Caterpillar Cat 312D L Excavator (Prefix HCW) Service Repair Manual (HCW00001 and up).pdf

Service Repair Manual
Models
312D and 312D L Excavator

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Product: EXCAVATOR
Model: 312D EXCAVATOR HCW
Configuration: 312D & 312D L Excavators HCW00001-UP (MACHINE) POWERED BY C4.2 Engine
Disassembly and Assembly
C4.2 Engine for Caterpillar Built Machines
Media Number -KENR8105-04 Publication Date -01/06/2013 Date Updated -12/06/2013
i02770970
Crankshaft - Install
SMCS - 1202-012
Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 6V-9120 Socket (1)
1
B 8T-5096 Dial Indicator 1
C 8T-9022 Silicone Gasket 1
D 198-9113 Seal Installer 1
( 1 )
Tooling (A) is a 46 mm socket.
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
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Illustration 1 g01377349
1. Install thrust washer (14) on the rear face of the crankshaft with the oil groove toward the
outside.
2. Position the upper halves of crankshaft main bearings (13) in the cylinder block. Install the
bearings with the main bearing tabs in the correct position. Lubricate the bearings with
clean engine oil.
3. Lubricate the crankshaft journals with clean engine oil. Attach a suitable lifting device to
crankshaft (12). The weight of crankshaft (12) is approximately 40 kg (88 lb). Use the
suitable lifting device in order to position crankshaft (12) onto the upper halves of the
crankshaft main bearings.
Note: Be careful not to damage the finished surfaces on the crankshaft.
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This Illustration is of the rear main bearing cap.
4. Install main bearings (11) onto crankshaft main bearing caps (7) (not shown). Install main
bearing (11) onto rear main bearing cap (8). Install bearings (11) with the main bearing tabs
in the correct position. Lubricate main bearings (11) with clean engine oil.
5. Install thrust washers (10) onto rear main bearing cap (8). Make sure that the oil grooves on
thrust washers (10) are facing away from rear main bearing cap (8) .
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6. Apply Tooling (C) to the corners and the sides of rear main bearing cap (8). Install rear
main bearing cap (8) to the cylinder block so that the rear face is even with the rear face of
the cylinder block.
7. Apply soapy water to seals (9). Position seals (9) in the grooves on rear main bearing cap
(8) with the rounded edges of seals (9) toward the outside. Use Tooling (D) in order to push
seals (9) into position. This will reduce the risk of damaging the metal cores of seals (9).
Apply Tooling (C) around seals (9). Cut off any excess length of seals (9) .
8. Install crankshaft main bearing caps (7). Put clean engine oil on the threads of new main
bearing cap bolts (6). Install main bearing cap bolts (6). Tighten main bearing cap bolts (6)
evenly to a torque of 137 ± 5 N·m (101 ± 4 lb ft).
Note: Ensure that crankshaft main bearing caps (7) are installed in the original locations.
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9. Check the end play of the crankshaft with Tooling (B). The end play must be 0.100 to 0.264
mm (0.0039 to 0.0104 inch). Refer to the Specification, "Crankshaft" for more information
on crankshaft end play.
Note: Remove tape or rubber tubing from the connecting rod bolts.
10. Apply a light coat of clean engine oil to the connecting rod bearing surfaces and to the
connecting rod journals. Install the connecting rods onto the connecting rod journals.
11. Install the lower half of the connecting bearings into the corresponding connecting rod caps
and install connecting rod caps (5) .
Note: Align the tabs on the back of the connecting rod bearings with the tab grooves in
connecting rod caps (5). Install new bolts (4) and the new nuts. Tighten bolts (4) to a torque
of 103 ± 5 N·m (76 ± 4 lb ft).
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12. Install the pistons and connecting rods. Refer to Disassembly and Assembly, "Pistons and
Connecting Rods - Install".
13. Check for free crankshaft rotation by rotating the crankshaft for two complete revolutions.
Use Tooling (A) on nut (3) in order to rotate the crankshaft.
14. Position oil supply tube (1) and the O-ring seal. Install bolts (2) in order to secure the oil
supply tube to the cylinder block.
