Caterpillar 922 Traxcavator Service Manual
13
CT-S-922TRAX L C C a a t t e e r r p p i i l l l l a a r r Service Manual 922 Traxcavator S/n 59A1 & up 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. Service Manual
Transcript of Caterpillar 922 Traxcavator Service Manual
CT-S-922TRAX L
CCaatteerr ppii ll llaarrService Manual
922 TraxcavatorS/n 59A1 & 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
~ ..... ' ...... '.'.\ ,'"Ii
(
A
Accessory Drive ........ . Accessory Drive Gear .............. . Adjustments:
Fuel Injection Pump Timing Dimension Setting .
Fuel Rack Setting ..... Governor
Air Cleaner Air Compressor Removal and Installation Air Compressor Air Inlet Manifold
Backlash, Timing Gear Balancer Bearings:
Connecting Rod Main
Breather, Crankcase Bypass:
Fuel Oil Filter Oil Pump
Camshaft Gear Chambers, Precombustion Cleaner, Air Cleaning:
Engine Valves Fuel Injection Valve Pistons
B
C
Clearances and Tolerances Compression Release Mechanism Connecting Rods and Bearings Coolers, Oil Cooling System Core, Radiator Cover, Timing Gear Crankshaft . . . . ........ . Crankshaft Pulley Cylinder Head Cylinder Liners
Directors. Water Drive:
Accessory Tachometer
D
E
Electric Starting Motor .................. . Electrical System ......................... . Engine Data ....... . Engine Removal and Installation .. . Exhaust Manifold .............. .
16A':10 Grl?:up 30.1 Page 1
ENGINE
INDEX
Group Page
265.1 320.1
1 2
250.1 - 7 260.1 - 4 260.1 - 3 270.2 2 420 1 421 1 270.2 - 1
320.1 - 4 300 - I
340.1 - 2 360 1 210.1 - 2
240.1 - 2 210.1 190 - 1
320.1 - 3 280.2 - 2 270.2 -=-2·
290 2 250.1 340.1 40.1 I
290 - 3 340.1 - 2 200.1 1
70.1 - 1 160.1 - 2 320.1 - 2 370.1 320.1 280.2 350
280.2 - 2
265.1 1 260.1 3
410.1 410.1 40.1
400 1 270.2 - 2
F
Fan Belt and Air Compressor Belt Fan Removal Filter:
Fuel, Primary Oil
Flow of Coolant Flow of Fuel Flow of Lubricating Oil .................... . Flywheel .................... . Front Support Fuel:
Bypass Injection:
Equipment Pumps Pump Housing Pump Lifters Valves
Group Page
. 130.1 - 1 130.1 - 1
240.1 - 3 210.1 - 1 70.1 - 1
230.1 1 170.1 1 390.1 1 310 1
240.1 - 2
250.1 - 1 250.1 - 2 250.1 - 3 250.1 6 250.1 1 230.1 1 240.1 1
System. Diesel Fuel Transfer Pump Priming Pump ....... ',' ..... . F.,.,·". '240.1 - 2
Gauge: Fuel
Oil Gear:
Accessory Drive Camshaft Crankshaft Idler
G
Ring. Flywheel Timing' Timing Marks
·········~·.o··············
Generator ......................... . Generator Regulator Governor:
Adjustments Operation and Lubrication Governor and Fue~njection
Pump Housing Removal
Head. Cylinder Heater Pipe, Air Inlet Housing:
Flywheel Fuel Injection Pump Governor
Idler Gear Injection, Fuel Inlet:
Air Heater Pipe Manifold Valves
H
I
. . .• 'i~."r;:,;S': : ..... ··.c·iu '""'; .• ·•.·
i~¢i~~TIf~ :i2It! - 2 320.1 - 3 370.1 1 .320.1 6 390.1. __ 1 320.1 .1 320.1 1 410.1 - 1 410.1 - 1
260.1\::'· '3 260 . .1' ~ I
280.2 - 1 270.2 - 1
390.1 - 1 250.i...;3 260.1-1
320.1 6 250.1 1
270.2 - 1 270.2 - 1 290 - 2
~r_oup30.1. ,:",-","';.- -,:-, --.
PdgE?2 16A-1O
L
Lifters: FuelInj ecllql.l· Pump Valve~ .... ~.,:; .. ', ... , ... , ....... , ....... ..
