Caterpillar Cat 330D2 L Excavator (Prefix PTE) Service Repair Manual (PTE00001 and up).pdf

Service Repair Manual
Models
330D2 L Excavator

Shutdown SIS
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Product: EXCAVATOR
Model: 330D2 L EXCAVATOR PTE
Configuration: 330D2 L Excavators PTE00001-UP (MACHINE) POWERED BY C7.1 Engine
Disassembly and Assembly
C7.1 Engines
Media Number -UENR0633-19 Publication Date -01/07/2015 Date Updated -29/10/2018
i05292421
Turbocharger - Remove - Turbocharger for Side Mounted
Engines
SMCS - 1052-011
Removal Procedure
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
before opening any compartment or disassembling any component
containing fluids.
Dispose of all fluids according to local regulations and mandates.
Note: Plug and cap all open ports and tube assemblies.
1. Disconnect the hose assemblies from the turbocharger inlet and the turbocharger outlet.
Refer to the Original Equipment Manufactures (OEM) for the correct procedure.
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2. Disconnect the exhaust tube assembly. Refer to the OEM for the correct procedure.
3. If the turbocharger has an exhaust elbow, remove the exhaust elbow. Refer to Disassembly
and Assembly, "Exhaust Elbow - Remove and Install" for the correct procedure.
Illustration 1 g03376116
4. Slide clip (9) along hose (10). Disconnect the hose from the actuator.
5. Follow Step 5.a through Step 5.d in order to remove tube assembly (4) from turbocharger
(1).
a. Remove bolt (5).
b. Remove banjo bolt (2) and remove sealing washers (3) (not shown).
c. Remove tube assembly (4) from the cylinder block.
d. Remove O-ring seal (7) (not shown).
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6. Follow Steps 6 through 6.d in order to remove tube assembly (11) from turbocharger (1).
a. Remove bolts (8).
b. Remove bolts (12).
c. Remove tube assembly (11) from turbocharger (1) and the cylinder block.
d. Remove gasket (6) (not shown) and gasket (13) (not shown).
7. Remove nuts (16) from turbocharger (1). Remove turbocharger (1) from exhaust manifold
(14).
Note: Ensure that the weight of the turbocharger is supported as the nuts are loosened.
8. If necessary, remove studs (15) from exhaust manifold (14).
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Sun Jun 21 15:41:35 UTC+0800 2020
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Shutdown SIS
Previous Screen
Product: EXCAVATOR
C7.1 Engines
i05292425
Turbocharger - Remove - Turbocharger for Top Mounted
Engines
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.
Dispose of all fluids according to local regulations and mandates.
Note: Plug and cap all open ports and tube assemblies.
1. Disconnect the hose assemblies from the turbocharger inlet and the turbocharger outlet.
Refer to the Original Equipment Manufactures (OEM) for the correct procedure.
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2. Disconnect the exhaust tube assembly. Refer to the OEM for the correct procedure.
3. If the turbocharger has an exhaust elbow, remove the exhaust elbow. Refer to Disassembly
4. Slide clip (2) along hose (3). Disconnect the hose from actuator (1).
5. Remove bolts (6) from the clip for tube assembly (5). Position the tube assembly away from
cylinder block.
6. Remove bolt (7) and spacer (8) (not shown).
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7. Remove bolt (12) and spacer (13).
8. Remove bolt (10) from tube assembly (9).
9. Remove tube assembly (9) from the cylinder block. Remove O-ring seal (11) (not shown).
10. Remove bolts (15) from tube assembly (14). Remove gasket (16) (not shown).
11. Remove exhaust manifold (4) and the assembly of the turbocharger from the cylinder head.
Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install" for the
correct procedure.
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12. Place exhaust manifold (4) and the assembly of turbocharger (19) in a suitable support.
