955L Traxcavator S/N 8Y1, 13X1, & 57M1 Volume 1 of 3

Transcription

1 Caterpillar Service Manual 955L Traxcavator S/N 8Y1, 13X1, & 57M1 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-955L TX8Y

2 3304 VEHICULAR ENGINES SPECIFICATIONS Air Inlet and Exhaust System Air Cleaner Camshaft Cylinder Head Glow Plug Positioning Exhaust Manifold Exhaust Pipe and Muffler Turbocharger Turbocharger Impeller Installation... 44, 45 Valves (01) Valves (PC) , 39 Valve Cover Valve Rocker Arms and Lifters...,. 37 Basic Engine Components Bearing Surface (Journal) Connecting Rods..., Main Bearings Connecting Rod Crankshaft Crankshaft Hub Cylinder Block Counterbored Block Spacer Plate Block Cylinder Liner Cylinder Liner Projection Counterbored Block Spacer Plate Block Fan Drive Flexible Drive Coupling... 76, 77 Checking and Adjusting Alignment of the Flexible Drive Coupling Flywheel Flywheel Housing..., Flywheel Housing Bore Flywheel Housing Tightening Flywheel Ring Gear 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 Electrical System Alternators Alternator Regulator Generator Regulators Generators ,85 Starter Magnetic Switches Starter Motors Starter Solenoids... _ INDEX Engine Design Engine Mounting Bolts Fuel System Fuel System Timing Fuel System Usage Chart... 6 Service Meter Tachometer Drive Fuel System ~ Scroll (01) Fuel Injection... : Fuel Injection Pump Housing Fuel Transfer Pump Governor Governor Housing... '" Injection Nozzle Fuel System ~ Scroll (PC) Fuel Bypass Valve Fuel Injection Equipment Fuel Transfer Pump Governor (Earlier) Governor (Later) Fuel System ~ Scroll (PC & 01) Timing Gears Fuel System ~ Sleeve Metering (01) Fuel Injection Equipment Fuel Ratio Control Fuel Transfer Pump Governor Control (04E) Governor Control (120G & 130G) Governor Control (225)...,c.. 24 Governor Control (518) Injection Nozzle...,~' Fuel System ~ Sleeve Metering (PC)... 8 Fuel Injection Equipment Fuel Ratio Control Fuel Transfer Pump... '" 13 Governor Control (920 & 930) Governor Control (950) Governor Control (951) Governor Control (955L) 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... 55,56 Oil Pump Oil Pressure Switch Torque for Flared and O-Ring Fittings

3 3304 VEHICULAR ENGINES SPECIFICATIONS 2 WATER PUMP 3 4 (1) Oil seal. Put engine oil on the seal lip. Assemble with the lip toward the bearings. (2) Water seal and ring. a. Put water on the seal. b. Install the seal and ring together in the housing bore, with the shiny face of the ring outside. (3) Seal assembly. a. Remove the spring from the seal. b. Put water inside the seal assembly. c. Install the seal assembly around the shaft, with the 7N7843 Installation Tool, (the tool is with the seal group) until the carbon face makes contact with the shiny face of the ring (2). d. Install the spring. (4) Torque for the bolt that holds the impeller ± 1 lb. ft. (39 ± 1 N m) (5) Torque for bolt that holds the gear ± 5 lb. ft. (43 ± 7 N m). I I, I ~,--.., X3 V-BELT TENSION CHART BELT TENSION BELT TENSION WIDTH TOP "INITIAL".. USED.. BELT SIZE WIDTH OF PULLEY BELT TOP GROOVE GAUGE READING GAUGE READING in_ mm in. mm lb. N Ib_ N 3/ ± ± ± ± 22 1/ ± ± ± ± 44 5V ± ± ± ± 44 11/ ± ± ± ± 44 3/ ± ± ± ± 44 15/ ± ± ± ± 44 MEASURE TENSION OF BELT FARTHEST FROM THE ENGINE BORROUGHS GAUGE NUMBERS OLD GAUGE NO. BT-33-73F BT BT BT BT BT "INITIAL" BELT TENSION is for a new belt. "USED" BELT TENSION is for a belt which has more than 30 minutes of operation at rated speed of engine. NEW GAUGE NO. BT BT BT-33-72C BT-33-72C BT-33-72C BT-33-72C A10232X5 57