Liners, Cylinder' .... , .. " ' .. , , . , ......... , .. Lubricating System ...... ,., .. ,.,. . . , . , .. , Lubrication:
Piston and' Ring
Maill Bearings , Manifolds:
Exhau.st. . , ...
~~li;~ ......• ' .. Meter:;>,$.e~vice ' " . , , .
oWS Byp~s#{:Valve ." .... " ·C~:c;l~'f- ' .... ~J.-<j~;:_. ,'-0:' _ •.
'Fi1t~r > .. '" ..•.• ",'
Manifold .... , •.. ~., ..
M
o
P
R
Liner
ENGINE' INDEX
Group Page
250.1 - 6 290 - 3 350 1 170.1
340.1
360 -' 1
270.2 - 2 230.1 1 270.2 - 1 170.1 - 1 265.1 - 2
210.1 200.1 210.1 170.1 - 1 180.1 180.1 1 190 - 1
70.1 - 1 230.1 1 170.1 - 2
70.1 - 1
180.1 340.1
. 340.1 180.1 1 280.2 - 2
250.1 - 2 240.1 - 2 240.1 1 190 - 1 140.1 - 1 1?jO,.lc;~2
170:'1"" 1
160.1 - 1 400 1 350 2 100.1 - 1 2~0' 3 390.1
• "- .-~-;,---;;-. c __ '.
Group . Page
Rings, Piston ., .............. " ....... '.' •.. Rocker Atins, Valve ..... , ........... , ...... . Roel, Connecting , ............... , .. , ...... . Running-in Schedule "'" , ., . , ..... ' ...... , .
s
340.1 ,... 2 290 - 1 340.1 - 2 340.1 - 2
Seals, ;Liner . , , .. , . . . . . . . . . . . . . . . . . . . . . . . . .. ~5o - 1 Seal Replacement; Water Pump ,.,. ". . ... . ..'i4o.1 - 3
~::~!~eA::t:sroi; 'D;i~~' :': : : : :: : : : :.: :.!.;~~J.;~~f}~~i~~l= i . . '320.1 - 2
Specifications ......................... ".... 40.1 1 Springs:
Governor .,' Valve ... ,
. . J> ..•••••. 0 •••••••• 0 ••••••
T
Testing Temperature Regulator Thrust Bearing, Crankshaft Timing:
Engine Gears '. Engihe Valves Fuel Injection
Timing Gear Cover 'Timing Gears , .. , . Timing Marks, ... Tolerances '-.'" ... , ...... , . , . , ............ . TUrbocharger ..... , ..... '. ' . . , .... , ... . Turbocharger Lubric;ation Valve Tur bocharger . Remov~l,
Valve: Bypass, Fuel Bypass, Oil ." Inlet and Exhaust Inspection and Reconditioning FuEtI;Injection. " . ' Lifters' ' ..
Timing .,. , . ' ....... , Valves and Valve Mechanism
w Water:
Directors, Sealsallcl Ferrules Pump
Seal Replacement .Temperature Regulator'
260.1 1 290 -; 2
.100.1 370.1
320.1 2~0 - 3 i50,.1- 7 320:1 - 2 lM.l 1 ~~o:i 1 '40.1 1
2nV; L . 2}O:1 - 2 9.'10.2 - 1
240;;~ff_ 2 . 1
n "
".j!.
U·'·'·' " -
~ENGINE SPECIFICATIONS
16A-IO ,ii, Group 40.1 Page ,3
"':':'{ii:'t ..
Drive gear retaining nut torque .... .-, . .10 lb. ft. Retainer .... : ... "."."., Flush within .002 in.
Generator Belt Tension Slack at point midway
between pulleys ." .. , .. ,,'" '9/16 - 13/16 in.
t;eri~~~tor Generator" : 12V-40A 24V-15A
DB 11 06943 DBll05213
Brush spring tension ~20 oz. .. -,;:';:::,
16 oz •
BottiljoIi (viewing driving end) . -~ .... :;-: - clockyrlse : clockwilile
Circuit --
A ,:A
Field current (800 F) Volts' 12 24 Amps 1.37-1.50 .94-1.02
Output (cold) 13;0
-. ~. . Volts' 28.5:"
Amps '"-,." 40 15\ Approximate BPM 1750 1800
Generator Regulator
Generator llegulator 12V-40A 24V-15A . DR1119627 DR1119626
Circ\iity)~~, !i<;, A A ,,- "-. ,".