13. Remove banjo bolt (17) and remove sealing washers (18) (not shown).
14. Remove tube assembly (9) from turbocharger (4).
15. Remove bolts (23) from tube assembly (14). Support the tube assembly as the bolts are
removed.
16. Remove gasket (21) (not shown).
17. Prior to and during removal of nuts (20) apply releasing fluid to the bolts. Remove nuts
(20).
18. Remove turbocharger (19) from exhaust manifold (4).
19. Remove spacer (22).
20. If necessary, remove studs (24) from exhaust manifold (4).
Sun Jun 21 15:42:30 UTC+0800 2020
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Shutdown SIS
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Product: EXCAVATOR
C7.1 Engines
i05292419
Turbocharger - Install - Turbocharger for Side Mounted
Engines
SMCS - 1052-012
Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 5P-3975 Rubber Lubricant 1
B 4C-5597 Anti-Seize Compound 1
NOTICE
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1. Ensure that turbocharger (1) is clean and free from damage. Inspect the turbocharger for
wear. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect" for more
information. If the turbocharger is worn, the complete turbocharger must be replaced.
2. Test the wastegate actuator (19) for correct operation. Refer to System Operation, Testing
and Adjusting, "Turbocharger Inspect". If the wastegate actuator is damaged or the
wastegate actuator does not operate within the specified limits, the turbocharger assembly
must be replaced.
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3. Clean the gasket surface of exhaust manifold (14).
4. If necessary, install studs (15) to exhaust manifold (14). Apply Tooling (B) to the threads of
studs (15). Tighten the studs to a torque of 18 N·m (159 lb in).
5. Position turbocharger (1) on exhaust manifold (14).
Note: Ensure that the turbocharger is correctly oriented.
6. Install nuts (16). Tighten the nuts to a torque of 44 N·m (32 lb ft).
7. If a new turbocharger is installed, check that the orientation of compressor housing (18) is
correct. Refer to Illustration 1. Follow Step 7.a through Step 7.c in order to orient the
compressor housing.
a. Loosen band clamp (20) sufficiently in order to allow the compressor housings to
rotate.
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Note: If the band clamp is damaged, replace the band clamp.
b. Rotate compressor housing (18) until the compressor outlet is in the correct position.
Refer to the turbocharger that was originally installed for the correct orientation.
c. Ensure that band clamps (20) are correctly oriented. Refer to the turbocharger that
was originally installed for the correct orientation. Tighten the band clamps finger
tight.
8. Ensure that tube assembly (11) and tube assembly (4) are clean, free from damage, and
restriction. Replace any damaged components.
9. Position a new gasket (6) (not shown) and bolts (8) onto tube assembly (11).
10. Install tube assembly (11) onto turbocharger (1). Tighten bolts (8) finger tight.
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11. Position a new gasket (13) between the flange of tube assembly (11) and the cylinder block.
Install bolts (12) finger tight.
12. Tighten bolts (8) and bolts (12) to a torque of 22 N·m (195 lb in).
13. If a new turbocharger has been installed, check that the orientation of compressor housing
(18) is correct. If the orientation of the compressor housing is not correct, rotate the
compressor housing until correctly positioned. Refer to Illustration 1. Tighten band clamps
(20) to a torque of 13 N·m (115 lb in).
14. Remove the plug from oil inlet port (17). Refer to Illustration 1. Lubricate the turbocharger
bearings with clean engine oil through the oil inlet port. Rotate the wheel of the compressor
several times in order to lubricate the bearings.
15. Use Tooling (A) in order to lubricate a new O-ring seal (7). Install the O-ring seal to tube
assembly (4).
16. Position a new sealing washer (3) (not shown) onto banjo bolt (2). Install the banjo bolt to
tube assembly (4).
17. Install tube assembly (4) onto turbocharger (1) and the cylinder block. Tighten banjo bolt
(1) finger tight.
18. Install bolt (5) finger tight. Ensure that tube assembly (4) is correctly positioned into the
cylinder block.
