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CT-S-922TX94A1
CCaatteerr ppii ll llaarrService Manual
922 TraxcavatorS/n 94A, 88J1,
74J1 & 97A1 & up
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
9A-S Group 10.9
SERVICE MANUAL
for
CATERPILLAR ®
922 TRAXCAYATOR
SERIAL NUMBERS 94A 1 -UP
Section
Engine _ _ _ _ _ _ _ _ _ _ _ __ _ _ _ _ __ _ __ _ _ _ _ __ _ __ __ _ _ __ __ __ _ _ _ _ _ _ _ _ _ _ __ ____ _ __ _ _ _ _ _____ _ __ __ 10
Starting Engine _ _ ____ _ _ __ ____________________________________________________ 20
Power Transmission Units ______________________________________________ 30
Air System and Brakes __________________________________________________ 50
Traxcavator Portion _____ ______ _ __________________________________________ 120
Seat, Fuel Tank and Miscellaneous ________________________________ 200
Page 1.
PRINTED IN U.S.A.
lAoS SERVICE MANUAL
GENERAL INSTRUCTIONS
Group 30 Page?
3. Install the assembled tube onto the tube end of the body, finger-tight. Tighten the nut positioning the body. Then tighten the nut on the tube assembly.
Assembly of Sleeves onto Tubes
Type A
It is necessary to preset this type of sleeve onto the tube before the tube assembly is installed on the fitting body.
Typical example of a sleeve-type fitting. Parts are: I-Tube. 2-Nut. 3-S1eeve. 4-Presetting tool. 5-Shoulder of tool (4).
1. Lubricate the sleeve and the threads on presetting tool and nut.
NOTE
Presetting tools are commerically available; however, the fitting body can be used in place of a presetting tool. If the fitting body is used, the body should be removed from the machine to permit satisfactory presetting.
2. Place the nut on the tube with the threaded end of the nut toward the end of the tube.
3. Place the sleeve onto the tube so the shorttapered heavy end faces the presetting tool as illustrated.
4. Bottom tube end against shoulder of tool.
5. Assemble the nut to the tool finger-tight. Then tighten the nut until the threads on the tool are no longer visible.
6. Remove the tube from the presetting tool. Check to be certain sleeve .does not move longitudinally. (The sleeve can rotate on the tube.)
7. When the tube assembly is assembled onto the fitting body, tighten the nut until the threads on the body are no longer visible. Refer to the topic FITTING BODIES WITH STRAIGHT THREADS AND O-RING SEALS for the installation of the fitting bodies.
TypeB
1. Place the nut and sleeve onto the tube. Install the sleeve so the thick end faces away from the body.
2. Install the insert into the tube.
Typical example of sleeve and insert-type fitting. Parts are: I-Nut. 2-Tube. 3-S1eeve. 4-Insert. S-Fitting body.
3. Bottom the tube and insert in the body as illustrated.
4. Tighten the nut lliz turns past finger-tight.
TypeC
T88384
Typical example of a shear-type fitting. Parts are: I-Nut. 2-S1eeve. 3-Fitting body. 4-Tube.
With the nut and sleeve installed loosely in the body, install the tube through the nut and sleeve until the end of the tube is seated against the shoulder in the fitting body.
Grip the tube firmly to prevent twisting or turning and tighten nut until a slight "give" or decreased resistance is felt. The "give" indicates that the sleeve has been sheared from the nut. Tighten the nut an additional lliz turns. It is not necessary to tighten the nut all the way down.
Hydraulic Valves Examine ~ll valves, valve bores and valve seats
for nicks, burrs and/or scratches. (Rough spots may be removed with a crocus cloth or fine emery
ENGINE
'I ABLE OF CON'IEN'IS
Index .......
Specifications
Cooling System
Water Temperature Regulator
Fan Group
Water Pump
Radiator .... '"
Lubricating System
Oil Pan and Oil Pan Plate
Oil Pump
Oil Cooler ..........
Oil Filter
Fuel System
Fuel Supply Equipment
Fuel Injection Equipment
Governor.
Accessory Drive
Air Induction and Exhaust System
Cylinder Head
Valve and Valve Mechanism
Front Support ..
Timing Gears
Pistons, Rings and Connecting Rods
Cylinder Liners
Main Bearings
Crankshaft
Balancer
. Flywheel and Flywheel Housing
Engine Removal and Installation
Electrical System
Air Compressor Removal and Installation
Air Compressor . . . . . . .
Section
9A-1O
9A-IO
9A-IO
9A-1O
9A-1O
9A-1O
9A-IO
9A-IO
9A-1O
9A-IO
9A-1O
9A-1O
9A-1O
9A-1O
9A-1O
9A-1O
9A-IO
9A-IO
9A-IO
lOA-IO
9A-IO
9A-1O
9A-1O
9A-IO
9A-10
9A-1O
9A-10
9A-10
9A-1O
9A-1O
9A-IO
9A-10
9A-1O
Group
30.9
40.9
70.6
100.6
130.8
140.10
160.7
170.12
180.8
190.6
200.5
210.12
230.8
240.10
250.6
260.11
265.13
270.14
280.13
290.2
310.2
320.9
340.4
350
360.1
370.1
380.3
390.9
400.8
410.8
420.2
421.2
Group 20.9
Page 1
A
Adjustments: Fuel Injection Pump Lifter Fuel Rack Setting Governor .. ' .. Rack Limiter Valve <Exhaust and Inlet> Variable Timing ....... .......... .
