d333 and g333 engines s/n 79b1, 80b1, 87b1 & 88b1 & up · 2018. 11. 3. · service manual service...
TRANSCRIPT
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Servic
e M
an
ual
Service Manual
THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF
CATERPILLAR OR IT’S SUCCESSORS. CATERPILLAR AND IT’S SUCCESSORS
ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.
TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS,
AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.
D333 and G333
Engines
S/N 79B1, 80B1,
87B1 & 88B1 & Up
CT-S-ENG333D&G
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IA-5 Group 30 Page 4 SERVICE MANUAL
GENERAL INSTRUCTIONS
Use bolts of the correct length. A bolt which is too long may "bottom" before the head is tight against the part it is to hold, and in addition the threads may be damaged when the bolt is removed.
If a bolt is too short, there may not be enough threads to hold the part securely.
Lockwashers, cotter pins or flat metal locks should be used to lock each nut and bolt. Flat metal locks must be installed properly to be effective. Bend one end of the lock sharply around the edge of the part. Bend the other end sharply against one flat surface of the nut or bolt head. Do not bend the lock against more than one side of the nut.
GENERAL USAGE (Tightening Torques)
SIZE TORQUE SIZE TORQUE (NC and NF) (Pound Feet! (NC and NF) (Pound Feet!
1/4" 6-12 3/4" 230-300 5/16" 13-23 7/8" 360-480
3/8" 27-37 1" 560-720
7/16" 40·60 1 1/8" 700-900
1/2" 65-85 1 1/4" 880-1120
9/16" 95·125 13/8" 1050-1350
5/8" 130-170 1 1/2" 1300-1700
HYDRAULIC VALVE BODIES (Tightening Torques)
SIZE TORQUE (NC and NF) (Pound Feet)
5/16" 13-17
3/8" 24·30
7/16" 39-47
1/2" 60-70
5/8" 118-142
DECIMAL EQUIVALENTS
The decimal dimensioning system provides a more accurate means of specifying dimensions and toler-ances .The following table includes the standard con-versions from fractions to decimals. Decimals are shown in the standard two, three and four place des-ignation. ~;"
METHOD FOR LOCK POSITIONING AND BENDING
When assembling a machine, complete each step in turn. Do not leave one part partially assembled and start assembling some other part. Make all ad-justments as recommended. Always check the job after it is completed to see that nothing has been overlooked.
PREPARATION FOR STARTING
After assembling a machine, lubricate it thor-oughly. Fill the various compartments with the type and grade of lubricant recommended in the Opera-tion and Maintenance Instructions.
Recheck the various adjustments by operating th.e machine before returning it to the job.
TORQUE VALUES
Unless reference is made in the copy to the topic, SPECIFICATIONS, the standard torque values listed in the chart should be used for standard heat-treated bolts and studs and steel nuts when assembling Caterpillar Equipment.
-'-64······ -'-32············
J_ 64······
I H··················
5 H·.···.
A ...........
-14 ...... Vs·····.···········
_'!... 64······
_5_ 32············
II H······
T3 •.................• 1.1-64······
-12 ............ U ......
114········ ....... 12 64· .. ···
9 n···········
l.'l. 64······
5 H··················
1.1 64······
11 -:;2············
it ...... 3/S·················
25 .4······
J..J. 32·· .. · .. ·····
27 64·····
J_ I b ..................
29 b4 .. · ...
.1.2. 32· .......... ·
3 I 64··· ...
1h ...............
.02 .016
.03 .031
.05 .047
.06 .062
.08 .078
. 09 .094
.10
. 11 .109
.12 .125
.14 .141
.16 .156
. 17 .172
. 19 .188
.20 .203
. 22 .219
.23 .234
. 25 .250
.27 .266
.28 .281
.30 .297
.31 .312
.33 .328
.34 .344
.36 .359
.38 .375
.39 .391
.40
.41 .406
.42 .422
.44 .438
.45 .453
.47 .469
.48 .484
.50 .500
.0156 J.1. .52 .516 .5156 64······
.0312 17 n··········· .53 .531 .5312
.0469 1.2- .55 .547 .5469 64-·····
.0625 _9_ .56 .562 .5625 lb··················
.0781 dZ .58 .578 .5781 64······
.0938 19 .59 .594 .5938 n············ .60
.1094 .l..'l. .61 .609 .6094 64······
.1250 5/S·················· .62 .625 .6250
.1406 .H .64 .641 .6406 64······
.1562 .21. .66 .656 .6562 32············
.1719 R ..... .67 .672 .6719
. 1875 +t ................ .69 .688 .6875
.2031 ~.:i .70 .703 .7031 64······
.2188 H. ......... .72 .719 .7188
.2344 ;!Z .73 .734 .7344 64······
.2500 314················· .75 .750 .7500
.2656 H ..... .77 .766 .7656
.2812 j~ .78 .781 .7812 ...........
