CT-S-955L TX8Y

CCaatteerr ppii ll llaarrService Manual

955L TraxcavatorS/N 8Y1, 13X1, & 57M1

Volume 1 of 3

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

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

Serv

ice

Man

ual

3304 VEHICULAR ENGINES SPECIFICATIONS

INDEX Air Inlet and Exhaust System

Air Cleaner..... ....... ................ ............... 43 Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 37 Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 42 Glow Plug Positioning ................................ 41 Exhaust Manifold ..................................... 43 Exhaust Pipe and Muffler. . . . .. . . . . . . . . . . . . . . . . . .. . . . .. 43 Turbocharger.. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .. 46-51 Turbocharger Impeller Installation .................. 44, 45 Valves (01) ........................................... 40 Valves (PC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 38, 39 Valve Cover .......................................... 42 Valve Rocker Arms and Lifters ....................... ,. 37

Basic Engine Components Bearing Surface (Journal)

Connecting Rods ................. , . . . . . . . . . . .. . . ... 69 Main Bearings. . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . .. . . . .. 68

Connecting Rod. .. ... ... .... .... ............. ........ 66 Crankshaft ........................................... 67 Crankshaft Hub. . .. . . . .. . . . . . . . . . . . . . . . . . . . . .. . . . . . ... 70 Cylinder Block

Counterbored Block ................................ 60 Spacer Plate Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 61

Cylinder Liner.. . . . . . . . . ... . . . . . .. . . . . . . .. . . . . . . . . . ... 62 Cylinder Liner Projection

Counterbored Block ................................ 62 Spacer Plate Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 63

Fan Drive.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 71 Flexible Drive Coupling ............................ 76, 77

Checking and Adjusting Alignment of the Flexible Drive Coupling ........................... 78

Flywheel ............................................. 73 Flywheel Housing ........................ , . . . . . . . . . . .. 74 Flywheel Housing Bore................... ............. 75 Flywheel Housing Tightening... .... .... ............... 72 Flywheel Ring Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 72 Main Bearing and Connecting Rod Bearings ........... 70 Pistons and Rings

Keystone ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 64 Straight Side ....................................... 65

Cooling System Coolant Flow Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 59 Fan Drive... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 71 Radiator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 58 V-Belt Tension Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 57 Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 57 Water Temperature Regulator. . . . . . . . . . . . . . . . . . . . . . . .. 59

Electrical System Alternators ........................................ 79-82 Alternator Regulator .................................. 83 Generator Regulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 85-87 Generators.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 84,85 Starter Magnetic Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 92 Starter Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 88-92 Starter Solenoids ............ _. . . . . . . . . . . . . . . . . . . . .. 93-95

Engine Design. . . . . . . . . .. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . 2 Engine Mounting Bolts. . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . .. 76

Fuel System Fuel System Timing. ... .......... .. . .. .... .. ... ..... .. 6 Fuel System Usage Chart ............................. 6 Service Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Tachometer Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Fuel System ~ Scroll (01) . . . .. .... ... . . . .. . .. ... .. . ... .. 31 Fuel Injection ....... : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 32 Fuel Injection Pump Housing. . . . . . . . . . . . . . . . . . . . . . . . .. 31 Fuel Transfer Pump. . . .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 35 Governor.. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .. 34 Governor Housing ....................... '" ... ....... 33 Injection Nozzle ...................................... 33

Fuel System ~ Scroll (PC) .............................. 27 Fuel Bypass Valve .................................... 30 Fuel Injection Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 27 Fuel Transfer Pump. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . .. 30 Governor (Earlier) .................................... 28 Governor (Later) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 29

Fuel System ~ Scroll (PC & 01) .... .. ......... ... ... .... 36 Timing Gears. . . . . .. . .. . . .. . . . . .. . . . . . . . . . . .. . . . . . . . .. 36

Fuel System ~ Sleeve Metering (01) ..................... 18 Fuel Injection Equipment..... ........ . .. ........... 18-20 Fuel Ratio Control .................................... 21 Fuel Transfer Pump. . . . . . . . . . . . . . . . . . . . . . . .. ... .. . . . .. 21 Governor Control (04E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 23 Governor Control (120G & 130G) . .. ................... 22 Governor Control (225) ........................... ,c. .• 24 Governor Control (518) ............................... 24 Injection Nozzle ................................. ,~'... 21

Fuel System ~ Sleeve Metering (PC) .................... 8 Fuel Injection Equipment ............................ 8-12 Fuel Ratio Control.. ......... ... ... ........ ........... 13 Fuel Transfer Pump ................................ '" 13 Governor Control (920 & 930) ......................... 14 Governor Control (950) ............................... 16 Governor Control (951) ............................... 17 Governor Control (955L) .............................. 15

Fuel System ~ Sleeve Metering (PC & 01) ............... 25 Timing Gears ................ '.,' . . . . . . . . . . . . . . . . . . . . . .. 26 Water Separator .............. ~ . . . . . . . . . . . . . . . . . . . . . .. 25

Gauges Converter Oil Temperature Indicator. . . . . . . . . . . . .. . . . .. 97 Fuel Pressure Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 96 Oil Pressure Indicator.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 97 Water Temperature Indicator. . . . . . . . . . . . . .. . . . . . . . . . .. 96

General Tightening Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Lubrication System Engine Oil Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 55 Oil Breather Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 56 Oil Filter ........................................... 55,56 Oil Pump...... .... .. ... . . . . . . .. . .. . . ... ... .... .. .. 52-54 Oil Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 97

Torque for Flared and O-Ring Fittings ................... 5

3

3304 VEHICULAR ENGINES SPECIFICATIONS

WATER PUMP

(1) Oil seal. Put engine oil on the seal lip. Assemble with the lip toward the bearings.

(2) Water seal and ring.

a. Put water on the seal.

b. Install the seal and ring together in the housing bore, with the shiny face of the ring outside.

(3) Seal assembly.

a. Remove the spring from the seal.

b. Put water inside the seal assembly.

c. Install the seal assembly around the shaft, with the 7N7843 Installation Tool, (the tool is with the seal group) until the car­bon face makes contact with the shiny face of the ring (2).

d. Install the spring.

