4 Bore 4 Cylinder Engine For D311 Engine Set D2 Crawler S/n 4U & 5U #122 Motor Grader

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Oswald Webster
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Caterpillar Service Manual 4 Bore 4 Cylinder Engine For D311 Engine Set D2 Crawler

INC. WITHOUT THE AUTHORIZATION OF CATERPILLAR OR IT S SUCCESSORS.

1 Caterpillar Service Manual 4 Bore 4 Cylinder Engine For D311 Engine Set D2 Crawler S/n 4U & 5U #122 Motor Grader Service Manual THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF CATERPILLAR OR IT S SUCCESSORS. CATERPILLAR AND IT S SUCCESSORS ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL. TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS. CT-S-ENGLATED2

2 FORM FE s (4" BORE 4 CYLINDER) D311 INDUSTRIAL D311 ELECTRIC SET D311 MARINE D2 TRACTOR NO MOTOR GRADER CATERPILLAR TRACTOR CO. PEORIA, ILLINOIS, U. s. A. Printed by Jensalel Inc. SOO

3 Table of Contents Specifications 4 General Instructions 9 Introduction 17 Cooling Systems 21 Lubricating System. 64 Fuel System 92 Governor. 115 Air Cleaners 130 Manifolds 131 Cylinder Head. 136 Valves and Valve Mechanism 145 Timing Gear Cover, Timing Gears and Timing Gear Housing 163 Camshaft. 167 Hour Meter 177 Connecting Rods I 79 Pistons and Rings 184 Cylinder Liners 187 Main Bearings. 194 Flywheel and Flywheel Housing 200 Crankshaft 206 Reverse and Reduction Gear. 211 Front Power Take-off 213 Auxiliary Drive Housing. 217 Aligning Attachments to Flywheel Printed by Jen.. ie. Inc. 800-<

4 TABLE OF CONTENTS-Continued Removal 223 Installation 224 Cooling System 225 Lubricating System. 225 Governor. 226 Electric Starting Motor 230 Manifold 232 Cylinder Head 234 Valves and Valve Mechanism 235 Timing Gear Cover. 238 Timing Gears 239 Camshaft and Gear 240 Connecting Rods 242 Pistons and Rings 245 Flywheel 247 Crankshaft 248 Main Bearings. 253 Clutch and Starter Pinion 255 Carburetor 261 Index Printed by Jenule. Inc. ~3-0625

5 Fuel Pump Plunger Length Maxim urn wear in in. Fuel Injection Pump Timing Flywheel Housing Bore run-out Face run-out Nut torque... Flywheel Run-out Outside diameter (Maximum) Face (Maximum).010 -in..0ld -in. 150 lb. ft In in. Cylinder Head Tighten nuts (see text for sequence): First time (112/1 nuts).... 9/16 /I nuts Second time (112/1 nuts).... 9/ 1 6/1 nuts Expected tightness after run-in (112/1 nuts) (9/16" nuts) lb. ft...70 lb. ft..... ' 60 lb. ft. 95 lb. ft..55 lb. ft..90 lb. ft. Accessory Shaft End clearance Maximum In in. Compression Release Clearance (non-adjustable) Between rocker arm button and compression release shaft Timing Gear Housing Capscrew torque Hour Meter Bearing clearance (Maximum) in. 35 lb. ft in. Pre-combustion Chamber Torque lb. ft. The following illustration shows the numbering of the cylinders and of fuel injection pumps. 6 Printed by Janule. Inc

6 ENGINE UNDER FULL LOAD Fig. G. A further increase in load results in additional movement of the rack to provide additional fuel. The stop pin (7) is in contact with the torque spring (6) or stop. As long as the load remains constant the fuel remains constant. F'IG.G. ENGINE OVERLOADED Fig. H. If additional load is imposed the engine speed will start to drop. reducing the (orce of the weights. and allowing the governor spring force to compress the torque spring to give a further increase in the amount of fuel being injected. HIGH AND LOW IDLE ADJUSTMENTS Fig. I. When the low idle stop lever (8) is in contact with the spring-loaded stop (9) as illustrated. the engine operates at low idle. The screw assembly (10) controls the low idle selting. When the lever (12) contacts the high idle screw (11) which is also adjustable. the engine operates at the high idle speed. GOVERNOR SHUT -OFF POSITION Fig. J. When the governor control is in the shut-off position, it causes the stop lever (8) to pivot the spring-loaded stop (9) and it will hold the fuel rack in the "fuel off" position. 118 Printed by Jenoaiel Inc. 8OIl-«3-0625

DISCONNECTIONS FOR STARTING ENGINE REMOVAL I-Fumes disposal tube. 2-Air inlet pipe. 3-Compression release rod. 4-Capscrew. 5-Nut. 6-Elbow. 7-Gauge panel.

7 DISCONNECTIONS FOR STARTING ENGINE REMOVAL I-Fumes disposal tube. 2-Air inlet pipe. 3-Compression release rod. 4-Capscrew. 5-Nut. 6-Elbow. 7-Gauge panel. Installation Before installing the starting engine, clean the gasket surfaces on the top of the Diesel engine flywheel housing and on the bottom of the starting engine block. Cement a new gasket in place on the flywheel housing and allow it to set. Coat the top of the gasket with heavy grease. Attach cables to the starting engine in a manner to balance the engine, to permit it to be lowered into place so as not to damage the gasket. Guide the starting engine down over the dowels in the flywheel housing and also engage the teeth of the clutch idler gear with the starter pinion LIFTING STARTING ENGINE FROM THE FLYWHEEL HOUSING 224 Printed by Jansale. Inc. 8IJO..4.oI3-0625

