caterpillar d6c crawler service manual - jensales … 10k1+ ccaatteerrppiillllaarr service manual...

CT-S-D6C 10K1+

CCaatteerr ppii ll llaarrService Manual

D6C CrawlerS/n 10K, 23U, 24U, 26K,46J, 47J, 49W, 55J, 56J,

69J, 69U, 90B & 99JVolume 1 of 2

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.

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Man

ual

http://www.jensales.com/products/caterpillar-crawler-service-manual-ct-s-d6c-10k1.html

C~TERPILLAR

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General Instructions

FORM NO. REG00684-03


GENERAL INSTRUCTIONS DISASSEMBLY AND ASSEMBLY

INDEX

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9 Bearings ........................................... 8

Anti-Friction ..................................... 8 Double Row, Tapered Roller ......................... 9 Heating Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9 Preload. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9 Sleeve Bearings .................................. " 9

Bolts and Bolt Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6 Torque Multipliers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7 Torque Wrench Extension ........................... 7 T-T-T Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6

Brake Linings ....................................... 9

Cleaning and Handling of Parts . . . . . . . . . . . . . . . . . . . . . . . . .. 4 Cleanliness ......................................... 3 Cylinders, Hydraulic. . . . . . . . . . . . . . . . . . . . . . . . . .. 14 thru 18

Cylinder Head Seals ................................ is Cylinder Installation ................................ 18 Disassembly and Assembly ........................... 15 Head Packing Adjustment ........................... 15 Removal ......................................... 14 Seal Guide ........................................ 15 Solid Seal Assemblies ............................... 16

Disassembly and Assembly 4

Filling and Bleeding the Hydraulic Track Adjusters ........................... 20

First Operation of a Rebuilt Engine ...................... 4 Fractions, Decimals and Millimeters

Chart ........................................... 22

Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9

Hydraulic Systems ................................... 11 Assembly of Fittings with Straight Threads

and O-ring Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 12 Cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11 Cylinder Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 18 Cylinders ................................. 14 thru 18 Hydraulic Line Installation. . . . . . . . . . . . . . . . . . . . . . . . . .. 12 Hydraulic Valves .................................. 14 Pumps ....................................... 18, 19

Assembly of Insert Vane Type Pumps ................ 18

General .............................. , ........ 19 Rotation ...................................... 19

Safety ........................................... 11 Sealing Elements .................................. 12 Solid Seal Assemblies ...................... " 16 thru 18 Torques for Flared and O-ring Fittings .................. 13 Torques for Other Fittings ........................... 13

Hydraulic Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 14

Lines and Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8 Locks .... , .... , ............ , ................. , .. .. 8 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8 Lubrication of Track Rollers and Idlers ................... 21

Front Idlers ...................................... 22 Track Carrier Rollers ............................... 21 Track Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 21

Pressing Parts ....................................... 6 Pumps .......................................... 18,19

Assembly of Insert Vane Type Pumps .................. 18 General .......................................... 19 Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 19

Relieving Track Tension ... . . . . . . . . . . . . . . . . . . . . . . . . . . .. 19 Hydraulic Adjusting Type ........................... 19 Screw Adjusting Type .............................. 20

Removal and Installation .............................. 3

Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3 Seals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9

Duo-Cone Floating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9 Lip-type .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11

Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4 Bearing Cup Pulling Attachment ...................... 5 Bearing Pulling Attachment .......................... 5 Puller Assembly (2 or 3 arm) ......................... 4 Push Puller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5

Shims............................ ................. 8 Sprocket Segment Removal and

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20

Tool Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6 Torque Multipliers ................................... 7 Torque Wrench Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7

NOTE: The lie" is an indication of a change from the former issue.

2


GENERAL INSTRUCTIONS

Bearing Pulling Attachment

Bearing Pulling Attachments can be used with forcing bolts, to remove shafts, bearings, gears, etc. They can be used with Push-Pullers to provide a variety of pulling combinations.

EXAMPLE OF TOOL INSTALLATION

1. Bearing puller attachment. 2. Forcing screws.

Bearing Cup Pulling Attachment

Bearing Cup Pulling Attachments are used to remove bearing races or cups, sleeve-type bearings, bearings, seats, etc. and can be used with Push Pullers.


1. Screw. 2. Bearing cup puller attachment. 3. Step plate.

Push Pu lIers

Push Pullers can be used to remove pulleys, gears, shafts, etc., and can be used in a variety of pulling combinations.

