Caterpillar Cat 312D2 L Excavator (Prefix MGJ) Service Repair Manual (MGJ00001 and up).pdf

Service Repair Manual
Models
312D2 and 312D2 L Excavator

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Product: EXCAVATOR
Model: 312D2 L EXCAVATOR MGJ
Configuration: 312D2 & 312D2 L Excavators MGJ00001-UP (MACHINE) POWERED BY 3054C Engine
Disassembly and Assembly
3054C Engines for Caterpillar Built Machines
Media Number -SENR5069-18 Publication Date -01/05/2015 Date Updated -19/09/2018
i07030444
Flywheel - Install
SMCS - 1156-012
Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A -
Guide Bolt
(1/2 inch - 20 NF by 4 inch)
2
B 138-7575 Link Bracket 1
NOTICE
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
1. Thoroughly clean the flywheel housing. Inspect the crankshaft rear seal for leaks. If there
are any oil leaks, refer to this Disassembly and Assembly Manual, "Crankshaft Rear Seal -
Remove" for the correct procedure.
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312D2 & 312D2 L Excavators MGJ00001-UP (MACHINE) POWERED BY 3054C E...
2020/6/6
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Illustration 1 g00909349
Always wear protective gloves when handling parts that have been
heated.
Note: If ring gear (3) has been removed from flywheel (2). Identify the orientation of ring
gear (3) on the flywheel for the correct positioning when the new ring gear is installed.
2. Heat the ring gear to 250 °C (480 °F) in an oven to install the ring gear onto the flywheel.
Ensure that the orientation of the ring gear is correct and quickly install the ring gear onto
the flywheel.
Note: Do not use a torch to heat the ring gear.
3. Clean flywheel (2) and ring gear (3) when the ring gear has cooled.
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4. Install the Tooling (A) on the crankshaft. Install the Tooling (B) and a suitable lifting device
on flywheel (2) and position the flywheel in the flywheel housing. The weight of the
flywheel is approximately 54 kg (119 lb).
5. Install bolts (1) to flywheel (2).
6. Remove Tooling (A). Install the remaining bolts (1) that secure flywheel (2) to the
crankshaft. Tighten the bolts (1) to a torque of 140 N·m (103 lb ft).
7. Check the alignment of flywheel (2) with the crankshaft. Refer to Testing and Adjusting,
"Flywheel - Inspect" for the correct procedure.
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All Rights Reserved.
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Sat Jun 6 22:57:07 UTC+0800 2020
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Product: EXCAVATOR
i02293665
Crankshaft Rear Seal - Remove
SMCS - 1161-011
Removal Procedure
Start By:
a. Remove the flywheel. Refer to Disassembly and Assembly, "Flywheel - Remove".
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, "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.
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Note: The crankshaft rear seal is nonserviceable. If the crankshaft rear seal is removed, the
complete housing assembly must be replaced.
1. Remove the setscrews (1) from the housing assembly (2).
2. Remove the housing assembly (2) from the cylinder block. Discard the housing assembly
(2).
Sat Jun 6 22:58:06 UTC+0800 2020
2/2
2020/6/6

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i02293676
Crankshaft Rear Seal - Install
SMCS - 1161-012
Table 1
Required Tools
A FT-2806 Alignment Tool 1
Note: The crankshaft rear seal and the housing for the crankshaft rear seal are manufactured as a
one-piece assembly. The assembly of the crankshaft rear seal uses ten setscrews in order to fasten
the assembly to the cylinder block.
Note: The following procedure assumes that the crankshaft rear seal is a replacement assembly.
Note: The crankshaft rear seal is lubricated. There is no need to lubricate the seal or the crankshaft
flange before installation.
Note: An installation sleeve (2) is supplied with the new housing assembly. The installation sleeve
must be in place when housing assembly is installed on the crankshaft flange in order to prevent
damage to the crankshaft rear seal during assembly.
NOTICE
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1. Ensure that the crankshaft flange (1) is clean, dry and free from rough metal edges. Ensure
that the face of the cylinder block and the bridge in the crankcase are clean and dry.
2. Remove the packaging from the new assembly of the crankshaft rear seal (3). Ensure that
the plastic sleeve (2) is squarely installed within the seal of the assembly of the crankshaft
rear seal (3). The plastic sleeve (2) is included in order to protect the lip of the seal as the lip
is pushed over the crankshaft flange (1).
