d3b s/n 3yc1, 5mc1, 23y1, 24y1, 27y1 28y1 & up volume 1 of 3 · senr3130-14 i04556274...

Serv

ice

Man

ual

Service Manual

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF CATERPILLAR OR IT’S SUCCESSORS. CATERPILLAR AND IT’S SUCCESSORS ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS, AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

D3B S/N 3YC1, 5MC1, 23Y1, 24Y1, 27Y1 28Y1 & Up

Volume 1 of 3

CT-S-D3B 3YC1+

http://www.jensales.com/products/caterpillar-d3b-crawler-service-manual-ct-s-d3b-3yc1.html

SENR7733-09

Table of Contents

Systems Operation Section

Safety Information............................... .................. 4

Index Section

Index ..................................................................... 13

3 Table of Contents


SENR7733-09

Index

Important Safety Information ................................. 2

s

Safety Information................................................. 4 Basic Precautions.............................................. 4 Burn Prevention ................................................. 9 Crushing Prevention and Cutting Prevention..... 9 Fire Prevention and Explosion Prevention......... 10 General Hazard Information... .... ......... ... ............ 7 Introduction .. ...... ............. ..... .... ........ ...... ...... ...... 4 Work Tools......................................................... 12

Systems Operation Section................................... 4

T

Table of Contents................................................... 3

13 Index Section


SENR3130-14

Table of Contents

Specifications Section

General Information .............................................. 4 Metric (ISO) Fasteners ....... .... .... ... ..... ...... ......... ... 5 English (SAE) Fasteners ............... ........... ............ 6 Ground Engaging Tool (G.E.T.) Fasteners ............ 8 Installation of Fittings .. ............ .... .............. ............ 9 Straight Thread a-Ring Fittings ............................ 10 Plugs ..................................................................... 12 a-Ring Face Seal Fittings ..................................... 14 Bulkhead Nuts ...................................................... 14 Flare Fittings ......................................................... 15 Air Conditioning Fittings ........................................ 16 Air Brake Fittings .................................................. 17 Tapered Pipe Thread Fittings................................ 17 Miscellaneous Fittings .......................................... 17 Hose Clamps ........................................................ 18

Index Section

Index ..................................................................... 20

3 Table of Contents


SENR3130-14

i04556274

Installation of Fittings SMCS Code: 7553

Note: The tightening sequence of the threaded adapters that attaches a tube assembly or hose assembly to the machine is critical to the proper function of the machine. The sealing surfaces of the tube assembly or hose assembly should be secured squarely. The sealing surfaces of the tube assembly or hose assembly should be tightened to the serviced component (control valve, cylinder, hydraulic motor, etc.). Perform this procedure prior to the final tightening of any clamps or clips that are used in order to fasten the tube assembly or the hose assembly to the machine.

Fittings have different connections. Fittings may have two different ends. Be sure to use the proper torque for the end of the fitting that is used. The following list contains some common types of fittings.

Protective caps and plugs should not be removed until the connector is ready to be assembled. All sealing surfaces should be free of contamination and damage. If a connector is damaged before or after assembly, it should be replaced .

• Straight Thread O-Ring (STOR)

• O-Ring Face Seal (ORFS)

• Tapered Pipe Thread (NPT and NPTF)

• 37 Degree Flare Fitting

• 45 Degree Flare Fitting

• Inverted Flare Fitting

• Hydraulic Four Bolt Flange

9 Specifications Section

Installation of Hydraulic Four Bolt Flange

Illustration 8 902724217

1. Position the flanges parallel over the port.

2. Evenly install bolts hand-tight, keeping the gap between flanges at a minimum.

3. Put the hose in a position so that the hose does no~ contact the machine or with another hose.

4. Tighten using one of the assembly torque values for bolts, used in Illustration 8 for proper torque sequence of various flange fittings.

5. Start the engine.

6. Move the implement control levers to all of the positions.

7. Look at the hose during movement of the implement. Ensure that the hose is not in contact with the machine or with other hoses.


Index

A M

Air Brake Fittings """""""""""""""""""""""', ... 17 Metric (ISO) Fasteners .......................................... 5 Air Conditioning Fittings, ......... ", ......... "" ............... 16 Hex Button Head Screw and Set Screws.......... 6

Metric (ISO) Machine Screws .............. .............. 6 Metric (ISO) Nuts and Bolts ............................... 5

B Metric (ISO) Taperlock Studs.................... ......... 5 Miscellaneous Fittings ........................................... 17

Bulkhead Nuts ....................................................... 14 Flex Fittings .................... , ....... ".,., ............ , ......... 18 Hi Duty Tube Fittings (Shear Sleeve) ................ 17 SAE Fla reless Fittings........................................ 18

E

English (SAE) Fasteners ....................................... 6 o English (SAE) Machine Screws......................... 7 English (SAE) Nuts and Bolts.......... ........... ....... 6 O-Ring Face Seal Fittings ..................................... 14 English (SAE) Taperlock Studs..... ............... ...... 7 Hex Button Head Screw and Set Screws.......... 7

p

F Plugs ... , .. , ............... , ........ , .. , ............... ,., ..... , ........... 12 Drain Plugs with Straight Threads ..................... 13

Flare Fittings .......................................................... 15 Straight Thread O-Ring Plugs ............................ 12 37 Degree Flare Fittings .................................... 15 45 Degree Flare and Inverted Flare Fittings ...... 16

s

G Specifications Section........................................... 4 Straight Thread O-Ring Fittings ............................. 10

General Information ..... ,......................................... 4 Introduction to Torque..... ............................. ...... 4 Torque Sequence .... ,.......................................... 4 T Torque-Turn .. , ............. , ...................... ,............... 4

Ground Engaging Tool (G.E.T.) Fasteners ............ 8 Table of Contents................................................... 3 Tapered Pipe Thread Fittings ................................ 17

H

Hose Clamps ................ , .... , .............................. , ... , 18 Constant Torque Hose Clamps .......................... 18 Worm Drive Band Type Clamps ......................... 18

Important Safety Information.... ........... ......... ........ 2 Installation of Fittings ...... , ...................... ,............... 9

Installation of Adjustable STOR Fittings ............ 10 Installation of Hydraulic Four Bolt Flange.. ........ 9

©2013. Caterpillar All Rights Reserved

Cat, Caterpillar, their respective logos, "Caterpillar Yellow" and the Power edge trade dress, as well as corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permission.


3204 VEHICULAR ENGINE SPECIFICATIONS

INTRODUCTION

The specifications given in this book are on the basis of information available at the time it was written. The specifications torques, pressures of operation, measurements, adjustments and other items can change at any time. These changes can effect the service given to the product. Get the complete and most current information before you start any job. Caterpillar Dealers have the most current information which is available. For a list of the most current modules and form numbers available for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE REGI139F.

When the words "use again" are in the description, the specification given can be used to detemline if a part

can be used again. If the part is equal to or within the specification given, use the part again.

When the word "permissible" is in the description, the specification given is the "maximum or minimum" tolerance permitted before adjustment, repair and/or new parts are needed.

A comparison can be made between the measurements of a worn part, and the specifications of a new part to find the amount of wear. A part that is worn can he safe to use if an estimate of the remainder of its service life is good. If a short service life is expected, replace the part.

77200X2

NOTE: The "c" is an indication of a change from the former issue.

NOTE: For Systems Operation and Testing and Adjusting, make reference to the 3204 Vehicular Engine, Form No. REGOl222.

INDEX

Accessory Drive Gear.. ................ ................. 18 Air Induction and Exhaust System

Air Cleaner ................ , .. . ........... .. .. .. .. . ... 20 Camshaft ............................................ , 19 Cylinder Head

01 .................................................. 26 PC ................................................. 25

Exhaust Manifold ..................................... 26 Muffler .......................................... , . . .. 27 Timing Gears. . . . . . .. . . . . . . . . . . . .. . . . .. .. . . . . . . . . . . . .. 19 Valve Cover .......................................... 24 Valve Rocker Arms and Lifters. . . . . . . . . . . . . . . . . . . . . . . .. 20 Valves and Valve Springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 21 Valve Seats and Inserts

01 .................................................. 23 PC ................................................. 22

Basic Engine Components Connecting Rod. . . . . . . . . . . . . . . . .... .. . . .. . . . . . . . . . . .. 32 Crankshaft ........................................... 34

Bearing Surface (Journal) ~ Connecting Rods. . . . . .. 35 Bearing Surface (Journal) - Mains ................. , 36

Cylinder Block ............................... '" . . . . .. 31 Engine Supports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 37 Flywheel ............................................. 37 Flywheel Housing ............... '" ..... ,. . . . . . . . . . . .. 37 Flywheel Housing Bore ............................... , 38 Flywheel Housing Runout ............................. 39 Flywheel Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 40 Pistons and Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 33

Cooling System

2

Pressure Cap. . . . . . . . . . .. .. . . . . . . . . . . . . . . . .. . . . . . . . . .. 30 Water Pumps. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 29 Water Temperature Gauges ........................... 30 Water Temperature Regulators (Thermostat) ........... 30 Vee Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 45

