caterpillar d5 crawler service manual - jensales … instructions disassembly and assembly remove...
TRANSCRIPT
CT-S-D5 6R+
CCaatteerr ppii ll llaarrService Manual
D5 CrawlerS/n 6R, 12R, 50J, 54J,
62J, 63J, 67J, 68J,93J, 95J, 96J & 97J
Volume 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.
Serv
ice
Man
ual
VOLUME1OF2
CATERPILLAR
SERVICE MANUAL
D5CRAWLER SIN 6R, 12R, 50J, 54J, 62J,
63J, 67J, 68J, 93J 94~ 95J,96~97J
GENERAL INSTRUCTIONS DISASSEMBLY AND ASSEMBLY
INDEX
Batteries Bearings
Anti-Friction _ ................................... . Double Row, Tapered Roller ........................ . Heating Bearings .................................. . Installation ...................................... . Preload ......................................... . Sleeve Bearings ................................... .
Bolts and Bolt Torque ................................ . Torque Multipliers ................................ . Torque Wrench Extension .......................... . T-T-T Procedure .................................. .
Brake Linings ...................................... .
9 8 8 9 9 9 9 9 6 7 7 6 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 a-ring Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 12 Cleanliness .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11 Cylinder Ins tallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 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 a-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
Disassembly and Assembly
Remove and install the bolts securing the cylinder head to the cylinder with the piston rod fully extended.
Cylinder Head Seals
The rubber O-ring seal and the back-up ring which form the seal between the head and cylinder bore are all assembled as illustrated.
Note that the toe or lip of all wiper seals (3) on all cylinders faces away from the cylinder head.
CORRECT INSTALLATION OF O-RING SEAL AND BACK-UP RING
THREE SEAL CYLINDER HEAD
1. Buffer seal. 2. U-cup seal (always installed with lip toward the oil). 3. Wiper seal.
Seal Guide for I nstallation of Cylinder Head
2
3
A hydraulic cylinder rod with a sharp edge, on the thread end of the rod, needs a seal guide to put
C the cylinder head on the cylinder rod. A complete list of seal guides is in the Vehicle System Tools section of the Tool Guide. To install the cylinder head:
1. Put lubricant on the seals. From the outside face of the cylinder head, push the small diameter end of the seal guide into the seals.
DISASSEMBLY AND ASSEMBLY
2. Place the thread end of the rod in the seal guide and push the cylinder head on the rod.
TYPICAL SEAL GUIDE AND CYLINDER HEAD
PUSH CYLINDER HEAD ON ROD
Cylinder Head Packing Adjustment
Oil leakage between the rod and the hydraulic cylinder packing can be the result of worn, cut, and/or distorted packing. Leakage can often be stopped by removing shims (2) located between retainer (1) and the cylinder head; this will allow the packing to be compressed against the rod when the retainer is tightened.
REMOVAL OF SHIMS
1. Retainer. 2. Shims.
15
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
SLEEVE METERING FUEL SYSTEM
8. Install tools as shown and loosen the drive gear for the fuel injection pump from the drive sleeve for the fuel injection pump.
TIMING BOLT INSTALLED
10. Bolt.
TIMING BOLT INSTALLED
10. Bolt.
TIMING BOLT LOCATION
Plug in hole for timing bolt (10).
9. Remove the 3/8"-16 NC bolt (10) from the flywheel. Turn the flywheel clockwise at least 60° beyond the point where the 3/8" -16 bolt (10) can be installed.
78
TESTING AND ADJUSTING
10. Tighten the bolt (5) finger tight. Be sure that the timing pin (1) is in the notch in the camshaft. Turn the flywheel counterclockwise until the 3/8" -16 bolt (10) can be installed in the flywheel.
II. Install a 3/8 in. -24 NF bolt, 1/2 in. (12.7 mm) long in one of the holes in the drive gear. Put a torque wrench on this bolt with the wrench in a line with the center of the drive gear, and give it a torque of 45 to 50 lb. ft. (60 to 70 N·m) in a clockwise direction as seen from the front of the engine. While holding this torque, tighten bolt (5) for the drive gear to a torque of 110 ± 5 lb. f1. (149 ± 7 N·m). Remove timing pin (1) from the fuel pump and the 3/8 in. -16 NC bolt from the flywheel.
