
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Illustration 5 g00741112
5. Align straight edge (7) with bolt (6) in order to check for distortion. If there is a visible
reduction in the diameter of thread (8) that has not been in engagement with the cylinder
block, the bolts must be replaced.
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Product: TELEHANDLER
Model: TH103 TELEHANDLER 3PN
Configuration: TH103 Telehandler 3PN00001-02026 (MACHINE) POWERED BY 3054 Engine
Disassembly and Assembly
3054 Engine for Caterpillar Built Machines
Media Number -SENR6241-13 Publication Date -01/08/2008 Date Updated -04/08/2008
i01645901
Cylinder Head - Install
SMCS - 1100-012
Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 9U-6238 Guide Bolt 2
B 8T-3052 Degree Wheel 1
1. Thoroughly clean the top of the cylinder block and the bottom of the cylinder head. Ensure
that there is no debris in the cylinder bores.
Illustration 1 g00550165
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2. Place cylinder head gasket (3) on dowels (4) on top of the cylinder block. The cylinder head
gasket (3) is stamped "FRONT TOP". Do not use any sealant or compound on the cylinder
head gasket.
3. Install Tool (A) in positions 15 and 20 in the cylinder block. Refer to Illustration 4.
Illustration 2 g00550163
Typical example
4. Attach a suitable lifting device to cylinder head (2) .
5. Place cylinder head (2) on the cylinder block. Ensure that the cylinder head is positioned on
dowels (4) and that cylinder head gasket (3) is positioned correctly.
6. Remove Tool (A) .
Illustration 3 g00550160
Typical example
7. Lubricate cylinder head bolts (1) with clean engine oil.
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Illustration 4 g00550162
8. Gradually tighten all of the bolts (1 through 22) in a numerical sequence to a torque of 110
N·m (80 lb ft).
9. Tighten all of the bolts (1 through 22) again in a numerical sequence to a torque of 110 N·m
(80 lb ft).
10. Place an index mark on the bolts and use Tool (B) in order to further tighten the bolts. Refer
to illustration 4.
a. Turn the short bolts that are marked with an "S" for an additional 150 degrees (2.5
flats).
b. Turn the medium length bolts that are marked with an "M" for an additional 180
degrees (3.0 flats).
c. Turn the long bolts that are marked with an "L" for an additional 210 degrees (3.5
flats).
End By:
a. Install the rocker shaft assembly. Refer to Disassembly and Assembly, "Rocker Arm and
Shaft - Install".
b. Install the water outlet manifold. Refer to Disassembly and Assembly, "Water Outlet
Manifold - Install".
c. Install the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove
and Install".
d. Install the fuel injection nozzles. Refer to Disassembly and Assembly, "Fuel Injection
Nozzles - Install".
e. Install the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold -
Remove and Install".
f. Install the inlet manifold. Refer to Disassembly and Assembly, "Air inlet Manifold -Install".
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g. Fill the coolant system. If the engine uses Extended Life Coolant (ELC), refer to Operation
and Maintenance Manual, "Cooling System Coolant (ELC) - Change". If the engine uses
Diesel Engine Antifreeze/Coolant (DEAC), refer to Operation and Maintenance Manual,
"Cooling System Coolant (DEAC) - Change".
h. Connect the electrical connections at the battery.
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Product: TELEHANDLER
Model: TH103 TELEHANDLER 3PN
Configuration: TH103 Telehandler 3PN00001-02026 (MACHINE) POWERED BY 3054 Engine
Disassembly and Assembly
3054 Engine for Caterpillar Built Machines
Media Number -SENR6241-13 Publication Date -01/08/2008 Date Updated -04/08/2008
i01745933
Lifter Group - Remove and Install
SMCS - 1209-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1U-7262 Telescoping Magnet 1
Start By:
a. Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove and
Install".
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
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Suggest:
For more complete manuals. Please go to
the home page.
https://www.ebooklibonline.com
If the above button click is invalid. Please
download this document first, and then
click the above link to download the
complete manual.
Thank you so much for reading
Illustration 1 g00540954
1. Use Tooling (A) to remove lifters (1).
Note: Ensure that the lifters are marked with the appropriate cylinder number for
installation purposes.
