Home

TECHNICAL MANUAL - Liberated Manuals

Contents

1. Figure 6 4 Preparing to remove sun gear ii E 1 2410 233 34 6 4 Figure 6 5 Pilot bearing and retaining ring removal and installation f Torque Divider Disassembly and Assembly 1 Remove planet carrier from the torque divider fig 6 6 TORQUE DIVIDER PLANET CARRIER ROTATING HOUSING ME 2410 233 34 6 6 Figure 6 6 Planet carrier removal and installation 2 Disassemble planet carrier assembly as follows b Remove the shafts 2 washers 3 gears 4 and bearing assemblies 5 a Remove the three shaft retaining bolts 1 and locks ND ME 2410 233 34 6 7 Bolts Planet gears Bearing assembly 6 Planet carrier ve 2 Planet gear shafts 3 3 Washers 6 Figure 6 7 Planet carrier disassembly and reassembly 6 9 3 Remove the output shaft assembly and b Remove flange 2 and bearing race disassemble shaft assembly as follows from output end of shaft a Remove retaining bolt 1 fig 6 B Romove the bearing 1 fig 6 9 from washer the output shaft 2 using a puller a bearing pulling attachment a step p
2. Hydraulic pump idler gear removal and installation k ME 2410 233 34 5 52 FLYWHEEL HOUSING 11 Loosen tbe bolts which secure tbe oil pan plate to tbe cylinder block 5 25 12 If the engine is being supported by the oil pan and oil pan plate raise the cylinder block and insert two 4 inch shims between the cylinder block and oil pan at the rear of the engine Be careful not to damage the oil pan plate gasket 13 Attach a hoist to the flywheel housing and remove tbe flywheel housing mounting bolts fig 5153 Remove tbe flywheel housing and discard mounting gasket 5 71 DA Figure 5 53 Flywheel housing ME 2410 233 34 5 53 removal and installation b Cleaning Clean all components in cleaning solvent Fed Spec P D 680 Dry with clean lint free cloths c Inspection and Repair 1 Inspect the housing for nicks chips cracks weld damage and other damage Repair or replace if necessary 2 Inspect the ring gear for damaged or missing teeth Replace if defective 3 Check the flywheel housing runout subpara d and flywheel runout subpara e Repair or replace as necessary d Checking Flywheel Housing Runout Mount a dial indicator to the flywheel housing as shown in figure 5 54 Total runout must not exceed 0 010 inch
3. Adjusting final drive 2 Aligning track roller frame with sprocket Brake pedal and support assembly removal and installation Tractor roller frame group Track pin and bushing cutaway Preparing to separate tracks Relief valve and fill valve Master pin removal group Track seal washers and spacers Installing seal washers and spacers Preparing to remove carrier rollers Removing gt a edendis ada bel ae Per ye asya tie os Removing metal float ring seals Removing bearing amp eda epe dese p de ence d eene ek lt bod Ra asa Assembling carrier roller Track roller disassembly Bushing assembly removal Bushingassembly RE Spe aren eee CERE Y ERA der e REA RUE Assembling track roller Preparing to remove guide plate Preparing to remove idler Front idler disassembly Idler bearing in low position Repositioning bearings 12 Number viii Title Preparing to remove yoke assembly Idler recoil rod alignment Aligning idl
4. OME 2410 233 34 7 3 2 Figure 7 3 Preparing to separate tracks 3 Release the pressure in the hydraulic track adjuster cylinder with CAUTION as given in the following steps WARNING Because of the hydraulic pressure in the track adjuster cylinder never visually inspect the vent holes and valves to see if grease is escaping Always observe the cylinder to see that it moves to the rear into the recoil spring front pilot 4 Turn relief valve one turn in a coun terclockwise direction and allow grease to escape from vent hole just below relief valve If grease does not appear when the relief valve is backed off one turn turn fill valve one turn in a counterclockwise direction If grease does not appear at the vent holes the machine should be started and moved forward and backward If grease still does not appear at the vent holes insert a bar such as a draw bar pin between the track and sprocket Move the machine backward so the track will be forced upward by the bar This will apply ad ditional tension to the track and move the front idler and track adjusting mechanism to the rear against tie force of the recoil springs thus forcing grease out the vent holes 5 If moving the machine does not relieve the hydraulic pressure continue loosening relief valve until the unthreaded section A fig 7 4 is exposed above the flange of the hydraulic cylinder The lower hexagonal s
5. Governor engine 5 1 H Hydraulic pump lift and ripper 4 7 Hydraulic pump steering dutch and transmission L 6 5 Hydraulic lift cylinders 48 Hydraulic tilt cylinder LL 49 ul vt B C o lr UJ JB BH 5 67 D d Ke Hd BBB B LI Paragraph Page Idler pinion and bearings 6 25 M Main 0 5 34 Manifold 5 18 5 40 Maintenance forms and records Maintenance repair parts L2 2 1 Major components removal and installation ND ode 0 2 7 Moldboard blade assembly 3 2 Muffler Oil coder 5 7 5 16 Oil pan oil pan plate 5 25 552 Oil pan 525 5 52 Oil 5 49 P Pinion final 6 111 Pistons connecting rods and cylinder 533 5275 Power take off drive gears and bearifi S s b eod osa rr E Pump fuel 5 21 Pump fuel transfer 5 13 Pump hydraulic j 4 65 Pump hydraulic system Pump 0
6. 5 24 Pump water 5 6 Push arms and braces L 33 32 R Radiator Radiator and radiator guard Radiator guard 5 3 5 6 Recoil 5 5 7 6 Records maintenance forms Relief valve bulldozer T 44 4 19 Repair parts maintenance Reporting of errors 1 3 1 1 ISIDDBE 2 3 5 3 3 Ripper control valve JI 45 222 Ripper hydraulic lift cylinder L 10 444 Rollers L 23 7 Rollers track carrier 4221 7 5 S Scarifies icu S vae ER ex 32 Scope C 1 1 Special tools and equipment 2 1 2 1 Paragraph S Sprocket and sprocket segments 6 23 Sprocket segments Sprocket shaft 6 26 s Exodo Sa dau 23 ase d 521 Starting motor 5 21 Steering dutch driving hub Er Steering Steering clutch hydraulic controls 6 17 T Tabulated data 1 6 Tank hydraulic n 42 Tank fuel pass od e ERR 5 14 Tilt control valve 4 6 Timing gears and 5 29 Torque divider 63 Track adjusting mechanism 7 7 Track assembly L 7 1 Track carrier rollers 72 Track roller foam
7. DD 5 10 d Broken or leaking high pressure d Repace high pressure fuel line line 5 1 3 Erratic engine speed Governor faliure Check for damage or broken Springs linkages or other governor related components Replace a defective governor 2 1 Malfunction 4 Excessive engine vibration 5 Engine smokes 6 Engine knocks excessively 7 Low or no lubricating oil pressure indication 8 Starter will not crank engine o Generator not charging 10 Fully charged battery and a high charging rate 11 Transmission does not operate in any speed 12 Tractor remains in gear with selector valve in neutral 13 Ripper will not raise 14 Ripper will not lower 15 Ripper will not stay in ground 16 Winch brake not holding properly Chart 2 1 Troubleshooting Continued Probable Cause Loose worn or defective engine mounts Loose pulley and damper Defective pulley or damper Misfiring Unbalanced fan Worn piston rings Defective valves Broken valve spring Carbon build up on pistons Loose connection rod bearing bolts or worn bearings Worn main bearing b Worn oil pump gears gt Pressure regulating valve worn or stuck thus restricting the flow of oil Armature burned out a Generator shorted b Brush spring tension too low a Short circuit in generator Generator regulator not operating properly Leakage in ex
8. IRECTLY R5 UNDER TAP SWITCH COMPLETELY FREE OF EPOXY AND RUBBER SEAL EPOXY LOCATIONS N 2 2 e Sp N D 4 INSULATOR LOCATIONS LO TAP SWITCH SLOTTED SCREW D1 D2 D3 B CHECKING COMPONENTS ME 2410 233 34 5 35 3 C1 Figure 5 35 3 Checking components and transistors ME 2410 288 84 5 35 8 If previous checks indicate the regulator should be repaired proceed as follows The panel is shown without the sealing com pound so the seven serviceable parts can be easily identified fig 5 35 3A b Remove screw transistor TR and pry apart heat sinks and panel board with serewdriver c Carefully inspect printed circuit for poor solder joints d Carefully inspect for broken parts e Check components as follows fig 5 35 3B Use 1 volt ohmmeter on low scale Reverse leads to get 2 readings Scratch hard with sharp instru ment to break through transparent coating over sol der to make ohmmeter contact Use 50 watt soldering gun 1 Tap switch and heat sink assembly Turn slotted screw with screwdriver to 5 positions If screw is loose replace assembly Also replace old type as semblies having brass slotted screw and attaching nut even if screw is not loose New assemblies have aluminum slotted screw and no attaching nut Make sure switch is expoxied to heat sink 2 Resistor R5 If any reading is over 1 ohm replac
9. Xa S lt a lt 2 lt 2272272272777 Sy LG ZRLLLID 57 75 Key Nga 777 2410 233 34 7 19 Bearing Floating duo cone seals Collars 2 Bearing Shaft Bushing assemblies 2 OU BRUN Figure 7 19 Front idler disassembly c Cleaning 1 Clean all parts using cleaning solvent F ed Spec P D 680 and dry with lint free cloth 2 Remove all dirt and rust from the floating ring seal mounting grooves Grooves must be dean smooth and dry 3 Wash protective coating from new ring seals with cleaning solvent d Inspection and Repair 1 Inspec the front idlers for damage and wear When the contact surf act of the idler is worn to the extent that the center flange height measure from 1 07 1 24 inches the idler will be repaired by welding an overlay on the wear surface Idlers worn to the extent that the center flange height measures 1 24 inches or more will be replaced Idler center flange height new is 0 88 inch 2 Inspect the idler sleeve bearings for pitting roughness and wear The specified shaft to bearing clearance is 0 008 0 012 inch The maximum allowable shaft to bearing dearance is 0 050 inch The specified shaft and clearance is 0 011 0 029 inch Replace pitted rough or excessively worn bearings 3 Inspect the idler shaft for pitting roughness and wear Replace a damaged ex cessively worn o
10. Figure 5 9 Radiator and radiator guard removal and installation 5 11 10 Remove the radiator guard and radiator from the tractor as shown in figure 5 10 Figure 5 10 Lifting radiator guard and radiator from tractor b Disassembly 1 Remove hydraulic cylinders and pivot assembly from radiator guard 5 2410 233 20 2 Remove radiator from radiator guard para 5 c Cleaning Clean radiator guard with soap and hot water Dry with a lint free cloth d Inspection and Repair Inspect radiator guard for dents cracks distortion broken welds corrosion or other damage Weld cracks and broken welds according to TM 9 237 Remove 5 12 excessive corrosion by sand blasting and repaint according to TM 9 213 e Installation Reverse removal procedure and install the radiator guard assembly on the tractor 5 4 Fan a Removal 1 Remove the radiator and radiator guard from the tractor para 5 B 2 Remove hydraulic cylinders and pivot assembly from radiator guard TM 5 2410 233 20 3 Remove fan guard mounting boltsl fig 5 7 and remove fan guard from radiator guard 4 Attach a hoist to the fan and lift fan from radiator guard b inspection Inspect fan and adapter assembly for bent missing or loose blades Replace a defective fan and adapter assembly c Install
11. 7 10 Track roller frame oer bearing _ 6 20 Track roller 7 3 Transmission 6 9 Transmission and steering dutch control check valve Transmission control linkage 6 12 Transmission hydraulic controls 6 4 Transmission hydraulic system testing and adjustment 6 11 Transmission lubrication junction Transmission removal installation 2 9 Troubleshooting Turbocharge LL 5 17 U Universal C62 V Valve 5 27 w Water 5 6 WICH m TIE C3 10 Winch control _3 3 Winch disassembly Winch reassembly 3 15 Wiring and wire harness repair 5 22 Y Yoke assembly front idler 1 5 Page 6 95 27 Se SIS N 7 18 6 66 6 22 6 62 6 61 2 20 Un UJ i Ul lkol E O m U N By Order of the Secretary of the Army W C WESTMORELAND General United States Army Official Chief of Staff VERNE L BOWERS Major General United States Army The Adjutant General Distribution To be distributed in accordance with DA Form 12 35 Section II qty block No 491 direct and general support maintenance requirements for Tractors Tracked Medium U S G
12. ME 2410 233 34 6 17 Figure 6 17 Rotating housing bearing and bearing retainer removal g Inspection and Repair 1 Scavenge pump a Inspection manifold spacer an end cover for cracks breaks scoring and wear Replace as required b Inspect the pump gears for scored chipped pitted cracked or worn teeth c Inspect sleeve bearings for damage and wear Bearing 1 0 new is 0 7422 to 0 7428 inch Replace damaged or excessively worn bearings d Inspect pump drive gear for chipped pitted cracked broken or worn teeth Replace damaged or excessively worn drive gear 2 Torque divider CAUTION If an inspection indicates a failure has occured in the torque converter te entire fluid system must be thoroughly cleaned NOTE The inspection and repair data is listed in the same sequence as the disassembly procedure a Inspect the planet gear shafts and bearings for scoring pitting and wear Replace scored pitted or excessively worn or rough shafts or bearings b Inspect the planet gears for chipped 6 19 pitted cracked broken or excessively worn teeth Inspect the bearing surface for scoring pitting and wear Replace damaged or excessively worn gears NOTE Replace the planet gears in sets only to prevent pos sible overloading of a single gear Inspect the non metallic washers for damage and wear The washer thickness new is 0 073 0 002 inch Replace damaged or
13. CH po 22255 T EN z 22 T SS oe D gt _ e GUARDS ME 2410 233 34 7 25 Figure 7 25 Removing guards ME 2410 233 34 7 27 l Recoil spring stops 2 Recoil spring front pilot 3 5 Nuts 4 Idler recoil rod ES 5 Cylinder Figure 7 27 Removing recoil spring stops 222 ME 2410 233 34 7 26 Recoil spring bolt nut Recoil spring rear pilot Drawbar pin eel Locking bolt and washer Figure 7 26 Removing tension from recoil spring stops 7 14 b Disassembly WARNING The springs in the recoil spring assembly are assembled under a force of several tons During the process of disassembly and assembly it is im perative that the proper tools be used in the proper manner when performing these operations 1 Remove bolt OU fig 7 28 and washer 2 securing retaining nut 6 to recoil spring bolt 9 2 Install the recoil spring assembly in a suitable press with rear pilot 7 positioned on the press bed and front pilot 3 centered with the press ram NOTE A press with a minimum throat depth of 35 inches is required to disassemble recoil spring assembly 3 Apply enough pressure to the recoil spring assembly to remove retaining nut 6 4 Remove retaining nut 6 5 Back off the press ram to decompress the recoil springs 4 and 5 6 Remove recoil spring bolt 9 front pilot 3 and sleeve 8 7 A
14. SPEED CLUTCH d DIRECTIONAL CLUTCH TOROUF CONVERTER INLET oRour CONVERTER om Un RU Fa ko ee UN Directional valve body Directional vavle spool Safety valve Steering clutch controls Speed selector valve spool Speed selector vavle body Oil filter Torque divider ratio valve spool Pressure differential valve spool Check valve Lubrication line to rear of transmission Lubrication line to front of transmission outlet relief valve Torque divider Pressure control valve body Pressure modulating relief valve spool LUBRICATION OR SUPPLY 011 SCAVENGE OIL 18 19 20 21 22 23 24 25 moo ME 2410 233 34 6 69 Load piston Magnetic Strainer Scavenge oil pump Oil pump Lubrication line to bevel gear and bevel pinion Torque divider Torque divider oulet relief valve spool Torque divider oil sump Directional clutch oil pressure tap Transmission oil filter pump pressure tap Lubrication oil pressure tap Speed clutch oil pressure tap Transmisson oil pump pressure tap Torque divider outlet oil pressure tap Figure 6 69 Transmission hydraulic control system schematic First forward 6 63 b Steering Clutch Control Tests Refer to table 6 1 and figure 6 70 to make necessary tests c Transmission and Torque Converter Hydraulic Controls Tests Refer t table 6 2 and figures 6 6d and 6 70 6 64 Key
15. 2 Slide the bearing cage 2 fig 6 58 and bearing cage and oil manifold 3 from the input shaft 1 while removing the ring 4 at the same time ME 2410 233 34 6 52 Bolts lock and retainer 2 Input flange Figure 0 52 Preparing to disassemble input shaft 6 46 ME 2410 233 34 6 53 Input shaft Bearing cage Bearing cage and oil manifold Ring t Figure 6 53 Bearing cage removal 3 Remove the oil seal fig 6 54 by tapping it from the rear with a small block of wood 4 Remove the retainer ring fig 6 55 NOTE The oil seal is correctly installed with the spring loaded lip toward the rear of the the transmission ME 2410 233 34 6 54 Figure 6 54 Oil seal removal Figure 6 55 Retainer ring removal 5 Separate the bearing cage 1 fig 6 56 from the bearing cage and oil manifold 2 6 47 8v 9 Figure 6 56 Bearing cage disassembly ME 2410 233 34 6 56 Key td figure 6 56 1 Bearing cage 2 Bearing cage and oil manifold 3 Bearing 4 Lockring 5 Piston ring type seals 6 Seal drain hole 7 Lockring 8 Bearing 6 Inspect the bearing 3 for wear or damage Remove the lockring 4 if bearing replacement is necessary 7 Inspect the piston ring type seals 5 for wear or damage and replace them if necessary NOTE Be sure the seal drain hole is not plugged 8 Inspect the bearing 8 for wear or damage If r
16. 5 Relief valve and quick release valve a Remove retainer 22 washers 21 spring 20 and piston 19 The washers 21 regulate relief valve pressure Add washers to increase pressure remove washers to decrease pressure The relief is as follows 225 psi at 6 gpm 1 000rpm Oil Temperature 70 b To check quick release valve spring 2 remove fitting 4 and piston 3 c After checking and cleaning all parts thorouhly lubricate with SAE No 10 engine oil and assemble in the reverse order of disassembly Replace pistons 19 and 3 with new parts if there are deep nicks and remove light nicks by lapping pore es n Qu D x P h 28 ME 2410 233 34 3 6 Gasket 18 Capscrew 2 Spring 19 Piston 3 Piston 20 Spring 4 Fitting 21 Washers 5 Capserews 22 Retainer 6 Spacer 23 Plug Spool 24 Spring 8 Preformed packing 25 Ball 9 Preformed packing 20 Plug 10 Spring 27 Plug ll Washer 28 Retainer I2 Snapring 29 Valve body I3 Spool 30 Support 14 Spring 31 Washer 15 Spring 32 Spring lo Plug 33 Ball I Snapring Figure 3 6 Winch control valve exploded view 3 14 Winch Disassembly a Power Takeoff Assembly REmoval Unbolt the power takeoff bearing carrier J and remove the complete power takeoff assembly Be careful not to damage shims behind bearing carrier 3 7 Ek Figure 3 7 Power takeoff bearing carrier and brake drum removal and installation ME 2410 233 34 3