Typical example
3. Place the assembly of the crankshaft rear seal (3) over the crankshaft flange (1) and engage
the plastic sleeve (2) onto the crankshaft flange.
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4. Ensure that the plastic sleeve (2) is engaged onto the crankshaft flange (1). Push the
assembly of the crankshaft rear seal (3) evenly and push the assembly smoothly onto the
crankshaft flange (1) until the assembly is against the cylinder block. During this process,
the plastic sleeve (2) will be forced out of the assembly of the crankshaft rear seal (3).
Discard the plastic sleeve (2).
5. Rotate the assembly of the crankshaft rear seal (3) in order to align the setscrew holes in the
assembly with the setscrew holes in the rear face of the cylinder block.
6. Install the setscrews (5) in order to position housing assembly (3) to the cylinder block. Do
Not tighten the bolts.
7. Place the Tooling (A) over housing assembly (2). This will center the housing assembly
onto the crankshaft flange (3).
8. Tighten the setscrews (1) in numerical order to a torque of 22 N·m (16 lb ft). Do not tighten
the setscrews (X) at this time.
9. Remove the Tooling (A). Tighten the setscrews (X) to a torque of 22 N·m (16 lb ft).
End By:
a. Install the flywheel. Refer to Disassembly and Assembly, "Flywheel - Install".
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i05322247
Crankshaft Wear Sleeve (Rear) - Remove
SMCS - 1161-011-ZV
Removal Procedure
Table 1
Required Tools
A
242-9955 Puller 1
- Spacer 1
Start By:
A. Remove the crankshaft rear seal. Refer to Disassembly and Assembly, "Crankshaft Rear
Seal - Remove and Install" for the correct procedure.
NOTICE
Note: Wear sleeves are used to reclaim worn seal surfaces or damaged seal surfaces. Wear sleeves
are not original equipment. The wear sleeve is supplied with a crankshaft rear seal that has a larger
internal diameter than a standard crankshaft rear seal. A standard crankshaft rear seal cannot be
used if a wear sleeve is installed.
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Typical example
1. Use Tooling (A) in order to remove crankshaft wear sleeve (1) from crankshaft (2) .
Sat Jun 6 23:00:05 UTC+0800 2020
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Product: EXCAVATOR
i05764187
Crankshaft Wear Sleeve (Rear) - Install
SMCS - 1161-012-ZV
Table 1
Required Tools
A
438-3244 Oil Seal Installer 1
8T-0375 Bolt 1
5P-8247 Hard Washer 1
B
438-3245 Oil Seal Locator 1
9U-6172 Bolt 2
NOTICE
Note: Wear sleeves are used to reclaim worn seal surfaces or damaged seal surfaces. Wear sleeves
are not original equipment. The wear sleeve is supplied with a crankshaft rear seal that has a larger
internal diameter than a standard crankshaft rear seal. A standard crankshaft rear seal cannot be
used if a wear sleeve is installed.
1. Ensure that the crankshaft is thoroughly clean and dry. Remove any areas of raised damage.
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2. Lubricate the inner surface of the crankshaft wear sleeve with clean engine oil.
Sectional view of the crankshaft, the wear sleeve, and the installation tool
3. Use Tooling (A) and Tooling (B) to install the crankshaft wear sleeve, as follows:
a. Align Tooling (B) with the dowels in crankshaft (2) and install Tooling (B) to the
crankshaft. Ensure the correct orientation.
Note: Verify that Tooling (A) will slide freely over Tooling (B).
b. Carefully slide crankshaft wear sleeve (1) over Tooling (B) until the crankshaft wear
sleeve contacts the rear of crankshaft (2).
c. Assemble Tooling (A) to Tooling (B) and install the bolt and the washer. Ensure that
the face of Tooling (A) with the deep counterbore is toward crankshaft wear sleeve
(1).
d. Tighten the bolt until Tooling (A) bottoms out on Tooling (B) in order to pull
crankshaft wear sleeve (1) onto crankshaft (2).
e. Remove Tooling (A) and Tooling (B).
End By:
a. Install the new crankshaft rear seal that was supplied with the crankshaft wear sleeve.
