Caterpillar Cat 993K Wheel Loader (Prefix Z8D) Service Repair Manual (Z8D00001 and up).pdf

Service Repair Manual
Models
993K Wheel Loader

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Product: WHEEL LOADER
Model: 993K WHEEL LOADER Z8D
Configuration: 993K Wheel Loader Z8D00001-UP (MACHINE) POWERED BY C32 Engine
Disassembly and Assembly
C27 and C32 Engines for Caterpillar Built Machines
Media Number -KENR8148-13 Publication Date -01/09/2018 Date Updated -05/09/2018
i06750410
Inlet and Exhaust Valves - Remove and Install
SMCS - 1105-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 5S-1330 Valve Spring Compressor 1
B 441-0714 Tool As 1
Start By:
a. Remove the cylinder head.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
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993K Wheel Loader Z8D00001-UP (MACHINE) POWERED BY C32 Engine(M0088...
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Illustration 1 g01015263
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.
1. Install Tooling (A) and compress the valve springs. Remove valve spring keepers (2) from
valve (1).
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2. Carefully remove Tooling (A) from valve (1).
3. Remove valve rotator (3).
4. Remove outer valve spring (5) and inner valve spring (4) from valve (1).
5. Remove washer (6) and valve (1) from the valve guide.
6. Use Tooling (B) to check the valve springs (spring force). Refer to Specifications, "Cylinder
Head Valves" for additional information on the valve springs.
7. Inspect the valves. Refer to Specifications, "Cylinder Head Valves" for additional
information on the inlet and exhaust valves.
Installation Procedure
Table 2
Required Tools
A 5S-1330 Valve Spring Compressor 1
NOTICE
Note: A small amount of grease can be used to hold the retainer locks in position during
installation.
1. Lubricate the valves with clean engine oil. Install the valves in the cylinder head.
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Improper assembly of parts that are spring loaded can cause bodily
injury.
To prevent possible injury, follow the established assembly procedure
and wear protective equipment.
2. Install washer (6) on the valve guide.
3. Install inner valve spring (4) and outer valve spring (5) on valve (1).
4. Install valve rotator (3) on valve (1).
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5. Use Tooling (A) to compress inner valve spring (4) and outer valve spring (5). Install valve
spring keepers (2) on valve (1).
The valve spring keepers can be thrown from the valve when the valve
spring compressor is released. Ensure that the valve spring keepers are
properly installed on the valve stem. To help prevent personal injury,
keep away from the front of the valve spring keepers and valve springs
during the installation of the valves.
6. Carefully remove Tooling (A).
End By:
a. Install the cylinder head.
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All Rights Reserved.
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Thu Mar 26 07:07:04 UTC+0800 2020
5/5
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i05887270
Inlet and Exhaust Valve Guides - Remove and Install
SMCS - 1104-010
Removal Procedure
Table 1
Required Tools
A(1)
9U-6895 Valve Guide Driver 1
(1)
Part of 9U-7530 Engine Tool Group
Start By:
a. Remove the inlet and exhaust valves. Refer to Disassembly and Assembly, "Inlet and
Exhaust Valves - Remove and Install".
NOTICE
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1. Remove valve stem seal (1) from valve guide (2).
2. Use Tooling (A) and a hammer to remove the valve guide from the cylinder head.
Table 2
Required Tools
A(1)
9U-6895 Valve Guide Driver 1
B(1)
9U-6894 Guide Collar 1
C(2)
455-0128 Seal Installer 1
375-2773 Seal Installer 1
(1)
(2)
Use Seal Installer 455-0128 with Seal 163-2478. Use Seal Installer 375-2773 with Seal 361-3926
NOTICE
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1. Lubricate the bores for the valve guides with clean engine oil.
2. Install valve guide (2) in the cylinder head with Tooling (A) and Tooling (B).
Note: Tooling (B) must be used in order to install the valve guide to the correct height.
Height to top of valve guide from cylinder head surface ... 35.00 ± 0.50 mm
(1.378 ± 0.020 inch)
Note: For more information, refer to Specifications, "Cylinder Head Valves".
3. Use Tooling (C) to install valve stem seal (1) on the valve guide.
End By:
a. Install the inlet and exhaust valves. Refer to Disassembly and Assembly, "Inlet and Exhaust
Valves - Remove and Install".