DISASSEMBLY AND ASSEMBLY


1. Adapters (use as required I. 2. Ratchet box wrench. 3. Push puller. 4. Step plate. 5. Legs.


1. Push puller. 2. Adapter. 3. Step plate.


1. Ratchet box wrench. 2. Push puller. 3. Reducing adapter.

5


SLEEVE METERING FUEl SYSTEM DISASSEMBLY AND ASSEMBLY

ALPHABETICAL INDEX

Page Oper. No. No.

Adapter Housings and Levers ........................................... 12,13 6

Fuel Check Valve and Bypass Valve ...................................... 24,25 10 Fuel I njection Pumps ................................................. 26,27 11 Fuel I njection Pumps, Disassemble & Assemble ............................. 28,29 12 Fuel Injection Pump Housing, Disassemble & Assemble ......................... 34 14 Fuel Injection Pump Housing and Governor ................................ 16-19 8 Fuel Ratio Control ................................................... 10,11 4 Fuel Ratio Control, Disassemble & Assemble ............................... 10,11 5 Fuel Shutoff Solenoid ................................................... 8,9 2 Fuel Shutoff Solenoid, Disassemble & Assemble ............................... 8,9 3 Fuel Transfer Pump ................................................... 30-33 13

General Information .................................................... 5-7 1 Governor, Disassemble & Assemble ....................................... 20-23 9

Speed Limiter ....................................................... 14-15 7

3


POWER TRAIN

FRONT IDLERS ASSEMBLE FRONT IDLERS 16-4159

Tools Needed A B C D

FT578 Bushing Alignment Tool 1

8S2328 Dial Test Indicator Group 1

5M2080 Nozzle Assembly 1

5M2196 Seal Installer 1

1. Put the oil holes in the bushings in alignment. Install bushing (1) in bushing (3) with a press. Drill two holes .281 in. (7.14 mm) in diameter, 1800 apart and .82 in. (20.8 mm) deep through bushing (1) and into bushing (3). Do not drill the holes through the lubrication grooves in bushing (1). Make the two holes larger with a reamer. The holes must be .3052 in. ± .0003 in. (7.752 mm ± 0.008 mm) in diameter and .75 in. (19.1 mm) deep. Make the holes larger again to a diameter of .308 in. ± .001 in. (7.80 mm ± 0.03 mm) and .25 in. (6.4 mm) deep. Install two new pins (2) which are .306 to .307 in. (7.77 mm to 7.80 mm) in diameter to a depth of .030 in. (0.76 mm) below the outside surface of bushing (1).

CAUTION: Do not drill holes in the lubrication grooves in the bearings.

30

c) Install new pins (2) each housing even with the face of the bearing.

2. Inspect the seals on the bushings. Install new seals if necessary. Put clean SAE 30 oil on the seals and contact surfaces of the bushings.

3. Install one of the bushings in the front idler with tool (A) and a press. Install the bolts in the bushing.

4. Turn the front idler over. Install shaft (4) in the bushing. Install the other bushing with tool (A) and a press. Install the bolts in the bushing.

5. Install tool (B) and check the clearance between the shaft and bushings. The clearance must be .020 ± .009 in. (0.51 ± 0.23 mm).

3--~

90456Xl


2

o


POWER TRAIN

FRONT IDLERS 6. Install the Duo-Cone seal in the housing

with tool (C).

7. Install Duo-Cone seal in the bearing with tool (C).

NOTE: The rubber seals and all surfaces that make contact with the seals must be clean and dry. After installation of the seals, put clean SAE 30 oil on the contact surfaces of the metal seals.

8. Inspect the seal on the shaft. Install a new seal if necessary. Put clean SAE 30 oil on the seal before installation.

9. Put 4S94l6 Anti-Seize Compound on the contact surfaces of the shaft and bearing. Install bearing (5) on the shaft. Make sure the groove on the shaft is in alignment with the hole in the bearing.

10. Put 4S9416 Anti-Seize Compound on the lock that holds the bearing to the shaft. Install the lock in the bearing. Install the washer and bolt that holds the lock in the bearing. Tighten the bolt to a torque of 40 lb.ft. (5.5 mkg). Hit the bolt with a hammer and punch. Tighten the bolt again.

11. Turn the front idler over. Do Steps 6 through 9 to the opposite side of the idler.

12. Put the front idler in position so the shaft is in a horizontal position. Remove plug (6)

. from the shaft. Install nozzle (D) and fill the front idler with the correct amount of oil. See LUBRICATION AND MAINTENANCE GUIDE.

end by: a) install front idler


6

31


ENGINE DISASSEMBLY AND ASSEMBLY

ALPHABETICAL INDEX

Page Oper. No. No.