(4) Torque for the bolt that holds the impeller. . . . . . . . . . . . . . . . . . . . . . .. 28 ± 1 lb. ft. (39 ± 1 N·m)

(5) Torque for bolt that holds the gear. . . . . . . . . . . . . . . . . . . . . . . . . .. 32 ± 5 lb. ft. (43 ± 7 N·m)

2

3

4

V-BELT TENSION CHART

WIDTH TOP BELT TENSION BELT TENSION

BELT SIZE WIDTH OF PULLEY "INITIAL"· .. USED .. ••

BELT TOP GROOVE GAUGE READING GAUGE READING

in_ mm in. mm lb. N Ib_ N

3/8 .422 10.72 .380 9.65 100 ± 5 445 ± 22 90 ± 5 400 ± 22

1/2 .547 13.89 .500 12.70 120 ± 5 534 ± 22 90 ± 10 400 ± 44

5V .625 15.88 .600 15.24 120 ± 5 534 ± 22 90 ± 10 400 ± 44

11/16 .688 17.48 .625 15.88 120 ± 5 534 ± 22 90 ± 10 400 ± 44

3/4 .750 19.05 .690 17.53 120 ± 5 534 ± 22 90 ± 10 400 ± 44

15/16 .938 23.83 .878 22.30 120 ± 5 534 ± 22 90 ± 10 400 ± 44

. I I , I

~,--..,.--

77723X3

BORROUGHS GAUGE NUMBERS

OLD GAUGE NO. NEW GAUGE NO.

BT-33-73F BT-33-95

BT -33-96-4-16 BT-33-95

BT -33-72-4-15 BT-33-72C

BT -33-72-4-15 BT-33-72C

BT-33-72-4-15 BT-33-72C

BT-33-72-4-15 BT-33-72C

MEASURE TENSION OF BELT FARTHEST FROM THE ENGINE

·"INITIAL" BELT TENSION is for a new belt. ·"USED" BELT TENSION is for a belt which has more than 30 minutes of operation at rated speed of engine. A10232X5

57

3304 VEHICULAR ENGINE INDEX

SYSTEMS OPERATION

Air Inlet and Exhaust System. . . . . . .. . . . . . . . . . . . . . . . . . ... 31 Air Inlet and Exhaust System. . . . . . . . . . . . . . . . . .. 31 and 32 Timing Gears. . . . .. . .. . . . . . . . . . . . .. .. . . . ... . .. . . . . . . .. 33 Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 32 Valves and Valve Mechanism .......................... 33

Basic Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 40 Crankshaft ........................................... 40 Cylinder Block and Liners. . . . . . . . . . . . ... . . . . . . . . . . . . .. 40 Pistons, Rings, and Connecting Rods. . .. . . . . . . . . . .. ... 40

Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 38 Coolant for Air Compressor. . . . . . . . . . . . . ...... . .. .. ... 39

Electrical System....... ..... ........................... 41 Charging System Components ........................ 41 Electrical System Schematic. . . . . . . . . . . . . . . . . . . . . . . . . .. 45 Other Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 44 Starting System Components. . . . . . . . . . . . . . .... . . .. . . .. 43

Fuel System (Scroll-Ol) ................................. 27 Fuel Injection Pump. . . . . . . . . . . . . ... . . . . . . .. . .. . .. ..... 27 Fuel System Timing. . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . .. 27 Governor (Hydra-Mechanical) ......................... 28 Injection Nozzles ..................................... 30 Introduction. . . . . . . . .. . . . .. . . . . . . . . . . . . .... . .. . .. . . ... 27

Fuel System (Scroll-PC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 24 Fuel Injection Pump. . . . . . . . .. . . . . . . .. .. . . . . .. . . .. .. . .. 24 Fuel Injection Valve. . . . .. . . . . . . . . . . . . . ... . . . . .. . ... ... 26 Fuel System Timing. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. 24 Glow Plugs.. . . . . . . . . . . . . . . . . . . . . .. . . . . . . .. ....... .... 26 Governor Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 25 Introduction. . . . . . . . . . . . . .. . . . . . . . . . . ... . . . . . . . .. . . ... 24

Fuel Systyem (Sleeve Metering) ......................... 6

Adjustments To The Sleeve Metering Fuel System... ... 18 Fuel Flow After Engine Stops Running................. 16 Fuel Flow Using The Priming Pump and Bleed Valve. . .. 15 Fuel Flow With Engine Running ....................... 7

System With Constant Bleed Valve. . . . . . . . . . .. . . . . . . . 9 System With Siphon Break. . . . . . . . . . . . . . . . . . . . . . . . . . 7 System With Siphon Break and

Constant Bleed Valve.. .... . ... . . ... . ... . .. ... .... 13 System Without Siphon Break or

Constant Bleed Valve ............................. 11 Fuel Injection Pump Operation.. ......... .......... ... 17 Fuel Injection Valve-PC. . . . . . . . . . . . . . . . . . . .. . . . . . . . .. 23 Fuel Injection Valves. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . 6 Fuel Priming Pump.. ............... ..... ............. 15 Fuel Ratio Control .................................... 22 Fuel System Operation............ . ................. .. 18 Fuel System Timing. . . . . . ... . . . . . . . . . .. . . . . . . . . . . . . . . . 6 Fuel Transfer Pump........... ............. .... ... .... 15 Glow Plugs-PC. . . .. . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . .. 23 Governor. . .. . .. . . . .. . . . . . . . . . . . . . . ... . . . .. . .. . . . . . . .. 20 Injection Nozzle-Ol .................................. 23 Introduction. . . . . . . .. .. . . . . .. . . . . .. . . . . . . . .. . .. . . . . . . . 6 Non-Adjustable Oashpot Governor.. . . . . . . . . . . . . . . . . . .. 21 Siphon Break................... ........... ......... .. 15 Water Separator. . . . . .. . . . . .. . . . ... . . .. . . . .. . . . . . . . .. . 6

General Information. . . . .. . . . . .. . . . . ... . . . . . . .. . . . . . .. . . . 5 Engine Oesign . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. .. . . . . . . . . 5 Fuel System Usage Chart ............................. 5

Lubrication System ..................................... 34 Oil Flow In The Engine... . . . . . . . . . . . .... . .. . .. . .. . . . .. 36 Oil Flow Through The Oil Filter and Oil Cooler. . .. . . . .. 36

3

3304 VEHICULAR ENGINE INDEX

TESTING AND ADJUSTING

Air Inlet and Exhaust System....... ..... ...... .... . .... 107 Flow Checking Fuel Injection Pump Timing

Checking Inlet Manifold Pressure At Torque Converter Stall Speed. ............. ................ 108

Compression. . . . . . . . .. . . . . . . .. . . . . . . . . . . . . . . .. . . .. .. 109 Crankcase (Crankshaft Compartment) Pressure....... 109 Cylinder Head.......... ..... ...... . . .. . ........ . . ... 109 Glow Plug and Precombustion Chamber Removal

and Installation .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 110 Measurement of Exhaust Temperatures............... 109 Measurement of Pressure in Inlet Manifold...... .... .. 107 Procedure for Measuring Camshaft Lobes. .... ........ 112 Restriction of Air Inlet and Exhaust.... ............... 107 Turbocharger........ .... ..... . ....... ... .... ........ 108 Valve Clearance ..................................... 111