TIGHTENING DRIVE GEAR FOR THE FUEL INJECTION PUMP
(Typical Example)
12. Turn the engine flywheel two complete revolutions. If the 3/8" -16 bolt goes in the hole in the flywheel when the timing pin is installed in the notch in the camshaft, the timing is correct.
13. Ifthe 3/8" -16 bolt can not be installed in the hole in the flywheel, do steps 4 through 11 again.
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 Pipesand 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. SENR 7593.
3
INDEX DISASSEMBL Y AND ASSEMBLY
05 ENGINE
INDEX
Air I nduction and Exhaust System Components ....................... 8 Air Inlet Pipe ........................•..................... 9
Basic Block Components 13
Camshaft ................................................ 11 Camshaft Bearings .......................................... 11 Camshaft Gears ............................................ 11 Connecting Rods ........................................... 13 Cooling System Components ......•............................ 19 Crankshaft ............................................... 13 Crankshaft Front Oil Seal ...................................... 11 Crankshaft Pulley ........................................... 10 Crankshaft Rear Oil Seal ...................................... 12 Cylinder Block ............................................. 13 Cylinder Head ............................................. 8 Cylinder Head and Valve Components ............................. 9
Engine Front Support ........................................ 10 Engine Removal and Installation ................................. 7 Exhaust Manifolds .......................................... 8
Fan Drive ................................................ 20 Flywheel ................................................. 12 Flywheel Housing ........................................... 12 Fuel Filter ................................................ 14 Fuel Priming Pump .......................................... 16 Fuel Injection Pump Housing ..........•........................ 17 Fuel System Components ...................................... 14 Fuel Transfer Pump ......................................... 16
Governor 14
Lubrication System Components ................................. 18
Main Bearings
Oil Cooler Oil Pump
Pistons
13
19 18
13
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Rings ................................................... 13 Rocker Arm and Push Rods .................................... 9
Service Guide .............................................. 4
Timing Gear Cover .......................................... 10 Timing Gears .............................................. 11 Torque Converter Oil Cooler .................................... 19
Valve Cover ............................................... 9 Valves .................................................. 9
Water Pump ............................................... 20 Water Temperature Regulator ................................... 19
3
SLEEVE METERING FUEL SYSTEM DISASSEMBL Y 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 Injection 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 Li miter ....................................................... 14-15 7
3
05 POWER TRAIN SPECI FICATIONS
INTRODUCTION
The specifications given in this book are on the basis of information available at the time the book was written. These specifications give the torques, operating pressure, measurements of new parts, adjustments and other items that will affect the service of the product.
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.
NOTE: The specifications given for "use again" and "permissible" are intended for guidance only and Caterpillar Tractor Co. hereby expressly denies and excludes any representation, warranty or implied warranty of the reuse of any component. 77200X1
NOTE: For Systems Operation and Testing and Adjusting, make reference to
the D5 TRACTOR POWER TRAIN, Form No. REG00660. For POWER
SHIFT TRANSMISSION TESTING AND ADJUSTING see Form No.
REG01333.
NOTE: The "e" is an indication of a change from the former issue.