Electrical System Alternators ........................................... 42 Alternator Installation ... , ...... . .. . .. .. ............... 41 Alternator Regulator .................................. 43 Glow Plug Connection. . . . . . . . .. . . . . . . . . . .. . . . . . . .. . . . 9 Pressure Switch ...................................... 28 Starter Solenoid ...................................... 44 Starter Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 44 Vee Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 45

Engine Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Fuel System. New Scroll Fuel Injection Equipment. .......... .... ...... ......... 6 Fuel Injection Lines. . . . . . . . . . . . . . . . . . . . .. . .... . .. . . . . . 7 Fuel Injection Nozzles. . . . . . . . . . . . . . ... . . . .. . .. . . . . . .. . 7 Governor............................................. 8 Timing Gears ....... , . . .. . . . . . . . . . . .. . ... . ..... . . . . . . . 8

Fuel System Fuel Injection ....... , . . .. . ... ...... ... . . . ...... . ...... 10 Fuel Injection Lines ....... " .................. , . . . . . .. 12 Fuel Injection Pump Housing. .. .. . . . . . . . . . . .. . . . . . .. . . 9 Fuel Transfer Pump...... .. .... ... . ............. .... .. 14 Governor. . . . . . . . . . . . . . . . . . . . . . . . . . ... ... .. ... . . . . . . .. 13 Governor Control Linkage ........ , . ........... ..... . .. 14 Nozzles

01.... .... .... . .. . . . .. . . .. ..... . . ... . . .. ... ......... 11 PC................................................. 11

Lubrication System Oil Filter. . . . . . . . . . .. . . . . . . . . . . . . . . . ... . . ... .. . . . . . . . .. 28 Oil Pan ............................................... 28 Oil Pressure Gauge .................. , .. . ... . . . . . . . . .. 28 Oil Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 28 Oil Pump ............................................. 27

Torque for Flared and O-ring Fittings. . . . . . . . . . . . . . .. . . . . 4


3204 VEHICLE ENGINE INDEX

SYSTEMS OPERATION

Air Inlet and Exhaust System............... ............. 16 Fuel System, New Scroll ................................ 6 Valves and Valve System Components.. . . . . . . . . . . . . . .. 17 Fuel Flow................. ......................... 6

Fuel Injection Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Basic Block ......................... '" .. . .. .. .. . . . . . . .. 25 Fuel Injection Nozzle. . . . . . . . . . . . . . . . . . . . . . . . . . 7

Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 25 Fuel Transfer Pump. . ......... .............. .. ..... 7 Connecting Rods ..................................... 25 Governor .... , . . .... .. . .. ......... .......... ......... . 8 Crankshaft ........................................... 25 Oil Flow for Fuel Pump and Governor.................. 10 Pistons and Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 25

Fuel System. . . . . . .. ... . .. ...... . . ... .. . . . .... . . .. . . . . .. 12 Coofing System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 23 Fuel Injection Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 13

Electrical System ....................................... 26 Charging System Components ........................ 26 Other Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 27 Starting Circuit Components .......................... 27 Wiring Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 27

Fuel Injection Valves (Nozzles) ........................ 13 Governor (Hydra-Mechanical) ......................... 14

Lubrication System ..................................... 20 Lubrication System (Engines with New Scroll

Fuel System) ....................................... 18

Engine Design. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

TESTING AND ADJUSTING

Air Inlet and Exhaust System ............................ 113 Compression ......................................... 114 Crankcase (Crankshaft Compartment) Pressure ........ 114 Cylinder Head ........................................ 114 Exhaust Temperature ................................. 113 Measurement of Camshaft Lobes ...................... 116 Measurement of Pressure in Inlet Manifold ............. 113 Restriction of Air Inlet and Exhaust .................... 113 Valve Clearance Setting ............................... 115

Basic Block .. '" ....... " ............................... 123 Connecting Rod and Main Bearings .................... 123 Connecting Rods and Pistons ......................... 123 Cylinder Block ........................................ 123 Flywheel and Flywheel Housing ....................... 124 Piston Rings .......................................... 123

Cooling System ......................................... 119 Testing the Cooling System ........................... 119 Vee Belt Tension Chart ................................ 122 Visual Inspection of the Cooling System ............... 119

Fuel System. New Scroll ..................... ',' . . . . . . . .. 42 Checking Engine Cylinders Separately... . ... . . . . . . . ... 42 Checking Engine Timing with 6V3100 Diesel

Engine Timing Indicator Group. . . . . . . . . . . . . . . . . . . . .. 49 Checking the Plunger and Lifter of an

Injection Pump ..................................... 46 Checking Timing by Fuel Flow Method.. . ... . . .. .. .. ... 50 Checking Timing by Timing Pin Method ............... 53 Engine Speed Measurement. ..... . . . . . . . . .... . . ... . . .. 59 Finding Top Center Compression Position

for No.1 Piston..................................... 49 Fuel Injection Lines. . . . . . .. .. . . . . . ..... .. .. .. .... .. . .. 46 Fuel Setting Procedure. . . . .. . . .. .. . . ... . . .. .. . . . .. .. .. 54 Fuel System Inspection ............................... 42 Governor Adjustments ................................ 59 Removal and Installation of Fuel Injection Pumps. . . .... 47 Testing Fuel Injection Nozzles. . . . . . ...... .. . .. .. .. . ... 42

(Cont. next page)

3


3204 VEHICLE ENGINE INDEX

TESTING AND ADJUSTING (Cont.)

Fuel System (Earlier & Later) . . . .. .... . . . . .. .. . .. . . . .. ... 62 Adjustment and Cleaning of 9L6969 Fuel

Governor Adjustments ................................ 84 Injection Pump (Install) (Earlier) ..... " . ... ... . .. .. .... 99

4

Injection Nozzles ................................... 69 Adjustment and Cleaning of 9N3979 and 1W5829

Fuel Injection Nozzles.... .... ...... ... ....... ... . ... 77 Checking Engine Cylinders Separately.. .. . . . . . ... .. . .. 62 Checking Engine Timing with 6V3100

Diesel Engine Timing Indicator Group (Later) ........ 92 Engine Speed Measurement. . . . . . . . . . . . . . . . . . . . . . . . . .. 85 Engine Timing (Dynamic Test) (Earlier) ............... , 102 Finding Top Center Compression Position

For No.1 Piston (Earlier) ............................ 101 Finding Top Center Compression Position

For No.1 Piston (Later) ........ . . . . . . . . . . . . . . . . . . . .. 89 Flow Checking Fuel Injection Pump Timing

01 Engines (Earlier) ................................. 105 PC Engines (Earlier) ................................ 106

Fuel Injection Lines (Earlier) .......................... , 101 Fuel Injection Lines (Later) .......... . . . . . . . . . . . . . . . . .. 88 Fuel Injection Service ............. , . . . . . . ... . . . . . .. . .. 83 Fuel Injection Timing Adjustment

Off Engine (Later) .................................. 94 Fuel Injection Timing Adjustment

On Engine (Later) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 93 Fuel Injection Timing Check (Fuel

Flow Method) (Later). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 90 Fuel Injection Timing Check (Timing

Pin Method) (Later) ........ . . . . . . . . . . . . . . . . . . . . . . . .. 90 Fuel Nozzle Test Sequence. . . . . .... . . . . . . .... . . . .. . . .. 81 Fuel Pressure Control (Earlier) ........................ 101 Fuel Pressure Control (Later) . . . . . . . . . . . . . . . . . . . . . . . . .. 89 Fuel Rack Setting (Earlier) ............................ 110 Fuel Rack Setting (Later) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 96 Fuel System Adjustments (Off Engine) (Earlier) ......... 108 Fuel System Adjustments (On Engine) (Earlier) ......... 105 Fuel System Inspection ............................... 62

Injection Pump (Remove) (Earlier) ..................... 98 Injection Pump (Install) (Later) ........................ 87 Injection Pump (Remove) (Later) ...................... 87 Setting Fuel Injection Pump Timing

Dimension (Off Engine) (Earlier) ..................... 108 Testing Capsule-Type Fuel Injection

Nozzles for PC Engines .......................... '" 80 Testing 9L6969 Fuel Injection

Nozzles For 01 Engines ............................. 63 Testing 9N3979 and 1W5829 Fuel Injection

Nozzles For 01 Engines ............................. 71 Timing the Accessory Drive Shaft (Earlier) ............. 103 Troubleshooting of 9L6969 Fuel

Injection Nozzles ................................... 67 Troubleshooting of 9N3979 and 1W5829 Fuel

Injection Nozzles ................................... 76

Electrical System ....................................... 127 Alternator Reg u lator .................................. 129 Battery ............................................... 128 Charging System ..................................... 128 Starting System ....................................... 129 Test Tools For Electrical System ....................... 127

Lubrication System ..................................... 117 Increased Oil Temperature ............................ 118 Measuring Engine Oil Pressure ........................ 117 Oil Pressure is High ................................... 118 Oil Pressure is Low ................................... 118 Too Much Bearing Wear .............................. 118 Too Much Oil Consumption ........................... 117

Troubleshooting ...................................... " 30

SPECIFI'CATIONS

NOTE: For Specifications with illustrations, make reference to SPECIFICATIONS for 3204 VEHICULAR ENGINE, Form No. REGOI254. If the Specifications in Form REGOl254 are not the same as in the Systems Operation and the Testing and Adjusting, look at the printing date on the back cover of each book. Use the Specifications given in the book with the latest date.