Installation Procedure
Table 2
Required Tools
Tool Part Number Part Description Qty
A 1U-7262 Telescoping Magnet 1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
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Illustration 2 g00540954
1. Use Tooling (A) to install lifters (1).
Note: Ensure that the lifters are seated correctly and that the lifters are in the correct
cylinders.
End By:
a. Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove and Install".
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Caterpillar Cat TH103 Telehandler (Prefix 3PN) Service Repair Manual Instant Download (3PN00001-02026).pdf

  • 1. Product: TELEHANDLER Model: TH103 TELEHANDLER 3PN Configuration: TH103 Telehandler 3PN00001-02026 (MACHINE) POWERED BY 3054 Engine Disassembly and Assembly 3054 Engine for Caterpillar Built Machines Media Number -SENR6241-13 Publication Date -01/08/2008 Date Updated -04/08/2008 i01054405 Valve Mechanism Cover - Remove and Install SMCS - 1107-010 Removal Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. Note: The engines are equipped with either an aluminum valve cover or with a composite valve cover. The aluminum valve cover has a seal that fits between the valve cover and the inlet 1/5(W) w 2022/5/30 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 2. manifold. The composite valve cover has a seal that is permanently fixed to the side of the valve cover. Illustration 1 g00547002 Typical example Illustration 2 g00547003 Aluminum valve cover 2/5(W) w 2022/5/30 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 3. Illustration 3 g00547004 Composite valve cover 1. Loosen hose clamp (1) . 2. Disconnect breather hose (2) . 3. Remove three nuts (3), steel washers (6), and sealing washers (8) . Note: When you remove nuts (3), ensure that the nuts on the rocker arm bracket are not loosened. Note: Current production engines have an additional shim washer (7) . 4. Remove valve cover (4), gasket (10), and seal (5) . 5. Remove seal (9) for the oil filler cap. Installation Procedure Note: The engines are equipped with either an aluminum valve cover or with a composite valve cover. The aluminum valve cover has a seal that fits between the valve cover and the inlet manifold. The composite valve cover has a seal that is permanently fixed to the side of the valve cover. 3/5(W) w 2022/5/30 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 4. Illustration 4 g00547002 Typical example Illustration 5 g00547003 Aluminum valve cover 4/5(W) w 2022/5/30 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 5. Illustration 6 g00547004 Composite valve cover 1. Inspect the condition of the gaskets and the seals. Replace the gaskets and the seals, if necessary. 2. Install seal (9) for the oil filler cap, if necessary. 3. Apply 8T-9022 Silicone Gasket to gasket (10) . Note: Ensure that the flat face of the gasket is toward the valve cover. 4. Install gasket (10), seal (5), and valve cover (4) . 5. Lubricate three nuts (3) with clean engine oil. 6. Install three nuts (3), steel washers (6), and sealing washers (8) . Note: When you install three nuts (3) without shim washers (7), tighten the nuts to a torque of 20 N·m (15 lb ft). Do not overtighten the nuts. Note: When you install three nuts (3) with shim washers (7), tighten the nuts to a torque of 30 N·m (22 lb ft). Do not overtighten the nuts. 7. Connect breather hose (2) . 8. Tighten hose clamp (1) . 5/5(W) w 2022/5/30 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 6. Product: TELEHANDLER Model: TH103 TELEHANDLER 3PN Configuration: TH103 Telehandler 3PN00001-02026 (MACHINE) POWERED BY 3054 Engine Disassembly and Assembly 3054 Engine for Caterpillar Built Machines Media Number -SENR6241-13 Publication Date -01/08/2008 Date Updated -04/08/2008 i01761173 Rocker Shaft and Pushrod - Remove SMCS - 1102-011; 1208-011 Removal Procedure Start By: a. Remove the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install". NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Illustration 1 g00635152 1/2(W) w 2022/5/30 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 7. Typical example Note: It is not necessary to remove the oil supply tube in order to remove the rocker shaft assembly and the pushrods. 1. Remove nuts (1) and bolt (2) from the rocker shaft assembly. Begin with the end brackets and move toward the center. 