CT-S-D4 39A1

CCaatteerr ppii ll llaarrService Manual

D4 CrawlerS/n 24A, 39A, 40A,

54A, 55A & 69A

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF CATERPILLAR OR IT’S SUCCESSORS. CATERPILLAR AND IT’S SUCCESSORSARE 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.

Serv

ice

Man

ual

for

CATERPILLAR

D4 TRACTOR SERIAL NUMBERS 39A l-UP AND 40A l-UP

i- Section

Engine _____________ ______________________________________________________ 10

Starting Engine ________________ _ 20

Power Transmission Units _ 30

Track Roller Frame _____________________ ____________________________ 40

Seat, Fuel Tank and Miscellaneous __________________________ 200

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.' . ,/

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ENGINE

TABLE OF CONTENTS

Index ................................................ .

Specifications .....................•...................

General Instructions ................................... .

Cooling System .......................... : ............ .

Water Temperature Regulator ......................... .

Fan Group ........................................... .

Water Pump .......................................... .

Radiator ............................................. .

Section

9A-1O

9A-1O

lA-lO

9A-1O

9A-1O

9A-1O

9A-1O

9A-I0

Lubricating System .................................... 9A-1O

Oil Pan ............................................... 9A-1O

Oil Pump ............................................... 9A-I0

Oil Filter .............................................. 9A-1O

Fuel System ........................................ , .. 9A-1O

Fuel Supply Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9A-1O

Fuel Injection Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9A-1O

Governor ............................................. 9A-1O

Accessory Drive ....................................... 9A-1O

Air Induction and Exhaust System ...................... 9A-1O

Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9A-1O

Valve and Valve Mechanism. . . . . . . . . . . . . . . . . . . . . . . . .. .. 9A-1O

Timing Gears ... , .... ' . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 9A-1O

Pistons, Rings and Connecting Rods ...................... 10A-1O

Cylinder Liners ........................... . . . . . . . . . . . .. 9A-I0

Main Bearings .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9A-I0

Crankshaft ............................................ 9A-1O

Balancer .............................................. 9A-1O

Flywheel and Flywheel Housing . . . . . . . . . . . . . . . . . . . . . . . .. 9A-1O

Engine Removal and Installation ...................... " 9A-I0

Electrical System ...................................... 9A-1O

91\-10

Group

30.3

40.3

50

70.2

100.1

130.3

140.3

160.3

170.3

180.2

190

210.3

230.2

240.3

250.1

260.3

····265.3

270.4::0 ,

280.4

290

320.3

340

350

360

370

380

390.2

400.2

410.2

GrcOup2Q.3 Page 1

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Accessory Drive Accessory Drive Gear Accessory Drive Shaft Adjustments:

A

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

B

C

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

Electric Starting Motor Electrical System Engine Data .. Exhaust Manifold

D

E

ENGINE

INDEX

265.3 - 1 320.3 2 265.3 3

250.1 260.3 260.3 270.4 270.4

320.3 380

380 340 360 210.3

240.3 210.3 190

320.3 280.4 270.4

290 250.1 340 100.1

40.3 290 340

70.2 160.3 320.3 370 320.3 280.4 350

280.4

265.3 260.3

410.2 410.2

40.3 270.4

7 4 4 1

5

2

2

2

4 2

2

3 2

2 1

2

1 4

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

F

G

Operation and Lubrication Governor and Fuel Injection

Pump Housing Removal

Head, Cylinder Heater Pipe, Air Inlet Housing:

Flywheel .. Fuel Injection Pump Governor

Idler Gear Injection, Fuel Inlet:

Air Heater Pipe Manifold Valves

H

9A-1O Group 30.3

Page I

130.3 - 1 130.3 130.3

240.3 210.3

70.2 230.2 170.3 390.2

240.3 240.3

250.1 250.1 250.1 250.1 250.1 230.2 240.3 240.3

230.2 170.3

320.3 320.3 370 320.3 390.2 320.3 320.3 410.2 410.2

260.3 260.3

265.3

280.4 270.4

390.2 250.1 260.3

320.3 250.1

270.4 270.4 290

3

2 3

2 3 6

3

2 4

5

4

1 3

5 1

2

:.:,0-

Group 30.3 Page 2

!.9A-IO

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:

L

M

o

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

P

R

. ~<- .. "

. . . . . . . .