NEW SCROLL FUEL SYSTEM

I. Make reference to Operation Instructions inside the lid of the 6V3100 Diesel Engine Timing Indicator Group for complete instructions and calibration.

2. Loosen all fuel line clamps that hold No. I fuel injection line and disconnect fuel injection line (8) for No. I cylinder at the fuel injection pump. Slide the nut up and out of the way. Put 5P7436 Adapter (7) in its place and turn adapter (7) onto the fuel pump bonnet until the top of the bonnet threads are approximately even with the bottom of the "window" in the adapter.

3. Put the 5P7435 Tee Adapter(6) on the Injection transducer (4) and put the end of the 5P7435 Tee Adapter (6) in the "window" of the 5P7436 Adapter (7).

4. Put fuel injection line (8) on top of 5P7435 Tee Adapter (6). Install 5P7437 Adapter (5) and tighten to 30 lb . ft. (40 Nom).

TRANSDUCER IN POSITION (TYPICAL EXAMPLE)

4. Injection transducer. 8. Fuel Injection line for No. 1 cylinder.

5. Remove the plug from the flywheel housing. Install pipe adapter (3) into the hole the plug was removed from. Tighten only a small amount.

6. Push the TDC magnetic transducer (2) into the pipe adapter (3) until it makes contact with the flywheel. Pull it back out 1.6 mm (.06 in .) and lightly tighten the knurled locknut.

7. Connect the cables from the transducers to the Engine Timing Indicator. Make a calibration check of the indicator . For calibration procedure, make reference to Special Instruction Form No. SEHS7742.

8. Start the engine . Get the engine to operating temperature. With the engine at low idle, check engine timing. Increase engine speed and check timing at 2100 rpm .

50


TRANSDUCER IN POSITION

2. TDC magnetic transducer.

The TIMING CHART gives the acceptable dynamic (engine in motion) timing range as read on the Timing Indicator Group. The TIMING CHART is for the 3204 Engine with 21 ± 1° static (engine stopped) timing.

TIMING CHART

ENGINE rpm INDICATOR READING

1000 15.7 to 18.2° 2100 16.9 to 19.3°

If the engine timing is not correct, make reference to CHECKING TIMING BY TIMING PIN METHOD for the procedure to change engine timing.

CHECKING TIMING BY FUEL FLOW METHOD

Tools Needed: 1 P540 Flow Checking Tool Group 5P6524 Engine Timing Indicator Group

9S215 Dial Indicator 3S3268 Contact Point, .25 In. (6.4 mm) long 5P7266 Adapter 3P1565 Collet

852296 Rod, 5.25 in. (133.4 mm) long 6V2023 Flow Checking Adapter

The distance of piston (7) from top center when inlet port (6) just closes can be determined by the use of the procedure that follows. Use the chart to find the conversion of dia.1 indicator reading to crankshaft degrees .


ENGINE

6

DISASSEMBLY AND ASSEMBLY

INDEX

Accessory Drive Housing ...................... ......... .................................................... ....................... ... 61-63 Accessory Drive Housing, Disassemble & Assemble .......... ....... .......... ............ ....... .................. 64-66 Air Cleaner Group ... ........... .. ..... .................. ................. .... .... ......................... .......... ...... ...... ......... ..... 10 Altemator ........... .. .... ........ ... ........... ............ ..... .... ... ............................. .... ... .. ........ .............. ................ 19

Camshaft ............... ................ ................... ........ ... ...... ........................... .. ............ ....... . , .. ... ........... . 74-76 Camshaft Bearings .. . ............ ......................... ... .. ...... .. .... ... ..................... .... ... .... ......... ........ ....... ... .... 77 Connecting Rod Bearings .................. ...................................... ....... ............... . '" ... ............ ... .. ....... ..... 42 Crankshaft Front Pulley ......................... .............. .................................. ............. .......................... 68,69 Crankshaft Front Seal . ... .... .... ... .... .... .... ........... ... ....... ... .............. ... ... ... ... ....... .... .... ..... ...... ...... .......... 69 Crankshaft and Gear . ..... ... .. ... .. .. ................... .... ....... .... ......... .... ...... .... ... ..... ... .. ..... ....... ... ....... ...... 84-86 Crankshaft Main Bearings ..... .......... ........... ........... ............................................. .. ........ ..... ........... 43,44 Crankshaft Rear Seal and Wear Sleeve .. ..... .... ........ ..... ..... . ... ........ ...... ..... ... ....... ... ........ ......... ... ..... 83 Cylinder Head ................. ................. ................. ....................................... , ...... ..... ..... .. .......... ....... 37,38 Cylinder Head, Disassemble & Assemble ............... .......................... .. ........... ........... ............ . ..... 39,40

Engine and Transmission (3F/3R), Separation and Connection ...... ............................................ ... 86 Engine and Transmission (3F/1R), Separation and Connection ..................... ...................... .. ........ 87 Engine Oil Cooler ..... ... .... .... .... ..... .... ....... ......... ... .. ....... ... .... ....... .. ............ .... ....... . ........ ... .... ............. . 15 Exhaust Manifold ........ .................................. ... ........... ................................................................. 67,68

Fan and Pulley ................................ ....... .................................................. ... ............... .................. 20,21 Flywheel ........................... ........................ ............ ........ ................................. ..... ............ ................... 81 Flywheel Housing ...... ...... . ..... .... .... ........ ..... .... ... ... ... ... ..... .... ..... ..... ........ .... .. ... ..... ............. ..... .... ... ..... 82 Flywheel Ring Gear . ...... .... ......... ....... ... .......... . ... ..... .... ...... ... ... ... ...... ...... .... ...... . .......... ...... ..... .......... 82 Fuel Injection Lines . ............................................................. ............ ...................................... ........... 27 Fuel Injection Nozzles ....... ............... ................. ............... .............. ........ ............ .................. ...... .. 32,33 Fuel Injection Nozzles, Disassemble & Assemble ........... ........ ............. ......... ............................ 33-36 Fuel Priming Pump ... ..................................... ........................... ....... ....................................... .. ........ 16 Fuel Injection Pump Housing, Disassemble & Assemble .. ............ ............ .. .......... ............ ....... 56-60 Fuel Injection Pump Housing and Governor ............................ ................................................... 48,49 Fuel Injection Pump Housing and Governor, Separation and Connection ......... ............ ......... ... 50,51 Fuel Transfer Pump .. ... ........... ... ........ .... ............. ...... ................. .................................... ........... ... ..... 16 Fuel Transfer Pump, Disassemble & Assemble ................ ............... ........... ........... ..................... 17,18

Governor, Disassemble & Assemble ................. .. .......... ... .. ......................................................... 52-55

Hood ....... .. ................. ............... ..................... ............ .... ............. ....................................................... .. 9

Muffler ....... .............. ........................ .... ........ .... ........ ................ ......... ......................... .. ...... ..... ........... 10

Oil Pan ....................................... ...................................................... ........ ............... .......... ......... .. ..... 41 Oil Pump and Relif:~f Valve ....... .............. ....... ... ........................................................... .. .. ...... ...... 72-74

Pistons .................... .... ............................. ............................. ............. : ......... ............. .................... 44,45 Pistons, Disassemble ........ ........................ ....................................... ............................................ 46,47 Radiator and Guard ..... .... ..... ...... .......... ..... ...... .... ....... ..... ...... ..... ........ .... .... .... ....... ......... ..... ........ 11-14 Rocker Shaft, Disassemble & Assemble .............. .... ....... ...................... ........ .. ....... ... .............. .. .. 30,31 Rocker Shaft and Push Rods ....... ......... .... ................ .................... ................. ........... ..... .... ......... 29,30

Starting Motor ... ... .......... .... ...... . ... . .... ....... .... ......... .... ..... .. .................... ... ........... ...... ....... .. ...... ..... ..... 15 Support Bracket (931 B) ......... .. ...................................................................................... ..................... 8

Timing Gear Cover ... ................................................... ......... .... ......... ...... ..................................... 70,71 Timing Gear Plate ...... ........... ....... ....... .. ... ... ....... .... .. ........ ........... ........ ..... ... .......... ................. ..... 78-80

Valve Cover ...................... ....... .................... ...... ......... ....... ............................. .... ............ ........ .......... 28 Valve Lifters ...... ... .................................................. .. ........... ..................... .......... ........................ ....... 41

Water Pump ... ......... ........ ... ...... .... .... ...... ..... .. ......... ... .. ... .. ........... ..... ............ ...... ......... .......... ....... ... .. 21 Water Pump, Disassemble & Assemble ......... .. ............. .......................... ....... .... ... ..................... 22-26 Water Temperature Regulator .............................. ................ ... ................................... .............. .... .... 19

& WARNING

DISCONNECT BATTERIES BEFORE PERFORMANCE OF ANY SERVICE WORK.

NOTE: "e" denotes a change from the former issue.