.2969 U ...... .80 .797 .7969
.3125 J..l. .81 .812 .8125 I b-·················
.3281 ~1. .83 .828 .8281 64··""
.3438 H ............ .84 .844 .8438
.3594 .5.2- .86 .859 .8594 64 .. ·· ..
.3750 ~8··············· .88 .875 .8750
.3906 R .... .89 .891 .8906 .90
.4062 H. 32······· .. ··· .91 .906 .9062
.4219 H .92 .922 .9219 b4 ......
.4375 +t .................. .94 .938 .9375
.4531 !! ...... .95 .953 .9531 (tJ .4688 .l.J. .97 .969 .9688 32··
.4844 k.l. .98 .984 .9844 b4· .... ·
.5000 .................. 1.00 1.000 1.0000
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ENGINE TABLE OF CONTENTS
Index ..... . .............................. . Specifications .. . . . . .. . ..................... . Cooling System (79B & 87B) ........................... . Cooling System - Heat Exchanger Cooled ............. . Cooling System - Keel Cooling (80B & 88B) ............ . Water Temperature Regulator (79B) ................... . Water Temperature Regulator (80B & 88B) ............. . Water Temperature Regulator (G333 & 87B) ........... . Expansion Tank .......................... . Fan Group (79B & 87B) ............ . Water Pump (79B & 87B) ................ . Water Pump (80B & 88B) ................ . Water Pump (G333 only) ................. . Raw Water Pump (80B & 88B) ....... . Radiator (79B & 87B) ................... . Heat Exchanger .............. . Lubricating System . . . . . . . . ....... . Oil Pan (79B & 87B) ......... . Oil Pan (80B & 88B) ...... . Oil Pump . .. .. .. .. . ......... . Oil Cooler. . ..... . Oil Cooler (80B & 88B) Oil Filter (79B & 87B) Oil Filter (80B & 88B) Oil Filter (G333 only) Fuel System Fuel Supply Equipment Fuel Injection Equipment (79B & 87B) Fuel Injection Equipment (80B & 88B) ............... . Ignition System (G333 with Fairbanks-Morse Magneto) .. Governor (79B & 87B) . . . . . . . ................. . Gov~rnor and Magneto Drive (G333 only) .............. . Governor - Hydraulic Type (80B & 88B) .. . ......... . Accessory Drive (79B & 87B) Accessory Drive (80B & 88B) ............... . Line Pressure Regulator (G333 only) ................... . Air Induction and Exhaust System (79B & 87B) ....... . Air Induction and Exhaust System (80B & 88B) ......... . Air Induction and Exhaust System
(G333 with Impco Carburetor) Turbocharger (Schwitzer 4D) Turbocharger (Schwitzer 4MD) Cylinder Head (79B & 87B) Cylinder Head (8oB & 88B) Cylinder Head (G333 only) .. . Valves and Valve Mechanism ... . Timing Gears . . . . . . ....... . Timing Gears (G333 only) . . . . . . . . . . ................ . Piston Rings and Connecting Rods (87B & 88B) .. Piston Rings and Connecting Rods (79B & 80B) Pistons, Rings and Connecting Rods (G333 only) .. Cylinder Liners Mairj Bearings (79B & 87B) Main Bearings (8oB & 88B) Crankshaft Flywheel and Flywheel Housing (79B & 87B) Flywheel and Flywheel Housing (80B & 88B) Flywheel and Flywheel Housing (G333 only) Electrical System (79B & 87B) Electrical System (80B & 88B) Alternator (80B & 88B)
10A-IO
Section Group
10A-IO 30.13 IOA-IO 40.12 IOA-I0 70.8 10A-IO 80 10A-IO . 90 10A-IO 100.9 10A-1O 100.1 0 10A-Io 10o.11 10A-Io 120.1 10A-Io 130.12 10A-1O 140.12 10A-1D 140.13 10A-1D 140.14 9A-Io 150