Aftercooler .. ' ............... . Air Cleaner Alternator ...................... ... . Alternator, Removal
Belt, Alternator Drive Belt Tension ..... Bearings:
B
Connecting Rod ....... .......... . Main ............................ .
Bell, Suction ...... . ........... . Breather, Crankcase ............... . Bypass:
Fuel ................. . Oil Cooler Oil Filter
Cam Follower Camshaft Assembly Camshaft Gear Chambers, Precombustion Cleaner, Air Cleaning:
Engine Valves Fuel Injection Valve Pistons
C
Temperature Regulators Clearances and Tolerances Compression Release Mechanism Clutch, Fan Drive ....... . Compression Release Shaft Seal Connecting Rods and Bearings Coolers, Oil Cooling System Cover, Front Crankshaft Crankshaft Pulley Cylinder Head Cylinder Liners
Damper, Vibration Drive:
Service Meter Tachometer
Engine Data
D
E
Engine Removal and Installation Exhaust Manifold
12A-IO Group 30.9 Page 1
ENGINE INDEX
Group Page
250.5 260.7 260.7 253.3 290.2 257.3 270.6 270.6 411 410.6
410.6 410.6
6 6 6 2 3 2 5 6 1
340.1 3 360 1 190.2 - 2 210.6 - 2
240.5 - 1 210.6 - 1 210.6 - 1
290.2 - 3 290.2 1 320.6 2 280.6 2 270.6 - 6
290.2 - 4 250.5 340.1 100.6 40.6
290.2 130.4 280.6 340.1 200.6
70.7 310.2 370.1 300.4 280.6 350
300.4
267.1 267.1
40.6 400.7 270.6
1 2 1 1 6 1 1 2
5
F Group Page
Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130.4 1 Fan Drive Clutch Filters:
. . . . . . . . . . . . . . . . . . . . . . . . .. 130.4
Fuel Oil
Flow of Air, Reversing ..................... . Flow of Coolant . . . . . . . . . . ........... . Flow of Fuel .............................. . Flow of Lubricating Oil ................... . Flywheel ................................. . Flywheel Housing ......................... . Follower, Cam ........................... . Front Cover ............................ . Front Support, Engine ..................... . Fuel:
Bypass Injection:
Equipment " . ... .. . . ........ . Pumps .............. . ........ . Pump Housing ....................... . Pump Lifter Setting ...... . . . . . . . . . . . . . .. Valve ................................ .
System, Diesel Transfer Pump Priming Pump
Gauge, Fuel Gears:
Camshaft: Drive Idler
G
Crankshaft ............................. . Hydraulic Pump:
Drive Idler
Ring, Flywheel Timing Timing Marks Transmission Pump:
Drive Idler Variable Timing:
Drive Idler
Glow Plugs Governor:
Adjustments Operation Seals
Guides, Valve
Head, Cylinder Housing:
Flywheel Fuel Injection Pump .. Governor Timing Gear,
Hydraulic Pump: Drive Gear Idler Gear
. . . . . . . .
H
........
240.5 2 210.6 1 13D.4 - 2
70.7 1 230.4 - 1 170.5 - 1 390.4 - 1 320.6 - 1 290.2 - 3 310.2 - 1 310.2 - 1
240.5
250.5 - 1 250.5 1 250.5 - 2 250.5 - 6 250.5 - 1 230.4 - 1 240.5 - 1 240.5 - 2
230.4 - 1
320.6 - 2 320.6 - 2 370.1 - 1
320.6 - 4 320.6 4 390.4 1 320.6 6 320.6 6
320.6 5 320.6 5
320.6 - 4 320.6 3 280.6 3
260.7 6 260.7 260.7 290.2 5
280.6
320.6 250.5 - 3 260.7 - 2 320.6 - 1
320.6 - 4 320.6 - 4
Group 30.9
Page 2
12A-IO ENGINE
INDEX
Group Page s Group Page
Injection: Pumps Valve
L
Lifter Setting, Fuel Injection Pump Limiter, Rack Limiter, Speed Liners, Cylinder Lubricating System Lubrication:
Piston and Ring Timing Gear ....
Main Bearings Manifold, Exhaust Meter, Service .. Motor, Starting
Oil: Bypass Valve Coolers Filters Pan Pump Pump Suction Bell Thrower ..
Operating Difficulties:
M
o
Engine Coolant Overheating Engine Fuel System Engine Lubricating System
Overflow, Sealed Pressure Overheating, Coolant
p
Pan, Oil ............................ . Pan, Scavenge Oil Pistons ..... Piston Pin Bearing Piston Rings Precombustion Chambers Primary Fuel Filter . . .. Pump:
Fuel: Injection Priming Transfer
Oil Water
Pressure Gauge, Oil Pressure, Oil Pressure Ratio Control
Rack Limiter Radiator.