Accessory Drive Housing and Shaft ....................................... 88,89 57 Air Cleaner Housing ...................................•.....•.......... 41 25 Alternator ..................•....•.........•.•.....•...•...•...••..... 10 5

Camshaft .............................•..............•.•..•........... 87 56 Camshaft Bearings ..............•.................•.................... 107 65 Connecting Rod Bearings .......................•..••.••.••.•.•.......... 64 43 Counterweight .........•...•.......... . . . . . • . . . • . • . • . . . • • • • • . • . . . . . • . •. 95 60 Crankcase Guard ....•.•.......•.•..........••..••.......•.•...•.•...•.. 58 38 Crankshaft ...........•.................•...•.....•................ 108,109 66 Crankshaft Front Seal ............................................•...... 84 54 Crankshaft Main Bearings ............................•................... 65 44 Crankshaft Rear Seal ..........•........................••.....•..... 104,105 63 Cylinder Head ....................................••.•............... 54,55 34 Cylinder Head Assembly .......................••.....•................ 51-53 33 Cylinder Liners ...................................................... 69,70 47

Engine and Flywheel Clutch (Special Application & Direct Drivel. ............... 91-94 59 Engine and Torque Divider (Power Shift) .................•............... 96-102 61 Engine Oil Cooler ...................................................... 31 15 Exhaust Manifold ...................................................... 47 28

Fan and Fan Drive ...................................................... 71 48 Fan Drive, Disassemble & Assemble ........................................ 72 49 Flywheel ......................................................... 103,104 62 Flywheel Housing ..................................................... 106 64 Fuel Filter Base and Bypass Valve ........................................... 9 4 Fuel Injection Pump Housing and Governor ................................ 16,17 8 Fuel Injection Pump Housing and Governor, Separation & Connection ........... 18,19 9 Fuel Injection Pump Housing, Disassemble & Assemble .•..................... 24-28 11 Fuel I njection Lines .................................................... 29 12 Fuel Injection Valves .................................................... 37 20 Fuel Priming ,Pump ...................................................... 8 2 Fuel Priming Pump, Disassemble & Assemble .................................. 8 3 Fuel Transfer Pump ..................... . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . .. 11 6 Fuel Transfer Pump, Disassemble & Assemble ............................... 11-15 7

Glow Plugs ...........•.........................•........•............ 38 21 Governor, Disassemble & Assemble ....................................... 20-23 10

3



ALPHABETICAL INDEX

Page Oper. No. No.

Hood ..................•........•.........•...•....•..•.............. 40 24

Muffler .............................................................. 40 23

Oil Filter Base .......................•..........•...................... 30 13 Oil Filter Base, Disassemble & Assemble ..................................... 30 14 Oil Pan .............................................................. 59 39 Oil Pan Plate .......................................................... 60 40 Oil Pump ..........•.......•.......................................... 61 41 Oil Pump, Disassemble & Assemble ......•..........•..................... 61-63 42

Pistons .........................•................................... 66-67 45 Pistons, Disassemble & Assemble ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 68 46 Precombustion Chambers ................................................ 38 22

Radiator Core and Hydraulic Oil Cooler .........................•......... 73-76 50 Radiator and Radiator Guard (Special Application & Direct Drive) ............... 77-78 51 Radiator and Radiator Guard (Power Shift) ................................ 79-81 52 Rocker Shaft and Push Rods ......................•....................... 49 31 Rocker Shaft, Disassemble & Assemble .........•............................ 50 32

Starting Motor ..................•........................... . . . . . . . . . . .. 7

Timing Gear Cover ................................................... 85-86 55 Timing Gears and Plate .................................................. 90 58 Torque Converter Oil Cooler .............................................. 32 16 Turbocharger .......................................... . . . . . . . . . . . . . . .. 42 26 Turbocharger, Disassemble & Assemble .................................... 43-46 27

Valves ......•......................................•................. 56 35 Valve Cover ........................................................... 48 30 Valve Guides .......................................................... 58 37 Valve Lifters .......................................................... 47 29 Valve Seat Inserts and Water Directors ...................................... 57 36 Vibration Damper and Pulley ...........................•............. ' .. 82-83 53

Water Pump ............... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 33 17 Water Pump, Disassemble & Assemble ..................................... 34-35 18 Water Temperature Regulator ............................................. 36 19

4



SERVICE INDEX

OPERATION PAGE NO. COMPONENT OPERATION OTHER NEEDED OPERATIONS NO.

