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KENR6052-01 November 2009 Disassembly and Assembly C 1 7 5 - 1 6 and C175-20

KENR6052-01

November 2009

KENR6052-01 November 2009 Disassembly and Assembly C 1 7 5 - 1 6 and C175-20 Engines

Disassembly and Assembly

C175-16 and C175-20 Engines for Caterpi llar Built Machines

B7B1-Up (Engine) B7C1-U p (Engine) JTL1-Up (Engine) LLM1-Up (Engine)

i03684547

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the neces sary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death.

Do not operat e or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heed ed, bodily injury or death could occur to you or to other persons.

The hazards are identied by the “Safety Alert Symbol” and followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. The Safe ty Alert “WARNING” label is shown below.

The Safe ty Alert “WARNING” label is shown below. The meaning of this safety alert symbol

The meaning of this safety alert symbol is as follows:

Attention ! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictorially presented.

A non-exh austive list of operations that may cause product damage are identi ed by “NOTICE” labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might invo lve a potential hazard. The warn ings in this publication and on the product are, therefore, not all inclusive. You must not use this product in any manner different from that considered by this manual without rst satisfying yourself that you have considered all safety rules and precautions applicable to the operat ion of the product in the location of use, including site-specic rules and precautions applicable to the worksite. If a tool, procedure, work method or operating technique that is not specically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that you intend to use.

The information, speci cations, and illustrations in this publication are on the basis of information that was av ailable at the time that the publication was written. The speci cations, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Caterpillar dealers have the most current information available.

dealers have the most current information available. When replacement parts are required for this product

When replacement parts are required for this product Caterpillar recommends using Caterpil- lar replacement parts or parts with equivalent specications including, but not limited to, phys- ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema- ture failures, product damage, personal injury or death.

In the United States, the maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establishment or individual of the owner's choosing.

KENR6052-01

3

Table of Contents

Table of Contents

Disassembly and Assembly Section

Air Starting Motor - Remove

4

Air Starting Motor - Install

4

Electronic Control Module (Engine) - Remove and Install

5

Fuel Filter Housing - Remove (Secondary)

6

Fuel Filter Housing - Remove (Secondary)

7

Fuel Filter Housing - Install

7

Fuel Filter Housing - Install

8

Fuel Priming Pump - Remove and Install

9

Fuel Transfer Pump - Remove

10

Fuel Transfer Pump - Install

10

High Pressure Fuel Rails - Remove and Install

11

Flow Limiter - Remove and Install

15

Fuel Control Valve - Remove and Install

17

Fuel Pump (High Pressure) - Remove and Install

18

Turbocharger - Remove

20

Turbocharger - Install

22

Air Inlet Manifold - Remove and Install

23

Exhaust Elbow - Remove and Install

23

Exhaust Manifold - Remove and Install

24

Water Pump - Remove

26

Water Pump - Disassemble

26

Water Pump - Assemble

28

Water Pump - Install

31

Fuel and Auxiliary Water Pump Drive - Remove and

Install

32

Auxiliary Water Pump - Remove

35

Auxiliary Water Pump - Disassemble

35

Auxiliary Water Pump - Assemble

37

Auxiliary Water Pump - Install

40

Engine Oil Cooler - Remove

41

Engine Oil Cooler - Disassemble

42

Engine Oil Cooler - Assemble

43

Engine Oil Cooler - Install

43

Engine Oil Pump - Remove

44

Engine Oil Pump - Disassemble

47

Engine Oil Pump - Assemble

48

Engine Oil Pump - Install

49

Engine Oil Filter Housing - Remove

51

Engine Oil Filter Housing - Install

52

Engine Oil and Water Pump Drive - Remove

52

Engine Oil and Water Pump Drive - Disassemble

53

Engine Oil and Water Pump Drive - Assemble

53

Engine Oil and Water Pump Drive - Install

54

Engine Oil Screen - Remove and Install

55

Engine Oil Pan - Remove

57

Engine Oil Pan - Disassemble

58

Engine Oil Pan - Assemble

59

Engine Oil Pan - Install

59

Engine Oil Scavenge Pump - Remove

61

Engine Oil Scavenge Pump - Disassemble

62

Engine Oil Scavenge Pump - Assemble

63

Engine Oil Scavenge Pump - Install

65

Crankcase Breather - Remove and Install

66

Valve Cover - Remove and Install

67

Rocker Shaft and Push Rods - Remove

68

Rocker Shaft - Disassemble

68

Rocker Shaft - Assemble

69

Rocker Shaft and Push Rods - Install

69

Valve Lifter - Remove

70

Valve Lifter - Disassemble

71

Valve Lifter - Assemble

71

Valve Lifter - Install

72

Electronic Unit Injector - Remove

72

Electronic U nit Injector - Install

74

Electronic Unit Injector Sleeve - Remove

75

Electronic Unit Injector Sleeve - Install

76

Cylinder Head - Remove

77

Cylinder Head - Install

78

Inlet and Exhaust Valve Springs - Remove and Install

80

Inlet and Exhaust Valves - Remove and Install

81

Inlet and Exhaust Valve Guides - Remove and Install

83

Inlet and Exhaust Valve Seat Inserts - Remove and

Install

84

Inlet Valve Seals - Remove and Install

85

Front Drive Housing - Remove and Install

87

Vibration Damper - Remove and Install

89

Crankshaft Front Seal - Remove

91

Crankshaft Front Seal - Install

91

Flywheel - Remove and Install

92

Crankshaft Rear Seal - Remove

93

Crankshaft Rear Seal - Install

94

Flywheel Housing - Remove

95

Flywheel Housing - Install

96

Idler Gears (Front) - Remove and Install

98

Gear Group (Rear) - Remove

100

Gear Group (Rear) - Install

101

Piston Cooling Jets - Remove and Install

102

Bearing Clearance - Check

103

Connec ting Rod Bearings - Remove and Install

104

Crankshaft Main Bearings - Remove

106

Crank shaft Main Bearings - Install

108

Pistons, Liners, and Connecting Rods - Remove

110

Pistons and Connecting Rods - Disassemble

112

Pistons and Connecting Rods - Assemble

113

Pistons, Liners, and Connecting Rods - Install

115

Camshaft - Remove

116

Camshaft Bearings - Remove

118

Camshaft Bearings - Install

119

Camshaft - Install

121

Crankshaft - Remove

123

Crankshaft - Install

125

Air Compressor - Remove and Install

128

Engine Trunnion - Remove and Install

129

Accessory Drive (Rear) - Remove

131

Acc essory Drive (Rear) - Install

132

In dex Section

Index

135

4

Disassembly and Assembly Section

KENR6052-01

Disassembly an d Assembly Section

i02649756

Air Starting Motor - Remove

SMCS Code: 1451-011

Removal Pro cedure

Note: Cleanliness is an important factor. Before the removal procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.

Note: Put identi cation marks on all hoses for installation purposes. Plug all hoses. This helps to prevent uid loss and this helps to keep contaminants from entering the system.

1. Turn OFF air supply valve, and purge the air from the hoses.

a i r supply valve, and purge the air from the hoses. Illustration 1 g01330208 2.

Illustration 1

g01330208

2. Disconnect hose assembly (1) from air starting motor (4).

3. Disconnect hose assembly (2) from air starting motor (4).

4. Disconnect hose assembly (3) from air starting motor (4).

Disconnect hose assembly (3) from air starting motor (4). Illustration 2 g01330211 5. Attach a suitable

Illustration 2

g01330211

5. Attach a suitable lifting device to air starting motor (4). The weight of air starting motor (4) is approximately 29 kg (63 lb).

6. Remove bolts (5).

7. Remove air starting motor (4).

i02649858

Air Starting Motor - Install

SMCS Code: 1451-012

Installation Procedure

Note: Cleanliness is an important factor. Before the installation procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.

KENR6052-01

5

Disassembly and Assembly Section

KENR6052-01 5 Disassembly and Assembly Section Illustration 3 g01330211 1. Attach a suitable lifting device to

Illustration 3

g01330211

1. Attach a suitable lifting device to air starting motor (4). The weight of air starting motor (4) is approximately 29 kg (63 lb).

