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