17. 2 The forward and reverse clutch packs are interchangeable but the spiders are not 3 Never assemble a clutch pack dry Presoak all parts in oil 4 Small parts and passages must be free of dirt and foreign matter 5 When sliding the clutch piston into the retainer plate be certain that the O rings 9 and 10 well lubricated and seated in their respective grooves 6 When assembled the holes in the clutch hub will be in line with the oil cooling valve 7 Blanked out teeth on friction discs 6 tig 3 17 must be in line 8 Assembled clearance to be from 0 040 inch to 0 070 inch Use shims as required 9 Torque capscrews 1 with 70 ft lb set screws 12 with 40 ft lb b Drum Shaft Assembly 1 Check all oil seals and install drum and drum shaft 2 Add two quarts of HDO 30 cavity before installing rh bearings 3 Bolt drum gear to drum torquing the bolts to 140 ft lb lubed or 225 ft lb dry to drum c Intermediate Shaft Assembly Install in termediate shaft with 0 004 inch to 0 007 inch end play bearings d Bevel Gear Shaft Assembly 1 Place all parts into winch case in the same order they were removed 2 Line up the marked pipe plugs in outer diameter of the retainer plate in the clutch packs with holes in the bevel gear shaft splines Only one of the plugs will be correct as cross hole goes through one major diameter and one miner diameter of spline 3 Sling
18. ME 2410 233 34 6 73 Rear support Cover Bolts Brake control lever P gt rs Steering clutch 6 Pin and cotter pin T Brake lever 8 Spring 9 Bolts Figure 6 73 Preparing to remove brake engaging mechanism 5 Remove the pin and cotter pin 6 securing the brake link to the brake lever 7 6 Remove brake lever return spring 8 7 Remove bolts 9 and steering clutch cover 5 8 Remove the bolts securing brake engaging mechanism to the bevel gear case and lift the engaging mechanism to the bevel gear case and lift the engaging mechanism straight up NOTE The brake band struts 1 6 7 will disengage from the brake band Be sure the struts engage the lugs 2 on the brake band at the time of installation 6 70 9 Install in reverse order of removal NOTE If the brake engaging mechanism has been disassembled and parts mechanism as described in e below 10 Tighten bolts 9 fig 6 73 securing steering clutch cover 5 to the bevel gear case to 100 5 lb ft replaced adjust the Strut 2 Lug Figure 6 74 Brake engaging mechanism removed c Disassembly and Reassembly 1 Remove the adjusting assembly 2 fig 6 73 2 Remove brake lever shaft 1 which joins the brake lever 17 and the brake strut support assembly 13 and secures them to the brake screw socket linkage support assembly 3 3 Remove brake lever shaft 4 4
19. j Add lubricant to the three quarters full tion will con By Order of the Secretary of the Army CREIGHTON W ABRAMS General United States Army Official Chief of Staff VERNE L BOWERS Major General United States Army The Adjutant General Distribution To be distributed in accordance with DA Form 12 25B qty rqr block No 479 direct and general support maintenance requirements for Tractor Tracked Medium 11 TECHNICAL MANUAL NO 5 2410 233 34 List of Illustration CHAPTERI Section 1 11 CHAPTER 2 Section II III IV CHAPTER Section I II III CHAPTER A Section I II III CHAPTER m Section I lI III IV VI sl Section 1 11 IIT 2 TRACTOR FULL TRACKED LOW SPEED DED HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON D C 12 October 1971 DIRECT AND GENERAL SUPPORT MAINTENANCE MANUAL MEDIUM DRAWBAR PULL OSCILLATING TRACK 78 IN GAGE CATERPILLAR MODEL D7F FSN 2410 177 7283 W RIPPER FSN 2410 177 7284 W WINCH INTRODUCTION General Mescnptioniand e cm oves K EE Eo Rec FR E ae a cA 8 RM Rr Re DES 18 q DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS Repair parts special tools and equipment Troubleshooting 2255 20 ROI UA RI Ies e RE che RU S dene I IR eR d ie 3 General Maintenance 4 c a
20. Fan C55 Fan drive asaembly 5 8 Final drive bearing adjustments C6 28 Final drive gear Final drive gear idler pinion 5 Final drive pinion group 6 27 Floating duo cone 5 622 Flywheel and flywheel houaing 5232 Flywheel housing Frame track Front idler Front idler yoke assembly Fuel injection 1 Fuel injectors and glow plugs Fuel tank secte di br d Fuel transfer Ka Bulldozer Cooling 5 1 Diesel Electrical 5 19 Engine lubrication system Final 6 19 Fuel system Hydraulic system 41 Maintenance 254 Removal and installation of major components eee 27 RIPPE h upaqa t a Odd 3 5 Steering clutches brakes bevel Torque divider and transmission 6 1 Troubleshooting ss 2 3 WING i oae nad urge oues Rr haba qs 3 10 Central instructions LL 26 5 20 Glow 5
21. Figure 4 30 Piston rod bearing disassembly d Cleaning Clean all parts with cleaning solvent Fed Spec P D 680 and dry with lint free cloth Inspection and Repair 1 Inspec the cylinders for scoring pitting and wear Inside diameter new is 4 7495 0 0015 inches Maximum permissible inside diameter is 4 7645 inches Repair or replace a damaged or worn cylinder CAUTION Do not weld on the cylinder assemblies as scoring may result from the bore shrinkage 2 Replace all seals packing and wear rings 3 Inspect the rod end bearing for scoring damage and wear Replace as required 4 Inspect the piston rod for nicks burrs pitting distortion and wear Repair or replace a damaged or distorted rod Remove minor nicks and burrs using a fine emery stone Pitted scored or worn rods may be repaired by metalizing or chrome plating and regrinding to original size A non corrosive metal will be used to metalize shafts 5 Inspect trunnion arm bearings for damage and wear Replace all defective parts f Reassembly 1 Assembly trunnion 5 and bearings 2 and 1 in piston rod 6 Use shims 3 as required between bearings and piston rod eye to obtain a free running fit between trunnion and bearings 2 Install seal 13 4 27 in retainer 5 with the lip of the seal facing away from the retainer 3 Place retainer 5 packing 11 and head 6 on the piston rod 4 Separate and oil all of th
22. G L ES t to 1212 2 94 2410 233 34 4 14 Bolt and lockwasher Plug O ring seal Spring Dump valve 4 5 Ripper Control Valve a Removal 1 Remove hydraulic tank from tractor para 4 2 and separate bottom plate from tank 2b 2 Remove bolts 3 and 14 fig 4 4 and remove oil lines 1 and 5 3 Disconnect rod 13 from ripper control valve bell crank 4 Remove bolts 15 and remove ripper control valve 16 from bottom plate 6 1 Bol 2 Lockwasher 3 Bracket 4 Seal 5 Plug 6 Spring 7 Valve 8 Bolt 9 Lockwasher 10 Retainer b Disassembly 1 Remove bolt 1 fig 4 15 lockwasher 2 and remove bracket 3 from ripper control valve 2 Remove seal 4 plug 5 spring 6 and valve 7 from valve body 20 3 Remove 2 bolts 8 and lockwashers 9 and remove retainer 10 4 Slide spool 17 from body 20 5 Remove bolt 11 lockwasher 12 from spool and remove washer 13 retainer 14 spring 15 and spacer 16 from spool 17 E due Ru ZUM ME 2410 233 34 4 15 11 Bolt 12 Lockwasher 13 Washer 14 Retainer 15 Spring 16 Spacer 17 Spool 18 Seal 19 Seal 20 Body Figure 4 15 Ripper control valve disassembly 4 22 c Cleaning Clean all parts with cleaning solvent Fed Spec P D 080 and wipe dry using a lint free cloth Clear passages in valve body with filtered compressed air d Inspection and Repair 1
23. item 9 fig 5 20 Turn the low idle adjusting screw 34 counterclockwise or clockwise as required to correct low idle speed 3 Check engine speed with the governor set in the high idle rpm position Tachometer in dication should be 2000 rpm 4 Turn the high idle adjusting screw 29 as necessary to correct the high idle speed 5 Place the governor control lever in an intermediate setting rpm then recheck low idle and high idle settings Repeat adjustments as necessary 5 13 Fuel Transfer Pump a General The self priming positive displacement gear type transfer pump delivers a constant supply of diesel fuel The fuel transfer pump forces fuel through a drilled passage to the outside of the fuel filter element A spring loaded by pass valve is located in the fuel filter housing to maintain a maximum pressure of 15 psi b Removal Refer figure 5 21 and remove the fuel transfer pump from the engine c Disassembly fig 5 20 1 Remove the bolt 1 gasket 2 spring 3 and plunger 4 Figure 5 21 Fud transfer pump removal and installation 5 28 6 9 10 21 ot 7 18 17 16 14 H 22 4 3 E DEN ai gt Xi 8 gt FUN Z 1 4 B T 20 1 GN A 24 Ge L I 4 5 Q S 23 B SSA H 2 2 CJ C 12 1 3 ME 2410 233 34 5 22 1 Bolt 13 Nut 2 Gasket 14 Gear 3 Spring 15 Key 4 Plunger 16 Bearing cage 5 Screw 17 Seal 6 Screw 18 Ring 7 Cover 19 Bearing 8 Se
24. two insulators from drive end of frame d Disassembly of End Bell and Brush Holder Plate 1 Remove nuts 30 and 1 and lock washers 2 flat washer 4 and insulator 38 from terminal stud Remove three roundhead screws 21 lockwashers 20 and flat washers 19 and pull plate assembly 18 from com mutator frame assembly 45 2 Remove bushing 41 seal 42 and two flat washers 49 from terminal stud 3 Disassemble end bell assembly only if parts require replacement Remove pipe plug 46 and wick 47 from end frame and bearing assembly 4 If sleeve bearing 44 is worn remove expansion plug 43 and press sleeve bearing from end frame 5 Remove screws 15 and lockwashers 16 securing brush leads to brush holders Lift each spring in turn and remove eight brushes 17 6 Remove long brush holder bolt 27 and lock washer 25 from each of two insulated brush holders 23 Remove two springs 24 from each screw Remove short screw 26 and lockwasher 25 from each insulated brush holder Remove two brush holders and spacer plates 22 7 Remove long brush holder screw 29 and lockwasher 32 from each of two grounded brush holders 23 Remove two springs 24 from each 5 48 screw Remove short screw 28 and washer 32 from each brish hlder and remove two grounded brush holders spacer plates 31 and non metallic plates 30 8 Separate plate assembly 33 insulation plate 34 and s
25. 1 Install the bearings so that the tapered edges are toward seals 2 Soak seals 8 and 17 fig 5 22 in a solution of 1part SAE 30 oil to one part diesel fuel to soften the seals Tamp the seals firmly into the pump body bore and around the shaft using a tamping tool 3 Install the gear 14 so that the grooved side is out 4 Tighten the nut 13 to a torque of 10 foot pounds 5 Apply a thin film of sealant to the mating surfaces of the pump body 23 and cover 7 Do not allow excess sealant to enter the pump g Installation Reverse removal procedure and install the fuel transfer pump on engine 5 14 Fuel Tank a General Refer to TM 5 2410 233 20 for fuel tank service instructions b Removal 1 Remove guard from tractor fig 5 23 2 Close fuel shutoff and remove the fuel supply and drain lines at the tank 3 Remove the seat TM 5 2410 233 20 and seat frame para 2 D 4 Disconnect fuel tank ground wire located on fuel tank just behind right rear corner of seat support fig 2 33 sheet 1 5 Remove bolt wire clip and pull light wire away from fuel tank 6 Remove 4 fuel tank mounting bolts 7 Pass a chain through each of the two passageways in the tank Attach chain ends to a hoist and remove fuel tank from tractor 5 29 LIGHT WIRE MOUNTING FUEL TANK PASSAGEWAY cs EH SC REMOVED FO
26. 1 Refer to paragraph 4 8 f 14 through 20 for installation procedures NOTE Point B 4 33 will be at the 8 25 inch mark the expander assembly for this cylinder g Packing Adjustment Hydraulic cylinder packing leakage can be caused by wear cuts and or distortion of the packing If the cylinder leaks around the rod shims can be removed to tighten the packing around the rod 1 Lower the bulldozer blade to the ground 2 Remove the bolts holding retainer 1 fig 4 40 to cylinder head 3 Pry on tap the retainer out far enough to permit cutting and removing shims 2 4 Remove one shim at a time If after removing two shims the cylinder still leaks replace the packing Key to figure 1 38 Piston Preformed packing Backup ring Head Bolts Retainer 1 Seal assemblies Wear ring q Packing ring IO Lip ty pe seal Il Rubber pressure ring VIEW VIEW B 6 ME 2410 233 34 4 38 Figure 4 38 Disassmbling piston head 4 43 PISTON RO 2410 233 34 4 39 Figure 4 39 Measuring clearance ME 2410 233 34 4 40 1 Retainer 2 Shins Figure 4 40 Removing shims h Installation Reverse removal procedure and install the tilt cylinder on the bulldozer 4 10 Ripper Hydraulic Lift Cylinder a General The ripper hydraulic lift cylinders are located on each side of the ripper and are used to raise and lower the ripper Both cylinders are removed and inst
27. 1 to the torque value given in table 1 2 6 42 Bolts 2 Cage Figure 6 15 Preparing to remove input shaft 1 x mmm 2410 233 34 6 46 Figure 6 46 Removing input shaft f Carriers 4 Prior clutch positi 1 Removal and Installation of Clutches and NOTE to disassembly identify and mark each of the housings They must be installed in the same m and location from which they are removed Remove bolts 1 fig 6 47 CAUTION During removal and installation of the No fold clutc out 2 and 1 clutch housing 3 and piston 4 the piston securely inside the h housing to prevent it from falling and causing damage to parts Remove No 1 clutch housing 3 piston No 2 clutch housing 7 NOTE Removal of the No 1 and No 2 dutch housings can be facilitated by the use of 9 inch 13 NC eyebolts During removal of tile No 2 clutch housing some of the springs 11 may drop out There are twelve of these springs between No 2 and No 3 clutch housings There are also twelve springs between No 3 and N L re 8 9 10 11 4 as well as No 4 and No 5 dutch housings A 14 ME 2410 233 34 6 4 7 Bolts No clutch ring gear No 1 clutch housing No 1 clutch piston Plate assembly Clutch reaction pins No 2 clutch housing No 2 clutch plates and disc assemblies No 1 clutch plates and dise as
28. 4 b Brake Band Removal 1 Remove both covers on lh side of winch 3 7 2 Release brake subpara 2 below 3 With brake band released position remove snap ring 1 Remove pins and slide the drum from the shaft with the brake band and crank attached c Brake Shaft Remoual 1 To remove brake springs remove pipe plug from housing and insert an eyebolt as shown in figure 3 8 2410 233 34 3 8 Evebolt 2 Sleeve 3 Pin Figure 3 8 Brake shaft removal 2 Thread eyebolt 1 into spring anchor sleeve 2 and using a pry bar as shown to relieve tension on spring remove anchor pin 3 NOTE Eyebolt may be made by welding a cut washer to a 16 U NF x 4 inch capscrew 3 Remove bearing retainers from both ends of shaft through opening in rh side frame d Bevel Gear Shaft Removal 1 Disconnect the hydraulic line to bearing retainer 3 3 9 3 9 Ko SSS SS Z 3 REC JE i d a p 2 22222250 gt i l pu pru EE DLL 55577772 i9 E q ME 2410 233 34 3 9 l Washer 2 Nut 3 Retainer 4 Snapring 5 Snapring Retainer Figure 3 9 Bevel gear shaft cross sectional view 2 Remove bearing retainer taking care to 11 Insert a 5 8 inch UNF bolt with a ring protect shims or washer welded to it into the threaded end of the 3 Remove
29. A 5 gt 3 t F r Typical pump assembly i LE Preparing to remove engine Sheet 1 of 6 Tl Preparing to remove engine Sheet 2 of 6 Preparing to remove engine Sheet 3 of 6 Coo Preparing to remove engine Sheet 4 of 6 Preparing to remove engine Sheet 5 of 6 204 2502 Races ee Be Gee 0 us Ga aE ROR EL Prepaing to remove engine Sheet 6 of 6 PV Cocco Preparing to remove transmission Sheet 1 of 3 Preparing to remove transmission Sheet 2 of 3 Preparing to remove transmission Sheet 3 of 3 Bulldozer assembly E E d St E Ga 3 A EE Scarifier i i Hydraulic cylinder link arm and beam assembly removal and installation LI Winch hydraulic pump exploded view r Control valve removal Winch control valve exploded view r Power take off bearing carrier and brake drum removal and installation ma Brake shaft removal We Bearing gear shaft cross sectional view Dm Bearing and clutch drive gear removal pr Bevel gear shaft removal UH Intermediate gear and drum pinion removal LLL Beanng wetainer temoval 5 dO Who 2 60 ae e er 4 90 4 xe AS ER a N Lr Drum shaft remoyal 452 2 ue d Rene k osos a Aude X Rod d aku A E S Ro S d LL Clutch separator plates LLLA Hydraulic clutch Lr Hydralic clutch exploded view Bevel ear
30. Carrier roller support assembly 7 8 Clutches steering 6 15 Coding system SH Connecting rodS esee 5 33 Control linkage transmission 6 12 Controls steering clutch hydraulic L 6 7 Control valve bulldozer 3 2 L 43 Control valve bulldozer tilt Control valve ripper L 45 Control valve winch Control transmission hydraulic 6 4 Cover timing gears 1 C5 29 Crankshaft and main bearings 5 34 Cylinder block 5 35 Cylinder bulldozer hydraulic PE PF Cylinder head and valve 5 27 Cylinder lift hydraulic L 48 Cylinder lt 5 Cylinder ripper hydraulic lift 4 10 D Data tabulated 1 4 Differences between models 1 5 Drive 56 6 2 E Engine oil cooler 5 7 Engine removal and installation 2 8 INDEX Page H a BBB D ER 6 8 SE Ss DA sea e N N N Ni SIO 5 79 444 1 1 H N T I d D Paragraph E Engine speed governor L 5 12 Equaliser L 7 9 Exhaust manifold C 5 18 F G REENEN a 5 4 Fan and fan drive assembly 5 8
31. Remove the idler gear 34 shaft and gear 23 key 24 driven gear 25 and spacer 26 assembly 35 dowel 36 and shaft and gear 6 Remove the cotter pin 27 nut 28 and assembly 37 Remove the bearings 38 and 39 washer 29 Using a puller remove the drive gear 5 51 8 Remove the ball 40 from the oil pump body 41 c Cleaning Clean all parts except bearings with cleaning solvent Fed Spec P D 680 and dry with clean lint free cloths or compressed air Clean bearings as instructed in paragraph 2 6 d Inspection and Repair 1 Inspect all parts for nicks burrs cracks or other damage Remove sm all nicks or burrs with a hone or crocus cloth 2 Inspect all parts for wear If any part is excessively worn replace the pump e Reassembly Assemble the pump in the reverse order of disassembly Observe the following 1 Ensure that all parts tools and the work area are clean 2 Lubricate parts in engine oil before assembling 3 Tighten the nut 28 to a torque of 60 foot pounds 5 52 f Installation 1 Install the oil pump in the reverse order of removal Install new gaskets at oil line connections 2 Check the backlash between the oil pump idler gear and the crankshaft gear If backlash exceeds 0 008 inch replace the idler gear 3 Install the oil pan para 5 25 and service the engine with lubricatingoil LO 5 2410 233 12 5 25 Oil Pan and Oil Pan Plate a Removal fig
