Caterpillar cat el200 b excavator (prefix 4sg) service repair manual (4sg00001 and up)

Service Repair Manual
Models
EL200B EXCAVATOR

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Product: EXCAVATOR
Model: E200B EXCAVATOR 4SG
Configuration: EL200B EXCAVATOR 4SG00001-UP (MACHINE) POWERED BY S6KT ENGINE
General Service Information
SK4 & SK6 ENGINES BASIC ENGINE COMPONENTS
Media Number -XEBR1230-00 Publication Date -01/05/1991 Date Updated -13/10/2001
Engine Accessory Removal And Installation
1. Preparatory Steps
This section explains the procedures and suggestions for removal and installation of the
accessories - the preparatory steps to go through for overhauling the engine.
(a) Shut off fuel supply, and disconnect the starting system from the engine.
(b) Loosen the drain cock, on the left rear side of crankcase, and drain coolant.
(c) Loosen the oil pan drain plug, and drain engine oil.
Hot engine oil can cause personal injury if it contacts the skin. Use
caution when draining the oil.
2. Engine Accessory Removal
(1) Removing turbocharger [turbocharged engines]
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(a) Disconnect pipe (1) between the turbocharge and inlet manifold.
(b) Disconnect turbocharger lubricating oil pipe (2) and drain pipe (3).
(c) Remove turbocharger (4) from the exhaust manifold.
(2) Removing exhaust manifold
Unscrew bolts securing exhaust manifold (1), and remove the manifold and gasket (2).
(3) Removing thermostat (S4K, S4K-T)

(a) Disconnect water bypass hose (1).
(b) Remove thermostat case (2).
(4) Removing water outlet pipe and thermostat (S6K, S6K-T)
(a) Disconnect water bypass hose (1).
(b) Remove water outlet pipe (2) and thermostat case (3) as an assembly.
(5) Removing fuel filter

(a) Disconnect fuel pipes (1)(2).
(b) Remove fuel filter (3) and bracket (4) as an assembly.
(6) Removing fuel injection pipes
(a) Remove pipe clamp (1), and disconnect injection pipes (2).
(b) Unscrew lock nut (3), and remove leak-off pipe (4).
NOTICE
Be sure to fit rubber caps to the openings of the injection pumps and
nozzle holders to prevent dust from getting inside the fuel system.
(7) Removing fuel injection nozzles

Take off nozzle gland (1), and remove injection nozzle (2) and gasket (3).
(8) Removing inlet manifold and air heater
Unscrew the bolts securing inlet manifold (1), and remove the manifold and gasket (2) complete
with air heater (3).
(9) Removing fuel injection pump

(a) Disconnect oil pipe (1), and remove cover (2).
(b) Unscrew bolts (3), and remove injection pump (4) complete with gear and mounting flange
from the front plate.
(10) Removing fan and water pump
(a) Remove fan (1), and slacken and remove fan belt (2).
(b) Unscrew the bolts securing water pump (3), and remove the pump and pulley (4) as an
assembly.
(11) Removing alternator

(a) Disconnect harness (1), and unscrew bolt (2) securing the belt adjusting plate.
(b) Unscrew bolts (3), and remove alternator (4).
(12) Removing starter
Disconnect harness (1). Unscrew bolts (2), and remove starter (3).
(13) Removing oil filter

Unscrew bolts (1), and remove oil filter (2) and filter bracket (3) with gasket (4).
(14) Removing oil pan
Unscrew bolts (1), and remove oil pan (2).
(15) Removing oil cooler

Unscrew bolts (1), and remove the oil cooler attached to cover (2). Remove gasket (3).
(16) Removing air heater
Unscrew the bolts securing air inlet elbow (1), and remove the elbow, air heater (2) and gasket (3)
(4).
NOTE: Gasket (4) is to come to the manifold side when installed.
3. Engine Accessory Installation