R
Removing Ring Ridge in Cylinder Liners Regulators, Water Temperature ........ . Release Compression Reversing Air Flow Ring Gear, Flywheel Rings, Piston Rod, Connecting Running-in Schedule
250.5 250.5
1
250.5 - 6 253.3 1 260.7 5 350 1 170.5
340.1 170.5 2
360 270.6 267.1 410.6
210.6 200.6 210.6 180.4 190.2 190.2 370.1
70.7 230.4 170.5 160.7 -70.7 -
180.4 180.4 340.1 340.1 340.1 280.6 240.5
1 5 1 1
1 2
1 2 1
1 1 1 3 2 2 2
250.5 - 1 240.5 - 2 240.5 1 190.2 1 140.4 1 170.5 2 170.5 2 270.6 2
253.3 - 1 160.7 - 1 350 2 100.6 - 1 290.2 - 6 130.4 - 2 390.4 - 1 340.1 - 2 340.1 2 340.1 - 2
Scavenge Oil Pan ........................ . Sealed Pressure Overflow Seals:
Cylinder Liner .......................... . Compression Release Shaft Governor Turbocharger
Service Meter ...................... . Setting Fuel Pump Lifter ............ . SpeCifications Speed Limiter Speed Sensing Variable Timing ............. . Starting Motor . . . . . . . . .. . .. Suction Bell .................. . Support, Engine Front
T
Tachometer Drive .. Testing Temperature Regulators Thrower, Oil ................ . Thrust Bearing, Crankshaft Timing:
Engine Gears Engine Valves Fuel Injection Variable Timing
Timing Gear Housing Timing Gears Timing Marks Tolerances Turbocharger Turbocharger Disassembly Turbocharger Lubrication Turbocharger Lubrication Valve Turbocharger Removal ...
v Valve:
Adjustment (Exhaust and Inlet) Bypass, Fuel ............ . Bypass, Oil Cooler ........ . Bypass, Oil Filter Fuel Injection Guides Inspection and Reconditioning Operation Pressure Regulator, Oil Pump Rotators ............. . Seat Specifications Timing Turbocharger Lubrication
Valves and Valve Mechanism Variable Timing Gears:
Drive Idler
Variable Timing, Speed Sensing Vibration Damper
Water: Seal and Ferrules Pump
Seal Replacement Temperature Regulator
w
180.4 160.7
350 1 280.6 1 260.7 - 1 271 - 2 267.1 - 1 250.5 - 6
40.6 - 1 260.6 - 5 257.3 1 410.6 - 1 190.2 - 2 310.2 - 1
267.1 100.6 370.1 370.1
320.6 290.2
6 6
250.5 - 7 257.3 - 1 320.6 - 1 320.6 6 320.6 6
40.6 1 271 1 271 2 170.5 210.6 270.6 4
290.2 - 3 240.5 - 2 210.6 1 210.6 - 1 250.5 - 1 290.2 - 5 290.2 - 4 290.2 - 1 190.2 - 2 290.2 - 1 40.6 - 4
290.2 - 6 210.6 - 2 290.2 - 1
320.6 - 4 320.6 - 3 257.3 - 1 300.4 - 1
280.6 - 2 '140.4 - 1 140.4 - 1 100.6 - 1
"-.
9A-IO ENGINE
Group 340.4 Page 3
PISTONS. RINGS AND CONNECTING RODS
Parts service connecting rods and rod caps with no cylinder number marks must be stamped or etched to assure correct installation of the rods.
CONNECTING ROD AND PISTON PIN
Removing and Installing Connecting Rod Bearings
The connecting rod bearings can be removed, inspected and replaced through the inspection opening on the side of the block without removing the rod and piston assembly from the engine.
1. Drain the engine lubricating oil and coolant.
2. Remove all items interfering with the removal of the inspection cover.
3. Remove the inspection cover and rotate the engine crankshaft until the bearing to be removed is accessible.
4. Remove the cotter pins and nuts from the connecting rod bolts and remove the cap and bearing lower half.
CAUTION
Be sure the connecting rod beari...'1g halves are reinstalled in their original location if they are not replaced with new bearings.
5. Remove the bearing upper half by turning the crankshaft or pushing the rod up slightly.
REMOVING CONNECTING ROD BEARING CAP
6. Inspect the connecting rod bearings. See the covering topic.
7. Before installing the bearing cap be sure the protruding tab on the back of each bearing half lines up with its corresponding recess in the connecting rod and bearing cap. This locks the bearing in place and keeps it from rotating.
CAUTION
Wipe the back of bearing halves and the rod bearing bore surface dry before installing the bearing halves to allow the bearing to seat properly and have the correct installed clearance.
Lubricate the bearing surface and install the cap with the identifying cylinder number toward the inspection opening and tighten the cap nuts to the torque value listed in the SPECIFICATIONS.
Tighten the nut additionally to align the nearest cotter pin hole and install new cotter pins.
Connecting Rod Bearing Inspection
Connecting rod bearings are steel-backed, aluminum-lined. Larger particles of dirt and abrasives in the oil do not tend to embed in aluminum bearings. Such particles roll around between the bearing and crankshaft journal causing scratches in the aluminum bearing without actually becoming embedded in the aluminum. Such scratches are not necessarily harmful and do not indicate that the bearings should be replaced.