2. Position air starting motor (4).

3. Install bolts (5).

2. Position air starting motor (4). 3. Install bolts (5). Illustration 4 g01330208 4. Connect hose

Illustration 4

g01330208

4. Connect hose assembly (3) to air starting motor

(4).

5. Connect hose assembly (1) to air starting motor

(4).

6. Connect hose assembly (2) to air starting motor

(4).

7. Turn ON air supply valve.

i02649946

Electronic Control Module (Engine) - Remove and Install

SMCS Code: 1900-010

Removal Procedure

- Remove and Install SMCS Code: 1900-010 Removal Procedure Illustration 5 g01811974 1. Remove screws (4)

Illustration 5

g01811974

1. Remove screws (4) and disconnect harness assemblies (1) and (5). Remove bolts (2), the mounts, the washers, and the spacers. Remove electronic control module (3).

6

Disassembly and Assembly Section

KENR6052-01

Installation P rocedure

and Assembly Section KENR6052-01 Installation P rocedure Illustration 6 g01811974 1. Position electronic control

Illustration 6

g01811974

1. Position electronic control module (3). Install the spacers, the washers, the mounts, and bolts (2). Position harness assemblies (5) and (1). Install screws (4). Tighten screws (4) to a torque of 6 ± 1 N·m (53 ± 9 lb in).

i02632312

Fuel Filter Housing - Remove (Secondary)

SMCS Code: 1262-011

S/N: SSP; B7B1-Up

S/N: EMD; B7C1-Up

S/N: ERM; JTL1-Up

Removal Procedure

Table 1

Required Tools

Tool

Part Number

Part Description Filter Strap Wrench

Qty

A

185-3630

1

NOTICE Care must be taken to ensure that uids are contained during perfor mance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before open- ing any compar tment or disassembling any compo- nent containing uids.

Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain uids on Caterpillar products.

Dispose of all uids according to local regulations and mandates.

1. Turn the fuel supply to the OFF position.

and mandates. 1. Turn the fuel supply to the OFF position. Illustration 7 g01818667 Note: Cap

Illustration 7

g01818667

Note: Cap tube assemblies, ttings, ports, and any openings on the fuel system in order to prevent contamination.

2. Use Tooling (A) to remove fuel lters (6).

3. Remove tube assembly (1) from fuel lter base (2).

4. Disconnect harness assembly (5). Disconnect hose assemblies (3) and (4).

KENR6052-01

7

Disassembly and Assembly Section

KENR6052-01 7 Disassembly and Assembly Section Illustration 8 g01818673 5. Remove bolt (12) and the washer.

Illustration 8

g01818673

5. Remove bolt (12) and the washer. Disconnect harness assemblies (14) and (11) from fuel lter base (2).

6. Disconnect hose assembly (9).

7. Remove tube assembly (13).

8. Remove bolts (7). Remove fuel lter bases (2). Remove bolts (8) and the washers. Remove support assembly (10).

i02630575

Fuel Filter Housing - Remove (Secondary)

SMCS Code: 1262-011

S/N: LAJ; LLM1-Up

Remo val Procedure

Table 2

Required Tools

Tool

Part Number

Part Description Filter Strap Wrench

Qty

A

185-3630

1

NOTICE Care must be taken to ensure that uids are contained dur ing performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before open- ing any compartment or disassembling any compo- nent containing uids.

Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain uids on Caterpillar

p roducts.

Dispose of all uids according to local regulations and

m andates.

1. Turn the fuel supply to the OFF position.

2. Use Tooling (A) to remove fuel lters (6).

2. Use Tooling (A) to remove fuel fi lters (6). Illustration 9 g01852154 3. Remove bolts

Illustration 9

g01852154

3. Remove bolts (8). Disconnect clamps (10). Relocate the hose assembly.

4. Disconnect harness assemblies (1), (4), and (5). Disconnect tube assemblies (3) and (2).

5. Remove bolt (11), the washer, and the spacer. Relocate the harness assembly.

6. Remove bolts (9). Remove fuel lter base (7). The weight of fuel lter base (7) is approximately 15 kg (33 lb).

i02634791

Fuel F ilter Housing - Install

SMCS Code: 1262-012

S/N: SSP; B7B1-Up

S/N: EMD; B7C1-Up

S/N: ERM; JTL1-Up

Installation Procedure

Tab le 3

Req uired Tools

Tool

Part Number

Part Description Filter Strap Wrench

Qty

A

185-3630

1

8

Disassembly and Assembly Section

KENR6052-01

8 Disassembly and Assembly Section KENR6052-01 Illustration 10 g01818673 1. Position support assembly (10). Install

Illustration 10

g01818673

1. Position support assembly (10). Install the washers and bolts (8). Install fuel lter base (2). Install bolts (7).

2. Install tube assembly (13). Connect hose assembly (9).

3. Connect harness assemblies (11) and (14) to fuel lter base (2). Install the washer and bolt (12).

fuel fi lter base (2). Install the washer and bolt (12). Illustration 11 g01818667 4. Connect

Illustration 11

g01818667

4. Connect harness assembly (5). Connect hose assemblies (4) and (3).

5. Connect tube assembly (1) to fuel lter base (2).

6. Use Tooling (A) to install fuel lters (6).

i02634790

Fuel Filter Housing - Install

SMCS Code: 1262-012

S/N: LAJ; LLM1-Up

Installation Procedure

Table 4

Required Too ls

Tool

Part Number

Part Description Filter Strap Wrench

Qty

A

185-3630

1

Part Description Filter Strap Wrench Q t y A 185-3630 1 Illustration 12 g01852154 1. Install

Illustration 12

g01852154

1. Install fuel lter base (7). The weight of fuel lter base (7) is approximately 15 kg (33 lb). Install bolts (9).

2. Position the harness assembly and install the spacer, the washer, and bolt (11).

3. Install tube assemblies (3) and (2). Connect harness assemblies (5), (4), and (1).

4. Position hose assembly. Connect clamps (10). Install bolts (8).

5. Use Tooling (A) to install fuel lters (6).

6. Turn the fuel supply to the ON position.

KENR6052-01

9

Disassembly and Assembly Section

i02944485

Fuel Priming Pump - Remove and Install

SMCS Code: 1258-010

Removal Procedure

NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, test- ing, adjust ing and repair of the product. Be prepared to collect the uid with suitable containers before open- ing any compartment or disassembling any compo- nent containing uids.

Refer to Special Publication, NENG2500, “Caterpillar Dealer Ser vice Tool Catalog” for tools and supplies suitable to collect and contain uids on Caterpillar products.

Dispose of all uids according to local regulations and mandates.

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Turn the fuel supply to the OFF position.

T u r n t h e fuel supply to the OFF position. Illustration 13 g01858476

Illustration 13

g01858476

3. Remove three bolts (2), the mounts, the spacers, and the washers. Remove bracket assembly (7).

Installation Procedure

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component l ife.

may cause rapid wear and shortened component l ife. Illustration 14 g01858476 1. Position bracket assembly

Illustration 14

g01858476

1. Position bracket assembly (7). Install the washers, the spacers, the mounts, and three bolts (2).

2. Install fuel priming pump (1). Install the nuts, the washers, and four bolts (6). Connect two harness assemblies (3). Connect hose assembly (5) to the IN position. Connect hose assembly (4) to the OUT position.

3. Turn the fuel supply to the ON position.

10

Disassembly and Assembly Section

KENR6052-01

i03482008

Fuel Transfer Pump - Remove

SMCS Code: 125 6-011

Removal Procedure

NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before open- ing any compartment or disassembling any compo- nent containing uids.

Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain uids on Caterpillar products.

Dispose o f all uids according to local regulations and mandates.

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

1. Turn the fuel supply to the OFF position.

life. 1. Turn the fuel supply to the OFF position. Illustration 15 g01820514 Illustration 16 g01820515

Illustration 15

g01820514

fuel supply to the OFF position. Illustration 15 g01820514 Illustration 16 g01820515 3. Remove bolts (8).

