Caterpillar Cat 307 EXCAVATOR (Prefix 2WM) Service Repair Manual (2WM00001-00499).pdf

Service Repair Manual
Models
S/N DAN00001 and up
307 MINI HYDRAULIC EXCAVATOR

Shutdown SIS
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Product: EXCAVATOR
Model: 307 EXCAVATOR 2WM
Configuration: 307 EXCAVATOR 2WM00001-00499 (MACHINE) POWERED BY 3054 ENGINE
Disassembly and Assembly
3054 Engine for Caterpillar Built Machines
Media Number -SENR6241-13 Publication Date -01/08/2008 Date Updated -04/08/2008
i02453078
Pistons and Connecting Rods - Remove
SMCS - 1225-011
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 8S-2269 Ridge Reamer 1
Start By:
A. Remove the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head -
Remove".
B. Remove the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump -
Remove".
C. Remove the piston cooling jets. Refer to Disassembly and Assembly, "Piston Cooling Jets -
Remove and Install".
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Use Tooling (A) to remove the liner wear ridge from the inner surface of the cylinder liner.
2. Position the two pistons that are being removed at the bottom center position.
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307 EXCAVATOR 2WM00001-00499 (MACHINE) POWERED BY 3054 ENGINE(...
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Illustration 1 g00550548
3. Remove nuts (1) and the bolts.
4. Remove connecting rod caps (2) and the connecting rod bearings. Keep connecting rod caps
(2) and the connecting rod bearings together for installation.
5. Push pistons (3) and the connecting rods out of the top of cylinder block (4) .
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All Rights Reserved.
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Tue Jan 28 23:25:23 UTC+0800 2020
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Shutdown SIS
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Product: EXCAVATOR
i02088687
Pistons and Connecting Rods - Disassemble
SMCS - 1225-015
Disassembly Procedure
Table 1
Required Tools
A 1U-6683 Ring Expander 1
B 1P-1857 Retaining Ring Pliers 1
Start By:
a. Remove the pistons and the connecting rods. Refer to Disassembly and Assembly, "Piston
and Connecting Rods - Remove".
NOTICE
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Typical example
1. Use Tooling (A) in order to remove three piston rings (1) from piston (2).
Typical example
2. Use Tooling (B) in order to remove retaining rings (3) that hold the piston pin in position.
3. Remove piston pin (4) from the piston.
Note: If the piston pin cannot be removed by hand, heat the piston to a temperature of
45 ± 5 °C (113 ± 9 °F). Do not use a torch to heat the piston.
4. Remove bearing (5) from connecting rod (6).
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5. Use a suitable press and a suitable adapter in order to remove piston pin bushing (7) from
connecting rod (6).
Tue Jan 28 23:26:20 UTC+0800 2020
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Shutdown SIS
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Product: EXCAVATOR
i02088688
Pistons and Connecting Rods - Assemble
SMCS - 1225-016
Assembly Procedure
Table 1
Required Tools
A 1U-6683 Ring Expander 1
B 1P-1857 Retaining Ring Pliers 1
NOTICE
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1. Ream piston pin bushing (7) in order to obtain a clearance of 0.0085 ± 0.0055 mm
(0.00030 ± 0.00020 inch) between the piston pin and the piston pin bushing.
2. Lubricate all components with clean engine oil.
3. Use a suitable press and a suitable adapter to install piston pin bushing (7) into connecting
rod (6).
Note: Ensure that the oil hole in the piston pin bushing is aligned with the oil hole at the top
of the connecting rod.
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Typical example
4. Install bearing (5) in connecting rod (6).
5. Install piston pin (4) into the piston and through connecting rod (6).
Note: If the piston pin cannot be installed by hand, heat the piston to a temperature of
45° ± 5°C (113° ± 9°F).
6. Use Tooling (B) in order to install retaining rings (3) that hold the piston pin in position.
7. Use Tooling (A) in order to install piston rings (1) on piston (2) with the following steps.
a. Install the oil control piston ring in the groove that is lowest on the piston. The latch
pin that is on the oil control ring must be inside the ends of the spring.