1 Starting Motor 7

2 Fuel Priming Pump 8

3 Fuel Priming Pump, Disassemble & Assemble 2 8

4 Fuel Filter Base and Bypass Valve 2 9

5 Alternator 10

6 Fuel Transfer Pump 11

7 Fuel Transfer Pump, Disassemble & Assemble 6 11-15

8 Fuel Injection Pump Housing and Governor 16,17

9 Fuel Injection Pump Housing and Governor, Separation & Connection 8 18,19

10 Governor, Disassemble & Assemble 8,9 20-23

11 Fuel Injection Pump Housing, Disassemble & Assemble 8,9 24-28

12 Fuel I njection Lines 29

13 Oil Filter Base 30

14 Oil Filter Base, Disassemble & Assemble 13 30

15 Engine Oil Cooler 13 31

16 Torque Converter Oil Cooler 13 32

17 Water Pump 33

18 Water Pump, Disassemble & Assemble 17 34,35

19 Water Temperature Regulator 24 36

20 Fuel I njection Valves 12 37

21 Glow Plugs 38

22 Precombustion Chambers 20,21 38,39

23 Muffler 40

24 Hood 23 40

25 Air Cleaner Housing 23,24 41

26 Turbocharger 23,24 42

27 Turbocharger, Disassemble & Assemble 23,24,26 43-46

28 Exhaust Manifold 12,23,24,25,26 47

29 Valve Lifters 23,24,25,30 47

30 Valve Cover 23,24,25 48

31 Rocker Shaft and Push Rods 23,24,25,30 49

32 Rocker Shaft, Disassemble & Assemble 23,24,25,30,31 50

33 Cylinder Head Assembly 12,23,24,25,30,31 51-53

34 Cylinder Head 12,19,23,24,25,26,28,30,31,48 54,55

35 Valves 12,19,22,23,24,25,28,30,31,48 56

36 Valve Seat I nserts, Water Directors 12,19,22,23,24,25,26,28,30,31, 35,48 57

37 Valve Guides 12,19,22,23,24,25,26,28,30,31, 35,48 58

5



r-

6

SERVICE INDEX

OPERATION NO. COMPONENT OPERATION OTHER NEEDED OPERATIONS

38 Crankcase Guard

39 Oil Pan 38

40 Oil Pan Plate 38,39

41 Oil Pump 38,39

42 Oil Pump, Disassemble & Assemble 38,39,41

43 Connecting Rod Bearings 38,39,40,41

44 Crankshaft Main Bearings 38,39,40,41

45 Pistons 12,23,24,25,30,31,33,38,39,40,41

46 Pistons, Disassemble & Assemble 12,23,24,25,30,31,33,38,39,40,41, 45

47 Cylinder Liners 12,23,24,25,30,31,33,38,39,40, 41,45

48 Fan and Fan Drive

49 Fan Drive, Disassemble & Assemble 48

50 Radiator Core, Hydraulic Oil Cooler 23,24,25,38

51 Radiator and Radiator Guard (Special Application & Direct Drive) 23,24,25,48,59

52 Radiator and Radiator Guard (Power Shift) 23,24,25,38,48

53 Vibration Damper and Pulley 23,24,25,38,48,52

54 Crankshaft Front Seal 23,24,25,38,48,51 or 52

55 Timing Gear Cover 5,17,23,24,25,38,39,48,51 or 52,53,54

56 Camshaft 5,17,23,24,25,29,30,32,38,51 or 52,53,55

57 Accessory Drive Housing and Shaft 5,17,23,24,25,38,48,51 or 52, 53,55

58 Timing Gears and Plate 5,17,23,24,25,38,48,51 or 52, 53,55

59 Engine and Flywheel Clutch (Special Application & Direct Drive) 23,24,25,38,48,59

60 Counterweight

61 Engine and Torque Divider (flower Shift) 23,24,25,38,48

62 Flywheel PT* 38

63 Crankshaft Rear Seal 38,62

64 Flywheel Housing 23,24,25,38,48,62,63

65 Camshaft Bearings 5,17,23,24,25,26,28,29,30,31, 34,39,40,41,45,53,55,56,60 or 61,62,64

66 Crankshaft 5,17,23,24,25,26,28,29,30,31,34, 39,40,41,45,53,55,56,60 or 61, 62,64

*Operation location in Power Train Section of Disassembly and Assembly.

DISCONNECT BATTERIES BEFORE PERFORMANCE OF ANY SERVICE WORK

PAGE NO.

