Service Repair Manual

Models

312D and 312D L Excavator

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Product: EXCAVATOR
Model: 312D EXCAVATOR RHL
Configuration: 312D & 312D L Excavators RHL00001-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

i02742863

Gear Group (Front) - Remove - Idler Gear Only

SMCS - 1206-011

Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 9U-6148 Idler Shaft Puller 1
B 1P-0510 Driver Group 1

Start By:

a. Remove the front housing. Refer to Disassembly and Assembly, "Housing (Front) -
Remove".

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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

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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.

Illustration 1 g01374732
(1) Fuel injection pump drive gear
(2) Idler gear
(3) Camshaft gear
(4) Crankshaft gear

Note: The No. 1 cylinder is at the top center position when these marks are in alignment.

Note: Ensure that the marks on the timing gears are in alignment.

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Illustration 2 g01374789

1. Remove idler gear bolt (5) and the washer from the idler gear shaft .

2. Remove thrust plate (6) from the idler gear shaft.

Illustration 3 g01374793

3. Remove idler gear (2) from the idler gear shaft.

Illustration 4 g01374804

4. If necessary, use Tooling (B) and a suitable press in order to remove bushing (7) (not
shown) from idler gear (2).

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Illustration 5 g01374810

Illustration 6 g01374811

5. The following items are components of Tooling (A).

◦ 9U-6147 Stud (9)

◦ 6V-8231 Nut (10)

◦ 9U-6146 Sleeve Assembly (11)

◦ 8T-4244 Nut (12)

6. Use Tooling (A) in order to remove idler shaft (8) (not shown) from the cylinder block.
Check idler shaft (8) for wear and damage. Replace idler shaft (8), if necessary.

Note: See the following list for the removal of the other gears in the front gear group.

◦ In order to remove camshaft gear (3), refer to Disassembly and Assembly, "Camshaft
- Remove".

◦ In order to remove fuel injection pump gear (1), refer to Disassembly and Assembly,
"Fuel Injection Pump - Remove".

◦ In order to remove the gear from the engine oil pump, refer to Disassembly and
Assembly, "Engine Oil Pump - Remove".

◦ In order to remove crankshaft gear (4), refer to Disassembly and Assembly,

"Crankshaft Gear - Remove and Install".

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Product: EXCAVATOR
Model: 312D EXCAVATOR RHL
Configuration: 312D & 312D L Excavators RHL00001-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

i02879402

Gear Group (Front) - Install - Idler Gear Only

SMCS - 1206-012

Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
a 1p-0510 Driver Gp 1

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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Illustration 1 g01374804

1. Use Tooling (A) and a suitable press in order to install a new bushing (7) (not shown), if the
bushing was removed.

Illustration 2 g01374810

2. Lower the temperature of idler shaft (8) . Install idler shaft (8) (not shown) onto the cylinder
block.

Note: When idler shaft (8) is installed, ensure that the oil hole of idler shaft (8) is up.

Illustration 3 g01374827

3. Install idler gear (2) onto idler shaft (8) .

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Illustration 4 g01374732

(1) Fuel injection pump drive gear

(2) Idler gear

(3) Camshaft gear

(4) Crankshaft gear

Note: The No. 1 cylinder is at the top center position when these marks are in alignment.

Note: Ensure that the marks on the timing gears are in alignment.

Illustration 5 g01374789

4. Install thrust plate (6) onto the idler shaft.

5. Install the washer and idler gear bolt (5) onto thrust plate (6) . Tighten idler gear bolt (5) to a
torque of 34 ± 5 N·m (25 ± 4 lb ft).

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Note: See the following list for the installation of the other gears in the front gear group.

◦ In order to install the camshaft gear, refer to Disassembly and Assembly, "Camshaft -
Install".

◦ In order to install the fuel injection pump gear, refer to Disassembly and Assembly,
"Fuel Injection Pump - Install".

◦ In order to install the gear to the engine oil pump, refer to Disassembly and
Assembly, "Engine Oil Pump - Install".

◦ In order to install the crankshaft front gear, refer to Disassembly and Assembly,
"Crankshaft Gear - Remove and Install".

