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

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Caterpillar Service Manual D Crawler S/n A, 9A, A, A, A & 69A Service

WITHOUT THE AUTHORIZATION OF CATERPILLAR OR IT S SUCCESSORS.

1 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 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-D 9A

2 ,GroupTO.~~ Pageit'c for CATERPILLAR D TRACTOR SERIAL NUMBERS 9A l-up AND A l-up i- Section Engine Starting Engine Power Transmission Units _ Track Roller Frame Seat, Fuel Tank and Miscellaneous Caterpillar Tractor Co., General Offices, Peorio,lIIinois. Caterpillar Americas Co., Peoria, Illinois.' Caterpillar Overseas S.A., Geneva. Caterpillar of Australia Pty. ltd.,melbourne. Caterpillar BrasiiS.A., SCioPaulo. Caterpillar Tractor Co. ltd., Glasgow. Caterpillar of Canada ltd.; Toronto. Caterpillar France' S.A., Grenoble.'.,/,,/ /

3 9\- GrcOupQ. Page TABLE OF CONTENTS Section Index.... 9A-O Specifications A-O General Instructions.... la-lo Cooling System... :.... 9A-O Water Temperature Regulator.... 9A-O Fan Group.... 9A-O Water Pump.... 9A-O Radiator.... 9A-I Lubricating System... 9A-O Oil Pan... 9A-O Oil Pump... 9A-I Oil Filter... 9A-O Fuel System...,.. 9A-O Fuel Supply Equipment A-O Fuel Injection Equipment A-O Governor... 9A-O Accessory Drive... 9A-O Air Induction and Exhaust System... 9A-O Cylinder Head A-O Valve and Valve Mechanism A-O Timing Gears...,... ' A-O Pistons, Rings and Connecting Rods... A-O Cylinder Liners A-I Main Bearings A-I Crankshaft... 9A-O Balancer... 9A-O Flywheel and Flywheel Housing A-O Engine Removal and Installation... " 9A-I Electrical System... 9A-O Group ::, ':t~~ Ce. ". ;,.,-.

4 9A-O Group. Page I INDEX A F Accessory Drive Accessory Drive Gear Accessory Drive Shaft Adjustments: Fuel Injection Pump Timing Dimension Setting Fuel Rack Setting.. Governor Air Cleaner Air Inlet Manifold Backlash, Timing Gear Balancer Bearings: Balancer Shaft Connecting Rod Main Breather, Crankcase.. By-pass: Fuel Oil Filter Oil Pump Camshaft Gear Chambers, Precombustion Cleaner, Air Cleaning: Engine Valves Fuel Injection Valve Pistons Temperature Regulator Clearances and Tolerances Compression Release Mechanism Connecting Rods and Bearings Cooling System Core, Radiator Cover, Timing Gear Crankshaft Crankshaft Pulley Cylinder Head Cylinder Liners Directors, Water Drive: Accessory Tachometer B C D Fan Assembly Fan Belt Fan Belt Tightener Filter: Fuel, Primary Oil Flow of Coolant Flow of Fuel Flow of Lubricating Oil Flywheel Fuel: By-pass Filter Housing Injection: Equipment Pumps Pump Housing Pump Lifters Valves System, Diesel Transfer Pump Priming Pump Gauge: Fuel Oil Gear: Accessory Drive Camshaft Crankshaft Idler Ring, Flywheel Timing Timing Marks Generator Generator Regulator Governor: Adjustments Operation and Lubrication Governor and Fuel Injection Pump Housing Removal Head, Cylinder Heater Pipe, Air Inlet Housing: Flywheel.. Fuel Injection Pump Governor G H Electric Starting Motor Electrical System Engine Data.. Exhaust Manifold E Idler Gear Injection, Fuel Inlet: Air Heater Pipe Manifold Valves

