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Caterpillar Cat 657E WHEEL TRACTOR (Prefix 90Z) Service Repair Manual (90Z00001 and up)

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Caterpillar Cat 657E WHEEL TRACTOR (Prefix 90Z) Service Repair Manual (90Z00001 and up)

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  1. Service Repair Manual Models 657E WHEEL SCRAPER

  2. w 1/5(W) Shutdown SIS Previous Screen Product: WHEEL TRACTOR Model: 657E WHEEL TRACTOR 90Z Configuration: 657E Tractor PS PP 90Z00001-UP (MACHINE) POWERED BY 3412C Engine Disassembly and Assembly 3408E and 3412E Engines for Caterpillar Built Machines Media Number -SENR1013-11 Publication Date -01/07/2015 Date Updated -22/08/2016 i02184090 Cylinder Head - Remove SMCS - 1100-011 Removal Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 138-7573 Link Bracket 2 B 5P-8700 Lifting Bracket 2 Start By: a. Remove the unit injector sleeves. Refer to Disassembly and Assembly, "Unit Injector Sleeve - Remove". b. Remove the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install". NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

  3. w 2/5(W) Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates. Illustration 1 g00570914 1. Remove hose assembly (1) from the front of the fuel manifold. Illustration 2 g00570923 2. Remove hose assembly (2) from the rear of the fuel manifold. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

  4. w 3/5(W) Illustration 3 g00582732 3. Remove tube assembly (3). Illustration 4 g00570979 4. Remove cylinder head bolts (5). Remove bolts (4). Illustration 5 g00570983 5. Attach Tooling (A) and a suitable lifting device to fuel manifold (6). The weight of the fuel manifold for the 3412E is approximately 60 kg (131 lb). The weight of the fuel manifold for the 3408E is approximately 39 kg (86 lb). Remove bolts (7). Remove fuel manifold (6). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

  5. w 4/5(W) vO Illustration 6 g01105094 6. Attach Tooling (B) and a suitable lifting device to the cylinder head. The weight of the cylinder head for the 3412E is approximately 172 kg (380 lb). The weight of the cylinder head for the 3408E is approximately 90 kg (200 lb). Remove cylinder head nuts (8). Illustration 7 g01105075 7. Remove cylinder head (9) and the gasket. Illustration 8 g01105076 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

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  7. w 5/5(W) 8. Remove seals (10). 9. Remove spacer plate (11). Illustration 9 g01105072 10. Remove O-ring seals (12) and gasket (13). Copyright 1993 - 2021 Caterpillar Inc. Fri Jan 22 11:07:14 UTC+0800 2021 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

  8. w 1/7(W) Shutdown SIS Previous Screen Product: WHEEL TRACTOR Model: 657E WHEEL TRACTOR 90Z Configuration: 657E Tractor PS PP 90Z00001-UP (MACHINE) POWERED BY 3412C Engine Disassembly and Assembly 3408E and 3412E Engines for Caterpillar Built Machines Media Number -SENR1013-11 Publication Date -01/07/2015 Date Updated -22/08/2016 i02184092 Cylinder Head - Install SMCS - 1100-012 Installation Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 138-7573 Link Bracket 2 B 5P-8700 Lifting Bracket 2 C 8C-8422 Sealant 2 NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: Thoroughly clean the spacer plate and the bottom surface of the cylinder head. A new spacer plate gasket must be installed when the cylinder head is removed. Note: Apply a thin film of clean engine oil on the seals and the O-ring seals prior to installation. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

  9. w 2/7(W) Illustration 1 g01105072 1. Install O-ring seals (12) and gasket (13). Illustration 2 g01105076 2. Install spacer plate (11). 3. Install seals (10). Illustration 3 g01105075 4. Position the gasket on the engine. Attach Tooling (B) and a suitable lifting device to the cylinder head. The weight of the cylinder head for the 3412E is approximately 172 kg https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

  10. w 3/7(W) (380 lb). The weight of the cylinder head for the 3408E is approximately 90 kg (200 lb). Install cylinder head (9). Illustration 4 g01105094 5. Install cylinder head nuts (8). Remove Tooling (B). Illustration 5 g00570607 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

