Caterpillar cat 336 d2 excavator (prefix elr) service repair manual (elr00001 and up)

Service Repair Manual
Models
336D2 and 336D2 L Excavator

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Product: EXCAVATOR
Model: 336D2 L EXCAVATOR ELR
Configuration: 336D2 & 336D2 L Excavators ELR00001-UP (MACHINE) POWERED BY C9 Engine
Disassembly and Assembly
C9 Engines for Caterpillar Built Machines
Media Number -RENR9579-20 Publication Date -01/02/2015 Date Updated -15/08/2018
i06737900
Unit Injector Sleeve - Remove
SMCS - 1713-011
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-3042 Plug Tap 1
B 221-0052 Guide Sleeve 1
C
9U-6858 Bridge Plate 1
1B-2886 Bolts 2
221-9778 Puller Stud 1
4K-0367 Full Nut 1
5P-8247 Hard Washer 1
9U-6877 Thrust Bearing 1
D 221-9803 Rubber Stopper 1
Start By:
a. Remove the unit injectors. Refer to Disassembly and Assembly, "Unit Injector - Remove".
NOTICE
Keep all parts clean from contaminants.
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336D2 & 336D2 L Excavators ELR00001-UP (MACHINE) POWERED BY C9 Engin...
2020/5/26
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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.
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. 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".
2. Position Tooling (D) at the bottom of the unit injector sleeve.
3. Coat Tooling (A) with clean grease. Use Tooling (A) and Tooling (B) to cut threads into the
unit injector sleeve.
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Illustration 1 g01137445
4. Install Tooling (C) in unit injector sleeve (1).
5. Remove unit injector sleeve (1). Remove the O-ring seals.
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Tue May 26 16:53:29 UTC+0800 2020
3/3
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Product: EXCAVATOR
i03742983
Unit Injector Sleeve - Install
SMCS - 1713-012
Installation Procedure
Table 1
Required Tools
E 221-9777 Sleeve Installer 1
F 4C-5552 Large Bore Brush 1
G 4C-9507 Retaining Compound 1
NOTICE
1. Thoroughly clean the unit injector sleeves and the bores for the unit injectors with Tooling
(F) .
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2. Apply clean engine oil to O-ring seals (2) . Install O-ring seals (2) on unit injector sleeve
(1) .
3. Position unit injector sleeve (1) on Tooling (E) .
4. Apply a thin coating of Tooling (G) around the outer circumference of unit injector sleeve
(1) at Area (C) .
5. Position unit injector sleeve (1) in the cylinder head. Use a hammer to install unit injector
sleeve (1) in the cylinder head.
Note: Allow Tooling (G) to cure for two hours at 21 °C (70 °F) before filling the engine
with fuel or coolant. Longer curing time is required for lower temperatures.
6. Fill the cooling system with coolant to the correct level. Refer to Operation and
Maintenance Manual, "Refill Capacities and Recommendations".
End By: Install the unit injectors. Refer to Disassembly and Assembly, "Unit Injector - Install".
Tue May 26 16:54:25 UTC+0800 2020
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Product: EXCAVATOR
i05701078
Unit Injector Hydraulic Pump - Remove
SMCS - 1714-011
Removal Procedure for Non-Dual Tapered Roller Bearing
HEUI Pump
Start By:
A. Remove fuel filter base, if necessary.
NOTICE
NOTICE
containing fluids.
Cat products.
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Non-Dual Taper Roller Bearing HEUI pump
Dual Taper Roller Bearing HEUI pump
Note: Refer to Illustrations 1 and 2 in order to identify each unit injection hydraulic pump.
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1. Disconnect tube assemblies (3) , (4) , (5) , and (6) .
2. Disconnect hose assembly (7) .
3. Disconnect harness assembly (2) from unit injector hydraulic pump (1) .
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4. Support unit injector hydraulic pump (1) by hand and remove bolts (8) . Remove unit
injector hydraulic pump (1) .
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5. Remove O-ring seal (9) .
Removal Procedure for Dual Tapered Roller Bearing HEUI
Pump
Start By:
A. Remove fuel filter base, if necessary.
NOTICE
NOTICE
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containing fluids.
Cat products.
1. Disconnect harness assembly (1) . Disconnect hose assemblies (4) and tube assembly (3) .
Remove tube assembly (2) and tube assembly (5) .
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2. Support unit injector hydraulic pump (7) and remove bolts (6) .
3. Rotate counterclockwise as shown, then remove unit injector hydraulic pump (7) .
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4. Remove O-ring seal (8) .
Tue May 26 16:55:21 UTC+0800 2020
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Product: EXCAVATOR
i05701091
Unit Injector Hydraulic Pump - Install
SMCS - 1714-012
Installation Procedure for Non-Dual Taper Roller Bearing
HEUI Pump
NOTICE
NOTICE
containing fluids.
Cat products.
1/9
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1. Install new O-ring seal (9) .
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2. Position unit injector hydraulic pump (1) in the front housing.
3. Support unit injector hydraulic pump (1) and install bolts (8) .
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4. Connect hose assembly (7) .
5. Connect tube assemblies (3) , (4) , (5) , and (6) .
6. Connect harness assembly (2) to unit injector hydraulic pump (1) .
Installation Procedure for Dual Tapered Roller Bearing
HEUI Pump
Table 1
Required Tools
A 129-1967 Multipurpose Grease -
Note: If replacing a non-dual tapered roller bearing HEUI pump with a dual tapered roller bearing
HEUI pump, refer to Special Instruction, REHS7902 for rework and installation procedures.
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Note: If a dowel pin is installed in the mounting flange of the unit injector hydraulic pump
or in the front housing at the unit injector hydraulic pump mounting location, remove the
dowel pin before installing the unit injector hydraulic pump.
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1. Install O-ring seal (8) . Apply Tooling (A) to O-ring seal (8) , the mounting flange of the
unit injector hydraulic pump, and the back of the front housing at the mounting location of
the unit injector hydraulic pump.
2. Position unit injector hydraulic pump (7) as shown, then rotate clockwise to final
installation orientation.
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3. Install bolts (6) hand-tight.
Note: Do not fully tighten bolts (6) until all of the hoses and the tubes are connected to unit
injection hydraulic pump (7) .
4. Install tube assembly (5) hand-tight.
5. Connect hose assemblies (4) . Install tube assembly (3) and tube assembly (2) hand-tight.
6. Tighten bolts (6) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
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7. Tighten tube assemblies (2) , (3) , (5) and hose assemblies (4) .
8. Connect harness assembly (1) .
End By: Install fuel filter base, if necessary.
Tue May 26 16:56:17 UTC+0800 2020
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Shutdown SIS
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Product: EXCAVATOR
i02297056
Turbocharger - Remove
SMCS - 1052-011
Removal Procedure
NOTICE
NOTICE
containing fluids.
Cat®
products.
1/2
2020/5/26