Illustration 16

g01820515

3. Remove bolts (8). Remove fuel transfer pump (7).

i03482861

Fuel Tran sfer Pump - Install

SMCS Code: 1256-012

Installation Procedure

Pump - Install SMCS Code: 1256-012 Installation Procedure Illustration 17 g01820515 1. Install fuel transfer pump

Illustration 17

g01820515

1. Install fuel transfer pump (7). Install bolts (8).

KENR6052-01

11

Disassembly and Assembly Section

KENR6052-01 11 Disassembly and Assembly Section Illustration 18 g01820514 2. Connect harness assembly (4). Connect

Illustration 18

g01820514

2. Connect harness assembly (4). Connect hose assemblies (6), (5), (3), (2), and (1).

3. Turn the fuel supply to the ON position.

i03350020

High Pressure Fuel Rails - Remove and Install

SMCS Code: 1274

Removal Procedure

Table 5

Required Tools

Tool

Part

Number

Part Description

Qty

339-9354

A

Fuel LineCap Kit

1

265 -2256

Wipers

1

Start By:

a. Remove the air inlet manifold. Refer to Di sassembly and Assembly, “Air Inlet Manifold - Remove and Install”.

b. Re move the ow limiters. Refer to Disassembly and Assembly, “Flow Limiters - Remove and Install”.

NOTICE Care must be taken to ensure that uids are contained during perfor mance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before open- ing any compar tment or disassembling any compo- nent containing uids.

Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain uids on Caterpillar products.

Dispose of all uids according to local regulations and mandates.

all fl uids according to local regulations and mandates. Do not open the high pressure fuel

Do not open the high pressure fuel system without allowing the fuel system to purge. After the engine has shut down, allow the fuel system to purge for ten minutes. This operating fuel system contains high pressure. Exposure to high pressure fuel can result in personal injury.

Note: Use Tooling (A) to cap tube assemblies, ttings, ports, and any opening in the fuel system in order to prevent contamination.

in the fuel system in order to prevent contamination. Illustration 19 g01285837 1. Remove bolt (1)

Illustration 19

g01285837

1. Remove bolt (1) and the clamp from tube assembly (2).

12

Disassembly and Assembly Section

KENR6052-01

12 Disassembly and Assembly Section KENR6052-01 Illustration 20 g01822393 Note: Do not remove all the quills

Illustration 20

g01822393

Note: Do not remove all the quills in order to maintain the alignment of the rail.

the quills in order to maintain the alignment of the rail. Illustration 21 g01443406 Note: Cap

Illustration 21

g01443406

Note: Cap tube assemblies, ttings, ports, and any opening in the fuel system in order to prevent contamination.

2. Disconnect tube assembly (3) and remove the bolts on tube assembly (2). Remove bolts (5). Disconnect tube assembly (4). Remove tube assembly (2) and the O-ring seals. Remove bolts

(6).

Note: If necessary, secondary fuel lter lines may need to be removed in order to remove tube assembly (2).

Note: Replace with new bolts (5)

remove tube assembly (2). Note: Replace with new bolts (5) Illustration 22 g01285008 Illustration 23 g01822394

Illustration 22

g01285008

Note: Replace with new bolts (5) Illustration 22 g01285008 Illustration 23 g01822394 3. Remove bolts (9).

Illustration 23

g01822394

3. Remove bolts (9). Remove bolts (10) and bolts (11). Repeat for the opposite side.

Note: Replace with new bolts (9)

4. Remove tube assembly (7). Remove tube assembly (8) and the O-ring seal.

assembly (7). Remove tube assembly (8) and the O-ring seal. Illustration 24 g01822395 5. Attach a

Illustration 24

g01822395

5. Attach a suitable lifting device onto fuel rail (13). The weight of fuel rail (13) is approximately 60 kg (131 lb). Remove bolts (12). Remove fuel rail (13).

6. Place the high pressure fuel rail on a clean surface. Support the rail so the weight is not resting on the quills. All openings should be capped or plugged in order to prevent contamination.

7. Repeat Step 5 for the opposite side.

KENR6052-01

13

Disassembly and Assembly Section

Installation P rocedure

Table 6

Required Tools

Tool

Part

Number

Part Description

Qty

339-9354

A

Fuel LineCap Kit

1

265-2256

Wipers

1

Note: When Tooling (A) is removed be careful to prevent contamination.

Tooling (A) is removed be careful to prevent contamination. Illustration 25 g01822395 1. Attach a suitable

Illustration 25

g01822395

1. Attach a suitable lifting device onto fuel rail (13). The weight of fuel rail (13) is approximately 60 kg (131 lb). Install fuel rail (13). Install bolts (12).

60 kg (131 lb). Install fuel rail (13). Install bolts (12). Illustration 26 2. Tighten bolts

Illustration 26

2. Tighten bolts (12) in the sequence that is shown in Illustration 26. Tighten bolts (12) to a torque of 100 ± 20 N·m (74 ± 15 lb ft).

bolts (12) to a torque of 100 ± 20 N·m (74 ± 15 lb ft). Illustration

Illustration 27

g01822394

g01443632

N·m (74 ± 15 lb ft). Illustration 27 g01822394 g01443632 Illustration 28 g01285008 3. Install the

Illustration 28

g01285008

3. Install the new O-ring seals. Lubricate the ends of tube assembly (8) and the O-ring seals with clean engine oil. Install new bolts (9) and the washers. Evenly hand tighten bolts (9) in order to assemble tube assembly (8) and the O-ring seals. This will prevent cutting or damage of the O-ring seal. Install tube assembly (7). Install bolts (10) and (11) hand tight. Evenly tighten new bolts (9) to a torque of 20 N·m (15 lb ft).

14

Disassembly and Assembly Section

KENR6052-01

Note: Bolts (9) do not rotate more than 90 degrees at a time.

4. Evenly tighten new bolts (9) to a torque of 40 N·m (30 lb ft).

Note: Bolts (9) do not rotate more than 45 degrees at a time.

5. Tighten bolts (10) and (11) to a torque of 40 ± 10 N·m (3 0 ± 7 lb ft).

(10) and (11) to a torque of 40 ± 10 N·m (3 0 ± 7 lb

Illustration 29

g01443406

of 40 ± 10 N·m (3 0 ± 7 lb ft). Illustration 29 g01443406 Illustration 30

Illustration 30

g01822393

Note: If necessary, secondary fuel lter lines may need to be installed after tube assembly (2) has been installed. Do not attempt to push the anges past O-ring seals by hand in order to prevent cutting or damage.

6. Install the new O-ring seals into the pump outlet, the inlet, and the junction block. Lubricate O-ring seals and the end of tube assemblies (2) and (4) with clean engine oil. Install new bolts (5) and washers. E venly hand tighten new bolts (5) in order to engage tube assemblies (2) and (4) with the O-ring seals. This will prevent cutting or damage of t he O-ring seal. Position bolts (6) and tighten by hand. Evenly hand tighten bolts (5). Evenly tighten bolts (6) to a torque of 20 N·m (15 lb ft). Evenly tighten new bolts (5) to a torque of 20 N·m (15 lb ft). Evenly tighten bolts (6) to a nal torque of 55 ± 10 N·m (41 ± 7 lb ft). Evenly tighten bol ts (5) to a nal torque of 40± 10 N·m (30± 7 lb ft).

Note: The bolts in tube assembly (2) do not rotate more than 90 degrees at a time.

7. Evenly tighten the bolts in tube assembly (2) to a torque of 40 N·m (30 lb ft).

Note: The bolts in tube assembly (2) do not rotate more than 45 degrees at a time.

assembly (2) do not rotate more than 45 degrees at a time. Illustration 31 g01285837 8.

Illustration 31

g01285837

8. Install the bracket, the clamp, and bolt (1) onto tube assembly (2). Use the bracket to adjust the position of the clamp and bolt (1) for alignment to tube assembly (2).

9. Repeat this process on the opposite side.

End By:

a. Install the ow limiters. Refer to Disassembly and Assembly, “Flow Limiters - Remove and Install”.

b. Install the air inlet manifold. Refer to Disassembly and Assembly, “Air Inlet Manifold - Remove and Install”.