32. Ring gap oil REAR POWER TAKEOFF AND PUMP D Backlash Oil pump drive gear to oil pump driven gear Power takeoff shaft drive gear to camshaft gear Bearing clearance End clearance ROCKER ARMS Bore bearing 0 7260 Shaft diameter 0 7240 Maximum permissible clearance bearing shaft SERVICE METER Permissible bearing clearance TURBOCHARGER Clearance between impeller and bearing housing shaft pushed toward impeller end 0 020 End clearance 0 0045 Bearing diameter 0 6880 Bearing diameter OD 0 8718 4 152 0 4056 0 402 2 5931 1 876 0 4956 0 8749 0 744 0 7266 0 7250 0 022 0 0015 0 6883 0 8722 Desired clearance 0 001 0 001 0 002 0 001 0 002 0 0020 1 6999 0 0028 0 023 0 0015 0 017 0 017 0 013 0 002 0 003 0 003 0 010 0 003 0 002 0 006 0 003 0 004 0 0035 1 7003 0 0046 0 0041 0 0033 0 023 0 023 0 023 0 016 0 016 0 006 0 020 Maximum allowable wear and clearance 0 008 0 005 0 010 0 005 0 005 0 006 0 0025 0 007 0 010 0 035 0 008 0 012 0 008 0 006 Table 1 3 Engine Repair and Replacement Standards Continued Manufacturer s dimensions Maximum Component and tolerances in inches allowable wear and clearance TURBOCHARGER Continued Note Bearing clearance is satisfactory if compressor wheel and turbine wheel have not rubbed governor housing Journal diameter Housing bore diameter Thickness of thrust bearing
33. Rotate the crankshaft and roll out the bearing upper half Roll out the bearing tab end first Remove the liners from the bearings 10 Cover the bearing cap studs with rubber hose or cloth to protect the crankshaft when it is removed 11 Lift the crankshaft from the engine Lubricate and wrap the bearing surfaces 12 Using a hydraulic puller pull the geat from the crankshaft Remove the ey b Cleaning Clean the crankshaft and bearings with cleaning solvent Fed Spec P D 680 and dry with clean lint free cloths Clean the oil holes in the block and ensure that the block is clean c Inspection and Repair 1 Insect the bearing caps for burrs and high spots Smoot surfaces with a soft hone or crocus colth Scratches on the bearig surfaces will not impair operation Replace beaings if the surface is excessively rough and abrasive If one bearing is replace replace all bearings if possible 2 Check the main bearing journals with a micrometer for out of round condition or excessive wear If crankshaft journals are worn more than 0 008 inch grid the journals with precision equipment checking diameter frequently with a micrometer Grind the journals undersize 0 030 5 78 inch At installation use undersize main and connecting rod bearings 3 After grinding clean the crankshaft thoroughly Check for runout with a dial indicator If crankshaft runout exceeds 0 008 inch replace the crankshaft 4 Inspect
34. SJ ZE 3 S mte i L 2 2 2472 27 22 m lt q Kata Pee Ln GPM RPM 2040 ae s ami KL ln A UI V z 2 7 Ys Gm j GE s lt de J Z e 2 222 i v 2 Aaya emm emm ws mmm giffen n X M gt INL Wi LL a E aidan in Wa ne 22 eee A GELT 182272 N OJ Re 2222222 L r ME 2410 233 34 FO 1 FO 1 Hydraulic flow schematic diagram 1 PIN 005390 000 This fine document Was brought to you by me Liberated Manuals free army and government manuals Why do I do it I am tired of sleazy CD ROM sellers who take publicly available information slap watermarks and other junk on it and sell it Those masters of search engine manipulation make sure that their sites that sell free information come up first in search engines They did not create it They did not even scan it Why should they get your money Why are not letting you give those free manuals to your friends I am setting this document FREE This document was made by the US Government and is NOT protected by Copyright Feel free to share republish sell and so on I am not asking you for donations fees or handouts If you can please provide a link to liberatedmanuals com so that free manuals come up first in se
35. cracks or other damage Replace a defective air deaner d Installation Reverse removal procedure and install the air cleaner 5 16 Muffler a Removal 1 Remove the hood para 5 2 Remove 2 bolts fig 5 25 and remove exhaust tube assembly from muffler Figure 5 25 Muffler 5 17 Turbocharger a General 1 The engine is equipped with an exhaust gas driven turbocharger Enengy originally lost by the diesel engine exhaust is used to drive the tur bocharger 2 As the engine starts the flow of exhaust 5 32 3 Remove 4 nuts and bolts securing muffler straps and remove the top half of the straps from muffler 4 Slide muffler with coupling from tur bocharger housing and remove muffler from engine b Inspection Inspect muffler for cracks dents corrosion broken welds or ruptures Replace a defective muffler Installation Reverse removal procedure and install the muffler on the tractor EXHAUST TUBE MOUNTING BOLTS ME 2410 233 34 5 25 removal and installation gases from the exhaust manifold is directed to the turbine wheel through vanes on the nozzle The turbine wheel and impeller are mounted on a common shaft The exhaust gages pass over the turb
36. fig 2 16 install the tube through the nut and sleeve until the end of the tube is seated against the shoulder in the fitting body b Grip the tube firmly to prevent twisting or turning and tighten nut until a slight give or decreased resistance is felt The give indicates that the sleeve has been sheared from the nut Tighten the nut an additional 1 turns It is not necessary to tighten the nut all the way down ME 2410 233 34 2 16 Nut 2 Sleeve 3 Fitting body 4 Tube Figure 2 16 Shear type fitting 6 Hydraulic valves a Examine all valves valve bores and valve seats for nicks burrs and or scratches Rough spots may be removed with a crocus cloth or fine emery cloth All valves which operate in bores must slide freely in their bores Be certain all passages are clean and open b On control valve spools having bolt retained centering or return springs fig 2 1y the bolt should be removed while the valve spool is in the valve body This procedure will prevent spool distortion and possible damage to the spool lands ME 2410 233 34 2 17 Figure 2 17 Removing bolt retained spring When installing shims to adjust pressure settings always place the thick shim or spacer against the spring 7 Cylinders a Rod end and head end The rod end 1 2 18 of a cylinder is that end that has the rod extending The head end 2 fig 2 18 is the other end of the cylinder the
37. illustrated in filare 6203 i NOTE The bearing cage assembly 3 166 64 and bearing cage 4 are removed as a unit from the output shaft BEARING ME 24105 233 34 6 63 Figure 6 63 Removing transfer gear outer bearings 2410 233 34 6 64 Figure 6 64 Separating cages 6 57 4 Remove lockring 1 5 Separate the bearing cage 4 from the bearing cage assembly 3 6 Inspect the bearing 2 in the bearing cage 4 and replace if necessary 7 Inspect the piston ring type seals 5 and replace if broken or damaged 8 The bearing outer race 5 fig 6 62 in the bearing cage assembly 3 can be removed if necessary after removing the plug 6 fis 6 6 and the dowel under the plug 9 Assemble the output shaft in the reverse order of disassembly 6 58 l Transfer Gear Disassembly and Assembly The transfer gear case has a removal cover which allows servicing the bevel pinion and bearings without complete disassembly of the transmission 1 Remove the transmission para 2 b 2 Remove bolts 1 bolts and locks 2 lockring 3 cage 5 and bearings 4 3 Remove dowels 6 with a forcing screw 8 nut 9 washers 10 and length of pipe 11 4 Refer tolfigure 6 65 and remove the transfer gear case cover with a hoist as shown 5 Remove plate 1 fig 6 66 bolts 2 and lock 3 Key to 15 6 6 1 Bolts 2 Bolts and locks 3 Lockring 4 Bearing 5 Cage 6
38. oil hoie in the mating part k Gaskets Be sure the holes in the gaskets correspond with the lubricant passages in the mating parts If it is necessary to make gaskets select stock of the proper type and thickness Be sure to cut holes properly Blank gaskets can cause serious damage l Seals 1 Floating seals a Floating ring seals have highly finished surfaces and are held together by toric sealing rings The flexibility of the toric sealing rings makes the floating ring seals self aligning and compensates for wear on the metal faces b During disassembly tape the metal floating ring seals together so they will be kept in matched sets Always install the metal floating ring seals in pairs that is two new seals together or two seals that have previously run together Never reinstall a used toric sealing ring Figure 2 8 shows the dimension 1 to be checked the metal floating ring seal 2 the rubber toric sealing ring 3 and the toric sealing ring retainer 4 The dimension must be uniform around the entire circumference of the floating ring seal Check the dimension at 90 intervals ME 2410 233 34 2 8 Dimension Metal floating ring seal Rubber toric sealing ring Toric sealing ring retainer wh Figure 2 8 Floating seal installation 2 5 d Handle all parts with care to avoid nicks File smooth any parts other than the sealing faces that have nicks that may make assembly difficult or qu
39. piston if surface damage is excessive 7 Inspect the cylinder sleeve for scratches scoring grooving and wear Measure the inside diameter using a micrometer Replace the sleeve if diameter exceeds 4 758 inch at any point d Reassembly and Installation fig 5 5b 1 Ensure that the engine block is clean 2 Install new rings 14 on the cylinder liner 13 3 Carefully lower the liner into the cylinder block Drive into place until the liner bottoms NOTE The liner should protrude 0 0020 to 0 0056 inch above the face of the cylinder block 4 Press the bearing 10 into place in the connecting rod 8 Secure the piston 9 to the connecting rod using the piston pin 7 Install the retaining rings 6 5 Using a piston ring expander install the piston rings 11 and 12 in their grooves Install the middle ring with the top mark up 6 Oil the piston and rings Place the piston and connecting rod assembly in the cylinder liner Use a piston ring compressor to aid in installation Position the V mark on top of the piston so that it is aligned with the V mark on the block 7 Install the bearing upper half 5 bearing lower half 3 and cap 2 Secure with bolt 4 and nut 1 Lubricate the threads with crankcase oil and tighten to a torque of 27 to 33 foot pounds Then tighten an additional 85 to 95 degrees 8 Install the cylinder block inspection covers or the oil pan if removed 9 Install the cylind
40. power shift transmission consists of five sets of planetary gear systems each of which has a hydraulically actuated clutch The power flows through two or more of these systems to the output shaft 4 of the transmission Three forward and three reverse speeds are available in the trans mission Selection of the desired speed and direction is accomplished by positioning spool valves in the transmission hydraulic controls located in the upper compartment 2 of the transmission case c The transmission output shaft 4 is splined to a transfer gear 5 within the transfer case 1 This transfer gear drives the bevel pinion 6 From the bevel pinion the power is transmitted through the bevel gear to the steering clutches then through the final drives to the tracks 6 1 6 2 N l 4 6 x ZAIN i lt VEN 8 pss aF N 16 Z SAA A INNA et p te Sa E KX awe CRIES SSS IW SX SX SS LS SS DJe TREES Sy TNH EST 53 Ew p gell 14 Torque divider housing 2 Rotating housing 3 Diesel engine flywheel 1 Ring gear gt Impeller 6 Sun gear Output shaft 8 Planet carrier 9 Planet gear 0 Turbine Figure 6 1 Torque divider Li lt u lt ID Ss a UN lI 12 13 14 15 16 l 18 19 pa zi MS ME 2410 233 34 6 1 Carrier Stator Torque converter gear Scaven
41. pressed air Clean the bearing as instructed in 2 Inspect the gear for broken damaged or missing teeth Replace as necessary 3 Inspect the shaft for damage distortion and wear Inspect the bearing contact surface for uneven or excessive wear Repair as required c Installation 1 Press the bearing onto the shaft Install the bearing retaining plate 2 Install the drive shaft into the timing gear housing CAUTION Do not allow the bearing retaining plate to fall into the timing gear housing when installing the drive shaft 3 Time the accessory drive shaft subpara d 4 Install the gear and secure with the retaining nut Tighten the nut to a torque of 90 to 110 foot pounds 5 Install the accessory drive housing to the timing gear plate and secure with bolts and locks 6 Install the fuel injection pump housing and governor para 5 11 Install the fuel transfer pump and fuel filter housing para 5 1p d Timing 1 Remove the fuel injection pump housing para 5 11 and position the engine crankshaft so that the No 1 piston is at top dead center TDC of compression stroke 2 Install a timing fixture plate on the rear face of the accessory drive housing as shown in figure 5 43 5 60 NOTE If the timing fixture plate can be installed timing is correct If it cannot be installed continue with this timing procedure TIMING FIXTURE PLATE ME 2410 233 34 5 43 p Figure 5 43 Timing
42. t VU T i Backup ring O ring seal Plate Dowels Ring Arrow Screws 8 9 10 11 12 13 2410 233 34 4 20 Plate Preformed packing Backup ring Vanes Insert vanes Rotor Figure 4 20 Cartridge disassembly small pump section 4 Large pump section a Remove bolts 1 4 21 and cover 2 a Hold cartridge 3 and using a plastic hammer tap on the end of the shaft to force the body and shaft from the cartridge CAUTION Vanes 11 fig 4 22 and insert vanes 10 are free to slide out of the rotor and ring and may be damaged if dropped c Refer to figure 4 22 and disassemble the cartridge ME 2410 233 34 4 21 1 Bolts 2 Cover 3 Cartridge Figure 4 21 Cover and cartridge renoval large pump section 4 31 6 Whe D 1 Plate Screws Ring Arrow Dowels Plate O ring seal 8 9 10 11 12 13 ME 2410 233 34 4 22 Backup ring Rotor Insert vane Vane Backup ring O ring seal Figure 4 22 Cartridge disassembly large pump section 5 Pump shaft removal Refer t figure 4 23 and remove the shaft seal and bearing ME 2410 233 34 4 23 Lockring O ring seal Shaft Lip tvpe seal Wiper Washer Snapring Bearing gt ei al va Zei Figure 4 23 Shaft seal and bearing removal Section Ill 4 8 Hydraulic Lift Cylinders a General Both blade lift cylinders are removed and installed in a similar manner
43. to the limit of its travel and the stop will he against the equalizer bar support The hydraulic cylinder could have high oil pressure in it even though the track is loose enough to remove the master pin without relieving the hydraulic track adjusting pressure 1 Separate the track and lay it out flat 7 1 2 Remove guards fig 7 2b 3 Remove either carrier roller support a para 7 8 or recoil spring assembly 7 6 4 Remove bolts and nuts 7 32 5 Remove the seal 3 7 33 antiextrusion ring 4 NOTE When installing antiextrusion ring 4 place the beveled edge toward the cylinder el Dei IDLER RECOIL ROD 2410 233 34 7 32 Preparing to remove cylinder Figure 7 32 Clover gt Bolt 51 A Meal L Xntiestrusion ring Figure 7 33 Removing seal and ring 6 Remove bolts 2 securing cover 1 to the recoil spring front pilot Pull the cylinder out of the bore Packing will come out with the cylinder b Disassembly 1 Push piston 8 7 34 out of cylinder 1 2 Inspect packing 3 and rings 2 3 Remove packing 3 and washer 6 after removing snapring 7 2410 233 34 7 34 1 Cylinder 5 Fill valve 2 Rings 6 Washer 3 Packing 7 Snapring 4 Relief valve 8 Piston Figure 7 34 Cylinder disassembly c Reassembly 1 Install packing with the lip
44. 4 17 for cuts breaks or deterioration Replace all defective packing 4 Reassembly a Reassemble the tilt control valve using figure 4 17 hs a guide b Install sufficient shims 20 to provide relief valve opening pressure of 1 975 25 psi C Be sure pilot valve seat 23 is bottomed square against the shoulder in control valve body 5 and spring is in its recess in seat 23 d Torque bolts 9 fig 4 17 to 25 1 ft lb 5 Installation a Install tilt control valve in reverse of removal b Torque bolts 1 fig 4416 to 60 2 ft Ibs NOTE Bolt 5 must be in place before installing manifold 3 on plate 2 4 7 Hydraulic Pump a General 1 The double section insert vane type hydraulic pump is bolted on the engine rear power takeoff housing and is driven by the rear power takeoff idler gear 2 The pump must have an adequate supply of clean oil as it is dependent upon a continuous flow of oil for lubrication of closely fitted parts If inlet oil is not available to the pump because of low oil level clogged or leaking inlet lines or for any 4 28 other reason the pump may seize or otherwise be damaged when the engine is started 3 The pump assembly consists of a small section pump and a large section pump utilizing a common inlet within the same pump assembly 4 The large section of the pump provides hydraulic power for the blade lift circuit which is controlled by a valve locate
45. 4 5 1 Housing 4 Valve spool 2 Plug assemblies Bolt and lockwasher 3 Valve body Figure 4 5 Valve spool removal 6 Detent 2 Retainer 3 Spacer Spring 5 Retainer 0 Spool Spacer 8 Shims Figure 4 6 Valve spool disassembled ME 2410 233 34 4 6 c Check Valve Removal 3 Use a inch 20 NC eyebolt to remove 1 Remove the bulldozer control valve and plug 5 Inspect preformed packing 3 remove the valve spool 4 Remove spring 4 and check valve 6 2 Remove bolts 1 fig 4 7 and flange 2 key to Cheek valve Valve body Bolts 2 Flange 3 Preformed packing 4 Spring Plug 6 1 4 10 gt Figure 4 7 Check valve removal ME 2410 233 34 4 7 d Makeup Valves 1 General Makeup valves are provided to supply tank oil directly to the bulldozer cylinder lines whenever the line pressure is less than tank pressure This occurs when the bulldozer blade raises or lowers rapidly The valves are located in a common valve body bolted to the bulldozer control valve A spring holds each valve seated during normal operation When oil pressure in the bulldozer circuit is reduced oil in the tank over comes the spring opens a valve and flows into the bulldozer circuit 4 12 2 Removal a Remove the hydraulic tank from tractor and remove the tank assembly from bottom plate 4 2 b Remove bolts 4 fig 4 8 and remove mak
46. 5 39 1 Lower the front section of the crankcase guard TM 5 2410 233 20 and drain the lubricating oil from the oil pan TM 5 2410 233 10 2 Remove the oil level dipstick 3 Remove the bolts and lockwashers that secure the oil pan to the timing gear cover and the oil pan plate 4 4 k OIL PAN MOUNTING BOL TS OIL PAN PLATE 2 OIL PAN PLATE MOUNTING BOLTS Figure 5 39 Oil pan and oil pan plate removal and installation OIL PAN ME 2410 233 34 5 39 4 Separate the oil pan gasket from the oil pan so that the gasket remains with the oil pan plate Remove the oil pan 5 Remove the bolts and secure oil lockwashers which pan plate to the cylinder block and flywheel housing Remove the oil pan plate and oil pan gasket b Cleaning Clean the oil pan and oil pan plate with cleaning solvent Fed Spec P D 680 Ensure that all sediment is removed from the sump in the oil pan Section VI 5 26 General The tractor is powered by the D333C 4 75 inch bore x 6 inch stroke six cylinder 638 cubic inch turbocharged diesel engine The engine is rated at 180 horsepower at 2000 rpm 5 27 Head and Valve Mechanism a Removal and Disassembly fig 5 4p 1 Drain the engine coolant Refer to TM 5 2410 233 10 2 Remove the exhaust tube muffler para 5 16 exhaust manifold 5 I8 air cleaner para 5 13 turbocharger para 5 11 and hood para 5 3 Remove