10A-1D 160 9A-Io 165
10A-IO 170.12 10A-1O 180.11 10A-1D 180.12 IOA-IO 190.9 9A-IO 200
10A-Io 200.12 10A-Io 210.15 10A-Io 210.16 10A-Io 21017 lDA-lO 230.7 1 oA-I 0 240.11 10A-Io 250.2 10A-Io 250.4 10A-Io 259.1 loA-IO 260.14 10A-Io 260.15 loA-lo 260.16 10A-1D 265.13 lOA-Io 265.14
IA-Io 269 lDA-lD 270.16 lOA-Io 270.17
10A-Io 270.13 2A-1D 271.1
10A-Io 271 lDA-1 0 280.13 10A-IO 280.14 10A-IO 280.15 9A-1D 290.2
10A-IO 320 10A-IO 320.7 9A-IO 340.2 9A-1D 340.3
IOA-I0 340.3 9A-Io 350
lOA-lD 360.2 IOA-I0 360.3 10A-1D 370.7 10A-lO 390.10 lDA-lD 390.11 IOA~10 390.12 10A-IO 410.9 10A-Io 410.10 10A-Io 411
Group 20.13 Page I
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ENGINE
INDEX
10A-IO Group 30.13 Page 1
A Group Page Group Page
Accessory Drive .......................... . Adapter, Spark Plug ....................... . Adjustments:
Alternator Regulator ..................... . Carburetor and Carburetor Regulator ...... . Fuel Injection Pump Timing Dimension Selting Fuel Rack Selting ....................... .
Fuel Ratio Control Setting ................ . Governor
Magneto ............................... . Shutoff Solenoid ........................ .
Aftercooler .......... ..................... .
Air Cleaner .............................. .
Air Inlet Manifold ......................... .
Alternator Removal RegulatoI'
B
Backlash, Timing Gear .................... .
Bearings: Connecting Rod Main .................................. .
Breather. Crankcase ...................... .
Bypass: Fuel Oil Filter .............................. .
Oil Cooler ............................. .
C
Camshaft Gear
Carburetor ............................... . Carburetor Regulator ...................... . Chambers, Precombustion .................. .
Cleaner, Air
Cleaning: Engine Valves ........................ . Fuel Injection Valve .................... . Pistons
Clearances and Tolerances Compression Release Mechanism ............ . Connecting Rods and Bearings ............. . Coole~. Oil ... . ............. .
320 - 2 280.15- 2
410.10- 1 270.13- I 250.2 - 7 260.14- 4 260.16- 5 260.14- 7 260.14- 4 260.15- 2 260.16- 5 259.1 - 4 260.16- 7 270.16- 3 270.17- 3 270 .. 16- 3 270.17- 3 270.16- 1 270.17- 1 411 1 410.10- 1 410.10- 1
320 - 4 320.7 - 4
340.3 - 3 360.2 - 1 360.3 - 1 210.15- 2 210.17- 2
240.11- 2 210.15- I 210.16- 1 210.17- 1 210.15- I 210.16- 1 210.17- 1
320 - 3 320.7 - 3 270.13- 1 270.13- 1 280.13- 2 280.14- 2 270.16- 3 270.17- 3
290.2 - 2 250.2 - 1 340.3 - 2
40.12- 1 290.2 - 4 340.3 - 2 200 - 1
Cooling System
Core, Radiator ............................ . Cover, Timing Gear .... , .................. .
Crankshaft Crankshaft Damper ....................... .
Crankshaft Pulley ......................... .
Cylinder Head ............................ .
Cylinder Liners
D
Damper, Crankshaft ....................... .
Directors, Waler .......................... .
Drive: Accessory
Tachometer
E
Electric Starting Motor
Electrical System ......................... .
Engine Data .............................. . Exhaust Manifold ......................... .