Polarity '~ .... < ?\ lfeg. groUnd Neg. ground -.
Cut-out relay: ..
Armature-yoke air gap (in.) .020 .017 Point opening (in.) i .020 .032 Closing voltage range 11.8-13.0 22.8-25.2
Voltage regulator: . ,~.
Armature-yoke air gap (in.) ;067 ':0~7 Point opening (in.) .016 .016 Voltage setting range 14.1-14.9* 27.4-29.4
Current regulator: Armature-yoke air gap (in.) .075 .075 Current setting range (amps) 38-42 14-16
'., {*14.0-14.6 on lower contacts "-".,
'Governor Backlash between drive gear
and driven gear . . . . . . . . . . . . . .. .002 - .006 in.
Oil Pump . Clearance between the gears and 'covers, total .. , ........ ',' , ... , .. .002 - .004 in .
.. Shaft diameter ..... , ..... ;.. . . ..7404 - .7410 in. Bearing bore .................. .7420 - .7430 in. Bearing clearcrnce , ...... ,..... .0010 -.0026 in. Permissible bearing clearance ...... : .. , .' .005 in. Idler gear: .•.•... ' _,' .
Backlash between idler gear and crankshaft gear .. . . . . . .. '. .002 - .006 in.
Bearing bore., .. ,,<: .. ,\,," 1.2505 - 1-.2515 in. Bearing clearance;~'" ., .. ::., .. '. '.0020- .0036 in.
, Drf:;~:!~le ,clef.~Ge. ,;>":;>:,;:.;~~,,q:,~-; ., .008 in.
Backlash betvr~~:ti--drivegearJi~" . " qnd idler geqr :'~-, .... '. ,>:~,;~:~<:,:.: .. .'Y~iiq9~7;,,0l0 in.
:;:i1 '~'9:: .001-9 in. '~-',006$
.006'm'i. . ';.·".i.:.:: ".
Piston Rings Piston ring side clearance:
Top ring ".:,.,",.:., " , .. . Intermediate ring ... , . , , , , .. . Oil control ring , .,' .. , , _ . , .. , Permissible clearance (top
',,,,,' '-~.: .
.0030 - .0041 in.
.0025 - .0036 in.
.0015 - .0030 in.
compression ring) ., .. , ........ ,.'. .010 in. Ring gap:
Top ring ,.,',:,; .... _ . , " .. , ... . Intermediate ring ,_. " ......... _. Oil ring .. , . , , , - , ';ttE~' ... , ... .
.016 - .021 in.
.015 - .025 in.
.013 - .023 in.
Precombustion Chambet;ji;. "',.)100"
Torque .. , .... ,., ... ,.......... 140 - 160 lb. ft. Glow plug torque. , ....... ; ... , . " 8 -10 lb: ft.
CENTERLINE OF ENGINE
HUll
PRECOMBUSTION CHAMBER POSITIONING DIAGRAM
The precombustion chamber gasket is .. ", U}JpU'o::;U"::~1jS , .:'~wp 'different thicknesses. With the ...... J .... , ..
.,. gasket and the recommended ,+;,;..14+,,,,;,,
chCiInbers into the head, the glow connections will be positioned in The' "go" range is the position ih which plug's will be clear of fuel lines dnd other
'., •... interference, when installed in the ...... ,~,..,...,.,., l .. "c,H,. ....
. chqID,l:;>er.
'The 'diagram can be used to position the,;pteeom~'l' , bustion chambers if new gaskets are installed. ,,'. ~.
Rocker Arm , Beciring bore .. , , , . , . , , .. , ..... - .7260 -;7266jn.
Clearance between shaft and" '.' -bearing ., ..... :'. :~. . . . . . . . .. .0010 - ;0026 in.
Permisf?ible clearance ........... ' .... : .' .008 iii.:, 'Retaining bolt torque. , . . . . . . . . . . .. 80 - 90ll?:"H.'
St~tingMotor(24V - Delco-Heiny n 13818) .. " . .~i-ushl?pring tension (minimum).' .. :". :" Stf8i.
:R6tqtic:m,(yiewing'drive end) Clockwise ',No load~t1~t: ,.. ., , .
Volts . ,'" ... '~'! ' ~""'Mi::-': ......... , ..... , Min~~, Am~:,~;:'~.