INDEX
Adjustment of the Brakes............................... 17 Adjustment of Linkage for Control of the
Steering Clutches..................................... 16 Adjustment of the Parking Brake.. . .. . . . .. .. . . . .. .. .. . .. 17 Adjustment of Final Drive Sprocket Bearings.. .. . .. . . .. .. 24 Adjustment of the Track ................................ 28 Alignment of the Sprocket .............................. 31
Direct Drive Transmission: Adjustment of Bearings for Bevel Gear Shaft. .. . .. . . ... 20 Adjustment of Brake for Flywheel Clutch ............... 15 Adjustment of Flywheel Clutch........................ 14 Adjustment of Free Movement (Backlash)
of Bevel Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20 Adjustment of Interlock Linkage for
Flywheel Clutch.. . .. . . . . .. . . . . . . . . .. .. ... .. . . . .. . .. 15 Adjustment of Tooth Contact of Bevel Gear. . . . . . .. . . .. 21 Bevel Gear and Pinion.. . . . . . . . . . . .. .. . . . .. .. . . . . . . . .. 20 Flywheel Clutch...................................... 13 Flywheel Clutch and Controls. . . . .. .. ... . . .. ... .. .. ... 14 Oil Filter for Transmission. . .. . . . .. . . . .. .. . . . . . . .. . . ... 12 Oil Pump for Transmission. . . . . . . . .. . . . . . .. . . . . . .. . . .. 11 Relief Valve for Steering Clutch Control. . . .. .. . .. .. .. .. 16 Transmission......................................... 12 Universal Joint....................................... 13
Final Drives .......................................... 22, 23 Front Idlers and Recoil Springs:
2
Hydraulic-Type Track Adjuster. . . . . . .. .. . .. ... . . . . . . .. 26 Mechanical (Screw)-Type Track Adjuster. . . . . . . .. . . ... 25
Hydraulic Control Valve for the Steering Clutches.. . . . . .. 11
Power Shift Transmission: Adjustment of Bearings for Bevel Gear Shaft. . . .. . . .. .. 19 Adjustment of Free Movement (Backlash)
of Bevel Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 19 Bevel Gear and Pinion ............................... . Bypass Valve for the Oil Cooler ...................... . Checking and Adjusting Alignment of
Flexible Coupling Drive ............................ . Flexible Coupling Drives ............................. .
19 9
5 4
Lubrication Relief Valve............................... 10" Oil Filter Bypass and Steering Clutch Check Valve.. ... 10 Oil Filter for Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Oil Pump for Transmission ........................... . Torque Converter .................................... . Transmission ........................................ . Transmission Hydraulic Controls ..................... .
9 6 7 8
Rollover Protective Structure (ROPS) ................. . .. 32
Steering Clutch and Bevel Gear Case. .. .. . .. . . . . . . . . . . .. 17 Steering Clutch Group.................................. 18
Track.................................................. 27 Track Adjustment. . . . . . . . . . . . . . . .. . . . . . . .. . . . .. . . . . .. 28, 29 Track Carrier Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 30 Track Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 30 Track Roller Guards. . . . . . . . .. . . . . . . . .. .. . . . . . . . ... . . . .. 31
05 POWER TRAIN INDEX
SYSTEMS OPERATION
Flywheel Clutch (Direct Drive) .......................... 18 Operation ........................................ 18 Lubrication ...................................... 18
Gear Shift and Interlock Mechanism (Direct Drive) .......... 19 General Information:
Direct Drive ...................................... 5 Power Shift ...................................... 4
Hydraulic System (Power Shift) ......................... 6 Magnetic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7 Oil Filter ........................................ 8 Transmission Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7 Transmission Oil Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8
Steering Clutches, Brakes and Final Drives ................. 21 Brakes and Brake Control Linkage . . . . . . . . . . . . . . . . . . . .. 22 Final Drives ...................................... 21 Hydraulic Steering Booster Control ... . . . . . . . . . . . . . . . .. 22 Steering Clutches .................................. 21
Torque Converter and Transmission .. . . . . . . . . . . . . . . . . . . .. 12 Clutch Operation .................................. 15
Planetary Transmission .............................. 13 Power Flows ...................................... 14 Torque Converter .................................. 12
Transmission (Direct Drive) ............................ 20 Transmission Hydraulic Controls ........................ 9
Operation ........................................ 10 Transmission Lubrication System (Direct Drive) ............. 16
Magnetic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17 Oil Filter ........................................ 17
Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 23 Front Idlers ...................................... 24
Front Idler Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . .. 25 Recoil Springs and Mechanisms for Track Adjustment . . . . .. 25
Hydraulic-Type Track Adjuster . . . . . . . . . . . . . . . . . . . .. 25 Mechanical-Type Track Adjuster .................... 25
Track ........................................... 26 Track Carrier Rollers ............................... 23
Track Carrier Roller Lubrication . . . . . . . . . . . . . . . . . . .. 23 Track Rollers .... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 24
Track Roller Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Track Roller Frames ...... ; . . . . . . . . . . . . . . . . . . . . . . . . . 23
TESTING AND ADJUSTING
Bevel Gear and Pinion (Direct Drive): Adjustment of Bearings for Bevel Gear Shaft ............ . Adjustment of Free Movement (Backlash) .............. . Adjustment of Tooth Contact Pattern ................. .