KENR6052-01

15

Disassembly and Assembly Section

i03349521

Flow Limiter - Remove and Install

SMCS Code: 1715-010

Removal Procedure

Table 7

Required Tools

Tool

Part

Number

Part Description

Qty

A

6V-6195

Interlocking Joint Pliers

1

B

339-9352

Inj. Sys Cap Kit

1

265-2256

Wipers

1

NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before open- ing any compartment or disassembling any compo- nent containing uids.

Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain uids on Caterpillar products.

Dispose of all uids according to local regulations and mandates.

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

may cause rapid wear and shortened component life. Do not open the high pressure fuel system

Do not open the high pressure fuel system without allowing the fuel system to purge. After the engine has shut down, allow the fuel system to purge for ten minutes. This operating fuel system contains high pressure. Exposure to high pressure fuel can result in personal injury.

Note: Use Tooling (B) to cap tube assemblies, ttings, ports, and any opening in the fuel system in order to prevent contamination.

in the fuel system in order to prevent contamination. Illustration 32 g01285474 1. Remove bolt (3)

Illustration 32

g01285474

1. Remove bolt (3) and the washer. Remove tube

assembly (1). Disconnect harness assembly (2).

Remove tube assembly (1). Disconnect harness assembly (2). I l l u s t ration 33

Illust ration 33

g01444306

2. Apply clean engine oil to area (X). Repeat for the oppos ite collar. Remove bolts (4) and bolts (6). Remove tube assembly (5).

Note: Replace with new bolts (4) and (6)

(5). N o t e : Replace with new bolts (4) and (6) Illustration 34 g01285667

Illustration 34

g01285667

16

Disassembly and Assembly Section

KENR6052-01

Note: Apply protective caps to ow limiter (7 ) in order to prevent contamination. Clean Tooling (A) before using in order to avoid contamination in the fuel system.

Installation Procedure

Table 8

Required Too ls

Tool

Part

Number

Part Descri ption

Qty

A

6V-6195

Interlocki ng Joint Pliers

1

B

339-9352

Inj. Sys Cap Kit

1

265-2256

Wipers

1

Note: When Tooling (B) is removed be careful to prevent contamination.

Tooling (B) is removed be careful to prevent contamination. Illustration 35 g01285667 1. Apply clean engine

Illustration 35

g01285667

1. Apply clean engine oil to the sealing face of the ow limiter and the fuel rail.

Note: Use a clean plastic squirt bottle to apply clean engine oil. Do not apply clean engine oil by hand.

2. Use Tooling (A) to install ow limiter (7) into the fuel rail.

Note: Clean Tooling (A) before using in order to avoid contamination in the fuel system.

using in order to avoid contamination in the fuel system. Illustration 36 g01444306 Illustration 37 g01285695

Illustration 36

g01444306

contamination in the fuel system. Illustration 36 g01444306 Illustration 37 g01285695 3. Apply clean engine oil

Illustration 37

g01285695

3. Apply clean engine oil to area (X). Repeat for the opposite collar. Apply clean engine oil to the ends of tube assembly (5). Replace external O-ring seals on tube assembly (5) and lubricate the O-ring seals on the tube assembly with clean engine oil. Install tube assembly (5). Install new bolts (4) and new bolts (6) hand tight. Evenly tighten new bolts (4) to a torque of 20 N·m (15 lb ft). Evenly tighten new bolts (6) to a torque of 20 N·m (15 lb ft). Evenly tighten new bolts (4) to a torque of 40 N·m (30 lb ft). Evenly tighten new bolts (6) to a torque of 40 N·m (30 lb ft).

of 40 N·m (30 lb ft). Evenly tighten new bolts (6) to a torque of 40

Illustration 38

g 01285474

KENR6052-01

17

Disassembly and Assembly Section

4. Connect harness assembly (2). Replace the O-ring seals on both ends of tube assembly (1). Install tube assembly (1). Install the washer and bolt (3).

i02682596

Fuel Control Valve - Remove and Install

SMCS Code: 1715-010

Removal Procedure

Start By:

a. Remove the fuel pump (high pressure). Refer to Disassembly and assembly, “Fuel Pump (High Pressure) - Remove and Install”.

NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before open- ing any compartment or disassembling any compo- nent containing uids.

Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain uids on Caterpillar products.

Dispose of all uids according to local regulations and mandates.

all fl uids according to local regulations and mandates. D o n o t open the

Do no t open the high pressure fuel system without allowing the fuel system to purge. After the engine has shut down, allow the fuel system to purge for ten minutes. This operating fuel system contains high pressure. Exposure to high pressure fuel can result in personal injury.

to high pressure fuel can result in personal injury. Illustration 39 g01347715 1. Remove bolts (2).

Illustration 39

g01347715

1. Remove bolts (2). Remove fuel control valve (1).

1. Remove bolts (2). Remove fuel control valve (1). Illustration 40 g01347728 2. Check O-ring seals

Illustration 40

g01347728

2. Check O-ring seals (3), (4), and (5) on fuel control valve (1).

Installation Procedure

Table 9

Required Tools

Tool

Part Number Part Description

Qty

A

5N-5561

Silicone Lubricant

1

Number Part Description Qty A 5N-5561 Silicone Lubricant 1 Illustration 41 g 0 1 3 47728

Illustration 41

g013 47728

1. Lubricate O-ring seals (3), (4), and (5) with Tooling (A).

18

Disassembly and Assembly Section

KENR6052-01

18 Disassembly and Assembly Section KENR6052-01 Illustration 42 g01347715 Illustration 43 g01347742 2. Position fuel

Illustration 42

g01347715

and Assembly Section KENR6052-01 Illustration 42 g01347715 Illustration 43 g01347742 2. Position fuel control valve

Illustration 43

g01347742

2. Position fuel control valve (1). Install bolts (2). Tighten bolts (2) in the sequence that is shown in Illustration 43. Tighten bolts (2) to a torque of 6 N·m (53 lb in). Tighten bolts (2) in the sequence that is shown in Illustration 43. Tighten bolts (2) to a torque of 12 N·m (106 lb in).

End By:

a. Install the fuel pump (high pressure). Refer to Disassembly and assembly, “Fuel Pump (High Pressure) - Remove and Install”.

i03591920

Fuel Pump (High Pressure) - Remove and Install

SMCS Code: 1288-010

Removal Procedure

Table 10

 

Required Tools

 

Tool

Part Number

Part Description

Qty

 

138-7575

Link Bracket

2

A

(1)

6V-3668

12 MM Bolt

2

 

5P-8245

Washer

2

 

339-9353

High Press. Cap Kit

1

B

265-2256

Wipers

1

C

246-8191

16 MM Socket

1

(1) Use one to remove the fuel pump from the EPG engine.

NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before open- ing any compartment or disassembling any compo- nent containing uids.

Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain uids on Caterpillar products.

Dispose of all uids according to local regulations and mandates.

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

may cause rapid wear and shortened component life. Do not open the high pressure fuel system

Do not open the high pressure fuel system without allowing the fuel system to purge. After the engine has shut down, allow the fuel system to purge for ten minutes. This operating fuel system contains high pressure. Exposure to high pressure fuel can result in personal injury.

Note: Use Tooling (B) to cap tube assemblies, ttings, ports, and any openings on the fuel system in order to prevent contamination.

KENR6052-01

19

Disassembly and Assembly Section

KENR6052-01 19 Disassembly and Assembly Section Illustration 44 g01824814 1. Remove hose assemblies (1), (2), and

Illustration 44

g01824814

1. Remove hose assemblies (1), (2), and (6). Remove bolt (4) and hose assembly (7). Remove clamp assembly (8) and remove hose assembly (3). Disconnect harness assembly (5).

remove hose assembly (3). Disconnect harness assembly (5). Illustration 45 g01824815 2. Remove bolts (10) and

Illustration 45

g01824815

2. Remove bolts (10) and the washers. Disconnect harness assembly (13) from the fuel pump. Remove tube assembly (9). Remove hose assembly (14). Remove bolt (12) and the washer. Remove plate assembly (11).

