New Replacement Options for Serviced Engines{1000} Caterpillar

Excavator:

320C (S/N: FBA1-UP; GAA1-UP; GLA1-UP; MAA1-UP; PAA1-UP; FBB1-UP; GAB1-UP; MAB1-UP; PAB1-UP; FBC1-UP; GAC1-UP; MAC1-UP; PAC1-UP; GAD1-UP; NAE1-UP; DBG1-UP; EAG1-UP; GNG1-UP; JTG1-UP; SAH1-UP; SBN1-UP; TBR1-UP; HKT1-UP; RAW1-UP; EGA1-UP)

320D (S/N: FNA1-UP; MDE1-UP; DHK1-UP; FXK1-UP; BWP1-UP; AZR1-UP; DFT1-UP; EBT1-UP; CXY1-UP; JGZ1-UP)

321C (S/N: KBB1-UP; MCF1-UP; KCR1-UP; DAX1-UP)

323D (S/N: SDC1-UP; CYD1-UP; PBM1-UP; DKW1-UP)

Introduction

Do not perform this Special Instruction until you have read this information and you understand the information.

Determining the Procedure

Procedures

Procedure A

1. Remove 222-8372 Serpentine Belt , 266-6326 Pulley As and 266-6337 Pulley from 239-6561 Engine Pulley Gp on the new engine. Discard the components.

2. Remove all components for 266-6331 Suction Fan Gp that are installed on the new engine.

3. 212-8585 Serpentine Belt , 222-8371 Pulley As and 266-6229 Fan Drive Pulley are removed from 266-6313 Engine Pulley Gp on the old engine.

4. Remove all parts of 255-2877 Fan Drive Gp on the old engine.

5. Install all parts that are removed in Step 4 onto the new engine. Torque the components to 35 ± 6 N·m (26 ± 4 lb ft).

6. Install all parts that are removed in Step 3 onto the new engine. Torque the nut for the crankshaft pulley to 490 ± 10 N·m (361 ± 7 lb ft). Torque the rest of the components to 35 ± 6 N·m (26 ± 4 lb ft).

Procedure B

1. Remove 222-8372 Serpentine Belt , 266-6326 Pulley As and 266-6337 Pulley from 239-6561 Engine Pulley Gp on the new engine.

2. Remove all components for 266-6331 Suction Fan Gp that are installed on the new engine. Discard the components.

3. 212-8585 Serpentine Belt and 266-6327 Pulley are removed from 266-6317 Engine Pulley Gp on the old engine.

4. Remove all parts of 255-2877 Fan Drive Gp on the old engine.

5. Install all parts that are removed in Step 4 onto the new engine. Torque the components to 35 ± 6 N·m (26 ± 4 lb ft).

6. Install all parts that are removed in Step 3 onto the new engine. Torque the components to 35 ± 6 N·m (26 ± 4 lb ft).

Procedure C

1. Remove 222-8372 Serpentine Belt , 266-6326 Pulley As and 266-6337 Pulley from 239-6561 Engine Pulley Gp that is installed on the new engine.

2. Remove all components for 266-6331 Suction Fan Gp that are installed on the new engine. Discard the components.

3. 212-8585 Serpentine Belt , 212-8575 Pulley As and 266-6229 Fan Drive Pulley are removed from the old engine.

4. Remove all parts of 255-2877 Fan Drive Gp on the old engine.

5. Install all parts that are removed in Step 4 onto the new engine. Torque the components to 35 ± 6 N·m (26 ± 4 lb ft).

6. Install all parts removed in Step 3 onto the new engine. Torque the nut for the crankshaft pulley to 490 ± 10 N·m (361 ± 7 lb ft). Torque the rest of the components to 35 ± 6 N·m (26 ± 4 lb ft).

Procedure D

1. Remove 222-8372 Serpentine Belt , 266-6326 Pulley As and 266-6337 Pulley from 239-6561 Engine Pulley Gp that is installed on the new engine.

2. Remove all components for 266-6331 Suction Fan Gp that are installed on the new engine. Discard the components.

3. 212-8585 Serpentine Belt , 222-8293 Pulley As and 266-6233 Fan Drive Pulley are removed from the old engine.

4. Remove all parts of 255-2877 Fan Drive Gp on the old engine.

5. Install all parts that are removed in Step 4 onto the new engine. Torque the components to 35 ± 6 N·m (26 ± 4 lb ft).

6. Install all parts that are removed in Step 3 onto the new engine. Torque the nut for the crankshaft pulley to 490 ± 10 N·m (361 ± 7 lb ft). Torque the rest of the components to 35 ± 6 N·m (26 ± 4 lb ft).

Procedure E

1. Remove 222-8372 Serpentine Belt , 266-6326 Pulley As and 266-6337 Pulley from 239-6561 Engine Pulley Gp that is installed on the new engine.

2. Remove all components for 266-6331 Suction Fan Gp that are installed on the new engine. Discard the components.

3. 222-8311 Serpentine Belt , 222-8293 Pulley As and 266-6233 Fan Drive Pulley are removed from the old engine.