(PC Engines Only) . . . . . . . . . . . . . . . . . . . . . . . .. .. . . . . . .. 73 Fuel Injection Lines. . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 72 Fuel System Inspection ............................... 60 Start-Up Procedure. . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .. . .. 73 Test Sequence - Precombustion Chamber (PC)

Fuel Nozzle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . .. 62 Testing 7N449 Fuel Injection Nozzles.... ....... ... .. .. 63 Testing Capsule-Type Fuel Injection Nozzles. . . . . . . . . .. 60 Troubleshooting of 7N449 Fuel Injection Nozzles. . . .. .. 69

Fuel System (Scroll-DI) ................................. 99 Checking the Fuel Injection Valves. . . . . . . . .. . . .. . . . . . .. 99 Checking the Plunger and Lifter Washer of an

Injection Pump ..................................... 99 Fuel Injection Pump Timing Dimension Setting:

Basic Block. . ........ ...... .... . . .......... ............ 122 Off Engine..... ....... ... . .. ....... ........... ..... 103 Connecting Rod and Main Bearings. . . . . . . . . . . . . . . . . .. 122 Connecting Rods and Pistons.. .......... ...... ...... 122 Cylinder Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 124 Cylinder Liner Projection ......................... 122,123

Counterbored Block....... ... ...... ......... ...... 122 Spacer Plate Block. ..... .......... ... ..... .... ..... 123

Flywheel and Flywheel Housing............. ..... 124-127 Oil Pump Installation. . . . . .. .. . . . . .... . . . . . . . .. . . . . . .. 127 Piston Ring Groove Gauge....... ... ............ ..... 122

Fuel Injection Timing Check (Timing Pin Method) ..... 102 Fuel Rack Setting............. ....... ................ 104 Fuel System Adjustments................. ...... ...... 101 Injection Pump (Install) .............................. 100 Injection Pump (Remove) ............................. 99

Fuel System (Scroll-PC) . . .. .... . . . .. . . . .. . . . . . . . . ... . . .. 91 Checking the Fuel Injection Valves. . . . . ... . . .. . . . .. . . .. 91 Checking the Plunger and Lifter Washer of an

Injection Pump..... ... ............................. 91 Fuel Injection Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 91

Cooling System ........................................ 115 Accessory Drive Shaft Timing ....................... 95 Checking Coolant Temperature.. ...... ... ............ 115 Checking Fan Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 117 Checking Radiator Air Flow .......................... 117 Filler Cap and Pressure Relief Valve..... ... .... ...... 119 Gauge for Water Temperature. . . . . . . . . . . . . . . . . . . . . . .. 119 Pressure Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 118 Testing Radiator and Cooling System for Leaks ....... 118 Testing the Cooling System.. . . . . . . . . . . . . .. . . .. . . .... 115 V-Belt Tension Chart................... .... .......... 121 Visual Inspection of the Cooling System... ........... 115 Water Temperature Regulators......... .............. 120

Checking With 8S4620 Gauge. . . . . . . . .. . . .. . . . . . . . .. 93 Checking With 8S7167 or 5P4158 Gauge ............. 94 Fuel Injection Pump Timing Dimension Setting:

Off Engine. . . . . . . . . . . . . . .. . .. . . .. . . . . . . . . . . .. . .. .. 94 Fuel Rack Setting. . . . . .. . .. . . . . . . . . . . . . . . .. .. . . .. . .. 96 Injection Pump ..................................... 91 Injection Pump Installation. .. . . . . . . . . . . . .. . . . .. . . ... 91 Injection Valve (Capsule-Type Nozzle) ............... 91

Governor Adjustments ................................ 97 Fuel Ratio Control Setting. . . . . . . . . . . .. . . . .. . . . . .. . .. 98

Electrical System ...................................... 129

Fuel System (Sleeve Metering) . . . . . . . . . . . . . . . . . . . . . . . . . .. 79 Fuel Injection Service. . . . . . .. . . . . . . . . . . . . . . .. .. . . . . . .. 79 Fuel Pump Calibration ................................ 86

Battery.......................... ... ... .............. 129 Charging System .................................... 129 Starting System...................... ... ............. 132

Fuel Ratio Control Setting. . . . . . . . . . . . . . .. . . . . . . . . . . . .. 85 Fuel System Adjustments. .. . .. . .. . . .. . . .. . . . .... . . . . .. 80 Fuel System Setting. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. 83

Flexible Drive Coupling.................... ..... ....... 128 Governor Adjustments ................................ 82

Checking Flexible Drive Coupling Alignment..... ..... 128 Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 60

Lubrication System .................................... 113 Oil Pressure is High .................................. 114

4

Adjustment and Cleaning of 7N449 Fuel Injection Nozzles............................................ 70

Checking Engine Cylinders Separately. . . . . . . . . . . . . . . .. 60 Checking Engine Timing With 6V3100 Diesel

Engine Timing Indicator Group. . . . . .. . . . . . . . . . . . . . .. 74 Engine Speed Measurement. . . .. . . . . . . . . . . . . . . . . . . . . .. 73 Finding Top Center Compression Position for

No.1 Piston ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 75

Oil Pressure is Low .................................. 113 Too Much Bearing Wear ............................. 114 Too Much Oil Consumption .......................... 113

Troubleshooting. .. . . . . . . . . . . . . . . .. .. . . . . . . .. . . . . . . .. 46-59

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

SPECIFICATIONS

NOTE: For Specifications with illustrations, make reference to SPECIFICA­TIONS for 3304 VEHICULAR ENGINE, Form No. SENR7590. If the Specifications in Form SENR7590 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.

FUEL SYSTEM

5. To see if No. I piston on the compression stroke, look at the valves of No. I cylinder. The valves will be closed if No. I cylinder is on the compres­sion stroke. You should be able to move the rocker arms (4) up and down with your hand.

LOCATING TOP CENTER

Plug in hole for timing bolt (3).

LOCATING TOP CENTER

3. Bolt.

VAL VE COVER REMOVED

4. Rocker arms.

6. If No. I piston is not on the compression stroke, remove the 3/8"-16 NC bolt and turn the fly­wheel 360 0 counterclockwise. Install the 3/8"-16 NC bolt as before. The No. I piston is now at top center on the compression stroke (TCI).

76

TESTING AND ADJUSTING

FLOW CHECKING FUEL INJECTION PUMP TIMING (PC Engines Only) Tools Needed: 1P540 Flow Checking Tool Group. 5P6524 Engine Timing Indicator Group.

5P7265 Adapter. 9S215 Dial Indicator. 3P1565 Collet. 3S3264 Rod, 7.12 in. (180.9 mm) long. 3S3269 Contact Point.