4 3304 VEHICULAR ENGINE INDEX SYSTEMS OPERATION Air Inlet and Exhaust System Air Inlet and Exhaust System and 32 Timing Gears Turbocharger Valves and Valve Mechanism Basic Block Crankshaft Cylinder Block and Liners Pistons, Rings, and Connecting Rods Cooling System Coolant for Air Compressor Electrical System Charging System Components Electrical System Schematic Other Components Starting System Components Fuel System (Scroll-Ol) Fuel Injection Pump Fuel System Timing Governor (Hydra-Mechanical) Injection Nozzles Introduction Fuel System (Scroll-PC) Fuel Injection Pump Fuel Injection Valve Fuel System Timing Glow Plugs Governor Operation Introduction Fuel Systyem (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 Engine Running... 7 System With Constant Bleed Valve System With Siphon Break System With Siphon Break and Constant Bleed Valve System Without Siphon Break or Constant Bleed Valve Fuel Injection Pump Operation Fuel Injection Valve-PC Fuel Injection Valves Fuel Priming Pump Fuel Ratio Control Fuel System Operation Fuel System Timing Fuel Transfer Pump Glow Plugs-PC Governor Injection Nozzle-Ol Introduction Non-Adjustable Oashpot Governor Siphon Break Water Separator General Information Engine Oesign Fuel System Usage Chart... 5 Lubrication System Oil Flow In The Engine Oil Flow Through The Oil Filter and Oil Cooler

5 3304 VEHICULAR ENGINE INDEX TESTING AND ADJUSTING Air Inlet and Exhaust System Flow Checking Fuel Injection Pump Timing Checking Inlet Manifold Pressure At Torque Converter Stall Speed Compression Crankcase (Crankshaft Compartment) Pressure (PC Engines Only) Fuel Injection Lines Fuel System Inspection Start-Up Procedure Cylinder Head Test Sequence - Precombustion Chamber (PC) 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 Fuel Nozzle Testing 7N449 Fuel Injection Nozzles Testing Capsule-Type Fuel Injection Nozzles Troubleshooting of 7N449 Fuel Injection Nozzles 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: Basic Block Off Engine Connecting Rod and Main Bearings Connecting Rods and Pistons Cylinder Block Cylinder Liner Projection ,123 Counterbored Block Spacer Plate Block Flywheel and Flywheel Housing Oil Pump Installation Piston Ring Groove Gauge Fuel Injection Timing Check (Timing Pin Method) Fuel Rack Setting Fuel System Adjustments Injection Pump (Install) Injection Pump (Remove) Fuel System (Scroll-PC) Checking the Fuel Injection Valves Checking the Plunger and Lifter Washer of an Injection Pump Fuel Injection Service Cooling System Accessory Drive Shaft Timing Checking Coolant Temperature Checking With 8S4620 Gauge Checking Fan Speed Checking With 8S7167 or 5P4158 Gauge Checking Radiator Air Flow Fuel Injection Pump Timing Dimension Setting: Filler Cap and Pressure Relief Valve Off Engine Gauge for Water Temperature Fuel Rack Setting Pressure Cap Injection Pump Testing Radiator and Cooling System for Leaks Injection Pump Installation Testing the Cooling System Injection Valve (Capsule-Type Nozzle) V-Belt Tension Chart Governor Adjustments Visual Inspection of the Cooling System Fuel Ratio Control Setting Water Temperature Regulators Electrical System Battery Charging System Starting System Fuel System (Sleeve Metering) Fuel Injection Service Fuel Pump Calibration Fuel Ratio Control Setting Fuel System Adjustments Fuel System Setting Flexible Drive Coupling Governor Adjustments Checking Flexible Drive Coupling Alignment Fuel System Adjustment and Cleaning of 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 Piston Lubrication System Oil Pressure is High Oil Pressure is Low Too Much Bearing Wear Too Much Oil Consumption Troubleshooting NOTE: This book has been completely changed from the former issue. SPECIFICATIONS 4 NOTE: For Specifications with illustrations, make reference to SPECIFICA TIONS for 3304 VEHICULAR ENGINE, Form No. SENR7590. If the Specifications in Form SENR7590 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.