2. Remove rocker shaft assembly (3). 3. Remove the oil seal from the oil supply passage in the cylinder head. Illustration 2 g00635153 Typical example 4. Remove pushrods (4). Place an identification mark on the pushrods for installation. 2/2(W) w 2022/5/30 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 8. Product: TELEHANDLER Model: TH103 TELEHANDLER 3PN Configuration: TH103 Telehandler 3PN00001-02026 (MACHINE) POWERED BY 3054 Engine Disassembly and Assembly 3054 Engine for Caterpillar Built Machines Media Number -SENR6241-13 Publication Date -01/08/2008 Date Updated -04/08/2008 i01667090 Rocker Shaft - Disassemble SMCS - 1102-015 Disassembly Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 1P-0510 Driver Group 1 Start By: A. Remove the rocker shaft assembly. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Remove". Illustration 1 g00550061 1/3(W) w 2022/5/30 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 9. 1. Use a screwdriver or a similar tool to remove retaining ring (1) from both ends of the rocker shaft assembly. Illustration 2 g00550062 (1) Retaining ring (2) Washer on the end of the rocker shaft (3) Rocker arm assembly (4) Rocker shaft bracket (5) Spring on the rocker shaft (6) Washer (7) Rocker shaft (8) Bolt (9) Oil supply connection (10) Rocker arm bushing 2. Remove the rocker arms and the rocker shaft brackets from the rocker shaft assembly. Note: Place an identification mark on each of the components for the proper order for installation. 3. Check the clearance between rocker arm assembly (3) and rocker shaft (7). Replace rocker arm bushing (10) if the clearance is larger than 0.13 mm (0.005 inch). Use Tool (A) and a suitable press in order to remove rocker arm bushing (10) from rocker arm assembly (3), if necessary. 4. Remove rocker shaft bracket (4) from rocker shaft (7) . 5. Remove springs (5), washer (6), bolt (8) and oil supply connection (9) from rocker shaft (7) . 2/3(W) w 2022/5/30 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 10. Product: TELEHANDLER Model: TH103 TELEHANDLER 3PN Configuration: TH103 Telehandler 3PN00001-02026 (MACHINE) POWERED BY 3054 Engine Disassembly and Assembly 3054 Engine for Caterpillar Built Machines Media Number -SENR6241-13 Publication Date -01/08/2008 Date Updated -04/08/2008 i01667093 Rocker Shaft - Assemble SMCS - 1102-016 Assembly Procedure 1. Lubricate all of the components with clean engine oil. Illustration 1 g00550062 (1) Retaining ring (2) Washer on the end of the rocker shaft (3) Rocker arm assembly (4) Rocker shaft bracket (5) Spring on the rocker shaft (6) Washer (7) Rocker shaft 1/2(W) w 2022/5/30 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 11. (8) Bolt (9) Oil supply connection (10) Rocker arm bushing 2. Install oil supply connection (9) and bolt (8) on rocker shaft (7) . Note: Ensure that the bolt and the connection are correctly positioned on the rocker shaft. Note: Ensure that all of the oil holes in the rocker shaft and in the rocker arms are not plugged before you begin the assembly procedure. 3. Install rocker arm bushing (10) in rocker arm assembly (3) with a suitable press. Ream the bushing to a clearance of 0.06 ± 0.03 mm (0.0024 ± 0.0012 inch), if necessary. 4. Install each of the components in the correct order onto rocker shaft (7). See Illustration 1. Illustration 2 g00550061 5. Install retaining ring (1). End By: Install the rocker shaft assembly. Refer to Disassembly and Assembly, "Rocker Shaft and Pushrod - Install". 2/2(W) w 2022/5/30 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 12. Product: TELEHANDLER Model: TH103 TELEHANDLER 3PN Configuration: TH103 Telehandler 3PN00001-02026 (MACHINE) POWERED BY 3054 Engine Disassembly and Assembly 3054 Engine for Caterpillar Built Machines Media Number -SENR6241-13 Publication Date -01/08/2008 Date Updated -04/08/2008 i01749382 Rocker Shaft and Pushrod - Install SMCS - 1102-012; 1208-012 Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Illustration 1 g00635153 Typical example 1. Install pushrods (4). 1/2(W) w 2022/5/30 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 13. Note: Ensure that the pushrods are installed in the original location and that the pushrods are seated in the valve lifters correctly. 