ENGINE DISASSEMBLY AND ASSEMBLY

7


ENGINE DISASSEMBLY AND ASSEMBLY

FUEL INJECTION PUMP HOUSING ASSEMBLE FUEL INJECTION PUMP HOUSING

Tools Needed

8S4613 Wrench

8S2244 Extractor

8S2241 Camshaft Bearing Installation & Removal Tool Group

9S6329 Driver

5P1665 Plate

1B9575 Bolt

104716 Nut

7S7113 Rack Setting Gauge

FT960 Fuel Injection Pump Installation Tool Group

1P510 Driver Group

1253-16

ABC D E F

1. Install the camshaft bearings in the fuel injection pump housing with tool (C). Install the bearing in governor end of housing so the lubrication hole in the bearing is in alignment with lubrication hole in housing. Install the camshaft bearings even with outside ends of fuel injection pump housing.

CAUTION Install the rack bearing in the governor end of the housing with the small holes in the bearing parallel to the vertical centerline of the pump.

2. Install the rack bearing in the governor end of the housing with tooling (F) . Install the bearing so it will be .195 ± .005 in. (4.95 ± 0.13 mm) lower than the face of the housing.

CAUTION Tooling (0) must be used to install the rack bearing in the accessory drive end of the housing. This will put the tab on the bearing in its correct position and install the bearing to the correct depth.

3. Install the rack bearing in the accessory drive end of the housing with tooling (D).

4 . Put clean engine oil on camshaft. Install the camshaft in fuel injection pump housing. Put the governor drive gear (1) and spring (2) in position on the camshaft. Install the camshaft plate (3), bolt and lock.

58


038 POWER TRAIN SPECIFICATIONS

INTRODUCTION

The specifications given in this book are on the basis of information available at the time it was written. The specifications torques, pressures of operation, measurements, adjustments and other items can change at any time. These changes can effect the service given to the product. Get the complete and most current information before you start any job. Caterpillar Dealers have the most current information which is available. For a list of the mostcLIrrent modules and fonn numbers available for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE REGl139F.

When the words "use again" are in the description, the specification given can be used to determine ira part


When the word "pemlissibJe" is in the description, the specification given is the' 'maximum or minimum" tolerance permitted before adjustment, repair and/or new parts are needed.

A comparison can be made between the measurements of a worn part, and the specifications of a new part to find the amount of wear. A part that is worn can be safe to use if an estimate of the remainder of its service life is good. If a short service life is expected, replace the part.

77200X2

NOTE: For Systems Operation and Testing and Adjusting, make reference to the D3B TRACTOR POWER TRAIN, Form No. SENR7916. For POWER SHIFT TRANSMISSION TESTING AND ADJUSTING, see Form No. SENR7917.

NOTE: The "e" is an indication of a change from the former issue.

INDEX

Bevel Gear and Pinion............................... 19-21 ROPS Mounting ........................................ 37 Brake Adjustment.. .................................... 26 Brake Drum Alignment ................................ " 27 Selector and Pressure Control Valve (27Y, 28Y). ...... 11, 12

Steering Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 23 Control Group for Transmission Steering Clutch Adjustment ............ ,................ 25

Oil System (Serial Nos. 23Y. 24Y) . 9 Steering Clutch Case and Frame. . . ... . . . . .. . . . . . . . . . . . .. 22 Steering Control Valve ................................ " 24

Drive Shaft (Serial Nos. 23Y. 24Y) . . . . . . . . . . . . . . 17 Sweep Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Drive Shaft (Serial Nos. 27Y, 28Y) , . . . . . . . . . . . ...... " 17

Torque Converter (23Y, 24Y) ....... ,.................... 7 Final Drive (23Y, 27Y) ........................ " ...... 28,29 Torque Converter (27Y. 28Y) .......................... 7,8 Final Drive (24Y, 28Y) .................. , ............. 30,31 Track (Sealed) ................................ , . . . . . . . .. 35 Final Drive Bearing Installation, . . . .. . . . .... . . . . .. .. . . . .. 32 Track (Sealed and Lubricated) . . . . . . . . . . . . . . . . . . . . . . . . . .. 34 Front Idler and Recoil Spring 33 Track Adjustment 36

Hydraulic Controls (23Y, 24Y) ........................... 9 Track Carrier Rollers. . . . . 33 Track Rollers ............................ , . . . . . . . . . . . . .. 34

Lines, Plugs and Fittings ................ , . . . . . . . . . . . . .. 4, 5 Lubrication Relief Valve (23Y, 24Y) . . . . . . . . . . . . . . . . . . . . . .. 10

Transfer Gears (23Y, 24Y) , .... , ................. , . . . . . 14 Transfer Gears (27Y, 28Y) ........ ............... 16 Transmission (23Y, 24Y) .............................. 13,14

Oil Pump for the Transmission (23Y, 24Y) . . . . . .. . . . . . . . . . 6 Oil Pump for the Transmission (27Y, 28Y) . . . . . . . . . . . . . . . . 6

Transmission (27Y, 28Y) ....... , ......... , 14,15 Transmission Oil Filter Group (27Y. 28Y) . . 10

Power Take-Off Drive (23Y, 24Y) .......... ,...... 18 Undercarriage Support .......... . .... 24

Power Take-Off Drive (27Y, 28Y). .. .. . . . . . . . . . .. .. ... . . .. 18

2


D3B TRACTOR POWER TRAIN INDEX

SYSTEMS OPERATION

Bevel Pinion and Bevel Gear . ....... ....... .... ...... .... ......... .... ...... ....... 38 Transmission: Serial Nos. 23Y, 24Y ............................................................... 11

General Information: Serial Nos. 23Y, 24Y ................................................................. 4 Serial Nos. 27Y, 28Y ............................................................... 18

Power Flows ......................................................................... 13 Serial Nos. 27Y, 28Y ............................................................... 29

Power Flows ......................................................................... 31

Transmission Hydraulic Controls:

Lubrication System for the Transmission: Serial Nos. 23Y, 24Y ................................................................. 6

Serial Nos. 23Y, 24Y ................................................................. 8 Serial Nos. 27Y, 28Y ............................................................... 23

Serial Nos. 27Y, 28Y ............................................................... 20 Transmission Hydraulic Pump: Oil Filter ................................................................................. 21 Serial Nos. 23Y, 24Y ................................................................. 6

Torque Converter: Serial Nos. 27Y, 28Y ............................................................... 20 Serial Nos. 23Y, 24Y ................................................................. 5 Serial Nos. 27Y, 28Y ..... ....... ..... ..... .... .... ...... ... ....... .... ... .... ...... 19 Transmission Oil Cooler:

Serial Nos. 23Y, 24Y ................................................................. 7 Serial Nos. 27Y, 28Y ............................................................... 22

Transfer Gears: Serial Nos. 23Y, 24Y ............................................................... 17 Serial Nos. 27Y, 28Y ............................................................... 37

Undercarriage . ... .... ... .... ....... .... .... ..... ... ..... ................ .......... ...... ..... 43 Hydraulic Track Adjusters ... ...... .... ...... ... ........ .... ... ... ................ 45 Recoil Spring and Mechanism for Track Adjustment .............. 44 Track Carrier Rollers ..... ..... .... ... .... ..... ..... ....... .............. ........... 43

Steering Clutches and Brakes and Final Drives .. .......... .... ... ........ 39 Track Rollers ..... ... ........ ..... ....... ......... ....... .............. .... .......... ... 43 Steering Clutches and Brake Control........ ............... ........... .... ..... 40 Front Idlers .... ..... ..... ....... ....... ..... ... ........ ......... ......... ..... ...... ..... 44

Brakes ...................................................................................... 42 Sealed and Lubricated Track ........... ... ..... ......... ......... ..... .... .... 45 Steering .................................................................................... 40 Sealed Track ........ ...... ................ ...... ...... ............................ ..... 45


Bevel Gear and Pinion: , Troubleshooting: Adjustment of Bearings for Bevel Gear Shaft . .......... ........... ...... • Serial Nos. 23Y, 24Y ............................................................... 47 Adjustment of Free Movement (Backlash) .................................• Check List During Operation ................................................ 47 Adjustment of Tooth Contact Pattern ......................................... . Steering and Brakes ............................................................. 49

i~~~~~i~~~e~~~.:::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: :~ Visual Checks ....................................................................... 47

Power Shift Transmission Testing and Troubleshooting: Adjusting . ... ......... ............... ................ See Form No. SENR7917 Serial Nos. 27Y, 28Y ............................................................... 50

Check List During Operation ................ ... ......... ...... ..... ..... .... 50 Steering and Brakes ... ....... .... ..... ...... ...... ....... ......... ...... ........ 53 Torque Converter .................................................................. 52

Steering Clutches, Brakes and Final Drives: Adjustment of Brakes ................................ ........... .... ....... ... ........ •

Transmission .......... .......... ... ... ....... ... ........ ............ ..... ...... ...... 50 Visual Checks .... .......... ....... ... ......... .... ....................... ..... ...... 50

Adjustment of Control Linkage for Steering Clutches ............. ... • Undercarriage: Adjustment of Final Drive Bearings .. .......... ............... ... ... ........... • Adjustment of Track ..... ...... ... ............. ... ... .................. ...... .... .... ... •

·See SPECIFICATIONS, Form No. SENR7915.