  11. w 4/7(W) Illustration 6 g00582780 6. Apply Tooling (C) to the shaded area of the fuel manifold. Tooling (C) is applied to the bottom portion of the fuel manifold. Tooling (C) is permitted on the entire face of the fuel manifold. Illustration 7 g00570983 7. Attach Tooling (A) and a suitable lifting device to fuel manifold (6). The weight of the fuel manifold for the 3412E is approximately 60 kg (131 lb). The weight of the fuel manifold for the 3408E is approximately 39 kg (86 lb). Install fuel manifold (6). Install bolts (7). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

  12. w 5/7(W) Illustration 8 g00570979 Illustration 9 g00570761 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

  13. w 6/7(W) Illustration 10 g00582808 Note: Apply clean engine oil to the bolts for the cylinder head. 8. Install cylinder head bolts (5). Install bolts (4). 9. Tighten the bolts in the following sequence: In a numerical sequence, tighten the bolts 1 through 26 for the 3412E. In a numerical sequence, tighten the bolts 1 through 18 for the 3408E. a. In a numerical sequence, tighten the bolts to a torque of 270 ± 15 N·m (200 ± 11 lb ft). b. In a numerical sequence, tighten the bolts to a torque of 450 ± 15 N·m (330 ± 11 lb ft). c. In a numerical sequence, again tighten the bolts to a torque of 450 ± 15 N·m (330 ± 11 lb ft). d. Tighten the upper row of nuts that are on the cylinder head in the following sequence: In a numerical sequence, tighten nuts 27 through 39 for the 3412E to a torque of 45 ± 7 N·m (33 ± 5 lb ft). In a numerical sequence, tighten nuts 19 through 27 for the 3408E to a torque of 45 ± 7 N·m (33 ± 5 lb ft). Illustration 11 g00582732 10. Install tube assembly (3). https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

  14. w 7/7(W) Illustration 12 g00570923 11. Install hose assembly (2) on the rear of the fuel manifold. Illustration 13 g00570914 12. Install hose assembly (1) on the front of the fuel manifold. End By: a. Install the exhaust manifold. Refer to Disassembly and Assembly, "Exhaust Manifold - Remove and Install". b. Install the unit injector sleeves. Refer to Disassembly and Assembly, "Unit Injector Sleeve - Install". Copyright 1993 - 2021 Caterpillar Inc. Fri Jan 22 11:08:10 UTC+0800 2021 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

  15. w 1/4(W) Shutdown SIS Previous Screen Product: WHEEL TRACTOR Model: 657E WHEEL TRACTOR 90Z Configuration: 657E Tractor PS PP 90Z00001-UP (MACHINE) POWERED BY 3412C Engine Disassembly and Assembly 3408E and 3412E Engines for Caterpillar Built Machines Media Number -SENR1013-11 Publication Date -01/07/2015 Date Updated -22/08/2016 i05933135 Lifter Group - Remove and Install SMCS - 1209-010 Removal Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 5P-7433 Valve Lifter Tool Group 1 Start By: A. Remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Remove". NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

  16. w 2/4(W) Illustration 1 g00571490 Illustration 2 g00571491 1. Install Tooling (A) in lifter assembly (1) . 2. Remove lifter assembly (1) from the lifter bore. Illustration 3 g00571492 3. Remove lifter guide spring (2) from the lifter assembly. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

  17. w 3/4(W) Installation Procedure Table 2 Required Tools Tool Part Number Part Description Qty A 5P-7433 Valve Lifter Tool Group 1 Note: Install new valve lifter guide springs on the valve lifter when the valve lifters are removed from the engine. Note: Apply clean engine oil to the ball socket for the pushrod and the bore for the valve lifter assembly. Illustration 4 g00571513 1. Make an alignment of the new lifter guide spring (2) in Tooling (A) . Illustration 5 g01104989 2. Install lifter assembly (1) in the cylinder block with Tooling (A) . https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

  18. w 4/4(W) End By: Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install". Copyright 1993 - 2021 Caterpillar Inc. Fri Jan 22 11:09:06 UTC+0800 2021 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

