caterpillar 12 | 6 | d318 | d6 | dw10 service manual · the caterpillar service manual \(ct-s-eng 4...
TRANSCRIPT
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Engine
.II::"I~I\IL.C~ INC. WITHOUT THE AUTHORIZATION OF :;CE=:SS;ORS. CATERPILLAR AND IT'S SUCCESSORS
THE QUALITY OR ACCURACY OF THIS MANUAL.
CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, PTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.
CT-S-E
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FORM FE030238-04
Diesel Engines (4 1h"BORE
D318 INDUSTRIAL
D3l 8 ELECTRIC SET
D318 MARINE
6·CYLINDER)
NO. 1 2 MOTOR GRADER
NO.6 TRAXCAVATOR . NO. 977 TRAXCAVATOR
D6 TRACTOR
DW10 TRACTOR
CATERPILLAR TRACTOR CO. • PEORIA, ILLINOIS, U.S.A.
Printed by J ....... Inc. 800-443-0625
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Specifications
General Instructions .
Introduction
Diesel Engine
Cooling Systems
Lubricating System.
Fuel System
Governor.
Air Cleaners
Table of Contents
Inlet and Exhaust Manifolds
Cy linder Head .
Valves and Valve Mechanism
Timing Gears
Camshaft .
Hour Meter
Connecting Rods
Pistons and Rings
Cylinder Liners
Main Bearings .
Flywheel and Flywheel Housing
Crankshaft
Reverse and Reduction Gear .
Front Power Take-off
Auxiliary Drive Housing.
Aligning Attachments to Flywheel.
2
Page
4
9
17
21
60
86
III
143
144
151
159
,176
181
189
191
193
198
205
210
215
219
221
224
226
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TABLE OF CONTENTS-Continued
Starting Engine
Starting Engine Removal and Installation
Cooling System
Lubricating System
Governor
Cylinder Head.
Top Cover
Valves and Valve Mecl~:::sm
Timing Gear Cover
Camshaft
Connecting Rods
Pistons and Rings
Flywheel
Crankshaft
Main Bearings
Starter Mechanism
Carburetor
Index
Printed by Jeoua" Inc. 80().443.0625
3
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232
234
235
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241
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265
271
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REMOVING OVERflOW VALVE (EARLIER ENGINES) 3-Cover. 4-Seal assembly. 5-Tube assembly.
6-Gasket. 7-0verllow.
On later engines, the radiator top tank contains an integral baffle plate (8) which eliIninates the need for tube assembly (5).
SEAL PRESSURE OVERFLOW (LATER ENGINES)
4-Seal assembly. a-Integral baffle plate.
WATER LINES REMOVAL (All Models)
When it becomes necessary to remove any of the water lines, they can be removed In most cases without disturbing other assemblies or attachments.
There are various drain plugs installed throughout the cooling system. Drain out only the amount of coolant necessary to permit the removal of the desired assembly without loss of the coolant. (When anti-freeze is drained out it can be drained into a container and reused, if desired).
30 Printed by Jensales Inc. 80CJ.443.0625
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nozzles require the thinner 9F4476 Rack Stop Clip which permits addi-tional fuel rack movement.
In this case, remove the clip. The other models do not require this stop which contacts the fuel pump housing slightly past the full load position.
Slide out the fuel rack assembly (2) which also has a stop attached to the forward end. This stop comes in contact with the fuel pump housing when the fuel rack is moved to the shut-off position. This prevents the fuel rack from being moved too far past the shut-off position.
REMOVING FUEL INJECTION PUMP RACK (DWIO ILLUSTRATED)
I-Clip. 2-Fuel rack assembly.
Governor Drive Gear and Camshaft Thrust Washer Removal and Installa-tion (All Models)
The governor drive gear can be pulled as illustrated, after removing the nut and lock from the end of the fuel pump camshaft. Use two suit-able capscrews 3" long with the 5F7465 Puller.
102 Printed by Jenoales Inc. 8QO.oI.43.0625
PULLING GOVERNOR DRIVE GEAR
•
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PISTON AND CONNECTING ROD INSTALLATION (All Models)
Be sure the carbon has been removed from the inside surface at the top of the cylinder liner.
PISTON INSTALLATION
•
Place the 5F6502 Ring Compressor on the top of the liner m which
the piston is to be installed.
Space the ring gaps evenly around the piston and thoroughly oil the
piston and the rings. Center the rings on the piston so they will not
protrude more on one side of the piston than on the other.
Place the piston and connecting rod into the ring compressor and the
liner and position the V -mark on top of the piston in alignment with the
V-mark on top of the cylinder block. This will place the crater of the
piston directly under the opening of the pre-combustion chamber and
the cutout portions of the piston in the correct location in relationship to
the inlet and exhaust valves. The identification number on the connect-
ing rod should be toward the inspection opening of the cylinder block.