Bevel Gear and Pinion (Power Shift): Adjustment of Bearings for Bevel Gear Shaft ............ . Adjustment of Free Movement (Backlash) .............. .
Flexible Drive Coupling .............................. . Flywheel Clutch (Direct Drive):
Adjustment of Brake .............................. . Adjustment of Flywheel Clutch ...................... . Adjustment of Interlock Linkage ..................... .
Hydraulic Tests for the Flywheel Clutch, Transmission
* * *
* *
*
* * *
and Steering Clutches (Direct Drive) ................... 31
Power Shift Transmission Testing and Adjusting. . . . . . . . . . . . . . . . . . . .. See Form No. REG01333
Steering Clutches, Brakes and Final Drives: Adjustment of Brakes .............................. . Adjustment of Control Linkage for Steering
Clutches ...................................... . Adjustment of Final Drive Sprocket Bearings ............ . Adjustment of Parking Brake Linkage ................. .
*
* * *
Troubleshooting (Direct Drive) .......................... 29 Checks During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .. 29 Check List During Operation .... . . . . . . . . . . . . . . . . . . . .. 29 Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 29
Troubleshooting (Power Shift) .......................... 27 Checks During Operation . . . . . . . . . . . . . . . . . . . . . . . . . . .. 27 Check List During Operation ... . . . . . . . . . . . . . . . . . . . . .. 27 Visual Checks ..................................... 27
Undercarriage: Adjustment of Final Drive Sprocket Bearings ............ . * Adjustment of Track .............................. . * Alignment of Track Roller Frame .................... . *
*See SPECIFICATIONS, FORM NO. SENR7340
SPECIFICATIONS
NOTE: For Specifications with illustrations, make reference to the SPECIFICATIONS FOR D5 POWER TRAIN Form No_ SENR7340. If the
Specifications in Form SENR 7340 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
STEERING CLUTCHES, BRAKES AND FINAL DRIVES
SYSTEMS OPERATION
STEERING CLUTCHES, BRAKES AND FINAL DRIVES
STEERING CLUTCH
1. Bevel gear shaft. 2. Bevel gear. 3. Coupling assembly. 4. Steering clutch shaft. 5. Steering clutch driving drum. 6. Release bearing assembly. 7. Pressure plate. 8. Driving discs. 9. Plate assemblies.
The main components of the steering clutches and final drives are: bevel gear (2), bevel gear shaft (1), steering clutch driving drum (5), plate assemblies (9), driving discs (8), steering clutch driven drum (10) [also the brake drum], final drive pinion (12), final drive gear (13), sprocket shaft (17) and sprocket (16).
STEERING CLUTCHES
The bevel gear and steering clutches are in the bevel gear and steering clutch case. The bevel gear case is the reservoir for the transmission and steering hydraulic systems. As the bevel gear turns, lubricant is thrown on the bevel gear, bevel pinion and steering clutches for lubrication. The bearings for the bevel gear shaft get lubrication from the control valve for the steering clutches.
The bevel pinion shaft in the transmission turns bevel gear (2). Coupling assemblies (3), on the ends of bevel gear shaft (1) connect with steering clutch shafts (4). Each steering clutch shaft is connected with splines into the hub of a steering clutch driving drum (5).
With a steering clutch engaged, the force of the springs keeps pressure plate (7), driving discs (8) and plate assemblies (9) against steering clutch driving drum (5). Power goes from the driving drum, through the discs to the driven drum. The steering clutches are normally engaged.
With a steering clutch released, release bearing assembly (6) moves toward bevel gear (2). This action releases the force of the springs and separates driving discs (8) from plate assemblies (9).
10
14
STEERING CLUTCH DRIVEN COMPONENTS
10. Steering clutch driven drum [also brake druml. 11. Pinion flange. 12. Final drive pinion. 13. Final drive gear. 14. Brake band. 15. Final drive hub.
Driving discs (8), plate assemblies (9), steering clutch driving drum (5) and pressure plate (7) are inside steering clutch driven drum (10). Teeth on the outer diameter of each plate assembly are engaged with teeth in the steering clutch driven drum.