Remove bolt (12) and the washer. Remove plate assembly (11). Illustration 46 g01825193 Note: When the

Illustration 46

g01825193

Note: When the fuel lines are removed, use clean engine oil to lubricate the outside diameter of tube assembly (20) in area (X). Use Tooling (C) in order to remove bolts (16) and (19). If the procedure is not followed, contamination and fuel leaks may occur.

3. Remove bolt (18), the washer, and the nut. Remove clamp assembly (17). Remove bolts (16) and (19). Remove tube assembly (20) and the O-ring seals.

4. Use Tooling (A) and attach a suitable lifting device onto fuel pump (15). The weight of fuel pump (15) is approximately 102 kg (225 lb). Remove bolts (21). Lower fuel pump (15) to the ground.

Note: The lifting device should not come into contact with the fuel shutoff valve. This will result in damage to the component.

Installation Procedure

Table 11

 

Required Tools

 

Tool

Part Number

Part Description

Qty

 

138-7575

Link Bracket

2

A

(1)

6V-3668

12 MM Bolt

2

 

5P-8245

Washer

2

 

339-9353

High Press Cap Kit

1

B

265-2256

Wipers

1

C

246-8191

16 MM Socket

1

D

1P-0808

M ultipurpose Grease

1

(1) Use one to remove the fuel pump from the EPG engine.

20

Disassembly and Assembly Section

KENR6052-01

Note: When Tooling (B) is removed be careful to prevent contam ination.

Tooling (B) is removed be careful to prevent contam ination. Illustration 47 g01825193 1. Use Tooling

Illustration 47

g01825193

1. Use Tooling (A) and attach a suitable lifting device onto fuel pump (15). The weight of fuel pump (15) is approximately 102 kg (225 lb). Raise fuel pump (15) into position on the engine. Install bolts (21).

2. Lubricate the O-ring seals with clean engine oil. Lubricate the ends of tube assembly (20) with Tooling (D). Install the O-ring seals on tube assembly (20). Install tube assembly (20). Install bolts (19) hand tight. Install bolts (16) hand tight. Position clamp assembly (17). Install bolt (18), the washer, and the nut. Use Tooling (C) and evenly tighten bolts (19) to a torque of 20 N·m (15 lb ft). Use Tooling (C) and evenly tighten bolts (16) to a torque of 20 N·m (15 lb ft).

Note: Do not rotate bolts (19) and (16) more than 90 degrees at a time.

3. Evenly tighten bolts (19) to a torque of 40 N·m (30 lb ft). Evenly tighten bolts (16) to a torque of 40 N·m (30 lb ft). Tighten bolt (18).

Note: Do not rotate bolts (19) and (16) more than 45 degrees at a time.

rotate bolts (19) and (16) more than 45 degrees at a time. Illustration 48 g01824815 4.

Illustration 48

g01824815

4. Position plate assembly (11) and install the washer and bolt (12). Install hose assembly (14). Install tube assembly (9). Connect harness assemblies (13) and install the washers and bolts (10).

assemblies (13) and install the washers and bolts (10). Illustration 49 g01824814 5. Connect harness assembly

Illustration 49

g01824814

5. Connect harness assembly (5). Install hose assembly (3) and clamp assembly (8). Install hose assembly (7) and bolt (4). Install hose assemblies (6), (2), and (1).

i03634303

Turbocharger - Remove

SMCS Code: 1052-011

Removal Procedure

Table 12

Required Tools

Tool

Part Number

Part Description

Qty

A

138-7573

Link Bracket

1

KENR6052-01

21

Disassembly and Assembly Section

Start By:

a. Remove the air cleaners. Refer to Disassembly and Assembly, “Air Cleaner - Remove and Install”.

NOTICE Keep all parts clean from contaminants.

Contaminan ts may cause rapid wear and shortened component life.

NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, test- ing, adjus ting and repair of the product. Be prepared to collect the uid with suitable containers before open- ing any compartment or disassembling any compo- nent cont aining uids.

Refer to Special Publication, NENG2500, “Caterpillar Dealer S ervice Tool Catalog” for tools and supplies suitable to collect and contain uids on Caterpillar products.

Dispose of all uids according to local regulations and mandates.

all fl uids according to local regulations and mandates. Illustration 50 g01826715 1. Remove hose assemblies

Illustration 50

g01826715

1. Remove hose assemblies (1), (2), and (3).

2. Disconnect hose assemblies (4) and (8).

3. Disconnect sensor (5) from turbocharger (7).

and (8). 3. Disconnect sensor (5) from turbocharger (7). Illustration 51 g01826997 5. Attach Tooling (A)

Illustration 51

g01826997

5. Attach Tooling (A) and a suitable lifting device onto turbocharger (7). The weight of turbocharger (7) is approximately 85 kg (187 lb).

6. Loosen clamp (10).

7. Remove bolts (9) and the washers. Remove turbocharger (7).

Remove bolts (9) and the washers. Remove turbocharger (7). Illustration 52 g01949854 8. Remove screen assembly

Illustration 52

g01949854

8. Remove screen assembly (8) from turbocharger support (10) and inspect. Remove O-ring seal (9).

9. Repeat Steps 1 through 7 for the remaining turbochargers.

22

Disassembly and Assembly Section

KENR6052-01

i03634304

Turbocharger - Install

SMCS Code: 1052-012

Installation Procedure

Table 13

Required Tools

Tool

Part Number

Part Description

Qty

A

138-7573

Link Bracket

1

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before open- ing any compartment or disassembling any compo- nent containing uids.

Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain uids on Caterpillar products.

Dispose of all uids according to local regulations and mandates.

all fl uids according to local regulations and mandates. Illustration 53 g01949854 1. Install clean screen

Illustration 53

g01949854

1. Install clean screen assembly (8) into turbocharger support (10). Install new O-ring seal (9).

into turbocharger support (10). Install new O-ring seal (9). Illustration 54 g01826997 2. Attach Tooling (A)

Illustration 54

g01826997

2. Attach Tooling (A) and a suitable lifting device onto turbocharger (7). The weight of turbocharger (7) is approximately 85 kg (187 lb). Position turbocharger (7). Install the washers and bolts (9).

3. Tighten clamp assemblies (10) to a torque of 12 ± 2 N·m (106 ± 18 lb in).

(10) to a torque of 12 ± 2 N·m (106 ± 18 lb in). Illustration 55

Illustration 55

g01826715

4. Position the bellows and install clamps (6). Tighten clamps (6) to a torque of 12 ± 2 N·m (106 ± 18 lb in). Tap clamps (6) all around and tighten again to a torque of 12 ± 2 N·m (106 ± 18 lb in).

5. Connect hose assemblies (8) and (4).

6. Install hose assemblies (3), (2), and (1).

7. Connect sensor (5) to turbocharger (7).

End By:

a. Install the air cleaners. Refer to Disassembly and Assembly, “Air Cleaner - Remove and Install”.

KENR6052-01

23

Disassembly and Assembly Section

i02635840

Air Inlet Manifold - Remove and Install

SMCS Code: 1058-010

Removal Procedure

- Remove and Install SMCS Code: 1058-010 Removal Procedure Illustration 56 g01321426 1. Disconnect the harness

Illustration 56

g01321426

1. Disconnect the harness assembly.

2. Attach a suitable lifting device onto air inlet manifold (2). The weight of air inlet manifold (2) is approximately 69 kg (150 lb). Remove top bolts (1) and loosen bottom bolts.

Note: The air inlet manifold can be removed in sections, if necessary.

3. Remove air inlet manifold (2).

Installation Procedure

3. Remove air inlet manifold (2). Installation Procedure I l lustration 57 g01321426 1. Attach a

Il lustration 57

g01321426

1. Attach a suitable lifting device onto air inlet manifold (2). The weight of air inlet manifold (2) is approximately 69 kg (150 lb). Position air inlet manifold (2).

2. Install top bolts (1) and tighten top and bottom bolts. Tighten bolts (1) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

3. If necessary, remove the air inlet manifold in sections. Tighten the clamp assemblies to a torque of 7.5 ± 1 N·m (66 ± 9 lb in).