SPECIFICATIONS

NOTE: For Specifications with illustrations, make reference to the SPECIFICATIONS for D3B TRACTOR POWER TRAIN, Fonn No. SENR7915. If the Specifications in Fonn SENR7915 are not the same as in the Systems Operation and the Testing and Adjusting, look at the printing date on the back cover of each book. Use the Specifications in the book with the latest date.

3


D3B AND 931B INDEX POWER TRAIN SUPPLEMENT

INDEX

SPECIFICATIONS

Brake Adjustment ............................................. .......................... 18 Lines, Plugs and Fittings .......................................................... 7, 8

Drive Shaft .................................................................................. 16 Oil Pump ....................................................................................... 9

Flywheel Clutch .... ....... ... .... ................... ........ .............. ... ......... .... 12 Flywheel Clutch and Brake Control Valve ............ ................ 10, 11 Power Take-off Drive .................................................................. 16

Flywheel Clutch Control Group ...... ... ...... ..................... .... .... .... ... 13 Flywheel Clutch Linkage Adjustment ...................... ......... ..... 13

Forward-Reverse Control Linkage ................... ..... .................. .... 16

Steering Clutch Control Group ............. .................... ...... ....... ..... 17 Steering Clutch Adjustment .................................................. 17

Adjustment Procedure for Forward-Reverse Control Linkage ........................................................ .......... 16 Transmission ..... ... ...... ........ ... .......................... .............. ... ... ........ 14

Transmission Brake Group ......................................................... 13 Gear Shift Group ..................... ... ......... ........ ..... .... ................. ..... 15 Transmission Oil Filter ................ ............ ....... ......... .... ...... ........ .... 9

SYSTEMS OPERATION

Flywheel Clutch and Transmission Brake ..... ................ ... ... ........ 27 Oil Filter ................................................................................. 21 Flywheel Clutch and Transmission Brake Control Valve .... ........ 23 Transmission Oil Filter. ....................... ... .... .............. .............. 22

Gear Shift and Interlock Mechanism .............. ....... ... .................. 28 General Information .................................................................... 19 Steering Clutches and Brakes ......... ....... ...... ...... ............... ......... 32

Brake Operation ...................................... ..... ......................... 34

Hydraulic System ........ ......... ... ........... .................... ... ... ... ... ......... 20 Filter Screen and Magnet .... ........ ...... .............. ......... ... ... ....... 22

Parking Brake Operation .... ........ ...... ........... ..... ........ ..... ........ 34 Steering Operation ... ... .......... ............ ....... .... ..... ............ ........ 32

Hydraulic Pump .. ... ... ...... .... .................. ...... .... ...... ................. 20 Magnetic Screen. ..... ........... ......... ... ............ .............. ............. 22 Transmission ....... ..... ......................... ........ ..... ..... ... ..................... 30


"Iywheel Clutch and Transmission Brake Valve ... ...................... 40 Troubleshooting ... ................................... ..... .............. ... ..... ..... .... 35 Adjustment Procedure ... ........................................................... 41 Checks During Operation ...................................................... 35 Test Procedure ......................................................................... 40 Check List During Operation.. .................. ..... ... ... ....... .... ....... 35

Power Train Testing and Adjusting ... .... .......... .......... ................. 38 Visual Checks ........................................................................ 35

Location of Pressure Taps .................................................... 38 Pressure Chart . ......... .............. ................... ....... ................. ... 38


Index for Disassembly and Assembly...... ............. ..... ...... ... ..... ... 42

NOTE: For components and systems not covered in this supplement, see Service Manual for D3B Tractor, Form SENR 7911, or Service Manual for 931 B TrackType Loader, Form SENR 7925.

5


Power Train Disassembly and Assembly

Index

Transmission Brake .......................................... 64 Transmission Gears ......................................... 70 Transmission Flywheel Clutch .. ...... .................. 65 Transmission Oil Filter Base And Bypass Valve .................................................... 43 Transmission Oil Pump .................................... 44 Transmission Oil Pump, Disassemble & Assemble ...................................................... 44 Transmission Oil Pump Idler Drive Gear .......... 70 Transmission Shift Group ................................. 48

42


Index

Bevel Gear And Pinion ............................................... 82

Drive Shaft .. ... ... .... ..... ............... .. ........... ................. .... 49 Duo-Cone Seals, Conventional . ... ........................ .... .. 4 Duo-Cone Seals, Inverted ........ .. .............. .......... ... .. ... 7

Engine And Transmission (3F/1R Power Shift) .... ... ... 88 Engine And Transmission (3F/3R Power Shift) ........ 115 Engine And Transmission (5F/4R Direct Drive) ....... 163 Engine And Transmission, Separation And Connection (3F /1R Power Shift) ........ ................ .... ..... ... ........ .. ...... 93 Engine And Transmission, Separation And Connection (3F /3R Power Shift) .. ....... .................................... .. ... 119 Engine And Transmission, Separation And Connection (5F/4R Direct Drive) .................... .... .... ...................... 167 Equalizer Bar (D3B SA) ... .. ......................................... 37

Final Drive Pinions ......... ....... ....... .......... ..................... 80 Front Idlers .................................. ...... .. .... ....... ....... .... . 27 Front Idlers, Disassemble & Assemble ... ... ... .... ... ... .... 28

Hydraulic Track Adjuster Seals ............... ... ... ............. 32

Pinion Flanges ............. ..... ...... ................ .. ........ ........ .. 78 Pivot Shaft (D3B SA) ... .. .. .. .... ....... ............. ....... ... ....... 36

Recoil Springs .... ................. ...... ............. ...... .. .. .......... 34

Sprocket Hubs ..................... ........................ .... ........... 39 Sprocket Segments (if equipped) ........... ... ... ... .. ......... 38 Sprocket Shaft, Gear And Cover ..... ... ... ....... ... .......... 43 Steering Clutches (Dry-Type) .. ........... ..... ........ ..... ...... 53 Steering Clutches (Oil Cooled) ........ .... ...... .. ... ..... .... ... 62 Steering Clutches, Disassemble & Assemble .. ... .. ..... 71 Steering Clutch Control Valves .. .... ... .... ............... ...... 50 Steering Clutch Control Valves, Disassemble & Assemble .......................... ..... .. ... ..................... .. .. .... ... 51 Steering Clutch Hub Couplings ...... .. .......... ....... .. .. .... . 79 Support Bracket (931 B) ................... ................ ... ...... .. 13

Torque Converter (3F/3R Power Shift) ................. ... . 132 Torque Converter (3F/3R Power Shift), Disassemble & Assemble .................................................................. 133 Torque Converter Clearance Checks (3F/3R Power Shift) .... .... ................................................................. 136 Torque Converter And Transmission (3F /1 R Power Shift) .......... ... ..... ........ ....... ........ .. .. ................ ......... ... 101 Torque Converter And Transmission (3F /1 R Power Shift), Disassemble & Assemble .... .......................... 102 Tracks (Separation And Connection) ... ....... ....... ... .. ... 24 Track Carrier Rollers ....... ...... ..... ...... .. .. ..... ............... ... 13 Track Carrier Rollers, Disassemble & Assemble .. ..... 15 Track Roller Frames ........... .......... .. .. ........... ....... ...... .. 35 Track Roller Guards ... .. ....... : .... ..... ....... .............. ........ 19 Track Rollers ................................ .... ... ........... ...... .. ..... 19 Track Rollers, Disassemble & Assemble .... ..... .. ........ 21

Power Train 3

Transfer Gears (3F/1R Power Shift) ............ ............. 111 Transfer Gears (3F/3R Power Shift) ............. .... ...... .. 127 Transfer Gears (3F/3R Power Shift), Disassemble & Assemble ... .............. ........... ... ... ... ......... ........... .. ....... 128 Transmission (3F/3R Power Shift), Disassemble & Assemble ........................... .. ...... ..... .... ....... ....... .... .... 138 Transmission Brake (Direct Drive) ............................ 186 Transmission Flywheel Clutch (Direct Drive) ..... .... ... 187 Transmission Gears (Direct Drive) ... ... ............ .. ... .... 189 Transmission Hydraulic Control Valves (3F/3R Power Shift) .... ....... .. ........... .. .... ........... .................. ... ....... .... 120 Transmission Hydraulic Control Valves (3F/1 R 931 B Power Shift), Disassemble & Assemble ........... ... ... .... 95 Transmission Hydraulic Control Valves (3F/1 R D3B Power Shift), Disassemble & Assemble ... ...... ..... ...... . 98 Transmission Hydraulic Control Valves (3F/3R Power Shift), Disassemble & Assemble ...... ............... ... ...... 121 Transmission Oil Filter (3F/3R Power Shift) ............. 162 Transmission Oil Filter (3F/3R Power Shift), Disassemble & Assemble .............................. .......... . 163 Transmission Oil Filter Base And Bypass Valve (Direct Drive) .. ..... .... .... ... ................ .. .................................... 167 Transmission Oil Pump (Direct Drive) ...................... 168 Transmission Oil Pump (Direct Drive), Disassemble & Assemble ... ... ... ...... ....... ....................... .... ..... ... .. .. ..... 168 Transmission Oil Pump (3F /1 R Power Shift), Disassemble & Assemble .............. ... ........ ....... .. ....... .. 95 Transmission Oil Pump And Pump Drive Gear (3F/3R Power Shift) ............... ............. .. .. .. .............. .......... .... 112 Transmission Oil Pump And Pump Drive Gear (3F/3R Power Shift), Disassemble & Assemble ...... ........... .. 113 Transmission Oil Pump And Transmission Hydraulic Control Valve (3F /1 R Power Shift) ....... ...................... 94 Transmission Oil Pump Idler Drive Gear (Direct Drive) .. .......... .. ... ........ ... ............. ........... .. ........ .......... 188 Transmission Shift Group (Direct Drive) .. ... ..... ......... 170

. A WARNING

Disconnect batteries before performance of any service work.