  19. w 1/6(W) Shutdown SIS Previous Screen Product: WHEEL TRACTOR Model: 657E WHEEL TRACTOR 90Z Configuration: 657E Tractor PS PP 90Z00001-UP (MACHINE) POWERED BY 3412C Engine Disassembly and Assembly 3408E and 3412E Engines for Caterpillar Built Machines Media Number -SENR1013-11 Publication Date -01/07/2015 Date Updated -22/08/2016 i06177964 Camshaft - Remove and Install SMCS - 1210-010 Removal Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 1P-0510 Driver Group 1 Start By: a. Remove the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove". b. Remove the lifter group. Refer to Disassembly and Assembly, "Lifter Group - Remove and Install". c. Remove the flywheel housing. Refer to Disassembly and Assembly, " Flywheel Housing - Remove and Install". NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. NOTICE https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

  20. w 2/6(W) Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates. Illustration 1 g00572086 1. Remove four bolts (1) and plate (2) from the rear of the camshaft. Remove gear (3) from the camshaft. Illustration 2 g00572090 2. Rotate the engine until the “V” marks on the front of the timing gears are in alignment. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

  21. w 3/6(W) Illustration 3 g00572095 3. Remove two bolts (5) and plate (4) from the camshaft. Illustration 4 g00572105 4. Remove camshaft (6) from the cylinder block. Illustration 5 g00572214 5. If necessary, remove camshaft gear (7) with Tool (A) and press. Installation Procedure https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

  22. w 4/6(W) NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Illustration 6 g00572220 Note: The key for gear (7) must be in position on the camshaft (6) before gear (7) is installed. 1. Do not use a torch to heat camshaft gear (7). Raise the temperature of camshaft gear (7) by one of the following methods. ◦ Use a suitable oven to raise the temperature of camshaft gear (7). Do not exceed 150° C (302° F) for more than four hours. ◦ Use a suitable induction heater to raise the temperature of the hub of camshaft gear (7). Do not exceed 150° C (302° F) at bottom of gear teeth root radius. 2. Install camshaft gear (7) to camshaft (6). 3. Put 8T-2998 Lubricant on the camshaft lobes and the rollers for the valve lifter. Put clean engine oil on the bearing journals of the camshaft. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

  23. w 5/6(W) Illustration 7 g00572105 4. Install camshaft (6) until the rear of the camshaft is even with the rear of the cylinder block. Illustration 8 g00572090 5. Make an alignment of the “V” marks on the camshaft gear and the idler gear. Illustration 9 g00572221 6. Install plate (4) on the cylinder block. Illustration 10 g00572086 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

  24. w 6/6(W) 7. Install gear (3) and plate (2) on the rear of the camshaft. End By: a. Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing - Remove and Install". b. Install the lifter group. Refer to Disassembly and Assembly, "Lifter Group - Remove and Install". c. Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Install". Copyright 1993 - 2021 Caterpillar Inc. Fri Jan 22 11:10:01 UTC+0800 2021 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

  25. w 1/5(W) Shutdown SIS Previous Screen Product: WHEEL TRACTOR Model: 657E WHEEL TRACTOR 90Z Configuration: 657E Tractor PS PP 90Z00001-UP (MACHINE) POWERED BY 3412C Engine Disassembly and Assembly 3408E and 3412E Engines for Caterpillar Built Machines Media Number -SENR1013-11 Publication Date -01/07/2015 Date Updated -22/08/2016 i01519738 Camshaft Bearings - Remove and Install SMCS - 1211-010 Removal Procedure Table 1 Required Tools Tool Part Number Part Description Qty 8S-2241 Camshaft Bearing Tool Group 1 A 8S-8293 Extension 1 5P-1667 Tube 1 Start By: A. Remove the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing - Remove and Install". B. Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove and Install". C. Remove the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Remove". NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

  26. w 2/5(W) NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. Illustration 1 g00569925 1. Remove the rear camshaft bearing with Tool (A) . 2. Remove the remainder of the camshaft bearings with Tool (A) through the rear of the engine block. Start from the rear of the cylinder block and move toward the front. Installation Procedure Table 2 Required Tools Tool Part Number Part Description Qty 8S-2241 Camshaft Bearing Tool Group 1 A 8S-8293 Extension 1 5P-1667 Tube 1 https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