Removing Ring Ridge in Cylinder Liners

ENGINE INDEX

250.1 290 350 170.3

340

360

270.4 230.2 270.4

6 3

170.3 1 . 265.3 - 3

210.3 210.3 170.3 180.2 1 180.2 - 1 190

70.2 230.2 170.3 - 1 160.3 - 1

70.2 - 1

180.2 - 1 340 340 180.2 280.4 - 2

250.1 - 2 240.3 3 240.3 190 140.3 1 170.3 - 2 170.3 - 1

160.3 - 1 350 - 2

Regulator, Water Temperature .............. . Release; Compression ........................ . Ring Gear, Flywheel· ....................... . Rings, Piston ................. . ........ . Rocker Arms, Valve .. Rod, Connecting Running-in Schedule ....

s Seal Replacement, Water Pump Seals, Liner ................ . Service Meter ... . ............... . Shaft, Accessory Drive "

Specifications Springs:

Governor Valve .............. .

T

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 ....... .

v

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

100.1 290 3 390.2 340 2 290 1 340 2 340 2

140.3 2 350 1 265.3 3 265.3 1 320.3 - 3

40.3 - 1

260.3 290 2

100.1 1 370 2

320.3 - 1 290 3 250.1 7 320.3 2 320.3 320.3

40.3

240.3 2 210.3 290 2 250.1 290 2 290 - 3 29.0 190 290

40.3 7 290 3 290 - 3 290

280.4 - 2 140.3 - 1 140.3 - 2 100.1 - 1

C'),

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Group 40.3 Page 2

9A-1O

Crankshaft

ENGINE SPECIFICATIONS

Main journal diameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3.499 - 3.500 in. Permissible main journal wear ........................ . . . .008 in. Main bearing clearance (Earlier) ....................... .0053 - .0082 in. Permissible bearing clearance (Earlier) ........................ .013 in. Main bearing clearance (Later-with lead-tin overlay) ..... .0030 - .0059 in. Permissible bearing clearance (Later) ...................... .0lD in. End clearance. . . . ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .0llO - .0180 in. Permissible end clearance ................. . . . . . . . . . . . .. .035 in. Main bearing nut torque.. .................................. 155 lb. ft. Connecting rod journal diameter .' . . . . . . . . . . . . . . . . . . . . .. 2.999 - 3.000 in. Permissible journal wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .007 in. Permissible out-of-round ........ ' . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .004 in. Pulley retaining bolt torque ............................ " 2lD - 250 lb. ft.

Cylinder Block Main bearing original bore dimension 3.8155 - 3.8165 in.

Cylinder Head Tighten bolts in sequence shown in illustration.

Initial ......... . ............. . . ............... 85 lb. ft. Final .' . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 - 130 lb. ft.

139261

17 II 0 0

8 6 0 0

10 4 0 0

16 14 0 0

I 0

2 0

13 o

12 o

3 0

5 0

15 0

9 0

7 0

18 O

CYLINDER HEAD BOLT TIGHTENING SEQUENCE

Cylinder Liner (Use 5F7362 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

Flywheel Housing Retaining bolt torque

Fuel Injection Equipment

4.500 - 4.501 in.

. . . . . . . . . . . . .. .015 in . .400 - .402 in. .403 - .405 in.

9/16 - 13/16 in.

ll8 - 142 lb. ft.

60 - 70 lb. ft.

Fuel injection pump timing .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9° BTC Fuel injection pump timing dimension setting (off engine

using 2M5219 Gauge) ............ . . . . . . . . . . . . . . . . .. 4.2655 - 4.2695 in. Fuel pump plunger length ................ ' .......... 2.5935 - 2.5937 in. Fuel injection pump timing dimension setting (on engine

with pistons at top center using 2M5219 Gauge) .... .. 4.2340 - 4.2380 in.

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Group 40.3 PageS

9A-IO

Precombustion Chamber

ENGINE SPECIFICATIONS

Torque ............................. . . . . . . . . . . . . . .. . . .. 150 lb. ft. Glow plug torque ................... . 8 - 10 lb. ft.

CENTERLINE OF ENGINE ., _'k ."

T47386

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 ........................... , ' .7260 - .7266 in. Clearance between shaft and bearing, . , ... ' , , , . ' , ' .0010 - .0026 in. Permissible clearance ","".',.','"., ... ',' , .. , .. ' .008 in. Retaining bolt torque , . , . , " ",.,., .. ,.,",.,., .. ," .. ,' 120 lb. ft.

Starting Motor 24 V (Delco-Remy 1113818)

Brush spring tension (minimum) Rotation (viewing drive end) .',', .. , ... , .. ""., .... ',.",. No load test:

Volts , ... ,,' , , , .. , , , . , .. , , ' .. , ....... , , . ' .. , . ' , . , , , . , Maximum amps

Lock test: Volts .,., .. ,. Maximum amps,. Minimum torque. ,

Timing Gear Housing Retaining bolt torque

Valves Exhaust:

35 oz. Clockwise

23.0 100

3.0 500

28 lb. ft.