6 FUEL SYSTEM TESTING AND ADJUSTING 5. To see if No. I piston on the compression stroke, look at the valves of No. I cylinder. The valves will be closed if No. I cylinder is on the compression stroke. You should be able to move the rocker arms (4) up and down with your hand. FLOW CHECKING FUEL INJECTION PUMP TIMING (PC Engines Only) Tools Needed: 1P540 Flow Checking Tool Group. 5P6524 Engine Timing Indicator Group. 5P7265 Adapter. 9S215 Dial Indicator. 3P1565 Collet. 3S3264 Rod, 7.12 in. (180.9 mm) long. 3S3269 Contact Point. 5P7307 Engine Turning Tool Group. 6V2023 Adapter Group. CAUTION DO NOT use the Fuel Flow Method of Fuellnjection Pump Timing on Direct Injection engines. LOCATING TOP CENTER Plug in hole for timing bolt (3). Travel of piston (7), from point of closing inlet port (6) to top center, can be found by using the procedure that follows: NOTE: The fuel system timing has a tolerance of ± 10. I. Put No. I piston at top center (TC) on the compression stroke. Make reference to FIND ING TOP CENTER COMPRESSION POSI TION FOR NO. I PISTON. LOCATING TOP CENTER 3. Bolt. VAL VE COVER REMOVED 4. Rocker arms. 6. If No. I piston is not on the compression stroke, remove the 3/8"-16 NC bolt and turn the flywheel counterclockwise. Install the 3/8"- 16 NC bolt as before. The No. I piston is now at top center on the compression stroke (TCI). MEASURING PISTON TRAVEL AS45tklX2 1. 3P1565 Collet Clamp Dial Indicator with Contact Point. 3. 5P7265 Adapter. 4. Precombustion chamber Rod, 7.12 in. (180.9 mm) long. 6. Inlet port. 7. Piston. 76

7 ENGINE DISASSEMBLY AND ASSEMBLY INDEX Accessory Drive Shaft (Compact Fuel System)... 73,74 Adapter Housing and Levers (Sleeve Metering Fuel System)... 42,43 Alternator Air Cleaner Housing... 8 Air Conditioner Compressor Balancer Shafts..., Balancer Shaft Bearings Camshaft Camshaft Bearings Connecting Rod Bearings Crankcase Guard Crankshaft ,129 Crankshaft Front Seal and Wear Sleeve Crankshaft Main Bearings... 83,84 Crankshaft Rear Seal and Wear Sleeve Crankshaft Pulley Cylinder Head ,110 Cylinder Liners Electric Starting Motor Engine OIl Cooler... 14,15 Engine... ~ Exhaust Manifold... 91,92 Fan and Alternator Belts Fan and Fan Drive... 16,17 Fan Drive, Disassemble & Assemble... 18,19 Flywheel Flywheel Housing Fuel Check Valve and Bypass Valve (Sleeve Metering Fuel System) Fuel Filter Base (Compact Fuel System) Fuel Filter Base (Sleeve Metering Fuel System) Fuel Injection Lines Fuel Injection Pumps (Compact Fuel System) (part of Fuel Injection Pump Housing Disassembly & Assembly) Fuel Injection Pumps (Sleeve Metering Fuel System) Fuel Injection Pumps (Sleeve Metering Fuel System), Disassemble & Assemble Fuel Injection Pump Housing and Governor (Compact Fuel System)... 49,50 Fuel Injection Pump Housing and Governor (Sleeve Metering Fuel System) Fuel Injection Pump Housing and Governor (Compact Fuel System), Separation and Connection... 55,56 Fuel Injection Pump Housing and Governor (Sleeve Metering Fuel System), Separation and Connection

