Service Manual

Service Manual

5-3/4 Bore
4 Cylinder
Diesel Engine

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF

CATERPILLAR OR IT’S SUCCESSORS. CATERPILLAR AND IT’S SUCCESSORS
ARE 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.

CT-S-ENG53/4x4
 Table of Contents
Page

Specifications . . ............................................. . 4

General Instructions ...................................... . 7

Diesel Engine
Cooling System 15
Lubricating System 27
Fuel System ........... , .. , ...... , ..................... , .. . 41
Accessory Drive and Governor Housing 52
Governor 55
Accessory Drive Gear and Shaft ............ . 61
Hour Meter 64
Manifold Group 65
Cylinder Head and Valve Mechanism ...... . 66
Timing Gears 81
Camshaft 88
Connecting Rods 89
Pistons and Rings 92
Cylinder Liners . 95
Main Bearings ... , .. ' ................ . 100
Crankshaft ...... , ................................. . 104
Flywheel .......................... ' ..... . 106
Installing and Aligning Engine .' ... , .. , . , ..... . 108

Starting Engine
Removal III
Installation ........................................... . 112
Main Bearings ................. ....................., .... . 113
Crankshaft ......................... , ..................... . 116
Camshaft 116
Governor 118
2
 TABLE OF CONTENTS-Continued

Page

Pistons, Cylinders and Connecting Rods 121

Starting Mechanism 125
Magneto Drive and Cranking Mechanism 133
Timing Gears 136
Valve and Valve Mechanism 137
Carburetor 140

Attachments
Lighting System without Battery 144
lighting System with Battery 160
Electric Starting System 182

Index 187

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 SPECIFICATIONS
DIESEL ENGINE.
Bore-5% in.; Stroke-8 in.
Firing Order-1-3-4-2.
Camshaft
Bearing, journal diameter. 2.619 - 2.620 -m.
Bearing clearance ..... .003 ..,006 -m.
Maximum permissible clearance. .010 -m.
End clearance . .. ........... . ...... . .005 .009 -m.
Max. end clearance (thrust plate and
washer) .............................. . .025 -in.
Crankshaft
Main journal, diameter. . . ........... . 3.749 - 3.750 -m.
Main bearing clearance (babbitt bearings) . .004 .006 -m.
Main bearing clearance (aluminum bearings) .006 - .0085 -m.
Maximum permissible clearance .. .015 -m.
End clearance (thrust plate and washer) .. .016 - .020 -m .
Maximum permissible end clearance. .035 -in.
Main bearing stud nuts, torque wrench. 5fa in. nuts- 700 lb. in.
7/8 in. nuts--4500 lb. in.
Connecting rod, journal diameter .. 3.624 3.625 -in.
Maximum permissible journal wear .. .009 -m.
Maximum permissible out-of-roundness
(journal) ................. . .007 -m.
Connecting Rod
Connecting rod bearing, clearance
(babbitt bearings) .0045 .006 -m.
Connecting rod bearing, clearance
(aluminum bearings) .006 .0085 -m.
Maximum permissible clearance .. .015 -in.
Connecting rod bolt nuts, torque wrench .. 1500 lb. in.
Center-to-center distance ................. . 14.999 -15.001 -m.
Cylinder Liner
Maximum permissible liner wear
(at top of ring travel) ...... . .020 -m.
Piston Pins
Clearance in rod bushing. ........... .001 .0018 -in.
Maximum permissible clearance in rod. .006 -m.
Maximum permissible clearance in piston. .006 -in.
Piston Rings
Piston Ring Side Clearance
Top ring • • • , < > •• .003 .0045 -In .
2nd and 3rd ring. . . . . . . . . . .0025 .004 -in.
Oil control ring .0015 .0035 -in.
Maximum permissible clearance
(top compression ring) . . . . . . .012 -in .
Ring gap, top • • • • < •• .012 .017 -In .
Ring gap, all others .020 .030 -in.

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 Where shims are used, be sure to remove them all. Tie the shims to-
gether and identify them as to their location. Then keep them clean and
flat until they are reinstalled.

Whenever fuel inj ection lines are disconnected, the ends of the lines
should be capped with the fittings supplied in the tool kit. Also cap the
pumps and valves. This will prevent dirt and other foreign matter from
entering the fuel injection system.

CLEANING AND INSPECTION

Clean all parts thoroughly after they are removed and inspect them.
Be sure all lubricant passages and oil holes are open. Badly worn or
damaged parts should not be put back in the machine. Cover all parts
to keep them clean until they are installed.

Anti-friction bearings should receive special handling. As soon as a

bearing is removed, cover it to keep out dirt and abrasives. Wash bear-
ings in non-inflammable cleaning solution and inspect the races and balls
or rollers. Discard the bearings if they are pitted, scored, or burned. If the
bearing is serviceable, coat it with light oil and wrap it in clea"n paper.
Do not unwrap new bearings until ready to install them.

ASSEMBLY
Clean the rust preventive compound from all machined surfaces of
new parts before installing them. Be sure to install parts in the proper
location and position.

When one part is pressed into another, use white lead· or a suitable
prepared compound ,to lubricate the mating surfaces. Tapered parts,
however, should be assembled dry. Before assembling P9rts with tapered
splines, be sure the splines are clean, dry and free from burrs. Then press
the parts together tightly.

SHIM STOCK

PROTECTING SEAL DURING

INSTALLATION

9835

10
 METHOD FOR LOCK
POSITIONING AND
BENDING

T7017 RIGHT WRONG

Install gaskets where required and use new ones if necessary. Never
use cork or felt gaskets or seals a second time. Be sure the holes in the
gaskets correspond with the lubricant passages in the mating parts. If it
is necessary to make gaskets, select stock of the proper type and thick-
ness and be sure to cut sufficient holes in the right places. Blank gaskets
can cause serious damage.
Use capscrews of the correct length. A capscrew which is too long may
"bottom" before the head is tight against th~ part it is to hold, and in
addition the threads may be damaged when the capscrew is removed.
If a capscrew is too short, there will not be enough threads to hold the
part securely.
Lockwashers, cotter pins, or flat metal locks should be used to lock
each nut and capscrew. Flat metal locks must be installed properly to be
effective. Bend one' end of the lock sharply around the edge of the part.
Bend the other end sharply against one flat surface of the nut or cap-
screw head. Do not bend the lock against more than one side of the nut.
When assembling a machine complete each step in turn. Do not leave
one part partially assembled and start assembling some other part. Make
all adjustments as recommended. Always check the job after it is com-
pleted to see that nothing has been overlooked.

PREPARATION FOR STARTING

After assembling a machine, lubricate it thoroughly. Fill the various
compartments with the type and grade of lubricant recommended in the
Operator's Instruction Book. Fill the crankcases of both the Diesel engine
and starting engine with the grade of oil recommended for the prevailing
temperature. Fill the cooling system with water or anti-freeze solution.
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