47. 92 c Installation 1 Replace seal 8 ig 6 113 in bearing assembly 7 Install seal 8 with the lip facing the outside of bearing assembly 7 NOTE Lubricate seal 8 with ball and roller bearing lubricating LO 5 2410 233 12 Install seal 8 with lip facing out 2 Using ball and roller bearing lubrication lubricate mating bolder 10 and bearing 9 Install bearing assembly 7 3 Place shims 5 and locating dowels 6 surfaces of retainer 2 on 4 Install retaining nut 4 and tighten to 1100 1200 lb ft NOTE Check track roller frame alignment and correct if necessary Correct alignment by adding or removing shims 5 whichever is needed para_6 29 5 Install lock 3 on locating dowels 11 Six lock positions can be obtained by reversing the lock 6 Using ball and roller bearing lubricant hand pack the bearing and install cap 1 7 Install the track roller frame para 7 10 and fill final drive compartment with lubricant to the specified lever LO 5 2410 233 12 6 21 a Removal Bearing Cage Holder Assembly 1 Remove track roller frame outer bearing para 6 20 NOTE Replace nut 3 fig 6 114 on the sprocket shaft 5 to retain bearing cage holder assembly 2 during removal Leave approximately inch clearance between the nut and holder assembly ME 2410 233 34 6 114 1 Nut 6 Cup 2 Holder assembly 7 Cage 3 Nut 8 Metal floating ring seal 4 Keyway 9
48. DIAL SZ Mk CG MAGNETIC BASE HOLDING ROD ME 2410 233 34 5 54 Figure 5 54 Checking flywheel housing runout Checking Flywheel Runout Mount a dial indicator to the flywheel bore as shown id figure 5 55 and check the runout Total runout must not exceed 0 006 inch 5 73 Ve Figure 2 20 Checking flvicheel runout zit 24 k crane 10 233 34 5 55 f Reassembly and Installation 1 Install a new mounting gasket and the flywheel housing fig 5 53 Secure with locks and the retaining bolts Tighten the bolts to a torque of 65 to 85 foot pounds 2 Tighten the bolts which secure the oil pan and oil pan plate to the engine black and flywheel housing 3 If removed heat the ring gear Mig 5 51 to not more than 600 F and install on the flywheel The chamfered side of the gear teeth should face the starter pinion when the flywheel is installed 1 Insert one j in 181NF guide pin into the flywheel housing and install the flywheel fig 5 1 50 Secure with lock and retaining bolts Tighten the retaining bolts to a torque of 130 to 170 foot pounds 5 Install the torque divider para 6 B 6 Install winch bulldozer and transmission hydraulic pumps and power take off drive gears bearings and cover on the flywheel housing 31 7 Install the starting motor on the
49. Dowels hidden 7 Locks 8 in 16 NC forcing screws 9 Nut 10 Washer 11 2 in lengtht of in id pipe 12 Transfer gear case cover ME 2410 233 34 6 65 Figure 6 65 Removing cover 6 59 ME 2410 233 34 6 66 Figure 6 66 Removing bevel pinion 6 60 Key to Tigure 6 66 1 Plate 2 Bolts 3 Lock 4 Bearing inner race and roller assembly 5 Gear 6 Spacer 7 Bearing inner race and roller assembly 8 Bevel pinion 6 Place the cover on blocks and also place a block under the bevel pinion shaft to prevent dam age to the teeth on the shaft when it is re moved 7 Drive out bevel pinion 8 8 Inspect bearing inner race and roller assembly 4 9 Remove gear 5 and spacer 6 10 Inspect bearing inner race and roller assembly 7 on the bevel pinion shaft If the bearing needs to be replaced it can be removed with a push puller and a bearing cup pulling at tachment 11 Remove plugs 3 4 fig 6 67 and the dowels beneath the plugs then remove the bearing outer races 1 and 2 ME 2410 23 1 Transfer gear bearing outer race 2 Bevel pinion shaft bearing outer race 3 Plug Plug Figure 6 67 Bearing outer race removal 6 10 Transmission Lubrication Junction Block a General The transmission lubrication junction block located on the front of the transmission case directs the flow of the transmission lubricating oil b Removal and Installation 1 Remove the floor plat
50. If the gage cannot be correctly positioned check accessory drive shaft timing para 5 2B 4 If the gage is correctly installed the fuel pump is correctly timed j Setting Fuel Injection Pump Timing Off Engine NOTE The fuel pump can be adjusted while removed from the engine 1 Install a pointer on tbe fuel injection pump housing 2 Place the timing plate on the drive end of the camshaft and secure 3 Refer to fable 5 1 band select the timing plate degree setting for the lifter to be set Set the lifter to be set Set the timing plate by rotating it counterdockwise until the proper degree setting aligns with the pointer Lock in position with the setscrew 4 The fuel injection pump timing dimension is 4 267 5 40 0005 inches Remove the in dividual fuel pumps and add spacers below the lifters as necessary to adjust timing k Seting Fud Rack 1 Remove the rack cover from the front of the accessory drive housing rear 5 28 Remove the cover from the rear of the governor housing para 5 10 2 Install a rack setting gage over the front end of the fuel rack 3 Loosely install a plug and push rod in the governor plug 59 fig 5 20 hole Force the speed limiter away from the plug hole 4 Move the governor control lever forward until the stop collar on the fuel rack just touches the stop bar on the torque spring If necessary insert a 0 003 inch feeler gage between the stop and spri
51. NE MUFFLER AIR OUTLET PIPE MUFFLE E is S BRACKETS TURBOCHAR OIL LINES MUFFLER SUPPORT BRACKET E CON Ge MOUNTING EXHAUST Sch A COLTS MANIFOLD po a BM CRANKCASE ER dus AS AT nen SR BREATHER EXHAUST MANIFOLD Cp ud PIPE RETAINING NUTS I AAN a GN WASHERS AND LOCKS DEED CC E e 24 2410 233 34 5 34 Figure 5 34 Exhaust manifold removal and installation b Inspection Repair Inspect exhaust manifold for cracks broken mounting flanges or other damage Weld cracks and other minor damage according to TM 9 237 Replace an ex cessively damaged exhaust manifold c Installation Reverse removal procedure and install the exhaust manifold on engine Section IV ELECTRICAL SYSTEM 5 19 General The tractor electrical system supplies the power to start the engine and operate the lights and in struments The system consists of batteries generator starting motor with solenoid and wiring Switches and other electrical components Refer to figure 1 1 for the tractor schematic wiring diagram 5 20 Generator a General The generator is a 24 volt 40 am pere type mounted on the right front of the engine It is fungus and corrosion resistant and is arranged for B type circuit with the field grounded inside the generator b Removal Refer to TM 5 2410 233 20 for the r
52. PSI is used in tlic operation of this equipment Death or severe injury imas result if personnel fail to observe safety precaution PASSENGER HAZARD Passengers are not permitted to cide other than in the seat as there is danger of being thrown inte the tracks when tractor is in motion Changes in force C 1 and C2 CHANGE No 2 5 2410 233 34 C 2 HEADQUARTERS DEPARTMENT OF THE ARMY WASHINGTON DC 29 October 1981 Direct Support and General Support Maintenance Manual TRACTOR FULL TRACKED LOW SPEED DED MEDIUM DRAWBAR PULL OSCILLATING TRACK 78 IN GAGE CATERPILLAR MODEL D7F WITH RIPPER NSN 2410 00 177 7283 WITH RIPPER AND ROPS NSN 2410 00 185 9794 WITH RIPPER ROPS CAB WINTERIZED NSN 2410 00 300 6665 WITH WINCH NSN 2410 00 177 7284 WITH WINCH AND ROPS NSN 2410 00 185 9792 WITH WINCH ROPS CAB WINTERIZED NSN 2410 00 300 6664 TM 5 2410 233 34 12 October 1971 is changed as follows The title is change to read as shown above Page iii list of illustrations Following 2 31 Preparing to remove engine sheet 2 of 6 add 2 31 1 Preparing to remove engine w ROPS sheet 2 of 6 Following 4 1 Hydraulic tank removal add 4 1 1 Hydraulic tank removal w ROPS Page iv following 5 23 Fuel tank removal and in stallation add 5 23 1 Fuel tank removal and in stallation w ROPS Page 1 1 Paragraph 1 3 is superseded as follows 1 3 Reporting Errors and Recommending Impro
53. Remove the retaining ring and pull the pin 6 securing the brake toggle links 8 and 9 to the brake link 5 5 Remove brake toggle link 9 and front brake lever assembly 12 as a unit 6 Guide the links 8 between the two support assembly braces and lift off the support assembly 3 1m 2 wow Brake lever shift 10 Adjusting screw socket assembly lI Brake linkage support assembly 12 Brake lever shaft 13 Brake link 14 Pin 15 Bolts l6 Brake toggle link 13 Brake toggle link 7 2410 233 34 6 75 Shim pack Stop Brake lever assembly Strut support assembly Pins Pins Struts Brake fever assembly Figure 6 75 Brake engaging mechanism disassembly 6 71 7 Remove bolts 7 securing shim pack 10 and stop 11 to support assembly 3 8 Remove the pins 14 that secure the brake toggle links 8 and 9 to the brake lever assemblies 12 and remove the toggle links 9 Remove pins 15 securing brake struts 16 to strut support assembly 13 and brake lever 12 10 Inspect bearings 2 3 4 and 6 in lever assemblies 1 and 5 and strut support 7 Replace bearings if they are worn or damaged NOTE An arbor press can be used for all bearing removal and installation ME 2410 233 34 6 76 Brake lever Bearing Bearings 5 Bearings 2 Brake lever Bearings 2 Strut support w Loi Li res Figure 6 76 Brake lever bear
54. SE 2 yo q 7 Be 3 Es SE W 7 SST 77 1 24 mones B Bes EU 10 Ns e 17 1315 19 14 A I H A SZ a a E p GEN Sch EC tN SIZE _ EU SS 21 4 23 1 PUN NN H a H EJ Brake drum Final drive pinion flange Final drive pinion inner bearing Final drive pinion Final drive pinion outer bearing Case Idler pinion Idler pinion outer bearing Sprocket Idler pinion inner bearing Dirt guard Final drive gear Outer bearing adjusting nut Final drive gear hub Bearing cage holder Figure 6 111 Final drive 29 D gt P o d AY RSG NNNM WY cae Z LJ ZZZZZZ234 272 lt lt lt i d N N JASS Pend ae E 2572 I 2526 2117 28 22 28 2 ST ME 2410 233 34 6 111 Hub inner support bearing Hub outer support bearing Sprocket shaft Retainer Floating duo cone seals Bearing cage Retaining nut Sprocket shaft retaining nut Bearing cage Sprocket retaining nut Gasket Lip type seal Outer bearing assembly Bearing cap b The final drives are splash lubricated Each final drive case provides an oil sump for each final drive group The oil level in the sump is established by the filler plug located in the steering clutch and bevel gear case 6 20 Track Roller Frame Outer Bearing
55. SOR BS ek Rho lt Ga Bd a Sa gl SUQ acs Equalizer bar and track roller frame REFERENCES Paragraph 73 Page LIST OF ILLUSTRATIONS Number Title Page CH Electrical system schematic diagram TI Lifting beam LL Lifting eyelet Pulley assembly Lp Bearing pulling attachment pelos New Lope pede dois Sod est e haie red LL Installing metal locks Co Locked anti friction bearing Chamfer on shouldered shaft CA Floating seal installation D Floating seal installation tool Floating seals installed with metal floating ring seal and toric sealing ring properly positioned mmm Lip type seal LJ Heel and toe type seals CIA Elbow body NEM bly Bak uade LL Sleeve type fitting bedi oe ee ante cere qtu L L Ol Sleeve and insert type fitting DT Shearstype TILIA ag ade pesan ae OR Ree gg ae CO d de c eo REE D EE Ae wa Qa C Removing bolt retainer spring LIN Hydraulic cylinder rod and head ends D Cylinder head seals LC Three seal cylinder head DCH Removing cylinder head shims 221 Packing and shims installed 4 Ba Measuring cylinder head clearance Iesse Solid seal assemblies installed piston LL Seal on expander 24 Compressing seals LL Pump cartridge Ring rotor and vane installation Back up ring installation 5 i s i A 4 A
56. The hydraulic system need not be drained to remove cylinders however do not move the control lever from neutral position after disconnecting cylinder oil lines b Removal 1 Lower the bulldozer blade to the ground 2 Remove bolt 3 fig 4 24 securing lockpin 2 to the bulldozer blade bracket 3 Remove pin 4 securing piston rod 1 to the bulldozer blade d Cleaning Clean all parts with cleaning solvent Fed Spec P D 680 Dry parts with a lint free doth Clear all passages in hydraulic pump of restrictions with filtered compressed air Inspection and Repair 1 Inspect the pump bearings for scoring damage and wear Replace bearings which are scored damaged or worn excessively 2 Inspect the plates ring rotor and vanes for damage and wear Install cartridge kits if parts are found damaged or worn excessively 3 Inspect pump housing for cracks breaks and other damage Replace defective parts 4 Install new seals washers and packing f Reassembly 1 Reverse disassembly procedure and assemble the hydraulic pump During assembly immerse each pump part in clean hydraulic oil 2 Pump rotation is counterclockwise when viewed from the drive spline end Be sure that the leading chamfered edge of the vanes arrow on the ring and arrow on the rotor all point in the direction of pump rotation 3 Tighten bolts to torque valve given in tabld 1 2 g Installation Refer to TM 5 2410 233 20
57. VALVE AND VALVE SEAT SPECIFICATIONS Valve seat Inlet valve seat insert diameter Bore for inlet valve seat insert Exhaust valve seat insert diameter Bore for exhaust valve seat insert Valve head diameter Inlet Exhaust Outside diameter of valve seat face new Exhaust Outside diameter of valve seat face after reconditioning Inlet Exhaust Stem diameter Valve guide bore inlet Exhaust Valve lip thickness inlet Exhaust Measurement from top of valve to face of head with valve seated inlet Exhaust Depth of bore for valve seat inserts Valve seat width inlet Exhaust Valve face angle VALVES Valve stem clearance in guide 0 009 Exhaust valve clearance hot Inlet valve clearance hot VALVE LIFTERS Lifter diameter Bearing bore 0 010 VALVE SPRING Free length 2 05 in Pounds force 54 8 60 When compressed 1 766 Outside diameter 1 386 in WATER TEMPERATURE REGULATOR Opening temperature 104 166 Fully open temperature 180 Measure valve guide bore in portion of guide which is pressed into cylinder head closest to valvehead Zu valve seat face exceeds the maximum width a fter grinding narrow the seat faceby using 159 stoneor fly cutter 1 6 Table 1 4 Power Transmission Units Repair and Replacement Standards Manufacturer s dimensions Maximum and tolerances in inches Desired clearance allowable wear and mae sen Component Torque Divider Engi
58. a General ttig 6 1 The torque divider is mounted in the torque divider housing 1 It pilots into the diesel engine flywheel 3 and is supported in the housing 1 by a bearing mounted in a carrier 11 b Operation 1 The torque divider is driven by the diesel emgine through a rotating housing 2 fig 6 1 and sun gear 6 to direct the torque output of the engine through two separate paths Most of the torque is transmitted by the rotating housing 2 and impeller 5 through a medium of oil to the 6 4 stator or reactionary member 12 which directs the oil to rotate the turbine 10 Since the turbine is splined to the same hub as the ring gear 4 the torque is transferred through the planet carrier 8 to the output shaft 7 A lesser amount of torque is transmitted from the engine flywheel 3 through the sun gear 6 and planet carrier 8 to the output shaft 7 2 The planetary system is composed of a sun gear 6 that turns with the diesel engine flywheel 3 a plane carrier 8 which is splined to the output shaft 7 and supports the planet gears 9 that mesh with the ring gear 4 3 The major components of the torque converter are the rotating housing 2 impeller 5 turbine 10 and stator 12 4 Oil for operation of the torque converter is supplied by the transmission and steering clutch control oil pump and enters the housing 1 passes through the inlet port in the carrier 11 to the torqu
59. a Removal 1 Drain the final drive compartment TM 5 2410 233 20 2 Remove the track roller frame para 7 10 3 Remove the outer bearing cap Lig 6 112 4 Remove retainer 2 lock 3 and nut 4 Remove the outer bearing assembly 7 0 Remove track roller frame outer bearing alignment shims 5 from locating dowels 6 CAUTION When separating the track roller frame outer bearing assembly 7 DE 6 113 from bearing cage holder 10 hold bearing assembly 7 level to prevent damage to seal 8 contained in the bearing assemblies 7 Key to 6 2 Cap 2 Retainer 3 Lock 4 Nut 3 Shims ME 2410 233 34 6 112 Dowels Track roller frame outer bearing assembly Figure 6 112 Outer bearing removal 6 91 M ji 3 3 BO 2 xm Len 3 22222222220 24 ch N ZA N Z LDS EM 4 ADAN 9 10 11 Figure 6 113 E 2zzzz zzz2 H N 222 WN KES ak 5555 S SA 1 1 NS 10 189 ME 2410 233 34 6 113 Cap Retainer Lock Nut Shims Dowels 2 Bearing assembly Seal Bearings Holder Dowels 2 Outer bearing insta atton b Inspection and Repair 1 Inspect bearing for corrosion pitting and Wear Replace a corroded rough or worn bearing 2 Inspect bearing cap l fig 6 115 for cracks breaks or other damage Replace a defective or damaged bearing cap 6
60. and install the hydraulic pump on the tractor HYDRAULIC CYLINDERS 4 Retract piston rod 1 and wire the rod end to the head of the cylinder Remove the cylinder with the rod in the retracted position 5 Attach a hoist to the cylinder 3 fig 4 25 6 Disconnect the hydraulic oil lines 1 and mark them in relation to their openings to assure proper connections when installing the cylinder 3 7 Cover all openings to prevent the entry of dirt into the hydraulic system 8 Remove bolts 2 and trunnion caps 4 and lift dinder 3 away from the tractor 4 33 ME 2410 233 34 4 24 Piston rod Lockpin Bolt Pin Figure 4 24 Disconnecting piston rod 4 34 4 2410 233 34 4 25 Hydraulic oil lines Bolts Cylinder Trunnion caps Figure 4 25 Lift cylinder removal c Disassembly 1 Drain both ends of the cylinder 2 Remove tube assemblies 26 1 and 2 3 Remove and inspect bearings 6 if necessary fig 4 Replace 4 Remove bolts 3 securing the head 5 to the cylinder S t Tube assembly Tube assembly Bolts Piston rod Head Bearings oV V Ga L ra Figure 4 26 Preparing to disassemble cylinder ME 2410 233 34 4 26 CAUTION Extend piston