If there is any question about the surface of a bearing, wash it with cleaning solvent to remove the oil. If the surface feels rough and abrasive, install a new bearing. Another indication of dirt in the bearing is excessive crankshaft wear.
Undersize connecting rod bearings are available for reground crankshafts. Clearances and tolerances for undersized as well as new connecting rod bearings are listed in the SPECIFICATIONS.
Bent rods should be discarded. Do not attempt to align the connecting rods by bending them.
Connecting rod bearing clearance can be measured by installing the lower bearing half and cap in place with a piece of SBl161 Lead Wire between the crankshaft and the bearing. The lead wire should extend across the width of the bearing and may be held in place with grease when installing the cap. Tighten the cap bolts to the torque value listed in the SPECIFICATIONS, then remove the ,cap and measure the thickness of the def0rmed wire. If the clearance exceeds the permissible value in the SPECIFICATIONS, or if the engine is being recon-
9A-20 Group 20.6 Page I
STARTING ENGINE
TABLE OF CONTENTS
Section Group
Index ................................................. 9A-20 30.6
Specifications ......................................... 9A-20 40.2
Lubrication System .................................... 10A-20 90.1
Fuel System .......................................... 10A-20 100
Cylinder Head and Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9A-20 110.1
Pistons, Ring and Connecting Rods. . . . . . . . . . . . . . . . . . . . .. 9A-20 120.1
Timing Chain Housing ............................. 9A-20 130.3
Magneto (Wico) ................................ 12A-20 135
Crankshaft and Main Bearings ................ . 9A-20 140.1
Starting Mechanism .................................. . 9A-20 160.2
9A-20 Group 30.6 Page 1
STARTING ENGINE
Adjustments: Carburetor Clutch . Control Mechanism Governor Valve Clearance
Bearings: Connecting Rod Main Piston Pin
Brake, Starter Pinion
Cable, Starter Camshaft Camshaft End Clearance Carburetor Chain, Timing Clearances and Tolerances
A
B
C
Cleaning Valves ..................... . Clutch Clutch Pinion and Brake Control Connecting Rods. . ....... . Connecting Rod Bearings Crankshaft Crankshaft End Clearance Cylinder Head Cylinder Bore
Data, Engine
Fuel System
Gear: Oil Pump
Governor
Head, Cylinder Housing:
Starter Pinion Timing Chain
Lifters, Valve Lubricating System
D
F
G
H
L
INDEX
Group Page M Group Page
100 2 160.2 5 160.2 - 6 130.3 - 4 110.1 - 2
120.1 140.1 120.1 160.2
1 2 1 3
130.3 2 130.3 - 5 130.3 6 100 1 130.3 2 40.2
110.1 2 160.2 - 4 160.2 5 120.1 120.1 140.1 1 140.1 - 2 110.1 I 120.1 - 2
40.2 - 1
100
90.1 130.3
110.1
- 1
3 3
160.2 - 1 130.3 2
110.1 - 2 90.1 - 1
Magneto: Adjustment Bearing Removal ................. . Disassembly and Assembly .......... . Impulse Drive Coupling ................ . Operation ........... . Maintenance Test Equipment Timing
Main Bearings Mechanism, Valve
Oil: Filter
o
Pump ............ . Pump Pressure Regulating Valve
Pan, Oil Pinion, Starter Pinion Mechanism Pistons Piston Pin Bearings Pressure Regulating Valve Pump, Oil
Recoil Starter Rings, Piston Rocker Arms Rods, Connecting
Specifications Starter Cable Starter Pinion Starter Pinion Brake Starter, Recoil Starting Engine Ring Gear Starting Mechanism
Timing Chain Timing Chain Housing Timing the Engine Tolerances
Valve: Clearance Adjustment
p
R
S
T
v
Lifters ......................... . Mechanism Pressure Reg'ulating Rocker Arms
135 - 5 135 4 135 2 135 3 135 - 1 135 - 5 135 - 5 135 6 140.1 2 110.1 1
90.1 - 2 90.1 - 3 90.1 - 4
90.1 - 3 160.2 1 160.2 1 120.1 2 120.1 - 1
90.1 - 4 90.1 - 3
130.3 120.1 2 11 0.1 1 120.1 - 1
40.2 - 1 130.3 - 2 160.2 1 160.2 3 130.3 -140.1 130.3 -
130.3 - 4 130.3 - 2 130.3 - 6 40.2
110.1 - 2 110.1 2 110.1 - 1 90.1 - 4
110.1 - 1
9A·20 STARTING ENGINE
SPECIFICATIONS
Group 40.2 Page 1
See the topic SPECIFICATIONS in the GENERAL INSTRUCTIONS
Bore and stroke ................. 23fa in. x 23fa in.