FI NAL DRIVES
Steering clutch driven drum (10) connects to pinion flange (11) on final drive pinion (12). Final drive hub (15) is connected with splines into sprocket (16). Sprocket (16) turns the track to move the tractor.
FINAL DRIVE
10. Steering clutch driven drum [also brake druml. 12. Final drive pinion. 13. Final drive gear. 15. Final drive hub. 16. Sprocket. 17. Sprocket shaft. 18. Duo-Cone seals. 19. Adjustment nut for the final drive bearings. 20. Support.
21
INDEX DISASSEMBLY AND ASSEMBLY
05 POWE R TRAI N
Adjustments: Aligning Track Roller Frame With Sprocket .......................... 64, 75 Bevel Gear Backlash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 54 Bevel Gear Shaft Bearing Preload. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 53 Checking Flexible Drive Coupling Alignment (Power Shift) .................. 25 Front Idler Alignment .......................................... ; .... 68 Hydraulic Track Adjuster ............................................ 74 Steering Clutch Booster .............................................. 51
Battery ............................................................. 79 Bevel Gear Backlash Adjustment ......................................... 54 Bevel Gear and Shaft Removal & Installation ................................ 53 Bevel Gear, Steering Clutches, Brakes and Final Drive ......................... 53 Bevel Gear Shaft Coupling .............................................. 55 Bevel Gear Shaft Disassembly and Assembly ........................... -..... 55 Brake Bands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 56
Dash Removal ....................................................... 70 Drawbar Removal (Stationary) ........................................... 82
Equalizer Spring ...................................................... 75
Fenders ............................................................. 81 Final Drive Disassembly ................................................ 60 Final Drive Pinion .................................................... 58 Final Drive Removal as a Unit ........................................... -59 Flexible Coupling Drive (Direct Drive) ..................................... 25 Flexible Coupling Drive, Checking Alignment (Direct Drive) .................... 25 Flywheel Clutch (Direct Drive) .......................................... 11 Flywheel Clutch Removal (Direct Drive) ................................... 11 Flywheel Clutch Disassembly (Direct Drive) ................................ 12 Front Idler ....................................................... 67,70 Fuel Tank ........................................................... 80
Hood Removal .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Hydraulic Track Adjuster, Filling and Bleeding .............................. 74
Installing Track ...................................................... 66
Magnetic Screen (Power Shift) ........................................... 43 Magnetic Strainer (Direct Drive) .......................................... 22
Oil Filter (Direct Drive) ................................................ 24 Oil Pump, Transmission (Direct Drive) ..................................... 21 Oil Pump, Transmission (Power Shift) ..................................... 46
Planetary Transmission Removal (Power Shift) .............................. 36 Planetary Transmission Disassembly (Power Shift) ............................ 37
Recoil Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Relief Valve, Transmission (Direct Drive) ................................... 21 Relieving Track Tension ................................................ 65
Seat Cushion .............• ' ........................ __ ................ 79 Seat, Fuel Tank and Miscellaneous ........................................ 77 Separating Track ..................................................... 65 Service Guide-Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7 Service Guide-Power Train (Direct Drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5 Service Guide-Power Train (Power Shift) .................................. 6 Sprocket Segments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 63 Steering Clutch ....................................................... 56 Steering Clutch Booster ................................................ 51 Steering Clutch Controls ............................................... 51
3
INDEX DISASSEMBLY AND ASSEMBLY
05 POWER TRAIN
Torque Converter Cover Assembly (Power Shift) ............................. 29 Torque Converter Disassembly ........................................... 30 Torque Converter, Transmission and Transfer Gears
(Power Shift) ...................................................... 27 Track Adjusting Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 73 Track Carrier Rollers ............................................... 67, 69 Track Disassembly .................................................... 66 Track Installation ..................................................... 66 Track Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 67, 69 Track Roller Frame Removal ............................................ 74 Track, Separating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 65 Transfer Gears (Power Shift) ............................................ 33 Transfer Gears Disassembly (Power Shift) .................................. 34 Transmission Controls ................................................. 20 Transmission and Controls (Direct Drive) ................................... 15 Transmission Disassembly (Direct Drive) ................................... 16 Transmission Hydraulic Controls (Power Shift) ............................. 48 Transmission Lubrication & Hydraulic Control Components
(Power Shift) ...................................................... 43 Transmission Lubrication System Components (Direct Drive) ................... 21 Transmission Oil Filter, Filter Bypass and Check Valve and
Relief Valve (Power Shift) ............................................ 44 Transmission Removal (Direct Drive) ...................................... 15
Undercarriage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Universal Joint (Direct Drive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9
4
_ , -- 153 HYDRAULIC CONTROL
Blade Tilt Circuit
Double Valve Tank
Hold Position
Introduction
Hydraulic System Test Procedures
Introduction
Lift Circuit Drift Test
Operational Checks Operational Check List
Bolt, Nut and Taper Lock Stud Torque
Control Valve Cylinders
External Control Valve
2
SYSTEMS OPERATION
6
5
4
3
Make-up Valves ........................... .
