D5B & D5E Crawlers S/n 22X1, 23X1,24X1, 25X1, 43X1, 44X1, 45X1, 46X1, 47X1, 48X1 & 49X1 & up Volume 1 of 3

Transcription

1 Caterpillar Service Manual D5B & D5E Crawlers S/n 22X1, 23X1,24X1, 25X1, 43X1, 44X1, 45X1, 46X1, 47X1, 48X1 & 49X1 & up Volume 1 of 3 Service Manual 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-D5B 22X1+

2 3300 ENGINE INDEX 3300 VARIABLE POWER SUPPLEMENT This supplement is to be used for those applications of 3300 Engines in a variable horsepower configuration. TABLE OF CONTENTS SYSTEMS OPERATION 3306 NSFS Hydraulic Actuator SMFS Air Only Actuator TESTING AND ADJUSTING 3306 NSFS Hydraulic Actuator SMFS Air Only Actuator NOTICE: A mechanic that has the proper training is the only one to make the adjustment oflow idle and high idle rpm. The correct low idle, high idle rpm and the measurement for adjustment of the fuel settings are in the FUEL SETTING AND RELATED INFORMATION FICHE. A WARNING Disconnect batteries before performance of any service work. 3

3 3306 VEHICULAR ENGINE SPECIFICATIONS INDEX c Accessory Drives Rear Drive (05B & 060) Rear Drive (07G) Air Induction and Exhaust System Air Cleaner Camshaft Cylinder Head Dust Ejector Glow Plug Positioning Exhaust Manifold Exhaust Pipe and Muffler Flywheel Flywheel Housing Flywheel Housing Bore Flywheel Housing Tightening Flywheel Ring Gear Timing Gear Cover Turbocharger... 43, 44 Turbocharger Impeller Installation Valves (01) Valves (PC)... 37,38 Valve Cover Valve Rocker Arms and Lifters Basic Engine Components Bearing Surface (Journal) Connecting Rods Main Bearings Connecting Rod Crankshaft Cylinder Block Counterbored Block Spacer Plate Block Cylinder Liner Cylinder Liner Projection Counterbored Block Spacer Plate Block Main Bearing and Connecting Rod Bearings Pistons and Rings Keystone Straight Side Cooling System Coolant Flow Switch Fan Drive Radiator V-Belt Tension Chart Water Pump... ',' Water Temperature Regulator..., 48 Electrical System Alternators Alternator Regulator Starter Magnetic Switch Starter Motors Starter Solenoids Engine Design Engine Mounting Bolts Front and Rear Bolts Fuel System - Scroll (01) Fuel Injection Fuel Injection Pump Housing Fuel Transfer Pump Governor Governor Control (05B & 060 ~O) Governor Control (05B & 060 PS) Governor Housing Injection Nozzle... ' Timing Gears...,'.. : Fuel System - Scroll (PC)... ',' Fuel Injection Equipment Fuel Ratio Control Fuel Transfer Pump Governor Governor Control (05B & 060 ~O) Governor Control (05B & 060 PS) Governor Control (07G ~O) Governor Control (07G PS) Governor and Decelerator (07G PS) Timing Gears Fuel System - Sleeve Metering (01) Fuel Injection Equipment Fuel Ratio Control Fuel Transfer Pump Governor Control (05B & 060 ~O) Governor Control (05B & 060 PS) Injection Nozzle...,.. 17 Fuel System - Sleeve Metering (PC)... 5 Fuel Injection Equipment Fuel Ratio Control Fuel Transfer Pump Governor Control (05B & 060 DO) Governor Control (05B & 060 PS) Governor Control (07G ~O) Governor Control (07G PS) Fuel System - Sleeve Metering (PC & 01) Timing Gears Water Separator Gauges Converter Oil Temperature Indicator Fuel Pressure Indicator Oil Pressure Indicator Water Temperature Indicator General Tightening Torques Lubrication System Engine Oil Pressure Oil Breather Cap Oil Filter Oil Pump Torque for Flared and O-Ring Fittings ( For Systems Operation and Testing and Adjusting, make reference to 3306 VEHICULAR ENGINE FOR D5B, D6D and D7G TRACTORS, Form No. SENR2226.