4. Remove all parts of 255-2877 Fan Drive Gp on the old engine.

5. Install all parts that are removed in Step 4 onto the new engine. Torque the components to 35 ± 6 N·m (26 ± 4 lb ft).

6. Install all parts removed in Step 3 onto the new engine. Torque the nut for the crankshaft pulley to 490 ± 10 N·m (361 ± 7 lb ft). Torque the rest of the components to 35 ± 6 N·m (26 ± 4 lb ft).

Procedure F

1. Remove 266-6326 Pulley As and 266-6337 Pulley from 239-6561 Engine Pulley Gp that is installed on the new engine.

2. Remove all components for 266-6331 Suction Fan Gp that are installed on the new engine. Discard the components.

3. Remove 212-8570 Pointer from 212-8547 Front Housing Gp that is installed on the new engine. Discard the component.

4. 222-8371 Pulley As and 266-6229 Fan Drive Pulley are removed from 255-2884 Engine Pulley Gp on the old engine.

5. Remove all parts of 255-2877 Fan Drive Gp on the old engine.

6. Remove 212-8570 Pointer from 222-8373 Front Housing Gp on the old engine.

7. Install the 212-8570 Pointer removed in Step 6 onto the new engine. Torque the pointer to 18 ± 3 N·m (13 ± 2.5 lb ft).

8. Install all parts removed in Step 5 onto the new engine. Torque the components to 35 ± 6 N·m (26 ± 4 lb ft).

9. Install all parts removed in Step 4 onto the new engine. Torque the nut for the crankshaft pulley to 490 ± 10 N·m (361 ± 7 lb ft). Torque the rest of the components to 35 ± 6 N·m (26 ± 4 lb ft).

Procedure G

1. Remove 5I-7602 Coupling As from 279-7860 Turbocharger Gp that is installed on the new engine.

2. Remove 5I-7587 Cover and 5I-7589 Turbocharger Cartridge from the new engine.

3. Remove 5I-7748 Ring from the new engine.

4. Position the compressor on the new engine at the same position as 233-1159 Turbocharger Gp on the old engine.

5. Install 5I-7748 Ring onto the new engine.

6. The components removed in Step 2 are installed on the new engine.

7. Install 5I-7602 Coupling As onto the new engine. Torque the coupling to 4 ± 1 N·m (35 ± 9 lb in).

Procedure H

1. Remove 5I-7602 Coupling As from 279-7860 Turbocharger Gp that is installed on the new engine.

2. Remove 5I-7587 Cover and 5I-7589 Turbocharger Cartridge from the new engine.

3. Remove 5I-7748 Ring from the new engine.

4. Position the compressor on the new engine at the same position as 287-0106 Turbocharger Gp on the old engine.

5. Install 5I-7748 Ring onto the new engine.

6. The components that are removed in Step 2 are installed on the new engine.

7. Install 5I-7602 Coupling As onto the new engine. Torque the coupling to 4 ± 1 N·m (35 ± 9 lb in).

Procedure I

1. Remove all components of 266-6344 Muffler Gp from the new engine.

2. Remove all components of 212-8553 Muffler Gp from the old engine.

3. Install all components that are removed in Step 2 onto the new engine. Torque the components to 35 ± 6 N·m (26 ± 4 lb ft).

Procedure J

1. Remove all components of 266-6344 Muffler Gp from the new engine.

2. Remove all components of 212-8615 Muffler Gp from the old engine.

3. Install all components that are removed in Step 2 onto the new engine. Torque the components to 35 ± 6 N·m (26 ± 4 lb ft).

Procedure K

1. Remove 266-6325 Plate from 266-6316 Alternator Mounting Gp installed on the new engine.

2. Remove 178-6597 Plate from 178-6531 Alternator Mounting Gp installed on the old engine.

3. Install the components that are remove in Step 2 onto the new engine. Torque 099-4483 Bolt to 64 ± 10 N·m (47 ± 7 lb ft). Torque 8T-4137 Bolt to 35 ± 6 N·m (26 ± 4 lb ft).

Procedure L

1. Remove 154-9024 Fluid Sampling Valve Gp , 157-0670 Dust Cap and 183-8222 Plug from 212-8614 Water Lines Gp on the new engine.

2. The components removed in Step 1 are reinstalled on the new engine with the same orientation as the 217-5615 Water Lines Gp on the old engine.

Procedure M

1. Remove all components of 266-6316 Alternator Mounting Gp on the new engine.

2. Remove 212-8561 Alternator Gp from the new engine. Discard the components.

3. Remove all components of 222-8309 Alternator Mounting Gp from the old engine.

4. Remove 222-8310 Alternator Gp from the old engine.

5. Install all components from Step 3 and Step 4 onto the new engine. Torque 5P-2566 Bolt to 105 ± 20 N·m (77 ± 15 lb ft). Torque 8T-4137 Bolt to 35 ± 6 N·m (26 ± 4 lb ft). Torque 8T-4183 Bolt , 8T-4648 Bolt and 178-6598 Bolt to 64 ± 10 N·m (47 ± 7 lb ft).

Procedure N

1. Remove the old film from the engine.

Show/hide table



Illustration 1	g01408705
Top view (1) Film location

2. Install the new film at location (1) .