4. Connect the harness assembly.

i02636137

Exhaust Elbow - Remove and Install

SMCS Code: 1060-010

Removal Procedure

Table 14

Required Tools

Tool

Part Number

Part Description

Qty

A

138-7573

Link Bracket

2

Part Number Part Description Qty A 138-7573 Link Bracket 2 Illustration 58 g01704859 1. Remove bolts

Illustration 58

g01704859

1. Remove bolts (3) and the washers. Remove bolts (2), the washers, and the nuts from platform assembly (1).

2. Attach Tooling (A) and a suitable lifting device onto platform assembly (1). The weight of platform assembly (1) is approximately 28 kg (63 lb). Remove platform assembly (1).

3. Attach Tooling (A) and a suitable lifting device onto exhaust elbow (5). The weight of exhaust elbow (5) is approximately 95 kg (209 lb). Loosen clamps (6). Remove bolts (4). Remove exhaust elbow (5).

24

Disassembly and Assembly Section

KENR6052-01

Installation P rocedure

Table 15

Required Tools

Tool

Part Number

Part Description

Qty

A

138-7573

Link Bracket

2

Part Number Part Description Qty A 138-7573 Link Bracket 2 Illustr ation 59 g01704859 1. Attach

Illustr ation 59

g01704859

1. Attach Tooling (A) and a suitable lifting device onto exhaust elbow (5). The weight of exhaust elbow (5) is approximately 95 kg (209 lb). Position exhaust elbow (5). Install bolts (4).

2. Tighten clamp assemblies (6) to a torque of 12 ± 2 N·m (106 ± 18 lb in). Tap the clamp assem blies all around. Repeat tightening clamp assemblies (6) to a torque of 12 ± 2 N·m (106 ± 18 lb in).

3. Attach Tooling (A) and a suitable lifting device onto platform assembly (1). The weight of platform assembly (1) is approximately 28 kg (63 lb). Position platform assembly (1).

4. Inst all the washers, bolts (3), and the nuts. Install the washers and bolts (2) in platform assembly (1).

i02636539

Exhaust Manifold - Remove and Install

SMCS Code: 1059-010

Removal Procedure

- Remove and Install SMCS Code: 1059-010 Removal Procedure Illustration 60 g01851633 1. Remove clamps (1).

Illustration 60

g01851633

1. Remove clamps (1). Remove exhaust bellow (3). Remove clamps (2). Remove exhaust bellow (4).

bellow (3). Remove clamps (2). Remove exhaust bellow (4). Illustration 61 g01321966 2. Attach a suitable

Illustration 61

g01321966

2. Attach a suitable lifting device onto exhaust manifolds (5). The weight of exhaust manifolds (5) is approximately 82 kg (180 lb). Loosen clamp (6).

KENR6052-01

25

Disassembly and Assembly Section

KENR6052-01 25 Disassembly and Assembly Section Illustration 62 g01851634 4. Remove exhaust manifold (9). 5. Repeat

Illustration 62

g01851634

4. Remove exhaust manifold (9).

5. Repeat Steps 1 through 4 for the opposite side.

Installation Procedure

Table 16

Required Tools

Tool

Part Number

Part Description

Qty

A

4C-5597

Anti-se ize Compound

-

Qty A 4C-5597 A n t i - s e ize Compound - Illustration 63 g01851634

Illustration 63

g01851634

1. Position exhaust manifold (9).

1 . P o s i t i o n exhaust manifold (9). Illustration 64 g01321966

Illustration 64

g01321966

2. Attach a suitable lifting device onto exhaust manifolds (5). The weight of exhaust manifolds (5)

is approximately 82 kg (180 lb). Position exhaust

manifolds (5). Tighten clamp assemblies (6) to a

torque of 12 ± 2 N·m (106 ± 18 lb in).

3. Apply Tooling (A) to bolts (7). Install bolts (7) in exhaust manifolds (5). Tighten bolts (7) and (8) to

a torque of 65 ± 5 N·m (48 ± 4 lb ft).

(7) and (8) to a torque of 65 ± 5 N·m (48 ± 4 lb ft).

Illustration 65

g01851633

4. Install exhaust bellow (4). Install clamp assemblies (2). Install exhaust bellow (3). Install clamp assemblies (1). Tighten clamp assemblies (1) and (2) to a torque of 12 ± 2 N·m (106 ± 18 lb in).

5. Repeat Steps 1 through 4 for the opposite side.

26

Disassembly and Assembly Section

KENR6052-01

i02636698

Water Pump - Remove

SMCS Code: 136 1-011

Removal Procedure

Table 17

Required Tools

Tool

Part Number

Part Descri ption

Qty

A

138-7573

Link Bracket

1

NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before open- ing any compartment or disassembling any compo- nent containing uids.

Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain uids on Caterpillar products.

Dispose of all uids according to local regulations and mandates.

1. Drain the coolant from the cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change”.

Maintenance Manual, “Cooling System Coolant - Change”. Illustration 66 g01323569 2 . R emove bolts (3).

Illustration 66

g01323569

2 . R emove bolts (3). Remove elbow (4). Remove the O-ring seal from elbow (4).

3. Remove bolts (6). Disconnect elbow (7). Remove the O-ring seal.

4. Use Tooling (A) and attach a suitable lifting device onto water pump (1). The weight of water pump (1) is approximately 44 kg (97 lb). Disconnect hose assembly (2). Remove bolts (5) and remove water pump (1).

i02088955

Water Pump - Disassemble

SMCS Code: 1361-015

Disassembly Procedure

Table 18

 

Required Tools

 

Part

   

Tool

Number

Part Description

Qty

A

1P-0510

Driver Gp

1

B

-

1 inch by 4 inch steel plate

2

C

248-3311

Holding Fixture

1

D

248-3310

Locknut Wrench

1

E

8H-0663

Bearing Puller Gp

1

Start By:

a. Remove the water pump. Refer to Disassembly and Assembly, “Water Pump - Remove”.

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

KENR6052-01

27

Disassembly and Assembly Section

KENR6052-01 27 Disassembly and Assembly Section Illustration 67 g01036014 1. Remove plug (1) and plug (2)

Illustration 67

g01036014

1. Remove plug (1) and plug (2) from bearing housing (3). Remove plug (6) from housing (5). Remove the O-ring seals from the plugs.

2. Remove water pump lter (4) from bearing housing (3).

Remove water pump fi lter (4) from bearing housing (3). Illustration 68 g01035264 3. Remove bolts

Illustration 68

g01035264

3. Remove bolts (7) and washers. Remove bearing housing (3) from housing (5). Remove O-ring seal (8) from bearing housing (3).

(5). Remove O-ring seal (8) from bearing housing (3). Illustration 69 g01035285 4. Install Tooling (B)

Illustration 69

g01035285

4. Install Tooling (B) under impeller (9). Use a suitable press and Tooling (A) to remove the impeller.

Note: Do not allow bearing housing (3) to fall to the oor when the impeller is removed from the pump shaft.

fl oor when the impeller is removed from the pump shaft. Illustration 70 g01035309 5. Remove

Illustration 70

g01035309

5. Remove socket head bolts (10). Remove retainer (11) and pump shaft (12) from bearing housing (3).

Note: Spring (14) and ceramic seal (13) will be removed from the shaft assembly when the pump shaft is removed from the bearing housing.

28

Disassembly and Assembly Section

KENR6052-01

28 Disassembly and Assembly Section KENR6052-01 Illustration 71 g01035407 6. Install pump shaft (12) in Tooling

Illustration 71

g01035407

6. Install pump shaft (12) in Tooling (C). Loosen set screws (15). Use Tooling (D) to remove bearing locknut (16) from the pump shaft.