5P7307 Engine Turning Tool Group. 6V2023 Adapter Group.

CAUTION

DO NOT use the Fuel Flow Method of Fuellnjec­tion Pump Timing on Direct Injection engines.

Travel of piston (7), from point of closing inlet port (6) to top center, can be found by using the procedure that follows:

NOTE: The fuel system timing has a tolerance of ± 10.

I. Put No. I piston at top center (TC) on the compression stroke. Make reference to FIND­ING TOP CENTER COMPRESSION POSI­TION FOR NO. I PISTON.

AS45tklX2

MEASURING PISTON TRAVEL

1. 3P1565 Collet Clamp. 2. 95215 Dial Indicator with Con­tact Point. 3. 5P7265 Adapter. 4. Precombustion chamber. 5.353264 Rod, 7.12 in. (180.9 mm) long. 6. Inlet port. 7. Piston.

ENGINE DISASSEMBLY AND ASSEMBLY

INDEX

Accessory Drive Shaft (Compact Fuel System) .......................................................................... 73,74 Adapter Housing and Levers (Sleeve Metering Fuel System) .................................................... 42,43 Alternator...... .............................................................................................................................. ....... 11 Air Cleaner Housing ............................................................................................................................ 8 Air Conditioner Compressor...... ...................... ............................ .......... ............. .... ..... ...................... 10

Balancer Shafts ....... . ,........... .................. ..... .............. ....... ..... .... ... ...... ..... ....... ......... ........ ......... ....... 119 Balancer Shaft Bearings ........... ......... ..... .......... ............ ........ ...... ...... ....... .............. ...... ................... 130

Camshaft... ............ .................. ....... ........ ..... ............ .... .... ................ ....... ......... ............. .......... ......... 103 Camshaft Bearings.......................................................................................................................... 131 Connecting Rod Bearings ................................................................................................................. 82 Crankcase Guard.. ............ .... ........... ..... .... .............. ............. ........ .......... ..... ....... ........ ...... ............. .... 75 Crankshaft ................................................................................................................................ 128,129 Crankshaft Front Seal and Wear Sleeve.......................................................................................... 99 Crankshaft Main Bearings............................................................................................................ 83,84 Crankshaft Rear Seal and Wear Sleeve.. ...... ....... ................. ............ ..... .... ................... ................. 126 Crankshaft Pulley.. ........ .................. ......... ... ...... .... ..... ....... ............. ...... ....... ............... ....................... 98 Cylinder Head........................................................................................................................... 109,110 Cylinder Liners... ..... ............. ...... ............ ........ ................. ...... ...... ..... ........ ..... ......... ........ .......... 116-118

Electric Starting Motor.... ................. ......... ............ ............. ...... ...... ...... ......... .............. ....... ..... ........... 11 Engine OIl Cooler ......................................................................................................................... 14,15 Engine ... ~.... .............. ........... ........ ....... ...... ...... .... ............... ....... ..... ..... ....... .............. ........ ...... ... 119-121 Exhaust Manifold .......................................................................................................................... 91,92

Fan and Alternator Belts......... ..... .......... ..... ................... ....... ...... ....... ...... ............... ....... ........... ... .... ... 9 Fan and Fan Drive ....................................................................................................................... 16,17 Fan Drive, Disassemble & Assemble .......................................................................................... 18,19 Flywheel...... ............. ....... .... ..... ..... ........... ...... .................. ...... ..... ........... ....... ............ ............... 122-125 Flywheel Housing .... ..... ...... ......... .................. ............... .... ....... .... ...... ....................... ..... .................. 127 Fuel Check Valve and Bypass Valve (Sleeve Metering Fuel System) ............................................ 64 Fuel Filter Base (Compact Fuel System) .......................................................................................... 32 Fuel Filter Base (Sleeve Metering Fuel System).............................................................................. 31 Fuel Injection Lines .......... ...... ......... ...... .... .......... ... ............ ....... ............ .............. ......... ........... .......... 28 Fuel Injection Pumps (Compact Fuel System) (part of Fuel Injection Pump Housing Disassembly & Assembly)............................................... 68-72 Fuel Injection Pumps (Sleeve Metering Fuel System) ..................................................................... 65 Fuel Injection Pumps (Sleeve Metering Fuel System), Disassemble & Assemble... ........ .................. ........... ...... ............. ..... ....... ....... .......... ....... ..... ............. 66 Fuel Injection Pump Housing and Governor (Compact Fuel System) ........................................ 49,50 Fuel Injection Pump Housing and Governor (Sleeve Metering Fuel System) ................................................................................................... 46-48 Fuel Injection Pump Housing and Governor (Compact Fuel System), Separation and Connection.......................................................................................................... 55,56 Fuel Injection Pump Housing and Governor (Sleeve Metering Fuel System), Separation and Connection ....... ....... .... ....... ......... ..... .......... ..... ..... ......... ....... ....... ......... ...... ........ 51-54

6

ENGINE DISASSEMBLY AND ASSEMBLY

INDEX

Fuel Injection Pump Housing (Compact Fuel System). Disassemble & Assemble ............................................................................................................ 68-72 Fuel Injection Pump Housing (Sleeve Metering Fuel System). Disassemble & Assemble ................... .................. ............... ......... ..... ................ ..... ...... ...... ....... ....... 67 Fuel Injection Valves.................................................................................................................... 28.29 Fuel Priming Pump (Sleeve Metering Fuel System) ........................................................................ 31 Fuel Ratio Control (Compact Fuel System) ... .................. .................. ....... .......... ..... ............. ............ 44 Fuel Ratio Control (Sleeve Metering Fuel System) ............. ............. ....... .... ............ ............. ............ 41 Fuel Ratio Control (Compact Fuel System), Disassemble & Assemble ..... ...... ...... .................... 44,45 Fuel Ratio Control (Sleeve Metering Fuel System). Disassemble & Assemble ................................................................................................................. 41 Fuel Transfer Pump (Compact Fuel System) ..................... .......... ..... .... .......... ....... ..... ....... .............. 32 Fuel Transfer Pump (Sleeve Metering Fuel System) .................................................................. 38-40 Fuel Transfer Pump (Compact Fuel System). Disassemble & Assemble .................................. 33-37

Governor (Compact Fuel System). Disassemble & Assemble.................................................... 61-63 Governor (Sleeve Metering Fuel System). Disassemble & Assemble........................................ 57-60

Hood .................................................................................................................................................... 8

Oil Filter Base ............................................................................................................................... 12.13 Oil Filter Base. Disassemble & Assemble..... ................................. ........................................... ....... 13 Oil Pan ............................................................................................................................................... 75 Oil Pan Plate...... ............. .................. ......................... ....................................................................... 76 Oil Pump ............................................................................................................................................ 77 Oil Pump. Disassemble & Assemble........................................................................................... 78-81