24 - 30 lb. ft.

Clearance (hot) ., ... , .. , ..... , .. , , ....... , .' ............ , . ,. .020 in. Clearance (cold) , ..... , ....... ,., ........... , ...... ' ....... :, .028 in. Stem cleara'nce in bushing .' .. , . , ........... , , , ' , . , , , , .' .003 - .005 in. Permissible clearance with new valve , ' , , ' , ' , , , , ", , , , , , , , , , " .009 in.

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I

9A-I0 Group 140.3 Page 2 ENGINE

WATER PUMP

IMPELLER REMOVAL

WATER PUMP BEARING REMOVAL

5. After the bearing and shaft have been removed, the bearing (13) 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 (12) 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.

10. Install the seal (16) 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.

12. See the topic, SPECIFICATIONS, for the proper pulley retaining nut torque.

13. Press the impeller onto the shaft. See the topic, SPECIFICATIONS, for the correct impeller to housing clearance.

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.

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 (1), a flexible seal (2), and a seal spring (4) all retained in a seal cup (5) by the seal retainer (3). The carbon thrust washer (1) is cemented to the flex­ible seal (2). The entire 'assembly must be replaced as a unit and is pressed in the water pump housing.

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SA-IO ··;;3'~;~~p 210.3

ENGINE OIL FILTER

Page I

Oil Filter FLOW OF OIL THROUGH THE OIL FILTER

Unfiltered oil is delivered by the oil pump through an external line (3) 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 (2) and into the oil distribution manifold.

FLOW OF OIL THROUGH OIL FILTER (SCHEMATIC) I-Filter element. 2-Passage. 3-Line. 4-By-pass valve.

4

If the oil filter should become restricted, excessive pressure will unseat the oil filter by-pass valve (4) 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.

Prior to installation, replace any damaged gaskets or O-ring seals.

PREPARING TO REMOVE OIL FILTER GROUP

D Remove

I-Oil filter inlet line. 2-0il filter group.

DISASSEMBLY

Unscrew the cover assembly (4) and remove the filter element (3) and case (2), after removing the retaining bolts, from the base (1).

OIL FILTER DISASSEMBLY

D Remove

I-Filter base. 2-Filter case. 3-Filter element. 4-Cover assembly. 5-By-pass valve plunger. 6-Spring.

7-Plug.

Prior to assembly, inspect and repace the O-ring seal if damaged.

Over

9A-20

STARTING ENGINE

Adjustments: Carburetor Clutch

Control Mechanism

Governor

Valve Clearance

Bearings: Connecting Rod Main Piston Pin

Brake, Starter Pinion

Cable, Starter

Camshaft

Camshaft End Clearance

Carburetor Chain, Timing

Clearances and Tolerances

A

B

C

Cleaning Valves ........... . Clutch ....... .

Clutch Pinion and Brake Control

Connecting Rods .. Connecting Rod Bearings Crankshaft . . . . . . . .......... . Crankshaft End Clearance Cylinder Head Cylinders

D

Data, Engine ......................... .

F

Fuel System ..

G Gear:

Oil Pump

Governor .............................. .

H

Head. Cylinder

INDEX

100 - 3 160 - 5 160.1 - 6 160 - 5 160.1 - 7 130 - 3 130.1 5 110 - 3

120 140 2 120 160 - 3 160.1 - 3

130 130.1 2 130 4 130.1 5 130 - 4 130.1 - 6 100 - 1 130 4 130.1

40 110 160 160.1 160 160.1 120 120 140 140 110 120

40

6

2 4 5 5 6

1 - 2 - 1 - 2

- 1

100 - 1

90 - 2 90.1 - 2

130 - 3 130.1 - 3

110 - 1

Housing: Starter Pinion

Timing Chain

Lifters, Valve Lubricating System

Magneto Drive Trunnion

Main Bearings Mechanism, Valve

Oil: Pump

L

M

o

Pump Pressure Regulating Valve

Pan, Oil Pan Plate, Oil Pinion, Starter

Pinion, Mechanism

Pistons

P

Piston Pin Bearings Pressure Regulating Valve

Pump, Oil

Recoil Starter

Removing Engine Rings, Piston Rocker Arms Rods, Connecting

Specifications Starter Cable

Starter Pinion

Starter Pinion Brake

Starter, Recoil

R

S

........

..............

.••.•••• ','f""

. . . . . . . . . . . . . . . . . . . . . .