23~O', :60
MaxIIn:~ ;~~pS' ..... . ~MiniiIium:l'mM , .. , , ..... . ?Maxiin¥iiij~gMS,., . :.' ' .
90 " 7000, J'O,700>
16A-1O ENGINE
Group 240.1
Page I FUEL SUPPLY EQUIPMENT
Fuel Supply Equipment FUEL TRANSFER PUMP
The gear-type fuel transfer pump is driven by a gear machined on the accessory drive shaft.
Removal and Installation
PREPARING TO REMOVE FUEL TRANSFER PUMP
D Remove • Disconnect
I-Bolt (four). 2-Service meter. 3-Bolts (three). 4-Fuel priming pump supply line. S-Drain line. 6-Fuel supply line.
Remove engine side shield on left side of machine.
Pull fuel transfer pump outward from accessory drive housing.
DISASSEMBLY AND ASSEMBLY
FUEL TRANSFER PUMP DISASSEMBLY
D Remove
I-Cover. 2-Retainer. 3-Seal. 4-Driven gear. S-Bearing. 6-Seal. 7-Spring. S-Seal. 9-Gear. IO-Retainer. ll-Nut. 12-Spring. 13-Gasket. 14-Drive Shaft Assembly. IS-Gasket. IS-Retainer. 17-Seat Assembly. IS-Retainer. 19-Bear-
ing. 20-Key.
1. Use an 8H695 Puller and a suitable step plate to remove the gear (9) from the shaft.
2. Bearing (5) (in the pump body) and bearin~ (19) (in the seat assembly) can be pressed oat and replaced. Install bearings with tapered edges toward seal.
3. Prior to installation, soak seals (3), (6) and (8) in a solution of Ih SAE 30 oil and Ih diesel fuel long enough to soften them. Tamp seals firmly into pump body bore and around shaft with a tamping tool. Use a guide over the end of pump shaft to guide seals over the threads and sharp corners of shaft. Guide should remain in place when using tamping tool.
I 600" ~ .J x 45' f-----3.00' .500" :':.OOZ'
)nnuu utnnu_{j~" @ Amuuu.- _m ________ m' ~
.562" DRILL KNURL Jy I ~ 3.00" DEEP 30' -l +.OOZ"
1. 250" ~. 000" DlA.
T56363 MAKE FROM MILD STEEL BAR STOCK
SEAL TAMPING TOOL
I 2'~ .4380 GRIND i .4378"
~. 3;4"-----1 f-. 13/16" J .4940" I i GRINO i i rS/8n .4935"
fJ~'~~~J \--cLue' lill -'" ", ~' ___ ) 1:1 ~ 1...:.) I I I: .... - / / GRI:~ 00 1-- ~~4~; -- -- -
3/16" SPHERICAL RADIUS .3860") DRILL
T56434 MAKE FROM MILD STEEL BAR STOCK
SEAL AND TAMPING TOOL GUIDE
4. Install gear with grooved side facing nut (11) and tighten nut. See SPECIFICATIONS.
5. Apply thin film of Permatex No.3 or equivalent to the surface between the pump body and pump cover. Do not aJlow Permatex to enter pump
6. Apply thin film of Permatex No.3 or equivalent to outside diameter of spring retainer (10)'. Retainer must be flush with cover to tolerance given in SPECIFIC A TIONS.
FUEL FILTER HOUSING
Removal and Installation
NOTE
If a fuel priming pump is used, remove the pump and filter housing as a unit.
