Caterpillar Cat D7G2 TRACK-TYPE TRACTOR (Prefix C7G) Service Repair Manual Instant Download.pdf

Product: TRACK-TYPE TRACTOR
Model: D7G2 TRACK-TYPE TRACTOR C7G
Configuration: D7G2 TRACK-TYPE TRACTOR C7G01000-UP (MACHINE) POWERED BY 3306 Engine
Disassembly and Assembly
3304B and 3306B Engines for Caterpillar Built Machines
Media Number -SENR5598-09 Publication Date -01/01/2013 Date Updated -25/01/2013
i01037991
Camshaft - Remove and Install
SMCS - 1210-010
Removal Procedure
Start By:
A. Remove the valve lifters. Refer to Disassembly and Assembly, "Lifter Group - Remove and
Install".
B. Remove the timing gear cover. Refer to Disassembly and Assembly, "Front Housing -
Remove".
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
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D7G2 TRACK-TYPE TRACTOR C7G01000-UP (MACHINE) POWERED BY 3306 ...
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Illustration 1 g00476744
1. Turn the crankshaft to top center compression stroke for the No. 1 piston. The "C" mark on
the crankshaft gear will be aligned with the "C" mark on the camshaft gear.
Note: Put a mark on the teeth of the fuel injection pump drive gear and the idler gear at
location (A). This will help to keep the engine timing correct during the removal and the
installation of the camshaft. Put a mark on the teeth of the idler gear and camshaft gear (2)
at location (B). When the camshaft is installed, the engine timing will be correct when the
mark at location (A) is aligned with the mark at location (B) and the "C" mark on the
crankshaft gear is aligned with the "C" mark on the camshaft gear.
2. Remove the bolts, the lock and washer (1) .
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NOTICE
Do not damage the lobes or the bearings when the camshaft is
removed.
3. Carefully remove camshaft (3) from the engine.
4. If necessary, remove the bolts that hold camshaft drive gear (2) to the camshaft and remove
the gear.
Installation Procedure
NOTICE
1. Put camshaft drive gear (2) in position on the end of camshaft (3). Install the bolts that hold
camshaft drive gear (2) to camshaft (3). Tighten the bolts to a torque of 55 ± 7 N·m (41 ± 5
lb ft).
NOTICE
Do not damage the lobes or the bearings when the camshaft is installed.
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2. Put 8T-2998 Camshaft Lubricant on the camshaft lobes only and put clean engine oil on the
bearing journals.
Note: During the installation of camshaft (3), rotate the camshaft in both directions in order
to prevent binding in the camshaft bearing bores.
3. Carefully install camshaft (3) into the engine.
4. Make sure that the mark on the teeth of the fuel injection pump drive gear and the idler gear
are in alignment at location (A). Make sure that the mark on the teeth of the idler gear and
camshaft gear (2) are in alignment at location (B). Align the "C" marks on the crankshaft
gear and camshaft gear (2). When all of the timing marks are in alignment the engine timing
is correct.
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5. Install washer (1), the lock and the two bolts that hold the camshaft in position in the
engine.
End By:
a. Install the valve lifters. Refer to Disassembly and Assembly, "Lifter Group - Remove and
Install".
b. Install the timing gear cover. Refer to Disassembly and Assembly, "Front Housing - Install".
5/5
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i02473351
Camshaft Bearings - Remove and Install
SMCS - 1211-010
Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A
8S-2241 Camshaft Bearing Tool Group 1
8H-0684 Ratchet Wrench 1
Start By:
A. Remove the Flywheel Housing. Refer to Disassembly and Assembly, "Flywheel Housing -
Remove and Install".
B. Remove the Oil Pan Plate. Refer to Disassembly and Assembly, "Oil Pan Plate - Remove
and Install".
C. Remove the Camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove and
Install".
NOTICE
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1. Use Tool (A) to remove the camshaft bearing from the cylinder block. Start with the front
bearings and work to the rear bearing.
Table 2
Required Tools
A
NOTICE
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1. Use Tool (A) to install the camshaft bearings in the 3304B and 3306B cylinder block.
