Caterpillar Cat 330C FM EXCAVATOR (Prefix B1K) Service Repair Manual (B1K00001 and up).pdf

Service Repair Manual
Models
330C FM EXCAVATOR

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Product: EXCAVATOR
Model: 330C FM EXCAVATOR B1K
Configuration: 330C Forest Swing Machines B1K00001-UP (MACHINE) POWERED BY C-9 Engine
Disassembly and Assembly
C9
Engine For Caterpillar Built Machines
Media Number -SENR9502-16 Publication Date -01/03/2014 Date Updated -06/03/2014
i04506590
Rocker Arm and Shaft - Install
SMCS - 1102-012
Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 8T-2998 Lubricant -
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Apply Tooling (A) to both ends of the pushrods.
2. Lubricate the pushrods with clean engine oil. Install the pushrods and the valve bridges.
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Illustration 1 g00953116
3. Position rocker shaft (4) on the cylinder head. Install bolts (1).
Rocker shaft hold down bolts tightening sequence
4. Tighten bolts (1) in the sequence shown. Tighten bolts (1) to standard torque.
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5. Apply Tooling (A) to each of the bottom faces of the rocker arms.
6. Position rocker arm adjustment screws (2) and tighten nuts (3). Adjust the valve lash of the
rocker arms. Refer to Testing and Adjusting, "Engine Valve Lash - Inspect/Adjust".
End By:
a. Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism
Cover - Remove and Install".
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Sat Sep 12 12:36:20 UTC+0800 2020
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Product: EXCAVATOR
C9
i02273201
Cylinder Head - Remove
SMCS - 1100-011
Removal Procedure
Table 1
Required Tools
A 138-7575 Link Bracket 2
Start By:
A. Remove the rocker arm and shaft. Refer to Disassembly and Assembly, "Rocker Arm and
Shaft - Remove".
B. Remove the unit injectors. Refer to Disassembly and Assembly, "Unit Injector - Remove".
C. Remove the alternator. Refer to Disassembly and Assembly, "Alternator - Remove and
Install".
D. Remove the valve mechanism cover base. Refer to Disassembly and Assembly, "Valve
Mechanism Cover Base - Remove and Install".
NOTICE
NOTICE
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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. Drain the coolant from the cooling system into a suitable container for storage or disposal.
Refer to Operation and Maintenance Manual, "Refill Capacities and Recommendations".
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2. Remove accessory drive group (1) .
3. Disconnect tube assemblies (3) and (4) .
4. Remove tube assembly (2) .
5. Disconnect hose (5) .
6. Disconnect hose assemblies (6) and (7) .
7. Disconnect the sensors.
8. Attach Tooling (A) and a suitable lifting device to cylinder head (9). The weight of cylinder
head (9) is approximately 147 kg (325 lb).
9. Remove bolts (8). Remove cylinder head (9) and the gasket.
Sat Sep 12 12:37:16 UTC+0800 2020
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Product: EXCAVATOR
C9
i05919858
Cylinder Head - Install
SMCS - 1100-012
Table 1
Required Tools
A 138-7575 Link Bracket 2
B 4C-5593 Anti-Seize Compound 1
NOTICE
1. Position a new gasket on the engine.
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2. Attach Tooling (A) and a suitable lifting device to cylinder head (9) . The weight of cylinder head (9)
is approximately 147 kg (325 lb). Position the cylinder head onto the dowels in the engine block.
3. Apply Tooling (B) to the threads of bolts (8) . Install bolts (8) .
Tighten the plugs (not shown) for the high-pressure oil gallery on each end of the cylinder head to
the following torque 285 ± 25 N·m (210 ± 18 lb ft).
Note: Refer to Reuse and Salvage Guidelines, SEBF8301, "Inspection and Reuse of Critical
Fasteners Used in All Engines" for reuse criteria of bolts (8) .
4. Tighten bolts (8) according to the following procedure:
a. Tighten Bolt (1) through Bolt (26) in a numerical sequence to a torque of 160 ± 15 N·m (118 ±
11 lb ft).
b. Loosen Bolt (1) through Bolt (26) until the washers are loose under the bolt heads.