End By:
a. Install the engine oil pan. Refer to Disassembly and Assembly, "Engine Oil Pan - Remove
and Install".
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b. Install the flywheel housing. Refer to Disassembly and Assembly, "Flywheel Housing -
Remove and Install".
c. Install the crankshaft rear seal, if the crankshaft wear sleeve was removed. Refer to
Disassembly and Assembly, "Crankshaft Rear Seal - Install".
d. Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) - Install".
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All Rights Reserved.
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Thu May 21 08:12:41 UTC+0800 2020
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Product: EXCAVATOR
i01131265
Crankshaft Gear - Remove and Install
SMCS - 1204-010-GE
Removal Procedure
Table 1
Required Tools
A
1P-0820 Hydraulic Puller 1
9U-6600 Hand Hydraulic Pump 1
0S-2398 Step Plate 1
3H-0468 Puller Plate 4
8B-7549 Puller Leg 2
1B-4207 Full Nut 2
8B-7551 Bearing Puller 1
Start By:
a. Remove the crankshaft. Refer to Disassembly and Assembly, "Crankshaft - Remove".
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1. Use Tool (A) to remove crankshaft gear (1) from crankshaft (2).
Note: Do not remove the gear by tapping with a hammer.
2. Check the key on the crankshaft. If the key is damaged, use a new part for replacement.
NOTICE
Always wear protective gloves when handling parts that have been
heated.
1. Use an oven and heat the crankshaft gear to a temperature of about 100 °C (212 °F). The
crankshaft gear is heated in order to ease installation of the crankshaft gear.
Wear eye protection in order to prevent possible personal injury while
performing the following steps.
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2. Install the crankshaft gear on the end of the crankshaft. Ensure that the key in the crankshaft
is aligned with the keyway in the gear. Tap lightly with a copper hammer until the
crankshaft gear is seated. Ensure that the crankshaft gear is seated against the shoulder on
the crankshaft.
Note: Ensure that the timing marks of the crankshaft gear are on the front.
End By:
a. Install the crankshaft. Refer to Disassembly and Assembly, "Crankshaft - Install".
Thu May 21 08:13:40 UTC+0800 2020
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Product: EXCAVATOR
i05977048
Bearing Clearance - Check
SMCS - 1203-535; 1219-535
Measurement Procedure
Table 1
Required Tools
A
198-9142
Plastic Gauge (Green)
0.025 to 0.076 mm
(0.001 to 0.003 inch)
1
198-9143
Plastic Gauge (Red)
0.051 to 0.152 mm
(0.002 to 0.006 inch)
1
198-9144
Plastic Gauge (Blue)
0.102 to 0.229 mm
(0.004 to 0.009 inch)
1
198-9145
Plastic Gauge (Yellow)
0.230 to 0.510 mm
(0.009 to 0.020 inch)
1
Note: Plastic gauge may not be necessary when the engine is in the chassis.
NOTICE
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Note: Cat does not recommend the checking of the actual bearing clearances particularly on small
engines. This is because of the possibility of obtaining inaccurate results and the possibility of
damaging the bearing or the journal surfaces. Each Cat engine bearing is quality checked for
specific wall thickness.
Note: The measurements should be within specifications and the correct bearings should be used.
If the crankshaft journals and the bores for the block and the rods were measured during
disassembly, no further checks are necessary. However, if the technician still wants to measure the
bearing clearances, Tooling (A) is an acceptable method. Tooling (A) is less accurate on journals
with small diameters if clearances are less than 0.10 mm (0.004 inch).
NOTICE
Lead wire, shim stock or a dial bore gauge can damage the bearing
surfaces.
The technician must be very careful to use Tooling (A) correctly. The following points must be
remembered:
• Ensure that the backs of the bearings and the bores are clean and dry.
• Ensure that the bearing locking tabs are properly seated in the tab grooves.
• The crankshaft must be free of oil at the contact points of Tooling (A).
1. Put a piece of Tooling (A) on the crown of the bearing that is in the cap.
Note: Do not allow Tooling (A) to extend over the edge of the bearing.
2. Use the correct torque-turn specifications in order to install the bearing cap. Do not use an
impact wrench. Be careful not to dislodge the bearing when the cap is installed.