Apply a gentle downward pressure on the piston. If the piston and
rings do not pass into the liner freely, check the rings. It is possible that
a ring can be positioned so it is protruding farther out on one side of
the piston than the other, thus causing the piston ring to bind and pre-
venting it from being compressed.
197 Printed by Jen ..... Inc. 8QO..4.(3-0025
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Disconnect and remove the coupling between the propeller shaft and the flange (4).
Disconnect or remove the supports (6)/ depending on the type of ill-stallatibn.
PULLING UNIT USING PULLER SCREWS
9-Flywheel housing. lO-PuHer screw.
TIIBS?
Remove the top inspection cover (2).
Remove the capscrews (7) which connect the unit to the flywheel.
Place suitable cables around the unit as illustrated.
TU85B
PILOT FLANGE AND BORE ll-Pilot flange. 12-Pilot flange bore.
220
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Index
Accessory Shott .
Adapter Housing
Adjustments: Fuel Inj ection Pump Lifter Fuel Rack Setting Governor:
Diesel Engine Starting Engine
Governor and Water Pump Belt, Starting Engine Starter Pinion Latches. Valve Clearance:
Diesel Engine Starting Engine
Air Cleaner .
Air Inlet Manifold
Air Silencer.
Aligning Attachments to Flywheel
Auxiliary Drive Housing
Bearings: Connecting Rod:
Diesel Engine Starting Engine
Main: Diesel Engine Starting Engine
Bell, Suction
Belt, Fan
Break-in Powder.
By-pass: Fuel Oil, Cooler Oil, Filter
Camshaft: Diesel Engine Starting Engine
Printed by Jenuleslnc. ~5
271
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186
40
107 130
129, 139 237 239 263
5 8, 244
143
144
144
226
224
191 248
205 256
69, 72
33
204
93 82 82
181 247
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INDEX~Continued
Camshaft Gear: Diesel Engine Starting Engine
Carburetor .
Chambers, Precombusticn
Cleaner, Air
Cleaning: Cooling System Fuel Injection Valve Pistons . Temperature Regulators
Clearances and Tolerances
Clutch, Starting Engine
Compression Release Mechanism
Connecting Rods and Bearings: Diesel Engine Starting Engine
Cooler, Oil .
Cooling System: Diesel Engine Starting Engine
Core: Oil Cooler Radiator
Coupling Alignment: Flexible Drive Self-Aligning
Cover: Timing Gear, Diesel Engine Timing Gear, Starting Engine Top, Starting Engine
Crankshaft: Diesel Engine Starting Engine
Crankshaft Gear: Diesel Engine Starting Engine
Crankshaft Pulley
Printed by JenNlea Inc:. 800-443-06.25
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Page
181 247
265
156
143
28 97
195 34
4
258
163
191 247
76
21 234
77 35
226 226
176 245 241
215 253
217 253
177
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INDEX-Continued
Cylinder Head: Diesel Engine Starting Engine
Cylinder Liners .
Cylinders, Starting Engine.
Data, Engine
Directors, Water
Drive: Accessory A uxiliary Housing Hour Meter and Tachometer Oil Pump Starting Motor
Engine Data
Etching Cylinder Liners
Exchanger, Heat .
Exhaust Manifold: Dry Water-cooled
Fan and Fresh Water Pump
Flow of Coolant, Fresh Water: Heat Exchanger-cooled System Radiator-cooled
Flow of Coolant, Raw Water
Filters: Fuel Oil.
Flywheel: Diesel Engine Starting Engine
FlywheeL Checking Top Center Marks
Flywheel Housing
Fresh Water Pump: Heat Exchanger-cooled Radiator-cooled
Front Power Take-off .
273
Page
151 240
198
251
4
154
186 224 189 73
264
4
202
36
149 150
42
23 21
26
87 78
210 253
173
210
54 43
221
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INDEX-Con tinued
Fuel: By-pass Filters Injection:
Equipment Pumps Pump Housing Pump Lifters Valves
Rack Setting System, Diesel Transfer Pump
Gauge: Fuel Oil
Gear~
Accessory Drive Camshaft
Diesel Engine Starting Engine
Crankshaft: Diesel Engine Starting Engine
Oil Pump Drive Ring, Flywheel Timing:
Diesel Engine Starting Engine
Governor: Diesel Engine Starting Engine
Head, Cylinder: Diesel Engine Starting Engine
Heat Exchanger
Hour Meter.
Housing: Flywheel Fuel Injection Pump Fuel Filter Regulator, Water Temperature Timing Gear, Diesel Engine
274
Page
93 87
94 97
101 104
95 131 86 88
87 64
186
181 247
217 253
73 212
176 246
III 236
151 240
36
189
210 101 109 32
176
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Idler Gear, Timing: Diesel Engine Starting Engine
Inj ection, Fuel
Inlet: Manifold Valve:
Diesel Engine Starting Engine
Installing Starting Engine
Latches, Starter Pinion
Lifters: Fuel Injection Pump Valve:
Diesel Engine Starting Engine
Liners, Cylinder .