High idle speed. . . . . . . . . . . . . . . . . . . . .. 4150 RPM
Low idle speed 2200 RPM
Camshaft Journal Diameter ............... 1.498· 1.499 in. Bearing bore .................. 1.500 . 1.503 in. Bearing clearance ................ .001 - .005 in. Permissible clearance .................. .006 in. End clearance .. . . . . . . . . . . . . . . . . .. .001 - .005 in. Permissible end clearance. . . . . . . . . . . . .. .0lD in.
Clutch Clutch springs: Free length . . . . . . . . . . . . . . . . . . . . . .. 2 11/64 in. Lbs. force . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 69 - 81
When compressed to ................. 1 % in. Adjustment: Clearance between spherical
head of adj usting screw in release lever and the clutch spring retaining plate ................. .055 - .065 in.
Clearance between brake back-up plate and rollers . . . . . . . . . . . . . . . . .. .030 in.
Free travel in linkage assembly . . . . . . .. .030 in.
Connecting Rod Connecting rod bearing clearance
(With lead-tin overlay) ......... .0009 -.0031 in. Permissible bearing clearance ....... . .. .005 in. Bolt nut torque ................. 180 - 220 lb. in. Center-to-center distance . . . . . . .. 3.839 - 3.841 in. Bore in piston pin bearing. . . . . .. .5409 - .5415 in.
Crankshaft Main journal diameter ........ 1.7497 - 1.7503 in. Permissible main journal wear ........ .0065 in. Main bearing clearance Front (with lead-tin overlay) .... .0005 - .0050 in. Rear (With lead-tin overlay-clearance to be measured vertically) ................... .0022 - .0035 in.
Permissible bearing clearance (front) .007 in. Permissible bearing clearance (rear) .... .008 in. End clearance ................... .002 - .013 in. Permissible end clearance . . . . . . . . . . . . .. .019 in. Main bearing bolt torque (rear) 28 - 30 lb. ft. Connecting rod journal diameter ................... 1.3747 - 1.3753 in.
Permissible rod journal wear . . . . . .. .0045 in. Permissible out-of-round .............. .0025 in. Gear and sprocket retaining bolt torque ..................... 118 - 142 lb. ft.
Cylinder Bore Diameter . . . . . .. ............ 2.376 - 2.377 in. Cylinder bore wear limit (out-of-round) .. .003 in. Cylinder bore wear limit (taper) ....... .005 in. Cylinder diameter for .020" oversize piston ....... 2.396 - 2.397 in.
Cylinder diameter for .040" oversize piston ........... 2.416 - 2.417 in.
Cylinder Head Bolt torque ....................... 31 - 39 lb. ft.
Magneto Point gap
Oil Filter Base Valve spring:
.015 in.
Free length .......................... .887 in. Lbs. force ......................... 6.73 - 6.79
When compressed to ................ .783 in. Oil pressure, minimum PSI at high idle 40
Oil Pump Clearance between gears and end
covers (total) .................... .001 - .003 in. Shaft diameter ................. .4919 - .4925 in. Bearing bore ................... .4930 - 4936 in. Bearing clearance .............. .0005- -.0017 in. Permissible bearing clearance .......... .006 in. Pressure relief spring: Free length .......................... .887 in. Lbs. force. . . . . . . . . . . .. . . . . . . . . . . . .. 17.5 - 18.5 When compressed to ................ .611 in.
Pinion Mechanism Gear backlash between pinion drive gear and clutch gear (through idler) .................. .004 - .021 in.
Idler gear bearing diameter (ID) ............... 1.1255 - 1.1275 in.
Bearing clearance .............. .0225 - .0255 in. Permissible bearing clearance .......... .030 in. Overrunning clutch gear bearing: Diameter (ID) ............... 1.9488 - 1.9494 in. Bearing clearance ............. .0005- .0040 in. Permissible clearance ................. .006 in.
Plunger spring: Free length ......................... 1.235 in. Lbs. force ....................... 28.71 - 30.29
When compressed to ............... .739 in. Pinion shaft bearing bore (inner) .8755 - .8775 in. Bearing clearance .............. .0015 - .0045 in. Permissible clearance ................. .012 in. Pinion return spring (Conical): Free length ........................ . Lbs. force ................... . When compressed to ...... .
Piston Pins
2.375 in. 60 - 70
.560 in.
Clearance in rod bearings .0007 - .0017 in. Permissible clearance in rod .......... .0030 in. Clearance in piston ............ .0004 - .0012 in. Permissible clearance . . . . . . . . . . . .0025 in.
Piston Rings Compression ring gap . . . . . . . . . . .. .0lD - .023 in. Oil ring gap ..................... .0.10 - .023 in. Compression ring side clearance. .0020 - .0035 in. Oil ring side clearance. . . . . . ... .. .0015 - .0031 in. Permissible side clearance . . . . . . . . . . . . .. .005 in.
