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

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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.