Caterpillar Cat 215C EXCAVATOR (Prefix 4HG) Service Repair Manual Instant Download.pdf

Service Repair Manual
Models
215C EXCAVATOR

Shutdown SIS
Previous Screen
Product: EXCAVATOR
Model: 215C EXCAVATOR 4HG
Configuration: 215C & 219 EXCAVATOR 4HG00001-UP (MACHINE) POWERED BY 3304 ENGINE
Disassembly and Assembly
3304B and 3306B Engines for Caterpillar Built Machines
Media Number -SENR5598-09 Publication Date -01/01/2013 Date Updated -25/01/2013
i01111261
Governor - Assemble
SMCS - 1264-016
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-1855 Retaining Ring Pliers 1
B 6V-2163 Spring Clamp 1
C 1P-0510 Driver Group 1
D 6V-2054 Shield Driver 1
Note: Put clean engine oil on all parts before assembly. Ensure that all of the oil passages are
clear.
Note: Check the condition of the gaskets and the O-ring seals. If the gaskets, the seals, or any
parts are worn or damaged, use new parts for replacement.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1/17
215C & 219 EXCAVATOR 4HG00001-UP (MACHINE) POWERED BY 3304 ENGI...
2020/12/19
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Illustration 1 g00453799
1. Install one race (1), bearing (2) and the other race (1) on the camshaft in the fuel injection
pump housing.
2. Put flyweights (4) in position on carrier (3) and install the dowels in order to hold the
flyweights in place. The flyweights must move freely on the dowels.
2/17
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3. Install dowel (5) in governor shaft (6) and install the governor shaft in the carrier (3) .
4. Put carrier (3) in position and install bolts (7) .
5. Install race (9), bearing (10) and race (9). Use Tool (A) in order to install ring (8) on riser
(11) .
3/17
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6. Install riser (11) .
7. Assemble the dashpot, as follows:
a. Install spring (13) on seat (12) and install seat (14) in spring (13) .
b. Put spool (15) and ring (16) in position on seat (14) and use Tool (A) in order to
install snap ring (17) .
4/17
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8. Install dashpot assembly (19). Install ring (18) in the lower groove in the governor shaft.
9. Install sleeve (20), spring (22), sleeve (20) and bearing (21) .
Note: Spring (22) is used in order to put a preload on the thrust bearing on the camshaft in
the fuel injection pump housing.
5/17
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10. Use Tool (B) in order to hold spring (22) compressed and install ring (23) in the groove in
the governor shaft. Remove Tool (B) .
11. Put lever (33) in position on the governor servo and install pin (32) in order to hold the lever
in place. Use a hammer and a chisel in order to move the metal (stake) at four places that are
spread apart 90 degrees. Perform this procedure on the outside surface on both legs of the
governor servo. This helps to hold pin (32) in place.
12. Install the O-ring seal on sleeve (25). Install piston (26) and sleeve (25) .
13. Install valve (24) .
14. Install one lockring (27) in the groove near the center of valve (24). Put sleeve (28), link
spring (29) and seat (30) in position on valve (24) and install second lockring (31) .
15. Put the governor servo in position on the fuel injection pump housing with piston (34) that
is engaged over rack control sleeve (35) and install the bolts that hold the rack control
sleeve in place.
6/17
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3304B engine
Note: The 3304B engine has one stop screw (36) and one locknut (38).
3306B
16. If the stop screws were removed, install two stop screws (36) in collar (37), as shown.
Install locknuts (38) .
7/17
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17. Install bolt (41) in block (42), as shown. Install spring (40) on bolt (41), as shown. Put collar
(37) in position on bolt (41) with the hole in the collar in alignment with the notch in bolt
(41) and install bolt (39) in order to hold the collar in place.
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18. Put block (42) in position on housing (43). Align the holes in block (42) with the dowels.
Tighten two bolts (44) .
3304B torque control
19. Assemble the torque control on the 3304B engine. Install retainer (51), two bars (49), spacer
(50), contact (46), and insulator (45) in position on bolts (52) .
9/17
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20. Assemble the torque control on the 3306B, as follows:
a. Install spring (48), spacer (47), contact (46) and spacer (50) on insulator (45), as
shown.
b. Install retainer (51) and bar (49) on bolts (52) .
10/17
215C & 219 EXCAVATOR 4HG00001-UP (MACHINE) POWERED BY 3304 EN...
2020/12/19