30e-30
POWER TRANSMISSION UNITS
TABLE OF CONTENTS
Section Group
Index ................................................ 30C-30 30
Specifications ....................................... . 30C-30 40
Transmission Hydraulic Control Testing and Adjustment ....... . 30C-30 42
Drive Shafts and Universal Joints ...................... . 19C-30 70
Torque Converter Removal ...................... . 30C-30 90
Transmission, Torque Converter and Range Selector Removal ...... . ................ . 30C-30 95
Torque Converter 30C-30 100
Transmission Hydraulic Control 30C-30 105
Transmission ... 30C-30 120 \
Transmission Lubrication System .................. . 30C-30 130
Range Selector 30C-30 135
Bevel Gear 19C-30 140
Differential 30C-30 150
Final Drive 30C-30 160
Axles and Wheels . 30C-30 170
Steering 30C-30 190
Group 20
Page 1
30C-30
POWER TRANSMISSION UNITS
INDEX
A Group Page G
Adjustments: Bevel Gear Backlash .... ................ . Bevel Gear and Pinion Setting ........ . Differential Bearing ...................... . Differential Pinion .................... . .. . Drag Link .............................. . Pressure Relief Valve, Transmission Range Selector Linkage ........ . Range Selector Rear Yoke. . . . . . . . ...... . Rear Bellcrank Bearings ....... . Rear Spindle Trunnion Bearing ............ . Steering .......................... . Steering Booster Pressure Relief Valve ..... . Steering Gear ........................... . Torque Converter Maximum Pressure
Relief Valve .............. . Transmission Hydraulic Controls
Wheel Bearing Axles and Wheels Axles:
Front Housing and Spindle, Rear Rear ...
Bevel Gear Backlash
B
Bevel Gear and Pinion Setting
c
Checking Hydraulic Control Pressure Relief Valve
Clearances, Checking Torque Converter Clearances and Tolerances Clutch Operation, Transmission Clutch Operational Check Clutches, Transmission Converter, Torque Converter Removal, Torque ........ . Control, Transmission Hydraulic
Differential Dimensions Drive Shafts
Filter, Transmission Oil Final Drive
Wheel Bearing Adjustment Gear, Ring Planet Gear Carrier
o
F
140 140 150 150 190 105 135 135 190 190 190 190 190
100 105 42
170 170
170 190 190
140 140 140
105 100 40
120 120 120 100
90 105
150 40 70
130 160 170 160 160
1 1 4 2 6 4 5 4 7 9
-13 5 2
5 4 3
1 9
-10
5 3 1 1 6 5 1 1
- 1
2 1 1 2
Gear: Bevel Final Drives
H
Hydraulic Control Transmission Hydraulic Control Testing and
Adjusting, Transmission
Introduction: Drive Shafts Torque Converter Transmission Transmission Lubrication System Differential ......... .
Joint, Universal
Lubrication: Range Selector Torque Converter Transmission
Oil Filter Oil Pump, Transmission Operation:
Final Drive Range Selector Steering Torque Converter Transmission
J
L
o
Transmission Hydraulic Control Transmission Lubrication
Regulator Valve Transmission Oil Filter
Operational Checks, Transmission
Planet Carrier, Final Drive Pump, Transmission Oil
Range Selector
P
R
Reconditioning, Torque Converter Regulator Valve, Transmission Lubrication
Safety and Direc.tional Valve Shafts, Drive
s . . . . . . i . . . .
Specifications, Tolerances and Clearances Speed Selector Valve .
Group 30 Page 1
Group Page
140 160
105
42
70 100 120 130 150
70
135 100 130
130 130
160 135 190 100 120 105
130 130 42
160 130
95 135 100 130
'105 70 40
105
1 2
1 1 1 1 1
- 1
1 1 1
2 2
1 1
1 2
2
1 1 1 1
4 1 1 4
30e-30 Group 30
Page 2 POWER TRANSMISSION UNITS INDEX
Steering Adjustment Bellcrank Sockets Booster Drag Link Dust Seal Gear Hydraulic Oil Pump Intermediate Bellcrank Knuckle Rear Bellcrank Rear Spindle and Housing Tie Rods Wheel
Testing and Adjusting:
T
Pressure Relief Valve Adjustment Neutralizer Valve Air Pressure Lubrication Oil Pressure Transmission Pressure Relief Valve
Group Page
190 - 1 190 -13 190 7 190 - 4 190 - 6 190 -12 190 2 190 - 2 190 - 5 190 -12 190 6 190 190 190
42 42 42
105
9 8 2
3 3 4 4
Torque Converter 100 Torque Converter, Reconditioning 100 Torque Converter Removal 90 Transmission Hydraulic Control
Testing and Adjusting 42 Transmission, Torque Converter and Range
Selector Removal 95 Transmission
Clutch Designation Chart Clutches Carriers Hydraulic Control Input Shaft Lubrication System Operation Output Shaft Oil Filter Oil Pump
u
120 120 120 120 105 120 130 120 120 130 130
1 5 7 1 5
6 2 2
Universal Joint 70 - 1
Valve: Neutralizer Pressure Control Pressure Relief Safety and Directional Speed Selector
V
Steering Booster Pressure Relief Torque Converter Maximum Pressure Relief Transmission Lubrication Regulator
Visual Checks, Transmission
105 105 105 105 105 190 100 130
42
5 5
AIR SYSTEM AND BRAKES
TABLE OF CONTENTS
Index
Specifications ........................................ .
Testing and Adjustment ................... .
Introduction
Brake System Air Valves ....................... .
Air Reservoir and Miscellaneous . _ ................ .