16A-20 Group 30.1 Page 1
STARTING ENGINE
INDEX
A Group Page L Group Page Adjustments:
Lifters, Valve 110 Carburetor 100 3 2
Clutch 160 6 Lubricating System 90 I
Control Mechanism 160 7
Governor 130 4 M
Starter Pinion 160 3 Magneto Drive Shaft 130 5 Valve Clearance 110 2 Main Bearings 140 3
Mechanism, Valve 110 1 B
Bearings: 0
Connecting Rod 120 I Oil: Main 140 3 Pump 90 2 Piston Pin 120 1 Pump Pressure Regulating Valve 90 3
Brake, Starter Pinion 160 3
P
C Pinion, Starter 160 - 1
Cable, Starter 130 Pinion Mechanism .. '.1<.i .•• .' 160 r Camshaft 130 5 Pistons 120 2 Camshaft End Clearance 130 5 Piston" Pin Bearings 120 Carburetor 100 Pressure Regulating Valve 90 3
/" Chain, Timing 130 3 Pump, Oil 90 2 ! Clearances and Tolerances 40 "- Cleaning Valves 110 2 R
Clutch 160 5
Clutch Pinion and Brake Control 160 6 Recoil Starter 130
Connecting Rods 120 Removing Engine 80.1 1
Connecting Rod Bearings 120 Rings, Piston 120 2
Crankshaft 140 2 Rocker Arms 110 1
Crankshaft End Clearance 140 3 Rods, Connecting 120 1
Crankshaft Sprocket and Gear 140 Cylinder Head 110 S
Specifications 40 D Springs:
Governor 130 4 Data, Specifications 40 Valve 110 2 Drive Shaft, Magneto 130 5 Starter Cable 130
Starter Pinion 160 1 F Starter Pinion Brake 160 3
Flywheel 160 5 Starting Mechanism 160 1
Fuel System 100 I Starter, Recoil 130 1
T G
Gear: Timing Chain Housing 130 2
Camshaft 130 5 Timing the Engine 130 6
Crankshaft 140 2 Tolerances 40 1 .. , ..... Oil Pump 90 3
Governor 130 3 V
Valve:
H Clearance Adjustment 110 2 ~" Lifters 110 2
•••••• 0 •••
"~
Hand Start Mechanism 130 1 Mechanism 110 1 Head, Cylinder 110 1 Pressure Regulating .......... 90 3 Housing, Timing Chain 130 2 Rocker Arms ......... 110 1
16A-20 STARTING ENGINE
TIMING CHAIN HOUSING
Group 130 Page 1
Timing Chain Housing The timing chain housing is located at the front of
the starting engine cylinder block. It has mounted on, or within it, the recoil starter and electric starting mechanism, magneto, magneto drive assembly, governor, governor drive assembly, timing chain and sprockets.
RECOIL STARTER MECHANISM
Removal and Installation
The recoil starter mechanism can be removed without removing the starting engine from the diesel engine. The accompanying illustrations show the starting engine removed from the diesel engine.
1. Remove the starting engine from the diesel engine. See the covering topic.
Ti80 30 8
PREPARING TO REMOVE RECOIL STARTER MECHANISM o Remove
I-Bolt (six). 2-Nut (two). 3-Recoil starter housing.
REMOVING RECOIL STARTER MECHANISM 3-Recoil starter housing. 4-Screws (four).
S-Recoil starter mechanism.
2. Remove the handle from the cable assembly and the screws (4) which secure the recoil starter mechanism (5) to the housing (3); remove- the recoil starter mechanism.
3. Inspect all parts for wear or damage.
4. Assemble recoil starter mechanism (5) to housing (3). See topic, STARTER CABLE REPLACEMENT. Install in reverse order of removal.
Starter Cable Replacement
1. Remove the recoil starter housing from the starting engine and the recoil starter mechanism from the housing.
CABLE REPLACEMENT I-Recoil starter housing. 2-Cable. 3-Sheave.
4-Bracket. 5-Handle.
2. Remove handle (5) from cable (2). Disconnect cable from sheave (3) and remove cable from housing (l).
3. Start the new cable through the sheave. The anchor end of the cable should not extend above the sheave after the cable is installed.
RECOIL STARTER MECHANISM &-Screw (four).
lSC-30
POWER TRANSMISSION UNITS
INDEX
Group 30 P~ge 1
A Group Page H Group Page
Adjustments: Bevel Gear Backlash .................... . Bevel Gear and Pinion Setting Differential Bearing ........ . Differential Pinion .......... . Drag Link ............. . Pressure Relief Valve ................. . Rear Bellcrank ............... . ...... . Rear Spindle Trunnion Bearing Steering .. " .......... " ........ . Steering Booster Pressure Relief Valve ..... . Steering Gear ... Torque Converter Pressure Relief Valve Transmission Hydraulic Controls Wheel Bearing ....... .
Axles and Wheels .. . ... " ... . Axles:
Front Housing, Rear Rear ..
Bevel Gear Backlash
B
Bevel Gear and Pinion Setting .....