Note: The camshaft bearings in the 3304B have pressure lubrication. The intermediate
camshaft bearings and the rear camshaft bearings in the 3306B have splash lubrication.
2. Install the camshaft bearings in the 3304B cylinder block, as follows:
(a) Install the front bearing to a depth of 0.57 ± 0.5 mm (0.022 ± 0.02 inch). Ensure that the
oil holes are in a horizontal position and that the camshaft bearing joint is at the top of the
engine. The camshaft bearing joint can not be more than 15° degrees from vertical in either
direction.
(b) Install the center bearing to a depth of 303.2 ± 0.5 mm (11.94 ± 0.02 inch). Ensure that
the oil holes in the camshaft bearing are in alignment with the oil holes in the cylinder
block.
(c) Install the rear bearing to a depth of 604.9 ± 0.5 mm (23.81 ± 0.02 inch). Ensure that the
oil holes in the camshaft bearing are in alignment with the oil holes in the cylinder block.
1. Install the camshaft bearings in the 3306B cylinder block, as follows:
2. Install front bearing (B) to a depth of 0.5 ± 0.5 mm (.02 ± .02 inch). Ensure that the oil holes
are in a horizontal position and that the camshaft bearing joint is at the top of the engine.
The camshaft bearing joint cannot be more than 15 degrees from the vertical position in
either direction.
3. Install the remainder of the bearings. Install the bearings to the dimensions that are given
from the front face of the cylinder block: (C) 154.0 ± 0.5 mm (6.06 ± .02 inch), (D) 303.2 ±
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0.5 mm (11.94 ± .02 inch), (E) 601.7 ± 0.5 mm (23.69 ± .02 inch) and (F) 903.4 ± 0.5 mm
(35.57 ± .02 inch).
End By:
a. Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove and Install".
b. Install the oil pan plate. Refer to Disassembly and Assembly, "Engine Oil Pan Plate -
c. Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing -
4/4
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i00974130
Engine Oil Pan - Remove and Install
SMCS - 1302-010
Removal Procedure
NOTICE
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the machine. 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 in Caterpillar machines.
Dispose of all fluids according to local regulations and mandates.
1. Drain the engine oil from the engine into a suitable container for storage or disposal.
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2. Loosen nut (4) and move the overflow tube away from the oil level gauge guide. Loosen nut
(3) and remove the oil level gauge guide from the engine.
3. Remove bolts (1) and the washers that hold the engine oil pan in position. Remove engine
oil pan (2) and the gasket from the engine oil pan plate.
NOTICE
1. Put the gasket and engine oil pan (2) in position on the engine oil pan plate. Install bolts (1)
and the washers that hold the engine oil pan in position.
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2. Install the oil level gauge guide and tighten nut (3). Fasten the overflow tube to the oil level
gauge guide and tighten nut (4) .
3. Fill the crankcase with engine oil to the proper level. Refer to Operation and Maintenance
Manual, "Refill Capacities".
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i01111802
Engine Balancer Shaft - Remove and Install
SMCS - 1220-010-JF
Removal Procedure
Start By:
A. Remove the front housing cover. Refer to Disassembly and Assembly, "Front Housing
Cover - Remove".
B. Remove the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump -
Remove".
NOTICE
NOTICE
of the product. Be prepared to collect the fluid with suitable containers
containing fluids.
Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
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Note: The oil pan plate has been removed for photo purposes only.
1. Remove plates (2) that hold the balancer shaft in the cylinder block.
2. Remove balancer shafts (1) from the cylinder block.
NOTICE
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1. Install the balancer shafts in each side of the cylinder block.
2. Install plates (2) and the bolts that hold the balancer shafts in position in the cylinder block.
Note: Ensure that the balancer shafts are in time before the oil pump is installed.
End By:
a. Install the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump -
Install".
b. Install the front housing cover. Refer to Disassembly and Assembly, "Front Housing Cover
- Install".
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i01135419
Engine Balancer Shaft Bearings - Remove and Install
SMCS - 1220-010-BD
Removal Procedure
Table 1
Required Tools
A
Start By:
A. Remove the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan -
Remove".