Illustration 6 g01374841

6. Install a dial indicator and rotate idler gear (2) back and forth in order to measure backlash.
Refer to Table 3.

Table 2
Item Standard at Assembly Service Limit

Backlash of crankshaft gear and

0.510 to 0.157 mm (0.0201 to 0.250 mm (0.0098
idler gear
0.0062 inch) inch)

Backlash of camshaft gear and

0.520 to 0.158 mm (0.0205 to 0.250 mm (0.0098
idler gear
0.0062 inch) inch)

Backlash of fuel injection pump

0.0560 to 0.205 mm (0.0022 to 0.250 mm (0.0098
gear and idler gear
0.0081 inch) inch)

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End play of idler gear

0.050 to 0.200 mm (0.0020 to 0.350 mm (0.0138
0.0079 inch) inch)

Clearance between idler gear

0.009 to 0.050 mm (0.0004 to 0.100 mm (0.0039
bushing and shaft
0.0020 inch) inch)

Illustration 7 g01374874

7. Measure the end play of idler gear (2) with a feeler gauge. Refer to Table 3.

End By: Install the front housing. Refer to Disassembly and Assembly, "Housing (Front) -
Install".

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Product: EXCAVATOR
Model: 312D EXCAVATOR RHL
Configuration: 312D & 312D L Excavators RHL00001-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

i02743335

Housing (Front) - Remove

SMCS - 1151-011

Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-0510 Driver Group 1

Start By:

a. Remove the alternator. Refer to Disassembly and Assembly, "Alternator - Remove and
Install".

b. Remove the water pump. Refer to Disassembly and Assembly, "Water Pump - Remove".

c. Remove the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley -
Remove and Install".

d. Remove the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump
- Remove".

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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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.

Illustration 1 g01374908

1. Loosen hose clamp (1) that secures hose (2) to the front housing.

2. Disconnect hose (2) from the front housing.

Illustration 2 g00605985

3. Remove bolts (3) and the washers that hold front housing (4) to the plate and the cylinder
block.

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4. Remove six bolts (5) (not shown) and the washers that mount front housing (4) to the oil
pan.

Illustration 3 g00606002

5. Remove bolts (6) and the washers that mount front housing (4) to front plate (8) and the
cylinder block.

6. Use two people in order to remove front housing (4) from the cylinder block and front plate
(8). The weight of front housing (4) is approximately 20 kg (45 lb).

Note: Check the condition of gasket (7) (not shown) for the engine oil pan. If gasket (7) is
damaged, it may be necessary to replace gasket (7). Refer to Disassembly and Assembly,
"Engine Oil Pan - Remove and Install" for replacement of gasket (7) for the engine oil pan.

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Illustration 4 g01377884

7. Remove baffle plate (9).

Illustration 5 g01377894

8. Use Tooling (A) in order to remove crankshaft front seal (10) (not shown) from front
housing (4), if necessary.

9. Check the teeth of the timing gears for the following items: wear, nicks, chips and uneven
contact. Check the keyway for wear or damage.

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Product: EXCAVATOR
Model: 312D EXCAVATOR RHL
Configuration: 312D & 312D L Excavators RHL00001-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

i02879387

Housing (Front) - Install

SMCS - 1151-012

Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-0510 Driver Group 1

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Note: Check the gaskets, and the seals for wear or for damage. Replace the components, if
necessary.

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Illustration 1 g00836619

Alignment marks for timing gears

1. Check the alignment of the timing gears.

Note: Ensure that the marks on the timing gears are in alignment. Align the "3" mark on the
fuel injection pump drive gear with the "33" mark on the idler gear. Make an alignment of
the "2" mark on the idler gear with the "22" mark on the camshaft gear. Align the "1" mark
on the crankshaft gear with the "11" mark on the idler gear. The No. 1 cylinder is at the top
center position when the timing marks are in alignment.

Illustration 2 g00606022

2. Ensure that the old gasket material (9) is removed from the mating surface of front housing
(4) and the timing gear plate. Install a new gasket (9) .

3. If the crankshaft front seal (10) (not shown) was removed, use Tooling (A) in order to
install a new crankshaft front seal (10) .

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Illustration 3 g00606002

4. Before installation of front housing (4) , check gasket (7) (not shown) for the oil pan for
damage. Replace gasket (7) , if necessary. Refer to Disassembly and Assembly, "Engine Oil
Pan - Remove and Install" for replacement of gasket (7) for the engine oil pan.