8 ENGINE DISASSEMBLY AND ASSEMBLY INDEX Fuel Injection Pump Housing (Compact Fuel System). Disassemble & Assemble Fuel Injection Pump Housing (Sleeve Metering Fuel System). Disassemble & Assemble Fuel Injection Valves Fuel Priming Pump (Sleeve Metering Fuel System) Fuel Ratio Control (Compact Fuel System) Fuel Ratio Control (Sleeve Metering Fuel System) Fuel Ratio Control (Compact Fuel System), Disassemble & Assemble ,45 Fuel Ratio Control (Sleeve Metering Fuel System). Disassemble & Assemble Fuel Transfer Pump (Compact Fuel System) Fuel Transfer Pump (Sleeve Metering Fuel System) Fuel Transfer Pump (Compact Fuel System). Disassemble & Assemble Governor (Compact Fuel System). Disassemble & Assemble Governor (Sleeve Metering Fuel System). Disassemble & Assemble Hood... 8 Oil Filter Base Oil Filter Base. Disassemble & Assemble Oil Pan Oil Pan Plate Oil Pump Oil Pump. Disassemble & Assemble Pistons Pistons. Disassemble & Assemble Precombustion Chambers Radiator Core ,94 Radiator and Guard... 96,97 Rocker Shaft and Push Rods Rocker Shaft. Disassemble & Assemble Timing Gear Cover Timing Gears and Plate Torque Converter Oil Cooler Turbocharger Turbocharger. Disassemble & Assemble Valves Valve Cover Valve Guides Valve Lifters Valve Seat Inserts Water Directors Water Pump Water Pump, Disassemble & Assemble Water Temperature Regulator A WARNING DISCONNECT BATTERIES BEFORE PERFORMANCE OF ANY SERVICE WORK. 7

9 955L 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 lvailable for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE REG1l39F. When the words "use again" are in the description, he specification gi ven 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, Testing and Adjusting, make reference to 955L TRACK-TYPE LOADER POWER TRAIN, Form No. SENR7677. For POWER SHIFT TRANSMISSION TESTING AND ADJUSTING, see Form No. SENR7678. NOTE: The "C" is an indication of a change from the former issue. INDEX Adjustments: Bevel Pinion , 22 Brake Control Linkage... 17,20 Final Drive Bearings Steering Clutch Control Linkage... ".., 17, 20 Track Alignments: Flexible Coupling Drive... ".. ".. 4 Track Roller Frames...,..., Bevel Pinion , 22 Adjustment of Tooth Contact Pattern Bevel Gear Shaft Bearing Preload Location Free movement (backlash) adjustment Bypass Valve for the Oil Cooler Case and Covers Group... " Control Valve for the Steering Clutch Crankcase Guard Final Drive , 24 Flexible Coupling Drive... 5 Alignment of the Flexible Coupling Drive Front Idlers and Recoil Springs Hydraulic Controls for the Transmission Pressure Control Valve Selector Valve Oil Filters: Steering Clutch Transmission Oil Pumps: Steering Clutch Transmission Pressure Control Valve Relief Valve for Transmission Lubrication Rollover Protective Structure Selector Valve...,..., "..., Steering Clutch... 15,16 Adjustment of the Controls for the Steering Clutches and Brakes... 17,20 Case and Covers Control Valve..., Oil Filter Oil Pump Torque Converter Track..., Adjustment Track Carrier Rollers Track Roller Frames Alignment Track Rollers Transmission , 9 Bypass Valve for the Oil Cooler Hydraulic Controls. " " Lubrication Relief Valve Oil Filter Oil Pump Pressure Control Valve Selector Valve Transmission Control... 6 Transmission Drain Plug Transmission Mounting Group