19. Tighten banjo bolt (1) to a torque of 20 N·m (177 lb in).
20. Tighten bolt (5) to a torque of 22 N·m (195 lb in).
21. Connect hose (10) to the actuator. Slide clip (9) along the hose. Ensure that the hose clip is
correctly positioned.
22. If the turbocharger has an exhaust elbow, install the exhaust elbow. Refer to Disassembly
23. Connect the exhaust tube assembly. Refer to the Original Equipment Manufactures (OEM)
for the correct procedure.
24. Connect the hose assemblies to the turbocharger inlet and the turbocharger the outlet. Refer
to the OEM for the correct procedure.
Sun Jun 21 15:43:26 UTC+0800 2020
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Shutdown SIS
Previous Screen
Product: EXCAVATOR
C7.1 Engines
i05292422
Turbocharger - Install - Turbocharger for Top Mounted
Engines
SMCS - 1052-012
Table 1
Required Tools
B 4C-5597 Anti-Seize Compound 1
NOTICE
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1. Ensure that turbocharger (19) is clean and free from damage. Inspect the turbocharger for
wear. Refer to System Operation, Testing and Adjusting, "Turbocharger Inspect" for more
information. If the turbocharger is worn, the complete turbocharger must be replaced.
2. Test the wastegate actuator (1) for correct operation. Refer to System Operation, Testing
and Adjusting, "Turbocharger Inspect". If the wastegate actuator is damaged or the
wastegate actuator does not operate within the specified limits, the turbocharger assembly
must be replaced.
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3. Place exhaust manifold (4) in a suitable support.
4. Clean the gasket surfaces of exhaust manifold (4) and spacer (22).
5. If necessary, install studs (24) to exhaust manifold (4). Apply Tooling (B) to the threads of
studs (24). Tighten the studs to a torque of 18 N·m (159 lb in).
6. Position spacer (22) onto the exhaust manifold. Ensure that the spacer is correctly
orientated.
7. Position turbocharger (19) onto exhaust manifold (4).
Note: Ensure that the turbocharger is correctly oriented.
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8. Apply Tooling (B) to the threads of nuts (20). Install the nuts. Tighten the nuts to a torque of
44 N·m (32 lb ft).
9. If a new turbocharger is installed, bearing housing (27) and compressor housing (26) must
be oriented to the correct positions. Refer to Illustration 1. Follow Step 9.a through Step 9.d
in order to orient the bearing housing and the compressor housing.
a. Loosen band clamps (28) sufficiently in order to allow the housings to rotate.
Note: If the band clamps are damaged, replace the band clamps.
b. Carefully turn bearing housing (27) until the port for oil feed (25) is upward.
c. Rotate compressor housing (26) until the compressor outlet is in the correct position.
Refer to the turbocharger that was originally installed for the correct orientation.
d. Ensure that band clamps (28) are correctly oriented. Refer to the turbocharger that
was originally installed for the correct orientation. Tighten the band clamps finger
tight.
10. Ensure that tube assembly (14) and tube assembly (9) are clean, free from damage, and
restriction. Replace any damaged components.
11. Position a gasket joint (21) (not shown) and bolts (23) onto tube assembly (14).
12. Install tube assembly (14) onto turbocharger (19). Tighten bolts (23) finger tight.
13. Remove the plug from oil inlet port (25). Refer to Illustration 1. Lubricate the turbocharger
bearings with clean engine oil through the oil inlet port. Rotate the wheel of the compressor
several times in order to lubricate the bearings.
14. Position a new sealing washer (18) (not shown) onto banjo bolt (17). Install banjo bolt (9) to
tube assembly (14).
15. Position tube assembly (14) onto turbocharger (19) and install remaining new sealing
washer (18) (not shown).
16. Tighten banjo bolt (9) finger tight.
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17. Install exhaust manifold (4) and the assembly of the turbocharger to the cylinder head. Refer
to Disassembly and Assembly, "Exhaust Manifold - Remove and Install" for the correct
procedure.
