CT-S-ENGLATED2
CCaatteerr ppii ll llaarrService Manual
4” Bore 4 Cylinder EngineFor D311 Engine Set
D2 Crawler S/n 4U & 5U#122 Motor Grader
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
FORM FE030524-02
Diesel Engines (4" BORE 4·CYLINDER)
D311 INDUSTRIAL
D311 ELECTRIC SET
D311 MARINE
D2 TRACTOR
NO. 21 2 MOTOR GRADER
CATERPILLAR TRACTOR CO. • PEORIA, ILLINOIS, U. s. A. Printed by Jensalel Inc. SOO-443-0625
Table of Contents
Page
Specifications 4
General Instructions 9
Introduction 17
Diesel Engine
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. 219
2
Printed by Jen .. ie. Inc. 800-<443-0625
TABLE OF CONTENTS-Continued
Page
Starting Engine
Starting Engine Removal 223
Starting Engine 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 271
3
Printed by Jenule. Inc. ~3-0625
Fuel Pump Plunger
Length Maxim urn wear
Fuel Injection Pump Timing
Flywheel Housing
Bore run-out Face run-out Nut torque ....
Flywheel Run-out
Outside diameter (Maximum) Face (Maximum)
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) ............ .
2.6575-2.6577 -in. .005 -in.
.010 -in.
.0lD -in. 150 lb. ft.
.006 -In.
.006 -in.
. 45 lb. ft. . .70 lb. ft.
. ...... ' 60 lb. ft. 95 lb. ft.
.55 lb. ft.
.90 lb. ft.
.003 - .010 -In.
Accessory Shaft
End clearance Maximum ... . ....................... 025 -in.
Compression Release Clearance (non-adjustable)
Between rocker arm button and compression release shaft
Timing Gear Housing
Capscrew torque
Hour Meter
Bearing clearance (Maximum)
Pre-combustion Chamber
.120 - .125 -in.
35 lb. ft.
.012 -in.
Torque .. . ............................................ 150 lb. ft.
The following illustration shows the numbering of the cylinders and of fuel injection pumps.
6
Printed by Janule. Inc. 800-443-0625
F'IG.G.
Printed by Jenoaiel Inc. 8OIl-«3-0625
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.
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
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.
Starting Engine 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
224
Printed by Jansale. Inc. 8IJO..4.oI3-0625
LIFTING STARTING ENGINE FROM THE FLYWHEEL HOUSING
•
Index
Accessory Shaft . Adjustments:
Fuel Injection Pump Litter Governor:
Diesel Engine Starting Engine
Governor 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 Break-in Powder . By-pass:
Fuel Oil Cooler Oil Filter
Camshaft: Diesel Engine Starting Engine
Camshaft Gear: Diesel Engine Starting Engine
Carburetor . Chambers, Precombustion Cleaner, Air Cleaning:
Cooling System Fuel Injection Valve Pistons . Radiator Temperature Regulators
Printed by Jen .. lel Inc. 800-443-0625
271
Page
172
III
128 226 229 260
5 8, 237
130 132 131 219 217
180 243
194 253
76 194
94,97· 83 83
167 240
167 240 261 142 130
28 101 185 58 32
INDEX-Continued
Clearances and Tolerances Clutch, Starting Engine Cock, Drain .
Compression Release Mechanism
Connecting Rods and Bearings: Diesel Engine Starting Engine
Cooler, Oil .
Cooling System: Diesel Engine Starting Engine
Core: Heat Exchanger Oil Cooler Radiator
Coupling, Alignment: Flexible Drive Self-Aligning
Cover: Timing Gear, Diesel Engine Timing Gear, Starting Engine Valve
Crankshaft: Diesel Engine Starting Engine
Crankshaft Gear: Diesel Engine Starting Engine
Crankshaft Pulley
Cylinder Head: Diesel Engine Starting Engine
Cylinder Liners .
Cylinders, Starting Engine.
Data, Engine
Directors, Water .
Drive: Accessory Hour Meter Housing, Auxiliary Oil Pump Starting Motor Tachometer .