Brakes
Parking Brake
Air Chambers and Master Cylinders .................. .
Section
30C-50
30C-50
30C-50
30C-50
30C-50
30C-50
30C-50
30C-50
30C-50
30C-5o
Group
30
40
41
70
85
140
160
170
201
Group 20
Page 1
AIR SYSTEM AND BRAKES
A
Adjustments: Air Compressor Governor Brake Shoes ....... . Parking Brake .................. . Safety Valve (Primary Air Reservoir)
Air Chambers and Master Cylinders Air System:
Air Compressor Governor Air Reservoirs Pressure Gauge Safety Valve
Bleeding the Brakes Brakes Brake, Parking Brake Shoes Brake System Air Valves Brake Control Valves
Check Valve Clearances and Tolerances Cylinder, Wheel Brake Cylinders, Master
Dimensions Double Check Valve
Gauge, Air Pressure Governor, Air Compressor
Horn Valve
B
C
D
G
H
Hydraulic Cylinder, Wheel Brake
Introduction
INDEX
Group Page
41 160 170 140 201
41 140
41 140
160 160 170 160 85 85
85 40
160 160
40 85
41 41
140 160
2
2
2 1
2.
2
2
2
2 2
2
70 - 1
M
Master Cylinders
o
Operation, Brake Control Valves Operation, Brakes ........ . Operational Checks, Brakes
Parking Brake Pressure Gauge, Air Primary Air Reservoir
Reservoirs, Air: Primary Two Section
Safety Valve, Air Specifications
Testing and Adjustment Tolerances Two Section Air Reservoir
Valves, Air: Brake System:
Brake Control Double Check Check
Horn Safety
Wheel Cylinder, Brake
p
R
s
T
V
w
30e-50 Group 30
Page 1
Group Page
160 - 2
85 160
41
170 41
140
140 140
140 40
41 40
140
85 85 85
140 140
2
2 1
2
I 2 2 2
160 - 1
TRAXCAYATOR PORTION
TABLE OF CONTENTS
Index ......................................... .
Specifications ...
Lift and Tilt (Loader) Hydraulic Control System
Hydraulic Oil Pump (4K3878)
Hydraulic Oil Filter
Lift and Tilt Control Valve Operation
Control Valve and Tank - Removal and Disassembly
Hydraulic Lines - Lift and Tilt
Hydraulic Lines - Implement
Hydraulic Cylinders - Lift and Tilt
Hydraulic Cylinders - Implement; Removal and Installation
Hydraulic Cylinder - Side Dump Bucket (2K6841)
Hydraulic Cylinders - Multi-Purpose Bucket (4K3415, 4K3416)
Bucket and Bucket Control ..
Side Dump Bucket
Multi-Purpose Bucket
Bucket Positioner and Lift Kickout
Section
30C-120
30C-120
30C-120
30C-120
30C-120
30C-120
30C-120
30C-120
30C-120
30C-120
30C-120
30C-120
29C-120
19C-120
30C-120
30C-120
30C-120
30C-120
Group
30
40
70
80
90
100
101
110
III
120
121
122
123
140
141
142
150
Group 20
Page 1
30C-120 Group 30
Page I
TRAXCAYATOR PORTION
A
Adjustments: Bucket Lift Kickout Bucket Positioner Lift and Tilt Cylinder
Packing Adjustment Multi-Purpose Bucket Cylinders
Packing Adjustment Side Dump Bucket Cylinder
Packing Adjustment Tilt Circuit Relief Valves Pressure Relief Valve
Arm, Lift
Bleeding Hydraulic Kickouts Bucket and Bucket Control
Bucket Front Levers Front Links Lift Arm Rear Levers Rear Links
Buckets
Bucket Positioner Bucket Teeth
Check Valves Clearances and Tolerances Control, Bucket
B
C
Control Linkage, Bucket Control Valve Operation Control Valve and Tank Control Valves and Valve Body Cylinder:
Lift Lift and Tilt Lines Tilt
D
Data, Clearances and Tolerances Detent Valves
Filter, Hydraulic Oil
Hydraulic Cylinders: Lift and Tilt Side Dump Bucket Multi-Purpose Bucket
Hydraulic Oil Supply Tank Hydraulic Lines:
F
H
Pump Pressure and Suction Tilt and Lift Cylinder
INDEX
Group Page Group Page
150 150
120
123
122 101 101 140
150 140 140 140 140 140 140 140 141 142 150 142
101 40
140 101 100 101 101
120 110 120
40 101
2 2
3 2 2
3
1 2
1 2
6 I 2 7 1 1 6
2 1 2
5
90 - 1
120 122 123 101
110 110
7
Hydraulic Lines, Implement
Hydraulic Oil Filter Bypass Valve
Hydraulic Oil Pump Hydraulic Control System
Installing Packing and Shims In Head: Lift and Tilt Hydraulic Cylinders Side Dump Bucket Hydraulic Cylinder Multi-Purpose Bucket Hydraulic Cylinder
Introduction: Hydraulic Oil Pump Hydraulic Oil Filter Control Valve and Tank Hydraulic Lines
Kickout Group, Bucket
Levers, Front and Rear Lift Lift Arm
K
L
Lift and Tilt (Loaderl Hydraulic Control System. Linkage, Control Links, Front and Rear Lines:
Hydraulic Pump Pressure and Suction Tilt and Lift Cylinder Implement
Make-Up Valves Multi-Purpose Bucket