Pistons ...... ...... ..... ....... .......... .............................. ...................... ............................................... 111.112 Pistons. Disassemble & Assemble... ........................................... ........................................... ........ 113 Precombustion Chambers............................................................................................................ 29.30

Radiator Core ................................................................. ................................. ............. ................ 93,94 Radiator and Guard...................................................................................................................... 96,97 Rocker Shaft and Push Rods......................................................................................................... 107 Rocker Shaft. Disassemble & Assemble ........................................................................................ 108

Timing Gear Cover................................................................................................................... 100-102 Timing Gears and Plate ........................................................................................................... 104.105 Torque Converter Oil Cooler ............................................................................................................. 95 Turbocharger ................ ................. .......................... ............................. ..... .... ................... ................. 85 Turbocharger. Disassemble & Assemble .................................................................................... 87-90

Valves.............................................................................................................................................. 114 Valve Cover..................................................................................................................................... 106 Valve Guides ................................................................................................................................... 116 Valve Lifters...................... .... ..... ....................................................................................... ............... 111 Valve Seat Inserts............. ....... ......................... .............. ................................................................ 115

Water Directors ......... ......................... ................ ....... ...................................................................... 115 Water Pump ................................................................................................................................. 21.22 Water Pump, Disassemble & Assemble...................................................................................... 23-27 Water Temperature Regulator .......................................................................................................... 20

A WARNING

DISCONNECT BATTERIES BEFORE PERFORMANCE OF ANY SERVICE WORK.

7

955L 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 most current modules and form numbers lvailable for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE REG1l39F.

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

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

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

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

77200X2

NOTE: For Systems Operation, Testing and Adjusting, make reference to 955L TRACK-TYPE LOADER POWER TRAIN, Form No. SENR7677. For POWER SHIFT TRANSMISSION TESTING AND ADJUSTING, see Form No. SENR7678.

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

INDEX

Adjustments: Bevel Pinion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 21, 22 Brake Control Linkage ............................. 17,20 Final Drive Bearings .................................. 24 Steering Clutch Control Linkage ............... " .. , 17, 20 Track ................................................ 26

Alignments: Flexible Coupling Drive ....................... " .. " . . 4 Track Roller Frames ............. , ... ,. . ....... .... ... 29

Bevel Pinion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. 21, 22 Adjustment of Tooth Contact Pattern .................. 22 Bevel Gear Shaft Bearing Preload. . . . . . . . . . . . . . . . . . . . .. 21 Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 21 Free movement (backlash) adjustment. . . . . . . . . . . . . . . .. 21

Bypass Valve for the Oil Cooler.. .... .. ........... .. ..... 10

Case and Covers Group ................ " ... .. ... . .... .. 29 Control Valve for the Steering Clutch. .. .. .... ... .. .. .. .. 14 Crankcase Guard....................................... 14

Final Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 23, 24 Flexible Coupling Drive ................................. 5

Alignment of the Flexible Coupling Drive. . . .. .. . . .. .. .. 4 Front Idlers and Recoil Springs. . . . . . . . . . . . . . . . . . . . . . . . .. 25

Hydraulic Controls for the Transmission ................. 11 Pressure Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11 Selector Valve ........................................ 12

Oil Filters: Steering Clutch. . . . . . .. . . ... ... . . . . . . .. .. ... ... . .. . . .. 13 Transmission. . . . . . . . . .. . . . . .. .... .. .. .. .. .. . .... .. ... 10

Oil Pumps:

2

Steering Clutch....................................... 13 Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10

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

Relief Valve for Transmission Lubrication ................ 12 Rollover Protective Structure. . . . . . . . . . . . . . . . . . . . . . . . . . .. 14

Selector Valve ..... , ............. , " ...... , .. ..... .. .... 12 Steering Clutch ...................................... 15,16

Adjustment of the Controls for the Steering Clutches and Brakes ............................. 17,20

Case and Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 29 Control Valve ............................... , ....... .. 14 Oil Filter. . . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . . . . . . . . .. 13 Oil Pump ............................................. 13

Torque Converter.. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Track ............................... , . . . . .. .. ..... .. ... 27

Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 26 Track Carrier Rollers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 28 Track Roller Frames .................................... 27

Alignment... .. . .. .. .. .. .... .. .... . .. ... .. ... ... .... .. 29 Track Rollers.. .. ... ............. .. . .... . .. . .. .. . . . .. ... 28 Transmission.. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .. 7, 9

Bypass Valve for the Oil Cooler.. .. . .. .. .. . . .. . . . . . .... 10 Hydraulic Controls. " " .. ..... ... . .... .. . .. . . . .. .. . . .. 11 Lubrication Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 12 Oil Filter. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10 Oil Pump ............................................. 10 Pressure Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11 Selector Valve ........................................ 12 Transmission Control ................................. 6 Transmission Drain Plug.. ...... .. . . . .. . . . . .. . ... . . . .. 11 Transmission Mounting Group. . . . . . . . . . . . . . . . . . . . . . . .. 30

955L POWER TRAIN INDEX

SYSTEMS OPERATION

Bevel Pinion ........................................ . ....................... 17

General Information ............................. . ....................... 4

Hydraulic System for Steering Clutches 22 Control Valve .... ............. ....... ........... 24 Oil Filter .. ...... ............ .... ....... ........ ............ .. .......... ...... 24 Oil Screen .... ................................................... 23 ~~....................... ....................................... ~

Hydraulic System for Torque Converter and Transmission .... ................ .. ........................ ........ ...... ....... 5

Magnetic Screen ..... ........................ ............................ 7 Oil Cooler ................................................. " ............. 8 Oil Filter ................................................... ............................. 8 Oil Temperature Bypass Valve ......... ............................ 8 Pump ...................................................................................... 7

Steering Clutches, Brakes and Final Drives ........... ....... ........ ..... 18 Steering and Brake Control ................................................... 20

Brake Operation ................................................................. 20 Parking Brake Operation .................................................... 21 Steering Operation ...... ............. ........... ........... .......... ......... 20

Torque Converter .......... .. Transmission .................... ..

Lubrication .. . Transmission Hydraulic Controls

Inlet Relief Valve for Torque Converter.