Expansion Tank
F Fan Assembly ............................ . Fuel Ratio Control ........................ . Filter:
Fuel Fuel, Priming ................. - ......... . Oil .................................... .
Flow of Coolant
Flow of Fuel ............................. . Flow of Lubricating Oil ...... - ........ . Flywheel ...... , ............. - ...... .
Fuel: Bypass
70.8 - 1 80 - I 90 - 1
160 - 1 320 - 2 320.7 - 2 370.7 - I 320 - I 320.7 - 1 320 1 320.7 - I 280.13- I 280.14- 1 280.15- 1 350 - I
320 - I 320.7 - 1 280.13- 1 280.14- 1 280.15- 1
265.13- I 265.14- 1 260.15- 3 265.14- 2
410.9 - 1 410.10- 1 410.9 - 1 410.10- 1 40.12- 1
270.16- 2 270.17- 2 120.1 - 1
130.12- 1 260.14- 7
240.11- 1 240.11- 3 210.15- 1 210.16- 1 210.17- 1
70.8 - 1 80 - 1 90 - 1
100.9 - 1 100.10- 1 100.11- 1 230.7 - 1 170.12- I 390.10- 1 390.11- 1 390.12- 1
240.11- 2
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Group 30.13 Page 2
10A-I0 ENGINE
INDEX
Group Page L
Filter .................................. . Injection:
Equipment ........................... . Pumps ............................... . Pump Housing ........................ . Pump Lifters .................... . Pump Valves ......................... .
System, Diesel ......................... . Transfer Pump Priming Pump
Gauge: G
Fuel .................................. . Oil .................................... .
Gear: Accessory Drive ........................ . Camshaft ...... : ....................... .
Crankshaft ............................. . Idler .................................. .
Ring, Flywheel
Timing
Timing Marks ..................... . Generator ............................... .
Generator Regulator
Governor: Adjustments
Operation and Lubrication ............... .
Governor and Fuel Injection Pump Housing Removal
Head, Cylinder
H
Heat Exchanger ... . . . . . . . . . . . . . . . . . . . . . . . .. Housing:
Flywheel .............................. .
Fuel Injection Pump ..................... . Governor
Idler Gear
Ignition Transformer .. ' .................. . Ignition System .................... . Injection, Fuel .................... . Inlet:
Manifold
Valves ................................. .
240.11- I
250.2 - 1 250.2 - 2 250.2 - 3 250.2 - 6 250.2 - 1 230.7 - 1 240.11- 1 240.11- 2
230.7 - I 170.12- 1
320 - 2 320 - 3 320.7 - 3 370.7 - I 320 - 5 320.7 - 5 390.10- 1 390.11- 1 390.12- 1 320 - I 320.7 - 1 320.7 - 1 410.9 - I 410.10- I 410.9 - 1 410.10- 1
260.14- 4 260.15- 2 260.16- 5 260.14- 1 260.15- 1 260.16- 1
260.14- 2 265.13- I 265.14- I
280.13- 1 280.14- 1 280.15- 1 165 - I
390.10- 1 390.11- 1 390.12- 1 250.2 - 3 260.14- 1 260.15- 1 260.16- 1
320 - 5 320.7 - 5 259.1 - 1 259.1 - 1 250.2 - 1
270.16- 1 270.17- 1 290.2 - 3
Lifters: Fuel Injection Pump ..................... . Valve ..................................
Line Pressure Regulator
Liners, Cylinder .......................... . Lubricating System ........................ . Lubrication:
Piston and Ring ......................... .
M
Magneto ................................. , Contact Points ........................... Cleaning and Inspection ................. . Disassembly and Assembly ............... . Drive .................................. . Drive Gear .............................. Drive Idler Gear ........................ . Drive Shaft ............................ . Edge Gap .............................. . Impulse Coupling ....................... . Removal and Installation ................. . Timing to Engine ....................... .
Main Bearings . . . . . . . . . . . . . . . . . . . . . . . .. .
Manifolds: Exhaust
Fuel Inlet
Oil .................................... . Meter, Service
o Oil:
Bypass Valves
Cooler ............................. . Filter .................................. .
Manifold Pan
Pump ................................. . Operating Difficulties:
Engine Coolant Overheating .............. .
Engine Fuel System ..................... . Engine Lubricating System ............... . Valves and Valve Mechanism ............ .
