Caterpillar cat 336 f excavator (prefix kcs) service repair manual (kcs00001 and up)

Service Repair Manual
Models
336F, 336F L and 336F LN
Excavator

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Product: EXCAVATOR
Model: 336F EXCAVATOR KCS
Configuration: 336F L & 336F LN Excavators KCS00001-UP (MACHINE) POWERED BY C9.3 Engine
Disassembly and Assembly
C9.3 Engines for Caterpillar Built Machines
Media Number -UENR0130-06 Publication Date -01/08/2015 Date Updated -22/05/2017
i07350680
Combustion Head - Remove and Install - Clean Emissions
Module
SMCS - 108B-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A - Loctite C5A Copper Anti-Seize -
B 195-4609 Seal Pick 1
C - Isopropyl Alcohol -
D 5P-4996 Plug 2
Fuel leaked or spilled onto hot surfaces or electrical components can
cause a fire. To help prevent possible injury, turn the start switch off
when changing fuel filters or water separator elements. Clean up fuel
spills immediately.
NOTICE
Keep all parts clean from contaminants.
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336F L & 336F LN Excavators KCS00001-UP (MACHINE) POWERED BY C9.3 En...
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Contaminants may cause rapid wear and shortened component life.
Hot engine components can cause injury from burns. Before performing
maintenance on the engine, allow the engine and the components to cool.
1. Turn the fuel supply to the OFF position and turn the power disconnect switch to the OFF.
Illustration 1 g03346521
2. Disconnect clamp assembly (1).
3. Remove three bolts (3).
4. Remove bolt (4). Remove tube assembly (2) and the gasket.
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Note: Cap all tube assemblies and fittings that are disconnected to prevent fluid loss. This
action will also keep contaminants out of the systems.
5. Disconnect tube assemblies (5), (6), and (7). Plug tube assemblies (7) with Tooling (D).
Remove bolt (8).
6. Disconnect ignition wire assembly (9) and cable assembly (11).
7. Remove allen bolt (10), the clamp assembly, and position wire assembly (12) out of the
way.
8. Disconnect flame detection temperature sensor (13).
9. Remove nuts (18) and remove combustion head (17).
10. Remove gasket (16), tube assembly (15), and gasket (14).
Note: The gaskets are for one time use only. Replace with new gaskets upon installation.
11. If required, remove studs (19).
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12. Remove fittings (20) and (22).
13. Remove spark plug (21).
14. Use Tooling (B) to remove O-ring seals (23) and (24) from cable assembly (12). Discard the
O-ring seals.
Installation Procedure
1. Install combustion head (17) in the reverse order of removal.
a. Apply Tooling (A) onto the threads of studs (19). Install the studs. Tighten studs (19)
to a torque of 17 ± 2 N·m (150 ± 18 lb in).
b. Apply Tooling (A) onto the threads of the studs and nuts (18). Tighten nuts (18) in a
crisscross pattern to a torque of 23 ± 3 N·m (204 ± 27 lb in). Tighten nuts (18) again
in a crisscross pattern to a torque of 28 ± 3 N·m (248 ± 27 lb in). Tighten nuts (18)
again in a crisscross pattern to a torque of 28 ± 3 N·m (248 ± 27 lb in).
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Use caution when you are using isopropyl alcohol. Avoid prolonged skin
contact with isopropyl alcohol.
Vapors may be harmful if inhaled. Use only in a well ventilated area. Do
not smoke while using isopropyl alcohol.
Isopropyl alcohol is flammable. Do not use near an open flame or near
welding operations. Keep isopropyl alcohol away from heated surfaces
exceeding 482°C (900°F).