Sat Jun 6 23:01:04 UTC+0800 2020
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i02294250
Flywheel Housing - Remove and Install
SMCS - 1157-010
Removal Procedure
Table 1
Required Tools
A 138-7575 Link Bracket 2
Start By:
a. Remove the electric starting motor. Refer to Disassembly and Assembly, "Electric Starting
Motor - Remove and Install".
b. Remove the flywheel. Refer to Disassembly and Assembly, "Flywheel - Remove".
NOTICE
NOTICE
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containing fluids.
Cat products.
1. The weight of the flywheel housing (3) is approximately 39 kg (85 lb). Use suitable lifting
equipment to support the flywheel housing (3) while the setscrews (1) are being removed
and while the flywheel housing is being removed.
2. Remove the setscrews (1) from the top of the flywheel housing (3).
3. Attach the Tooling (A) and a suitable lifting device to the flywheel housing (3).
4. Remove the setscrews (2) that attach the flywheel housing (3) to the cylinder block.
5. Remove the flywheel housing (3). If necessary, tap the flywheel housing with a soft faced
hammer in order to separate the flywheel housing from the cylinder block.
Table 2
Required Tools
A 138-7575 Link Bracket 2
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NOTICE
1. Clean the rear face of the cylinder block and the mating surface of the flywheel housing (3).
2. If a felt seal (5) is installed, replace the felt seal. Inspect the dowels (4) in the cylinder block
that align the flywheel housing (3). Replace the dowels, if necessary.
3. The weight of the flywheel housing (3) is approximately 39 kg (85 lb). Use the Tooling (A)
and a suitable lifting device to position the flywheel housing (3) on the dowels (4) that are
on the cylinder block.
4. Install the setscrews (1) that attach the flywheel housing (3) to the cylinder block.
5. Install the setscrews (2) that attach the flywheel housing (3) to the cylinder block.
Tighten the setscrews (1) and the setscrews (2) to the following torque:
M10 "8.8" ... 44 N·m (33 lb ft)
M10 "10.9" ... 63 N·m (46 lb ft)
M12 "8.8" ... 75 N·m (55 lb ft)
M12 "10.9" ... 115 N·m (85 lb ft)
6. Remove Tooling (A) and the lifting device from the flywheel housing.
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7. Check the alignment of the flywheel housing with the cylinder block. Refer to Testing and
Adjusting, "Flywheel Housing - Inspect".
End By:
a. Install the flywheel. Refer to Disassembly and Assembly, "Flywheel - Install".
b. Install the electric starting motor. Refer to Disassembly and Assembly, "Electric Starting
Motor - Remove and Install".
Sat Jun 6 23:02:03 UTC+0800 2020
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i02294252
Crankshaft Pulley - Remove and Install
SMCS - 1205-010
Removal Procedure
Start By:
a. Remove the V-Belts. Refer to Disassembly and Assembly, "V-Belts - Remove and Install".
NOTICE
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1. Remove the setscrews (1). Remove the thrust block (2).
2. Remove the pulley (3) from the crankshaft (4).
1. Clean the pulley (3) and clean the thrust block (2). Inspect the pulley (3) and the thrust
block (2) for wear and for damage. If necessary, replace any damaged component. Inspect
the area on the pulley (3) that is normally in contact with the crankshaft front seal. If there is
excessive wear then a wear sleeve can be installed. Refer to this Disassembly and Assembly
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Manual, "Crankshaft Wear Sleeve (Front) - Remove and Crankshaft Wear Sleeve (Rear) -
Install" for further details.
2. Position the pulley (3) onto the crankshaft (4).
3. Lubricate the threads and the shoulder of the setscrews (1). Position the thrust block and
install the setscrews (1). Tighten the setscrews evenly to a final torque of 115 N·m
(85 lb ft).
End By:
a. Install the V-Belts. Refer to Disassembly and Assembly, "V-Belts - Remove and Install".
Sat Jun 6 23:03:02 UTC+0800 2020
3/3
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i02294258
Crankshaft Front Seal - Remove
SMCS - 1160-011
Removal Procedure
Start By:
a. Remove the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley -
Remove and Install".
NOTICE
NOTICE
containing fluids.
Cat products.
