Caterpillar 12 | 6 | D318 | D6 | DW10 Service Manual · The Caterpillar Service Manual \(CT-S-ENG 4...

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

http://www.jensales.com/products/caterpillar-service-manual-ct-s-eng-4-1-2.html

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


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


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

Page

232

234

235

236

240

241

242

245

247

247

250

253

253

256

257

265

271


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


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

•


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


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


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:


Air Cleaner .

Air Inlet Manifold

Air Silencer.

Aligning Attachments to Flywheel

Auxiliary Drive Housing

Bearings: Connecting Rod:


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

Page

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


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

272

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


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


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


Crankshaft: Diesel Engine Starting Engine

Oil Pump Drive Ring, Flywheel Timing:


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


Idler Gear, Timing: Diesel Engine Starting Engine

Inj ection, Fuel

Inlet: Manifold Valve:


Installing Starting Engine

Latches, Starter Pinion

Lifters: Fuel Injection Pump Valve:


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


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

276

Page

82 76 78 84 74

64 70 71

73 69, 72

27 94 64

27

74

257

193 250

193 249

196 252

204

221

143

156

97 88 65 49


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

Page

54 43

234

131

35

201

49

31

163

232

219

196 250

161

191 247

203

212

29

200

107 131

186

144

199

4 7

168


INDEX-Continued

Springs: Governor:


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

278

Page

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


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:


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

Page

176 246

180 246

4

241

88

93 82

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.


Caterpillar 12 | 6 | D318 | D6 | DW10 Service Manual · The Caterpillar Service Manual \(CT-S-ENG 4...

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Transcript of Caterpillar 12 | 6 | D318 | D6 | DW10 Service Manual · The Caterpillar Service Manual \(CT-S-ENG 4...