5. Use two people in order to install front housing (4) onto front plate (8) and the cylinder
block. The weight of front housing (4) is approximately 20 kg (45 lb).

6. Install bolts (6) in order to fasten front housing (4) onto the cylinder block and front plate
(8) .

Illustration 4 g00605985

7. Install the washers and six bolts (5) (not shown) in order to secure front housing (4) onto
engine oil pan.

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8. Install bolts (3) and washers that secure front housing (4) to the front plate and the cylinder
block.

Illustration 5 g01374908

9. Connect hose (2) to the front housing.

10. Tighten hose clamp (1) in order to secure hose (2) to the front housing.

End By:

a. Install the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump -
Install".
b. Install the crankshaft pulley. Refer to Disassembly and Assembly, "Crankshaft Pulley -
Remove and Install".
c. Install the water pump. Refer to Disassembly and Assembly, "Water Pump - Install".
d. Install the alternator. Refer to Disassembly and Assembly, "Alternator - Remove and
Install".

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Product: EXCAVATOR
Model: 312D EXCAVATOR RHL
Configuration: 312D & 312D L Excavators RHL00001-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

i01615486

Front Plate - Remove

SMCS - 1163-011

Removal Procedure
Start By:

a. Remove the idler gear. Refer to Disassembly and Assembly, "Gear Group (Front) -
Remove".

b. Remove the camshaft. Refer to Disassembly and Assembly, "Camshaft - Remove".

c. Remove the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump
- Remove".

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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Illustration 1 g00611711

1. Remove one bolt (1) and the washer from the front plate (2).

2. Remove front plate (2) from the engine.

3. Remove gasket (3) (not shown) from the engine or from the front plate (2).

Note: Ensure that all mating surfaces are clear of old gaskets.

Note: Check the cylinder block for the following conditions: scale buildup, corrosion and
other damage.

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Product: EXCAVATOR
Model: 312D EXCAVATOR RHL
Configuration: 312D & 312D L Excavators RHL00001-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

i01576831

Front Plate - Install

SMCS - 1163-012

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1 g00611711

1. Place gasket (3) (not shown) in position on the engine.

Note: Ensure that all mating surfaces are clear of old gaskets.

2. Place front plate (2) in position on the engine.

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3. Install one bolt (1) and the washer in order to secure front plate (2) to the engine. Tighten
the bolt to a torque of 35 ± 5 N·m (26 ± 4 lb ft).

End By:

a. Install the fuel injection pump. Refer to Disassembly and Assembly, "Fuel Injection Pump -
Install".

b. Install the camshaft. Refer to Disassembly and Assembly, "Camshaft - Install".

c. Install the idler gear. Refer to Disassembly and Assembly, "Gear Group (Front) - Install".

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Product: EXCAVATOR
Model: 312D EXCAVATOR RHL
Configuration: 312D & 312D L Excavators RHL00001-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

i02879389

Crankcase Breather - Remove and Install

SMCS - 1317-010

Removal Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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.

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Illustration 1 g01374569

1. Loosen clamps (3) and remove hose (2) .

2. Remove breather assembly (1) .

Installation Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 2 g01374569

1. Install new breather assembly (1) .

2. Install hose (2) and tighten hose clamps (3) .

Wed May 27 08:38:50 UTC+0800 2020

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Product: EXCAVATOR
Model: 312D EXCAVATOR RHL
Configuration: 312D & 312D L Excavators RHL00001-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

i02768517

Valve Mechanism Cover - Remove and Install

SMCS - 1107-010

Removal Procedure

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 1 g01384853

1. Remove bolts (1) and remove cover (2) .

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Illustration 2 g01385013

2. Disconnect hose (3) .

3. Remove bolts (4) and remove valve mechanism cover (5) and the O-ring seal.

Installation Procedure
Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the
components, if necessary.

NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

Illustration 3 g01385013

1. Position valve mechanism cover (5) and the O-ring seal. Install bolts (4). Tighten bolts (4)
to a torque of 18 ± 2 N·m (13 ± 1 lb ft).

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2. Connect hose (3) .

Illustration 4 g01384853

3. Position cover (2) and install bolts (1). Tighten bolts (1) to a torque of 17 ± 2 N·m (13 ± 1 lb
ft).

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