Caterpillar Cat 436C BACKHOE LOADER (Prefix 2BR) Service Repair Manual (2BR00911 and up).pdf

Service Repair Manual
Models
436C BACKHOE LOADER

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Product: BACKHOE LOADER
Model: 436C BACKHOE LOADER 2BR
Configuration: 436C Backhoe Loader Center Pivot, Parallel Lift 2BR00911-UP (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
i01741450
Flywheel Housing - Remove and Install
SMCS - 1157-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7574 Link Bracket 2
Start By:
a. Remove the electric starting motor. Refer to Disassembly and Assembly, "Electric Starting
Motor - Remove and Install".
b. Remove the flywheel. Refer to Disassembly and Assembly, "Flywheel - Remove".
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
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436C Backhoe Loader Center Pivot, Parallel Lift 2BR00911-UP (MACHINE) POWE...
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before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Dealer Service
Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
1. Support the engine with blocks or with a suitable lifting device on a flat level surface.
Illustration 1 g00541891
Typical example
2. Remove mounting bolts (1) from the top of flywheel housing (2).
Typical example
3. Attach Tooling (A) and a suitable lifting device to flywheel housing (2).
4. Remove mounting bolts (3) that attach the flywheel housing to the cylinder block.
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5. Remove flywheel housing (2). If necessary, hit flywheel housing (2) with a soft faced
hammer in order to separate flywheel housing (2) from the cylinder block. The weight of
flywheel housing (2) is approximately 32 kg (70 lb).
Installation Procedure
Table 2
Required Tools
A 138-7574 Link Bracket 2
NOTICE
1. Clean the rear face of the cylinder block and the mating surface of the flywheel housing.
Inspect the felt seal on the rear flange of the engine oil pan. Replace the felt seal, if
necessary. Inspect the dowels in the cylinder block that align the flywheel housing. Replace
the dowels, if necessary.
2. Use Tooling (A) and a suitable lifting device to position flywheel housing (2) on the dowels
that are on the cylinder block. The weight of flywheel housing (2) is approximately 32 kg
(70 lb).
3. Install mounting bolts (3).
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Typical example
4. Install mounting bolts (1) that attach flywheel housing (2) to the cylinder block.
Tighten the bolts for an aluminum flywheel housing to a torque of 70 N·m (52 lb ft).
Tighten the cast iron flywheel housing bolts to the following torque:
M10 "8.8" ... 44 N·m (33 lb ft)
M10 "10.9" ... 63 N·m (46 lb ft)
M12 "8.8" ... 75 N·m (55 lb ft)
M12 "10.9" ... 115 N·m (85 lb ft)
5. Remove Tooling (A) from the flywheel housing.
End By:
a. Install the flywheel. Refer to Disassembly and Assembly, "Flywheel - Install".
b. Install the electric starting motor. Refer to Disassembly and Assembly, "Electric Starting
Motor - Remove and Install".
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sun Nov 3 13:06:44 UTC+0800 2019
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i01461242
Crankshaft Pulley - Remove and Install
SMCS - 1205-010
Removal Procedure
Start By:
A. Remove the V-Belts. Refer to Disassembly and Assembly, "V-Belts - Remove and Install".
Typical example
1. Remove three bolts (2) that hold thrust block (3) in position.
2. Remove thrust block (3) from the end of the crankshaft. The thrust block holds the
crankshaft pulley in position on the end of the crankshaft.
3. Remove crankshaft pulley (1) from the engine.
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Note: Some engines have a water immersion seal that is placed on the front cover. The seal has a
flexible lip on the front. The plastic mandrel that is supplied with the seal must be installed in the
seal when the crankshaft pulley is removed. This will ensure that the lip maintains the correct
shape.
Typical example
1. Remove the plastic mandrel, if necessary.
2. Put crankshaft pulley (1) in position on the crankshaft.
3. Apply 9S-3263 Thread Lock Compound to the threads of three bolts (2) .
4. Put thrust block (3) in position and align the holes with the holes in the end of the
crankshaft.
Note: It may be necessary to keep the crankshaft from rotating while you torque bolts (3).
Use the appropriate tools in order to keep the crankshaft from rotating.
5. Install three bolts (2) that hold the thrust block in position. Tighten bolts (2) to a torque of
115 N·m (85 lb ft).
End By: Install the V-Belts. Refer to Disassembly and Assembly, "V-Belts - Remove and Install".
Sun Nov 3 13:07:40 UTC+0800 2019
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i01742537
Crankshaft Front Seal - Remove
SMCS - 1160-011
Removal Procedure
Table 1
Required Tools
A 1U-8145 Drill Bit 1
B 1U-7600 Slide Hammer Puller 1
Start By:
a. Remove the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley -
Remove and Install".
NOTICE
NOTICE
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containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Dealer Service
Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Typical example
1. Use Tooling (A) to drill three evenly spaced holes in crankshaft front seal (1).
2. Place Tooling (B) in the holes in order to remove crankshaft front seal (1). Use Tooling (B)
in each of the three holes to evenly remove the crankshaft front seal.
Note: Do not damage the flange of the crankshaft during the removal process for the
crankshaft front seal.
NOTICE
Ensure that the main lip is used in order to remove the crankshaft
front seal. Do not damage the edge of the housing for the crankshaft
front seal.
Sun Nov 3 13:08:36 UTC+0800 2019
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i01742545
Crankshaft Front Seal - Install
SMCS - 1160-012
Table 1
Required Tools
A 9U-6210 Front Seal Installer 1
NOTICE
1. Clean the housing for the crankshaft front seal and inspect the housing for damage.
2. Lubricate the lip of the crankshaft front seal with clean engine oil.