NOTE: This book has been completely changed from the former issue.

Index


54. Heat seal carrier (105) to a temperature of 1380 to 1650 C (2800 to 3300 F) for ten minutes. Install seal carrier (105) on housing (107). Make sure the groove (slot) in the seal carrier is in alignment with the hole in the housing.

B01

55. Install pin (106) that holds the seal carrier in place.

56. Install the O-ring and smaller teflon ring (30) on the piston. Install larger teflon ring (30) on the piston. The larger teflon ring has a lip on the ring and the lip must be toward the housing. Install piston (26) in housing (107).

Power Train 159

57. Install shaft (25) into housing (107). Install one spacer (29), spring (27) and other spacer (29).

58. Put housing assembly (22) in a press. Use tooling (E) and the press and put spring (27) under compression until the groove for the retaining ring is above spacer (29).

59. Install retaining ring (28) with tool (8).

60. Install seal rings (24) on the seal carrier.

Disassembly and Assembly


INTRODUCTION

The specifications given in this book are on the basis of information available at the time it was written. The specifications torques, pressures of operation, measurements, adjustments and other items can change at any time. These changes can effect the service given to the product. Get the complete and most current information before you start any job. Caterpillar Dealers have the most current information which is available. For a list of the most current modu les and form numbers available for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE REGI139F.


When the word "permissible" is in the description, the specification given is the "maximum or minimum" tolerance permitted before adjustment, repair and/or new parts are needed.

When the words "use again" are in the description, the specification given can be used to determine if a part

A comparison can be made between the measurements of a worn part, and the specifications of a new part to find the amount of wear. A part that is worn can be safe to use if an estimate of the remainder of its service life is good. If a short service life is expected, replace the part.

77200X2

2

NOTE: For Systems Operation, Testing and Adjusting, make reference to D3B TRACTOR HYDRAULICS, Form No. SENR7920.

NOTE: The "e" is an indication of a change from the former issue.

INDEX

Angling Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17

Cylinders Blade Angle........................................................................ 17 Lift .................................... ..... ..... .......... .. . . . ..... . ......... ..... 13 Tilt (8J6893) ......................................................... ' ...... . . ...... 14 Tilt (9J8674) .. ... . ...... ... . . ..... ... . ........ ....... . .. . . . .... .. . . ....... . . ... ... .. 15 Ripper.............................................................................. 16

Control Valve ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11

Filter......................................... .................... .................... 12

Hydraulic Pump (3G4096) ............................................................. 8 Servovalve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Hydraulic Pump (3G5046) ............................................................. 10 Hydraulic Pump (8J4513. 3G5385) ..................................................... 6 Hydraulic Pump (8J4515. 3G5386) ..................................................... 7


D38 TRACTOR HYDRAULICS

SYSTEMS OPERATION

Control Assembly .... ..... ............... ............ ..... ...... .... ............................ .............................. ... .... ... ......... 6 Hydraulic Pump (Axial Piston-Type) ................................................................................................. 12 Hydraulic System ....... .... .............................. .................................... ... ...... ........................... .... ........... 4 Make-Up Valve ...................... ............................................. ...... .................................... .... ................. 12 Relief Valve ........ .... .... ... ....................... ..... ........................ ................. ........... ...................... .............. 12 Ripper Hydraulics ........ ...... ....... ...................... ..... ...... ................. .... ...... ...... .... ....................... .... ........ 14 Valve Section in RAISE and LOWER ..... ........... ... .... ...................... ........ ... .... ...................... ... .... ........ 8

FLOAT Position ........................................................................................................................... 11 HOLD Position ......... ............................ ... ............. ................... .... ... ........... ......... ............ ................ 9 LOWER Position .......................... ......................... ......... ................................ .............................. 10 RAISE Position ...................... ......... ............................................................. ........... ..................... 10

Valve Section for Ripper in HOLD Position ............................... ................................ ....................... 16 Valve Section for Ripper in LOWER Position ........................... ................ ...................... ................. 17

RAISE Position ........................................ ...... ................................ ........... .................... ...... ......... 17 Valve Section in ANGLE LEFT Position ............................................................................................. 8 Valve Section in ANGLE RIGHT Position .......................................................................................... 8 Valve Section in HOLD Position ............................. ...................................... ......................... ............. 6 Valve Section in TILT LEFT Position .............................................................. .................................... 8 Valve Section in TILT RIGHT Position ............................. ............................... ................................... 7


Checking Pump Efficiency ................................................................................................................ 18 Hydraulic System .................. ......... ....................................... ......... ........................ ............ ............... 18 Lift Cylinder Rod Drift ....................................................................................................................... 19 Main Relief Valve .............................................................................................................................. 21 Main Relief Valve Adjustment ........................................................................................................... 21 Main Relief Valve or Servovalve Pressure Setting Test .................................................................. 20 Oil Pump Test for Axial Piston-Type Pump ...................................................................................... 23 Performance Test List ....................................................................................................................... 18 Relief Valves ...................... ................................ ........ .............................. ....... ............................ ...... 20 Relief Valve Test Fixture .................................................................................................................. 22 Ripper Cylinder Rod Drift ..... ................................ ...... ..................................... ............... ................... 20 Ripper Relief Valve ........................................................................................................................... 21 Servovalve Pressure Setting Adjustment ......................................................................................... 21 Visual Checks .. .......................... ..... ............. .... ..... ...... .................. ..... ............................. .......... ........ 18

SPECIFICATIONS

NOTE: For Specifications with illustrations, make reference to the SPECIFICATIONS for D3B TRACTOR HYDRAULICS, Form No. SENR7919. If the Specifications in Form SENR7919 are not the same as in the Systems Operation and the Testing and Adjusting, look at the printing date on the back cover of each book. Use the Specifications given in the book with the latest date.

INDEX

3


6

INDEX

Angling Blade Group (D3B) ....................................................................................................... 23,24

Blade Angling Cylinders (D3B) ................................................................................................... 20-22 Bucket (931 B) .............................................................................................................................. 39,40 Bucket Positioning and Kickout (931 B) ............................................................................................ 44

C-Frame (D3B) ............................................................................................................................ 25-27

Fuel Tank Group ......................................................................................................................... 54-59

Hydraulic Control Valves ............................................................................................................. 60-63 Hydraulic Control Valves, Disassemble and Assemble ................. , ............................................. 64-79 Hydraulic Cylinders, Disassemble & Assemble .......................................................................... 33-37 Hydraulic Pump ................................................................................................................................... 8 Hydraulic Pump, Disassemble & Assemble ................................................................................. 9-14 Hydraulic Tank Group ................................................................................................................. 49-53

Lift Arms (931 B) .......................................................................................................................... 45-48 Lift Cylinders (D38) ..................................................................................................................... 15-17 Lift Cylinders (931B) ................................................................................................................... 28-30 Link Assemblies (931B) ............................................................................................................... 40,41 Loader Frame, Lift Arms, Tilt Levers, Link Assemblies, Bucket, Seals and Pins (931 B) .................................................................................................... .................. 38

Tilt Cylinder (D3B) .................................................................................................................... 17-19 Tilt Cylinder (931 B) .............................................................................................................. 31-32 Tilt Levers (931B) ............................................................................................................... 42,43

Support Bracket (931 B) ...................................................................................................................... 7

&. WARNING



03 AND 931 BACKHOE INDEX

SPECIFICATIONS

Actuator for Boom Swing .. ................................ ..... ......... ...... ....... 15 Cylinder for Stick .... ....... ......................... ....... .... ... ..... ........ ........... 16

Pump, Hydraulic (3G2873, 3G4096) ........................................... 10 Control Valve (3G646) ................................................................. 13 Pump, Hydraulic (8J4515, 3G5386) ............................................ 12 Control Valve (3G5634) ................................................................ 14 Cylinder for Boom .......... .......... .............. ..... .................................. 15 Cylinder for Bucket ......... ................... .............. ...... ............ ........... 16

Servovalve (3G3710) .................................................................... 11 Servovalve (3G7421) .................................................................... 11

Cylinder for Stabilizer (Fixed Pivot) ................... ................ ........... 17 Cylinder for Stabilizer (Side Shift) ................................................. 17 Torque Chart ................................................................................... 7

SYSTEMS OPERATION

Backhoe Hydraulic System ...................... .................................... 18 Swing Actuator .............................................................................. 28

Control Valve for Backhoe ............................................................ 20 Cushion Valve in Swing Actuator ................................................ 28 Valve Section for Boom, Stick and Swing ................................... 24