Note: This connection is an electrical connection and cannot be lubricated with a
petroleum-based lubricant. Isopropyl alcohol is the only approved lubrication for this
connection.
c. Lubricate new O-ring seals (23) and (24) with Tooling (C) prior to installation.
d. Tighten fitting (22) to a torque of 60 ± 6 N·m (44 ± 4 lb ft).
e. Tighten fittings (20) to a torque of 30 ± 2 N·m (266 ± 18 lb in).
f. Tighten spark plug (21) to a torque of 57.5 ± 4 N·m (42 ± 3 lb ft).
g. Apply Tooling (A) to the threads of flame detection temperature sensor (13) and
install the sensor. Tighten flame detection temperature sensor (13) to a torque of
45 ± 5 N·m (33 ± 3 lb ft).
h. Tighten tube assemblies (5) and (6) to a torque of 16 ± 2 N·m (142 ± 18 lb in).
i. Tighten tube assembly (7) to a torque of 11 ± 2 N·m (97 ± 18 lb in).
j. Check the coolant level. If necessary, refer to Operation and Maintenance Manual,
"Coolant - Change" for the proper filling procedures.
2. Perform the ARD ignition test. Refer to Troubleshooting Manual, "ARD Ignition - Test".
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
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Sun Jul 5 08:38:18 UTC+0800 2020
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i05281840
Relay (ARD Nozzle Heater) - Remove and Install
SMCS - 4493-HTR
Removal Procedure
1. Remove tube assembly (1) and disconnect connector plugs (2). Remove bolts (3) and
relocate plate (4) with the harness assembly attached.
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2. Remove bolts (5) and remove relay (6).
1. Install relay (6) in the reverse order of removal.
Sun Jul 5 08:39:14 UTC+0800 2020
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i05254532
Solenoid Valve (ARD Fuel) - Remove and Install
SMCS - 5479-010
Removal Procedure
The fuel manifold is located on the Clean Emissions Module. Pilot valve is valve assembly (1) and main
valve is valve assembly (2).
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Note: Cleanliness is an important factor. Before the disassembly procedure, clean the
exterior of the component thoroughly. This action will help to prevent dirt from entering the
internal mechanism.
1. Remove nut (6), washer (5), and solenoid (4) from valve assembly (1).
2. Remove cartridge assembly (3) and remove O-ring seals (2).
1. Install the solenoid valve (1) and solenoid valve (2) in the reverse order of removal.
a. Tighten cartridge assembly (3) to a torque of 50 ± 5 N·m (37 ± 4 lb ft).
b. Tighten nut (6) to a torque of 20 ± 2.5 N·m (177 ± 22 lb in).
Sun Jul 5 08:40:09 UTC+0800 2020
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i06723299
Exhaust Manifold - Remove and Install
SMCS - 1059-010
Removal Procedure
Table 1
Required Tools
A 2P-2333 High Temperature Sealer 1
B - Loctite C5A Copper Anti-Seize 1
Start By:
a. Remove the turbocharger.
b. Remove the exhaust cooler.
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1. Remove locknuts (1) and remove the spacers. Discard all locknuts (1).
2. Remove manifold assembly (2).
Note: Note the orientation of the exhaust manifold sections for use in installation procedure.
3. Remove studs (7).
4. Separate manifold sections (3), (4), and (5). Remove and discard gaskets (6).
1. Install manifold assembly (2) in the reverse order of removal.
a. Apply a thin coat of Tooling (A) to the outside of the male ends of manifold sections
(5) and (3). Assemble manifold sections (3), (4), and (5), as shown.
b. Apply Tooling (B) on the threads of studs (7) . Install and tighten studs (7) to a torque
of 35 ± 5 N·m (26 ± 4 lb ft).
c. Install new gaskets (6) with the tabs facing down.
d. Apply Tooling (B) on the threads of new locknuts (1). Install the locknuts.
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Torque Sequence
e. Use the above sequence to tighten locknuts (1) (represented by Callout (X)) to a
torque of 55 ± 5 N·m (41 ± 4 lb ft).
Sun Jul 5 08:41:05 UTC+0800 2020
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i06758959
Exhaust Elbow - Remove and Install
SMCS - 1061-010-E4
Removal Procedure
1. If reusing the exhaust elbow, and or the bellows, refer to Special Instruction, REHS5014,
"Reuse Guideline for the Lines Group - Flex pipe on Tier 4 Engines".