......................... 9 10 12 13 16

Undercarriage ............. ..... .... ...... ........... 26 Front Idlers .... ............. ................. ............. 28

Lubrication ............... ............................................ 28 Position ..................... ............................................ 28

Recoil Spring and Mechanisms for Track Adjustment .......... 29 Hydraulic Track Adjuster.. ............ ................... ....... 29

Track ..................... ................. .. ................................... 30 Track Carrier Rollers .. .. ...................................... 26

Lubrication ............................ ............................................. 27 Track Rollers .... .......... .. ................................................. 27

Lubrication .............. .............................................. 27 Track Roller Frame ............................................................... 26

TESTING AND ADJUSTING

Bevel Gear and Pinion ................................................................ .. Troubleshooting .......................................................................... 31 Brakes ........................... . ....................................................... . Checks During Operation ..................................................... 31

Check List During Operation ................................................. 31 Final Drives .................................................................................. . Steering ........... ...................... ............................... 33

Torque Converter .............................................................. 33 Power Shift Transmission Testing Transmission ........... .. ............................................ 31

and Adjusting .................................... See Form No. SENR7678 Visual Checks ........... ..................................................... 31

Steering Clutches........................................................................... • Undercarriage: Pressure Check of the Hydraulic System ............................. 34 Track ....................................................................................... .

Track Roller Frame ........... .. ............................................. .

'See the Specifications, Form No. SENR7676.

SPECIFICATIONS

NOTE: For Specifications with illustrations, make reference to the SPECIFICA­TIONS FOR 955L TRACK-TYPE LOADER POWER TRAIN, Form No. SENR7676. If the Specifications in Form SENR7676 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

POWER TRAIN DISASSEMBL V AND ASSEMBL V

INDEX

Adjustment of Front Idlers .................................................................................................................. 31

Brake Actuating Mechanisms, Disassemble & Assemble ... ...................... ... ................... ............. 75-80 Bevel Gear and Pinion Settings ..... ............................ ........ ........................................... ............ 102,103 Bevel Gear Shaft, Disassemble & Assemble............ ............. ................................. ...................... 95,96

Crankcase Guard (Rear) ........ ... ...................... ........... ....... ................... ...... ... ................................... 109

Final Drive Cases, Gears, Idler Pinions and Bearings ..... ...... ............................. ......................... 56-62 Final Drive Pinions and Flanges ........................................... , ................................................... 104-108 Flexible Coupling .......... ......................................................................................... .... ....................... 110 Front Idlers .......................................................................................... '" ... ...... .......... .................... 29,30 Front Idlers, Disassemble & Assemble ......................................................................................... 32-36 Front Idler yokes ................................................................................................................................ 37 Fuel Tank ....................................................................................................................................... 65,66

Hydraulic Track Adjusters. .......................................... ..... ......................... ...... .............................. 38,39 Hydraulic Track Adjusters, Disassemble & Assemble ........... ... ......................................................... 40

Pinion ........................................................................................................................................... 97-101 Pump Drive, Disassemble & Assemble .................................................................................... 138-140

Recoil Springs ........................................ ................................... ............. ... ............. ....................... 41,42 Recoil Springs, Disassemble & Assemble .................................................................................... 43,44

Sprocket Assemblies.............................................................................. ... .................................... 49-55 Sprocket Segments.. ............................. ............. .......................... ............................... .................. ....... 9 Sprocket Shafts ............................................................................................................................. 63,64 Steering Clutches and Bevel Gear Shaft............................ ............. ................. ............ .... ............ 85-87 Steering Clutches, Disassemble & Assemble...... ............................. ................................. ... ........ 88-94 Steering Clutch Case Cover, Steering Clutch Control Linkages and Brake Actuating Mechanisms ........................................................................................................ 67-70 Steering Clutch Control Linkages, Disassemble & Assemble ...................................................... 81-84 Steering Clutch Hydraulic Mechanism, Disassemble & Assemble ............................................... 71-74 Steering Clutch Oil Filter.......................... ....................................... ................................. ................ 177 Steering Oil Pump....................... ............................................................................... .............. .... .... 178 Steering Oil Pump, Disassemble & Assemble .......................................................................... 180-182

6

POWER TRAIN DISASSEMBLY AND ASSEMBLY

INDEX

Torque Converter and Pump Drive ........................................................................................... 126-130 Torque Converter, Disassemble & Assemble ........................................................................... 131-137 Tracks, Separation And Connection ....... .................................................... .................................. 22,23 Tracks, Disassemble & Assemble .................................................. ............... ..... ... ....................... 24-28 Track Carrier Rollers........................................................................................................................ .. 10 Track Carrier Rollers, Disassemble & Assemble..... ........ ... ... ... ...... ......... ... ... .......... ......... ............ 11-15 Track Rollers ..................... ....................... ... ................ ... ......... .................. ........ ................. ........... 16,17 Track Rollers, Disassemble & Assemble ...................................................................................... 19-21 Track Roller Frames....... ..... ....... ............ ......... ............. ... ...... ... .... ........... ...... ..... ..................... ...... 45-48 Transmission .......... ...... ........ ............... .... ............ ....... ...... ........................ ... ........ ..... ........................ 141 Transmission, Disassemble & Assemble ......... .......... ................................. ...................... ........ 142-163 Transmission and Torque Converter ........................................................................................ 120-125 Transmission Control Linkages...................................................................... ........................... 164-166 Transmission Hydraulic Controls...................... ...... ................................................................... 112,113 Transmission Hydraulic Controls, Disassemble & Assemble ................................................... 114-119 Transmission Lubrication Relief Valve ...................... ....................................................................... 173 Transmission and Torque Converter Oil Cooler Bypass Valve ....................................................... 111 Transmission Mounting Adapter and Transfer Gears ...................................................................... 167 Transmission Mounting Adapter and Transfer Gears, Disassemble & Assemble................................................... .............. ........................ ................ 168-172 Transmission Oil Filter and Bypass Valve ................................................................................ 175,176 Transmission Oil Screen .................................................................................................................. 174 Transmission Oil Pump .................................................................................................................... 182 Transmission Oil Pump, Disassemble & Assemble .................................................................. 184-186

&. WARNING

DISCONNECT BATTERIES BEFORE PERFORMANCE OF ANY SERVICE WORK.

7

POWER TRAIN DISASSEMBL V AND ASSEMBL V

A781 04X 1-"'"

8

POWER TRAIN

DISASSEMBLE TORQUE CONVERTER

Tools Needed

5P4808 Adapter

8B7554 Bearing Cup Puller Attachment

8H684 Ratchet Box Wrench

8B7548 Puller Assembly

8H663 Bearing Puller Attachment

8B7560 Step Plate

2P8312 Retaining Ring Pliers

lP483 Drive Plate

lP476 Drive Plate

lP531 Handle

start by:

TORQUE CONVERTER

3100-15

ABC D E

2

1 1

1 1

a) remove torque converter and pump drive

1. Remove twenty-four bolts (1).

2. Install two 3/8"-16 NC forcing screws as shown. Make a separation of the impeller and the housing.

3. Remove two races (2) and bearing (3) from the turbine assembly. Remove the retainer from the stator.

4. Remove turbine assembly (6) from the housing. Remove bearing (5), two races (7) and retainer (4).

DISASSEMBLY AND ASSEMBLY

131

955L LOADER HYDRAULIC SYSTEM 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 REG 1139F.