61. and replaced provided the bushing is not damaged NOTE Install new bearings if the shaft clearance exceeds that given in table 1 5 7 Press the bearing out of the bushing and cut off the projecting pins with a hacksaw 8 Smooth the face of bushing with a file 9 Press the new bearing into place making certain the lubricant holes are aligned 10 Drill two 9 32 inch holes 13 16 inch deep through the flange of the bearing and into the wall of the cast iron bushing CAUTION Be sure the holes do not interfere with lubrication grooves in the face of the bearing flange 11 Install the proper pins so they do not extend above the face of the bearing 12 Smooth the face of the bearing flange PIN BEARING BUSHING e A ME 2410 233 34 7 15 Figure 7 15 Bushing assembly c Cleaning 1 Clean all parts using cleaning solvent F ed Spec P D 680 and wipe dry with a lint free cloth 2 Remove all dirt and rust from the floating ring seal mounting grooves Grooves must be dean smooth and dry 3 Wash protective coating from new ring seals with deaning solvent d Inspection and Repair 1 Inspect the track rollers for damage and wear When the contact surface of the roller is worn from 8 38 to 8 00 inches in diameter the roller will be repaired by welding an overlay on the
62. body 4 25 Zz 36 c co WAWKU l Plug 14 2 O ring 15 3 Spring 10 4 Check valve 17 5 Valve body 18 0 Check valve seat 19 O ring seals 20 8 O ring seal 21 9 Bolt and lockwasher 22 10 Bolt and lockwasher RA Washer 24 12 Housing 25 13 Spacer 26 Figure 4 17 Tilt control valve disassembly c Tilt Control Lever 1 Removal and disassembly Loosen bolt 2 fig 4 18 and remove lever 1 plate 4 4 26 ME 2410 233 34 4 17 Spring Spacer Valve spool Cover Bolt loekwasher Sleeve Shims Spring Pilot valve Seat O ring Spring Dump valve b Remove key 3 c Remove lever 6 and washer 7 from 1 Lever 2 Bolt 3 Key 4 Blade tilt control mounting plate valve Figure 4 18 Tilt control lever removal ME 2410 233 34 4 18 5 Lip type seal 6 Lever 7 Washer 8 Bearing 2 4 27 2 Cleaning Clean all parts with cleaning solvent Fed Spec P D 680 Dry parts with a lint free doth Clear all passages in tilt control valve of restrictions with filtered compressed air 3 Inspection and repair a Inspect springs for weak or damaged condition and free movement of valves in bores Inspect valve seating surface and seat in bore for nicks burrs and proper contact Examine edges of valve land for damage and wear Replace defective parts b Inspect O ring seals 7 and 8 fig
63. brake pedal assembly 30 2 Drain oil from transmission LO 5 2410 233 12 3 Disconnect wiring from the disconnect switch mounted the seat frame assembly fig 24 33 sheet 1 4 Disconnect the transmission hydraulic control linkage fig 6 71 from the seal frame assembly 5 Remove the seat frame assembly mounting bolts fig 2 33 sheet 1 Attach a hoist and remove seat frame assembly DISCONNECT A SWITCH WIRING SEAT FRAME MOUNTING BOLTS ME 2410 233 34 2 33 IIS Figure 2 33 Preparing to remove transmission sheet 1 of 3 6 Remove transmission vent line 2 3B 8 Disconnect oil temperature sensing unit sheet 2 from the torque converter 7 Remove the torque divider oil supply line and the scavenge pump oil outlet line fig 2 31 sheet 4 2 21 Figure 2 33 Preparing to remove transmission sheet 2 of 3 9 Remove 8 capscrews and remove the drive shaft 10 Disconnect the transmission oil filter oil outlet line and oil cooler oil outlet transmission sheet 2 11 Remove the steering clutch control valve oil supply line fig 2 31 sheet 4 12 Disconnect magnetic strainer oil inlet line from line 2 22 from transmission Loosen one hose clamp and rotate oil line out of way 13 Disconnect oil pressure line from trans mission 14 Install four in 10 NC eyebolts in top of transmission and attach a hoist Remove the transmission mounting bolt
64. clutch shaft With one sterring clutch removed the clutch shaft can be retained by applying the opposite brake ME 2410 233 34 6 91 Guide pins Steering clutch pressure plate Bolts Figure 6 91 Compressing steering clutch springs wise ME 2410 2332 34 6 93 Steering cluteh piston Figure 6 93 Removing steering clutch piston 2410 233 34 6 94 Steering clutch driving hub 2 Steering clutch shaft ME 2410233 34 6492 5 Retaining nut BO Retaining washe Steering clutch assembly qn INIM diti eoe dri bae die Figure 6 94 Preparing to remove hub retaining hub 3 Forcing screws Figure 6 92 Removing steering clutch assembly from outer drum 6 80 Bolts 2 Wrench socket Figure 6 95 Removing hub retaining nut 4 ME 2410 233 34 6 96 Steering clutch driving hub Steering clutch piston Retainer washer Retaining nut Seal ring Seal ring Steering clutch piston pilot Seal ring 9 Preformed packing IO Groove 11 Lock 1S d Zei lS x Figure 6 96 Steering clutch hub assembly exploded view 4 Remove the nut and retainer washer 4 5 Remove the steering clutch piston pilot 7 fig 6 96 by inserting a screw driver in the machined groove 10 and prying against the end of the clutch shaft 6 Install the retaining nut 1 fig 6 97 on the clutch shaft so that there is approximately 7 inch clearance between the nut an
65. eyebolts Attach a hoist and remove torque divider housing 9 from carrier assembly 8 10 Remove the impeller assembly retaining bolts 18 fig 6 1 11 Remove the impeller assembly 5 12 Remove the eight stator assembly to carrier assembly retaining bolts 19 13 Remove the stator as shown inLfigure 6 11 by placing two wood blocks on the impeller and prying upward ME 2410 233 34 6 1 Figure 6 11 Removing stator 14 Disassemble the impeller assembly as follows a Remove the scavenge pump drive gear retaining bolts 1 fig 6 1 2410 233 34 6 12 Bolts 2 Gear 3 Impeller 4 Bearing 5 Carrier 6 Bearing retaining ring Figure 6 12 Impdle disassembly b Remove the drive gear 2 c Remove the bearing retainer 6 and bearing 4 from impeller 3 d Remove the bearing from retainer e Remove the retaining ring 6 from bearing 6 13 15 Disassemble the carrier assembly as follows a Using a hammer and punch remove the lip type seal from carrier assembly b Remove the bearing assembly retaining ring c Using hammer and punch remove the bearing assembly 1 fig 6 13 from carrier 2 d Remove the sleeve from carrier e Remove the ring seals 3 from the carrier 16 Remove the turbine retaining ring 17 Turn the housing over and drive the retaining pind f
66. g OIL SUPPLY LINE MAGNETIC STRAINER OIL INLET LINE SCAVENGE PUMP OIL OUTLET LINE E TORQUE DIVIDER POWER TAKE OFF 4 DRIVE GEARS j xia OIL OUTLET LINE LUBRICATION LINE TRANSMISSION OIL PUMP OIL OUTLET LINE 2222 2410 233 34 2 31 Figure 2 31 Preparing to remove engine sheet 4 of 6 14 Disconnect the oil cooler oil outlet line from the oil cooler fig 2 31 sheet 3 15 Disconnect the steering clutch control rods at both fig 2 31 sheet 5 and slide the rods toward the rear of tractor Figure 2 31 Preparing to remove engine sheet 5 of 6 2 18 16 Remove the transmission vent line fig 2 31 sheet 4 17 Remove oil pressure line from engine and transmission 18 Remove 8 capscrews and remove the drive shaft 19 Disconnect oil temperature sensing line from the torque divider 20 Remove the transmission oil pump oil outlet line 21 Disconnect the oil outlet line from the Scavenge pump 22 Disconnect the torque divider oil supply line from the torque divider 23 Remove the two engine front support to frame mounting bolts 2 31 sheet 1 24 Remove the four engine rear support to frame mounting bolts sheet 6 Remove the two dash support brace mounting bolts DASH SUPPORT BRACE MOUNTING BOLTS 2410 233 34 2 31 Figure 2 31 Preparing to remo
67. group H NYZ 2 RE IS LLL LL i 1 2 3 4 5 6 7 8 Figure 7 2 Section Il ant SS ART E gt 2 VL LLL SS 2 b ME 2410 233 34 7 2 Spacer Master pin Coned dis seal washers Master bushing Track bushing Link Track pin Coned disc seal washers Track pin and bushing cutaway TRACKS AND SUSPENSION 7 1 Track Assembly a Removal and Disassembly 1 Remove all dirt or other debris that may prevent retraction of the idler WARNING Be certain the hydraulic pressure in the track adjusting mechanism is com pletely relieved and the cylinder can be moved to the rear into the recoil spring front pilot before attempting to separate the track or remove the track adjusting mechanism On machines that have badly worn track it is possible for the hydraulic track adjuster to be adjusted forward to the limit of its travel and the stop will be against the equalizer bar support The hydraulic cylinder could have high oil pressure in it even though the track is loose enough to remove the master pin wit bout relieving the hydraulic track adjusting pressure 2 Remove the track roller frame guard from over the track adjusting mechanism Clean vent holes fig 7 8 thoroughly 7 2 FILL VALVE RELIEF VALVE pe Pese
68. install the hydraulic pump c Disassembly and Assembly 1 Refer to figure 6 31 and disassemble the pump 2 When the pump is disassembled inspect oil seal 20 in cover assembly 18 3 Bolts 5 have flat washers which must be in place when the pump is assembled 4 Assemble the pump in the reverse order of disassembly 5 Fill the pump with clean oil and rotate the drive gear prior to installation This will place a film of oil on the pump gears and body and aid in priming the pump 6 Inspect the preformed replace if necessary before connecting the hydraulic lines packings and Key to figure 6 31 1 Bolt 2 Washer 3 Screw 4 Washer 5 Bolt 6 Washer flat 7 Manifold flat 8 Packing 9 Bearing 10 Body 11 Packing 12 Gear 13 Gear 14 Bearing 15 Bearing 16 Bolt 17 Washer 18 Cover assembly 19 Packing 20 Seal 21 Plug 9 Figure 6 31 Hydraulic pump disassembly ME 2410 233 34 6 31 6 6 Torque Converter Inlet Relief Valve a General The torque converter inlet relief valve is an integral part of the directional valve body assembly and is also located within the transmission case fig 6 3p b Removal Refer to paragraph 6 4 and remove the directional valve body assembly from trans mission case c Disassembly Refer to figure 6 33 land disassemble the inlet relief valve from directional valve body ME 2410 233 34 6 32 Safety valve Speed selector body Torq
69. must be replaced 5 Inspect armature for short circuits using a growler fixture and a steel strip Strip will vibrate against armature over a shorted area as the ar mature is turned Replace armature if a short circuit is found 6 Turn down commutator if grooved or out of round Undercut mica to a depth of 0 025 to 0 032 inch below surface of commutator Do not widen slots when undercutting mica 7 Check field winding in frame for in sulation breakdown with an ohmmeter Attach one probe of ohmmeter to frame and other to one of the field winding terminals The reading should not be less than one megohm Replace defective coil worn teeth Inspect clutch splines for wear and damage Inspect shell for cracked or broken condition Check to make sure pinion will drive in one direction and will slip in opposite direction Replce drive with if defective 9 Inspect shift lever shaft and solenoid plunger for cracks or distortion Replace defective parts 10 Inspect bellows for tears punctures and deterioration 11 Inspect solenoid relay windings Tor shorts or grounds with a pair of test probes Inspect case for cracks or other damage Replace solenoid relay if defective g Assembly of End Bell and Brush Holder Plate 1 If wick was removed during disassembly saturate a new wick and ping with oil and install in end bell Wick must not be in fill hole 2 Apply sealer to expansion plug hole and install plug Fill r
70. n Ro 909 4 a a 08 343535444 4 5 Ro eo Removal and installation of major components REPAIR OF EARTH MOVING EQUIPMENT AND Bulldozer Ripper Winch REPAIR OF HYDRAULIC SYSTEM Hydraulic tank Hydruhic control valves and hydtaulic pumps 202 2214 OR d a qe oe UR Hydraulic cylimdsts 0256 EE EAR deb Sake Be x gh are EUR RR Ae EORR CE RUN CAU RUE 461 cube de bee eg REPAIR OF THE POWER PLANT Cooling mom seu cR OC 42 45 mede ER rex ue 2 un AH S uU ES wu Pm US dE SUA Weed 05 mis u od IPGL Sy UIN unos Rete e Bole do dern D QS seat 5 2462 4 Air induction and exhaust system Electrical system Engine TIubricatims System 2 3 45 ooo e ce EE Eo 2 Bota ae eus Diesel engine REPAIR OF DRIVE TRAIN Torque divider and traismission A o Xo y eo noo 0 oo 5 ESO o hc OU TR A oo Steering clutches brakes and bevel gear drive x ou ses MA RUM wc RUE XO boum eR NES amp amp Ro Hx amp s Roto 5 4205 eo WINCH Paragraph ATM 5 2410 233 34 Page CHAPTER ds Section I IT REPAIR OF TRACK ROLLER FRAME AND TRACKS General ss ees goce AXE HEIN RRA EE Rd RSE RR Moss n cap s q 5 5 544 44 5
71. not remain replace the drum 6 Inspect washers 3 and 11 fig 6 78 for dam age and wear Replace if damaged or worn excessively 7 Inspect all springs for cracks breaks and distortion Replace defective springs e Adjustment 1 Install a wood block as shown in figure 6 79 and turn the adjusting screw clockwise until the lever assemblies are firmly against their stops 2 Lift brake link with a pul of ap proximately 30 pounds 3 Measure the distance from the top of the pin which joins the brake link to the brake toggle links to the milled flat on the support assembly 4 Add or remove shims behind the stop to obtain a distance of 0 860 inch to 0 900 inch 5 Install the support assembly in the steering clutch and bevel gear case subpara a above 6 Turn the adjusting screw socket assembly until the brake band is tight on the steering clutch outer drum Back off the socket assembly 1 turns or nine clicks 7 Install the remaining brake linkage 8 The parking brake lever 1 6 80 be adjusted by disengaging the parking brake and adjusting the parking brake linkage 4 to obtain dimension B which is the distance between the front face of the seat arm rest support and cen terline of parking brake lever 0 82 to 0 94 inches The brake pedal 2 can be adjusted by disengaging the parking brake and adjusting the brake linkage 3 to dimension C which is the dis
72. of the vanes 2 and the arrows fig 2 28 on the ring and rotor must point in the direction of PUMP ROTATION when the cartridge is installed in the pump cover Note that the passage A and passages C are angled toward the direction of pump rotation If new O ring seals and back up rings are to be installed on the pressure plate they must be installed as shown on figure 2 29 Lubricate the components and then install the back up rings so the concave side faces the mating O ring seal ME 2410 233 34 2 29 D Back up rings EO O ring seals Figure 2 29 Back up ring installation d Be certain the pins 3 fig 2 30 in the cartridge 1 align with the holes in the pump cover 4 The arrow on the pump cartridge must point in the same direction as the pump shaft turns ME 2410 233 34 2 30 Pump cartridge Pump body Pins I 3 4 Pump cover Figure 2 30 Typical pump assembly Section IV REMOVAL AND INSTALLATION OF MAJOR COMPONENTS 2 7 General The two major components of the tractor are the engine and the transmission This section covers direct and general support maintenance in structions for the removal and installation of these components as authorized by the allocation chart maintenance 2 8 Engine a Removal 1 Remove the hood 5 2 drain the cooling system and disconnect the negative battery cable from the battery TM 5 2410 233 20 2 Drain the oil from the flywhee
73. planet gear shafts 2 part of the way out of the carrier and remove the No 5 planet gears 3 washers 6 and bearings 7 3 Pull the shafts 2 from the carrier and remove the No 4 inner planet gears 5 together with the bearings and washers NOTE Use care to avoid loss of the balls 4 and 9 in the planet gear shafts 2 anf 8 Two bearings 7 and two washers 6 one on either side of each planet gear are provided with each planet gear in the carrier 4 The No 4 outer planet gears 10 complete with bearings and washers can be removed after removing the planet gear shafts 8 5 Inspect all gears bearings washers and shafts in the carrier and replace any that are worn or damaged 6 Assemble the carrier in the reverse order of disassembly making certain the ball is in place in each planet gear shaft and correctly aligned with the notch in the carrier 6 53 P 5 ME 2410 233 34 6 60 Figure 6 60 No 2 carrier disassembly 6 54 key to 6 00 No 2 carrier No 5 planet gears Ball No 4 inner planet gears Washers Bearings 1 2 Planet wear shafts 3 1 amp Planet gear shafts 9 Ball 0 No 4 outer planet gear j Clutch Disassembly and Assembly The five clutches are identical except for the number of disc assemblies and plates used No 1 No 3 and No 4 clutches have three disc assemblies and two plates No 2 clutch has four disc assemblies and three plates and
74. plug openings 4 Remove the bolts and locks which secure the oil pump to the cylinder block and remove the oil pump fig 5 3 5 49 ee E hs 6 ie e PUMP BOLT e A CN N R AND LOCK D Z t 34 ei 2410 233 34 5 37 4 Figure 5 37 Oil pump removal and installation e 5 50 b Disassembly fig 5 3B 1 Remove the bolts 1 lock 2 and cover 3 Remove the spring 4 and plunger 5 2 Remove the bolts 6 lock 7 elbow 8 and gasket 9 3 Remove the bolts 10 11 and 12 and locks 13 14 and 15 Remove the scavenge pump body 16 from the oil pump body and press out the bearings 17 and pins 18 Key td figure 5 38 22 Gasket 1 Bolt 23 Gear 2 Lock 24 Key 3 Cover 25 Gear 4 Spring 26 Spacer 5 Plunger 27 Cotter pin 6 Bolt 28 Nut 7 Lock 29 Washer 8 Elbow 30 Gear 9 Gasket 31 Key 10 Bolt 32 Shaft and 11 Bolt gear assembly 12 Bolt 33 Bearing 13 Lock 34 Gear 14 Lock 35 Shaft 15 Lock 36 Dowel 16 Body 37 Shaft and 17 Bearing gear assembly 18 Pin 38 Bearing 19 Bolt 39 Bearing 40 Ball 20 Lock 41 Body 21 Suction bell ME 2410 233 34 5 38 Figure 5 38 Oil pump exploded view 4 Remove the bolts 19 lock 20 suction 30 and key 31 Remove the shaft 32 from the bell 21 and gasket 22 oil pump body 41 Drive out the bearing 33 5 Remove the scavenge pump drive gear 7
75. press to the sprocket Rock the sprocket back and forth to equalize the load h Press the sprocket on to 60 65 tons i When a new sprocket or final_drive hub has been installed measure distance Al fig 6 122 between the end of the sprocket and the end of the splines on the final drive hub Distance A should be 0 44 0 56 inches 1 2 mp 4 Z Ki Ke es 1 Lock 2 Nut 3 Hub 4 Bearing cone A Dimension to be checked 5 ME 2410 233 34 6 122 Figure 6 122 Checking sprocke location j Install lock 1 and using a spanner wrench install sprocket retaining nut 2 K After locking the retaining nut heat outer bearing cone preferably in oil and drive it onto final drive gear hub 3 until it seats against retaining nut 2 6 100 1 Lock 2 Nut 3 Hub Figure 6 123 Installing retaining nut 1 Remove the installation tools and install the metal floating ring seald para 6 20 b Sprocket Segments 1 General The segmented sprockets consist of a hub with sprocket segments bolted into place around the hub Sprocket segments can be replaced without removing the hub from the tractor 2 Removal a Remove dirt guards to provide access to sprocket segments b Loosen track adjustment and insert pin 1 fig 6 124 in the last slot of the segment 3 just behind the segment 2 to be replaced WARNING Refer to paragraph 7 2 for correct procedure on