5 :.:,-. ~<-.. " Group. Page!.9A-IO INDEX Lifters: Fuel Injection Pump.. Valve.... Liners, Cylinder.... Lubricating System Lubrication: Piston and Ring... Ma\n Bearings Ma~ifolds: Exhaust Fuel Inlet... Oil Meter, Service Oil: By-pass Valve Filter Manifold.. Pan Pan Plate Pump ):::.:... Operatirtg:DiIficulties: Engine Coolant Overheating Engine Fuel System. Engine Lubricating System Overflow, Sealed Pressure Overheating, Coolant... Pan, Oil Pistons Piston Rings Plate, Oil Pan Precombustion Chambers Pump: Fuel: Injection Priming Transfer Oil Water Pressure, Oil Gauge Radiator Removing Ring Ridge in Cylinder Liners L M o P R Regulator, Water Temperature.... Release; Compression.... Ring Gear, Flywheel.... Rings, Piston Rocker Arms, Valve.. Rod, Connecting Running-in Schedule... Seal Replacement, Water Pump Seals, Liner.... Service Meter Shaft, Accessory Drive " Specifications Springs: Governor Valve.... Testing Temperature Regulator Thru~t Bearing, Crankshaft. Timing: Engine Gears.... Engine Valves... Fuel Injection... Timing Gear Cover Timing Gears... Timing Marks '" Tolerances Valve: By-pass, Fuel.... By-pass, Oil Inlet and Exhaust. Fuel Injection.... Inspection and Reconditioning Lifters.... Operation.... Pressure Regulator, Oil Pump Rocker Arm Assembly.. Seat Specifications Stem Bushings... Timing.... Valves and Valve Mechanism W Water: Directors, Seals and Ferrules.... Pump Seal Replacement.... Temperature Regulator s T v C'), ) )

6 Group. Page 9A-O SPECIFICATIONS Crankshaft Main journal diameter in. Permissible main journal wear in. Main bearing clearance (Earlier) in. Permissible bearing clearance (Earlier).... in. Main bearing clearance (Later-with lead-tin overlay) in. Permissible bearing clearance (Later)....lD in. End clearance llo -. in. Permissible end clearance in. Main bearing nut torque..... lb. ft. Connecting rod journal diameter.' in. Permissible journal wear in. Permissible out-of-round... ' in. Pulley retaining bolt torque... " ld - lb. ft. Cylinder Block Main bearing original bore dimension in. Cylinder Head Tighten bolts in sequence shown in illustration. Initial lb. ft. Final.' lb. ft II I o o 8 O 9 7 {"{., ': l- t- CYLINDER HEAD BOLT TIGHTENING SEQUENCE Cylinder Liner (Use F76 Adapter Plate for Removal) Inside diameter.... Permissible liner wear (increase in diameter at top of ring travel).... Counter bore dimension in block.. Flange thickness Fan Belt Tension Slack at point midway between pulleys.. Flywheel Retaining bolt torque. -. in in.. -. in.. -. in. 9/6 - /6 in. ll8 - lb. ft. Flywheel Housing Retaining bolt torque 6-7 lb. ft. Fuel Injection Equipment Fuel injection pump timing BTC Fuel injection pump timing dimension setting (off engine using M9 Gauge) in. Fuel pump plunger length... ' in. Fuel injection pump timing dimension setting (on engine with pistons at top center using M9 Gauge) in. ( : J ;.

7 Group. PageS 9A-IO SPECIFICATIONS Precombustion Chamber Torque lb. ft. Glow plug torque lb. ft. CENTERLINE OF., _'k." ). T786 PRECOMBUSTION CHAMBER POSITIONING DIAGRAM The precombustion chamber gasket is supplied in two different thicknesses. With the proper thickness gasket and the recommended torque to tighten the chambers into the head, the glow plugs and electrical connections will be positioned in the "go" range. The "go" range is the position in which the glow plugs will be clear of fuel lines and other points of interference, when installed in the precombustion chamber. The diagram can be used to position the precombustion chambers if new gasket are installed. Rocker Arm Bearing bore..., ' in. Clearance between shaft and bearing,.,... ',,,. ', '. -.6 in. Permissible clearance ","".',.','".,... ',',..,.. '.8 in. Retaining bolt torque,.,., " ",.,.,..,.,",.,.,..,"..,' lb. ft. Starting Motor V (Delco-Remy 88) Brush spring tension (minimum) Rotation (viewing drive end).',',..,...,.. "".,... ',.",. No load test: Volts,...,,',,,..,,,.,..,, '..,...,,. '..,. ',.,,,., Maximum amps Lock test: Volts.,.,..,. Maximum amps,. Minimum torque., oz. Clockwise.. 8 lb. ft. Timing Gear Housing Retaining bolt torque - lb. ft. Valves Exhaust: Clearance (hot).,...,..,...,..,,...,.'...,.,.. in. Clearance (cold),...,...,.,...,...'... :,.8 in. Stem cleara'nce in bushing.'..,.,...,,, ',.,,,,.'. -. in. Permissible clearance with new valve, ',, ', ',,,, ",,,,,,,,,, ".9 in. "-"'. \,-,! U ""! ',,'> I i I