21. Put torque control (53) in position on block (40). Install bolts (54) .
Note: When housing (43) is installed on the fuel injection pump housing, the flange on bolt
(38) must be behind the dashpot. If housing (43) is installed with the flange on bolt (38) on
the wrong side of the dashpot, the riser in the governor will be held in the maximum fuel
delivery position.
22. Install gasket (56) on the fuel injection pump housing. Put housing (43) in position on the
fuel injection pump housing with bolt (38) behind the dashpot, as shown. Install bolts (55)
that hold housing (43) in place.
11/17
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23. Use Tool (C) in order to install lip type seal (57) in the outer governor housing with the lip
inward.
24. Install adjustment screw (58) and the locknut for the high idle adjustment.
25. Install check valve (59) .
12/17
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26. Put lever (60) in position, as shown. Install shaft (61) .
27. Put the gasket and shutoff solenoid (62) in position and install two bolts (63) .
28. Put the gasket and cover (64) in position and install two bolts (65) .
29. Install body (66) and contact (67) .
30. Put the O-ring seal on adapter (68) and put the coupling and adapter (68) in position. Install
two bolts (69) .
31. Install spring (70) in shaft assembly (71). Install pin (72) in shaft assembly (71). The tip of
pin (72) should be engaged in the hole in spring (70). Install pin (73) in shaft assembly (71)
in order to hold pin (72) in place.
13/17
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32. Put stop (76) and plates (74) in position on shaft assembly (71) and install pins (75). Install
snap rings (77) .
33. Put levers (79) and (78) in position in the housing, as shown. Install shaft assembly (71) .
14/17
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34. Install low idle adjustment screw (81) and the locknut. Install spring (80) in the hole in the
shaft assembly and in the housing.
35. Use Tool (C) in order to install lip type seal (82) in cover (83) with the lip, as shown. Install
the seal so that the seal is 2.0 ± 1.5 mm (.08 ± .06 inch) below the surface of the cover.
36. Put the gasket and cover (83) in position on the housing and install six bolts (84) .
15/17
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Note: Ensure that seat (85) and spring (86) are on top of lever (79). These parts must be
kept in this position when housing (87) is put in position on the inner governor housing.
37. Install seat (85) and spring (86) on the guide in the housing.
38. Put the gasket and housing (88) in position on the inner governor housing and install six
bolts (87) and two bolts (89) .
16/17
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39. Install fuel ratio control (90) onto governor (91) .
40. Make the governor adjustments. Refer to the Testing and Adjusting, "Fuel System" topic for
more information on governor adjustments.
End By: Install the fuel injection pump housing and the governor. Refer to the Disassembly and
Assembly, "Fuel Injection Pump Housing and Governor - Install".
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Sat Dec 19 15:29:47 UTC+0800 2020
17/17
2020/12/19