Valve Section for Bucket in CLOSE Position ............................... 23 Hydraulic Pump (Axial Piston-Type) ............................................ 26 Valve Section for Bucket in DUMP Position ................................. 22

Valve Section for Bucket, Left and Right Stabilizers ................... 20 Relief Valves ................................................................................ 25 Valve Section for Swing in SWING RIGHT Position .................... 24


Backhoe Hydraulic System .. ..... ......... ......... ...... ...... ............ ......... 30 Relief Valve Adjustment ................................................................ 35 Relief Valve Test .......................................................................... 34

Checking Pump Efficiency .... ..................... ............ ....................... 30 Servovalve Adjustment .. ....... ........................... ..... .............. ..... ..... 33

Hydraulic Pump (Axial Piston-Type) ............................................ 32 Servovalve Pressure Test ............................................................ 32

Oil Leakage Test for Axial Piston-Type Pump ............................. 35 Tests for Drifts of Cylinder Rods .................................................. 31 Operation Times ........................................................................... 31 Stabilizer Cylinders .................................................................. 31

Stick and Boom Cylinders ....................................................... 31 Performance Test List .................................................................. 30 Too Much Cylinder Rod Drift ............. ..................................... 31

Relief Valves ........................................................................ ......... 34 Visual Checks ..................... ......... ........ ......................................... 30


Index for Disassembly and Assembly..... ........ ........ ........ ................ 37

5


D3B AND 931B BACKHOE INDEX

INDEX

SPECIFICATIONS

Actuator Groups: Mounting and Control Groups ................... ...... .................... 21 Rotary ................. ......................................................... 18 Swing ................................................................. 17 Pins and Bearings for Bucket Linkage ....... ..................... 22-25

Pump, Hydraulic:

Backhoe Frame .................................................................. 17 Backhoe ........................................................................ 10 D3B Implement............ ..... ............................................ 13 931 B Implement ............................................................. 12

Cylinders: Boom ............................................................................. 19 Torque Chart ........................................................................ 7

Bucket ........................................................................... 20 Stabilizer (Fixed Pivot) ..................... ............... ............... 21 Stabilizer (Side Shift) .. ............................................ ........ 20 Stick .............................................................................. 19

Valves: Control Valve for Backhoe ............................................. 14 Main Relief Valve ........................................................... 16 Relief Valve Adjustment .................................................. 16 Sections of the Backhoe Control Valve .......................... 15

Lines, Plugs and Fittings .... ................................... ................ 8 Servo Valve ................................................................... 11

SYSTEMS OPERATIONS

Backhoe Hydraulic System ................................................ 26 Section for Bucket in CLOSE Position .............. ......... 32 Section for Bucket in DUMP Position ................ .... ..... 31

Introduction - Backhoe Hydraulic System............................. 26 Section for Stick in IN Position ...................... ............ 35 Section for Stick in OUT Position............................... 34

Pump, Hydraulic............... ......... .............................. ............ 36 Section for Swing ...................................................... 35 Section for Swing in Swing Left Position ..... ............... 35

Swing Actuator .......... .............................. ............... ............ 39 Section for Swing in Swing Right Position .................. 35

Relief Valve .................................................................... 35 Main Relief Valve ...................................................... 36

Valves: Protective Relief Valve ......... ..................................... 36 Control Valve for Backhoe ......................................... .... 29 Relief Valve for Swing Actuator ................................. 36

Section for Boom and Stick ..................................... 33 Servo Valve for D3B .... ................................. ........... ...... 38 Section for Bucket and Left and Right Stabilizers ...... 30 Servo Valve for 931B .................................................... 37


Backhoe Hydraulic System ................................................. 40 Release of Pressure in the Hydraulic System ...................... 43 Relief Valves ....................................................... ...... .......... 44

Checking Pump Efficiency .............. ..................................... 41 Boom, Stick and Main Pressure Adjustment .................... 47 Boom, Stick and Main Pressure Test .............................. 46

Operation Checks ............................................................... 42 Swing Adjustment ........................................................... 48 Operation Times..................................... ............................. 42 Swing Test ..................................................................... 45

Performance Test List ......................................................... 41 Pump, Hydraulic .. ................................................. ............... 43 Tests for Drifts of Cylinder Rods ............... ..... ............... ...... 42

Oil Leakage Test for Axial Piston-Type Pump ..... ~........... 47 Stabilizer Cylinders ......................................................... 42 Servo Valve ...... ....................................... ...................... 43 Stick and Boom Cylinders .............................................. 42 Servo Valve Adjustment ................................... ........ ...... 43 Too Much Cylinder Rod Drift .......................................... 43


Index for Disassembly and Assembly .................................. 49

5


D3B AND 931B BACKHOE INDEX

INDEX

Backhoe Stabilizers (FP) .. .. ..... .. ............. . '" ... :.. .. ... .... ........... ...... .. .. .... 89 Piston Hydraulic Pump ....... ... ...... .. ................. ........ ... ..... .. .. ... ......... .. . 106 Backhoe Service Warning ...... .... .. ... ..... . ... ........ .. ....... ........ ....... ...... .... 50 Piston Hydraulic Pump. Disassemble & Assemble ...... ... ....... ..... ........ 110 Boom and Boom Cylinder (FP) ...... ... ...................... .... .. ... ... .......... ...... 59 Boom and Boom Cylinder (SS) .. . ............ .. .... ..... ... .... .... . ... . ...... .. ... ...... 64 Bucket (Backhoe) .... ... .. .. .. .... .. ....... .... ..... ... .......... .... .... . ... .... ........... ... 52 Bucket Cylinder ....... ... .. .. ...... .... .. ... ............... ..... .... ....... ... ... ...... .......... 55 Bucket Linkage .... ... ..... ...... ......... .. ....... .. ... .. ... .... .. ... ... ... .. ........ .. ....... .. 53

Sideshift Lock Cylinder (SS) .. .... ........ .. ....... .. .. .. .. ............. . ...... .. ....... . 101 Sideshift Lock Cylinder Control Valve (SS) ........ ... ... ........ ... ... ........ . .... 98 Stabilizer Cylinders (FP) .. .. ..... .. .. .... .. ..... .. ... .. ...... .. .. .. ... .... .. .. .. ...... .... .. . 70 Stabilizer Cylinders (SS) .... ...... .... ... ...... .. .. . .... ...... ............ ... ............. .. . 71

Console .. . .......... ...... ....... .... ........ ... .......... .... .... ... .. .... .. .... . ............. ...... 89 Stick Cylinder ... .. ... ..... .. ...... ...... ....... ............ ... ........ ........... ..... .... .. .. ... . 69 Swing Actuator .. .. ............... ...... .......... ... ..... ..... . ........ ... ... ....... .. .... .. ... . 80

Frame (FP) .... .. ...... .... .... .... .. ... ... . .. .... .. ... ... ...... .. ......... ... ... ... .... .... . .... 103 Frame (SS) ... . ....... .. .. .. ...... .... .. .. .. ... .... . ... ...... .. ... .. .. ... .. ..... .... .. ... .... .. .. 104

Swing Actuator. Disassemble & Assemble ... .. ........ ..... ...... .. .... ......... ... 82 Swing Frame (FP) ................. .... .. .......... .............. ...... ..... ....... ... ...... ... . 86 Swing Frame and Sliding Frame ............... ... ........ .. .. .. ....... ......... .. ....... 87

Hoe Stick ...... ........ .. ... . ......... ....... ... .............. ..... ........ .... .. .. .... ... ....... ... 57 Hydraulic Control Valves ..... ........ .. ...... ... .... ... ...... ..... ... ... ....... .. .... .. ... .. 92 Tips and Sidecutters ........... .. .. ...... .. . ......... .... ... .... ... . ............... .. ...... ... 51 Hydraulic Cylinders. Disassemble & Assemble ... .. ......... .... ....... .... .... ... 73 FP - Fixed Pivot Backhoe Hydraulic Oil Cooler ... ..... ........ .. .. .. .. .... .. .... .... ... ..... ..... ... ...... ..... ..... .. . 121 SS - Side Shift Backhoe

A WARNING


49


D3B AND 931B BACKHOE DISASSEMBLY AND ASSEMBLY

STABILIZER CYLINDER (SIDESHIFT)

REMOVE STABILIZER CYLINDER

Toots Needed A

6V2156 . Link Bracket

1. Lower all hydraulically controlled equipment to the ground.

2. Remove covers (I) from both ends ofthe stabilizer.

3. Remove plates (2) from both ends of the stabilizer.

4. Remove plate (3) and guard.

5. Fasten tool (A) to cylinder (4).

6. Disconnect hose assemblies (5) and (6).

7. Lift stabilizer cylinder (4) out of the stabilizer frame. The weight of the stabilizer cylinder is 52 kg (I 15 lb.).

71


SENR7923 D38 & 9318 OPERATOR'S STATION CONTENTS

CONTENTS

COMFORT ITEMS Operator's Seat ............................................................................................................................. 4 Pressurizer .. ..... ....... ................................. ....... .............................. ....... .......................................... 4 Air Conditioner . ...... .......................................... .................................................................... .......... 5 Heater ............................................................................................................................................ 5