58

59

60

61

61-63

64

65

66,67

68

69,70

71

72

73-76

77,78

79-81

82,83

84

85,86

87

88,89

90

91-94

95

96-102

103,104

104,105

106

107

108,109


C~TERPILLAR FORM NO. SENR7593-01

®W®~®ITffi)® @[p)®[fClli~D@[ft) U ®®~D[ft)~ ~ t%(Q]D(ill®~D[ft)~ 3306 Vehicular Engine

3N1-UP 8Z1-UP 44V1-UP

47V1-UP 49V1-UP 62Z1-UP


3306 VEHICULAR ENGINE INDEX

SYSTEMS OPERATION

Air Inlet and Exhaust System............................ 26 Aftercooler ........................................... 27 Timing Gears ............. " ... .. . .. ... ... .. . . . .. . . ... 28 Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 27 Valves and Valve Mechanism .......................... 28

Basic Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 36 Crankshaft ........................................... 36 Cylinder Block and Liners ........ " . .. ... .. . . . .. .. .. .. 36 Pistons, Rings and Connecting Rods ................ , .. 36 Vibration Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 36

Cooling System. . .. .. .. . . . . . . . . .. . .. . .. .. . .. .. . .. .. .. ... 34 Coolant for Air Compressor. . .. .. . .. . .. .. . .. .. . . . . . ... 35 Cooling System Components.. ... .. . .. . .. ... .. .. .. .. .. 35 980 Wheel Loader Torque Converter Cooler.. . .. .. .. ... 35

Electrical System ....................................... 37 Charging System Components ........................ 37 Electrical System Schematic. . . . . . . . . . . . . . . . . . . . . . . . . .. 41 Other Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 40 Starting System Components. . . . . . . . . . . . . . . . . . . . . . . . .. 39

Fuel System (Scroll-PC) ............................... 23 Fuel Injection Pump. . .. .. .. . . . .. . .. ... ... .. .. . . . . . .. .. 23 Fuel Injection Valve .............................. " ... 25 Fuel System Timing ...... " . . . .. . .. ... ... .. .. .. . . . .. .. 23 Glow Plugs ...................................... " ... 25 Govenor Operation ................................... 24 Introduction. . .. . . . . . .. .. .. . . . .. ... ... .. . . . .. .. .. .. . .. 23

Fuel System (Sleeve Metering) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Adjustments to the Sleeve Metering Fuel System....... 17 Fuel Flow after Engine Stops Running ................. 16

Fuel Flow Using the Priming Pump and Bleed Valve .................................... 14

Fuel Flow with Constant Bleed Valve. . . . . . . . . . . . . . . . . . . 9 Fuel Flow with Siphon Break. .. .. . . . .. . . . .. .. . . . . . . . .. 7 Fuel Flow with Siphon Break and

Constant Bleed Valve :.............................. 13 Fuel Flow without Siphon Break or

Constant Bleed Valve ............................... 11

Fuel Injection Pump Operation ........................ 16 Fuel Injection Valve (PC) ..... " . . . . .. .. . . . .. . . . . . . . ... 21 Fuel Injection Valves. .. . . . . .. .. .. . .. . . . .. .. .. .. . . . . . . . 6 Fuel Priming Pump ................................... 14 Fuel Ratio Control .................................... 21 Fuel System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 18 Fuel System Timing. . . . .. . . . . . . . .. . .. . . . . . .. .. . . .. . . . . 6 Fuel System Usage Chart ............................. 5 Fuel Transfer Pump ................................... 15 Glow Plugs (PC) ..... " .. .. .. .. .. . .. . . . . . .. .. . . .. . . ... 21 Governor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20 Injection Nozzle (01) . .. .. . . .. .. .. . .. . . . . . .. .. . . .. . . . .. 21 Introduction. . . . . .. .. . . . . . . . . . . .. .. . . . .. . . . . . . . . . . . . .. 6 Si phon Break ....................................... " 14 Sleeve Position ....................................... 17 Water Separator ...................................... 6

General Information. . . .. . . . . .. . . .. . .. .. . . . .. . . . . .. . . .. .. 5 Fuel System Usage Chart ............................. 5

Lubrication System ..................................... 29 Lubrication System Components ...................... 31 Oil Flow in the Engine.. .... ...... .. .. ........ .. ...... 32 Oil Flow through the Oil Filter and Oil Cooler. .. . . . . . .. 31

3


3306 VEHICULAR ENGINE INDEX

TESTING AND ADJUSTING

Air Inlet and Exhaust System. . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Checking Engine Cylinders Separately........ .. .. .. .. 57 Checking Inlet Manifold Pressure at Torque

Converter Stall Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Crankcase (Crankshaft Compartment) Pressure.. ..... 100 Compression ........................................ 100 Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 100 Glow Plug and Precombustion Chamber Removal

and Installation .................................... 101 Measurement of Exhaust Temperatures............... 100 Measurement of Pressure in Inlet Manifold. . . . . . . . . . . . 98 Procedure for Measuring Camshaft Lobes..... ........ 103 Restriction of Air Inlet and Exhaust. . . . . . . . . . . . . . . . . . . 98 Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Valve Clearance ..................................... 102