Group 30.3

Page 1

160 160.1 130 130 - 3 130.1 -130.1 - 6

110 - 3 90 90.1

130 - 3 130.1 4 140 - 2 110 - 1

90 - 2 90.1 2 90 - 3 90.1 3

90.1 -90.1 - I

160 - I 160.1 1 160 - 2 160.1 - 2 120 - 2 120 - I

90 - 3 90.1 3 90 2 90.1 - 2

130 130.1

80 120 110

2

120 - 1

40 - 1 130 130.1 2 160 160.1 160 3 160.1 3 130

Group 30.3 Page 2

9A-20

Starting Engine Ring Gear Starting Mechanism

Timing Chain

Timing Chain Housing

Timing the Engine

Tolerances

T

STARTING ENGINE·· INDEX

140 130 130.1

130 - 4 130.1 6 130 - 1 130.1 - i 130 - 4 130.1 - 6

40 - 1

Trunnion, Magneto Drive ..

Valve: Clearance Adjustment Components Lifters Mechanism Pressure Regulating

Rocker Arms

v

130 - 3 130.1 - 4

110 110 110

- 3 - 1 - 3

110 - 1 90 - 3 90.1 - 3

110 - I

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12B-30

POWER TRANSMISSION UNITS

Adjustments: Bevel Gear Backlash Bevel Gear Bearing

A

Bevel Pinion Location ..... .... Brakes ............. . Final Drive

Sprocket Sprocket Hub Bearings

Flywheel Clutch (Dry Typel Flywheel Clutch (Oil Typel

Brake ............. . Steering Clutch Controls Transmission:

Bearing Races ...

Bevel Gear Bevel Gear Bearings ...

B

Bevel Gear and Pinion Settings Brakes:

Flywheel Clutch .. . Steering Clutch ... .

Cementing Seals Clearances and Tolerances Clutch:

Flywheel (Dry Typel . Flywheel (Oil Typel Steering ........ .

Controls, Steering Clutch

Final Drive .... Gear Pinion Seal ............. . Shaft, Sprocket ........ .

C

F

Sprocket ................. . Flywheel Clutch (Dry Typel .. . Flywheel Clutch (Oil Typel ... .

Oil Pump ............... .

INDEX

140 3 140 2 140 3 150 - 2 180 9

180 - 6 180 7

80 6 80.1 7 80.1 7

170 2

120 4

140 - 1 140 - 1 140 2

80.1 6 ISO

180 40

80 80.1

160 170

8 - I

- 1

180 1 180 - 3 180 8 180 - 8 180 4 180 2

80 1 80.1 1 80 3

Gear: Bevel Final Drive Pinion, Final Drive Shift Mechanism

G

Gear Shift and Interlock Mechanism

Idler Pinion, Final Drive Interlock Mechanism, Gear Shift

Oil Pump: Flywheel Clutch ....

Pinion, Final Drive Idler Plate, Steering Clutch ..

Seals, Cementing Seals, Final Drive Shaft, Final Drive Sprocket Specifications Sprocket, Final Drive Steering Clutch

Brakes ... Controls Plates Release Bearing and Yoke Shaft

Transmission

o

p

s

T

Gear Shift and Interlock 'Mechanism ..

Y

Yoke, Steering Clutch Release

Gr9u~'30' Page 1

140 180 180 110 110

180 110

1 3 8

9

80.1 - 3

180 160

180 180 180

40 180 160 150 170 160 160 160

8 4

- 8 8

- 4 1 2

1 1

- 4 5 3

120 1 110 1

160 - 5

A

Adjustments: Front Idler Track Adjusting Mechanism Track Carrier Roller

Bushings, Track Pins and

Carrier Rollers, Track Clearances and Tolerances

Equalizer Spring

B

c

E

F

Floating Ring Seal Installation Frame Removal, Track Roller Front Idler

Idler, Front Introduction, Track Roller Frame

Links, Track Lubrication:

Front Idler Track Carrier Rollers Track Rollers

L

12B-40

TRACK ROLLER FRAME

INDEX

M

Master Pin Mechanism, Track Adjusting 100

100 90

3 5 3

Metal Floating Ring Seal Installation

80 - 3

90 40

110

90 120 100

100 70

80

100 90 90

- 1

6

- 1

3

Pins and Bushings, Track

Recoil Spring Rollers:

Carrier, Track Track

Roller Frame Removal, Track

Separating Tracks Specifications Spring:

Equalizer Recoil

Tracks Track:

Adjusting Mechanism Carrier Rollers Installing Links Pins and Bushings Rollers Separating

p

R

s

T

Track Roller Frame Introduction Track Roller Frame Removal

Group'30

Page 1

80 100 - 5

90 6

80 - 3

100 4

90 - 1 90 3

120 - 1

80 - 1 40 - 1

110 100 4

80 - 1

100 90 80 80 80 90 80 70

120

5

2 3 3 3