10 955L POWER TRAIN INDEX SYSTEMS OPERATION Bevel Pinion General Information Hydraulic System for Steering Clutches 22 Control Valve Oil Filter Oil Screen ~~ ~ Hydraulic System for Torque Converter and Transmission Magnetic Screen Oil Cooler... "... 8 Oil Filter Oil Temperature Bypass Valve Pump... 7 Steering Clutches, Brakes and Final Drives Steering and Brake Control Brake Operation Parking Brake Operation Steering Operation Torque Converter..... Transmission..... Lubrication... Transmission Hydraulic Controls Inlet Relief Valve for Torque Converter Undercarriage Front Idlers Lubrication Position Recoil Spring and Mechanisms for Track Adjustment Hydraulic Track Adjuster Track Track Carrier Rollers Lubrication Track Rollers Lubrication Track Roller Frame TESTING AND ADJUSTING Bevel Gear and Pinion... Troubleshooting Brakes Checks During Operation Check List During Operation Final Drives... Steering Torque Converter Power Shift Transmission Testing Transmission and Adjusting... See Form No. SENR7678 Visual Checks Steering Clutches... Undercarriage: Pressure Check of the Hydraulic System Track... Track Roller Frame 'See the Specifications, Form No. SENR7676. SPECIFICATIONS NOTE: For Specifications with illustrations, make reference to the SPECIFICA TIONS FOR 955L TRACK-TYPE LOADER POWER TRAIN, Form No. SENR7676. If the Specifications in Form SENR7676 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. 3

11 POWER TRAIN DISASSEMBL V AND ASSEMBL V INDEX Adjustment of Front Idlers Brake Actuating Mechanisms, Disassemble & Assemble Bevel Gear and Pinion Settings ,103 Bevel Gear Shaft, Disassemble & Assemble ,96 Crankcase Guard (Rear) Final Drive Cases, Gears, Idler Pinions and Bearings Final Drive Pinions and Flanges..., Flexible Coupling Front Idlers... '" ,30 Front Idlers, Disassemble & Assemble Front Idler yokes Fuel Tank... 65,66 Hydraulic Track Adjusters ,39 Hydraulic Track Adjusters, Disassemble & Assemble Pinion Pump Drive, Disassemble & Assemble Recoil Springs ,42 Recoil Springs, Disassemble & Assemble... 43,44 Sprocket Assemblies Sprocket Segments Sprocket Shafts... 63,64 Steering Clutches and Bevel Gear Shaft Steering Clutches, Disassemble & Assemble Steering Clutch Case Cover, Steering Clutch Control Linkages and Brake Actuating Mechanisms Steering Clutch Control Linkages, Disassemble & Assemble Steering Clutch Hydraulic Mechanism, Disassemble & Assemble Steering Clutch Oil Filter Steering Oil Pump Steering Oil Pump, Disassemble & Assemble

12 POWER TRAIN DISASSEMBLY AND ASSEMBLY INDEX Torque Converter and Pump Drive Torque Converter, Disassemble & Assemble Tracks, Separation And Connection ,23 Tracks, Disassemble & Assemble Track Carrier Rollers Track Carrier Rollers, Disassemble & Assemble Track Rollers ,17 Track Rollers, Disassemble & Assemble Track Roller Frames Transmission Transmission, Disassemble & Assemble Transmission and Torque Converter Transmission Control Linkages Transmission Hydraulic Controls ,113 Transmission Hydraulic Controls, Disassemble & Assemble Transmission Lubrication Relief Valve Transmission and Torque Converter Oil Cooler Bypass Valve Transmission Mounting Adapter and Transfer Gears Transmission Mounting Adapter and Transfer Gears, Disassemble & Assemble Transmission Oil Filter and Bypass Valve ,176 Transmission Oil Screen Transmission Oil Pump Transmission Oil Pump, Disassemble & Assemble &. WARNING DISCONNECT BATTERIES BEFORE PERFORMANCE OF ANY SERVICE WORK. 7

13 POWER TRAIN DISASSEMBL V AND ASSEMBL V A781 04X 1-"'" 8

14 POWER TRAIN DISASSEMBLY AND ASSEMBLY TORQUE CONVERTER DISASSEMBLE TORQUE CONVERTER P4808 8B7554 8H684 8B7548 8H663 8B7560 2P8312 lp483 lp476 lp531 Adapter Tools Needed Bearing Cup Puller Attachment Ratchet Box Wrench Puller Assembly Bearing Puller Attachment Step Plate Retaining Ring Pliers Drive Plate Drive Plate Handle ABC D E start by: a) remove torque converter and pump drive 1. Remove twenty-four bolts (1) Install two 3/8"-16 NC forcing screws as shown. Make a separation of the impeller and the housing. 3. Remove two races (2) and bearing (3) from the turbine assembly. Remove the retainer from the stator. 4. Remove turbine assembly (6) from the housing. Remove bearing (5), two races (7) and retainer (4). 131