Note: Ensure that the latch pin that is on the oil control ring is 180 degrees from the
oil control ring gap.
b. Install the intermediate piston ring with the tapered face into the second groove on the
piston. The stamp "TOP" must be toward the top of the piston.
Note: Intermediate piston rings that are new have a green mark which must be on the
left of the piston ring gap when the piston ring is installed.
c. Position the piston ring gaps at 120 degrees away from each other.
d. Install the top piston ring with the barrel face and the molybdenum insert into the top
groove on the piston. The top piston ring has a wedge shape. The stamp "TOP" must
be toward the top of the piston.
Note: Top piston rings that are new have a red mark which must be on the left of the
ring gap when the ring is installed.
End By:
a. Install the pistons and the connecting rods. Refer to Disassembly and Assembly, "Piston and
Connecting Rods - Install".
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Product: EXCAVATOR
i02453085
Pistons and Connecting Rods - Install
SMCS - 1225-012
Installation Procedure
Table 1
Required Tools
B 1U-6684 Piston Ring Compressor 1
C 8T-0455 Liner Projection Tool Group 1
NOTICE
1. Thoroughly clean all of the components.
2. Lubricate the piston and the cylinder liner with clean engine oil.
3. Rotate the crankshaft until the connecting rod journal is at the bottom center. Lubricate the
connecting rod journal with clean engine oil.
4. Install the upper connecting rod bearing cap in the connecting rod. Ensure that the locating
tab is correctly installed in the connecting rod.
5. Lubricate the bearing for the upper connecting rod journal with clean engine oil.
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6. Align the piston rings on the piston so that the distance between the gaps is 120 degrees.
7. Install Tooling (B) on the piston.
Note: Ensure that Tooling (B) is installed correctly and that the piston can easily slide out of
the Tooling.
Note: The arrow or "FRONT" Mark that is on the top of the piston must be toward the front
of the engine.
8. Push the piston and the connecting rod assembly into the cylinder liner and onto the
connecting rod journal.
9. Install the lower connecting rod bearing in the connecting rod cap. Ensure that the locating
tab is correctly installed in the connecting rod cap.
10. Lubricate the lower connecting rod bearing with clean engine oil.
11. Install connecting rod caps (2) with the bolts and nuts (1) .
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12. Use the following procedure with serrated connecting rods and flat connecting rods:
a. If the connecting rod cap is held in position with bolts and nuts, tighten the nuts to a
torque of 125 N·m (92 lb ft).
b. If the connecting rod cap is held in position with bolts, tighten the bolts to a torque of
155 N·m (114 lb ft).
13. Use the following procedure with hydraulically fractured connecting rods:
Note: Do not reuse the bolts. New bolts should be used.
a. Tighten the bolts to a torque of 70 N·m (52 lb ft).
b. Tighten the bolts for an additional 120 degrees.
14. Rotate the crankshaft in order to ensure that there is no binding.
15. Use Tooling (C) in order to check the height of the piston above the cylinder block. Refer to
Testing and Adjusting, "Piston Height - Inspect".
End By:
a. Install the piston cooling jets. Refer to Disassembly and Assembly, "Piston Cooling Jets -
b. Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump -
Install".
c. Install the cylinder head. Refer to Disassembly and Assembly, "Cylinder Head - Install".
Tue Jan 28 23:28:14 UTC+0800 2020
3/3
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Shutdown SIS
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Product: EXCAVATOR
i01463918
Connecting Rod Bearings - Remove
SMCS - 1219-011
Removal Procedure
Start By:
A. Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove
and Install".
NOTICE
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.
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Typical example
1. Remove bolt (2) and two bolts (1) that hold the engine oil relief valve in position.
2. Remove the engine oil relief valve in order to gain access to the connecting rods.
3. Remove two bolts (4) that fasten the oil line to the engine oil pump. Remove bolt (3) that
holds the oil strainer in position.
4. Remove the oil strainer and the oil line in order to gain access to the connecting rods.
5. In order to remove the connecting rod caps, turn the crankshaft in a clockwise direction until
the piston is at the bottom center position.
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Type A connecting rod.
Type B connecting rod.