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3. Place crankshaft front oil seal (1) into the housing.
NOTICE
Ensure that the lip of the crankshaft front seal that is spring loaded is
facing toward the inside of the front housing and that it is square with
the bore of the housing for the crankshaft front seal.
4. Use Tooling (A) to install crankshaft front oil seal (1).
5. Apply clean engine oil on the area of the crankshaft pulley that will be in contact with
crankshaft front seal (1).
End By:
a. Install the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley -
Sun Nov 3 13:09:32 UTC+0800 2019
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i02108315
Front Cover - Remove
SMCS - 1166-011
Removal Procedure
Start By:
A. Remove the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley -
B. Remove the water pump. Refer to Disassembly and Assembly, "Water Pump - Remove".
C. Remove the alternator. Refer to Disassembly and Assembly, "Alternator - Remove and
Install".
1. Remove bolts (1) and nuts (3) from the front cover.
2. Remove front cover (2) and the gasket from the cylinder block.
Sun Nov 3 13:10:27 UTC+0800 2019
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i01694904
Front Cover - Install
SMCS - 1166-012
Table 1
Required Tools
A 9U-6210 Front Seal Installer 1
B 4C-5501 Front Cover Installer 1
NOTICE
1. Clean all surfaces of the front housing and clean the front cover thoroughly.
2. If necessary, use Tool (A) to install the crankshaft front oil seal. Refer to Disassembly and
Assembly, "Crankshaft Front Seal - Install".
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3. Install a new gasket and front cover (2) .
4. Install two bolts (1) in order to hold the gasket and the cover in place.
5. Use Tool (B) and the bolts for the crankshaft pulley in order to center the front cover.
NOTICE
The location of the front cover is critical. If the front cover is not
centered, the backlash between the fuel injection pump gear and the
water pump gear could be affected. This could result in damage to the
fuel injection pump.
6. Install the remaining bolts (1) and the two nuts (3). Tighten the nuts and the bolts to a torque
of 22 N·m (16 lb ft).
End By:
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a. Install the alternator. Refer to Disassembly and Assembly, "Alternator - Remove and
Install".
b. Install the water pump. Refer to Disassembly and Assembly, "Water Pump - Install".
c. Install the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley -
Sun Nov 3 13:11:23 UTC+0800 2019
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i02253357
Gear Group (Front) - Remove
SMCS - 1206-011
Removal Procedure
Table 1
Required Tools
A 8S-2264 Puller Group 1
B 173-9774 Wrench Bit 1
Start By:
A. Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove".
NOTICE
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Note: It may be necessary to pin the fuel pump in order to maintain the correct timing.
Refer to Disassembly and Assembly, "Fuel Injection Pump - Remove"for the correct
procedure.
1. Align the timing marks on the crankshaft gear, the camshaft gear, and the idler gear, as
shown.
2. Remove bolts (1) from idler gear (2) .
3. Remove idler gear (2) and retainer plate (3) .
4. Remove bushing (4) from idler gear (2) , if necessary.
5. Remove the bushing with a suitable puller. If the bushing cannot be removed with a puller,
grind the face off of one bushing. The remainder of the bushing can then be removed with a
press.
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6. Remove idler gear hub (5) from the cylinder block.
7. Remove nut (6) and the spring washer from fuel injection pump gear (8) .
8. Remove bolts (7) from fuel injection pump gear (8) .
Note: Some fuel injection pump gears may have a tamper proof torx screw in place of one
of the four bolts. Use Tooling (B) to remove the tamper proof torx screw, if necessary.
9. Use Tooling (A) to remove fuel injection pump gear (8) .
Sun Nov 3 13:12:19 UTC+0800 2019
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i01744102
Gear Group (Front) - Install
SMCS - 1206-012
NOTICE
1. Install fuel injection pump gear (8) on the engine.
2. Install bolts (7) on fuel injection pump gear (8).
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3. Install nut (6) and the spring washer on fuel injection pump gear (8). Tighten the nut to a
torque of 80 N·m (59 lb ft).
4. Install idler gear hub (5) on the engine.
5. Use a suitable press to install new bushings (4) into idler gear (2).
6. Machine the bores for clearance on idler gear hub (5). The bore should have a clearance of
0.04 to 0.010 mm (0.0016 to 0.0039 inch) on idler gear hub (5). The bore can have a
diameter of 57.14 to 57.18 mm (2.250 to 2.251 inch).
7. Machine the front faces of the bushings for the end play of idler gear (2). The gear and the
bushings can have a thickness of 30.14 to 30.16 mm (1.186 to 1.187 inch).
8. Install idler gear (2) and retainer plate (3) on the engine.
Note: Ensure that the timing marks on the camshaft gear, the crankshaft gear, and the idler
gear are aligned.
9. Install bolts (1) on idler gear (2). Tighten the bolts to a torque of 44 N·m (32 lb ft).
10. Check the end play of idler gear (2). Idler gear (2) should have end play of 0.10 to 0.20 mm
(0.004 to 0.008 inch).
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11. Check the backlash between the camshaft gear and idler gear (2). The gears must have a
minimum backlash of 0.08 mm (0.003 inch).
End By:
a. Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Install".
Sun Nov 3 13:13:15 UTC+0800 2019
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i01744128
Housing (Front) - Remove
SMCS - 1151-011
Removal Procedure
Start By:
a. Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove
and Install".
b. Remove the front gear group. Refer to Disassembly and Assembly, "Gear Group (Front) -
Remove".
c. Remove the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Remove
and Install".
NOTICE
NOTICE
containing fluids.
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Caterpillar Cat 436C BACKHOE LOADER (Prefix 2BR) Service Repair Manual (2BR00911 and up).pdf

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