15 955L LOADER HYDRAULIC SYSTEM 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 REG 1139F. 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, 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, Testing and Adjusting, make reference to 955L LOADER HYDRAULIC SYSTEM, Form No. SENR7681. INDEX Bucket Positioner... 9 Bucket Positioner Master Valve... 8 Cycle Times Hydraulic Pump Hydraulic Tank and Valve Group... 6 Lift and Tilt Control Valve Lift Cylinders Lift Kickout Lines, Plugs and Fittings , 5 Master Valve for the Bucket Positioner... 8 Relief Valve for Main Pressure Tilt Cylinders Tilt Relief Valve for Head Ends Tilt Relief Valve for Rod Ends

16 955L LOADER HYDRAULIC SYSTEM INDEX SYSTEMS OPERATION Bucket Positioner Hydraulic Circuit Check Valves Lift Circuit Operation Lift Kickout Loader Hydraulic System... 4 Main Pressure Relief Valve Make-Up Valves Tilt Circuit Operation... 6 Tilt Circuit Relief Valves Tilt and Lift Control Valve TESTING AND ADJUSTING Bucket Positioner Circuit Adjustments Checking Pump Efficiency Hydraulic Troubleshooting Lift Kickout Adjustment Lift and Tilt Circuit Drift Lift and Tilt Circuit Speeds Loader Hydraulic System Loader System Tests Main Pressure Relief Valve Master Valve Adjustment Multi-Purpose Bucket Circuit Drift Operation Checks Ripper Cylinder Circuit Drift Slave Cylinder Internal Cam and Roller Spring Adjustment Tilt Circuit Relief Valve (Rod Ends)... '" Tilt Circuit Relief Valve (Head Ends) Visual Checks SPECIFICATIONS NOTE: For Specifications with illustrations, make reference to the SPECIFICA TIONS FOR 955L LOADER HYDRAULIC SYSTEM, Form No. SENR7680. If the Specifications in Form SENR 7680 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. NOTE: The "e" is an indication of a change from the former issue. 3

17 TABLE OF CONTENTS Equipment Installation... 3 Machine Warm-up... 3 System Test (CHART A)... 3 Trouble Shooting... 4 Pump Test (CHART B)... 5 Pump Test for Aeration... 6 Trouble Shooting Blocked Cylinder Tests (CHART C)... 7 Right Hand Cylinders Blocked... 8 Trouble Shooting

18 VEHICLE SYSTEMS DISASSEMBLY AND ASSEMBLY INDEX Bucket Bucket Positioner Bucket Positioner Master Valve Bucket Positioner Master Valve, Disassemble & Assemble Front Levers And Links Hydraulic Pump Hydraulic Pump, Disassemble & Assemble Hydraulic Tank Hydraulic Tank And Valve Group, Disassemble & Assemble Lift Arms Lift Cylinders Lift Cylinders, Disassemble & Assemble Rear Levers Swivel Joints Swivel JOints, Disassemble & Assemble Tilt Cylinders Tilt Cylinders, Disassemble & Assemble &. WARNING DISCONNECT BATTERIES BEFORE PERFORMANCE OF ANY SERVICE WORK. 6

19 VEHICLE SYSTEMS DISASSEMBL Y AND ASSEMBLY ~ A78104X1 7

20 VEHICLE SYSTEMS DISASSEMBLY AND ASSEMBLY REMOVE AND INSTALL HYDRAULIC PUMP Lift the bucket and install the support link or lift cylinder brace to hold the lift arms in the "up" position. 2. Remove sheet assemblies (1) and (2) from over the left side of the engine. HYDRAULIC PUMP &,.WARNING Slowly loosen the cap on the hydraulic tank to release the pressure and let the hydraulic oil become cool before it is drained from the tank to prevent bodily injury. 3. Drain the oil from the hydraulic tank. The capacity of the hydraulic tank is 39 U.S. gal. (147.6 litre). 4. Disconnect tube assembly (3) and hose assembly (4) from the hydraulic pump. 5. Remove the two bolts (5) and remove hydraulic pump (6) from the machine. NOTE: The following steps are a description for installation of the hydraulic pump. 6. Make sure the O-ring seal is in position and put clean hydraulic oil on it. 7. Put hydraulic pump (6) in position and install bolts (5) to hold it. 8. Make sure the O-ring seals are in position in tube assembly (3) and hose assembly (4). Put clean hydraulic oil on the O-ring seals and connect the hose and tube assemblies to the hydraulic pump. 9. Install sheet assemblies (1) and (2) on the left side of the machine. 10. Fill the hydraulic system to the correct level. See LUBRICA TION AND MAINTENANCE GUIDE. 11. Lower the bucket to the ground. 8