C
140 140 150 150 190 105 190 190 190 190 190 130 105 170 170
170 190 190
140 140 140
1 1 4 2 6 5
-13 - 9 -13 - 5 - 2
3 5 1
- 1 -12 -10
Checking Hydraulic Control Pressure 105 5 3 1 1 5 1 1 1
Clearances, Checking Torque Converter 100 Clearances and Tolerances ........... 40 Clutch Operation, Transmission 120 Clutches, Transmission ............... 120 Converter, Torque .......................... 100 Converter Removal, Torque .................. 90 Control, Transmission Hydraulic. . . . . . . . . . . . .. 105
D
Differential .. ............................. . Drive Shafts .............................. .
F
Filter, Transmission Oil ... . ............ . Final Drive ............................... .
Bearing Adjustment ..................... . Gear, Ring ............................. . Planet Gear Carrier ............ ......... .
G
Gear: Bevel Final Drives ............................ .
Guide, Power Shift Transmission Trouble Shooting ........................ .
150 1 70 1
130 2 160 1 170 1 160 2 160 1
140 - 1 160 - 2
118 -I
Hydraulic Control, Transmission
Joint, Universal ...
Lubrication: Range Selector Torque Converter Transmission
Oil Filter Oil Pump, Transmission Operation:
Final Drive .. ' Range Selector Steering ..... . Torque Converter Transmission
L
o
P
Planet Carrier, Final Drive Power Shift Transmission Trouble
Shooting Guide Pump, Transmission Oil
R
Range Selector
Reconditioning, Torque Converter ....... . Regulator Valve, Transmission Lubrication ..
S
Safety and Directional Valve ........... . Shafts, Drive ......... . ......... . Specifications, Tolerances and Clearances Speed Selector Valve .................. . Steering .......... .
Adjustment ........ . Bellcrank Sockets Booster ............ . Drag Link ....... " Dust Seal ........ . Gear ........ . Hydraulic Pump ... . .................. . Intermediate Bellcrank Knuckle ................................ . Rear Bellcrank .......................... . Rear Spindle and Housing . . . . ............ . Tie Rods ............................... . Wheel ................................. .
105
70
135 100 130
130 130
160 135 190 100 120
160
118 130
95 135 100 130
- 1
- 1
1
2 2
1 2
105 4 70 1 40_ 1
105 - 4 190 - 1 190 -13 190 8 190 4 190 6 190 -12 190 2 190 - 2 190 - 5 190 -11 190 7 190 9 190 8 190 2
19C-30 Group 30
Page 2 POWER TRANSMISSION UNITS INDEX
T
Torque Converter
Torque Converter, Reconditioning Torque Converter Removal .......... . Transmission, Torque Converter and Range
Selector Removal ................... . Transmission
Clutch Designation Chart Clutches ...... . Carriers Hydraulic Control Input Shalt Lubrication System Operation Output Shalt Oil Filter Oil Pump
Trouble Shooting Guide, Power Shilt Transmission
Universal Joint
Valve:
U
V
Neutralizer .... _ ..........
Pressure Control .................
Pressure Reliel . _ ..........
Salety and Directional Speed Selector ............... Steering Booster Pressure Reliel ........
Torque Converter Pressure Relief Transmission Lubrication Regulator
Group Page
95 - 1 100 - 1 100 1
90 1
95 1 120 1 105 1 120 5 120 - 7 105 - 1 120 - 5 130 - 1 120 - 1 120 - 6 130 - 2 130 - 2
118 - 1
70 - 1
105 - 2 105 - 2 105 -4 105 -4 105 -4 190 - 5 130 - 3 130 - 1
/"-
19C-30 POWER TRANSMISSION UNITS
STEERING
Groull 190
Pa~e 9
Disassembly and Assembly
6
TIE ROD SOCKETS (EARLIER MACHINES) I-Lock. 2-Retainer. 3-Bearing. 4-Dust cover. 5-Shield. 6-Spring. 7-Spring. 8-Plug.9-Seat. 10000cket housing.
ll-Washer. I2-Stud bolt.
-NOTE
Later tie rod sockets are disassembled in essentially the same manner as the bellcrank sockets on later machines. See that topic.
Tighten socket stud nuts on the frame ends of tie rods to the torque given in SPECIFICATIONS.
Tighten all tapered link connections on earlier machines to the torque listed in SPECIFICATIONS.