Shutdown SIS
Previous Screen
Product: EXCAVATOR
i00893695
Fuel Injection Pump - Remove
SMCS - 1251-011
Removal Procedure
Table 1
Required Tools
A 8T-5287 Wrench 1
B 6V-4186 Fuel Pump Timing Pin 1
C 8S-2244 Pump Extractor 1
NOTICE
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the machine. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
1/3
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Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop
Products Guide", for tools and supplies suitable to collect and contain
fluids in Caterpillar machines.
Dispose of all fluids according to local regulations and mandates.
1. Remove the bolts and the plate from the side of the fuel injection pump housing.
2. Install Tool (B) in the fuel injection pump housing. Move the fuel rack until Tool (B) can be
installed in order to hold the fuel rack in the center position for removing the fuel injection
pumps.
3. Use Tool (A) in order to remove bushing (1) .
4. Remove the O-ring seal from the fuel injection pump housing.
5. Install Tool (C) on the bonnet and remove the fuel injection pump.
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6. Remove spacer (2) .
Note: Keep spacers (2) and the fuel injection pump together and identify spacers (2) with
the location in the fuel injection pump housing.
7. Perform Steps 3 through 6 in order to remove the other fuel injection pumps.
Sat Dec 19 15:30:42 UTC+0800 2020
3/3
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Shutdown SIS
Previous Screen
Product: EXCAVATOR
i00894023
Fuel Injection Pump - Disassemble
SMCS - 1251-015
Disassembly Procedure
Start By:
A. Remove the fuel injection pumps. Refer to Disassembly and Assembly, "Fuel Injection
Pump - Remove".
NOTICE
NOTICE
When the fuel injection pumps are disassembled, handle the parts
carefully. Do not damage the surfaces of the plungers, the barrels and
the bonnets. Any scratches will cause leakage inside the fuel injection
pump. The plunger and the barrel for each pump are made as a set. Do
not intermix the plunger of one pump in the barrel of another pump. If
one part is worn, install a completely new plunger and barrel assembly.
Be careful when placing the plunger into the bore of the barrel.
1/2
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1. Pull plunger (1) and washer (5) out of barrel (3) and spring (2) .
Note: Do not remove the gear from the plunger. The gear and the plunger are assembled
and adjusted at the factory.
2. Remove washer (5) and spring (2) .
3. Remove ring (6). Separate barrel (3) from bonnet (4) .
4. Remove check valve assembly (7) and spring (8). If check valve assembly (7) is
disassembled, do not mix parts with parts from another check valve assembly.
Sat Dec 19 15:31:38 UTC+0800 2020
2/2
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Shutdown SIS
Previous Screen
Product: EXCAVATOR
i00894164
Fuel Injection Pump - Assemble
SMCS - 1251-016
Assembly Procedure
NOTICE
Note: Put clean engine oil on all parts before assembly.
1. Install spring (8) and check valve assembly (7) in bonnet (4) .
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2. Install bonnet (4) on barrel (3) and install ring (6).
Note: Do not slide bonnet (4) across barrel (3). Check valve assembly (7) in the bonnet may
cause damage to the face of barrel (3) .
3. Install spring (2). Install washer (5) on plunger (1). Ensure that the flat side is facing toward
the gear on plunger (1) .
4. Install plunger (1) in barrel (3) until washer (5) is engaged in the spring.
End By: Install the fuel injection pumps. Refer to Disassembly and Assembly, "Fuel Injection
Pump - Install".
Sat Dec 19 15:32:34 UTC+0800 2020
2/2
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Shutdown SIS
Previous Screen
Product: EXCAVATOR
i00894497
Fuel Injection Pump - Install
SMCS - 1251-012
Installation Procedure
Table 1
Required Tools
A 8S-2244 Pump Extractor 1
B 6V-4186 Fuel Pump Timing Pin 1
C 8T-5287 Wrench 1
D
6V-9128 Rack Position Tool Group
1
3S-3270 Indicator Contact Point 1
C-clamp 1
NOTICE
1/4
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1. Install spacer (1) in the fuel injection pump housing.
2. Install Tool (B) in the fuel injection pump housing. Move the rack until Tool (B) can be
installed in order to hold the rack in the center position. The rack must be in the center
position in order to install the fuel injection pumps.
2/4
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3. Turn the camshaft until the lobe of the camshaft is downward so that the fuel injection pump
can be installed.
4. Install Tool (A) on the bonnet of the fuel injection pump.
5. Install the fuel injection pump in the fuel injection pump housing. Ensure that slot (3) that is
cut in the gear is aligned with the small pin (2) and groove (4) in the barrel. The small pin
(2) and groove (4) in the barrel are aligned with dowel (5) in the fuel injection pump
housing.
6. Put clean engine oil on O-ring seal (6) and install the O-ring seal in the fuel injection pump
housing.
7. Install bushing (7) by hand until the bushing is even with the top of the fuel injection pump
housing. If bushing (7) cannot be installed by hand, remove bushing (7). Remove the fuel
injection pump. Put the pump in alignment and reinstall bushing (7) .
8. Install Tool (C) on bushing (7) and tighten the bushing to a torque of 163 ± 14 N·m (120 ±
10 lb ft).
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9. Install Tool (D) in order to measure the total travel of the rack. The correct travel for the
rack is 15.70 mm (.618 inch). A smaller measurement is an indication of improper fuel
injection pump installation.
10. Repeat Steps 1 through 9 in order to install the remaining fuel injection pumps.
11. Install the cover and the gasket on the fuel injection pump housing.
Sat Dec 19 15:33:30 UTC+0800 2020
4/4
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Shutdown SIS
Previous Screen
Product: EXCAVATOR
i01117604
Turbocharger - Remove
SMCS - 1052-011
Removal Procedure
NOTICE
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.
1/2
2020/12/19

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1. Remove bolt (2) and the clamp that holds the oil supply tube and the oil drain tube in
position.
2. Remove two bolts (1) that hold the oil supply tube to the turbocharger. Remove two bolts
(3) that hold the oil drain tube to the turbocharger.
3. On the 3304B, loosen the two hose clamps and remove the hose from the turbocharger.
Slide the hose onto the pipe that goes to the cylinder head.
4. Loosen nut (4) and remove the oil supply tube from the engine.
5. Loosen four bolts (6) and the nuts that hold turbocharger (5) to the exhaust manifold.
Remove turbocharger (5) and the gasket from the exhaust manifold. Remove oil drain tube
(7) from the engine and check the O-ring seal for damage. If the O-ring seal is worn or
damaged, use a new part for replacement.
Sat Dec 19 15:34:25 UTC+0800 2020
2/2
2020/12/19

Shutdown SIS
Previous Screen
Product: EXCAVATOR
i01009195
Turbocharger - Disassemble
SMCS - 1052-015
Disassembly Procedure
Table 1
Required Tools
A 9S-6363 Turbocharger Fixture Group 1
Start By:
A. Remove the turbocharger. Refer to Disassembly and Assembly, "Turbocharger - Remove".
NOTICE
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