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c. Tighten Bolt (1) through Bolt (26) again in a numerical sequence to a torque of 160 ± 15 N·m
(118 ± 11 lb ft).
d. Place a mark on Bolt (1) through Bolt (26) .
e. Rotate Bolt (1) through Bolt (26) in a numerical sequence. Rotate the bolts in the clockwise
direction for 90 degrees (1/4 turn) from the mark on the bolts.
f. Loosen Bolt (1) through Bolt (26) until the washers are loose under the bolt heads.
g. Tighten Bolt (1) through Bolt (26) in a numerical sequence to a torque of 160 ± 15 N·m (118 ±
11 lb ft).
h. Place a mark on Bolt (1) through Bolt (26) .
i. Rotate Bolt (1) through Bolt (26) in a numerical sequence. Rotate the bolts in the clockwise
direction for 90 degrees (1/4 turn) from the mark on the bolts.
j. Tighten Bolt (27) through Bolt (31) in a numerical sequence to a torque of 28 ± 7 N·m (21 ± 5
lb ft).
Tighten the plugs (not shown) for the high-pressure oil gallery on each end of the cylinder
head to the following torque 285 ± 25 N·m (210 ± 18 lb ft).
5. Connect the sensors.
6. Connect hose assemblies (6) and (7) .
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7. Connect hose (5) .
8. Install tube assembly (2) .
9. Connect tube assemblies (3) and (4) .
10. Install accessory drive group (1) .
11. Fill the cooling system. Refer to Operation and Maintenance Manual, "Refill Capacities and
Recommendations".
End By:
a. Install the valve mechanism cover base. Refer to Disassembly and Assembly, "Valve Mechanism
Cover Base - Remove and Install".
b. Install the alternator. Refer to Disassembly and Assembly, " Alternator - Remove and Install".
c. Install the unit injectors. Refer to Disassembly and Assembly , "Unit Injector - Install".
d. Install the rocker arm and shaft. Refer to Disassembly and Assembly , "Rocker Arm and Shaft -
Install".
Sat Sep 12 12:38:12 UTC+0800 2020
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Shutdown SIS
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Product: EXCAVATOR
C9
i06809044
Lifter Group - Remove and Install
SMCS - 1209-010
Removal Procedure
Table 1
Required Tools
A FT-2730 Hook 1
Start By:
a. Remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head -
Remove".
NOTICE
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1. Use Tooling (A) to remove valve lifters (1). Place identification marks on the valve lifters
for installation purposes.
Table 2
Required Tools
A FT-2730 Hook 1
B 8T-2998 Lubricant 1
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1. Apply Tooling (B) to valve lifters (1) prior to installation. Use Tooling (A) to install valve
lifters (1) in the original location in the cylinder block.
End By:
a. Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".
Sat Sep 12 12:39:07 UTC+0800 2020
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Shutdown SIS
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Product: EXCAVATOR
C9
i02274059
Camshaft - Remove
SMCS - 1210-011
Removal Procedure
Table 1
Required Tools
A FT-2730 Hook 12
Start By:
a. Remove the rocker arm and the shaft. Refer to Disassembly and Assembly, "Rocker Arm
and Shaft - Remove".
b. Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove".
NOTICE
1. Use Tooling (A) to reposition the valve lifters out of the way of the camshaft.
2. Set the No. 1 piston to top center on the compression stroke. Refer to Testing and Adjusting,
"Finding Top Center Position for No. 1 Piston".
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3. Ensure that the timing marks on camshaft gear (1) and idler gear (2) are aligned.
4. Remove bolts (3) and thrust plate (4) from the cylinder block.
NOTICE
Do not damage the lobes or the bearings when the camshaft is removed
or installed.
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5. Remove camshaft (5) from the cylinder block.