2. Install a new oil seal in the oil supply hole in the cylinder head. Illustration 2 g00635152 Typical example 3. Put rocker shaft assembly (3) in position on the cylinder head. Make sure that the connection for the oil supply is installed correctly into the oil seal. Note: Ensure that the adjustment screws are properly seated in the ends of pushrods (4). Note: It may be necessary to loosen the adjustment screws on each rocker arm. This will help prevent a bent valve or a bent pushrod during the installation of the rocker shaft. 4. Lubricate nuts (1) and bolt (2) with clean engine oil. 5. Install nuts (1) and bolt (2). 6. Alternately tighten the nuts and the bolt. Start from the center and work toward the outside. Tighten the nuts and the bolt on an aluminum bracket to a torque of 40 N·m (30 lb ft). Tighten the nuts and the bolt on a cast iron or a steel bracket to a torque of 75 N·m (55 lb ft). 7. Adjust the inlet valve lash to 0.20 mm (0.008 inch) and adjust the exhaust valve lash to 0.45 mm (0.018 inch). Refer to Testing and Adjusting, "Air Inlet and Exhaust System" for more information on adjusting the valve lash. End By: a. Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install". 2/2(W) w 2022/5/30 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 14. Product: TELEHANDLER Model: TH103 TELEHANDLER 3PN Configuration: TH103 Telehandler 3PN00001-02026 (MACHINE) POWERED BY 3054 Engine Disassembly and Assembly 3054 Engine for Caterpillar Built Machines Media Number -SENR6241-13 Publication Date -01/08/2008 Date Updated -04/08/2008 i01645897 Cylinder Head - Remove SMCS - 1100-011 Removal Procedure Start By: A. Disconnect the electrical connections at the battery. B. Drain the coolant system. If the engine uses Diesel Engine Antifreeze/Coolant (DEAC), refer to Operation and Maintenance Manual, "Cooling System Coolant (DEAC) - Change". If the engine uses Extended Life Coolant (ELC), refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change". C. Remove the air inlet manifold. Refer to Disassembly and Assembly, "Air Inlet Manifold - Remove". D. Remove the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install". E. Remove the fuel injection nozzles. Refer to Disassembly and Assembly, "Fuel Injection Nozzles - Remove". F. Remove the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install". G. Remove the water outlet manifold. Refer to Disassembly and Assembly, "Water Outlet Manifold - Remove". H. Remove the rocker shaft assembly and the pushrods. Refer to Disassembly and Assembly, "Rocker Arm and Shaft - Remove". 1/4(W) w 2022/5/30 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 15. Illustration 1 g00550160 Typical example Illustration 2 g00550162 1. Gradually loosen 22 cylinder head bolts (1) in the reverse order that is shown in Illustration 2. This will help prevent distortion of the cylinder head. 2/4(W) w 2022/5/30 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 16. Illustration 3 g00550163 Typical example 2. Attach a suitable lifting device to cylinder head (2). Carefully lift cylinder head (2) off the engine block. The weight of the cylinder head is 41 kg (90 lb). NOTICE Place the cylinder head on a surface that will not scratch the face of the cylinder head. Illustration 4 g00550165 3. Remove cylinder head gasket (3) . 4. Note the location of dowels (4) on each end of the cylinder block. Dowels (4) hold cylinder head gasket (3) in place while cylinder head (2) is installed. 3/4(W) w 2022/5/30 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 17. Illustration 5 g00741112 5. Align straight edge (7) with bolt (6) in order to check for distortion. If there is a visible reduction in the diameter of thread (8) that has not been in engagement with the cylinder block, the bolts must be replaced. 4/4(W) w 2022/5/30 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 18. Product: TELEHANDLER Model: TH103 TELEHANDLER 3PN Configuration: TH103 Telehandler 3PN00001-02026 (MACHINE) POWERED BY 3054 Engine Disassembly and Assembly 3054 Engine for Caterpillar Built Machines Media Number -SENR6241-13 Publication Date -01/08/2008 Date Updated -04/08/2008 i01645901 Cylinder Head - Install SMCS - 1100-012 Installation Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 9U-6238 Guide Bolt 2 B 8T-3052 Degree Wheel 1 1. Thoroughly clean the top of the cylinder block and the bottom of the cylinder head. Ensure that there is no debris in the cylinder bores. Illustration 1 g00550165 1/4(W) w 2022/5/30 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 19. 