Thu Mar 26 07:08:01 UTC+0800 2020
3/3
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i04947937
Inlet and Exhaust Valve Seat Inserts - Remove and Install
SMCS - 1103-010
Removal Procedure
Table 1
Required Tools
A 166-7441 Valve Seat Extractor Tool Group 1
Start By:
a. Remove the inlet and exhaust valves. Refer to Disassembly and Assembly, "Inlet and
Exhaust Valves - Remove and Install".
NOTICE
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1. Use Tooling (A) to remove valve seat insert (1) from the cylinder head.
2. Clean the bores in the cylinder head for the valve seat inserts. Remove any rough areas from
the bores.
Table 2
Required Tools
B(1)
9U-6898 Valve Seat Driver (Exhaust) 1
9U-6897 Valve Seat Driver (Inlet) 1
(1)
NOTICE
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1. Lower the temperature of new valve seat insert (1).
2. Use Tooling (B) to install the new valve seat insert in the cylinder head.
Note: Do not machine the prefinished valve seat inserts in order to correct the valve stem
projection. An excessive valve stem projection indicates that the valve seat insert is not
seated or material was not cleaned from the bottom of the counterbore.
End By:
a. Install the inlet and exhaust valves. Refer to Disassembly and Assembly, "Inlet and Exhaust
Valves - Remove and Install".
Thu Mar 26 07:08:58 UTC+0800 2020
3/3
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i04576124
Engine Oil Filter Base - Remove and Install
SMCS - 1306-010
Removal Procedure
Table 1
Required Tools
A 185-3630 Strap Wrench As 1
B LOCTITE 271 1
1. Disconnect hose assemblies (4). Remove elbow (1) and the O-ring seal.
2. Use Tooling (A) to remove engine oil filters (3).
3. Remove the engine oil filter base (2).
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4. Remove studs (5).
1. Install the engine oil filter base (2) in the reverse order.
a. Apply Tooling (B) to the threads of studs (5). Tighten to 80 ± 14 N·m (59 ± 10 lb ft).
b. Apply clean engine oil to the oil filter seals prior to installation. Install the engine oil
filters until the oil filter seal contacts the base, then turn the engine oil filters one full
turn.
c. Apply clean engine oil to the bore for elbow (1).
Thu Mar 26 07:09:54 UTC+0800 2020
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i04577496
Engine Oil Cooler - Remove and Install
SMCS - 1378-010
Removal Procedure
Table 1
Required Tools
A
207-1600(1)
Rubber Lubricant 1
207-1601 Rubber Lubricant 1
(1)
For Use in EAME
Start By:
a. Remove the exhaust cooler (NRS).
1. Refer to Operation and Maintenance Manual, "Coolant - Change" for the proper draining
and filling procedures.
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2. Remove flow switch (2) and position harness assembly (3). Discard any cable straps.
3. Remove hose assemblies (1) and spacer assembly (6). Remove tube assembly (4).
4. Remove bypass tube assembly (5) and the O-ring seals.
5. Remove cooler outlet elbow (7) and bypass body (8) from bypass tube (9). Remove the O-
ring seals from bypass tube (9).
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6. Remove bolts (12) and plate (14).
7. Remove and discard gasket (10). Remove springs (11) and remove valve plungers (13) from
bypass body (8).
8. Use two people to remove engine oil cooler assembly (17). The weight of engine oil cooler
assembly (17) is approximately 40 kg (88 lb).
9. Remove elbow assembly (16). Remove bolts (15) and (18). Remove engine oil cooler
assembly (17).
10. Remove tube (19) and discard the gasket.
11. Remove coupling (23) and remove the O-ring seals .
12. Remove bonnets (20) and (22) from oil cooler core (21). Discard the gaskets for the
bonnets.
13. Remove O-ring seals (24) from oil cooler core (21)
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View from the left side of the engine with the NRS exhaust cooler removed.
14. Remove tube assembly (28) and remove bonnet (26). Discard the gasket.
15. Remove tube (27) and remove coupling (25) from bonnet (26). Remove the O-ring seals
from coupling (25).