Group. Page 9A-I WATER PUMP. Install the seal (6) with the wiping edge toward the inside. II. Prior to installing the pulley make certain the key is in the shaft.

8 Group. Page 9A-I WATER PUMP. Install the seal (6) with the wiping edge toward the inside. II. Prior to installing the pulley make certain the key is in the shaft. Also make certain the mounting bolts are in place in the water pump housing.. See the topic, SPECIFICATIONS, for the proper pulley retaining nut torque.. Press the impeller onto the shaft. See the topic, SPECIFICATIONS, for the correct impeller to housing clearance. o IMPELLER REMOVAL INSTALLING IMPELLER ASSEMBLY ('. ~. \ WATER PUMP SEAL REPLACEMENT Water leaking from the drain opening on the bottom of the pump housing indicates that the water seal assembly should be replaced. WATER PUMP BEARING REMOVAL. After the bearing and shaft have been removed, the bearing () can be pressed off the shaft. NOTE To avoid damaging the carbon-faced, selfadjusting seal, it should be installed after the shaft and bearings are assembled in the housing. 6. When pressing the bearing onto the shaft, place the shielded side of the bearing so it will be toward the outside of the water pump housing. 7. Install the seal () into the housing. Install the seal so the lip will be toward the impeller. 8. Pack the rear bearing with ball and roller bearing lubricant and install the shaft and bearing assembly into the water pump housing. 9. Pack the bearing compartment with ball and roller bearing lubricant. Inspect the ceramic bearing surface on the impeller which contacts the carbon thrust washer. The contact surface must be smooth and free of roughness or nicks. INSPECTING BEARING SURFACE.ON IMPELLER The seal assembly consists of a carbon thrust washer (), a flexible seal (), and a seal spring () all retained in a seal cup () by the seal retainer (). The carbon thrust washer () is cemented to the flexible seal (). The entire 'assembly must be replaced as a unit and is pressed in the water pump housing., '~'

.".:... OIL FILTER SA-IO ;;'~;~~p. Page I Oil Filter FLOW OF OIL THROUGH THE OIL FILTER Unfiltered oil is delivered by the oil pump through an external line () to the oil filter.

9 .".:... OIL FILTER SA-IO ;;'~;~~p. Page I Oil Filter FLOW OF OIL THROUGH THE OIL FILTER Unfiltered oil is delivered by the oil pump through an external line () to the oil filter. The oil flows up around the filter element (I) and is filtered as it passes through the element. The filtered oil flows down the center of the element, through passage () and into the oil distribution manifold. Prior to installation, replace any damaged gaskets or O-ring seals. PREPARING TO REMOVE OIL FILTER GROUP D Remove I-Oil filter inlet line. -il filter group. DISASSEMBLY Unscrew the cover assembly () and remove the filter element () and case (), after removing the retaining bolts, from the base (). FLOW OF OIL THROUGH OIL FILTER (SCHEMATIC) I-Filter element. -Passage. -Line. -By-pass valve. If the oil filter should become restricted, excessive pressure will unseat the oil filter by-pass valve () permitting the oil to by-pass the filter and flow directly into the engine manifold. REMOVAL AND INSTALLATION Removing the oil filter inlet line (I) drains the oil from the filter. OIL FILTER DISASSEMBLY D Remove I-Filter base. -Filter case. -Filter element. -Cover assembly. -By-pass valve plunger. 6-Spring. 7-Plug. Prior to assembly, inspect and repace the O-ring seal if damaged. Over