Sat Sep 12 12:40:03 UTC+0800 2020
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Shutdown SIS
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Product: EXCAVATOR
C9
i05278252
Camshaft - Install
SMCS - 1210-012
Table 1
Required Tools
A FT-2730 Hook 12
B 8T-2998 Lubricant -
NOTICE
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NOTICE
Do not damage the lobes or the bearings when the camshaft is removed
or installed.
Note: During the installation of the camshaft, rotate the camshaft in both directions in order to
prevent binding in the camshaft bearing bores.
1. Lubricate the camshaft lobes and the valve lifter bore with a 50/50 mixture of Tooling (B). Apply
clean engine oil on the camshaft bearing journals. Carefully install camshaft (10) in the cylinder
block.
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(5) Gear for the high-pressure fuel pump
(6) Camshaft gear
(7) Idler gear
(8) Crankshaft gear
(9) Timing marks
NOTICE
When installing the camshaft, make sure the number one cylinder is at
top center of the compression stroke with the timing bolt installed in
the flywheel. The camshaft timing is very important. The timing mark
on the camshaft drive gear must line up with the timing mark on the
idler gear. Refer to the Specifications Manual for more information.
2. Correct fuel injection timing and correct valve mechanism operation is determined by properly
timing crankshaft gear (8) and camshaft gear (6) to idler gear (7). Also, high-pressure fuel pump gear
(5) must be timed to camshaft gear (6). During installation of the front gear, timing marks (9) on
idler gear (7) must be in alignment with the timing marks on crankshaft gear (8) and the timing
marks on camshaft gear (6). The "0" mark on camshaft gear (6) must align with the timing mark on
idler gear (7). The "V" mark on camshaft gear (6) must align with the "V" mark on fuel pump gear
(5).
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3. Install thrust plate (4) and bolts (3).
4. The maximum permissible end play for a worn camshaft is 0.46 mm (0.018 inch). The maximum
permissible end play for a new camshaft is 0.13 ± 0.08 mm (0.005 ± 0.003 inch).
5. Use Tooling (A) to position the valve lifters in the cylinder block.
6. Calibrate the speed/timing sensor. Refer to Troubleshooting, "Engine Speed/Timing Sensor -
Calibrate".
End By:
a. Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Install".
b. Install the rocker arm and the shaft. Refer to Disassembly and Assembly, "Rocker Arm and Shaft -
Install".
Sat Sep 12 12:40:59 UTC+0800 2020
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Product: EXCAVATOR
C9
i02408922
Camshaft Gear - Remove and Install
SMCS - 1210-010-GE
Removal Procedure
Start By:
a. Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove".
1. Wrap the camshaft with a protective covering in order to prevent damage to the camshaft.
NOTICE
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Do not allow the camshaft to fall to the floor when pressing it from the
drive gear. Also make sure that the camshaft lobes do not catch on the
press plates.
2. Use a suitable press to remove the camshaft from camshaft gear (1).
Note: The temperature of the camshaft gear must not exceed 177 °C (350 °F) during
installation.
1. Raise the temperature of the camshaft gear up to a temperature of 177 °C (350 °F).
2. Align the key in the camshaft with the groove (keyway) in the camshaft gear.
3. Install the camshaft gear on the end of the camshaft.
End By:
a. Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Install".
Sat Sep 12 12:41:55 UTC+0800 2020
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Shutdown SIS
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Product: EXCAVATOR
C9
i02545687
Camshaft Bearings - Remove
SMCS - 1211-011
Removal Procedure
Table 1
Required Tools
A 8S-2241 Camshaft Bearing Tool Group 1
Start By:
a. Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove".
b. Remove the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing-
Remove and Install".
Note: Note the oil hole orientation in each camshaft bearing prior to removal for assembly
purposes.
NOTICE
NOTICE
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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, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain fluids on
Cat®
products.
Dispose of all fluids according to local regulations and mandates.
1. Use Tooling (A) to remove the camshaft bearings from the cylinder block.
Sat Sep 12 12:42:51 UTC+0800 2020
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Caterpillar Cat 330C FM EXCAVATOR (Prefix B1K) Service Repair Manual (B1K00001 and up).pdf

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