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1. Disconnect hose assembly (1).
2. Remove bolts (4) and tube assembly (5).
3. Attach a suitable lifting device onto turbocharger (2). The weight of turbocharger (2) is
approximately 27 kg (60 lb). Remove nuts (3). Remove turbocharger (2) and the gasket.
Tue May 26 16:57:13 UTC+0800 2020
2/2
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Shutdown SIS
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Product: EXCAVATOR
i04000968
Turbocharger - Install
SMCS - 1052-012
Installation Procedure
Table 1
Required Tools
A 5P-3931 Anti-Seize Compound -
NOTICE
1. Apply Tooling (A) to the turbocharger mounting studs on the exhaust manifold.
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2. Attach a suitable lifting device to turbocharger (2). The weight of turbocharger (2) is
approximately 27 kg (60 lb). Position the gasket and turbocharger (2) on the exhaust
manifold.
Note: Discard the nuts after use. Use new nuts for installation.
3. Install nuts (3). Tighten nuts (3) to a torque of 54 ± 5 N·m (40 ± 4 lb ft).
4. Position tube assembly (5) and install bolts (4).
5. Connect hose assembly (1).
Tue May 26 16:58:08 UTC+0800 2020
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2020/5/26

Caterpillar cat 336 d2 excavator (prefix elr) service repair manual (elr00001 and up)

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