1/3
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Note: Do not remove the crankshaft front seal at this time if the housing (front) will also be
removed. It is easier to remove the crankshaft front seal when the housing (front) has been
removed from the engine. Refer to this Disassembly and Assembly Manual, "Housing (Front) -
Remove".
1. Use a suitable puller (1) with three legs and install the legs under the crankshaft front seal
(2). Lock the legs into position.
2. Install a suitable adapter (3) between the crankshaft (4) and the puller (1).
NOTICE
Ensure that the main lip is used in order to remove the crankshaft
front seal. Do not damage the edge of the housing for the crankshaft
front seal.
3. Use the puller (1) in order to remove the crankshaft front seal (2). Discard the crankshaft
front seal (2).
NOTICE
Ensure that the main lip is used in order to remove the crankshaft
front seal. Do not damage the edge of the housing for the crankshaft
front seal.
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Sat Jun 6 23:04:02 UTC+0800 2020
3/3
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Product: EXCAVATOR
i02294259
Crankshaft Front Seal - Install
SMCS - 1160-012
Table 1
Required Tools
A 9U-6210 Front Seal Installer 1
NOTICE
Note: This procedure assumes that the housing (front) is still on the engine. Do not follow this
procedure if the housing (front) has been removed from the engine. Refer to this Disassembly and
Assembly Manual, "Housing (Front) - Install" if the housing (front) has been removed from the
engine.
1. Clean the oil seal housing (8) and inspect the oil seal housing for damage. If necessary,
replace the housing (front). Refer to this Disassembly and Assembly Manual, "Housing
(Front) - Remove and Housing (Front) - Install".
2. Check the face on the pulley that contacts the crankshaft front seal for wear. If necessary,
repair the crankshaft pulley. Refer to this Disassembly and Assembly Manual, "Crankshaft
Wear Sleeve (Front) - Remove and Crankshaft Wear Sleeve (Front) - Install" for further
details.
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Note: A sleeve (5) is attached to the new crankshaft front seal (6). Do not remove the sleeve
(5) at this time. Discard the new crankshaft front seal (6) if the sleeve (5) is not installed on
the new crankshaft front seal.
The Tooling (A) includes items 1, 2, 3, 4, 7 and 9.
3. Install the fastener plate (7) onto the front of the crankshaft. Install the nut (1) and the
pressure plate (2) onto the threaded bar (3).
Note: Do not lubricate the crankshaft front seal (6). Do not lubricate the oil seal housing (8).
NOTICE
Ensure that the lip of the crankshaft front seal that is spring loaded is
facing toward the inside of the front housing and that it is square with
the bore of the housing for the crankshaft front seal.
4. Align the assembly of the sleeve (5) and the crankshaft front seal (6) to the front of the oil
seal housing (8).
5. Install the adapter (4) onto the sleeve (5).
6. Install the pressure plate (2) onto the adapter (4) and tighten the threaded bar (3) onto the
fastener plate (7). Check the alignment of the assembly and the crankshaft front seal (6) to
the oil seal housing (8).
7. Insert a suitable rod through the hole (9) in the threaded bar (3) in order to prevent the
threaded rod from turning as the nut (1) is tightened. Tighten the nut (1) in order to push the
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crankshaft front seal (6) into the oil seal housing (8). Continue to tighten the nut (1) until
contact is made with the bottom face of the oil seal housing (8).
8. Turn the sleeve (5) counterclockwise and pull the sleeve at the same time in order to remove
the sleeve from the oil seal housing (8). Remove the adapter (7).
9. Immediately install the crankshaft pulley. Refer to this Disassembly and Assembly Manual,
"Crankshaft Pulley - Remove and Install".
Sat Jun 6 23:05:01 UTC+0800 2020
3/3
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Product: EXCAVATOR
i02294796
Front Cover - Remove and Install
SMCS - 1166-010
Removal Procedure
Start By:
a. Remove the water pump. Refer to Disassembly and Assembly, "Water Pump - Remove and
Install".
Note: It is not necessary to remove the fan, the crankshaft pulley or the alternator in order to
remove the front cover. The fan, the crankshaft pulley and the alternator have been removed for
illustration purposes.
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Caterpillar Cat 312D2 L Excavator (Prefix MGJ) Service Repair Manual (MGJ00001 and up).pdf

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