REAR SPINDLE AND HOUSING
Removal and Installcdion
1. Raise the redl'd the machine and block securely under the rear axle housing. Block the front wheels.
2. Remove the final drive carrier and the wheel as outlined in the covering topics.
rnJo.r-"'ftJJ"'"'' TO REMOVE REAR SPINDLE AND HOUSING
I-Brake hose. 2-Trunnion. 3-Seal. 4-Tie rod socket. 5-Housing. 6-Trunnion. ,
3. Support hou~ing (5) with ex lifting device.
4. Mark trunnions (2) qnd (6) Ond-remove them. Shims are provided~ti~der eac;htItunmon. Protect the shims from dirt oI'dqmag~ " ,',
REMOVING SPINDLE AND HOUSING
5. Remove the spindle and housing as a unit.
6. When installing the housing, pack the trunnion bearings with the proper lubricant.
7. Adjust the trunnion bearings as outlined in the topic, TRUNNION BEARING ADIVSTMSNT.
, "0.
Trunnion Bearing Adjustment
Install shims (1) and (3) under upper and IqNV~ trunnions (2) and (5) such that housing (4) will rotate freely with .000" - .001" end clearance.
2
3
T40832
TRUNNION BEARING ADJUSTMENT I-Shims. 2-Upper trunnion. 3-Shims. 4-Housing.
5-Lower trunnion.
Shims (1) must be equal in thickness to shims (3).
Disassembly and Assembly
Inspect seal (3) and bearing (4). Install the seal with the lip toward the bearing.
CAUTION
Spindle (2) must be installed with the oil groove at the top, and the brake assembly must be installed with the wheel hydraulic brake cylinder at the top.
)
19C-50
AIR SYSTEM AND BRAKES
A
Adjustments: Brake Control Valve (Later Machines) Brakes Shoes ........................... . Parking Brake .......................... . Safety Valve (Air Reservoir) .............. .
Air Chamber and Master Cylinder (Later Machines) ........................ .
Air System: Brake Air Booster (Earlier Machines) ..... . Pressure Gauge . . ....................... . Safety Valve. . . . . . . . . . . . ............ .
B
Bleeding the Brakes ....................... . Brake Air Booster (Earlier Machines) ......... . Brakes ................................... . Brakes, Parking ........................... . Brake Shoes .............................. . Brake System Air Valves (Later Machines) Brake Control Valve (Later Machines) ....... . Brake Control Valve Testing and Adjustment
(Later Machines) ................. .
C
Check Valve (Later Machines) Clearances and Tolerances ................. . Cylinder, Hydraulic ........................ . Cylinder, Hydraulic Master ............ .
D
Double Check Valve (Later Machines)
G
Gauge, Air Pressure
H
Horn Valve ............................... . Hydraulic Cylinder ........................ . Hydraulic Master Cylinder (Earlier Machines) ..
Group
85 160 170 140
201
190 140 140
160 190 160 170 160 85 85
85
85 40
160 200
85
140
140 160 200
INDEX
Page
- 3 2 1 1
- 3 1 1 1 1 1
- 1
- 3
1 1 1 1
- 1
- 2
I
Introduction (Earlier Machines) Introduction (Later Machines) ............... .
M
Master Cylinder (Earlier Machines)
Master Cylinder (Later Machines)
Parking Brake ..... Pressure Gauge, Air
Reservoirs, Air
Safety Valve, Air Specifications ...
Testing:
P
R
s
T
Air Chamber (Later Machines) Brake Control Valve (Later Machines)
V
Valves, Air: Brake System (Later Machines):
Brake Control . . . . . . . . . .. .... ......... . Double Check . . . . . . . . ............ . Check ................ ' .............. ,.
Horn ................................. . Safety ................. .
Group 30 Page 1
Group Page
70 70
160 200 201
170 140
1 - 1
- 3 1
- 1
1 - 2
140 - 1
140 40
201 85
85 85 85
140 140
2 3
1 1 1
)
lSC-120
TRAXCAYATORPORnON
A
Adjustments: Bucket Lift Kick-out Group Bucket Positioner Lift Cylinder
Packing Adjustment Tilt Circuit Relief Valve Tilt Cylinder
Packing Adjustment Pressure Relief Valve
Arm, Lift
Bucket and Bucket Control Bucket Front Lever Front Link Lift Arm Rear Lever
B
.. Rear Link _ ......... . Bucket Positioner
Check Valves Clearances and Tolerances Control, Bucket Control Tank Control Valve and Tank
C
Control Valves and Valve Body Cylinder:
Lift Lift Lines Tilt Tilt Lines
D
Data, Clearances and Tolerances Detent Valves
Filter, Hydraulic Oil
Hydraulic: Cylinders
Lift Tilt
Lines:
F
H
Pump Pressure and Suction Tilt and Lift Cylinder
Oil Filter Bypass Valve
Pump Operation
System ...