4 3306 VEHICULAR ENGINE SPECIFICATIONS (SLEEVE METERING FUEL SYSTEM - PC) ( ENGINE DESIGN Bore in. (120.7 mm) Stroke in. (152.4 mm) Number of Cylinders... 6 Cylinder Arrangement *in-line Firing Order (Injection Sequence)... 1,5,3,6,2,4 Direction of Rotation (when seen from flywheel end) Counterclockwise *No. 1 Cylinder Is Opposite Flywheel End. FUEL INJECTION EQUIPMENT Firing order (injection sequence) ,5,3,6,2,4 Injection Timing before TC (top center): D7G (SA) ' ± 1 (0 All others ' ± 1 " Torque for bolt in hole for timing pin..., 108 ± 36 lb. in. (12.2 ± 4.1 N m) Torque for bolts that hold governor weight carrier to camshaft ± 10Ib.in.(10.2 ± 1.1 N m) (1) Diameter of rear bearing surface ijournal) of the camshaft (new) ±.0005 in. ( ± mm) Bore in the rear bearing for the camshaft (new) ±.0005 in. ( ± mm) Maximum permissible clearance between the bearing and the camshaft bearing surface ijournal) (worn) in. (0.15 mm) (2) Diameter of fuel control shaft (new) ±.0003 in. (8.966 ± mm) Bore in the housing for fuel control shaft (new) ±.0005 in. (8.999 ± mm) Maximum permissible clearance between the bore in the housing and the fuel control shaft (worn) in. (0.08 mm) (3) End play for camshaft with sleeve installed (new) ±.018 in. (0.58 ± 0.46 mm) NOTE: When installing sleeve on end of camshaft, support the cam shaft to prevent damage to parts inside of injection pump and governor housing. (4) Diameter of front bearing surface ijournal) of the camshaft (new) ±.0005 in. ( ± mm) Bore in the front bearing for the camshaft (new) ±.0005 in. ( ± mm) Maximum permissible clearance between the bearing and the camshaft bearing surface ijournal) (worn) in. (0.08 mm) 5

5 SYSTEMS OPERATION Air Inlet and Exhaust System Aftercooler Timing Gears Turbocharger Valves and Valve Mechanism Basic Block Crankshaft Cylinder Block and Liners Pistons, Rings and Connecting Rods Vibration Damper Cooling System Cool ing System Components Engines with Aftercooler Engines without Aftercooler Electrical System Charging System Components Electrical System Schematic Other Components Shutoff Circuit Starting System Components Fuel System (Scroll-PC) Fuel Injection Pump Fuel Injection Valve Fuel System Timing Glow Plugs Governor Operation Introduction Fuel System (Scroll-Ol) Fuel Injection Pump Fuel System Timing Governor (Hydra-Mechanical) Injection Nozzles Introduction Fuel System (Sleeve Metering)... 6 Adjustments to the Sleeve Metering Fuel System Fuel Flow after Engine Stops Running Fuel Flow Using the Priming Pump and Bleed Valve Fuel Flow with Siphon Break... 7, 8 Fuel Flow without Siphon Break... :..."... 9, 10 Fuel Injection Pump Operation..., Fuel Injection Valve (PC) Fuel Priming Pump Fuel Ratio Control Fuel System Operation Fuel System Timing Fuel Transfer Pump Glow Plugs (PC) Governor Injection Nozzle (01) Introduction Siphon Break Sleeve Position Water Separator General Information... 5 Lubrication System... 30, 31 Lubrication System Components Oil Flow in the Engine Oil Flow through the Oil Filter and Oil Cooler

6 3306 VEHICULAR ENGINE TESTING AND ADJUSTING Air Inlet and Exhaust System Checking Inlet Manifold Pressure at Torque Converter Stall Speed Crankcase (Crankshaft Compartment) Pressure Compression Cylinder Head Glow Plug and Precombustion Chamber Removal and Installation..., Measurement of Exhaust Temperatures Measurement of Pressure in Inlet Manifold Procedure for Measuring Camshaft Lobes Restriction of Air Inlet and Exhaust... '" Turbocharger Valve Clearance Basic Block Connecting Rods and Main Bearings Connecting Rods and Pistons...,..., Cylinder Block Cylinder Liner Projection Flywheel and Flywheel Housing Piston Ring Groove Gauge Vibration Damper Cooling System Checking Fan Speed Checking Radiator Air Flow Filler Cap and Pressure Relief Valve Gauge for Water Temperature Pressure Cap Testing the Cooling System Testing Radiator and Cooling System for Leaks Visual Inspection of the Cooling System Water Temperature Regulator Electrical System Battery Charging System Shutoff Solenoid... " Starting System Fuel System Adjustment and Cleaning 7N449 Fuel Injection Nozzles Checking Engine Cylinders Separately Checking Engine Timing with 6V3100 Diesel Engine Timing Indicator Group Engine Speed Measurement Finding Top Center Compression Position for No.1 Cylinder.... Flow Checking Fuel Injection Pump Timing (PC Engines Only).... Fuel Injection Lines.... Fuel System Inspection.... Start-Up Procedure.... Test Sequence - Precombustion Chamber (PC) Fuel Nozzle Testing 7N449 Fuel Injeciton Nozzles... : Testing Capsule Type Fuel Injection Nozzles Troubleshooting of 7N449 Fuel Injection Nozzles Fuel System - Sleeve Metering..., Fuel Injection Service Fuel Pump Calibration...,.. 85 Fuel Ratio Control Setting Fuel System Adjustments Fuel System Setting Governor Adjustments... '"... " Fuel System (Scroll-PC) Checking the Fuel Injection Valves Checking the Plunger and Lifter Washer of an Injection Pump Decelerator Control Adjustment Fuel Injection Service Governor Adjustments Governor Control and Decelerator Linkage Adjustments Governor Linkage Adjustment Fuel System (Scroll-DI) Checking the Fuel Injection Valves Checking the Plunger and Lifter Washer of an Injection Pump Fuel Injection Pump Timing Dimension Setting; Off Engine Fuel Injection Timing Check (Timing Pin Method) Fuel Rack Setting Fuel System Adjustments Injection Pump (Install) Injection Pump (Remove) Lubrication System Oil Pressure is High... '.' Oil Pressure is Low Too Much Bearing Wear Too Much Oil Consumption Troubleshooting

7 /' Index Air Induction And Exhaust System Air Cleaner Camshaft Cylinder Head Ether Starting Aid Exhaust Manifold Exhaust Pipe And Muffler Turbocharger Valves Valve Cover Valve Rocker Arms And Lifters Basic Engine Components Bearing Surface (Journal) for Connecting Rods Bearing Surface (Journal) for Main Bearings Camshaft Bearings Connecting Rod Connecting Rod And Main Bearings Crankshaft Crankshaft Hub And Damper Cylinder Block Cylinder Liner Cylinder Liner Projection Flywheel Flywheel Housing Flywheel Housing Bore Flywheel Housing Runout Flywheel Runout Pistons And Rings Rear Accessory Drive Gear Timing Gears Timing Gear Cover Trunnion Cooling System Radiator Water Temperature Regulators Water Pump V-Belt Tension Chart Electrical System Alternator And Regulator Starter Motor Starter Solenoid Engine Design Fuel System Automatic Timing Advance... 7 Fuel Injection... 4 Fuel Injection Lines Fuel Injection Nozzle Fuel Injection Pump Fuel Injection Pump Housing Fuel Priming Pump And Primary Fuel Filter Fuel Ratio Control Fuel Transfer Pump Governor Governor Control... 8 Primary Fuel Filter Lubrication System Engine Oil Pressure... : Oil Breather Cap Oil Filter Oil Pump Introduction When the words "use again" are in the description, the specification given can be used to determine if a part can be used again. If the part is equal to or within the specification given, use the part again. When the word "permissible" is in the description,. thespecification given is the "maximum or minimum" tolerance permitted before adjustment, repair and/or new parts are needed. A comparison can be made between the measurements of a worn part and the specifications of a new part to find the amount of wear. A part that is worn can be safe to use if an estimate of the remainder of its service life is good. If a short service life is expected, replace the part. REFERENCE: See 3306 Direct Injection Vehicular Engine With New Scroll Fuel System, Form No. SENR Vehicular Engine 3 Index

8 Index Systems Operation Air Inlet and Exhaust System..., Cylinder Head and Valves Turbocharger Turbocharger and Aftercooler Valve Mechanism Basic Block Crankshaft Cylinder Block and Liners Pistons, Rings and Connecting Rods Vibration Damper Cooling System Cooling System Components Coolant Flow Engine Without Aftercooler Engine With Aftercooler Electrical System Charging System Components Other Components Starting System Components Engine Design... 4 Fuel System... 5 Fuel Flow... 5 Fuel Injection Nozzle... 7 Fuel Injection Pump... 6 Fuel Ratio Control Fuel Transfer Pump... 7 Governor Oil Flow for Fuel Pump and Governor... 9 Lubrication System System Oil Flow Testing And Adjusting Air Inlet and Exhaust System Checking Aftercooler Operation Crankcase (Crankshaft Compartment) Pressure Compression Cylinder Head... : Exhaust Temperature Measurement of Pressure In Inlet Manifold Procedure for Measuring Camshaft Lobes Turbocharger Restriction of Air Inlet and Exhaust Valve Clearance Basic Block Connecting Rod and Main Bearings Connecting Rods and Pistons Cylinder Block Vehicular Engine 3 Cylinder Liner Projection Flywheel and Flywheel Housing... : Piston Rings Vibration Damper Cooling System Testing the Cooling System Checking Pressure Cap Test Tools for Cooling System Testing Radiator and Cooling System for Leaks Water Temperature Regulator V-Belt Tension Chart Visual Inspection of the Cooling System Electrical System...,... ; Battery Charging System... : Starting System Test Tools for Electrical System Fuel System Checking Engine Cylinders Separately Checking Engine Timing With 8T5300 Timing Indicator Group And 8T5301 Diesel Timing Adapter Group Checking the Plunger and Lifter of an Injection Pump Checking Engine Timing by Timing Pin Method Engine Speed Measurement Fuel Injection Lines Fuel Setting Procedure Fuel System Inspection Governor Adjustments Fuel Ratio Control Locating Top Center Compression Position for No.1 Piston Removal and Installation of Fuel Injection Pumps Testing Fuel Injection Nozzles Lubrication System Increased Oil Temperature Measuring Engine Oil Pressure Oil Pressure is High Oil Pressure is Low Too Much Bearing Wear Too Much Oil Consumption Troubleshooting Specifications NOTE: For Specifications with illustrations, make reference to Specifications for 3306 Direct Injection Vehicular Engine With New Scroll Fuel System, Form No. SENR2781. If the Specifications in Form SENR2781 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. Index

9 6V7941 Compressor Assembly (13) Rod. (14) Knob. Adjusting Tool Installed (16) 6V2017 Governor Adjustment Tool. B74901Pl Compressor Assembly Installed (15) 6V7941 Compressor Assembly. Governor Linkage Adjustment (17) 6V21 06 Rack Adjustment Tool Group. 13. Turn rod (13) out of the 6V7941 Compressor Assembly (15) until knob (14) is 25.4 mm (1.0 in) from the compressor body. Install 6V7941 Compressor Assembly (15) in the hole plug (9) was removed from. NOTE: The 6V7941 Compressor Assembly is used to compress the over fueling spring. The over fueling spring must be compressed to get an accurate fuel setting measurement. 15. Move the governor control to the full load position and hold in this position. 16. Turn the over fueling spring compressor rod IN (clockwise) until the indicator hands move approximately 1 mm. 14. Move the governor control lever to the fuel off position. Use two Bolts and install 6V2017 Governor Adjustment Tool (16). Be sure the end of the tool is behind the governor linkage, and that the flange is completely against the governor housing (the filter screen may have to be removed. NOTE: If it is expected to be necessary to change the setting, install the outer part of 6V21 06 Rack Adjusting Tool (17) along the left side of the 6V2017 Governor Adjusting Tool when the 6V2017 Adjusting Tool is. installed Vehicular Engine 57 Testing And Adjusting Prirted for...ierlsids Company H1625

10 Index Specifications Fuel Injection Equipment... 4 Fuel Injection Lines... 6 Fuel Injection Nozzle... 6 Fuel Ratio (Air) Control... 9 Governor... 7 Systems Operation Fuel Flow Fuel Injection Nozzle Fuel Injection Pump Fuel Ratio (Air) Control Fuel Supply Pump Governor Variable Power Actuator Testing And Adjusting Checking Engine Cylinders Separately Checking Engine Timing and Timing Advance with 8T5300 Engine Timing Indicator Group Checking Timing by Timing Pin Method Engine Speed Measurement Fuel Injection Lines..., Fuel System Fuel System Inspection Governor Adjustments Low Idle Adjustment Locating Top Center Compression Position for No. 1 Piston Testing Fuel Injection Nozzles Disassembly And Assembly See Index on Page ( 3306 Fuel System Supplement 3 Index Prid8d far JensaIes CorI1*'Y 1-8Q0.443-()825

11 C26872Pl 56. Put shaft (18) and washers in position in the governor housing cover (2). Put plate (15) and guide block (17) in position and slide shaft (18) into place to hold the washers and guide block. 57. Put springs (20) and lever (19) in position in the governor housing cover. Slide shaft (18) into position to hold the lever in place. 58. Make an alignment of the holes in shaft (18) with the holes in guide block (17). Install two pins through the guide block and the shaft 60. Invert fuel injection pump on tool (A) as shown. This places the barrel (12) in the proper position to install the barrel in the fulcrum lever (13). 61. Put the gasket in place for the governor cover. As governor cover (2) is put in position, it is necessary to slide barrel (12) into fulcrum lever (13). 59. Install plate (15). Install bolt (14). Put governor cover gasket in position. Put tool (P) in position. The groove (slot) on tool (P) must slide on to shaft (58) of the guide block. Add or remove shims as necessary under plate (15). 62. Install the six screws (59) that hold the governor cover (2) to the governor housing Fuel System Supplement Prtrted for JonsaIes Company 1-fIOO.44~25 56 Disassembly And Assembly

12 Engine Disassembly and Assembly Index Accessory Drive Housing And Shaft Fuel Injection Lines Fuel Injection Nozzles... 12,13 Fuel Injection Nozzles, Disassemble & Assemble Fuel Injection Pumps Fuel Injection Pumps, Disassemble & Assemble Fuel Injection Pump Housing, Disassemble & Assemble Fuel Transfer Pump... 7 Fuel Transfer Pump, Disassemble & Assemble Governor, Disassemble & Assemble AWARNING Disconnect batteries before performance of any service work. IMPORTANT NOTICE This is a temporary information manual to aid in the disassembly and assembly of the 3300 Series Direct Injection Scroll Fuel System. 6

13 Index Fuel Filter And Base Fuel Injection Lines Fuel Injection nozzles Fuel Injection Pump Housing, Disassemble And Assemble Fuel Injection Pump Housing And Governor Fuel Injection Pumps Fuel Injection Pumps, Disassemble And Assemble Fuel Priming Pump And Base Fuel Ratio Control Fuel Ratio Control, Disassemble And Assemble Fuel Transfer Pump Fuel Transfer Pump, Disassemble And Assemble Governor Governor, Disassemble And Assemble Governor Shutoff Solenoid A WARNING Disconnect batteries before performance of any service work. ( NOTICE This is a information manual to aid in the disassembly and assembly of the 3300 Series Direct Injection New Scroll Fuel System Vehicular Engine 3 Index

14 Engine Disassembly and Assembly Index Air Cleaner Assembly Air Conditioning Compressor Alternator... 47,48 Camshaft ,125 Camshaft Bearings ,144 Connecting Rod Bearings... 75,76 Crankshaft Crankshaft Main Bearings Crankshaft Front Seal And Wear Sleeve ,120 Crankshaft Rear Seal And Wear Sleeve ,141 Cylinder Head Cylinder Liners Without Spacer Plate Cylinder Liners With Spacer Plate Engine (Power Shift, Direct Drive and Special Application) Engine Front Support ,122 Engine Oil Cooler Exhaust Manifold Fan Drive and Fan ,105 Fan Drive, Disassemble & Assemble. 106,107 Flywheel Flywheel Housing ,142 Fuel Check Valve and Bypass Valve Fuel Filter and Base... 8,9 Fuel Injection Lines... 11,12 Fuel Injection Nozzles Fuel Injection Pumps... 18,19 Fuel Injection Pumps, Disassemble & Assemble Fuel Injection Pump Housing and Governor Fuel Injection Pump Housing and Governor, Separation and Connection Fuel Injection Pump Housing, Disassemble & Assemble... 40,41 Fuel Injection Valves Fuel Priming Pump... 8 Fuel Transfer Pump Glow Plugs Governor, Disassemble & Assemble Hood... 46,47 Hydraulic Oil Pump Hydraulic Oil Pump, Disassemble & Assemble Muffler Oil Filter and Base... 9,10 Oil Filter Base, Disassemble & Assemble Oil Pan Oil Pan Plate Oil Pump Oil Pump, Disassemble & Assemble Pistons Pistons (Earlier), Disassemble & Assemble... 96,97 Pistons (Later), Disassemble & Assemble Piston Cooling Orifices ,151 Precombustion Chambers... 44,45 Radiator and Radiator Guard Radiator Core (Direct Drive, Special Application and Later Model Power Shift) Radiator Core and Torque Converter Oil Cooler Early Model Power Shift Rocker Shaft and Push Rods... 78,79 Rocker Shaft, Disassemble & Assemble... 79,80 Spacer Plate... 88,89 Starting Motor... 48,49 Timing Gears and Plate Timing Gear Cover Transmission Oil Cooler Valves ,90 Valve Cover Valve Guides... 92,93 Valve Lifters Valve Seat Inserts Vibration Damper and Pulley ,119 Water Directors Water Pump Water Pump, Disassemble & Assemble Water Temperature Regulator A WARNING Disconnect batteries before performance of any service work. 6

15 058 POWER TRAIN SPECIFICATIONS INTRODUCTION The specifications given in this book are on the basis of information available at the time it was written. The specifications torques, pressures of operation, measurements, adjustments and other items can change at any time. These changes can effect the service given to the product. Get the complete and most current information before you start any job. Caterpillar Dealers have the most current information which is available. For a list of the most current modules and form numbers available for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE REGl139F. When the words "use again" are in the description, the specification given can be used to determine if a part can be used again. If the part is equal to or within the specification gi ven, use the part again. When the word "permissible" is in the description, the specification given is the 'maximum or minimum" tolerance permitted before adjustment, repair and/or new parts are needed. A comparison can be made between the measurements of a worn part, and the specifications of a new part to find the amount of wear. A part that is worn can be safe to use if an estimate of the remainder of its service life is good. If a short service life is expected, replace the part X2 NOTE: For Systems Operation and Testing and Adjusting. make reference to the 058 TRACTOR POWER TRAIN, Forn1 No. SENR7555. For POWER SHIFT TRANSMISSION TESTING AND ADJUSTING see Form No. SENR7556. NOTE: The "e" is an indication of a change from the former issue. INDEX Adjustment of the Control Linkage for the Steering Clutches... " 20, 21 Adjustment of the Final Drive Bearings Adjustment Procedure for the Brakes Alignment of the Track Roller Frame Parking Brake Direct Drive Transmission: Adjustment of.transmission Control Linkage Bevel Gear and Pinion Flywheel Clutch Flywheel Clutch and Controls Flywheel Clutch Brake Adjustment Oil Filter for Transmission Oil Pump for Transmission Relief Valve for Steering Clutch Control Tooth Contact Adjustment Transmission Drawbar Group..., 39 Final Drive D, 31 Front Idlers and Recoil Springs..., 34 Hydraulic Control Mechanism for the Brakes Hydraulic Control Valve for the Steering Clutches , 18 Mounting Group (ROPS) Power Shift Transmission: Bevel Gear and Pinion Bypass Valve for the Oil Cooler Checking and Adjusting Alignment of the Flexible Coupling Drive... 4 Flexible Coupling Drive... 5 Lubrication Relief Valve Oil Filter Bypass and Steering Clutch Check Valve... 10, 11 Oil Filter for Transmission Oil Pump for Transmission Torque Converter...,..., Transmission... 8 Transmission Hydraulic Controls... 9 Steering Clutch and Bevel Gear Case..., 29 Steering Clutch Group... 32,33 Sweep Group Track Track Adjustment Track Carrier Rollers... '.J 35 Track Guiding Guard Track Rollers..., 35 Track Roller Guard

16 Index Adjustment Procedure For The Brakes Bevel Gear and Shaft Bevel Gear and Pinion Shaft Settings Brake Hydraulic Controls and Actuating Mechanisms Brake Hydraulic Controls and Actuating Mechanisms (Earlier), Disassemble & Assemble Brake Hydraulic Control and Actuating Mechanisms (Later), Disassemble & Assemble Bypass Valve, Disassemble & Assemble. 173 Crankcase and Radiator Guards Dash Equalizer Spring Equalizer Spring, Disassemble & Assemble Final Drive Bearings, Adjust Final Drive Case, Gear and Hub Final Drive Pinion Shafts and Flanges Flexible Coupling (Power Shift) Flywheel Clutch (Direct Drive and Special Application) Flywheel Clutch (Direct Drive and Special Application), Disassemble & Assemble Flywheel Clutch Brake (Direct Drive and Special Application) Front Idler Front Idler, Disassemble & Assemble Front Idler Support Fuel Tank Hydraulic Oil Tank Hydraulic Track Adjusters Hydraulic Track Adjusters, Disassemble and Assemble Lubrication Relief Valve (Power Shift) Lubrication Relief Valve (Power Shift) Disassemble & Assemble Parking Brake Control Valve (Later Models Only)... ~'. 297 Parking Brake Control Valve (Later Models Only), Disassemble & Assemble Priority Valve (Power Shift) (Earlier Models Only), Disassemble & Assemble Recoil Springs Sprocket Assemblies Sprocket Shaft Sprocket Segments... 8 St~ering Clutch and Scavenge Oil Pump (Direct Dnve and Special Application) St~ering Clutch and Scavenge Oil Pump (Driect Dnve and Special Application), Disassemble & Assemble Steering Clutches Steering Clutches, Disassemble & Assemble Steering Clutch Hubs Steering Clutch Hydraulic Control Valve Steering Clutch Hydraulic Control Valve Disassemble & Assemble... : Steering Clutch Relief Valve (Direct Drive and Special Application) Steering Clutch Relief Valve (Direct Drive and Special Application), Disassemble & Assemble Support and Seat Group

17 Torque Converter, Transmission and Transfer Gears (Power Shift) Torque Converter (Power Shift) Torque Converter (Power Shift), Disassemble & Assemble Track Carrier Rollers... 9 Track Carrier Rollers, Disassemble & Assemble Track Rollers Track Rollers, Disassemble & Assemble Track Roller Frames Tracks, Separation and Connection Tracks, Disassemble & Assemble Transfer Gears (Power Shift) Transfer Gears (Power Shift), Disassemble & Assemble Transmission (Direct Drive and Special Application) Transmission (Direct Drive and Special Application), Disassemble & Assemble Transmission (Power Shift), Disassemble & Assemble Transmission Oil Filter and Priority Valve (Power Shift) Transmission Hydraulic Controls (Power Shift) Transmission Hydraulic Controls (Power Shift), Disassemble & Assemble Transmission Oil Filter and Bypass Valve (Power Shift) (Later Models Only) Transmission Oil Pump (Power Shift) Transmission Oil Pump (Power Shift), Disassemble & Assemble Universal Joint (Direct Drive and Special Application) AWARNING Disconnect batteries before performance of any service work. 7

18 153 &163 HYDRAULIC CONTROLS INDEX SYSTEMS OPERATION Control Valves... 6 Double Control Valve Single Control Valve Hydraulic System... 4 Relief Valve... 9 Ripper Control Valve... 8 Make Up Valve... 9 TESTING AND ADJUSTING Checking Pump Efficiency Testing on the Bench Testing on the Machine Cylinder Drift Relief Valve Relief Valve Adjustment....' Relief Valve Test (Double Valve Tank) Relief Valve Test (Single Valve Tank) Hydraulic System Visual Checks Operation Checks DISASSEMBLY AND ASSEMBLY External Control Valve Assemble Disassem ble One Spool Control Valve Assemble Disassemble Two Spool Control Valve Assemble Disassemble Tank and Valve;... 15,16 Install Control Valve Remove Control Valve Valve Tank Control Lever Bearing Housing: lnstall Remove Control Lever Bearing Housing: Assemble Disassemble Filler Cap and Strainer: Assemble Disassemble Filter Cover: Assemble Disassemble SPECI FICATIONS Control Linakage Make-Up Valve Control Valve (9J9403) Control Valve (9J9833) Oil Filter Cylinders Relief Valve, Pressure Hydraulic Oil Pump (9J7115) Ripper Mounting Group (9J6215) Hydraulic Oil Pump (9J8771) Ripper Mounting Group (3K9880) Prirted for JonsaIes ConlrooY ~25 3

19 153 & 163 HYDRAULIC CONTROLS SYSTEMS OPERATION _STOPPED OIL c=jreturn OIL ~PUMPOIL through passage ( 13) and the head end of the left side tilt cylinder increases to approximately 2250 psi ( kpa), relief valve (6) opens. When relief valve (6) is open, the oil pressure does not increase any farther. Release the control lever held in the TILT RIGHT position and spring (2) moves valve stem (1) to HOLD position (H). The control lever (and valve stem) must be moved to change the TILT RIGHT position of the bulldozer. 13 AS5028Xt 14 CONTROL VALVE IN TI L T RIGHT POSITION 1. Valve stem (for tilt cylinders). 2. Spring. 3. Valve stem (for lift cylinders). 4. Inlet passage (relief valve also connects to this passage). 5. Passage to filter and tank. 6. Relief valve. 7. Passage. 8. Passage for tilt cylinderls). 9. Make up valve. 10. Check valve. 11. Passage (for rod ends of lift cylinders). 12. Check valve. 13. Passage for tilt cylinder(s). 14. Passage connected to passage (5). 15. Passage (for head ends of lift cylinders). F. FLOAT position. H. HOLD position. L. LOWER position. R. RAISE position. TL. TILT LEFT position. TR. TILT RIGHT position. Move the control lever to the right and it moves valve stem (1) to the TILT RIGHT position (TR). Now, the pump oil in passage (4) is stopped by the position of valve stem (1) and pump oil pressure increases. The increase in the pressure of the pump oil opens check valve (10). The pump oil goes through the open check valve into passage (13) and to the head end of the tilt cylinder on the left side of the push arms for the bulldozer. The pump oil in the head end of the tilt cylinder pushes the piston and rod, connected to the top left corner of the bulldozer, and the right bottom edge of the bulldozer goes down. This puts the bulldozer in a tilt right position. When the bulldozer has only one tilt cylinder, the oil pushed from the rod end by the piston goes into passage (8), then to passage (5) and out of the control valve. When the bulldozer has both left and right side tilt cylinders, the oil from the rod end of the left cylinder goes into the rod end of the right cylinder. The oil in the rod end of the right cylinder pushes the piston and rod, connected to the top right corner of the bulldozer, and right bottom edge of the bulldozer goes down. If the pressure of the pump oil in passage (4) Move the control lever to the left and valve stem (1) moves to TILT LEFT position (TL). The pump oil in passage (4) increases (no illustration), opens check valve (10) and goes into passage (8). The pump oil in passage (8) goes to the rod end of the left tilt cylinder, if the bulldozer has only one cylinder. The pump oil in passage (8) goes to the head end of the right side tilt cylinder if the bulldozer has two tilt cylinders. The action of either of these tilt cylinders moves the lower left edge of the bulldozer down and the bulldozer is in a TILT LEFT position. RIPPER CONTROL VALVE (EXTERNAL) The third control valve is for the operation of the ripper. This valve is not in the hydraulic tank. With the double valve, the valve stems in the double valve must be in HOLD positions for the pump oil to get to inlet passage (2). ~PUMPOll _STOPPED Oil 4 A,50?QXl RIPPER CONTROL VALVE 1. Check valve. 2. Inlet passage. 3. Spring. 4. Valve stem. 5. Passage for rod end of cylinder. 6. Passage for head end of cylinder. 7. Outlet passage. H. HOLD position. L. LOWER position. R. RAISE position. When valve stem (4) is in HOLD position (H), the pump oil goes through inlet passage (2) and then through outlet passage (7) to the filter and tank. The oil in both the rod end in passage (5) and in the head end in passage (6) for the ripper cylinder is stopped when valve stem (4) is in HOLD 3 8 PrIrDd for JenseIes Con1BJY HlOO

20 153 & 163 HYDRAULIC CONTROLS DISASSEMBLY AND ASSEMBLY EXTERNAL CONTROL VALVE 2. Use tool setup (A) to install oil seal in retainer with spring-loaded lip of seal up. 3. Put spool (1) in valve body. 4. Install retainer (2), spacers (3), spring (5) and spacer, bolt and lock (4) X2 5. Hold spool (1) as shown and tighten bolt. 6. Install cover (6). 34

21 OPERATOR'S STATION CONTENTS Item CONTENTS Page No. SAFETY ITEMS Electric Horns... 4 Back-Up Alarm... 4 Parking Brake Control Transmission Safety Lock (Power Shift Only)... " 5 Seat Belt... 5' Windshield Wipers, Windshield Washer Pump, Reservoir and Nozzle... 5 Windshield Wiper Motor and Linkage... 5 GAUGES Engine Oil Pressure... 6 Engine Water Temperature... 6 Fuel Pressure Ammeter... 6 Hour Meter... 6 Torque Converter Oil Temperature Gauge Tachometer OPERATOR COMFORT ITEMS Cab Pressurizer/Heater/Air Conditioner ELECTRICAL SYSTEMS Electrical Schematics TROUBLESHOOTING Wiper and Washer Typical Switch Test SEMI-MODULAR CAB Tilt Procedure Prirted for Jens$es Cor\1)any

22 OPERATOR'S STATION DISASSEMBL V AND ASSEMBL V INDEX Air Conditioning and Heating Unit Back-up Warning Alarm and Switch Batteries... 30,31 Cab Cab Door Cab Door Latch and Striker Cab Light Assembly Cab Liners Cab Window Glass... 66,67 Dash Disconnect Switch Front Windshield Wiper Motor... 37,38 Governor Control Horn Instrument Panel Rear Windshield Wiper Motor and Linkage... 39,40 Rear Windshield Wiper Motor and Linkage, Disassemble & Assemble ,42 Roll-Over Protective Structure ,25 Seat Seat, Disassemble & Assemble... 64,65 Seat Belt Steering Clutch and Brake Linkage Support and Seat Group Tilt Cab Back Tilt Cab Forward Windshield Washer Group DISCONNECT BATTERIES BEFORE PERFORMANCE OF ANY SERVICE WORK 4