2. Loosen clamp assemblies (1), (3) and (5).
Note: Mark the orientation of clamp assembly (3) prior to removal.
Note: Discard clamp assemblies (1) and (5). The clamp assemblies are a one time use part.
3. Slide elbow (2) into bellows (4) to gain clearance. Remove the bellows assembly.
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1. If reusing the exhaust elbow, and or the bellows, refer to Special Instruction, REHS5014,
"Reuse Guideline for the Lines Group - Flex pipe on Tier 4 Engines".
Alignment wrap (A) is not shown for photographic purposes.
Note: Alignment wrap (A) will be included with the new bellows assembly. The Tooling
will be pre-installed on the bellows.
Note: The alignment wrap (A) should not be removed until Step 11. Bellows (4) should
never be flexed during installation.
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2. Distance (X) is 40 mm (1.6 inch). Place Mark (B) onto elbow (2). a Distance (X) from the
end of elbow (2).
3. Insert elbow (2) into the bellows. The elbow should be inserted as far as possible without
using force. This action will minimize the overall length of the bellows assembly and will
help with installation.
Alignment wrap (A) is not shown for photographic purposes.
The photo is a cutaway view of the ball clamp assembly.
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The photo is a cutaway view of the ball clamp assembly.
4. Prior to installation, position both ball clamp assemblies (1) and (5) onto the bellows
assembly.
5. Position the bellows assembly between the Clean Emissions Module and the turbocharger
adapter. Adjust the length of elbow (2) in the slip joint at clamp assembly (3) to position the
bellows assembly.
6. Verify that the cup of the ball joint (E) does not touch the radius of the ball (D). Position
ball clamp (1) and hand tighten ball clamp (1). Measure Distance (Y) and Distance (Z). The
two measurements should be equal. Repeat the measurements every 90° around ball clamp
(1). If necessary, adjust ball clamp (1).
7. Repeat Step 6 for ball clamp (5) which is located near the turbocharger.
8. Verify that Mark (B) is not visible at the slip joint that is positioned near clamp assembly
(3).
Note: Do not use power tools to torque clamp assemblies (1), (3), and (5).
9. Torque ball clamp (1) to a torque of 35 ± 2 N·m (26 ± 1 lb ft).
10. Torque ball clamp (5) to a torque of 35 ± 2 N·m (26 ± 1 lb ft).
11. Remove alignment wrap (A) from bellows (4).
12. Torque clamp assembly (3) to a torque of 55 ± 8 N·m (41 ± 6 lb ft).
Sun Jul 5 08:42:01 UTC+0800 2020
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i05420438
Catalyst (SCR) - Remove and Install
SMCS - 1091-010
Removal Procedure
1. Remove clamp assembly (1) and temperature sensor (3) from catalyst (SCR) (2).
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2. Attach a suitable lifting device to catalyst (SCR) (2). The weight of catalyst (SCR) (2) is
approximately 56 kg (124 lb).
3. Disconnect clamp assemblies (4).
4. Use the suitable lifting device to remove catalyst (SCR) (2).
Note: When installing a new catalyst or a cleaned catalyst, a SCR reset must be performed. Refer
to Special Instruction, REHS8180, "Aftertreatment Filter Maintenance on Tier 4 Final Products
Equipped with a Diesel Particulate Filter (DPF), Diesel Oxidation Catalyst (DOC), and a Selective
Catalyst Reduction (SCR) Filter" for the correct procedure.
1. Install catalyst (SCR) (2) in the reverse order of removal.
a. Tighten clamp assembly (1) to a torque of 35 ± 2 N·m (26 ± 1 lb ft).
b. Tighten temperature sensor (3) to a torque of 45 ± 5 N·m (33 ± 4 lb ft)
c. Tighten clamp assemblies (4) to a torque of 12 ± 1 N·m (106 ± 9 lb in).
Sun Jul 5 08:42:57 UTC+0800 2020
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i05420439
Diesel Particulate Filter - Remove and Install
SMCS - 108F-010
Removal Procedure
Table 1
Required Tools
A - Loctite Nickel Anti-Seize Lubricant -
Start By:
a. Remove the inlet module (catalyst).