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.

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 955L LOADER HYDRAULIC SYSTEM, Form No. SENR7681.

INDEX

Bucket Positioner ..................................... ........... ............................................ ............................. ..... 9 Bucket Positioner Master Valve .............. .................................... ........................................ .............. 8

Cycle Times .... .................... ........................ .............. ............ ... .... ..... ................................................. 11

Hydraulic Pump ................... ................ ... ... ........................... ....... ..... ..... .... .......... ..... ...... ................... 8 Hydraulic Tank and Valve Group ...................................................................................................... 6

Lift and Tilt Control Valve ...... ..... .......... ...... ... ............ ............ .... ..... ... .................................. .............. 11 Lift Cylinders ... .............. ...... .................... .................................... ................... ...... .............................. 9 Lift Kickout ............................................................................................................................... .......... 10 Lines, Plugs and Fittings ... .... ..... ............. ...... .................... .... ...... ......... ...... ......... ..... ... .................... 4, 5

Master Valve for the Bucket Positioner ............................................................................................ 8

Relief Valve for Main Pressure .. .... ... .... ......... .................... .......... ...... ...... ............. ....... ..................... 8

Tilt Cylinders .. ............ ......... ... .... ....... ... .... ... ....... ........ .... ..... ..... .... ... ... ..... .... ...... ........... ........ .............. 10 Tilt Relief Valve for Head Ends ...... .......... ..... ................... .... .... ... ..... ...... ............. .............................. 7 Tilt Relief Valve for Rod Ends .. .... ... ........ ........ ........ ............... .... ..... ...... ..................... ....... ....... ......... 7

955L LOADER HYDRAULIC SYSTEM

SYSTEMS OPERATION

Bucket Positioner Hydraulic Circuit.................................................... 10

Check Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Lift Circuit Operation.. . . . ... .. . .. .. .. .. .. . . . .. . .... . . . .. . .. . .. . ... .. . .. . . . .. .. . . .. . . . 7 Lift Kickout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11 Loader Hydraulic System ............................................................. 4

Main Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Make-Up Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Tilt Circuit Operation ................................................................. 6 Tilt Circuit Relief Valves.. ... . .. ..... .. .... .. . ..... .... ... .. .... ... ... .. . . . .. . . . ....... 8 Tilt and Lift Control Valve. . . . .. .. .. ... . .. . .. .. .. .. .. .. .. ... ... . .. ... ... . . .. . . . . . . . .... 6

TESTING AND ADJUSTING

Bucket Positioner Circuit Adjustments................................................. 19

Checking Pump Efficiency............................................................ 14

Hydraulic Troubleshooting............................................................ 12

Lift Kickout Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 21 Lift and Tilt Circuit Drift. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15 Lift and Tilt Circuit Speeds............................................................ 15 Loader Hydraulic System............................................................. 13 Loader System Tests.................................................................. 15

Main Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Master Valve Adjustment.............................................................. 19 Multi-Purpose Bucket Circuit Drift..................................................... 16

Operation Checks.................................................................... 14

Ripper Cylinder Circuit Drift........................................................... 16

Slave Cylinder Internal Cam and Roller Spring Adjustment... .. .......... . ... . . ... . . .... 20

Tilt Circuit Relief Valve (Rod Ends) ..................... '" ... .. . . .......... .. . . . .... .. 17 Tilt Circuit Relief Valve (Head Ends)................................................... 18

Visual Checks........................................................................ 13

SPECIFICATIONS

NOTE: For Specifications with illustrations, make reference to the SPECIFICA­TIONS FOR 955L LOADER HYDRAULIC SYSTEM, Form No. SENR7680. If the Specifications in Form SENR 7680 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.

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

INDEX

3

TABLE OF CONTENTS

Equipment Installation ........................................ 3

Machine Warm-up ............................................ 3

System Test (CHART A) ...................................... 3

Trouble Shooting .......................................... 4

Pump Test (CHART B) ....................................... 5

Pump Test for Aeration ..................................... 6

Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6

Blocked Cylinder Tests (CHART C) .............................. 7

Right Hand Cylinders Blocked ................................ 8

Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7

2

VEHICLE SYSTEMS DISASSEMBLY AND ASSEMBLY

6

INDEX

Bucket ................................................................................................................................................. 43 Bucket Positioner......................................................................................................................... ....... 44 Bucket Positioner Master Valve ......................................................................................................... 45 Bucket Positioner Master Valve, Disassemble & Assemble......................................................... 46-50

Front Levers And Links ............................................................................................. .................... 78-82 Hydraulic Pump ............................................. ....................................................................................... 8 Hydraulic Pump, Disassemble & Assemble .................................................................................... 9-18 Hydraulic Tank .............................................................................................................................. 19-21 Hydraulic Tank And Valve Group, Disassemble & Assemble ...................................................... 22-42

Lift Arms............................ ............................................................................................................ 88-94 Lift Cylinders.................................................................................................................................. 62-66 Lift Cylinders, Disassemble & Assemble ...................................................................................... 67-73

Rear Levers ................................................................................................................................... 83-87 Swivel Joints ....................................................................................................................................... 74 Swivel JOints, Disassemble & Assemble ...................................................................................... 75-77

Tilt Cylinders .................................................................................................................................. 51-54 Tilt Cylinders, Disassemble & Assemble ...................................................................................... 55-61

&. WARNING

DISCONNECT BATTERIES BEFORE PERFORMANCE OF ANY SERVICE WORK.

VEHICLE SYSTEMS

~ A78104X1

DISASSEMBL Y AND ASSEMBLY

7

VEHICLE SYSTEMS

HYDRAULIC PUMP REMOVE AND INSTALL HYDRAULIC PUMP 5055-10

1. Lift the bucket and install the support link or lift cylinder brace to hold the lift arms in the "up" position.

2. Remove sheet assemblies (1) and (2) from over the left side of the engine.

&,.WARNING

Slowly loosen the cap on the hydraulic tank to release the pressure and let the hydraulic oil become cool before it is drained from the tank to prevent bodily injury.

3. Drain the oil from the hydraulic tank. The capac­ity of the hydraulic tank is 39 U.S. gal. (147.6 litre) .

4. Disconnect tube assembly (3) and hose assembly (4) from the hydraulic pump.

5. Remove the two bolts (5) and remove hydraulic pump (6) from the machine.

NOTE: The following steps are a description for instal­lation of the hydraulic pump.

