Caterpillar Cat 301.4C Mini Hydraulic Excavator (Prefix LJK) Service Repair Manual (LJK00001 and up).pdf

Service Repair Manual
Models
301.4C Mini Hydraulic Excavator

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Product: MINI HYD EXCAVATOR
Model: 301.4C MINI HYD EXCAVATOR LJK
Configuration: 301.4C Mini Hydraulic Excavator LJK00001-UP (MACHINE)
Disassembly and Assembly
3TNV70 and 3TNV76
Engines for Caterpillar Built Machines
Media Number -UENR3279-00 Publication Date -01/07/2013 Date Updated -23/07/2013
i05260516
Fuel Injection Lines - Remove and Install
SMCS - 1252-010
Removal Procedure
Note: Put identification marks on all hoses, on all hose assemblies, on all wires, and on all tube
assemblies for installation purposes. Plug all hose assemblies and all tube assemblies. Plugging
the lines will help to prevent fluid loss, and will help to keep contaminants from entering the
system.
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.
Dispose of all fluids according to local regulations and mandates.
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301.4C Mini Hydraulic Excavator LJK00001-UP (MACHINE)(SEBP5955 - 26) - Doc...
2020/4/17
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Illustration 1 g03348893
1. Use line wrench in order to loosen fuel injection line nuts. Use two wrenched to avoid
turning lower nut. Disconnect fuel injection line nuts (2) from the injector pump and the fuel
injectors. Remove fuel injector line assemblies (3).
Installation Procedure
NOTICE
performance of inspection, maintenance, testing, adjusting, and repair
containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
2/3
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1. Position fuel injection lines assemblies (3) on the fuel injection pump and the fuel injectors.
Start fuel injection line nuts (2) on by hand before tightening with a wrench. Hold wrench
on lower nut for the return line to avoid moving the return line. Tighten fuel injection line
nuts (2) to a torque of 29 to 34 N·m (257 to 300 lb in).
.
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Fri Apr 17 09:05:56 UTC+0800 2020
3/3
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3TNV70 and 3TNV76
i05260707
Fuel Injection Pump - Remove and Install
SMCS - 1251-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 8S-2264 Puller Gp 3
Start By:
A. Remove fuel injection lines
Note: Refer to Specifications, ""Engine Design"" for non-specified engine torques.
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1. Remove fuel injection pump drive gear access cover (1) from front housing (2).
Note: The cover is secured with adhesive sealant. Use a scraper to separate the cover from
the gear case.
Note: After marking the position of the fuel injection pump drive gear (3) , do not
rotate the engine crankshaft. Rotating the crankshaft will cause the fuel injection
pump to become misaligned.
2. Place a mark on the fuel injection pump drive gear (3) and the idler gear for installation
purposes. Loosen center nut (4) and back out to the end of the fuel injection pump shaft. DO
NOT loosen the four bolts (5) that hold the fuel injection pump gear to the hub.
Note: Do not loosen or remove the four bolts (5) retaining the fuel injection pump
drive gear (3) to the fuel injection pump hub (3A). Do not disassemble the fuel
injection pump drive gear from the hub. Correct fuel injection timing will be difficult
or next to impossible to achieve.
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3. Install Tooling (A) onto the end of the fuel injection pump shaft nut (4). Loosen the pump
drive gear (3) from the shaft, remove Tooling (A) and remove nut and washer (4) .
Note: Fuel injection pump drive gear (3) can be removed from the gear case, however,
would be best to let the gear remain in the gear housing.
4. Locate and highlight the timing mark (9) on the base of fuel injection pump (6) for
installation purposes. Make a corresponding mark on the gear case. Unplug the stop
solenoid harness assembly. Remove lube oil line (7) from the fuel injection pump and the
block assembly. Remove mounting nuts (8) and fuel injection pump (6).
Table 2
Required Tools
B Loctite 593 Silicone Sealer
3/5
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1. Position fuel injection pump (6) into the housing and the pump drive gear. Install nuts (8).
Line up timing marks (9) if the old fuel injection pump is being reused. If new fuel injection
pump is being installed, refer to Testing and Adjusting, "Fuel Injection Timing -
Check/Adjust" for the correct fuel injection timing procedures. Install lube oil line (7).
Tighten nut (8) to a torque of 23 to 28 N·m (204 to 248 lb in).
2. Make sure that fuel injection pump drive gear (3) is aligned with the idler gear using the
reference marks made earlier. Install the washer and nut (4). Tighten nut (4) to a torque of
59 to 69 N·m (44 to 51 lb ft) while holding the crankshaft pulley bolt with a socket wrench
to prevent the crankshaft from turning.
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3. Apply Tooling (B) on mating surface of cover (1). Install cover (1) on front housing (2).
End By: Install fuel injector lines
Fri Apr 17 09:06:53 UTC+0800 2020
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3TNV70 and 3TNV76
i05261431
Fuel Injector - Remove and Install
SMCS - 1290-010
Removal Procedure
Start By:
A. Remove fuel injector lines
Note: Put identification marks on all hoses, on all hose assemblies, on all wires, and on all tube
assemblies for installation purposes. Plug all hose assemblies and all tube assemblies. Plugging
will prevent fluid loss, and will help to keep contaminants from entering the system.
NOTICE
performance of inspection, maintenance, testing, adjusting, and repair
containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat products.
1/2
2020/4/17