Checking Engine Timing with 6V3100 Diesel Engine Timing Indicator Group. .. ..... .. .. ....... .. .... ... 71

Engine Speed Measurement. ....... .... ..... ...... ... 70 Finding Top Center Compression Position for

No.1 Cylinder..................................... 72 Flow Checking Fuel Injection Pump Timing

(PC Engines Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 73_ Fuel Injection Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Fuel System Inspection .............................. 57 Start-Up Procedure .................................. 70 Test Sequence - Precombustion Chamber (PC)

Fuel Nozzle... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Testing 7N449 Fuel Injection Nozzles... .. ............ 60 Testing Capsule Type Fuel Injection Nozzles. . . . . . . . . . 57

Basic Block.. ..... ..... .. ........ ........ ............ .. 113 Troubleshooting of 7N449 Fuel Injection Nozzles. . . . . . 66 Connecting Rods and Main Bearings.... .............. 113 Fuel System - Sleeve Metering ........................ 76 Connecting Rods and Pistons ........................ 113 Fuel Injection Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Cylinder Block.. ... .. ... ................. ............ 115 Fuel Pump Calibration ............................... 83 Cylinder Liner Projection .......................... 113, 114 Fuel Ratio Control Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Flywheel and Flywheel Housing ...................... 115 Fuel System Adjustments..... .. .. ............... ..... 77 Piston Ring Groove Gauge ........................... 113 Fuel System Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Vibration Damper...... . . . . . . . . . . . . . . . . . . . . .. . . . . . . .. 118 Governor Adju.stments ............................... 79

Cooling System. .. ..... .......... .................... .. 106 Fuel System (Scroll-PC) .............................. 88

Checking the Fuel Injection Valves.. ................. . 88 Checking Fan Speed. .............................. .. 108 Checking Radiator Air Flow .......................... 108 Filler Cap and Pressure Relief Valve...... ............ 110 Gauge for Water Temperature............ ............ 110 Pressure Cap... ....... ...... .................. ...... 109 Testing the Cooling System.... .................. .... 106 Testing Radiator and Cooling System for Leaks... .. .. 109 Visual Inspection of the Cooling System.......... .. .. 106 Water Temperature Regulator ........................ 111

Checking the Plunger and Lifter Washer of an Injection Pump .................................... 88

Decelerator Control Adjustment ...................... 96 Fuel Injection Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Fuel Rack Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Fuel Ratio Control Setting............ .. ..... ......... 95 Governor Adjustments... .. .. .. ....... .... .......... . 94 Governor Control and Decelerator Linkage

Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Electrical System ...................................... 119 Governor Linkage Adjustment. . . . . . . . . . . . . . . . . . . . . . . . 97

Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 119 Charging System .................................... 119 Shutoff Solenoid. ... .. .......... ..... ... .......... ... 125 Starting System... .. .. ..... .......... ... ............. 122

Lubrication System .................................... 104 Oil Pressure is High... ..... .. .. ..... .. ....... .. .... .. 105 Oil Pressure is Low. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 104 Too Much Bearing Wear... .. .. .. ... .. .. ............. 105

Fuel Sl!stem ....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Too Much Oil Consumption.. .. .. ............... ..... 104

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Adjustment and Cleaning 7N449 Fuel Injection Nozzles .................................. 67

Troubleshooting .................................. 42 thru 56

SPECIFICATIONS

NOTE: For Specifications with illustrations, make reference to SPECIFICATIONS for 3306 VEHICULAR ENGINE, Form No. SENR7592. If the Specifications in Form SENR7592 are not the same as in the Systems Operation and the Testing and Adjusting, look at the printing date on the back cover of each book. Use the Specifications given in the book with the latest date.


FUEL SYSTEM

2. Remove the fuel nozzle from the precombustion chamber for No.1 cylinder.

3. Put a small amount of clean oil on 3S3264 Rod (5) and put the rod in adapter (3).

4. Put 5P7265 Adapter (3) in precombustion chamber (4) and tighten the adapter finger tight.

CAUTION

Do not use a wrench to tighten the adapter. There will be damage to the nozzle seat if the adapter is too tight.

5. Put the correct Contact Point and 3P1565 Collet Clamp on 9S215 Dial Indicator.

6. Put the assembled indicator into adapter (3). Position the dial indicator (up or down) so small pointer is on + .300 in 0.62 mm) (black numbers) and tighten collet (1).

CAUTION

Do not tighten collet too much or damage to the dial indicator can result.

7. Loosen the screw that locks the dial face. Move the dial face until the large pointer is on "0" (zero) and tighten the lock screw.