1. Connect the engine to Caterpillar Electronic Technician (Cat ET) before the DPF is
removed from the engine. Once the engine is connected to Cat ET, then perform an ash
service test. This test is a manual regeneration. Allow the DPF to cool before proceeding.
Wear goggles, gloves, protective clothing, and a National Institute for
Occupational Safety and Health (NIOSH) approved P95 or N95 half-
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face respirator when handling a used Diesel Particulate Filter or
Catalytic Converter Muffler. Failure to do so could result in personal
injury.
2. Put Identification Mark (X) on both sides of clamp (1) for installation purposes.
3. Put Identification Mark (W) on the diesel particulate filter for installation purposes.
Identification Mark (W) is showing the flow of exhaust gases through the diesel particulate
filter.
4. Loosen clamp (1) and disconnect strap (2) from diesel particulate filter (3).
5. Use two people to remove diesel particulate filter (3). The weight of diesel particulate filter
(3) is approximately 27 kg (60 lb).
6. Discard clamp (1).
Note: When installing a new diesel particulate filter or a cleaned diesel particulate filter, an Ash
Model reset must be performed. Refer to Special Instruction, REHS8180, "Aftertreatment Filter
Maintenance on Tier 4 Final Products Equipped with a Diesel Particulate Filter (DPF), Diesel
Oxidation Catalyst (DOC), and a Selective Catalyst Reduction (SCR) Filter" for the correct
procedure.
1. Install diesel particulate filter (3) in the reverse order of removal.
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Facing the Inlet Module Assembly.
a. Install clamp (1) to Dimension (Y). Dimension (Y) is 30° ± 5°. Tighten clamps (1) to
a torque of 60 ± 5 N·m (44 ± 4 lb ft).
Typical Example
Note: Do not use power tools in order to torque strap (2).
b. Apply Tooling (A) to the threads of strap (2) along Distance (Z). Distance (Z) is
25 mm (1.0 inch) above the trunnion. Tighten strap (2) to a torque of 15 + 3 - 0 N·m
(133 + 27 - 0 lb in).
Sun Jul 5 08:43:52 UTC+0800 2020
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i05420441
Inlet Module (Catalyst) - Remove and Install
SMCS - 108F-010; 1091-010
Removal Procedure
Table 1
Required Tools
A - Loctite Nickel Anti-Seize Lubricant -
Wear goggles, gloves, protective clothing, and a National Institute for
Occupational Safety and Health (NIOSH) approved P95 or N95 half-
face respirator when handling a used Diesel Particulate Filter or
Catalytic Converter Muffler. Failure to do so could result in personal
injury.
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1. Remove temperature sensor (3). Disconnect tube assembly (4). Loosen clamp (1) and
disconnect strap (2).
2. Disconnect band clamp (6) and remove inlet module (catalyst) (5).
Note: When installing a new inlet module (catalyst) or a cleaned inlet module (catalyst), a DOC
reset must be performed. Refer to Special Instruction, REHS8180, "Aftertreatment Filter
Maintenance on Tier 4 Final Products Equipped with a Diesel Particulate Filter (DPF), Diesel
Oxidation Catalyst (DOC), and a Selective Catalyst Reduction (SCR) Filter" for the correct
procedure.
1. Install inlet module (catalyst) (5) in the reverse order of removal.
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Facing the Inlet Module Assembly.
a. Install clamp (1) to Dimension (Y). Dimension (Y) is 30° ± 5°. Tighten clamp (1) to a
torque of 60 ± 5 N·m (44 ± 4 lb ft).
Typical Example
Note: Do not use power tools in order to torque strap (2).
b. Apply Tooling (A) to the threads of strap (2) along Distance (Z). Distance (Z) is
25 mm (1.0 inch) above the trunnion. Tighten strap (2) to a torque of 15 + 3 - 0 N·m
(133 + 27 - 0 lb in).
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