8 Index Accessory Shaft. Adjustments: Fuel Injection Pump Litter Governor: Governor Belt, Starter Pinion Latches. Valve Clearance: Air Cleaner. Air Inlet Manifold Air Silencer. Aligning Attachments to Flywheel Auxiliary Drive Housing Bearings: Connecting Rod: Main: Bell, Suction Break-in Powder. By-pass: Fuel Oil Cooler Oil Filter Camshaft: Camshaft Gear: Carburetor. Chambers, Precombustion Cleaner, Air Cleaning: Cooling System Fuel Injection Valve Pistons. Radiator Temperature Regulators III , , Printed by Jen.. lel Inc

9 INDEX-Continued Clearances and Tolerances Clutch, Cock, Drain. Compression Release Mechanism Connecting Rods and Bearings: Cooler, Oil. Cooling System: Core: Heat Exchanger Oil Cooler Radiator Coupling, Alignment: Flexible Drive Self-Aligning Cover: Timing Gear, Timing Gear, Valve Crankshaft: Crankshaft Gear: Crankshaft Pulley Cylinder Head: Cylinder Liners. Cylinders,. Data, Engine Directors, Water. Drive: Accessory Hour Meter Housing, Auxiliary Oil Pump Starting Motor Tachometer , Printed by Jen.. le. Inc. S()O

10 INDEX-Continued Engine Data Etching Cylinder Liners Exchanger, Heat. Exhaust Manifold: Dry Water-cooled Fan and Water Pump. Flow of Coolant, Fresh Water: Heat Exchanger-cooled System Radiator-cooled Flow of Coolant, Raw Water Filters: Fuel Oil Flywheel: Flywheel, Checking Top Center Marks Flywheel Housing Fresh Water Pump: Heat Exchanger-cooled Radiator-cooled Front Power Take-off. Fuel: By-pass Filters Injection: Equipment Pumps Pump Housing Pump Lifters Valves System, Diesel Transfer Pump Gauge: Fuel Oil Gear: Accessory Drive Camshaft: Fuel Pump , Printed by Janaale. Inc

11 INDEX-Con tin ued Crankshaft: Oil Pump Drive. Reverse and Reduction Ring, Flywheel Timing: Governor: Head, Cylinder: Heat Exchanger Heat Indicator Hour Meter. Housing: Auxiliary Drive Flywheel Fuel Injection Pump Fuel Filter Timing Gear, Idler Gear, Timing: Inj ection, Fuel Inlet: Manifold Valve: Installing Latches, Starter Pinion Lifters: Fuel Injection Pump Valve: Liners, Cylinder. Lubricating System: Printed by Jenoalea loc. 8QO

12 INDEX-Con tin ued Lubrication: Governor, Hour Meter. Piston and Ring Timing Gear Main Bearings: Manifolds: Exhaust: Dry Water-cooled Fuel Inlet Oil Model Views Motor, Electric Starting Oil: By-pass Valves Cooler. Filters Manifold Pan Pressure: Gauge Regulating Valve Relief Valve Pump Pump Drive. Pump Suction Bells Operating Difficulties: Coolant Overheating Fuel System. Lubricating System Overheating, Coolant. Pan, Oil Pinion, Starter Pistons: Piston Pin Bushings: ,18,19, Printed by Jenule. Inc. ~3-0625

13 INDEX-Continued Piston Rings: Powder, Break-in Power Take-off, Front. Precleaner. Precombustion Chambers Pump: Fuel Injection Fuel Transfer Oil Raw Water, : Centrifugal Type Gear Type Sump Water, Fresh: : Heat Exchanger-cooled Radiator-cooled Radiator Raising Ring Ridge in Cylinder Liners Raw Water Pump Regulators, Water Temperature Release, Compression Removing. Reverse and Reduction Gear Rings, Piston: Rocker Arms, Valve Rod, Connecting: Running-in Schedule Run-out: Flywheel Housing Sealed Pressure Overflow. Seals, Liner. Setting Fuel Pump Lifter Shaft, Accessory Drive Silencer, Air Sleeve, Liner , III Printed by Jensaiel Inc

14 INDEX-Con tinued Specifications: Valve Springs: Governor: Valve: Starter Pinion, : Camshaft Carburetor Clutch. Connecting Rods Cooling System Crankshaft Cylinder Head Flywheel Governor Installation Lubricating System Main Bearings Manifold Operation Pistons and Rings Removal Starting Motor. Starter Pinion Timing Gears Valves and Valve Mechanism Suction Bells Support, Engine Front Tachometer Drive Testing Temperature Regulators Thrust Bearing: Camshaft Crankshaft Timing: Gears Valves Fuel Injection III Printed by Jensalel Inc. 800-<

15 INDEX-Contin ued Timing Gears: Timing Marks: Tolerances. Transfer Pump, Fuel Valve: By-Pass, Fuel By-Pass, Oil., Inlet and Exhaust Fuel Injection Inspection and Reconditioning Lifters: Pressure Regulating Pressure Relief Rocker Arm., Inlet and Exhaust Stem Bushings Timing. Valves and Valve Mechanism:. Water: Directors, Seals and Ferrules Lines Pump: Fresh, Heat Exchanger-cooled Fresh, Radiator-cooled Raw: Centrifugal Type Gear Type Seal Replacement: Fresh Water Pump, Heat Exchanger-cooled Fresh Water Pump, Radiator-cooled Temperature Regulator Wear Limits , , PRINTED IN U.S.A. Printed by Jenule. Inc

D4 Crawler S/n 24A, 39A, 40A, 54A, 55A & 69A

D4 Crawler S/n 24A, 39A, 40A, 54A, 55A & 69A Caterpillar Service Manual D Crawler S/n A, 9A, A, A, A & 69A Service Manual THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF CATERPILLAR OR IT S SUCCESSORS. CATERPILLAR AND IT S