B. Remove the balancer shaft. Refer toDisassembly and Assembly, "Balancer Shaft -
Remove".
C. Remove the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing
Remove" .
NOTICE
NOTICE
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containing fluids.
Use Tool (A) to remove the six balancer shaft bearing. Pull the balancer shaft bearings toward the
flywheel end of the engine.
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(A) The front bearing depth is 0.8 ± 0.5 mm (0.03 ± 0.02 inch).
(B) The center bearing depth is 290.6 ± 0.5 mm (11.44 ± 0.02 inch).
(C) The rear bearing depth is 601.0 ± 0.5 mm (23.66 ± 0.02 inch).
NOTICE
NOTICE
containing fluids.
3/4
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1. Install the balancer shaft front bearing with Tool (A). Ensure that the holes in the bearings
are aligned with the holes in the cylinder block. The bearing must be 0.8 ± 0.5 mm (0.03 ±
0.02 inch) inside the front face of the cylinder block after installation.
2. Install the balancer shaft center bearing with Tool (A). Ensure that the holes in the bearings
are aligned with the holes in the cylinder block. The bearing must be 290.6 ± 0.5 mm (11.44
± 0.02 inch) inside the front face of the cylinder block after installation.
3. Install the balancer shaft rear bearing with Tool (A). Ensure that the holes in the bearings
are aligned with the holes in the cylinder block. The bearing must be 601.0 ± 0.5 mm (23.66
± 0.02 inch) inside the front face of the cylinder block after installation.
4. Check the bore of the bearings. The balancer shaft bearing bore must be 53.05 ± 0.06 mm
(2.089 ± 0.002 inch) after installation.
End By:
a. Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing -
Install" .
b. Install the balancer shaft. Refer to Disassembly and Assembly, "Balancer Shaft - Remove
and Install".
c. Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove
and Install".
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i00912474
Cylinder Liner - Remove
SMCS - 1216-011
Removal Procedure
Table 1
Required Tools
A
8T-0812 Cylinder Liner Puller 1
1U-6317 Bridge 1
1U-6319 Socket 1
Start By:
A. Remove the spacer plate. Refer to Disassembly and Assembly, "Spacer Plate - Remove and
Install".
B. Remove the engine oil pump. Refer to Disassembly and Assembly, "Engine Oil Pump -
Remove".
NOTICE
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1. Turn the crankshaft until two of the pistons are at the bottom center. Remove two
connecting rod cap bolts (2) from each rod. Remove connecting rod caps (4) .
2. Tap connecting rod (3) away from the crankshaft with a soft hammer. Remove bearing half
(1) .
3. Use tool (A) to remove cylinder liners (5) .
4. Remove the pistons and connecting rods from the cylinder liners.
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i01048841
Cylinder Liner - Install
SMCS - 1216-012
Table 1
Required Tools
A 8T-0455 Liner Projection Tool 1
B 2P-8260 Cylinder Liner Installation Tool 1
Note: The following procedure alleviates the need for the crossbar to hold the cylinder liners
during cylinder liner projection measurements.
1. Clean the cylinder liner flange and the cylinder block surface. Remove any nicks on the top
of the cylinder block.
2. Install clean cylinder liners without the rubber seals or the filler band. Install a new spacer
plate gasket and the clean spacer plate.
Table 2
Required Components
Item Part
Number
Part
Description
Quantity For One
Cylinder
Quantity For Six
Cylinders
1 0S-1589 Bolt 6 36
2 2S-0736 Washer 6 36
3 8F-1484 Washer 6 36
4 7K-1977 Washer 6 36
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3. Install the bolts and washers in the order that is shown in Illustration 1 in order to seat the
cylinder liner in the block. Tighten bolts (1) evenly to a torque of 95 N·m (70 lb ft).
(5) Bolt
(6) Dial Indicator
(7) Gauge Body
(8) Gauge
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4. Loosen bolt (5) until dial indicator (6) can be moved. Place gauge body (7) and dial
indicator (6) on the long side of gauge (8) .
5. Slide dial indicator (6) into position until the point contacts gauge (8). Slide dial indicator
(6) until the needle of the dial indicator makes a quarter of a revolution clockwise. The
needle should be in a vertical position. Tighten bolt (5) and zero dial indicator (6) .