INDEX
Group Page
150 150
120 100
120 100 140
140 140 140 140 140 140 140 150
100 40
140 100 100 100
120 110 120 110
40 100
90
120 120 120
110 110 90 90 80 80 70
2 2
4 3
4 2 2
2 1
5
2 7 1 6
5
5
- I
1 5 1
1 1 1 1 1 1 1
Kick-Out Group, Bucket
Levers, Front and Rear Lift Lift Arm Link:
Front Rear
Lines: Hydraulic
K
L
Pump Pressure and Suction Tilt and Lift Cylinder
Oil Filter, Hydraulic Oil Pump, Hydraulic Operation:
o
Bucket Positioner and Kick-out Group Detent Valves Hydraulic Pump Hydraulic System Make-up Valves Pressure Relief Valve Pump Pressure and Suction .Lines Tilt Circuit Relief Valve
P
Positioner, Bucket .................... . Pressure Relief Valve, Hydraulic Pressure and Suction Lines, Hydraulic Pump, Hydraulic Oil
s Specifications, Clearances and Tolerances
T
Tank, Control Tank and Control Valve Tilt and Lift Cylinders ........ . Tilt Circuit and Relief Valve ......... .
Valve: Check Control Detent
v
Hydraulic Oil Filter Bypass ........... . Make-up ....................... . Pressure Relief ........... . ....... . Tilt Circuit Relief . . . . . . . . . . . . ....... .
Valve Body and Control Valve
Group 30
Page 1
Group Page
150
140 140
140 140
110 110 110
90 80
150 100
80 70
100 100 110 100
150 100 110
80
40
- 1
1 2
1 1 1
1 5 1 1 4 2 1 3
1 2 1 1
- 1
100 7 100 1 120._ 1 100 3
100 - 5 100 1 100 5
90 1 100 4 100 2 100 3 100 6
)
\
19C-120 TRAXCAVATOR PORTION
BUCKET AND BUCKET CONTROL
Group 140 Page 1
BUCKET REMOVAL
Support the bucket with a suitable hoist. The bucket weighs approximately 1000 lbs.
PREPARING TO REMOVE THE BUCKET I-Bolts (two). 2-Pins (two). 3-Bolts (two).
4-Pins. (two). 5-Bucket.
BUCKET CONTROL REMOVAL
Front and Rear Links
The front link is interchangeable with either side and end for end. Rear links are interchangeable.
REMOVING THE FRONT OR REAR LINK I-Pins (two). 2-Bolts (two). 3-Rear links (two). 4-Pins (two). 5-Bolts (two). 6-Pins (two). 7-Bolts (two). 8-Pins
(two). 9-Bolts (two). IO-Front links (two).
Rear Levers
1. Raise the bucket, move it to the full DUMP position and place blocking beneath the cutting edge of the bucket. Levers (4) must bottom on blocks (8).
2. Attach a suitable hoist to the tilt cylinder.
3. Remove pins (3) and (6) and move lever (2) away from the piston rod.
REMOVING THE REAR LEVERS I-Cover. 2-Rear lever. 3-Pin. 4-Front lever. 5-Tube
assembly. 6-Pin. 7-Bolt. 8-Block.
CAUTION
Lever (2) is top heavy and will swing down if not controlled.
4. Secure tube assembly (5) to the tilt cylinder and lower the cylinder.
5. Attach hoist to lever (2), remove plate (1) and lever (2).
Front Levers
Remove the front levers with the bucket resting on the ground.
Note the contour of the levers and make sure they are installed properly.
REMOVING FRONT LEVERS I-Pins (two). 2-Bolts (two). 3-Front levers (two) •. _
4-Bolts (two). 5-Pins (two). 6-Pins (two). 7-Bolts (two).
BUCKET CONTROL ASSEMBLY REMOVAL
1. Raise and move the bucket to the full DUMP position. The front levers must bottom on the blocks. See topic, REAR LEVER REMOVAL.
2. Attach a hoist to tilt cylinder (1) and remove pins (5) and (3).
CAUTION
Lever (4) is top heavy and will swing around if not :controlled.