1. Install engine oil cooler assembly (17) in the reverse order of removal.
Note: Replace all discarded gaskets and O-ring seals.
a. Apply Tooling (A) to the O-ring seals for couplings (25) and (23).
b. Apply Tooling (A) to O-ring seals (24).
c. Lubricate the bores for bypass tube (9) with the lubricant that is being seals.
d. Tighten cable straps for harness assembly (3) to 120 to 140 N (27 to 31 lb).
Thu Mar 26 07:10:51 UTC+0800 2020
4/4
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i02289189
Engine Oil Pump - Disassemble
SMCS - 1304-015
Disassembly Procedure
Table 1
Required Tools
A 1P-0510 Driver Group 1
B 1P-2320 Puller Assembly 1
Start By:
a. Remove the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump -
Remove".
NOTICE
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1. Remove bolt (5), thrust plate (6), and idler gear assembly (7) from shaft assembly (8).
2. Use Tooling (A) and a suitable press in order to remove the bearing from idler gear
assembly (7).
3. Remove shaft assembly (8) from body (4). Remove bolt (1) and washer (2).
4. Use Tooling (A) and Tooling (B) to remove drive gear (3) from body (4). Remove the key
from the pump shaft.
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5. Remove bolts (9) and separate body (10) from spacer (12) and body (4).
6. Use Tooling (A) and a suitable press in order to remove the bearings from body (10).
7. Remove gears (11). Remove spacer (12).
8. Remove the bearings from spacer (12).
9. Remove shaft assemblies (13).
10. Remove bolts (14) and retainer (15).
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11. Remove spring (16), plunger ring (17), and plunger (18).
12. Use Tooling (A) and a suitable press in order to remove the bearings from body (4).
Thu Mar 26 07:11:48 UTC+0800 2020
4/4
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i02289486
Engine Oil Pump - Assemble
SMCS - 1304-016
Assembly Procedure
Table 1
Required Tools
A 1P-0510 Driver Group 1
NOTICE
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Improper assembly of parts that are spring loaded can cause bodily
injury.
To prevent possible injury, follow the established assembly procedure
and wear protective equipment.
1. Use Tooling (A) to install the bearings in body (4) until the bearings are even with the
outside surface of body (4). Install the bearings so the junctions in the bearings are 30 ± 15
degrees from the center line of the bearing bores and toward the outlet passage in the oil
pump.
2. Install plunger (18), plunger ring (17), and spring (16).
3. Install retainer (15) and bolts (14).
4. Install shaft assemblies (13) into body (4).
5. Use Tooling (A) to install the bearings in spacer (12). Install the bearings in the center of the
bores. Make sure that the oil holes in the bearings are in alignment with the oil holes in the
spacer. Make sure that the junctions in the bearings are in alignment with the cavity in the
spacer.
6. Use Tooling (A) to install the bearings in body (10) until the bearings are 1.52 ± 0.25 mm
(0.060 ± 0.010 inch) from the inside edge of the bearing bores. Install the bearings so the
junctions in the bearings are 30 ± 15 degrees from the center line of the bearing bores, and
toward the outlet passage. The outlet passage has a cavity between the bearing bores.
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7. Install spacer (12). Install gears (11) onto shaft assemblies (13).
8. Install body (10) on spacer (12). Install bolts (9).
9. Install the key into the pump shaft. Install drive gear (3). Install washer (2) and bolt (1).
Tighten bolt (1) to a torque of 55 ± 7 N·m (40 ± 5 lb ft). Install shaft assembly (8) on body
(4).
10. Use Tooling (A) and a suitable press in order to install the bearing in idler gear assembly
(7).
11. Install idler gear assembly (7), thrust plate (6), and bolt (5).
End By:
a. Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump -
Install".
Thu Mar 26 07:12:45 UTC+0800 2020
4/4
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i04578502
Engine Oil Pump - Remove and Install
SMCS - 1304-010
Removal Procedure
Start By:
a. Remove the engine oil pan.
1. Remove suction bell assembly (1). Remove tube assemblies (3), (4), and (5).
2. Remove engine oil pump (2).
1. Install engine oil pump (2) in the reverse order of removal.
a. Apply fluid that is being sealed to the O-ring seals and bores of tube assemblies (3),
(4), and (5).
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