6. Place gauge body (7) on the spacer plate with the dial indicator point on the cylinder liner
flange. Read the dial indicator in order to find the amount of liner projection. Check the
liner projection at four locations (every 90 degrees) around each cylinder liner.
Table 3
Specifications
Liner Projection 0.033 mm (.0013 inch) to
0.175 mm (.0069 inch)
Maximum Variation in Each Cylinder
0.051 mm (.0020 inch)
Maximum Average Variation Between Adjacent Cylinders
0.051 mm (.0020 inch)
Maximum Variation Between All Cylinders
0.102 mm (.0040 inch)
7. If the cylinder liner projection is out of specification, rotate the cylinder liner in the bore and
repeat the procedure. If the cylinder liner projection measurements are again out of
specification, try installing the cylinder liner in a different cylinder bore to improve the
measurements.
Note: Do not exceed the maximum liner projection of 0.175 mm (0.0069 inch). Cracking in
the flange of the cylinder liner results from excessive cylinder liner projection
measurements.
8. If the maximum variation between cylinder liners is greater than the recommended
specification, shims must be used in order to reach the correct specification.
9. When the cylinder liner projection for each cylinder liner is within the recommended
specification, mark each cylinder liner for the proper location in the bore and remove the
cylinder liners.
10. Lubricate the O-ring seals, the cylinder liner, and the upper filler band before installation.
Note: If the lower O-ring seals are black in color, apply liquid soap on the lower O-ring
seals and the cylinder block. Use clean engine oil on the upper filler band.
Note: If the lower O-rings are brown in color, apply engine oil on the lower O-ring seals,
the cylinder block, and the upper filler band.
NOTICE
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Apply 5P-3975 Rubber Lubricant and/or clean engine oil immediately
before assembly. If the 5P-3975 Rubber Lubricant or engine oil is
applied too early, the filler bands and/or O-ring seals may swell and
the filler bands and/or O-ring seals may be pinched under the cylinder
liner during installation.
11. Apply liquid soap on the bottom cylinder liner bore in the cylinder block. Apply liquid soap
on the grooves of the cylinder liner and on O-ring seals (4). Install O-ring seals (4) on the
cylinder liner.
12. Lubricate filler band (5) with clean engine oil and install filler band (5) on cylinder liner (6).
Install cylinder liner (6) into the engine block immediately after you lubricate the cylinder
liner. This helps to prevent swelling of the filler band.
13. Ensure that the mark on the cylinder liner is in alignment with the mark on the cylinder
block. Use Tool (B) to press each of the cylinder liners into position.
End By:
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a. Install the Pistons and Connecting Rods. Refer to Disassembly and Assembly, "Pistons and
Connecting Rods - Install".
b. Install the cylinder head. Refer to Disassembly and Assembly, "Spacer Plate - Remove and
Install".
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i01112806
Piston Cooling Jets - Remove and Install
SMCS - 1331-010
Removal Procedure
Start By:
A. Remove the crankshaft. Refer to Disassembly and Assembly, "Crankshaft - Remove".
NOTICE
1/3
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1. Use a soft punch to remove piston cooling jet (1) from the cylinder block.
Table 1
Required Tools
A 6V-7772 Driver 1
NOTICE
Note: On the 3304B, the piston cooling jets are installed in the No. 2 and the No. 4 main bosses.
On the 3306B, the No. 2 and the No. 6 bosses for the main bearings have two jets. The No. 3 and
No. 5 bosses for the main bearings have one jet. A replacement is necessary if the jets are
damaged. Normally, it will only be necessary to ensure that the jets are clean.
1. Use Tool (A) to install piston cooling jet (1) with the small end first. Install the jets in the
bosses for the main bearing until the jets are against the counterbore.
2. Ensure that the passage is open after piston cooling jet (1) is installed.
End By: Install the crankshaft. Refer to Disassembly and Assembly, "Crankshaft - Install".
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Caterpillar Cat D7G2 TRACK-TYPE TRACTOR (Prefix C7G) Service Repair Manual Instant Download.pdf

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