Matching marks on timing gears
To install the accessories, follow the reverse of removal procedure, and take the following steps:
(a) Installing fuel injection pump
When installing the pump, make sure that matching marks on pump drive gear and other gears are
aligned with those on idler gear respectively, as shown.
NOTE: With these matching marks are all aligned, No. 1 cylinder piston is at top dead center on
compression stroke.
(b) Refill the engine with recommended oil up to the specified level.
(c) Refill the cooling system with coolant.
(d) Check each pipe connection for oil or coolant leaks.
(e) Prime the fuel system.
(f) After installing the fuel injection pumps, inspect and adjust the injection timing. (Refer to 1.3,
Group No. 5.)
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Shutdown SIS
Previous Screen
Product: EXCAVATOR
Model: E200B EXCAVATOR 4SG
Configuration: EL200B EXCAVATOR 4SG00001-UP (MACHINE) POWERED BY S6KT ENGINE
General Service Information
SK4 & SK6 ENGINES BASIC ENGINE COMPONENTS
Media Number -XEBR1230-00 Publication Date -01/05/1991 Date Updated -13/10/2001
Engine Proper
1. Cylinder Heads And Valve Mechanism
1.1 Disassembly

(1) Rocker cover
(2) Eye bolt
(3) Oil pipe
(4) Adjusting screw
(5) Bolt (short)
(6) Bolt (long)
(7) Valve cap
(8) Snap ring
(9) Washer
(10) Inlet rocker arm
(11) Rocker shaft bracket

(12) Exhaust rocker arm
(13) Rocker shaft spring
(14) Rocker shaft
(15) Valve pushrod
(16) Cylinder head bolt
(17) Cylinder head
(18) Valve cotter
(19) Valve retainer
(20) Valve spring
(21) Valve
(22) Valve stem seal
(23) Cylinder head gasket
(1) Removing rocker shaft assemblies
(a) Loosen the adjusting screw of each rocker about one rotation.
(b) Loosen the rocker bracket short bolt and long bolt in that order, and remove the rocker shaft
assembly from the cylinder head.
NOTICE
If these bolts are loosened in reverse order, the rocker shaft bracket
might suffer damage.
(2) Disassembling rocker shaft assemblies

Lay the disassembled rockers in the order removed, and install them in that order at the time of
reassembly. This is for reproducing the same rocker shaft-to-rocker arm clearance as before.
(3) Removing cylinder head
Unscrew the cylinder head bolts, and lift the head off the crankcase.
NOTE:
(a) When removing the gasket from the crankcase, be careful not to damage the mounting face of
crankcase.
(b) If any cylinder head parts are out of order, check the cylinder head bolts for tightening torque
with a torque wrench before removing the head bolts.
(4) Removing valves and valve springs

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Using valve spring pusher (A) (30691-04500), compress the valve spring squarely, and remove the
valve cotters.
NOTE: If the valves are to be reused, mark them for their locations to aid installation at the time of
reassembly.
1.2 Inspection and repair
Measuring rocker bushing and rocker shaft
Rocker arms, rocker bushings and rocker shafts
(1) Measuring inside diameter of rocker bushing and diameter of rocker shaft
Compute the clearance of the bushing on the shaft on the basis of the measurements. If the Repair
limit is reached, replace the bushing. If it is exceeded, replace both bushing and shaft.

(2) Replacing rocker bushings
Replacing rocker bushing
When installing a replacement bushing, align the oil holes in the bushing and rocker arm.
Valves, valve guides and valve seats

Measuring valve stem
(1) Measuring diameter of valve stem
If the Service limit is exceeded, or if the stem is abnormally worn excessively, replace the valve.
(2) Measuring valve stem clearance in guide

Measuring valve guide
The valve guide wears more rapidly at its both ends than at any other parts. Measure the guide at its
ends and in two directions at right angles to each other. If the Service limit is exceeded, replace the
guide.
(3) Replacing valve guides

Caterpillar cat el200 b excavator (prefix 4sg) service repair manual (4sg00001 and up)

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