Note: There are two types of connecting rods that may be used in the engine. Type A
connecting rods have serrated mating faces on the connecting rod and the connecting rod
cap. Type A connecting rods are held together with a through bolt and a nut. Type B
connecting rods have an alignment pin in the connecting rod cap. Type B connecting rods
are held together with a bolt that is threaded into the connecting rod.
6. If you have Type A connecting rods, remove two nuts (9) and two bolts (10) that fasten the
connecting rod cap to the connecting rod. If you have Type B connecting rods, remove two
bolts (11) that fasten the connecting rod cap to the connecting rod.
7. Remove connecting rod cap (8) from the connecting rod.
8. Remove lower connecting rod bearing (5). Keep the connecting rod bearings together with
the respective connecting rod caps for installation purposes.
9. Carefully push the connecting rod into the cylinder liner in order to remove upper
connecting rod bearing (6). The connecting rod may need to be rotated in order to prevent
contact with the piston cooling jet.
10. Remove upper connecting rod bearing (6). Keep the connecting rod bearings together with
the respective connecting rods for installation purposes.
11. Repeat Steps 5 through 9 for the remaining connecting rod bearings.
Tue Jan 28 23:29:10 UTC+0800 2020
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Product: EXCAVATOR
i01463939
Connecting Rod Bearings - Install
SMCS - 1219-012
Installation Procedure
NOTICE
1/3
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Type A connecting rod.
Type B connecting rod.
Note: There are two types of connecting rods that may be used in the engine. Type A
connecting rods have serrated mating faces on the connecting rod and the connecting rod
cap. Type A connecting rods are held together with a through bolt and a nut. Type B
connecting rods have an alignment pin in the connecting rod cap. Type B connecting rods
are held together with a bolt that is threaded into the connecting rod.
1. Clean the bearing surface of connecting rod (7) and connecting rod cap (8) .
2. Clean upper connecting rod bearing (6) and lubricate the bearing face with clean engine oil.
3. Clean lower connecting rod bearing (5) and lubricate the bearing face with clean engine oil.
Note: Align the tabs on the connecting rod bearings with the tab grooves in the connecting
rod.
4. Install upper connecting rod bearing (6) in connecting rod (7) .
5. Pull the connecting rod into position against the crankshaft. The connecting rod may need to
be rotated in order to prevent contact with the piston cooling jet.
6. Install lower connecting rod bearing (5) in connecting rod cap (8) .
7. Put connecting rod cap (8) in position on connecting rod (7). Ensure that the identification
numbers are stamped on the same side.
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8. If you have Type A connecting rods, install two bolts (10) and two nuts (9) that fasten the
connecting rod cap to the connecting rod. Tighten the nuts for the connecting rod cap to a
torque of 125 N·m (92 lb ft). If you have Type B connecting rods, install two bolts (11) that
fasten the connecting rod cap to the connecting rod. Tighten the bolts for the connecting rod
cap to a torque of 155 N·m (114 lb ft).
9. Repeat Steps 1 through 8 for the remaining connecting rod bearings.
10. Put the oil line in position on the engine oil pump and install bolts (4). Install bolt (3) that
holds the oil strainer in position.
11. Put the engine oil relief valve in position on the engine and install two bolts (1) and bolt
(2) .
End By: Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan -
Tue Jan 28 23:30:07 UTC+0800 2020
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Shutdown SIS
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Product: EXCAVATOR
i01758964
Crankshaft Main Bearings - Remove
SMCS - 1203-011
Removal Procedure
Table 1
Required Tools
A 9U-6282 Torque Wrench Extension 1
Start By:
a. Remove the engine oil relief valve and the oil strainer. Refer to Disassembly and Assembly,
"Engine Oil Relief Valve - Remove and Install".
NOTICE
Note: Remove the following components from the engine in order to remove the rear main
bearing with the crankshaft in position: flywheel, flywheel housing, rear oil seal housing and
bridge assembly.
Note: Use Tooling (A) in order to remove the front main bearing cap with the front housing and
the engine oil pump in place. If Tooling (A) is not available, removal of the front cover and the
engine oil pump will be necessary. The engine oil pump is attached to the front main bearing cap.
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Caterpillar Cat 307 EXCAVATOR (Prefix 2WM) Service Repair Manual (2WM00001-00499).pdf

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