1. Remove nuts (3). Use two wrenches on nut (3) and on fuel injector (1) in order to hold fuel
injector (1) from turning. Be careful to keep the return line (4) from twisting. Remove return
line hose (2). Remove return line (4) .
2. Remove copper washer (5) and fuel injector (6) .
1. Install fuel injectors (6) with new copper washers (5) in the reverse order of removal.
Tighten fuel injectors (6) to a torque of 49 to 59 N·m (36 to 44 lb ft)
2. Tighten fuel return line nuts (3) to a torque of 24 to 33 N·m (212 to 292 lb in).
Fri Apr 17 09:07:49 UTC+0800 2020
2/2
2020/4/17

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3TNV70 and 3TNV76
i05262100
Exhaust Manifold - Remove and Install
SMCS - 1059-010
Removal Procedure
Note: Refer to Specifications, ""Engine Design"" for non-specified engine torques.
1. Remove bolts (1). Remove exhaust manifold (2).
1. Install exhaust manifold (2) in the reverse order of removal.
Fri Apr 17 09:08:46 UTC+0800 2020
1/1
2020/4/17

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3TNV70 and 3TNV76
i05282070
Inlet and Exhaust Valve Springs - Remove and Install
SMCS - 1108-010
Removal Procedure
Table 1
Required Tools
A 9U-6195 Valve Spring Compressor 1
Start By:
A. Remove the rocker arm and shaft.
Note: The following procedure should be adopted in order to remove the valve springs when the
cylinder head is installed to the engine.
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(X) Top Center
Note: Ensure that the appropriate piston is at top center before the valve spring is removed.
Failure to ensure that the piston is at top center may allow the valve to drop into the cylinder bore.
Each cylinder is marked top center on flywheel as shown in above photo.
NOTICE
Plug the apertures for the push rods in the cylinder head in order to
prevent the entry of loose parts into the engine.
A typical example of Tooling (A) installation.
2/4
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Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
NOTICE
Ensure that the valve spring is compressed squarely or damage to the
valve stem may occur.
1. Install Tooling (A) into position on the cylinder head in order to compress valve spring (4)
for the appropriate piston.
2. Use Tooling (A) in order to compress valve spring (4) and open valve (1) slightly.
Note: Do not compress valve spring (4) so that valve spring retainer (3) touches valve stem
seal (5) .
3. Rotate crankshaft carefully, until the piston touches valve (1) .
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Note: Do not use excessive force to turn the crankshaft. The use of force can result in bent
valve stems.
4. Continue to rotate the crankshaft and gradually release the pressure on Tooling (A) until the
piston is at the top dead center position. The valve is now held in a position that allows
valve spring (4) to be safely removed.
NOTICE
Do not turn the crankshaft while the valve springs are removed.
5. Apply sufficient pressure to Tooling (A) in order to allow removal of valve keepers (2) .
Note: Do not compress valve spring (4) so that valve spring retainer (3) touches valve stem
seal (5) .
6. Remove valve keepers (2) .
7. Slowly release the pressure on Tooling (A). Remove valve spring retainer (3), remove valve
spring (4) and valve spring seal (5).
1. Install valve springs (4) in the reverse order of removal.
Fri Apr 17 09:09:43 UTC+0800 2020
4/4
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3TNV70 and 3TNV76
i05389588
Inlet and Exhaust Valves - Remove and Install
SMCS - 1105-010
Removal Procedure
Table 1
Required Tools
A 1P-3527 Valve Spring Compressor 1
Start By:
A. Remove the cylinder head.
1/4
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1. Remove valve stem caps (1). Using Tooling (A), compress valve springs (4). Remove valve
keepers (2). Release Tooling (A). Remove valve spring retainers (3) valve springs (4) and
valve seals (5). Remove inlet and exhaust valves (6).
Note: Mark the valves so that they can be reinstalled in the same location.
2/4
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1. Place new valve seals (5) onto valve guides (7).
Note: Intake valve seals have white seal springs. Exhaust valve seals have black seal
springs.
2. Install valve seals (5) to a height on dimension (8) to 10.9 to 11.2 mm (0.430 to 0.440 inch)
from the cylinder head.
Note: Install valves in the original location.
1. After thorough inspection and replacement of parts, assemble inlet and exhaust valves (6)
into the cylinder head.
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2. Install valve springs (4) and valve spring retainers (3). Use Tooling (A) to compress valve
springs (4). Install valve keepers (2). Release Tooling (A). Install valve stem caps (1) .
End By: Install the cylinder head.
Fri Apr 17 09:10:39 UTC+0800 2020
4/4
2020/4/17

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3TNV70 and 3TNV76
i05284654
Inlet and Exhaust Valve Guides - Remove and Install
SMCS - 1104-010
Removal Procedure
Table 1
Required Tools
A 423-9663 Valve Guide Driver 1
Start By:
A. Remove the inlet and the exhaust valves.
A typical example of the removal process.
1/2
2020/4/17

Caterpillar Cat 301.4C Mini Hydraulic Excavator (Prefix LJK) Service Repair Manual (LJK00001 and up).pdf

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Caterpillar Cat 301.4C Mini Hydraulic Excavator (Prefix LJK) Service Repair Manual (LJK00001 and up).pdf