Pressure Relief Valve
Ripper Circuit ..... .
Single Valve Tank
TESTING AND ADJUSTING
9 Pressure Relief Valve
8 Pump
9 Ripper Circuit Drift Test
8 Tilt Circuit Drift Test
......... 8 Visual Checks
SPECIFICATIONS
13
14 15
14
Oil Filter.
Pump
Relief Valve
. INDEX
5
5,7
6
4
10 9
10
9
8
14
14
15
153 & 163 HYDRAULIC CONTROL SPECIFICATIONS
2
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. 77200
NOTE: For Systems Operation and Testing and Adjusting, make reference to
153 & 163 HYDRAULIC CONTROL, Fonn No. REG01226.
INDEX
Control Valve (Double) (8J1835) .......................................... 6
Control Valve (Single) (8J3555) ........................................... 5
Cylinders ............................................................ 7
Hydraulic Oil Pump (For D6 Tractor) ...................................... 4
Hydraulic Oil Pump (For D5 Tractor) ...................................... 4
Make·up Valve (Anti·Cavitation) .......................................... 5
Oil Filter ............................................................ 7
Pressure Relief Valve ................................................... 6
153 & 163 HYDRAULIC CONTROL TESTING AND ADJUSTING
SYSTEMS OPERATION
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5 Operation in Hold Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8 Operation of the Double Valve Tank & Double
Valve Tank with External Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9 Blade Lift Circuit ................................................ 9 Blade Tilt Circuit ................................................ 10 Ripper Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10 Ripper Control Valve External ...................................... 10 Ripper Control Valve in Tank ....................................... 10
Operation of the Single Valve Tank ........................................ 8 Blade Lift Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8 Make-up Valve (Anti-Cavitation Valve) .................................. 8 Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9
TESTING AND ADJUSTING
Checking Pump Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11 Hydraulic System Test Procedures ........................................ 12
Lift Circuit Drift Test ............................................... 12 Pump ............................................................ 12 Ripper Circuit Drift Test ............................................. 13 Tilt Circuit Drift Test ............................................... 13
Introduction ........................................................ , 11 Operation Checks ..................................................... 12 Test on the Bench .................................................... 12 Test on the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11 Testing the Pressure Relief Valve ......................................... 13 Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11
DISASSEMBLY AND ASSEMBLY
Alphabetical Index .................................................... 15 One Valve Tank ...................................................... 17 Service Index ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 16 Two Valve Tank ...................................................... 28
SPECIFICATIONS
NOTE: For Specifications with illustrations, make reference to the HY
DRAuLIc SPECIFICATIONS for 153 & 163 HYDRAULIC CONTROL,
Form No. REGOI693. If the Specifications given in Form REG01693 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
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.
ONE VALVE TANK Control Lever Bearing Housing ........................... . Control Lever Bearing Housing, Disassemble and Assemble ......... . Filler Cap and Strainer, Disassemble and Assemble ............. . Filter Cover, Disassemble and Assemble .................... . Lift Cylinder Control Valve ............................. . Lift Cylinder Control Valve, Disassemble and Assemble ........... . One Valve Tank ..................................... .
No. No.
17 25 26 24 24 17 19 17
6 7 5 4 2 3
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
15