  27. w 3/5(W) NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. Note: Ensure that the inside of the cylinder block is clean. Inspect the camshaft bore for metal burrs. Put a thin film of clean engine oil on the inside of the camshaft bearing bores and on each camshaft bearing prior to installation. Note: Two different camshaft bearings are used. Install the wider camshaft bearings in the front and rear camshaft bores. Install the narrow camshaft bearings in the inner bores. Illustration 2 g00570127 1. Install all the camshaft bearings with Tool (A) so that the oil hole in the camshaft bearing is in a horizontal position. Installation angle (1) is 90 ± 15°. 2. Install the camshaft bearings with Tool (A) on the front side of the engine. Start the bearing that is being installed from the rear of each bore. Pull the bearing into the bore with Tool (A). Use the following procedure for achieving the proper installation depth for the bearings. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

  28. w 4/5(W) Illustration 3 g00583232 a. Install the rear camshaft bearing. Pull the bearing into the bore until the front face of the bearing is flush with the front face of bore (2). b. Install the narrow internal camshaft bearings. Start at the rear of the engine and work forward. Pull each bearing into the bore until the front face of the bearing is flush with the front face of the bore. Illustration 4 g00569930 Measure the depth of the front camshaft bearing. c. Install the front camshaft bearing with Tool (A) until the bearing is at the specified depth. the depth is measured from the front of the engine block. The front camshaft bearing for the 3412E should be 7.4 ± 0.5 mm (0.29 ± 0.02 inch) from the front face of the engine block. The front camshaft bearing for the 3408E should be 4.6 ± 0.5 mm (0.18 ± 0.02 inch) from the front face of the engine block. Note: Refer to Specifications, "Camshaft Bearings" for more information about camshaft bearings. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

  29. w 5/5(W) End By: a. Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove and Install". b. Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing - Remove and Install". c. Install the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and Connecting Rods - Install". Copyright 1993 - 2021 Caterpillar Inc. Fri Jan 22 11:10:57 UTC+0800 2021 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

  30. w 1/4(W) Shutdown SIS Previous Screen Product: WHEEL TRACTOR Model: 657E WHEEL TRACTOR 90Z Configuration: 657E Tractor PS PP 90Z00001-UP (MACHINE) POWERED BY 3412C Engine Disassembly and Assembly 3408E and 3412E Engines for Caterpillar Built Machines Media Number -SENR1013-11 Publication Date -01/07/2015 Date Updated -22/08/2016 i01057286 Engine Oil Pan - Remove and Install SMCS - 1302-010 Removal Procedure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

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  32. w 2/4(W) Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. 1. Drain the oil from the engine oil pan into a suitable container for storage or disposal. Illustration 1 g00552331 Typical example 2. Remove tube assembly (1). Remove the gaskets. Illustration 2 g00552333 Typical example 3. Remove bolts (2) from engine oil pan (3). 4. Use two technicians in order to remove engine oil pan (3). The weight of the engine oil pan for the 3408E is approximately 14 kg (31 lb). The weight of the engine oil pan for the 3412E is approximately 27 kg (60 lb). 5. Thoroughly remove gasket (4) from the engine oil pan and the cylinder block. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

  33. w 3/4(W) Make sure that all of the old gasket material has been removed from the mating surfaces of the engine oil pan and the cylinder block. Make sure that all surfaces are clean and free of dirt and debris. Installation Procedure NOTICE Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. 1. Use 5H-2471 Adhesive to install a new gasket on the engine oil pan. Illustration 3 g00552333 Typical example 2. Put new gasket (4) into position on engine oil pan (3). 3. Use two technicians in order to put engine oil pan (4) in position on the engine. The weight of the engine oil pan for the 3408E is approximately 14 kg (31 lb). The weight of the engine oil pan for the 3412E is approximately 27 kg (60 lb). 4. Install bolts (2) that hold engine oil pan (3) to the cylinder block. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

  34. w 4/4(W) Illustration 4 g00552331 Typical example 5. Install tube assembly (1). 6. Fill the engine to the correct level with the recommended oil. Refer to the Operation and Maintenance Manual. Copyright 1993 - 2021 Caterpillar Inc. Fri Jan 22 11:11:53 UTC+0800 2021 All Rights Reserved. Private Network For SIS Licensees. https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2021/1/22

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