2. Place cylinder head gasket (3) on dowels (4) on top of the cylinder block. The cylinder head gasket (3) is stamped "FRONT TOP". Do not use any sealant or compound on the cylinder head gasket. 3. Install Tool (A) in positions 15 and 20 in the cylinder block. Refer to Illustration 4. Illustration 2 g00550163 Typical example 4. Attach a suitable lifting device to cylinder head (2) . 5. Place cylinder head (2) on the cylinder block. Ensure that the cylinder head is positioned on dowels (4) and that cylinder head gasket (3) is positioned correctly. 6. Remove Tool (A) . Illustration 3 g00550160 Typical example 7. Lubricate cylinder head bolts (1) with clean engine oil. 2/4(W) w 2022/5/30 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 20. Illustration 4 g00550162 8. Gradually tighten all of the bolts (1 through 22) in a numerical sequence to a torque of 110 N·m (80 lb ft). 9. Tighten all of the bolts (1 through 22) again in a numerical sequence to a torque of 110 N·m (80 lb ft). 10. Place an index mark on the bolts and use Tool (B) in order to further tighten the bolts. Refer to illustration 4. a. Turn the short bolts that are marked with an "S" for an additional 150 degrees (2.5 flats). b. Turn the medium length bolts that are marked with an "M" for an additional 180 degrees (3.0 flats). c. Turn the long bolts that are marked with an "L" for an additional 210 degrees (3.5 flats). End By: a. Install the rocker shaft assembly. Refer to Disassembly and Assembly, "Rocker Arm and Shaft - Install". b. Install the water outlet manifold. Refer to Disassembly and Assembly, "Water Outlet Manifold - Install". c. Install the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base - Remove and Install". d. Install the fuel injection nozzles. Refer to Disassembly and Assembly, "Fuel Injection Nozzles - Install". e. Install the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install". f. Install the inlet manifold. Refer to Disassembly and Assembly, "Air inlet Manifold -Install". 3/4(W) w 2022/5/30 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 21. g. Fill the coolant system. If the engine uses Extended Life Coolant (ELC), refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) - Change". If the engine uses Diesel Engine Antifreeze/Coolant (DEAC), refer to Operation and Maintenance Manual, "Cooling System Coolant (DEAC) - Change". h. Connect the electrical connections at the battery. 4/4(W) w 2022/5/30 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 22. Product: TELEHANDLER Model: TH103 TELEHANDLER 3PN Configuration: TH103 Telehandler 3PN00001-02026 (MACHINE) POWERED BY 3054 Engine Disassembly and Assembly 3054 Engine for Caterpillar Built Machines Media Number -SENR6241-13 Publication Date -01/08/2008 Date Updated -04/08/2008 i01745933 Lifter Group - Remove and Install SMCS - 1209-010 Removal Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 1U-7262 Telescoping Magnet 1 Start By: a. Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove and Install". NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1/3(W) w 2022/5/30 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 23. Suggest: For more complete manuals. Please go to the home page. https://www.ebooklibonline.com If the above button click is invalid. Please download this document first, and then click the above link to download the complete manual. Thank you so much for reading
  • 24. Illustration 1 g00540954 1. Use Tooling (A) to remove lifters (1). Note: Ensure that the lifters are marked with the appropriate cylinder number for installation purposes. Installation Procedure Table 2 Required Tools Tool Part Number Part Description Qty A 1U-7262 Telescoping Magnet 1 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 2/3(W) w 2022/5/30 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...
  • 25. Illustration 2 g00540954 1. Use Tooling (A) to install lifters (1). Note: Ensure that the lifters are seated correctly and that the lifters are in the correct cylinders. End By: a. Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove and Install". 3/3(W) w 2022/5/30 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw...