941 Traxcavator S/n 16U, 70H, 80H & up

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Caterpillar Service Manual 941 Traxcavator S/n 16U, 70H, 80H & up Service

WITHOUT THE AUTHORIZATION OF CATERPILLAR OR IT S SUCCESSORS.

1 Caterpillar Service Manual 941 Traxcavator S/n 16U, 70H, 80H & up 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-941TX16U+

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2 . " \'. SERVICE MANUAL 4.75" BCRE FCUR CYLINDER VEHICLE ENGINE "J, ' ;.;; " :..!

3 4.75" BORE, FOUR CYLINDER TWO VALVE VEHICLE ENGINE SYSTEMS OPERATION Alternator Circuit Breaker... 9 Fuel Injection Pump Operation Fuel Injection Valve... 5 Fuel System... 4 Generator 8 Generator Regulator Governor Operation Lubrication System Solenoid Starting Motor... 8 Starting and Charging Systems TESTING AND ADJUSTING Accessory Drive Shaft Timing Air Induction and Exhaust System Alternator Regulator Basic Block Battery... " 4 Charging System Checking Fuel Injection Pump Timing-On Engine Compression; Connecting Rods and Pistons... 9 Cooling System Crankcase Pressure Crankshaft... 9 Cylinder Head Cylinder Liner Projection... 9 Excessive Oil Consumption Flexible Drive Coupling Alignment Flywheel Fuel Injection Pump Timing Dimension Setting-Off Engine Fuel Injection Service Fuel System... 2 Fuel System Adjustments Fuel Rack Setting Generator Regulator Governor Adjustments High Oil Pressure... 1 Locating Top Center Compression Position for No.1 Piston Low Oil Pressure Lubrication System Measuring Inlet Manifold Pressure-Turbocharged Engines Oil Pump Installation Pinion Clearance Adjustment Precombustion Chamber Position Pressure Cap... Pressure Relief Valve Problem Solving Restriction of Air Inlet and Exhaust Starting and Charging Systems... 4 Starting System Testing Cooling System... _ Testing Fuel Injection Equipment Unusual Bearing Wear... 1 Valve Clearance Setting Water Temperature Regulator SPECIFICATIONS Alternators Piston Rings Bolt, Nut and Taperlock Stud Torque Radiator Connecting Rod Starter Solenoids Crankshaft Starting Motors Cylinder Block Cylinder Head Temperature Regulator Cylinder Liner Timing Gears Turbocharger (AiResearch-T0490) Flexible Drive Coupling Turbocharger (AiResearch-TI210) Fuel Bypass Valve Turbocharger (Schwitzer E Model) Fuel Injection Equipment Fuel Transfer Pump Valves Valve Cover Generators... _... _... _... _ Valve Guide and Seat Inserts Generator Regulators.. _ Valve Rocker Arms and Lifters Governor... _... _... _ Water Pump Oil Filter Oil Pump... 54

4 FUEL SYSTEM SYSTEMS OPERATION FUEL SYSTEM FUEL.. TANK BYPASS VALVE MAIN FILTER 2.987X1 PRIMARY FILTER PIIMP FUEL SYSTEM SCHEMATIC The fuel system is a pressure type with a separate injection pump and injection valve for each cylinder. Fuel is injected into a precombustion chamber, not directly into the cylinder. A transfer pump supplies fuel to the manifold from which the injection pumps get fuel. Before the fuel is delivered to the manifold, it is filtered first by a primary filter which removes dirt particles, and later by a main or final filter which removes more minute particles. The amount of fuel pumped each stroke is varied by turning the plunger in the barrel. Action of the governor moves the fuel rack which turns the pump gear segment on the bottom of the pump plunger. 1 The transfer pump can supply more fuel than is required for injection, so a bypass valve is used to limit the maximum pressure within the supply system. The injection pumps receive fuel from the manifold and force it under high pressure to the injection valves. The injection valves spray atomized fuel into the precombustion chambers. An air vent valve in the system permits removal of air. Air is removed by opening the valve and pressurizing the fuel system. The system can be pressurized by using the priming pump. The vent valve must be open until a stream of fuel, without air bubbles, flows from the vent line. FUEL INJECTION PUMP OPERATION The injection pump plungers and the lifters are lifted by lobes on the camshaft and always make a full stroke. The lifters are held against the cam lobes by spring force applied to the plungers. 4 1 FUEL INJECTION PUMP 1-Fuel manifold. 2-lnlet port. -Check valve. 4-Gear segment. 5-Pump plunger. 6-Spring. 7-Fuel rack. 8-Lifter. 9-Camshaft

5 4.75" BORE, FOUR CYLINDER TWO VALVE VEHICLE ENGINE SPECIFICATIONS ALTERNATORS (DELCO-REMY) 5S9088 (24V-50A-DR Circuit-negative ground B Belt adjustment (amount deflected I ±.125 in. (22,0 ±,0 mm) force midway between pulleys lb. (11, kg) RPM-testing Rotation-clockwise Output-cold: 5000 RPM (load battery with carbon pile to obtain maximum output A Rated output (hot) A Field 24V 80" F (27" C) A Voltage regulator: Voltage setting range... ; V Adjust voltage setting to V then increase speed to produce maximum output A (11 Torque-nut ± 51b. ft. (10,4 ± 0,7 mkg) (21 Torque-output terminal ± 1 lb. ft. (1,8 ± 0,14 mkg) ALTERNATORS (PRESTOLlTE) 7S5897 (24V-19A ANB6001) 9S4070 (24V 19A ANB70011 Negative ground Rated 28V A Output V A Rotor resistance at 77 0 F (25 0 C) ohms Current draw at 77 0 F (25" 24 V A (1 I Torque-pulley retaining nut ±2.5Ib.ft.(12,1±O,mkg) (21 Torque-through bolts ± 2.5 lb. in. (1,7 ± 2,9 cm.kg) (1 Torque-brush holder screws ±2.5Ib.in.(14,4±2.9cm.kg) (41 Torque-terminal stud nuts ±2.5 lb. in. (7,5 ±2,9 cm.kg) (51 Torque-regulator retaining bolts ± 2.5 lb. in. (54,8 ± 2,9 cm.kg) *Includes VSH S229 Regulator 55

6 941 POWER TRAIN SPECI FICATIONS INTRODUCTION The specifications in this book are given on the basis of information that was current at the time the book was written. These specifications give the torques, operating pressures, measurements of new parts and other items. When the word "permissible" is used in the description, the specification value given is the "maximum or minimum" normally permitted before adjustment, repair and/or new parts are needed. Make a comparison of the measurements of a worn part with the specifications of a new part to find the amount of wear. The wear factor is not the only basis for the replacement of parts. The expected service life of the worn part is a factor. A part that is worn can be safe to use if an estimate of the remainder of its service life is good. When a disassembly is made for the purpose of reconditioning, the recommendation is the replacement of parts not completely worn out if a short service life is expected NOTE: For Systems Operation and Testing and Adjusting, make reference to 941 POWER TRAIN, Form No. REG Alignment of Track Roller Frame Alignment of Sprocket Parallel Alignment of Roller Frames Bevel Gear and Steering Clutch (Lever Steer) Bevel Gear and Steering Clutch (Pedal Steer) Bevel Pinion Bevel Gear Shaft Bearing Preload Bevel Pinion Location Free Movement (Backlash) Adjustment Free Movement (Backlash) and Alignment Check Controls for the Steering Clutch (Lever Steer) Adjustment for Steering Clutch Control Levers Adjustment of Brakes Case and Cover for Steering Clutch Filter for Steering Clutch (Pedal Steer) Final Drive Flexible Coupling Drive... 4 Alignment of Flexible Coupling Front Idler and Recoil Spring Hydraulic Controls for the Transmission... 8 Hydraulic Controls for Steering Clutch (Pedal Steer) Adjustment for Steering Clutch and Brake Controls Checking Hydraulic Pressure of Steering Clutch Release Oil Pump for Steering Clutch (Pedal Steer) Rollover Protective Structure..., 18 Torque Converter... 6 Track..., 16 Track Carrier Roller Track Rollers Track Roller Frame Hydraulic Adjusted Track Mechanical Adjusted Track Transmission.... Transmission Filter.... Transmission Pump

7 POWER TRAIN SYSTEMS OPERATION General Information Planetary Transmission First Speed Forward First Speed Reverse... 7 Second Speed Forward Third Speed Forward Steering Clutch Brakes: Lever Steer Pedal Steer Steering Clutches and Final Drive Steering Clutches, Brake and Final Drive Steering Clutch Control Mechanism: Lever Steer... 1 Pedal Steer Steering Clutch Hydraulic System, Pedal Steer Steering Clutch Release Hydraulic Control, Pedal Steer Torque Converter Torque Converter and Transmission Transmission Hydraulic Controls... 8 Transmission Lubrication System TESTING AND ADJUSTING Backlash, Bevel Gear Bevel Gear and Pinion Bevel Gear Shaft Bearing Preload Bevel Pinion Location Control Linkage, Transmission Flexible Drive Coupling Alignment Hydraulic Pressure Test, Steer Clutch Release Instrument Test, Chart Oil Pump Specifications, Transmission Operational Check List Problem Solving Steering Clutches and Brakes, Lever Steer Brake Clutch Linkage Steering Clutches and Brakes, Pedal Steer Clutch and Brake Control Linkage Steering Clutch Release Hydraulic Pressure Check Torque Converter, Transmission and Hydraulic Controls Track Roller Frame Alignment Tracks: Hydraulic Mechanical Transmission Control Linkage Transmission Oil Pump, Specifications Undercarriage Adjusting Track Aligning Track Roller Frames Visual Checks SPECIFICATIONS Bevel Gear and Steering Clutch Bevel Pinion... Bolt, Nut and Taperlock Stud Torque Case and Cover for Steering Clutch Final Drive... 9 Flexible Drive Coupling (80HI-80H2629)... Flexible Drive Coupling (80H260-UP)... Oil Filter for the Steering Clutch... 8 Oil Pump for the Steering Clutch... 7 Pressures of the Hydraulic Controls... 6 Recoil Spring, Front Idler Steering Clutch Control... 9 Steering Clutch Release Hydraulic Control Steering Clutch, Pedal Steer... 7 Torque Converter Track Track Carrier Roller Track Rollers Track Roller Frame Transmission Transmission Hydraulic Controls... 5 Transmission Filter... 5 Transmission Pump

8 941 POWER TRAIN SYSTEMS OPERATION General Information Steering Clutches, Brakes and Final Drive Steering Clutches and Final Drive Steering Clutch Brakes (Lever Steer) Steering Clutch Brakes (Pedal Steer)... 1 Steering Clutch Control Mechanism (Lever Steer)... 1 Steering Clutch Control Mechanism (Pedal Steer) Steering Clutch Hydraulic System (Pedal Steer) Steering Clutch Release, Hydraulic Control (Pedal Steer) Torque Converter and Transmission Torque Converter... 5 Planetary Transmission... 5 First Speed Forward Second Speed Forward Third Speed Forward... 6 First Speed Reverse Transmission Hydraulic Controls Transmission Lubrication System TESTING AND ADJUSTING Alignment of Track Roller Frame... * Alignment of Sprocket... * Parallel Alignment of Roller Frames... * Bevel Pinion * Bevel Gear Shaft Bearing Preload * Bevel Pinion Location... * Free Movement (Backlash) Adjustment * Controls for The Steering Clutch (Lever Steer)... * Adjustment for Steering Clutch Control Levers * Adjustment of Brakes... * Flexible Coupling Drive... * Alignment of Flexible Coupling * Hydraulic Controls for Steering Clutch... * Adjustment for Steering Clutch and Brake Controls... * Checking Hydraulic Pressure of Steering Clutch Release... * Power Shift Transmission Testing and Adjusting... See Form No. REG0124 and REG012 Track * Hydraulic Adjusted Track.... * Mechanical Adjusted Track.... * Troubleshooting Visual Checks Operational Checks Operational Check List Transmission Torque Converter Steering *See SPECIFICATIONS, Form No. SENR7001. SPECIFICATIONS NOTE: For Specifications with illustrations, make reference to the POWER TRAIN SPECIFICATIONS FOR 941 TRACK TYPE LOADER Form No. SENR7001. If the Specifications in Form SENR7001 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 in the book with the latest date.

9 LOADER HYDRAULIC SYSTEM SYSTEMS OPERATION Bucket Positioner Hydraulic Circuit 7 Main Pressure Relief Valve 8 Lift Circuit Lift Kickout Loader Hydraulic System 8 9 Systems Operation Tilt Circuit Tilt Circuit Relief Valves TESTING AND ADJUSTING Bucket Positioner Circuit Adjustments IS Master Valve Adjustment 16 Lift Circuit Drift Lift Kickout System Lift and Tilt Circuit Speeds Loader Hydraulic System Loader System Test Procedures Main Pressure Relief Valve 1 Operational Checks Slave Cylinder 11 Tilt Circuit Drift 12 Tilt Circuit Relief Valves.. 1, 14 Visual Checks II SPECIFICATIONS Bolt, Nut and Taperlock Stud Torque Bucket Positioner Master Valve Cylinders Head End Tilt Relief Valve Hydraulic Oil Pump Loader Frame Main Control Valve Main Pressure Relief Valve Rod End Tilt Relief Valve

10 LOADER HYDRAULICS SYSTEMS OPERATION Bucket Positioner Hydraulic Circuit Main Pressure Relief Valve... 1 Bucket Positioner Hydraulic Circuit (Early Machines) Systems Operation... 8 Lift Circuit... 1 Lift Kickout (Mechanical)... 1 Tilt Circuit... 9 Loader Hydraulic System... 5 Tilt Circuit Relief Valves TESTING AND ADJUSTING Bucket Positioner Hydraulic Circuit Operational Checks Bucket Positioner Hydraulic Circuit (Early Machines) Tilt Circuit Relief Valves Checking Pump Efficiency Visual Checks... " 15 Lift Kickout System Loader Hydraulic System Loader System Test Procedures Main Pressure Relief Valve... ' SPECI FICATIONS Auxiliary Control Valve Loader Frame Bucket Positioner Master Valve Main Control Valve Bucket Positioner Master Valve (Early Machines) Main Pressure Relief Valve Cylinders Rod End Tilt Relief Valve Head End Tilt Relief Valve Hydraulic Oil Pump... 27

11 SLEEVE METERING FUEL SYSTEM DISASSEMBLY AND ASSEMBLY ALPHABETICAL Page No. Oper. No. Adapter Housings and Levers... 12,1 6 Fuel Check Valve and Bypass Valve..."... 24,25 10 Fuel Injection Pumps... 26,27 11 Fuel I njection Pumps, Disassemble & Assemble... 28,29 12 Fuel Injection Pump Housing, Disassemble & Assemble Fuel Injection Pump Housing and Governor 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 Fuel Transfer Pump Generallnformation Governor, Disassemble & Assemble... 2()'2 9 Speed Limiter

12 DISASSEMBLY AND ASSEMBLY 941 & 951 POWER TRAIN Bevel Gear and Pinion Setting Bevel Gear Shaft Bearings and Bevel Gear Removal Bevel Pinion Disassembly and Assembly Bevel Pinion Removal and Installation Checking Flexible Drive Coupling Alignment... 7 Control Pedals Removal... 9 Final Drive Assembly Final Drive and Bearing Cage Disassembly Final Drive Disassembly Final Drive Pinion Removal and Installation Final Drive Removal and Installation Flexible Coupling Drive Planetary Transmission Disassembly and Assembly Planetary Transmission Removal and Installation Power Train Service Guide Steering Clutch and Bevel Gear Case and Cover Removal Steering Clutch and Brake Controls (Pedal Steer Machines)... 9 Steering Clutch and Bevel Gear Shaft Removal (Lever Steer Machines) Steering Clutch and Bevel Gear Shaft Removal (Pedal Steer Machines) Steering Clutch Control Adjustments Steering Clutch Case Cover Removal (Lever Steer Machines)... 4 Steering Clutch Case Cover Removal (Pedal Steer Machines) Steering Clutch Disassembly and Assembly Steering Clutch Lever Bumper Stops Steering Clutch Control Mechanism (Lever Steer Machines) Disassembly and Assembly Steering Clutch Oil Filter Disassembly Steering Clutch Oil Strainer Disassembly Steering Clutch Release Hydraulic Control Removal Torque Converter Disassembly and Assembly Torque Converter, Transmission and Bevel Pinion Removal.. 9 Torque Converter Removal and Installation Transmission Hydraulic Controls Disassembly and Assembly Removal and Installation Transmission Lubrication System Components Disassembly and Assembly Removal and Installation UNDERCARRIAGE Alignment of Track Roller Frames Filling and Bleeding the Hydraulic Track Adjuster Front Idler Disassembly Front Idler Removal and Installation Installing Track Recoil Spring Relieving Track Tension Track Adjusting Mechanism Track Carrier Roller Disassembly Track Carrier Roller Removal and Installation Track Disassembly and Assembly Track Roller Frame Removal Track Roller Disassembly Track Roller Removal and Installation Undercarriage Undercarriage Service Guide Separating Track

941 & 951 POWER TRAIN DISASSEMBLY AND ASSEMBLY BEVEL PINION REMOVAL AND INSTALLATION Refer to SERVICE GUIDE for Preliminary Information. 1-0il line from transmission sump.

13 941 & 951 POWER TRAIN DISASSEMBLY AND ASSEMBLY BEVEL PINION REMOVAL AND INSTALLATION Refer to SERVICE GUIDE for Preliminary Information. 1-0il line from transmission sump. 2-Bolts and lockwashers (fifteen each). Use two %"-16 forcing screws to separate torque converter case from transmission housing. -%" NC forged eyebolts (two). Attach hoist. 4-Torque converter and lubrication system groups. 5-Bolts (eight). Do not remove the three short bolts marked "S". 6-Bolts (twelve). Use two as forcing screws to separate transmission housing from transfer gear case. 7-%" NC forged eyebolts (two). Attach hoist. a-planetary transmission housing. 9-Locking pliers (two). Grip planetary transmission as shown to prevent clutch pack No. 5 (rotating clutch) from dropping during planetary transmission removal. 10-%" NC forged eyebolts (two). Attach chains. 11-Planetary transmission. 12-Planetary transmission manifold. 1-Transfer gear case. <+> CAUTION-Any attempt to remove the transfer gear case from the transmission housing without first removing the planetary transmission can result in damage to clutch pack No. 5 (rotating clutch). 27

14 941 & 951 LOADER COMPONENTS DISASSEMBLY AND ASSEMBLY Bucket Bucket Control Bucket Positioner Mechanism Control Valve and Linkage Removal... 6 Control Valve Disassembly Hydraulic Oil Pump... 9 Hydraulic System Components... 6 Lift Circuit Make-up Valve Lift and Tilt Control Valve Lift Cylinder... _... _ Lift Cylinder Oil Lines... _ Loader Frame Main Pressure Relief Valve Service Guide... _ Tank Removal and Installation... _ Tilt Cylinder... _ Tilt Cylinder Oil Lines Tilt Circuit Make-up Valve Tilt Kickout Valve

15 DISASSEMBL Y AND ASSEMBLY 941 & 951 ENGINE Air Induction and Exhaust System Components Basic Block Components Ca mshaft... 1 Camshaft Bearings... 1 Camshaft Gears... 1 Connecting Rods Cooling System Components Crankshaft Crankshaft Front Oil Seal... 1 Crankshaft Pulley Crankshaft Rear Oil Seal Cylinder Block Cylinder Head Cylinder Head and Valve Components Engine Front Support Engine Removal and Installation... 9 Exhaust Manifolds Fan Drive Flywheel Flywheel Housing Fuel Filter Fuel Priming Pump Fuel Injection Pump Housing Fuel System Components Fuel Transfer Pump Governor Lubrication System Components Main Bearings Oil Pump Pistons Radiator Rings Rocker Arm Cover Rocker Arm and Push Rods Service Guide Timing Gear Cover Ti ming Gears... 1 Torque Converter Oil Cooler Valves Water Pump... 2 Water Temperature Regu lator

16 GENERAL INSTRUCTIONS DISASSEMBLY AND ASSEMBLY Bearings Bearing Cup Pulling Attachment. Bearing Pulling Attachment Bolts and Bolt Torque Brake Linings Cleanliness Cylinders Filling and Bleeding the Hydraulic Track Adjuster Fractions, Decimals and Millimeters Chart. Gaskets Hydraulic Fittings Hydraulic Lines Hydraulic Systems Hydraulic Valves Lines and Wires Locks Lubrication Pressing Parts Puller Assembly (2 or Arm) Pumps Push Pullers Relieving Track Tension Removal and Installation Rust Preventive Compound.... Safety Seals Sealing Elements Service Tools Shims Solid Seal Assemblies Tool Safety

17 TABLE OF CONTENTS Periodic Service Index Service Hours Service Hours Service Hours Service Hours Service Hours Service Hours Service Hours Lift Arm Support Safety Precautions General Instructions Lubricating Oil Lubricating Grease Diesel Fuel Hydraulic System Air Cleaner Elements Glow Plugs Wiring Diagram Bucket Teeth Ripper Teeth Servicing Hints... 6 Booster Batteries Index Capacities Locations of Serial Numbers TABLE OF CONTENTS

18 A Page Air cleaner Changing elements Cleaning elements Service indicator B Batteries Battery charge rate Bevel gear compartment Breather Checking Oil change Bevel gear and steering clutch compartment* Breather Checking Filter... 7 Screen... 7 Booster batteries Brake pedal bearings Bucket control linkage and pivots Bucket positioner Adjustment Fill cup Bucket teeth Change Check C Capacities Cooling system Check Flush D Diesel engine crankcase Change filter... 4 Change oil... 4 Check oil Wash breather Diesel engine valve lash Diesel fuel Filler cap... 2 Filler strainer Tank F Fan and generator belts Fan drive bearing... 0 Final drives Change oil Check Final fuel filter Fuel tank G General instructions Glow plugs Governor control linkage H Hydraulic hoses and cylinders Hydraulic system Change oil Check oil Filter... 6 General Screen L Page Lift arm support Lift kickout Locations of serial numbers Lubricating grease Lubricating oil M Multi-purpose bucket P Precleaner Primary fuel filter R Radiator Check... 9 Cores Hoses and clamps Pressure overflow unit Ripper teeth Change Check Ripper linkage and pivots S Safety precautions Servicing hints Steering clutch Adjust Brakes... 0 Compartments Control shaft bearings Levers Release bearings Steering clutch and brake pedal bearings* T Track Adjusting screws Adjustment Roller frame outer bearings Transmission Breather... 5 Change oil... 8 Check Control linkage Filter... Screen... 8 U Undercarriage W Walk-around inspection Wiring diagram * For machines with pedal steering ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ 65

951B Traxcavator S/n 79H, 32F, 69H & 86J Volume 1 of 2

951B Traxcavator S/n 79H, 32F, 69H & 86J Volume 1 of 2 Caterpillar Service Manual 91B Traxcavator S/n 79H, 2F, 9H & 8J Volume 1 of 2 Service Manual THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF CATERPILLAR OR IT S SUCCESSORS. CATERPILLAR