10 9A- Group. Page STARTING INDEX Adjustments: Carburetor Clutch Control Mechanism Governor Valve Clearance Bearings: Connecting Rod Main Piston Pin Brake, Starter Pinion A B Housing: Starter Pinion Timing Chain Lifters, Valve Lubricating System Magneto Drive Trunnion Main Bearings Mechanism, Valve L M Cable, Starter Camshaft Camshaft End Clearance Carburetor Chain, Timing Clearances and Tolerances Cleaning Valves.... Clutch.... Clutch Pinion and Brake Control Connecting Rods.. Connecting Rod Bearings Crankshaft Crankshaft End Clearance Cylinder Head Cylinders Data, Engine.... Fuel System.. C D F Oil: Pump Pump Pressure Regulating Valve Pan, Oil Pan Plate, Oil Pinion, Starter Pinion, Mechanism Pistons Piston Pin Bearings Pressure Regulating Valve Pump, Oil Recoil Starter Removing Engine Rings, Piston Rocker Arms Rods, Connecting o P R I 6 - I I Gear: Oil Pump Governor.... Head. Cylinder G H Specifications Starter Cable Starter Pinion Starter Pinion Brake Starter, Recoil S ','f""

11 Group. Page 9A- STARTING INDEX Starting Engine Ring Gear Starting Mechanism Timing Chain Timing Chain Housing Timing the Engine Tolerances T i Trunnion, Magneto Drive.. Valve: Clearance Adjustment Components Lifters Mechanism Pressure Regulating Rocker Arms v I.\ ~'

12 B- Gr9u~'' Page POWER TRANSMISSION UNITS INDEX Adjustments: Bevel Gear Backlash Bevel Gear Bearing Bevel Pinion Location Brakes.... Final Drive A - 9 Gear: Bevel Final Drive Pinion, Final Drive Shift Mechanism Gear Shift and Interlock Mechanism G 8 Sprocket Sprocket Hub Bearings Flywheel Clutch (Dry Typel Flywheel Clutch (Oil Typel Brake.... Steering Clutch Controls Transmission: Bearing Races... B Idler Pinion, Final Drive Interlock Mechanism, Gear Shift Oil Pump: Flywheel Clutch... o 9. - Bevel Gear Bevel Gear Bearings... Bevel Gear and Pinion Settings Brakes: Flywheel Clutch... Steering Clutch ISO Pinion, Final Drive Idler Plate, Steering Clutch.. p s 6 8 Cementing Seals Clearances and Tolerances Clutch: Flywheel (Dry Typel. Flywheel (Oil Typel Steering.... Controls, Steering Clutch Final Drive... Gear Pinion Seal.... Shaft, Sprocket.... Sprocket.... Flywheel Clutch (Dry Typel... Flywheel Clutch (Oil Typel.... Oil Pump.... C F I Seals, Cementing Seals, Final Drive Shaft, Final Drive Sprocket Specifications Sprocket, Final Drive Steering Clutch Brakes... Controls Plates Release Bearing and Yoke Shaft Transmission Gear Shift and Interlock 'Mechanism.. Yoke, Steering Clutch Release T Y

13 B- Group' Page TRACK ROLLER FRAME INDEX A M Adjustments: Front Idler Track Adjusting Mechanism Track Carrier Roller Master Pin Mechanism, Track Adjusting Metal Floating Ring Seal Installation - 6 Bushings, Track Pins and Carrier Rollers, Track Clearances and Tolerances Equalizer Spring B c E - - Pins and Bushings, Track Recoil Spring Rollers: Carrier, Track Track Roller Frame Removal, Track p R s Floating Ring Seal Installation Frame Removal, Track Roller Front Idler F 6 Separating Tracks Specifications Spring: Equalizer Recoil - - T Idler, Front Introduction, Track Roller Frame Links, Track Lubrication: Front Idler Track Carrier Rollers Track Rollers L 7 - Tracks Track: Adjusting Mechanism Carrier Rollers Installing Links Pins and Bushings Rollers Separating Track Roller Frame Introduction Track Roller Frame Removal - 7

D6 Crawler S/n 37A1 & 44A1 & up

Caterpillar Service Manual D6 Crawler S/n 37A1 & 44A1 & up Service Manual THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF CATERPILLAR OR IT S SUCCESSORS. CATERPILLAR AND IT S SUCCESSORS