76. removal I Tank assembly 2 Bolts 3 Blade tilt control valve mounting plate 4 Bottom plate A Bulldozer relief valve 6 Manifold Figure 4 2 Preparing to disassemble tank 4 3 ME 2410233 34 4 3 Filter inlet oil line 2 Bolts 3 Oil filter 4 Hose clamp Figure 4 3 Filter inlet line disconnect Section Il HYDRAULIC CONTROL 4 3 Bulldozer Control Valve a Removal 1 Remove the hydraulic control tank from the tractor para 4 2 2 Remove the tank assembly from bottom plate 6 4 4 3 Remove bolts 3 and 14 and remove oil line 5 4 Disconnect rod 4 from end of control valve spool 5 Remove bolt 9 and remove oil line 1 6 Remove bolts 7 and 8 and remove elbows 10 and 11 7 Remove bolts 12 and remove bulldozer control valve 2 The bulldozer control valve weighs approximately 70 pounds 4 4 c Cleaning Flush and clean inside of hydraulic tank with cleaning solvent Fed Spec P D 680 Wipe outside of tank with a cloth dampened with cleaning solvent Wipe dry using a lint free cloth d Inspection 1 Inspect hydraulic tank for cracks breaks dents broken welds and corrosion Tank will be free of major denta and distortion that will affect serviceability capacity or appearance Replace a tank that is uneconomical to repair 2 Inspect hydraulic tank cap gasket strainer gage filter springs seat and filter by pass valve for damage or disto
77. rod 4 out of the cylinder before removing bolts 3 This will prevent possible scoring of cylinder walls when removing the piston from the cylinder 5 Remove the head piston rod and piston 6 Remove nut Drees and washer 2 7 Remove piston 10 8 Remove wear ring 3 by expanding it slightly and sliding it off piston 10 9 Expand the outer ring of seal assembly 9 and remove the outer and inner rings 10 Press plungers 1 fig 4 2B inserts 2 and 3 from piston 4 using a driver fabricated as shown irj figure 4 29 11 Remove preformed packing 8 fig 4 2y and backup ring 7 12 Remove head 6 13 Remove bolts 4 securing retainer 5 to the head ME 2410 233 34 4 27 Nut Washer Wear ring Bolts Retainer Cylinder head Backup ring Preformed packing Seal assembly 10 Piston 11 Packing rings 12 Rubber pressure ring 13 Seal Figure 4 27 Disassembling piston and head Ui P UJ NJ 4 36 ME 2410 233 34 4 28 1 Plunger 2 Insert 3 Insert 4 Piston Figure 4 28 Rdief valve removal 375 DRILL 50 DEEP ME 2410 233 34 4 29 Figure 4 29 Driver dimensions 14 Remove packing rings 11 rubber pressure ring 12 and seal 13 15 Remove bolts 4 4 30 securing bearings 1 and 2 and shims 3 to piston rod 6 16 Remove trunnion 5 from piston rod 6 Bearing Bearing Shims Bolts Trunnion Piston rod OU RUN
78. scale deposits the cooling system must be cleaned TM 5 2410 233 20 1 Discard all gaskets dean all parts with dry deaning solvent Fed Spec P D 680 and dry with compressed air 2 Inspect oil cooler core and oil filter base for cracks breaks leaks or other defects Replace a defective core or oil filter base 3 Inspec all mounting hardware or hose for damage or defects Replace all defective parts 4 Repair all small leaks in oil cooler core by brazing or silver soldering C Test The oil cooler core will be immersed in water and compressed air applied to test for leaks Cap both openings of core and apply 10 12 Ibs of air on the coolant side of the core d Installation Reverse removal procedure and install the engine oil cooler on the engine Install new gaskets and oil filters Start engine and check oil level and replenish if low LO 5 2410 233 12 5 8 Fan and Fan Drive Assembly a Removal 1 Remove the radiator and radiator guard from the tractor para 5 3 2 Loosen and remove 57 3 Remove the fan guard para 5 4 and lift the fan assembly from radiator guard 4 Attach a hoist to the fan drive assembly fig 5 7 5 Remove the bolts 18 fig 5 18 securing tbe fan drive assembly and remove from the engine 5 18 b Disassembly 1 Remove 2 bolts 7 and washers 8 and remove the large washer 9 from bracket assembly 17 2 Pull the hub 13 with bearing 1
79. shaft g Fi Pinion depth Hydraulic tank removal Preparing 10 disassemble anke a Aen Packed bb ee ob te aie obedit Ae ak e oet Ge be it ve RoR ice a a Filter inlet line disconnect JBHHHBBBBHHHBBH ga8BB8BIBBBBHBHBHBBBBBBHBHHBBBIBBBBBBBBBS DARAANAN E Number Title Bulldozer and ripper control valves Sheet 1 of 2 Bullsdozer and ripper control valves Sheets 2 of 2 Valve Valve spool removal spool disassembled Check valve removal Make up valve body removal Makeup valve disassembled Control lever assembly Sheet 1 of 2 Control 1 assembly Sheet 2 of 2 Control lever disassembly Measuring clearance Bulldozer relief valve removal Relief valve disassembly Ripper control valve disassembly Blade tilt manifold and valve removal Tilt control valve Tilt control lever Cover and cartridge removal small pump section Cartridge disassembly small pump section Cover and cartridge removal large pump Cartridge disassembly large pump section Shaft seal and bearing removal Disconnecting piston rod Lift cylinder removal Preparing to disassemble cylinder Disassembling piston and head Relief valve removal Driver dimensions Piston rod bearing assembly Measuring clearance Piston reassembly Seal assembly installation tools Removing shims Tilt cylinder removal Preparing to disassemble cylinder Removing nut Disassem
80. spool for nicks burrs pitting and wear Light scratches or a light grey wear appearance are not harmful to the valve Examine the valve land edges for wear If wear or damage exists the complete valve assembly must be replaced 2 Inspect detent plug assemblies 2 fig 4 5 for weak or damaged springs and worn or damaged balls Replace as required 3 Inspect the check valve for weak or damaged spring A fig 4 7 and free movement of valve in bore Inspect valve chamfered seating surface and valve seat in body 7 for nicks burrs and proper contact Replace as required 4 Inspect the make up valves for weak or damaged springs 3 4 9 and free movement of valve 4 in bores Inspect valve chamfered seating surfaces and valve seats in body 5 for nicks burrs and 100 percent contact Finger pressure against the face of the valve should open it and the spring should return the valve to closed position Replace defective springs or valves 5 Inspect control shaft bearings 6 fig 4 11 for corrosion roughness and wear Replace corroded rough or worn bearings 6 Replace control shaft oil seal 7 Examine control shaft for wear due to seal contact Replace shaft if deeply grooved h Reassembly 1 Reassemble the control lever using figure 4 11 as a guide Install the seal 7 with the lip toward bearings 6 and the metal case flush with the outside face of the housing 5 Position and install the outer l
81. spray pattern and checking the injector unseating pressure Unseating pressure must be between 400 and 800 psi If pressure fails to reach 400 psi replace the injector Test for leakage by applying 300 psi pressure If pressure falls more than 100 psi in 30 seconds replace the injector Replace an injector that does not produce an even atomized spray pattern after the orifice has been cleaned If screen filter in the injector is broken or clogged replace the injector nozzle NOTE Only the capsule type nozzle and injector body need be replaced Tighten nozzle in valve body only finger tight Reassembly and Installation 1 Install the nozzle 5 fig 5 17 to the body 1 and tighten finger tight Insert the injector into the opening in the precombustion chamber fig 5 16 2 Install new seals 2 and 4 fig 5 17 3 Secure with the nut 3 and tighten to a torque of 100 to 110 foot pounds Ul ON PE ME 2410 233 34 5 17 Body Seal Nut Seal Nozzle Figure 5 17 Fue injector disassembly and reassembly 4 Connect the fuel line fig 5 16 5 Bleed the fuel system as instructed in TM 5 2410 233 20 5 11 Fuel Injection Pump a General 1 The fuel injection pump fig 5 19 is composed of six individual pumps installed in the fuel injection pump housing 2 The pump is camshaft operated and driven by an adapter from the accessory drive shaft Fuel enters the fuel injection pump housing t
82. tbe top and oil drain passage 6 in the cage to the bottom Final drive pinion 2 and bearings are serv iced after the steering clutch and final drive pinion flange have been removed 6 107 6 108 Figure 1 2 3 4 5 6 6 ME 2410 233 34 6 133 Bolts and locks Pinion gear Cage Cup Forcing screws Oil drain passage 133 Removing bearing cage ME 2410 233 34 6 134 1 Roller assembly 2 Dowel Figure 6 134 Removing outer race and roller assembly 16 Inspect hub inner bearing cup 4 17 Replace cup 4 if necessary NOTE If the teeth of the final drive gears and pinions are worn considerably more on one face than on the other they can be switched from one side of the tractor to the other This will provide a longer service life for the gears and pinions by wearing both faces of the teeth b Installation Install final drive gear idler pinion and bearings in the reverse order of removal NOTE Heat the bearing races in oil at installation 6 26 Sprocket Shaft a Removal 1 Remove final drive gear para 6 25 2 Remove the locking 1 fig 6 13p 3 Remove the pin securing sprocket retaining nut 2 to the sprocket shaft 4 Using a spanner wrench remove the retaining nut 2 5 Remove sprocket shaft 1 Lockring 2 Retaining nut and winch removed Figure 6 135 Removing retaining nut b I
83. td figure 6 70 A Directional clutch oil pressure tap B Transmission oil pressure tap Lubrication oil pressure tap D Speed clutch oil pressure tap F Torque converter outlet oil pressure tap B E Transmission oil pump pressure tap 15 Transmission pump C G Left steering clutch oil pressure tap H Right steering clutch oil pressure tap I Transmissin oil pump pressure tap Figure 6 70 Hydraulic control system pressure tap locations 6 65 Pressure Steering clutch piston steering clutchs Hydraulic oil pump engine at high idle disengaged and engine at Table 6 1 Steering clutch control tests low idle Locations Value G H 290 psi E 350 psi Table 6 2 Transmission and torque divider hydraulic control test Pressure Transmission oil pump engine at high idle and transmission selector lever in neutral Speed clutch engine at high idle speed and clutch engaged Directional cluitch engine at high idle speed and clutch engaged Transmission lubrication junction block at engine high idle speed Torque divider outlet relief valve with engine at high idle speed and brakes locked move transmission selector lever to third range Watch Taachometer engine should be 921 10 51 rpm Torque converter inlet relief valve bench test only see the adjustment column Location B Filter E Pump D Value 350 psi 270 290 psi 47 63 psi less than speed clutch pres sure reading 9 15 p
84. the bevel gear shaft 4 Lower the shaft through side frame being certain that the match marks on the shaft line up with the match marks on the clutches The two holes in the shaft for hydraulic oil to the clutches shown in figure 3 18 will then line up with the holes in the clutch retainer plate Do not use a hammer to drive the shaft through the component parts NOTE Coat side and top of seals with Lubriplate before inserting in shaft en DIE n ME 2010 233 34 3 18 Figure 3 18 Bevel gear shaft 5 Fix the shaft in place and revolve winch to upright position 6 Lock the bearings on the end of the shaft that is towards brake compartment with snap rings provided 7 Install the bearing nut on the opposite end torque to 200 ft lb 25 and lock it with lock washer provided Always use new lockwasher Do not install metal seal rings on ends of shaft 8 Adjust end play to 0 000 0 004 by use of shims under each bearing retainer 9 Remove bearing retainers and install metal seal rings on ends of shafts Be sure these seal rings are not broken or damaged when reinstalling bearing retainers e Brake Shaft Assembly 1 Install brake shaft with 0 006 inch to 0 009 inch end play in bearings 2 Apply Plastic Lead Seal No 2 equivalent to threads of capscrews holding oil seal retainer at brake end of shaft f Power Takeoff Assembly 1 Install the power takeoff shaft Be sure the bevel pinion is in pla
85. the fuel injection plug openings 5 1 4 Remove the glow plugs 5 Steam dean the engine 6 Remove the rocker arm cover 2410 233 20 7 Loosen the rocker arm adjusting screw locknut 3 front each of the rocker arms Back off the adjusting screws 4 one or two turns Cylinder lines Cap or TM 5 5 54 Inspection and Repair Inspect the oil pan and oil warpage surfaces with a hone or file pan plate for chips cracks weld damage and other damage Smooth contact Repair cracks by welding TM 9 237 Replace parts if warpage is excessi ve d Installation Install the oil pan and oil pan plate by reversing the removal procedure Use a new oil pan gasket Service the engine with lubricating oil LO 5 2410 233 12 DIESEL ENGINE 8 Remove the bolt 1 and washer 2 from each rocker arm bracket Carefully pry the rocker arm assembly from the cylinder head NOTE Tag rocker arm components for proper installation Do not mix parts from one assembly to another 9 Disassemble the rocker arms as follows a Remove the locknut 3 and adjusting screw 4 b Remove the ring 5 washer 6 and 7 Remove the rocker arm 8 and pull the hushing 9 d Remove the bracket 10 rocker arm 11 washer 12 spring 13 and washer 14 from the rocker arm shaft 15 10 Remove the push rods 16 and tag them for proper installation 11 Remove the cylinder head bolts 17 and wash
86. the machine 2 The checking tool is fabricated from a sleeve seal bushing and pipe nipple f g 6 4B special tool 3 The clutch packs can be checked one at a time by inserting the tool sleeve into the inlet port as shown in figure 6 44 Jand injecting air under pressure If the clutch pistons are operating properly there should be approximately 1 4 inch Y inch travel in each piston with very little leakage If any of the pistons fail to move this is an indication of binding and the transmission should be disassembled to determine the cause 4 To check the input shaft seals insert the air tool into the opening shown figure 6 44 and inject air under pressure not to exceed 80 psi NOTE The input shaft n ius t be installed in the transmission be fore performing this check The sei ils will lea K vers slowly if properly installed 1M6475 SLEEVE 387263 PIPE NIPPLE BUSHING 8M4389 SEAL BLOW GUN OPENING FOR INPUT SHAFT SEAL CHECK INLET PORTS TO CLUTCH PISTONS ME 2410 233 34 6 44 Figure 6 44 Checking clutch operation e Input Shaft Remoual and Installation 1 Remove bolts 1 that secure the cage 2 to the No 1 carrier 2 Install two inch 16 NC eyebolts and lift the input shaft from the transmission fia 16 49 3 Install the input shaft in the reverse order of removal 4 Tighten the bearing cage to No 1 carrier retaining bolts
87. the spacer 15 and the valve lifter 16 11 Remove the bolt 17 lock 18 spring retainer 19 and spring 20 12 Remove the ring gear 21 and spacer 22 13 Remove the camshaft 23 from the housing 14 Remove the bearing 24 and 25 Scrape the gaskets 26 and 27 from the housing 28 d Cleaning Clean all components except bearings with Fed Spec P D 680 deaning solvent and dry with compressed air Clean bearings as instructed in paragraph 2 6 e Inspection and Repair 1 Inspect all components for cracks chips nicks grooves scores pitting and wear Repair or replace parts as required 2 Inspect the sliding surfaces of pump plungers for grooves and scratches Ensure that edges are not rounded 3 Inspect the check valve collar for grooves and scratches Replace if surfaces cannot be smoothed with emery cloth 4 Replace pump plungers and barrels as a unit 5 Replace the check valve as a unit 6 Inspect camshaft cams and camshaft bearings for wear Replace as necessary 7 inspect the control rod for worn notches 8 Replace pump plunger washers which show signs of wear 9 Measure pump plungers using a micrometer Replace any plunger less than 2 5881 inches long 5 24 f Reassembly fig 5 19 NOTE Immerse all parts in clean diesel fuel before reassembling 1 Install the bearing 25 so that the hole in the bearing aligns with the oil passage in the housing Install th
88. the transmission all dirt and grease accumulations should be removed from the exterior of the transmission case The transmission should be disassembled and assembled in clean surroundings with clean tools Dirt or grit introduced into the transmission will cause erratic operation and will shorten the service life of the transmission 6 39 2 Input shaft front oil seal removal and installation a Remove the universal joint 6 2 b Remove the bolts lock and retainer 2 fig 6 40 and the flange 1 from the input shaft c Remove the oil seal using a puller screw and step plate d Install the new oil seal with the spring loaded lip toward the transmission Replace the flange bolts lock and retainer in the reverse order of removal iN Nes S g SE D d 5555 1 eee Led Ezzzz 222 ISO 477777 SS lt i TAN 5 2410 233 34 6 40 Flange 2 Bolts lock and retainer 3 Oil seal Figure 6 10 Preparing to remove input shaft front oil seal Figure 6 11 Removing input shaft front oil seal 6 40 c Transmission Case Removal 1 Position the transmission assembly on end input end up 2 Remove control levers from shafts 6 fig 6 42 NOTE The keys which position the control levers on the shafts 6 should be r
89. the valve 5 6 5 3 Radiator and Radiator Guard a Removal 1 Drain the cooling system TM 5 2410 233 10 and remove the engine upper right guard assembly TM 5 2410 233 20 2 Remove the radiator bottom guard 5 6 and lower the front section of the crankcase guard TM 5 2410 233 20 Figure 5 6 Radiator bottom guard removal and installation 3 Disconnect the upper elbow 2 fig 5 B 5 Support fan assembly by placing a wooden from the radiator top tank block between bottom fan blade and radiator 4 Disconnect the lower elbow 8 from the shroud Remove eight bolts from fan adapter radiator 5 7 and separate from fan drive assembly Figure 5 7 Fan adapter and fan drive and support assembly coupling 6 Disconnect and loop bulldozer lift cylinder hydraulic lines fig 5 B 5 8 6 5 RM Figure 5 8 Bulldozer lift cylinder hydraulic lines disconnect couplings Dn il iit 7 Remove the bolts securing bracket to 9 Attach a hoist for support block crank frame fig 5 9 case guard hinge and remove the bolts that secure 8 Tag and disconnect headlight leads and the radiator guard to the tractor fig 5 9 remove leads from radiator guard fig 521