Overheating, Coolant ...................... .
p
Pan, Oil
Pistons Piston Rings . . . . . . . . . . . ............ . Precombustion Chambers ........ . ...... .
Group Page
250.2 - 6 290.2 - 3 269 - 1 270.13- 2 350 1 170.12- 1
340.3 - 1 170.12- 1
259.1 - 1 259.1 - 4 259.1 - 4 259.1 - 1 260.15- 3 320.7 - 2 320.7 - 5 320.7 - 2 259.1 - 4 259.1 - 3 259.1 - 1 259.1 - 5 360.2 - 1 360.3 - 1
270.16- 2 270.17- 2 230.7 - 1 270.16- 1 270.17- 1 170.12- 1 265.13- 2 265.14- 2
190.9 - 1 210.15- 1 210.16- 1 210.17- 1 200 - 1 210.15- 1 210.16- 1 210.17- 1 170.12- 1 180.11- 1 180.12- 1 190.9 - 1
70.8 - 1 80 - 2 90 - 2
230.7 - 1 170.12- 1 290.2 - 1
70.8 - 1 80 - 2 90 - 2
180.11- 1 180.12- 1 340.3 - 1 340.3 - 1 280.13- 2 280.14- 2
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Pump: Fuel:
Injection Priming Transfer .................. .
Oil ............................. , ... ,.,' Raw Water Water
Pressure, Oil Gauge
Radiator Raw Water Pump
R
Removing Ring Ridge in Cylinder Liners Regulator, Alternator , .... , ... , ....... . Regulator, Carburetor ........ . Regulator, Line Pressure , , ,. , ...
Regulator, Water Temperature
Release, Compression Ring Gear, Flywheel
Rings, Piston Rocker Arms, Valve Rod, Connecting Running-in Schedule
Seals, Liner Service Meter
Shaft, Accessory Drive
Shutoff Solenoid , .. ,' Spark Plug ... Spark Plug Adapter Specifications Springs:
Governor
Valve Starting Motor .
S
T
Testing Temperature Regulator
ENGINE INDEX
10A-I0 Group 30.13 Page 3
Group Page
250.2 - 2 240.11- 2 240.11- 1 190.9 - 1 150 1 140.12- 1 140.13- 1 140.14- 1 170.12- 1 170.12- 1
160 - 1 150 - 1 350 410.10- 1 270.13- 1 270.13- 2 269 1 100.9 - 1 100.10- 1 100.11- 1 290.2 - 4 390.10- 1 390.11- 1 390.12- 1 340.3 - 2 290.2 - I 340.3 - 2 340.3 - 2
350 - 1 265.13- 2 265.14- 2 265.13- I 265.14- 1 320 - 2 260.16- 7 259.1 - 6 280.15- 2 40.12- I
260.14- 1 260.15- 1 260.16- 1 290.2 - 2 410.10- 1
109.9 - 1 100.10- 1 100.11- 1
Thrust Bearing, Crankshaft Timing:
Engine Gears
Engine Valves ............. ,', .. ,'".,.,. Fuel Injection ..................... . Magneto ... , .............. , .. , ....... , ..
Timing Gear Cover ..... ' .................. .
Timing Gears
Tolerances .. Tur bocharger
Turbocharger Lubrication Valve
Turbocharger Removal ..
Valve: Bypass, Fuel Bypass, Oil Filter
Bypass, Oil Cooler ..
Inlet and Exhaust Fuel Injection
v
Inspection and Reconditioning Lifters Operation ... Pressure Regulator, Oil Pump Rocker Arm Assembly Rotators Seat Specifications Stem Bushings Timing ....... .
Valves and Valve Mechanism
w Water:
Directors, Seals and Ferrules
Pump
Seal Replacement "
Pump, Raw Water Temperature Regulator ...