TIMING INDICATOR GROUP INSTALLED

2. 9S215 Dial Indicator. 3. 5P7265 Adapter.

8. Turn the crankshaft a minimum of 30° in the CLOCKWISE direction (when seen from the flywheel end of the engine).

9. Turn the crankshaft in the COUNTERCLOCK WISE direction (when seen from the flywheel end of the engine) until the dial indicator gives an indication of maximum piston travel. Make an adjustment to the dial indicator, if necessary, to put both points of the dial indicator on "0" (zero).

74


10. Disconnect the fuel line for No.1 injection pump at the injection pump housing. Put the 6V2023 Adapter Group on No.1 injection pump.

a. Turn fitting (8) so that less than.2 in. (5 mm) of pin (14) is extended.

b. Remove tube (13). Put the adapter group in position on No.1 injection pump. Tighten nut (11) to 30 lb. ft. (40 N.m) maximum.

c. Push washer ( 10) against adapter ( 12). Tighten nut (9) finger tight. Install tube (13) on the adapter group.

6V2023 ADAPTER GROUP

8. Fitting. 9. Nut. 10. Washer. 11. Nut. 12. Adapter. 13. Tube. 14. Pin.

1P540 FLOW CHECKING TOOL GROUP

15. 5J4634 Hose Assembly. 16. Tank assembly.

11. Disconnect the fuel line at the fuel filter. Use an adapter to connect 5J4634 Hose Assembly (15) to the fuel line. Disconnect the fuel return line


3306 VEHICULAR ENGINE SPECIFICATIONS

INDEX

Air Cleaner. . . . . . . . . . . . . . . . . . . . .. .. . .. . . . . . . . . . .. . . . . . .. 36 Alternator Regulator .................................... 77 Alternators ........................................... 73-76

Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .. 31 Connecting Rod..... .. ........ ..................... .. .. 56 Coolant Flow Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 48 Crankshaft ............................................. 57

Bearing Surface (Journal) for Connecting Rods ........ 59 Bearing Surface (Journal) for Main Bearings. . . . . . . . . .. 58 Main Bearings and Connecting Rod Bearings .......... 60

Crankshaft Hub and Damper ............................ 60 Cylinder Block ........................................ 49, 50 Cylinder Head .................. .-. . .. . . . . . . . . . . . . . . . . . .. 35 Cylinder Liner. . . . . . . . . . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . .. 52 Cylinder Liner Projection .............................. 52, 53

Dust Ejector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 37

Electric Service Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 90 Engine Decelerator Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 30 Engine Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Engine Mounting Bolts........... . . . . . . . . . . .. . . . .. . . . . .. 62 Engine Oil Pressure. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . .. 45 Exhaust Manifold ....................................... 36 Exhaust Pipes and Muffler. . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. 36

Fan Drive........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 61 Flexible Drive Coupling ............................... 70, 71

Checking and Adjusting Alignment of the Flexible Drive Coupling ............................. 72

Flywheel ............................................... 67 Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 63 Flywheel Housing Bore........... . . .. . . . . . . . . . . . . . . . . . .. 69 Flywheel Housing Face Runout . . . . . . . . . . . . . .. . . . . . . . . . .. 68 Flywheel Housing Tightening............................ 66 Flywheel Ring Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 62 Flywheel Bore Runout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 67 Flywheel Face Runout. . . . . . . . .. . . .. . . . . .. . . . . . . .. . . . . . .. 67 Fuel Bypass Valve ...................................... 30

. Fuel Injection Equipment (Scroll Fuel System) . . . . . . . . . . .. 26 Fuel Injection Equipment (Sleeve Metering

Fuel System) ...................................... 8 & 18 Fuel Ratio Control (Scroll Fuel System) ................ .. 29 Fuel Ratio Control (Sleeve Metering

Fuel System) ..................................... 12 & 21 Fuel System Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Fuel System Usage Chart ............................... 6 Fuel Transfer Pump (Scroll Fuel System) . . . . . . .. . . . . . . . .. 28 Fuel Transfer Pump (Sleeve Metering

Fuel System) ..................................... 12 & 21

Generator Regulators ................................. 79-81 Generators ........................................... 78, 79 Glow. Plug Positioning (PC Engines) . ............... ..... 35 Governor (Scroll Fuel System) . . . . . . . . . . . . . . . . . . . . . . . . . .. 27 Governor Control 815 & 816 Compactors.......... .. ..... 13 Governor Control 977L Track-Type Loader. . . . .. . . . . . . . .. 14 Governor Control 966C Wheel Loader & 814 Tractor...... 15 Governor Control 627 Tractor ........................... 16 Governor Control 627 Scraper. .............. ........ .... 17 Governor Control 12G, 14G, and 140G Motor Graders.... 22 Governor Control 5610 Pipelayer . . . . . . . . . . . . . .. . . . . . . . .. 23 Governor Control 528 Skidder . . . . . . . . . . . . . . . . . . . . . . . . . .. 24 Governor and Decelerator Control (Scroll Fuel System) ... 29 Governor and Decelerator Control (Sleeve Metering