90. their original positions 3 Heating bearings Bearings which require expansion for installation should be heated in oil not to exceed 250 F 121 C When more than one part is heated to aid in assembly they must be allowed to cool and then pressed together again Parts often separate as they cool and shrink 4 Installation Lubricate new or used bearings before installation Bearings that are to be preloaded must have a film of oil over the entire assembly to obtain accurate preloading When installing a bearing spacer or washer against a shoulder on a shaft be sure the chamfered side is toward the shoulder fig 2 7 When pressing bearings into a retainer or bore apply pressure to the outer race If the bearing is pressed on the shaft apply pressure on the inner race INCORRECT CORRECT ME 2410 233 34 2 7 Figure 2 7 Chamfer on a shouldered shaft 5 Preload Preload is an initial force placed on the bearing at the time of assembly Determine preload or end clearance from the SPECIFICATIONS Care should be exercised in applying preload Misapplication of preload to bearings requiring end clearance can result in bearing failure 6 Sleeve bearings DO NOT INSTALL SLEEVE BEARINGS WITH A HAMMER Use a press if possible and apply the pressure directly in iine with the bore If it is necessary to drive on a bearing use a driver or a bar with a smooth flat end If a sleeve bearing has an oil hole align it with the
91. there are deep nicks spool must be replaced b Replace preformed packings 8 and inspection rein 9 O Use light parts before reassembly Install preformed packing 9 and install spool in reverse manner from removal Preformed packing 8 is replaced last and does not pass over port CAUTION Do not pull on spool 7 to get preformed packing 8 compressed into spool bore Tap end of spool to ac complish this and avoid overtravel causing damage to preformed packing 8 in internal ports 3 Brake inching spool removal a Plug 16 or spring 15 be removed without removing the inching spool 13 by removing snap ring 17 b To remove spool 13 remove capscrews 5 and detach the valve body 29 from the support 30 c Remove the spool stop capscrew 18 on the under side of the valve body while pressing gently on the inching spool to take the load off the stop d Remove the spool and return spring 14 4 Inching spool inspection and assembly a Check bore and spool 13 for dirt or nicks Remove light nicks by lapping Deep nicks necessitate new parts b Oil all parts generously Place new preformed packing firmly in groove and install spring 14 and spool Tap spool gently to pass over preformed packing and while holding in position replace spool stop capscrew 18 c Clean out socket for travel spring 15 grease lightly and replace spring and cable plug 16
92. toward snapring 7 2 Lubricate the inside of cylinder 1 and install piston assembly d Installation Install in reverse order of removal rotating the cylinder so the flat or guard on the recoil rod flange aligns with the flat on the cylinder Install the adjusting mechanism Install and adjust the track e below e Track Adjustment NOTE Operate the tracks without excessive tension to minimize wear When properly adjusted there should be 1 inch to 1 inch sag measured at a point half way between the track carrier roller and front idler 1 Raise the inspection plate on the track roller frame guard 2 With relief valve 1 fig 7 35 opened one turn counterclockwise force GAA lubricant through fitting in fill valve 3 3 When the grease coming out vent hole 2 front the opened relief valve 1 is thick close the relief valve and continue filling with lubricant until the track has 1 inch to 1 inch sag 4 Operate the machine backward and for ward to equalize the adjustment Recheek ad justment NOTE The torque values for valve 1 and 3 are given in paragraph il6 5 Make subsequent track ad justments as outlined in 5 2410 233 20 e Way ur dem cxx ME 2410 233 34 7 35 1 Relief valve 2 Vent hole 3 Fill valve Figure 7 35 Rdie amp valve and fill valve 7 8 Carrier Roller Support Assembly a Removal WARNING Be certain the hydraulic pressure i
93. 1 and seal 10 from bracket assembly 17 3 Remove seal 15 bearing 14 and spacer 16 from bracket assembly 17 c Cleaning Clean all parts except bearings with cleaning solvent Fed Spec P D 680 Refer 21 the care and cleaning of bearings d Inspection and Repair 1 Inspect the fan assembly 3 for bent cracked or missing blades Rotate each blade thru both the suction and blower positions and note if blade shaft detent securely locks blade at the correct attitude 2 Inspect fan drive assembly for cracks a bent shaft or other damage Weld minor cracks according to TM 9 237 3 Replace fan assembly or fan drive assembly if defective e Reassembly and Installation Reverse disassembly and removal procedure and reassemble and install the fan and fan drive assembly on the engine Refer to LO 5 2410 233 12 and lubricate fan hub NOTE Be certain all blades are in the same position suction or blower in the fan assembly Key td figure 5 15 1 Bolt 2 Washer 3 Fan assembly 4 Bol 5 Washer 6 Adapter 7 Bolt 8 Washer 9 Washer 10 Seal 11 Bearing 12 Spacer 13 Hub 14 Bearing 15 Seal 16 Spacer 17 Bracket assembly 18 Bolt ME 2410 233 34 5 15 5 19 Figure 5 15 Fan and fan drive disassembly Section Il FUEL SYSTEM 5 9 General The fuel system consists of a supply tank fuel injection valves fuel injection pump pressure gage fuel filters transfer pump vent valve and
94. 1 3883 Bevel gear Bevel gear and pinion backlash as marked on pinion gear with pinion held in forward position 0 015 0 016 Bevel gear bearing preload Shims to be removed after end clearance taken up approximately 0 013 in Steering clutch Clutch springs Outer Pounds force 286 316 When compressed to 3 90 in Inner Pounds force 185 205 When compressed to 3 7 in Steering clutch hub to bevel gear shaft press fit tons 35 40 Dimension between the face of the hub and the shoulder of the bevel gear shaft when pressed on with 35 40 tons 095 in Steering clutch in thick discs Overall width of 10 new disc 2 923 3 189 assemblies and 9 new discs Minimum overall width of 10 disc assemblies and 9 discs worn 2 744 in Table 1 4 Power Transmission Units Repair nd Replacement Standards Component Pressure relief valve set to bypass at 35 psi Steering clutch control valve minimum pressure with clutch disengaged engine at low speed 265 300 psi Steering clutch and transmission hydraulic pump Permissible clearance between pump shafts and bearings Capacity at 2 080 rpm pump speed at 1 200 rpm engine speed 42 7 gpm When developing pressure of 350 psi Brakes Adjustment Tighten down adjusting socket until band is tight and back off l tur Distance between top of pin and the milled notch in the engaging mechanism support Distance between front face of seat armrest support and center line of parking brake l
95. 10 Housing Ca at Figure 6 22 Disassembly of pressure control value 6 26 2410 233 34 6 23 Pin Stop Differential valve piston gt Ti Figure 6 23 Differential valve removal h Remove slug 3 from end of relief valve piston 4 i Remove retainer ring 2 fil 6 23 retainer 3 spring 4 and plunger 5 from relief valve piston 1 and Y BA Pin 2 Stop 3 Slug 4 Relief valve piston 5 Stop Figure 6 24 Pressure relief valve removal IN SN EH Wm TR RN n m ei DE i NN S 42 BOSS Koch IK LVI Z AA E 9 10 11 12 13 14 15 16 17 18 19 20 Relief valve piston 2 Retainer ring ME 2410 233 34 6 26 3 Retainer 4 Spring 1 Stop 5 Phinger 2 Differential valve piston 3 Housing Figure 6 25 Pressure rdief valve disassembly 4 Spring 2 Pressure control value inspection and S repair Inspect valve housings and pistons for 2 gene nicks burrs or pitting Inspect the valve body land 8 Cover edges for wear caused by recirculating of abrasive 9 Stop particles Light scratches and light grey wear 10 Slug 11 Retainer ring appearance are not detrimental to valve Replace 12 Retainer all springs when reconditioning a valve with ap I3 Spring preciable service hours Valves must move freely in 14 Plunger housings Be sure slug 10 19 6 26 is free to 15 Relief valve piston move in relief valve pist
96. 2 for correct torque values ME 2410 233 34 4 32 Piston Plunger l Insert e Insert Figure 4 32 Piston reassembly ME 2410 233 34 4 33 I Expander assembly 2 Clamp assembly 3 Seal compressor A Edge of adjustable block B Seal diameter scale Figure 4 33 Seal assembly installation tools g Packing Adjustment Hydraulic cylinder packing leakage can be caused by wear cuts and or distortion of the packing If the cylinder leaks around the rod shims can be removed to tighten the packing around the rod 1 Lower the hydraulically controlled equipment to the ground to relieve cylinder pressure 2 Remove bolts holding retainer 2 4 1 34 to cylinder head 3 Pry or tap retainer out to permit cutting and removng shims 1 4 Remove one shim at a time If after removing two shims the cylinder still leaks disassemble cylinder and replace packing NOTE Only remove shims 1 which measure 0 010 inch thickness Phe thicker shim should not be removed to adjust the packing 2410 233 34 4 34 1 Slims 2 Retainer Figure 4 34 Removing shims h Installation Reverse removal procedure and install the hydraulic cylinders on the tractor 4 9 Hydraulic Tilt Cylinder a General The hydraulic system need not be drained to remove the tilt cylinder however do not move the bulldozer tilt control lever from the HOLD position after disconnecting the cylinder oil lines b Remo
97. 20 b Replace a defective generator brush spring para 3 28 d Disassemble generator and repair or replace as s ees 20 b Adjust Refer to TM 5 2410 233 20 a Refer to TM 5 2410 233 20 b Check pressures at test points para 6 c Remove valve for inspection and repair para 6 4 d Remove valve for inspection and repair para 6 8 e Remove valve for inspection and repair para 6 4 f Adjust safety valve para 6 4 g Refer t Inspect directional valve and remove any obstruction para 6 3 b Adjust linkage para 6 4 c Adjust valves para 6 4 a Remove valve for inspection and repair para 4 3 b Adjust valve para 4 4 Remove and inspect valv parr 4 Inspect and repair cylinder 4 10 a Replace broken brake spring para 3 14 b Remove valve for inspection and repair para 2 19 2 1 Malfunction Trouble Continued Probable Cause Corrective Action Worn poppet on valve selector c Remove valve for inspection and spool repair 3 13 17 Winch clutch pressure low a Broken seal ring on bevel gearshaft a Remove winch for inspection and repalce broken seal ring 34 b Damaged preformed packing in 14 clutch pack b Remove winch for inspection and replace preformed packing paral DO Section GENERAL MAINTENANCE 2 5 General This section provides direct support and general support ma
98. 4 4 Lift discs 6 and separator plates 7 from 5 Lift drive hub 3 and clutch piston 8 from retainer plate 11 6 The cross drilled stud with three holes is the cooling valve 5 left and disassemble for cleaning Remove by unscrewing to the ME 2410 233 34 3 17 O ring O ring Plate Setseres h Inspection and Repair 1 Inspect bearings for corrosion roughness and wear Replace corroded rough or excessively worn bearings para 2 2 Inspect all gears for chipped pitted cracked or excessively worn teeth Replace gears which are chipped cracked or excessively worn or pittted TB ENG 364 may be used as a guide for determining gear replacement 3 Inspect housing and covers for cracks breaks and other damage Repair by welding TM 9 237 replace the part 4 Inspect clutch disks for scoring cracks damaged teeth war page or a burned blue black appearance Replace burned warped or ex cessively worn disks Replace disks which have a Chipping on the edge of the disk b Cracks at the root of any of the teeth c Worn teeth only when wear has ob changed tooth d Excessive foreign material imbedded in the face 3 15 Winch Reassembly a Clutch Reassembly viously contour NOTE Reassembly is opposite of disassembly Observe the follow ing precautions during reassembly 1 Dish in separator plate must all face same way as a unit The direction of the unit is unim portant
99. 5 to facilitate reassembly in the correct relationship 2 Remove five socket head capscrews 100 and one socket head capscrews 99 and pull drive con assembly from starter Remove gasket go 3 Disassemble housing assembly only if parts require replacement Press out sleeve bearing Remove pipe plugs expansion plug and wick 4 Loosen terminal screw on solenoid relay and disconnect terminal of lead 37 Remove hex nut and remove lead 5 Remove plugs 13 and gaskets 12 Remove brush and field coil connection and at taching screws from each of the holes Mark screw holes to identify them during assembly of brushes damaged 2410 233 34 5 36 Figure 5 36 Starter motor exploded view sheet 1 of 2 5 45 Figure 5 36 Starter motor exploded view sheet 2 of 2 ME 2410 233 34 5 36 2 Key td figure 5 36 1 Nut 2 Lockwasher 3 Connector 4 Washer 5 Washer 6 Bushing 7 Washer 8 Armature assembly 9 Coil assembly 10 Insulation 11 Pole shoe 12 Gasket 13 Plug 14 Screw 15 Screw 16 Lockwasher 17 Brush assembly 18 Plate assembly 19 Washer 20 Lockwasher 21 Screw 22 Plate 23 Holder 24 Spring 25 Lockwasher 26 Screw 27 Bolt 28 Screw 29 Screw 30 Plate 31 Plate 32 Washer 33 Plate assembly 34 Plate 35 Plate 36 Nut 37 Lead assembly 38 Insulator 39 Bolt 40 Lockwasher 41 Bearing 42 Seal 43 Plug 44 Bearing 45 Frame assembly 46 Plug 47 Felt 48 Packing 49 Washer 50 Insulato
100. 500 2 999 3 000 3 8155 2 5625 3 8165 2 5635 1 4 Maximum Desiredclearance allowable wear and clearance 0 002 0 006 0 008 0 004 0 010 0 025 0 0042 0 0071 0 010 0 0008 0 0030 0 0059 0 010 0 0025 0 0145 0 005 0 008 0 008 0 004 Table 1 3 Engine Repair and Replacement Standards Continued Manufacturer s dimensions Component andtolerancesin inches Se wee CYLINDER LINER Inside diameter 4 150 Permissible liner wear 4 in diameter at top of ring travel Liner flange thickness 0 4040 Counterbore dimension in block 0 400 FUEL INJECTION EQUIPMENT Fuel injection pump timing before top center 13 30 Fuel injection pump lifter setting on engine with 857107 Gauge 4 2179 0020 Fuel injection pump lifter setting off engine 4 2075 0005 Fuel pump plun length 2 5931 Perm wear decrease in length of plunger Fuel injection camshaft bearing bore 1 875 Camshaft bearing clearance FUEL TRANSFER PUMP Clearance between gears and covers total Bearing bore 0 4950 Bearing clearance GOVER Backlash between bevel drive and driven gears Clearance between top cover bearing and shaft Dimension X seetest 2 125 2 145 ide low idle speed adjustment 600 100 rpm OIL PUMP Clearance between gears and end covers Drive gear shaft diameter 0 8145 Bearing bore 0 743 PISTON PINS Pin bore STON RINGS PISTON ringsideclearance ring 2d ring Oil ring Ring gap top Ring gap 2d
101. 6 If coil assemblies 20 38 39 and 41 require replacement remove two screws 17 securing each pole shoe 18 to housing Remove pole shoes windings and insulators 19 d Cleaning 1 Clean the armature and field windings of any dirt or magnetized particles To remove grease and oil apply a light coat of cleaning solvent F ed Spec P D 68 with a brush Wipe clean then use compressed air to remove any remaining dirt film Do not use any decreasing compounds or submerge the armature in a degreasing tank as this would damage the insulation 2 Clean the commutator with 00 sandpaper and remove sand particles with compressed air 3 Clean the commutator end frame drive end frame and components with cleaning solvent Fed Spec P D 680 and dry thoroughly CAUTION Do not soak insulators Key to fs 23 Serew loekwasher 24 Elbow gt Nut 25 Gasket Screw 20 Spacer 4 Plate 27 Lead assembly 5 Bearing Lead assembly 6 Bol 20 Nut bockwasher 30 Washer 6 Frame 31 Lockwasher 9 Dowel 33 Plate lO Plate assembly 34 Frame Washer 35 Collar 12 Arm 30 Bearing Spring 37 Plate assembly IA Bursh 36 Coil assembly 5 Screw 30 Coil assembly In Lead assembly Ju Armature assembly l Screw Jl Coil assembly lo Pole 42 Nut 19 Insulator 43 Band assembly 20 Coil assembly Il Screw 2 Screw do Screw Receptacle assembly J6 Serew 2410 233 34 5 35 Figure 5 35 Generator disassembly C Ins
102. 7 Figure 3 4 Winch hydraulic pump exploded view Page 3 8 Figure 3 7 is superseded as follows Figure 3 7 Power take off bearing and brake drum removal and installation Page 4 3 Figure 4 1 1 is added as follows Figure 4 1 1 Hydrailic tank removal w ROPS Change title of key from Key to figure 4 1 to Key to figure 4 1 and figure 4 1 1 Page 5 30 Figure 5 23 1 is added as follows Figure 5 23 1 Fuel tank removal and installation w ROPS Page 5 54 paragraph 5 27d 10 b is changed from 170 180 foot pounds to 173 197 foot pounds c is changed from 170 180 foot pounds to 173 197 foot pounds Page 6 75 Paragraph 6 15c 3 is superseded as follows 3 Place the plate on the bolt NSN 5306 00 426 4617 Insert the bolt thru the center of the steering clutch assembly and place the plate 2 fig 6 86 over the bolt Page FO 1 fold out figure FO 1 Chart A Delete no 3 Quick Drop Valve By Order of the Secretary of the Army E C MEYER General United States Army Official Chief of Staff ROBERT M JOYCE Brigadier General United States Army The Adjutant General DISTRIBUTION To be distributed in accordance with DA Form 12 25B Direct and General Support Maintenance requirements for Tractor Tracked Medium n No 1 TM 5 2410 233 34 C1 HEADQUARTERS DEPARTMENT OF THE ARMY Washington D C 30 April 1973 Direct Support and General Support Maintenan
103. 8 and oil deflector 16 Lubricate thrust face of thrust bearing 17 8 Using finger pressure only carefully install dirt deflector ring 14 with seal 15 en tering bore of insert 12 CAUTION Do not force If seal does not enter bore easily remove deflector and recenter sleeve 9 Place shaft insert 12 over turbine wheel shaft 9 and carefully lower into position 10 Install insert retaining ring 11 in groove with flat side of ring resting against insert 11 Apply a film of grease to threads and face of self locking nut fig 5 B0 install and torque nut to 30 ft lbs Check clearance between block and face of housing with two sets of thickness as illustrated in figure 5 33 Clearance must be 0 019 to 0 0222 in Shims 0 003 0 005 and 0 010 in thickness are available to obtain correct clearance NOTE Torque self locking nut fig 5 30 to 30 ft Ibs each time clearance is checked TURBINE HOUSING ME 2410 233 34 5 33 Figure 5 33 Turbocharger clearance check between spacer block and housing face 12 With spacer block in place check the shaft end play End play must be 0 004 to 0 006 in Correct end play can be obtained by adding or removing shims 13 Remove nut 5 spacer block 5 39 14 Apply a film of grease to bore in com pressor wheel 10 and install the wheel on shaft Position the unit in an arbor press with square extension on turbine wheel resting on bloc