Group Page
370.7
320 320.7 290.2 - 3 250.2 - 7 259.1 - 5 320 2 320.7 - 2 320 - 1 320.7 - 1 40.12- 1
271 1 271.1 - I 210.15- 1 210.16- I 270.16- 1 270.17- 1
240.11- 2 210.15- 1 210.16- 1 210.17- I 210.15- 1 210.16- I 210.17- I 290.2 - 2 250.2 - I 290.2 - 2 290.2 - 3 290.2 - 1 190.9 - 1 290.2 - I 290.2 - 1
40.12- 3 290.2 - 3 290.2 - 3 290.2 - 1
280.13- I 280.14- 1 280.15- 1 140.12- 1 140.13- 1 140.14- 1 140.12- 3 140.13- 3 140.14- 3 150 1 109.9 - 1 100.10- 1 100.11- I
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IOA-IO Group 40.12 Page 2 ENGINE
SPECIf1CA TIONS
Fuel injection pump timing dimension setting with 2M5219 Gauge (off engine) .......... 4.2675 -+-.0020 in.
Fuel injection pump timing dimension with 2M5219 Gauge (on engine with pistons at top center) .................. 4.2255 -+-.0020 in.
Fuel Injection Equipment (80BI - Up & 88Bl - Up) Fuel injection pump timing
(Before top center) ....................... 14° Fuel injection pump timing dimension setting with 2M5219 Gauge (6ff engine) ... 4.2675 -+-.0020 in.
Fuel injection pump timing dimension setting with 2M5219 Gauge (on engIne with pistons at top center) ................ 4.2139 -+-.0020 in.
LIFTER SETTING IN DEGREES (OFF ENGINE)
LIFTER NO. Numbered consecutively TIMING PLATE DEGREES
(front to rear)
I 1800
2 600
3 3000
4 1200
5 2400
T77850 6 00
Fuel pump plunger length . . . .. 2.5931 - 2.5937 in. Permissible wear (decrease in length of plunger) .................... .005 in.
Injection nozzle orifice (Use a 5B2178 Drill to clean the inj ection nozzle orifice) ........................ .025 in.
Injection pump retaining bushing torque ........................ 140 - 160 lb. ft.
TIMING DIMENSION SETTING (OFF ENGINE) I-IF8747 Plate Assembly.* 2-Lockscrew. 3-2M5220 Pointer
Assembly. 4-Washer. S-Bolt. *On earlier IF8747 Plate Assemblies the drive shaft must be replaced with a 2M5218 Shaft Assembly.
Nozzle retaining nut torque ..... . 100 - 110 lb. ft. Fuel rack: Bearing bore. . . . . . . . . . . . . . . . .. .5007 - .5013 in. Bearing clearance ... .002 - .003 in. Permissible clearance ................. .005 in.
CHECKING TIMING DIMENSION SETTING l-Spacer. 2-2M5219 Gauge. 3-4-5" depth micrometer.
A-Timing dimension setting. If the reading is less than 4.2655 inches (off engine) re-place the spacer (1) with a .004 inch thicker spacer. If the reading is greater than 4.2695 inches (off engine) replace the spacer (1) with a .004 inch thinner spacer.
Fuel line nut torque ............... 25 - 35 lb. ft. Camshaft:
Bearing bore . . . . . . . . . . . . . . .. 1.8750 - 1.8760 in. Bearing clearance. . . . . . . . . . . .. .0015 - .0035 in. Permissible clearance. . . . . . . . . . . . . . . .. .010 in.
Fuel Transfer Pump Clearance between gears and
covers, total .................. .0010 - .0022 in. Permissible clearance ................. .0035 in. Bearing bore . . . . . . . . . . . . . . . . . .. .4950 - .4956 in. Shaft diameter ................. .4936 - .4938 in. Bearing clearance .............. .0012 - .0019 in. Permissible bearing clearance . . . . . . . . .. .003 in.
Govemor Backlash between drive gear and driven gear . . . . . . . . . . . . . . . .. .002 - .006 in.
Generator
12V 24V 32V DRll05148 DRll05214 DRll05221
Rotation (viewing drive end) Clockwise Clockwise Clockwise
Brush spring 16 oz. tension 28 oz. 28 oz.
Circuit A A A
Field current (80°F)
35 Volts 12 24 Amps 1.54 - 1.67 .94 - 1.02 .96 - 1.02
Output (cold) Volts 14.0 26.0 35.0 Amps 35 18 18 Approximate
2500 RPM 1950 1900
Generator Belt Tension Slack at point midway between pulleys @ 25 Ibs. .............. 9/16 - 13/16 in.
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