21 955L OPERATOR'S STATION CONTENTS CONTENTS Item Page No. SAFETY ITEMS Horns (electric) Windshield Wipers/Washers Back-up Alarm Parking Brake Lights Mirror COMFORT ITEMS Operators Seat Pressurizer Air Conditioner and Heater... 6 CONTROL GROUPS Hydraulic Control Console Transmission Control Console Brake Pedals STRUCTURAL COMPONENTS Cab... 9 Cab Doors and Windows ELECTRICAL SYSTEMS Instrument Panels ELECTRICAL TROUBLESHOOTING Index ELECTRICAL SCHEMATiC... 26,27 3

22 OPERATOR'S STATION DISASSEMBLY AND ASSEMBLY INDEX Air Conditioning Condenser... 72,73 Air Conditioning and Heating Fan Motors... 74,75 Air Conditioning and Heating Unit Back-Up Warning Alarm and Switch (955L) Back-Up Warning Alarm and Switch (977L & 983B)... 78,79 Batteries (955L & 977L) Batteries (983B) Cab (955L) Cab (977L & 983B) Cab Air Filters Cab Doors Cab Door Latch and Striker... 62,63 Cab Door Lock (977L & 983B) Cab Light Assembly Cab Window Glass ,50 Dash (955L) Dash (955L), Disassemble & Assemble Dash (977L) Dash (983B) Disconnect Switch (955L) Disconnect Switch (977L & 983B) Fan Control Switch Front Windshield Wiper Motor and Linkage... 44,45 Horns and Switch (955L) Horns and Switch (977L)... 21,22 Horns and Switch (983B) ,24 Hydraulic Control Levers Instrument Panel and Gauges Mirror and Bracket Rear Window Rear Windshield Wiper Motor and Linkage... 45,46 Seat Seat, Disassemble & Assemble Seat Belt Sound Suppression... 67,68 Tilt Cab Back (955L) Tilt Cab Back (977L & 983B) Tilt Cab Forward (955L) Tilt Cab Forward (977L & 983B) Transmission and Governor Control Linkage (955L) Transmission and Governor Control Linkage (977L & 983B) Wiper Blade Windshield Washer Group... 42,43 Windshield Wiper Motors and Linkage, Disassemble & Assemble... 47,48 A WARNING DISCONNECT BATTERIES BEFORE PERFORMANCE OF ANY SERVICE WORK. 6

23 OPERATOR'S STATION CAB (955L) DISASSEMBL V AND ASSEMBL V REMOVE CAB (955L) Remove brackets (1) from the storage position on each side of the dash. Turn brackets (1) over and install them as shown to hold the dash to the loader frame when the cab is tilted. 2. Remove the floormat from the cab. Remove the five bolts (4) and fourteen plugs (2). 3. Disconnect wiring harness (3) from the cab wiring harness. \, r ' J. i. i/.=~.. 4. Remove plastic covers (5) from the inside front corners of the cab. 5. Remove bolts (6) that hold the cab to the dash. 110

24 Safety... 3 Maintenance Recommendations... 6 Walk-Around Inspection... 8 Fuel and Lubricant Specifications... 9 Lubrication and Maintenance Chart Every 10 Service Hours or Daily Every 50 Service Hours or Weekly Every 100 Service Hours or 2 Weeks Every 250 Service Hours or Monthly Every 500 Service Hours or 3 Months Every 1000 Service Hours or 6 Months Every 2000 Service Hours or 1 Year When Required Cutting Edge Bolt Torques Refill Capacities Serial Number Locations