Lubricating System: Diesel Engine Starting Engine
Lubrication:
INDEX-Continued
Fresh Water Pump, Radiator-cooled Governor, Diesel Engine Hour Meter. . Piston and Ring . Raw Water Pump Timing Gear
Main Bearings: Diesel Engine Starting Engine
Manifolds: Exhaust:
Dry Water-cooled
Fuel Inlet Oil
Model Views
Printed by Jen .. 1n Inc. 800-443-0625
275
Page
180 245
86
144
164 242
232
263
104
175 244
198
60 235
48 120 190 194 48 62
205 256
149 150 87
144 84
230
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Oil: By-pass Valves Cooler . Filters Manifold Pan Pressure:
Gauge Regulating Valve Relief Valve
Pump: Drive Suction Bells
Operating Difficulties:
INDEX-Con tin ued
Diesel Engine Coolant Ove;~;eating Diesel Engine Fuel System Diesel Engine Lubricating S":"stem
Overheating, Coolant.
Pan, Oil
Pinion, Starter
Pistons and Rings: Diesel Engine Starting Engine
Piston Pin Bushings: Diesel Engine Starting Engine
Piston Rings: Diesel Engine Starting Engine
Powder, Break-in
Power Take-off, Front.
Precleaner
Precombustion Chambers
Pump: Fuel Inj ection Fuel Transfer Oil Raw Water, Diesel Engine
Printed by J.",..1ea Inc. ~5
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82 76 78 84 74
64 70 71
73 69, 72
27 94 64
27
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193 249
196 252
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143
156
97 88 65 49
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INDEX-Con tin ued
Water, Fresh: Diesel Engine:
Heat Exchanger-cooled . Radiator-cooled
Starting Engine
Rack Setting, Fuel
Radiator
Raising Ring Ridge in Cylinder Liners
Raw Water Pump
Regulators, Water Temperature.
Release, Compression
Removing Starting Engine
Reverse and Reduction Gear
Rings, Piston: Diesel Engine Starting Engine
Rocker Arms, Valve
Rod, Connecting: Diesel Engine Starting Engine
Running-in Schedule
Run-out: Flywheel Housing
Sealed Pressure Overflow
SecrIs, Liner .
Setting: Fuel Pump Lifter Fuel Rack
Shaft, Accessory Drive
Silencer, Air
Sleeve, Liner
Specifications: Diesel Engine Starting Engine Valve
Printed by Jensa •• Inc. 8CJO.443-0625 277
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31
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196 250
161
191 247
203
212
29
200
107 131
186
144
199
4 7
168
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INDEX-Continued
Springs: Governor:
Diesel Engine Starting Engine
Valve: Diesel Engine Starting Engine
Starter Pinion, Starting Engine
Starting Engine: Camshaft Carburetor Clutch Connecting Rods Cooling System Crankshaft Cy linder Head Flywheel Governor Installation Lubricating System Main Bearings Operation Pistons and Rings Removal Starter Pinion Top Cover Timing Gears Valves and Valve Mechanism Water Pump
Suction Bells
Tachometer Drive
Testing Temperature Regulators
Thrust Bearing: Camshaft Crankshaft
Timing: Diesel Engine Gears Diesel Engine Valves Fuel Inj ection
Printed by Jan ..... Inc. 8ClO-443-0625
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112 236
165 243
257
247 265 258 247 234 253 240 253 236 232 235 256 231 250 232 257 241 246 242 234
69, 72
189
33
186 216
180 168 107
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INDEX-Continued
Timing Gears: Diesel Engine Starting Engine
Timing Marks: Diesel Engine Starting Engine
Tolerances .
Top Cover, Starting Engine
Transfer Pump, Fuel
Valve: By-Pass, Fuel By -Pass, Oil . Diesel Engine, Inlet and Exhaust Fuel Inj ection Inspection and Reconditioning Lifters:
Diesel Engine Starting Engine
Pressure Regulating Pressure Relief Rocker Arm. Starting Engine, Inlet and Exhaust Stem Bushings Timing.
Valves and Valve Mechanism: Diesel Engine Starting Engine
Water: Directors, Seals and Ferrules Lines Pump:
Fresh, Heat Exchanger-cooled Fresh, Radiator-cooled . Raw
Seal Replacement: Fresh Water Pump, Heat Exchanger-cooled Fresh Water Pump, Radiator-cooled
Temperature Regulators
Wear Limits
FORM FE30238-4
279 Printed by JenNlea Inc:. 800-443-0625
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180 246
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164 95
167
175 244 70 71
161 242 166 168
159 242
154 30
54 43 49
58 45 31
4
9-60 PRINTED IN U.S.A.
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