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6. Make sure the O-ring seal is in position and put clean hydraulic oil on it.

7. Put hydraulic pump (6) in position and install bolts (5) to hold it.

8. Make sure the O-ring seals are in position in tube assembly (3) and hose assembly (4). Put clean hydraulic oil on the O-ring seals and connect the hose and tube assemblies to the hydraulic pump.

9. Install sheet assemblies (1) and (2) on the left side of the machine.

10. Fill the hydraulic system to the correct level. See LUBRICA TION AND MAINTENANCE GUIDE.

11. Lower the bucket to the ground.

DISASSEMBLY AND ASSEMBLY

955L OPERATOR'S STATION

CONTENTS

Item Page No.

SAFETY ITEMS Horns (electric).... .... .. ...... .. .... .. .. .... .. ...... .. .. .. .. .... ... 4 Windshield Wipers/Washers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4 Back-up Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4 Parking Brake.. .. . . . . . . . . .. . . . . . . .. .. .. . . .. . . . . . . . . . . . . . . . . . . . . . . .. 5 Lights. ...... ........ ...... .. ...... ...... .... .. .. .... ............ .. 5 Mirror. . . . . . . . .. . . . . .. . . . . . . . . . . . . .. . .. . . . . . .. . . . . . . . . . . .. . . . . . . . .. 5

COMFORT ITEMS Operators Seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6 Pressurizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6 Air Conditioner and Heater ......................................... 6

CONTROL GROUPS Hydraulic Control Console. . . . . . . . . . .. . . .. . . . . . . . . . . .. .. . . .. . . . . .. .. 7 Transmission Control Console. . . . . . . .. . . . .. .. . . .. . . . . . . . . . . . . . . . . . .. 7 Brake Pedals.... ........ .. .. .. ...... ...... ............ .... ......... 8

STRUCTURAL COMPONENTS Cab ............................................................... 9 Cab Doors and Windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9

ELECTRICAL SYSTEMS Instrument Panels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-12

ELECTRICAL TROUBLESHOOTING Index................ ................ .............. ............ ... 13

ELECTRICAL SCHEMATiC........................................ 26,27

CONTENTS

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6

OPERATOR'S STATION DISASSEMBLY AND ASSEMBLY

INDEX

Air Conditioning Condenser ......................................................................................................... 72,73 Air Conditioning and Heating Fan Motors ................................................................................... 74,75 Air Conditioning and Heating Unit .............................................................................................. 68-71

Back-Up Warning Alarm and Switch (955L) .......................................................... ........................... 77 Back-Up Warning Alarm and Switch (977L & 983B) .................................................................. 78,79 Batteries (955L & 977L) .................................................................................................................... 60 Batteries (983B) ................................................................................................................................ 61

Cab (955L) .............................................................................................................................. 110-115 Cab (977L & 983B) .................. ................................................................................................ 116-123 Cab Air Filters ................................................................................................................................... 76 Cab Doors ........................................................................................................................................ . 67 Cab Door Latch and Striker ......................................................................................................... 62,63 Cab Door Lock (977L & 983B) ................................................................................................... 64-66 Cab Light Assembly .......................................................................................................................... 52 Cab Window Glass ............................... .... ................................ ................ ................................... 49,50

Dash (955L) ................................................................................................................................. 92-95 Dash (955L), Disassemble & Assemble ..................................................................................... 96-99 Dash (977L) ............................................................................................................................. 100-103 Dash (983B) ............................................................................................................................. 104-109 Disconnect Switch (955L) ................................................................................................................. 25 Disconnect Switch (977L & 983B) .................................................................................................... 26

Fan Control Switch ............................................................................................................................ 53 Front Windshield Wiper Motor and Linkage ................................................................................ 44,45

Horns and Switch (955L) .................................................................................................................. 20 Horns and Switch (977L) ............................................................................................................. 21,22 Horns and Switch (983B) ................................. ............................................................................ 23,24 Hydraulic Control Levers ............................................................................................................. 90-92

Instrument Panel and Gauges ............................................................................... ...................... 54-60

Mirror and Bracket ............................................................. ............................................................... 41

Rear Window .................................................................................................................................... 51 Rear Windshield Wiper Motor and Linkage ................................................................................. 45,46

Seat ................................................................................................................................................... 27 Seat, Disassemble & Assemble .................... ............................................................................... 28-40 Seat Belt ........................................................................................................................................... 25 Sound Suppression ...................................................................................................................... 67,68

Tilt Cab Back (955L) ........................................................................................................................ 7-9 Tilt Cab Back (977L & 983B) ....................................................................................................... 13-15 Tilt Cab Forward (955L) ............................................................................................................... 10-12 Tilt Cab Forward (977L & 983B) ...................... ............................ ................................................ 16-19 Transmission and Governor Control Linkage (955L) ........ ......................................................... 80-83 Transmission and Governor Control Linkage (977L & 983B) .................................................... 84-89

Wiper Blade ...................................................................................................................................... 41 Windshield Washer Group ........................................................................................................... 42,43 Windshield Wiper Motors and Linkage, Disassemble & Assemble ............................................ 47,48

A WARNING

DISCONNECT BATTERIES BEFORE PERFORMANCE OF ANY SERVICE WORK.

OPERATOR'S STATION

CAB (955L)

REMOVE CAB (955L) 7325-11

1. Remove brackets (1) from the storage position on each side of the dash. Turn brackets (1) over and install them as shown to hold the dash to the loader frame when the cab is tilted.

2. Remove the floormat from the cab. Remove the five bolts (4) and fourteen plugs (2).

3. Disconnect wiring harness (3) from the cab wir­ing harness.

4. Remove plastic covers (5) from the inside front corners of the cab.

5. Remove bolts (6) that hold the cab to the dash.

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DISASSEMBL V AND ASSEMBL V

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

Maintenance Recommendations .................................................................................................... 6

Walk-Around Inspection .................................................................................................................. 8

Fuel and Lubricant Specifications ................................................................................................. 9

Lubrication and Maintenance Chart .............................................................................................. 10

Every 10 Service Hours or Daily ................................................................................................... 13

Every 50 Service Hours or Weekly ............................................................................................... 15

Every 100 Service Hours or 2 Weeks ........................................................................................... 17

Every 250 Service Hours or Monthly ............................................................................................ 18

Every 500 Service Hours or 3 Months .......................................................................................... 24

Every 1000 Service Hours or 6 Months ....................................................................................... 30

Every 2000 Service Hours or 1 Year ............................................................................................ 32

When Required ................................................................................................................................. 38

Cutting Edge Bolt Torques ............................................................................................................. 47

Refill Capacities ............................................................................................................................... 48

Serial Number Locations ................................................................................................................ 48

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