Printed by Jen .. le. Inc. S()O.4.43-0625
272
Page
4 255
62 150
179 242
79
21 225
60 59,81
57
220 219
163 238 148
206 248
210 249 165
136 234 187 245
4 140
172 177 217
78 231 128
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: Diesel Engine Starting Engine
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:
Diesel Engine Fuel Pump Starting Engine
Printed by Janaale. Inc. 800-+43-0625
273
Page
4 192
59
135 135
34
23 21 24
92 82
200 247 160 200
41 34
213
94, 97 92
98 101 105 108 99 91 93
92 67
172
167 107 240
INDEX-Con tin ued
Crankshaft: Diesel Engine Starting Engine
Oil Pump Drive . Reverse and Reduction Ring, Flywheel Timing:
Diesel Engine Starting Engine
Governor: Diesel Engine Starting Engine
Head, Cylinder: Diesel Engine Starting Engine
Heat Exchanger
Heat Indicator
Hour Meter.
Housing: Auxiliary Drive Flywheel Fuel Injection Pump Fuel Filter Timing Gear, Diesel Engine
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
Printed by Jenoalea loc. 8QO.443-0625
274
Page
210 248
78 211 202
163 239
115 226
136 234 59 62
177
217 200 105 113 163
174 240
91
132
151 235 224 260
108
162 237 187
64 225
INDEX-Con tin ued
Lubrication: Governor, Diesel Engine Hour Meter . Piston and Ring Timing Gear
Main Bearings: Diesel Engine Starting Engine
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: Diesel Engine Coolant Overheating Diesel Engine Fuel System . Diesel Engine Lubricating System
Overheating, Coolant.
Pan, Oil
Pinion, Starter
Pistons: Diesel Engine Starting Engine
Piston Pin Bushings: Diesel Engine Starting Engine
Printed by Jenule. Inc. ~3-0625
275
Page
119 177 186 66
194 253
135 135 92
132 88
16,18,19,20
230
83 79 82 88 69
67 71 71 71 78 76
27 98 68 27 69
255
184 245
183 244
INDEX-Continued
Piston Rings: Diesel Engine Starting Engine
Powder, Break-in
Power Take-off, Front.
Precleaner .
Precombustion Chambers
Pump: Fuel Injection Fuel Transfer Oil Raw Water, Diesel Engine:
Centrifugal Type Gear Type
Sump Water, Fresh:
Diesel Engine: Heat Exchanger-cooled Radiator-cooled
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 .
Seals, Liner .
Setting Fuel Pump Lifter
Shaft, Accessory Drive
Silencer, Air
Sleeve, Liner
Printed by Jensaiel Inc. 800-443-0625
276
Page
184 245 194 213 130 142
101 93 71
45 49 89
41 34 56
191 45 29
150 223 211
184 245
139, 148
179 242 193
203 29
190 III
172 131 188
INDEX-Con tinued
Specifications: Diesel Engine Starting Engine Valve
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 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: Diesel Engine Gears Diesel Engine Valves Fuel Injection
Printed by Jensalel Inc. 800-<143-0025
277
Page
4 7
154
117 227
152 235 255
240 261 255 242 225 248 234 247 226 224 225 253 232 223 245 223 230 255 239 235
76 165 128
32
170 195
163 154 III
INDEX-Contin ued
Timing Gears: Diesel Engine Starting Engine
Timing Marks: Diesel Engine Starting Engine
Tolerances .
Transfer Pump, Fuel
Valve: By-Pass, Fuel By-Pass, Oil . Diesel Engine, Inlet and Exhaust Fuel Injection 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:
Centrifugal Type Gear Type
Seal Replacement: Fresh Water Pump, Heat Exchanger-cooled Fresh Water Pump, Radiator-cooled
Temperature Regulator
Wear Limits
278
Printed by Jenule. Inc. 1500-443-0625
Page
163 239
163 239
4
93
94, 97 82
151 99
153
162 237
71 71
148 235 152 154
145 235
140 29,61
41 34
45 49
43 39 29
4
5-58 PRINTED IN U.S.A.
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