PROTECTIVE ITEMS Horn ............................................................................................................................................... 6 Windshield Wiper/Washers ........................................................................................................... 6 Parking Brake ..................... ...... .............................. .................................... ................................... 6 Backup Alarm .. .......................................... ...... ............................. ..................................... ............ 7

OPERATOR COMPARTMENT ........................................................................................................... 8

CONTROL GROUPS Hydraulic Controls (931 B) ............................................................................................................. 9 Hydraulic Controls (D3B) ......................... ............... ................... ..... ............ ........................ ........ ... 9 Ripper Control .... ..................... ........................................ ............................... ............................. 10 Governor Control ....... ........ .............. ....................... ......... ............................................................ 10 Governor Control-Attachment .............................. ........................... ...................... .................... 11 Transmission Seleclor Control ............... ..................................... .......... ............. ......... ................ 11 Transmission Lock Lever ....... ...................... ....................................... ..... ..................... ...... ......... 11 Steering Controls .................................. ....................................... ......... .............................. ......... 12 Brakes ....................................................................................................... , ................................... 12

ELECTRICAL SYSTEMS Instrument Panel ............ ......... ................................. .................................. ................................. 14

ELECTRICAL TROUBLESHOOTING .......................................................................................... 17-45

ELECTRICAL SCHEMATICS ........................................................................................................... 47

3


D38 & 9318 OPERATOR'S STATION ELECTRICAL TROUBLESHOOTING INDEX

INDEX

BLOCK DIAGRAM .................................................................................................................... 18,19

CODES AND ABBREVIATIONS ....................................................................................... . 20

ELECTRICAL SCHEMATICS ........................................................................................................... 47

INDIVIDUAL CIRCUIT DESCRIPTION (SIMPLIFIED SCHEMATICS) Air Conditioner . .......... .................................................. ...... .......................................................... 27 Back-Up Alarm .......................... ,." .. ,',., ..... " .................................. " .. , .. """', .. , .. ,"', .. ,.,',., ............ 23 Bucket Positioner Kickouts (931 B) .............................................................................................. 29

5S7255 Solid State Switch Assembly ........................................................................... " .... " ... 29 Cab Pressurizer Circuit ............................................. , .................................................................. 26 Front Horn Circuit ..................................................... , .................................................................. 23 Lights Circuit ................................................................. , .. ,., ....... , .. , .............................................. 24 Service Meter ............. .......... ..................................................................... .................................. 24 Start Circuit ..... , .... '.' ........................................................ , ....... , .................................................... 22 Starting Aid Circuit ....................................... , .......... , ................ , ....................... , ........................... 22 Windshield Wiper Circuit ......................................... ,., ................................................................. 25

LOCATION OF ELECTRICAL COMPONENTS ............................................. . . .. " ... , ..... , .......... 21

RELAYS ........................... , ............. , .. , .... , .. , ... , ..................... , .......................... , ......... '., .. , ..... , ............ 45

TROUBLESHOOTING METHODS ............ ,' ............................... , ......... , ...... , .. ,., .......... , .................. 18

TROUBLESHOOTING THE BUCKET }(ICKOUTS Controls For Bucket Lift and Tilt Circuit ....................................................................... " ............ 28 Lift Kickout ................................................ , ........... , ............................................. " ....... , .. ,............ 31

Troubleshooting ......................... , .................................................... , ... , ...................... "....... 32-37 Tilt Kickout ................. " ........................................................................ , .................... , ... , .............. 38

Troubleshooting .................................................. , ................ , .............................................. 39-44

WIRING COLORS ON DASH PANEL ............................. " .............................................................. 45

17


OPERATOR'S STATION DISASSEMBLY AND ASSEMBLY

6

INDEX

Backup-Warning Alarm ............... .. ....... ...... ......... .......... ............. .... ... ....... ... .... .... ................ .. ... ... ...... 32 Battery, D3B . ...................... ........... ............... ................. ...... ... .... .................................. ...... ..... .. ... 28,29 Battery and Battery Frame, 931 B ......................................................................................... .... .. . 30,31

Cab, D3B ...... ................. ............. .. .............. .................... ...... ......... ..... .... .............. ....... ................ 78-83 Cab Door Latch ................................... .......... ...... ... ........... .... ....... ...... .... ... .................. ................. 74-77 Cab Pressurizer Group, D3B ................ .... .. ............. .................... .. ... .................. ......................... 71,72 Cab Window Glass .............................................. ......... ........ .. .. ................................................... 17,18

Dome Light .. .. ................... ...... .... .. ............ .. ............. ... ...... .... ....... ..... ........ ........ .. ... ..... .. .. .... ............ .. 8,9 Doors ................................................. ... ... ..... ..... .. ......... .... ... .. .... ..... ...... .. ...... .. ...... .......... .... ........... .. .. 14

Fan Blower Switch .... .. .... .... . ....... ........... .. ....... ......... ...... ....... ... ............. .. ...................... ... ...... .. ........... 7

Horn and Horn Switch ................................... ................. ........... ....... .................................................. . 7 Hydraulic Control Levers (3F/3R-D3B) ....................................................................................... 54-59 Hydraulic Control Levers (3F/1 R-931 B) .......................................... .................. .......................... 60-65

Instrument Panel .......................... ............................................................................................ ... 19-21 Instrument Panel, Disassemble & Assemble ........ ...... ........................................... .... ..... .. .......... 22-27

Mirror ........ .. ..................................................... ...................................................... ... ........................... 8

Roll-Over Protective Structure ...... ................ ...... .. .... .............. ......... .............. ........ ...... .... . ........ ...... .. 73 Seat and Seat Frame ......................................................................... ........... .... ..................... ...... 10,11 Seat Belt ....................................................... .... ..... ................... .... ..... ....... .. ........ ..... .......... ... .. .. ... .... . 12 Sound Suppression ............................................................ ..... ...... ....... ..... .. ............... .............. ....... .. 33 Steering and Brake Pedals .... ....... ................................. ...................... .. ......... ............................. 66,67 Steering and Brake Pedals, Disassemble & Assemble ............................................................... 67-70

Trans. ,'ission and Govemor Control Linkage, D3B ..................................................................... 34-43 Transmission and GovQmor Control Linkage, 931 B ................................................................... 44,45 Transmission and Govemor Control Linkage. 931B, Disassemble & Assemble ................. ... ... 46-53

Windshield Washer r;,:,'.lP .... ......... .. .............. ...... .............. ... ............................................................ 12 Windshield Wiper Molor .. .... ........ ...... ................ .. .............. .................... .. ........... ... ....................... 15,16 Wiper Arm Linkage Assembly ........... ....... .......... ......................................................... .... ............ ... ... 13 Wiper Blades ......... ..... ... ........ .... .................. .. .... .......... .... .... .. .. .. ...... ... .. ....... ..... .. .. ................. .. .......... 14

&. WARNING



Table of Contents

Operation Section Lubrication And Maintenance Section

Foreword .......................................................... 2 Foreword ........................................................ 51 Model Views ..................................................... 3 Safety............. ....... ....... ................................. 52

Safety ............................................................... 5 Symbol Identification ........................................ 8 Operator's Compartment ............................... 11 Controls .......................................................... 19

Walk-Around Inspection ....... ........ .................. 54 Maintenance Recommendations ................... 55 Fuel and Lubricant Specifications ................. 57 Lubrication and Maintenance Chart .............. 58

Before Starting ............................................... 27 Starting the Engine .... ........ ...... ...... ............... 31 After Starting .................................................. 34 Moving the Machine ....................................... 36 Parking the Machine ...................................... 40 Stopping the Engine...................................... 41 Operating Adjustments .................................. 42 Operating Techniques .................................... 43 Transportation Hints ....................................... 49

Every 10 Service Hours or Daily .. ................ 60 Every 50 Service Hours or Weekly (whichever occurs first) .................................................... 63 Every 250 Service Hours or 3 Months (whichever occurs first) ................................... ................ 65 Every 500 Service Hours or 6 Months (whichever occurs first) .................................................... 72 Every 1000 Service Hours or Yearly (whichever occurs first) .................................................... 75 When Required ............................................. 83 Refill Capacities ............................................. 96 Bolt Torques for Ground Engaging Tools ..... 96 Serial Number Locations ................................ 96

1


Table of Contents

Foreword .......................................................... 2

Safety ............................................................... 3

T . oWing .............................................................. 3

Operation Section

Machine Controls ............................................. 5

Before Starting the Engine .~............................. 8

Starting the Engine ........................................ 10

After Starting the Engine ............. .................. 12

Moving and Stopping the Machine ................ 13

Parking the Machine ...................................... 19

1

Maintenance Section

Coolant, Fuel and Lubricant Specifications ................................................. 21

Refill Capacities ............................................. 21

Lubrication and Maintenance Chart .............. 22

Every 50 Service Hours or Weekly ............ .... 23

Every 250 Service Hours or 3 Months ........... 23

Every 500 Service Hours or 6 Months .,. ........ 24

When Required .............................................. 27


d3b s/n 3yc1, 5mc1, 23y1, 24y1, 27y1 28y1 & up volume 1 of 3 · senr3130-14 i04556274...

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