Note: The splined end of the pump shaft is marked in order to indicate either RH threads or LH threads on the pump shaft.

indicate either RH threads or LH threads on the pump shaft. I l lustration 72 g01035429

Il lustration 72

g01035429

7. Use Tooling (E) to remove bearing assembly (17) fr om pump shaft (12).

to remove bearing assembly (17) f r om pump shaft (12). Illustration 73 g01035437 8. Remove

Illustration 73

g01035437

8. Remove ceramic seal (18) and lip seal (19) from bearing housing (3).

i02088665

Water Pump - Assemble

SMCS Cod e: 1361-016

Assembly Procedure

Table 19

 

Required Tools

 

Part

   

Tool

Number

Part Description

Qty

A

1P-0510

Driver Gp

1

C

248-3311

Holding Fixture

1

D

248-3310

Locknut Wrench

1

E

8H-0663

Bearing Puller Gp

1

F

1U-6396

O-Ring Assembly

-

Compound

G

7N-8268

Installation Tool

1

H

8H-8581

Feeler Gauge

1

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

KENR6052-01

29

Disassembly and Assembly Section

KENR6052-01 29 Disassembly and Assembly Section Illustration 74 g01040290 1. Use Tooling (E) and a suitable

Illustration 74

g01040290

1. Use Tooling (E) and a suitable press to install bearing assembly (17) on pump shaft (12).

2. Install bearing cone (23) on the pump shaft.

3. Install spacer (22) and bearing cups (21) on the pump shaft.

4. Install bearing cone (20) on the pump shaft.

pump shaft. 4. Install bearing cone (20) on the pump shaft. Illustration 75 g01035607 Note: The

Illustration 75

g01035607

Note: The torque wrench must be 90 degrees to Tooling (D).

6. Install set screws (15) and tighten to a torque of 4 ± 1 N·m (35 ± 9 l b in).

and tighten to a torque of 4 ± 1 N·m (35 ± 9 l b in).

Illustration 76

g01035690

Note: Do not damage the wear surfaces of the carbon ring or the ceramic ring. Do not touch the wear surfaces of the carbon ring or the ceramic ring. Install the ceramic ring with the smoothest face of the ring toward the carbon seal.

7. Apply Tooling (F) to the outside diameter of ceramic seal (18). Use Tooling (G) and hand pressure to install ceramic seal (18) in bearing housing (3).

to install ceramic seal (18) in bearing housing (3). Illustration 77 g 0 1 035699 8.

Illustration 77

g01 035699

8. Use Tooling (A) and a suitable press to install lip seal (19) in bearing housing (3). Ensure that the li p is toward the outside.

Note: Install the lip seal dry. Install the lip seal within tw o minutes of removal from the shipping sleeve.

30

Disassembly and Assembly Section

KENR6052-01

30 Disassembly and Assembly Section KENR6052-01 Illustration 78 g01035809 9. Lubricate pump shaft (12) with clean

Illustration 78

g01035809

9. Lubricate pump shaft (12) with clean engine oil. Install the pump shaft in bearing housing (3). Install retainer (11). Install socket head bolts (10) and tighten to a torque of 12 ± 3 N·m (9 ± 2 lb ft).

(10) and tighten to a torque of 12 ± 3 N·m (9 ± 2 lb ft).

Illustration 79

g01035829

Note: Do not damage the wear surfaces of the carbon ring or the ceramic ring. Do not touch the wear surfaces of the carbon ring or the ceramic ring. Install the ceramic ring with the smoothest face of the ring toward the carbon seal.

10. Remove spring (14) from ceramic seal (13).

11. Apply Tooling (F) to the inside diameter of ceramic seal (13). Use hand pressure and the tool that is supplied with the water pump seal group to install the ceramic seal. The face of ceramic seal (13) should make li ght contact with ceramic seal (18).

12. Install spring (14).

13. Lubricate pump shaft (12) on bearing housing (3) with clean engine oil. Position impeller (9) on the pump shaft.

clean engine oil. Position impeller (9) on the pump shaft. Illustration 80 g01035846 14. Place bearing

Illustration 80

g01035846

14. Place bearing housing (3) on impeller (9). Use a suitable press and press pump shaft (12) into the impeller. Install the impeller so the dimension between the impeller and the pump shaft is 0.000 ± 0.076 mm (0.0000 ± 0.0030 inch).

dimension between the impeller and the pump shaft is 0.000 ± 0.076 mm (0.0000 ± 0.0030

Illustration 81

g01035264

KENR6052-01

31

Disassembly and Assembly Section

15. Install O-ring seal (8) on bearing housing (3). Lubricate the O -ring seal with clean engine oil.

16. Position bearing housing (3) in housing (5). Install washers and bolts (7) nger tight.

housing (5). Install washers and bolts (7) fi nger tight. Illustration 82 g01036084 17. Tighten the

Illustration 82

g01036084

17. Tighten the bolts in a numerical sequence to a torque of 50 ± 9 N·m (35 ± 7 lb ft).

18. Use Tooling (H) and measure the gap between the impeller and the pump housing. The minimum gap between the impeller and the pump housing is 0.20 mm (0.008 inch).

the impeller and the pump housing is 0.20 mm (0.008 inch). Illustration 83 g01036014 19. Install

Illustration 83

g01036014

19. Install the O-ring seal on plug (6). Install the plug in housing (5). Tighten the plug to a torque of 177 ± 7 N·m (131 ± 6 lb ft).

20. Install the O-ring seal on plug (2). Install the plug in bearing housing (3). Tighten the plug to a torque of 8 ± 1 N·m (6 ± 1 lb ft).

22. Install water pump lter (4) in bearing housing (3).

End By:

a. Install the water pump. Refer to Disassembly and Assembly, “Water Pump - Install”.

i02636819

Water Pump - Install

SMCS Code: 1361-012

Installation Procedure

Table 20

Required Tools

Tool

Part Number

Part Description

Qty

A

138-7573

Link Bracket

1

Part Number Part Description Qty A 138-7573 Link Bracket 1 Illustration 84 g01323569 1. Use Tooling

Illustration 84

g01323569

1. Use Tooling (A) and attach a suitable lifting device onto water pump (1). The weight of water pump (1) is approximately 44 kg (97 lb). Position water pump (1) onto the engine and install bolts (5). Connect hose assembly (2).

2. Position the O-ring seal and elbow (7). Install bolts

(6).

3. Position the O-ring seal onto elbow (4). Install elbow (4). Install bolts (3).

4. Fill the cooling system with coolant. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change”.

32

Disassembly and Assembly Section

KENR6052-01

i03490381

Fuel and Auxiliary Water Pump Drive - Remove and Install

SMCS Code: 1288-010; 1371-010-DRV

Removal Procedure

Table 21

 

Required Tools

 

Tool

Part Number

Part Description

Qty

 

A 138-7575

Link Bracket

1

 

B 1P-0520

Driver Gp

1

Start By:

a. Remove the fuel pump. Refer to Disassembly and Assembly, “Fuel Pump (Manifold) - Remove and Install”.

b. Remove the auxiliary water pump. Refer to Disassembly and Assembly, “Auxiliary Water Pump - Remove”.

and Assembly, “Auxiliary Water Pump - Remove”. Illustration 85 g01827734 1. Attach Tooling (A) and a

Illustration 85

g01827734

1. Attach Tooling (A) and a suitable lifting device onto housing (1). The weight of housing (1) is approximately 23 kg (50 lb). Remove bolts (2). Remove housing (1).

23 kg (50 lb). Remove bolts (2). Remove housing (1). Illustration 86 g01213648 2. Remove O-ring

Illustration 86

g01213648

2. Remove O-ring seals (3) from housing (1).

86 g01213648 2. Remove O-ring seals (3) from housing (1). Illustration 87 g01213 659 3. Use

Illustration 87

g01213 659

3. Use Tooling (B) and a suitable press in order to remove bearing (4) from housing (1).

press in order to remove bearing (4) from housing (1). Illustration 88 g01827737 4. Remove the

Illustration 88

g01827737

4. Remove the fuel and auxiliary water pump drive gear (5).

KENR6052-01

33

Disassembly and Assembly Section

KENR6052-01 33 Disassembly and Assembly Section Illustration 89 g01215057 5. Remove bolts (6). Remove adapter (7).