Note: Do not turn the crankshaft when Tooling (A) is installed.
3. Carefully remove the cap, but do not remove Tooling (A). Measure the width of Tooling
(A) while Tooling (A) is in the bearing cap or on the crankshaft journal. Refer to Illustration
1.
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Typical Example
4. Remove all of Tooling (A) before you install the bearing cap.
Note: When Tooling (A) is used, the readings can sometimes be unclear. For example, all
parts of Tooling (A) are not the same width. Measure the major width in order to ensure that
the parts are within the specification range. Refer to Specifications Manual, "Connecting
Rod Bearing Journal" and Specifications Manual, "Main Bearing Journal" for the correct
clearances.
Thu May 21 08:14:40 UTC+0800 2020
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Product: EXCAVATOR
i02741821
Crankshaft Position Sensor - Remove and Install - Primary
Speed Timing Sensor
SMCS - 1912-010
Removal Procedure
NOTICE
1. Disconnect harness assembly (1). Remove bolt (3) and crankshaft position sensor (2).
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Note: Check the O-ring seals for wear or for damage. Replace the components, if necessary.
NOTICE
1. Install crankshaft position sensor (2). Install bolt (3). Tighten bolt (3) to a torque of
17 ± 2 N·m (13 ± 1 lb ft). Connect harness assembly (1).
Thu May 21 08:15:39 UTC+0800 2020
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Product: EXCAVATOR
i02741883
Coolant Temperature Sensor - Remove and Install
SMCS - 1906-010
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, "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.
NOTICE
1. Drain the coolant from the cooling system into a suitable container for storage or for
disposal. Refer to Operation and Maintenance Manual, "Cooling System Coolant (ELC) -
Change".
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2. Disconnect harness assembly (1).
3. Remove water temperature sensor (2) and the O-ring seal.
1. Install the O-ring seal onto water temperature sensor (2). Install water temperature sensor
(2). Tighten water temperature sensor (2) to a torque of 15 ± 3 N·m (11 ± 2 lb ft).
2. Connect harness assembly (1).
3. Fill the cooling system. Refer to Operation and Maintenance Manual, "Cooling System
Coolant (ELC) - Change".
Thu May 21 08:16:38 UTC+0800 2020
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Product: EXCAVATOR
i02771200
Engine Oil Pressure Sensor - Remove and Install
SMCS - 1924-010
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
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1. Disconnect harness assembly (2) .
2. Remove engine oil pressure sensor (1) and the O-ring seal.
NOTICE
1. Install the O-ring seal onto engine oil pressure sensor (1). Install engine oil pressure sensor
(1). Tighten engine oil pressure sensor (1) to a torque of 10 ± 2 N·m (89 ± 18 lb in).
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2. Connect harness assembly (2) .
Thu May 21 08:17:38 UTC+0800 2020
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Product: EXCAVATOR
i02879394
Position Sensor (Fuel Injection Pump) - Remove and Install
SMCS - 1911; 7400
Removal Procedure
Start By:
A. Remove the hydraulic fuel injection pump. Refer to Disassembly and Assembly, "Fuel
Injection Pump - Remove".
NOTICE
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1. Remove bolt (2) in order to remove position sensor (1) and the O-ring seal.
NOTICE
Note: Check the O-ring seal for wear or for damage. Replace the component, if necessary.
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1. Install the O-ring seal and position sensor (1) . Install bolt (2) .
End By: Install the hydraulic fuel injection pump. Refer to Disassembly and Assembly, "Fuel
Injection Pump - Install". Refer to Disassembly and Assembly, "".
Thu May 21 08:18:37 UTC+0800 2020
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Product: EXCAVATOR
i02741932
Fuel Pressure Sensor - Remove and Install
SMCS - 7414-010
Removal Procedure
NOTICE
Fuel leaked or spilled onto hot surfaces or electrical components can
cause a fire.
Turn the disconnect switch OFF when draining and/or removing any
fuel system components.
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Caterpillar Cat 312D L Excavator (Prefix HCW) Service Repair Manual (HCW00001 and up).pdf

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Caterpillar Cat 312D L Excavator (Prefix HCW) Service Repair Manual (HCW00001 and up).pdf