Hydraulic Lines Hydraulic Cylinders
Oil Filter, Hydraulic Oil Pump, Hydraulic Oil Supply Tank, Hydraulic Operation:
M
o
Bucket Positioner and Lift Kickout Control Valve Detent Valves Hydraulic Oil Pump Hydraulic System Make-up Valves Pressure Relief Valve Pump Pressure and Suction Lines Side Dump Bucket Latch Mechanism Tilt Circuit Relief Valves
111 III III
90 90 80 70
120 122 123
80 90
101 110
2 3
5 2 3
150 - 1
140 140 2
70 101 7 140 1
110 110 110 111
101 4 142 1 III 2 123 - 1
90 80
101
150 100 101
80 70
101 101
7
2 5
4 2
110 - 1 141 2 101 3
Group 30 30C-120 Page 2 TRAXCAVATOR PORTION
INDEX ~.:
P Group Page T Group Page
Positioner. Bucket . , . . . . . . . . . . . . . . . . 150 Tank. Hydraulic Oil Supply . . . . . . . . 101 7 Pressure Relief Valve. Hydraulic 101 2 Tank and Control Valve 101 1 Pressure and Suction Lines. Tilt and Lift Cylinders 120 1
Hydraulic Oil Pump 110 1 Tilt and Lift Cylinder Lines 110 1 Pump. Hydraulic Oil 80 - 1 Tilt Circuit Relief Valves 101 3
V S
Valve: Side Dump Bucket 141 1 Check 101 6
Hydraulic Lines 111 2 Control 101 Hydraulic Cylinder . . . . . . . . 122 Detent 101 5 Latch Mechanism .......... 141 2 Hydraulic Oil Filter Bypass 90
Specifications. Clearances and Tolerances 40 1 Make-up 101 4 Supply Tank. Hydraulic Oil 101 7 Pressure Relief 101 - 2 System. Lift and Tilt (Loader! Hydraulic Tilt Circuit Relief . . . . . . . . 101 3
Control 70 - 1 Valve Body and Control Valves 101 6
30C-120
TRAXCAVATOR PORTION HYDRAULIC CYLINDERS - LIFT AND TILT
Group 120
Page 3
WARNING
Do not attempt to remove the cylinder until the bucket is blocked securely and the hydraulic pressure has been relieved.
2. Remove the bolt which retains the pin (2) and remove the pin (2) by driving the pin toward the outside of the machine.
REMOVING LIFT CYLINDER
11. See the group HYDRAULIC LINES - LIFT AND TILT for the proper installation procedure for the hydraulic lines .
. T 6 '2 32 3 . . DISASSEMBLY AND ASSEMBLY
PREPARING TO REMOVE LIFT CYLINDER
2-Pin. 3-Tubes. 4-Tube assembly. 5-Retainer. 6-Horn. 7-Bars. 8-Hose.
WARNING
The cylinder will swing to an upright position
when the pin (2) is removed. This motion can be
restrained with moderate hand force.
3. Retract the rod into the cylinder by placing the hand control lever in the LOWER position.
4. After the rod is fully retracted, move the hand control lever to the HOLD position to prevent the drainage of the hydraulic oil supply tank when the cylinder is disconnected.
5. Disconnect the hose that cor:.nects to the tube assembly on the bottom of the cylinder.
6. Cover all openings to keep out foreign particles.
7. Attach a suitable lifting device to the lift cylinder and remove the retainers (5) which serve as pivots for the lift cylinder.
8. Remove the lift cylinder.
9. Install in the reverse order of removal.
10. Install the retainers with the fbt side toward the
front to allow for installation of the bars (7).
The lift and tilt cylinders can be disassembled and assembled in a similar manner. Only the lift cylinder is shown.
Disassemble and assemble the hydraulic cylinder on a clean surface. Clean all metal parts in a nonflammable cleaning fluid.
1. Drain both ends of the cylinder.
2. Loosen bolts (2). Extend rod (1) out of the cylinder to prevent the scoring of the cylinder wall when removing the piston from the cylinder. Remove bolts (3) and free head (4) from cylinder (5). Then remove the rod, piston and head as a unit from the cylinder.
T81732
PREPARING TO REMOVE ROD ASSEMBLY l-Piston rod. 2-Bolts (two). 3-Bolts (four). 4-Head.
5-Cylinder.
30C-200
SEAT, FUEL TANK AND MISCELLANEOUS
TABLE OF CONTENTS
Section Group
Seat ................................................ 30C-200 70
Fuel Tank ........................................... 30C-200 70
Supporting Lift Arms ...................... 30C-200 70
Hood and Panels ......................... . 30C-200 70
Counterweights .......................... . 30C-200 70
Cab Glass Installation ................... . . . . .. 30C-200 70
Platform and Fenders ................... . 30C-200 70
Floor Plates 30C-200 70
Group 20
Page 1