18. If a new turbocharger has been installed, check that the orientation of bearing housing (27)
is correct. If the orientation of the bearing housing is not correct, rotate the bearing housing
until tube assembly (14) and tube assembly (9) are correctly positioned. Refer to Illustration
2.
19. Use Tooling (A) in order to lubricate a new O-ring seal (11) (not shown). Install the O-ring
seal to tube assembly (9). Refer to Illustration 3.
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20. Install tube assembly (9) to the cylinder block. Ensure that the tube assembly is correctly
positioned into the cylinder block.
21. Install bolt (10) hand tight.
22. Install bolt (12) and spacer (13) hand tight.
23. Tighten banjo bolt (9) to a torque of 20 N·m (177 lb in). Refer to Illustration 2.
Tighten bolt (12) to a torque of 44 N·m (32 lb ft).
25. Position a new gasket (16) (not shown) between the flange of tube assembly (14) and the
cylinder block. Install bolts (15) finger tight.
26. Install bolt (7) and spacer (8) (not shown) hand tight.
27. Tighten bolts (23) to a torque of 22 N·m (195 lb in). Refer to Illustration 2.
Tighten bolt (7) to a torque of 44 N·m (32 lb ft).
29. If a new turbocharger has been installed, tighten band clamps (28) to a torque of 13 N·m
(115 lb in). Refer to Illustration 1.
30. Connect hose (3) to actuator (1). Slide clip (2) along the hose. Ensure that the hose clip is
correctly positioned.
31. Install bolts (6) to the clip for tube assembly (5). Tighten the bolt to a torque of 22 N·m
(195 lb in).
32. If the turbocharger has an exhaust elbow, install the exhaust elbow. Refer to Disassembly
33. Connect the exhaust tube assembly. Refer to the Original Equipment Manufactures (OEM)
for the correct procedure.
34. Connect the hose assemblies to the turbocharger inlet and the turbocharger the outlet. Refer
to the OEM for the correct procedure.
Sun Jun 21 15:44:22 UTC+0800 2020
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Shutdown SIS
Previous Screen
Product: EXCAVATOR
C7.1 Engines
i05292434
Wastegate Solenoid - Remove and Install
SMCS - 1057-010
Removal Procedure
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1. Disconnect harness assembly (1) from harness assembly (2). Slide connection for harness
assembly (2) from bracket (3).
2. Remove allen bolts (4) and remove bracket (3).
3. Make temporary mark on wastegate solenoid (5) for installation purposes. Remove
wastegate solenoid (2) from inlet manifold connection (6).
Table 1
Required Tools
1. Ensure that all components of wastegate solenoid are clean and free from wear and damage.
If necessary, replace the wastegate solenoid as an assembly if any of components are worn
or damaged.
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2. Ensure that O-ring seals (7) on wastegate solenoid (6) are free from damage and wear.
3. If the O-ring seals are damaged or worn, the wastegate solenoid should be replaced as an
assembly.
4. Ensure that the ports in Position (X) are clean and free from restriction.
5. Use Tooling (A) in order to lubricate O-ring seal (7) on wastegate solenoid (6).
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6. Install wastegate solenoid (5) to inlet manifold connection (6).
Note: Ensure that the wastegate solenoid is correctly orientated.
7. Position bracket (3) onto wastegate solenoid (5). Ensure that the bracket is correctly
orientated.
8. Install allen bolts (4) to wastegate solenoid (5). Tighten the bolts to a torque of 5 N·m
(44 lb in).
9. Slide the connection for harness assembly (2) onto bracket (3). Connect harness assembly
(1) to harness assembly (2).
Sun Jun 21 15:45:17 UTC+0800 2020
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Caterpillar Cat 330D2 L Excavator (Prefix PTE) Service Repair Manual (PTE00001 and up).pdf

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