Fuel System) ......................................... 13

Injection Nozzle ........................................ 21

Oil Breather Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 45 Oil Filter....... . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. 44 Oil Pan ................................................. 45 Oil Pump ............................................. 43, 44

Pistons and Rings ..................................... 54, 55

Rear Accessory Drive Gears ........................... 64, 65 Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 47

Service Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Service Meter Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Shutoff Solenoid. . . . . . . . . . . . . . . . .. . . . . . .. . . . . . . . . . . . . . .. 90 Starter Magnetic Switches. . . . .. . . . .. . . . . . . . . . . . . . . . . . . .. 89 Starter Solenoids ..................................... 86-88 Starting Motors ....................................... 82-86

Tachometer Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Timing Gear Cover.. ... .......... .. ................ ..... 61 Timing Gears (Scroll Fuel System) .. ................ ..... 28 Timing Gears (Sleeve Metering Fuel System) . . . . . . . . . . . .. 25 Trunnion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 61 Turbocharger ......................................... 39-42 Turbocharger Impeller Installation ..................... 37,38

Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 32 & 34 Valve Cover ............................................ 35 Valve Rocker Arms and Lifters. . . . . . . . . . . . . . . . . . . . . . . . . .. 31 V-Belt Tension Chart.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 46

Water Pump. . . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. 46 Water Separator ........................................ 25 Water Temperature Regulator ........................... 48

NOTE: For Systems Operation and Testing and Adjusting, make reference to 3306 VEHICULAR ENGINE Form No. SENR7593.

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153 & 163 HYDRAULIC CONTROL DISASSEMBLY AND ASSEMBLY

ALPHABETICAL INDEX

The Alphabetical Index aids in quickly locating the page number of the operation to be performed and refers to the operation number as listed in the Service Index on the following page.

Page Oper. No. No.

ONE VALVE TANK ............................. . 17 Control Lever Bearing Housing ........................... . 25 6 Control Lever Bearing Housing, Disassemble and Assemble ......... . 26 7 Filler Cap and Strainer, Disassemble and Assemble ............. . 24 5 Filter Cover, Disassemble and Assemble .................... . 24 4 Lift Cylinder Control Valve ............................. . 17 2 Lift Cylinder Control Valve, Disassemble and Assemble ........... . 19 3 One Valve Tank ..................................... . 17 1

TWO VALVE TANK ............................. . 28 Control Lever Bearing Housings ........................... . 37 6 Control Lever Bearing Housings, Disassemble and Assemble ....... . 38 7 External Control Valve, Disassemble and Assemble ............. . 40 8 Filler Cap and Strainer, Disassemble and Assemble ............. . 36 5 Filter Cover, Disassemble and Assemble ..................... . 36 4 Lift Cylinder and Tilt Cylinder Control Valves ................. . 28 2 Lift Cylinder and Tilt Cylinder Control Valves, Disassemble and Assemble 30 3 Two Valve Tank .......................... ' ........... . 28 1

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163 HYDRAULIC CONTROL INDEX

SYSTEMS OPERATION

Blade Tilt Circuit .................................... 6 Make-up Valves. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5

Double Valve Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5 Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5, 7

Hold Position ....................................... 4 Ripper Circuit ........................ ',' . . . . . . . . . . . .. 6

Introduction ............................... '.' . . . . . .. 3 Single Valve Tank .... _ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4


Hydraulic System Test Procedures ... _ ....... _ . . . . . . . . . .. 9 Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10 Pump ................... _ ......................... 9

Introduction .................... _ ...... _ . . . . . . . . . . .. 8 Ripper Circuit Drift Test ............................... 10

Lift Circuit Drift Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9 Tilt Circuit Drift Test ............... . . . . . . . . . . . . . . . . .. 9

Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8 Operational Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8 Visual Checks ....................................... 8


External Control Valve ................................ 21 General Instructions .................................. 12

Double Valve Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17 Single Valve Tank ..................................... 13

SPECIFICATIONS

Bolt, Nut and Taper Lock Stud Torque ................... 23 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . .. 25

Control Valve ....................................... 24 Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 25

Pump ............................................. 25

External Control Valve ................................ 24 Relief Valve ........................................ 25

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