Illustration 89

g01215057

5. Remove bolts (6). Remove adapter (7).

89 g01215057 5. Remove bolts (6). Remove adapter (7). Illustration 90 g01215 060 6. Remove O-ring

Illustration 90

g01215 060

6. Remove O-ring seals (8) and (9).

90 g01215 060 6. Remove O-ring seals (8) and (9). Illustration 91 g01215061 7. Use Tooling

Illustration 91

g01215061

7. Use Tooling (B) and a suitable press in order to remove bearing (10) from adapter (7).

Installation P rocedure

Table 22

 

Required Tools

 

Tool

Part Number

Part Description

Qty

 

A 138-7575

Link Bracket

1

 

B 1P-0520

Driver Gp

1

Link Bracket 1   B 1P-0520 Driver Gp 1 Illustration 92 g01215071 1. Use Tooling (B)

Illustration 92

g01215071

1. Use Tooling (B) and a suitable press in order to install bearing (10) into adapter (7).

press in order to install bearing (10) into adapter (7). Illustration 93 g 0 1 2

Illustration 93

g012 15060

Note: Check the O-ring seals for wear or for damage. If necessary, replace the O-ring seals.

2. Install O-ring seals (8) and (9).

34

Disassembly and Assembly Section

KENR6052-01

34 Disassembly and Assembly Section KENR6052-01 Illustration 94 g01215057 3. Install adapter (7). Install bolts (6).

Illustration 94

g01215057

3. Install adapter (7). Install bolts (6).

94 g01215057 3. Install adapter (7). Install bolts (6). Illustration 95 g01827 737 4. Install the

Illustration 95

g01827 737

4. Install the fuel and auxiliary water pump drive gear

(5).

Install the fuel and auxiliary water pump drive gear (5). Illustration 96 g01213693 5. Use Tooling

Illustration 96

g01213693

5. Use Tooling (B) and a suitable press in order to install bearing (4) into housing (1).

press in order to install bearing (4) into housing (1). Illustration 97 g01213648 Note: Check the

Illustration 97

g01213648

Note: Check the O-ring seals for wear or for damage. If necessary, replace the O-ring seals.

6. Install O-ring seals (3) into housing (1).

O-ring seals. 6. Install O-ring seals (3) into housing (1). Illustration 98 g0182 7734 7. Attach

Illustration 98

g0182 7734

7. Attach Tooling (A) and a suitable lifting device onto housing (1). The weight of housing (1) is approximately 23 kg (50 lb). Position housing (1). Install bolts (2).

End B y:

a. Install the auxiliary water pump. Refer to Dis assembly and Assembly, “Auxiliary Water Pump - Install”.

b. Ins tall the fuel pump. Refer to Disassembly and Assembly, “Fuel Pump (Manifold) - Remove and Install”.

KENR6052-01

35

Disassembly and Assembly Section

i02637878

Auxiliary Water Pump - Remove

SMCS Code: 1371-011

Removal Procedure

Table 23

Required Tools

Tool

Part Number

Part Description

Qty

A

138-7573

Link Bracket

1

NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before open- ing any compartment or disassembling any compo- nent containing uids.

Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain uids on Caterpillar products.

Dispose of all uids according to local regulations and mandates.

1. Drain the coolant from the auxiliary cooling system into a suitable container for storage or for disposal. Refer to Operation and Maintenance Manual, “Cooling System Coolant - Change”.

Maintenance Manual, “Cooling System Coolant - Change”. Illustration 99 g 0 1323519 2. Disconnect tube assembly

Illustration 99

g0 1323519

2. Disconnect tube assembly (1). Remove bolts (3). Remove elbow (4 ). Remove bolts (6). Remove elbow (7).

3. Use Tooling (A ) and attach a suitable lifting device onto auxiliary water pump (2). The weight of auxiliary water pump (2) is approximately 31 kg (69 lb). Remove nuts (5). Remove auxiliary water pump (2).

i02638305

Auxiliary Water Pump -

Disassemble

SMCS Code: 1371-015

Disassembly Procedure

Table 24

 

Required Tools

 

Tool

Part Number

Part Description

Qty

A

1P-0510

Driver Gp

1

B

-

1 inch by 4 inch

2

steel plate

C

248-3311

Holding Fixture

1

D

248-3310

Spanner Wrench

1

E

8H-0663

Bearing Puller Gp

1

Start By:

a. Remove the auxiliary water pump. Refer to Disassembly and Assembly, “Auxiliary Water Pump - Remove”.

auxiliary water pump. Refer to Disassembly and Assembly, “Auxiliary Water Pump - Remove”. Illustration 100 g01036014

Illustration 100

g01036014

36

Disassembly and Assembly Section

KENR6052-01

1. Remove plugs (1) and (2) from bearing housing (3). Remove plug (6) from housing (5). Remove the O-ring seals from the plugs.

2. Remove water pump lter (4) from bearing housing (3).

e r p u m p fi lter (4) from bearing housing (3). Illustration 101 g01035264

Illustration 101

g01035264

3. Remove bolts (7) and the washers. Remove bearing housing (3) from housing (5). Remove O-ring seal (8) from bearing housing (3).

(5). Remove O-ring seal (8) from bearing housing (3). Illustration 102 g01035285 Personal injury can result

Illustration 102

g01035285

(8) from bearing housing (3). Illustration 102 g01035285 Personal injury can result from being struck by

Personal injury can result from being struck by parts propelled by a released spring force.

Make sure to wear all necessary protective equip- ment.

Follow the recommended procedure and use all recommended tooling to release the spring force.

4. Install Tooling (B) under impeller (9). Use a suitable press and Tooling (A) to remove impeller

(9).

Note: Do not allow bearing housing (3 ) to fall to the oor when the impeller is removed from the pump shaft.

fl oor when the impeller is removed from the pump shaft. Illustration 103 g01035309 5. Remove

Illustration 103

g01035309

5. Remove socket head bolts (10). Remove retainer (11) and pump shaft (12) from bearing housing (3).

Note: Spring (14) and ceramic seal (13) will be removed from the shaft assembly when the pump shaft is removed from the bearing housing.

KENR6052-01

37

Disassembly and Assembly Section

KENR6052-01 37 Disassembly and Assembly Section Illustration 104 g01035407 6. Install pump shaft (12) in Tooling

Illustration 104

g01035407

6. Install pump shaft (12) in Tooling (C). Loosen set screws (15). Use Tooling (D) to remove bearing locknut (16) from the pump shaft.

Note: The splined end of the pump shaft is marked in order to indicate either RH threads or LH threads on the pump shaft.

indicate either RH threads or LH threads on the pump shaft. I l lustration 105 g01035429

Il lustration 105

g01035429

7. Use Tooling (E) to remove bearing assembly (17) fr om pump shaft (12).

to remove bearing assembly (17) f r om pump shaft (12). Illustration 106 g01035437 8. Remove

Illustration 106

g01035437

8. Remove ceramic seal (18) and lip seal (19) from bearing housing (3).

i02638976

Auxiliary Water Pump - Assemble

SMCS Code: 1371-016

Assembly Procedure

Table 25

 

Required Tools

 

Tool

Part Number

Part Description

Qty

A

1P-0510

Driver Gp

1

C

248-3311

Holding Fixture

1

D

248-3310

Spanner Wrench

1

E

8H-0663

Bearing Puller Gp

1

F

1U-6396

O-Ring Assembly

-

Compound

G

7N-8268

Installation Tool

1

H

8H-8581

Feeler Gauge

1

NOTICE Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

38

Disassembly and Assembly Section

KENR6052-01

38 Disassembly and Assembly Section KENR6052-01 Illustration 107 g01040290 1. Use Tooling (E) and a suitable

Illustration 107

g01040290

1. Use Tooling (E) and a suitable press to install assembly (17) on pump shaft (12).

2. Install bearing cone (23) on the pump shaft.

3. Install spacer (22) and bearing cups (21) on the pump shaft.

4. Install bearing cone (20) on the pump shaft.

pump shaft. 4. Install bearing cone (20) on the pump shaft. Illustration 108 g01035607 Note: The

Illustration 108

g01035607

Note: The torque wrench must be 90 degrees to Tooling (D).

6. Install set screws (15) and tighten to a torque of 4 ± 1 N·m (35 ± 9 l b in).

and tighten to a torque of 4 ± 1 N·m (35 ± 9 l b in).

Illustration 109

g01035690