104. E 2410 233 34 5 35 1 1 VOLTAGE REGULATOR CHECK REGULATOR CH GENERATOR VOLTMETER TRACTOR AMMETER BATTERY METER CONNECTIONS FOR VOLTAGE REGULATOR CHECK CUTOUT RELAY CHECK REGULATOR AMMETER VOLT METER TEST HARNESS NO BATTERY B METER CONNECTIONS FOR CHECKING CUTOUT RELAY CLOSING VOLTAGE CURRENT REGULATOR CHECK REGULATOR TRACTORS AMMETER x AMME TER GENERATOR BATTERY C METER CONNECTIONS FOR CURRENT REGULATOR CHECK ME 2410 233 34 5 35 1 2 C1 Figure 5 35 1 Generator regulator sheet 2 of 2 ME 2410 233 84 5 35 1 2 c Adjustment for high temperature 1 When high battery temperatures are ob tained battery overcharge may be experienced even though the voltage regulator setting is within specifications and correct for all normal operating conditions This overcharging condition may be re lieved by reducing the voltage setting slightly How ever the voltage regulator setting must not be re duced unless it is actually necessary The cutout re 4 lay likewise m st be reduced so the voltage regulato setting is still safely above the setting of the cutoui relay 2 If such voltage reductions are made dur ing hot weather the voltage settings should be re turned to normal for low temperature d Replacement If voltage regulator cannot be adjusted it must be replaced Paragraph 5 20 2 is added as follows 5 20 2 Alternator a Gen
105. ECT CORRECT c od ME 2410 233 34 2 5 Figure 2 5 Installing metal locks h Lines and Wires When removing or disconnecting a group of lines or wires tag each one to assure proper assembly i Shims When shims are removed tie them together and identify them as to location Keep shims clean and flat until they are reinstalled j Bearings 1 Anti friction bearings a When anti friction bearing 2 is removed cover it to keep out dirt and abrasives Wash bearings in nonflammable cleaning solution and allow them to drain dry The bearing may be dried with compressed air but DO NOT SPIN THE BEARING b Discard the hearings if the races and balls or rollers are pitted scored or burned If the bearing is serviceable coat it with oil and wrap it in clean paper Do not unwrap new bearings until time of install ation The life of an anti friction bearing will be shortened if not properly lubricated SHAFT TURNS INSIDE ME 2410 233 34 2 6 Figure 2 6 Locked anti friction bearing 2 Double row tapered roller Double row tapered roller bearings are precision fit during manufacture and the components are not in terchangeable The cups cones and spacers are usually etched with the same serial number and letter designator If no letter designators are found wire the components together to assure correct installation Reusable bearing components should be installed in
106. Metal floating ring seal 5 Shaft Figure 6 114 Bearing cage holder removal 6 93 2 Remove the clamping bolt and lock securing bearing cage holder assembly 2 to outer bearing adjustment nut 1 3 Using a puller and a step plate force holder assembly 2 from taper on sprocket shaft 5 NOTE It may be necessary to strike the holder assembly with a soft hammer to free it from taper on the shaft 4 Attach a hoist to support holder assembly 2 Remove retaining nut 3 and the holder assembly Remove adjusting nut 1 metal floating ring seal 9 holder assembly 2 and gasket 10 bearing cage 7 and bearing cup 6 as a unit 5 Inspect the mating surfaces of metal floating ring seals 8 and of fa 6113 for damage or excessive wear para 6 2p 6 Align keyway 5 in the holder assembly hub with the key on the sprocket shaft 6 and install the unit in reverse order of removal NOTE The bearing preload adjustment for the hub support bearings is not made until the track roller frame outer bearing has been installed To set the bearing preload refer to paragraph 6 28 b Disassembly 1 Remove the dust guard 2 Remove metal floating ring seal 2 fig 115 if replacement is necessary para 6 20 3 Remove outer bearing adjusting nut 1 from bearing cage holder assembly 3 4 Using a bearing cup pulling attachment a forcing bolt a suitable spacer to cover the hole in the holder ass
107. No 5 clutch has two disc assemblies and one plate Disassembly of the No 3 clutch is shown for illustration 1 Remove the ring gear 1 6 6 2 Remove the clutch disc assemblies 2 and plates 3 3 Remove the piston 4 from the clutch housing 4 Inspect the piston rings 5 on the piston and in the clutch housing Replace the rings if damaged 5 Assemble the clutches in the reverse order of disassembly To install the piston center the piston rings and tap the clutch housing with a soft hammer while gently pushing the piston into the housing CAUTION Under no circumstance should the piston be hammered into place Broken piston rings will result from such action Figure 242 ME 2410 233 34 6 61 Ring gear Disc assembly Plate Piston Piston rings Figure 6 61 Clutch disassembly 6 55 Output Shaft Disassembly and Assembly 1 Remove the retainer ring l fig 6 62 and transfer gear 2 ME 2410 233 34 6 62 l Retainer ring 2 Transfer gear 3 Bearing cage assembly 4 Bearing cage 5 Bearing outer race Figure 6 62 Transfer gear removal 6 56 2 Remove the bearing cage assembly 3 and the bearing cage 4 3 Inspect the transfer gear outer bearings for wear or damage and remove if necessary using a bearing pulling attachment a puller a hydraulic puller and a suitable spacer having an outside diameter of 4 inches and about 4 inches in length as
108. OVERNMENT PRINTING OFFICE 1994 0 300 421 82343 SRA aww Lan TI CRT al wA Iy CHART A PART NAME DESCRIPTION LIFT CYLINDER BORE 4 75 S TROKE 37 62 ROG 1 50 TILT CYLINDER BORE 6 50 STROKE 6 00 3 00 TILT CYLINDER BORE s 00 STROKE 4 00 ROD 2 50 QUICK DROP VALVE MOUMTED ON LIFT CYLINDERS SELECTOR VALVE R H RIF SHANK OR L H SELECTOR SELECTOR VALVE L H L H RIP SHANK OR TILT CYLINDER TANK CLOSED RESERVOIR LIFT VALVE BULLDOZER H A 1 j c2 ag SEEN M SS ES N on MAIN RELIEF VALVE 2250 PSI TILT VALVE d ke f CONTROL VALVE RIPPER sd ae Rn O SE PILOT VALVES CONTROLS SELECTOR VALVES reer ee eed RIPPER CYLINDER BORE 5 00 STROKE 19 70 ROD 1 75 VALVE AS PRESS REDUCING 300 PS TO PILOT VALVE RIPPER CONTROL LEVER pe weg M JY n w w der SY BULLDOZER CONT LEVER D PIS Vd SE Ke d teg PT RB be D Q NENNEN SMA D7 TILT RETURN LINE mare 8 d q lt PALL H TT SN PET Poin PA 10 See EE SMALL PUMP PS PUMP PSI s pume esi PUMP PSI gt cke
109. Push against rod compressing spring 22 until dump valve contacts plug 20 Tap on end of rod forcing plug 20 out of body 5 8 Remove bolts 19 cover 18 plug 20 spring 22 and dump valve 23 d Cleaning Clean all parts with cleaning solvent Fed Spec P D 680 Dry parts with a lint free cloth Clear all passages in relief valve of restric tions with filtered compressed air e Inspection and Repair 1 Inspect springs for weak or damaged condition and free movement of valves in the bores Inspec valve seating surface and seats in body for nicks burrs and proper contact Replace defective parts 2 Inspect preformed packing 16 fig 4 14 for cuts breaks or deterioration Replace all defective packing f Reassembly 1 Reassemble relief valve usind figure 4 14 as a guide 2 Torque bolts 13 to 24 2 ft lbs 3 Install sufficient shims 10 to provide a relief valve opening pressure of 1 975 25 psi g Installation Install relief valve in reverse of removal Torque bolts B figure 4413 to 43 2 ft Ibs and bolts 4 to 60 2 ft lbs OC S Bolt and lockwasher Cover O ring seal Plug assembly Dump valve body Bolt and lockwasher za zov Cover O ring seals O ring seals Shims Spring Pilot valve 13 14 15 16 17 18 Bolt and lockwasher Pilot valve body Pilot valve seat O ring seal Plug assembly Cover Figure 4 14 Relief valve disassembly
110. R CLARITY 72 Gi j E FUEL TANK MOUNTING BOLTS FUEL TANK DRAIN LINE FUEL SHUT OFF VALVE 34 5 23 2410 233 Figure 5 23 Fud tank removal and installation c Cleaning 1 Drain the fuel tank TM 5 2410 233 20 2 Flush the tank with cleaning solvent F ed Spec P D 680 and rinse with dean diesel fuel d Inspection and Repair 1 Inspect the fuel tank for corrosion cracks punctures dents or other damage Inspect cap strainer and drain valve for damage 2 Weld cracks and punctures according to TM 9 237 CAUTION Fill tank with water prior to welding tank 3 Remove corrosion with sandpaper or by sand blasting and paint tank according to procedures in TM 9 213 4 Replace a defective cap strainer drain valve or a severely dented or otherwise defective fuel tank d Installation Reverse removal procedure and install the fuel tank on the tractor Section Ill AIR INDUCTION AND EXHAUST SYSTEM 5 15 Air Cleaner a Removal 1 Refer to TM 5 2410 233 20 and remove air deaner element 5 30 2 Remove 5 bolts fig 5 24 loosen 2 hose clamps precleaned damp and remove predeaner air deaner body and elbows 15 5 Figure 5 24 Air cleaner body removal and installation b Cleaning Refer to TM 5 2410 233 20 for the deaning of the air cleaner elements and air cleaner body interior C Inspection Inspect air cleaner for dents
111. Remove the bolt 1 and washer 2 remove the pulley assembly Remove six bolts 3 and lockwashers 4 and separate the vibration damper 5 from the pulley 6 6 Remove four bolts 7 and lockwashers 8 and remove the front support 9 7 Remove the bolts 10 and lockwashers 11 which secure the oil pan 12 to the timing gear cover Loosen the remaining bolts which secure the oil pan to the cylinder block Using a thin knife or screwdriver carefully separate the oil pan and gasket from the timing gear cover b Inspection and Repair 1 Inspect the timing gear cover for chips cracks and other damage and for distortion Repair as required 2 Inspect the timing gears for broken or missing teeth excessive or uneven wear and cracks chips and other damage Repair or replace as required 3 Inspect the seal item 18 fig 5 44 for damage and deterioration and replace if necessary 4 Inspect the crankshaft pulley and vibration damper for damage and wear Repair or replace as required c Reassembly and Installation fig 5 41 1 Heat the camshaft gear 34 and install on the camshaft Align the timing marks subpara e Secure with four camshaft gear retaining bolts 32 and the lock 33 Check the gear backlash subpara f 2 Install the plate 30 spacer 31 and accessory drive idler gear 29 Secure with two bolts 27 and locks 28 3 Install the washer 25 retainer 26 and the accessor
112. TE Keep the shims from beneath guide plate 3 together The same shims will be used for assembly The following removal procedure is applicable to both sides of theidler and for both front track idlers 7 9 2410 233 34 7 17 1 2 Bolts 3 Guide plate Figure 7 17 Preparing to remove guide plate 3 Remove bolts 1 securing collar 2 to bearing 4 and yoke 5 and remove shims from between the bearing and the collar Install one of the bolts 1 through the collar into bearing 4 to hold the collar in place 4 Remove bolts 3 securing bearing 4 to yoke 5 Support the idler and roll it forward 7 10 ME 2410 233 34 7 18 1 Bolts 2 Collar 3 Bolts 4 Bearing 5 Yoke Figure 7 18 Preparing to remove idler b Disassembly 1 Remove the nuts and washers and drive out the tapered pins that secure bearings fig 71 19 and 4 to shaft 5 2 Remove bearings 1 and 4 from shaft 5 3 Remove floating duo cone seals 2 from the bearings and from the bushing assemblies 6 Be careful not to damage the metal floating ring seals as they are removed 4 Tape each pair of seals together to prevent intermixing them with other seals NOTE When installing bearings 1 and 4 apply anti seize compound in bearing bores and on bearing contact surfaces of shaft 5 5 Remove collars 3 from both sides of idler A cJ p Z N ZX
113. TE The overall thickness of ten new disc assemblies and nine new driving discs is given in table 1 4 If the overall thickness is less than the minimum overall width they should be replaced ME 2410 233 34 6 84 Brake band 2 Steering clutch driven drum outer drum Figure 6 84 Removing outer drum 3 Place the plate on the bolt insert the bolt through the center of the steeering clutch assembly and place the plate 2 fig 6 84 over the bolt 4 Place a hydraulic puller over the bolt so that the base is against the plate Extend the ram about 1 inches 5 Install a heavy washer and a nut onto the bolt and tighten it until it is against the puller 6 Apply just enough pressure with the puller to hold the clutch springs compressed and remove the bolts 7 Relieve the pressure on the puller and remove the puller and the steering clutch pressure plate 1 fig 6 84 8 Remove the clutch disc assemblies GL gel 6 85 and the clutch driving discs 4 from the inner drum 5 numbering the disc assemblies and discs as they are removed NOTE If the same driving discs are reused they must be replaced on the inner drum with the same face up but better wear distribution can be obtained if they are switched from the top to the bottom of the clutch stack 9 Remove the clutch springs 3 and 6 and the clutch spring sleeves 2 10 The steering clutch spring retainer 7 over which the springs and sleeves
114. TM 5 2410 233 34 DEPARTMENT OF THE ARMY TECHNICAL MANUAL TECHNICAL MANUAL DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL TRACTOR FULL TRACKED LOW SPEED DED MEDIUM DRAWBAR PULL OSCILLATING TRACK 78 IN GAGE CATERPILLAR MODEL D7F FSN 2410 177 7283 W RIPPER HEADQUARTERS DEPARTMENT OF THE ARMY OCTOBER 1971 ANGEROUS GASES are generated as a result of operating of this equipment DEATH orsevere injury may pesal if personnel fail tu observe safely precautions Utilize extreme caution do not smoke or use open flame in vicinity when servicing batteries Batteries generate explosive gas during charging Is MN S Always maintain metal contact when filling the facltank Parse open flame in vieinily when Biluig ihe fuel tank Do nol smoke c Do not attempt to Fill fuel tank when tractor is running Do not operate tractor in inelosed areas unless exhaust gases are properly vented to the outside Exhaust discharge econtais noxious and deadly fumes LIQUIDS UNDER PRESSURE are generated asa result of operation of this equipment INJURY DE QU ses e p if personnel fail to absceve safety precautions may result Never remove radiator cap antess engine has stopped and cooled io redace pressure ep hands or other exposed areas of body away from any malfunetion of high pressure faei lines or fuel injectors HYDRAULIC OiL UNDER PRESSURE 19754
115. The valve 7 must slide freely in its bore in valve body 20 Inspect chamfered seating surface of valve 7 and mating seat in body for nicks or burrs 2 Inspect seals 18 and 19 and replace if deteriorated 3 Inspect body 20 for smooth bores Replace if bore surfaces are nicked scored or pitted Reassembly and Installation Reverse disassembly and removal procedure and assemble and install the ripper control valve in the hydraulic tank 4 6 Tilt Control Valve a Removal 1 Drain the hydraulic tank Refer to TM 5 2410 233 20 2 Remove the blade tilt control valve mounting plate and manifold from the tank 4 2 3 Remove bolts 1 4 16 securing manifold 3 to plate 2 NOTE Bolt 5 must be in plate installing manifold 3 on plate 2 4 Remove bolt 4 and remove tilt control valve 7 from plate 2 At installation be sure bolt holes in valve body are aligned with bolt holes in plate to receive bolts 1 5 Remove bolts 9 and baffle tube 10 4 23 VIEW C VIEW B VIEW ME 2410 233 34 4 16 Figure 4 16 Blade tilt manifold and valve removal 4 24 Key to 6 1 2 Blade tilt control valve mounting plate 2 Manifold t Bolt Bolt 6 Flat on valve spool 7 Blade tilt control valve 8 Lever 9 Bolts 10 Baffle tube b Disassembly 1 Remove bo
116. ace as required 3 Inspect the valve springs for cracks breaks distortion or weak condition Replace defective springs 4 Inspect control lever shafts and bearings for corrosion roughness and wear Replace corroded rough or worn shafts and bearings 5 Install control lever shaft seals with the lip facing inward 6 Inspect the pressure relief valve for nicks burns scoring and proper operation Relief valve should bypass at 350 to 400 psi pressure Replace a defective relief valve e Adjustment Adjust the steering clutch control linkage as instructed in TM 5 2410 233 20 6 18 Bevel Gear a Removal and Installation 1 Drain the oil from the transmission steering clutch compartment and bevel gear compartment Refer to TM 5 2410 233 20 2 Remove the seat frame para 2 9 and the fuel tank para 5 10 3 Remove the steering clutch hydraulic control para 6 17 steering clutches para 6 1b and the steering clutch driving hubs para 6 16 4 Remove bevel gear compartment plate At installation apply liquid gasket to bevel gear case and tighten bolts to 45 3 lb ft 5 Remove nuts 2 and locks 3 6 Remove oil tube 1 6 107 At in stallation apply liquid gasket to bevel gear case under tube flange 6 86 ME 2410 233 346 106 1 Bevel gear 2 Nuts 3 Locks 4 Bolts Bevel gear shaft Figure 6 106 Preparing to remove bevel gear and bev
117. aching the lower contact bracket and raise or lower the contact bracket as required to ob tain a 0 048 inch measurement Be sure the points are properly lined up and tighten the screws well after adjustment b Point opening Measure the point opening and adjust by bending the upper armature stop to obtain a 0 035 inch measurement Closing voltage To check the closing voltage on the cutout relay insert special test harness in the generator circuit and connect a voltmeter be tween T 1 armature and the ground screw at the end of the regulator Gradually increase generator speed and note the voltage at which the relay con tact points close Adjust the closing voltage if necessary by turning the adjusting screw at the base of the cutout relay frame Voltage should be between 25 to 27 volts Adjust to 26 volts Increasing the spiral spring tension increases the relay closing voltage and decreasing the spiral spring tension lowers the closing voltage 2 Voltage regulator Two checks and adjust ments are required on the voltage regulator air gap and voltage setting Note that the AIR GAP and not the POINT OPENING is checked and adjusted a Air gap The air gap should be measured between the armature and the part of the core not the residual pin in the core next to the residual pin with the points just touching The proper way to measure this air gap 1s to push the armature down until the points open release until the poi
118. air d Inspection and Repair 1 Inspect gears for chipping or evidence of wear 3 4 kinks or a damaged connector Replace a defective hose 3 Inspect tips and protectors for wear and damage Replace a worn or defective tip or protector TM 5 2410 233 20 4 Inspect all pins for wear fatigue and peening 3 9 Reassembly and Installation Reverse removal and disassembly procedure to reassemble and install the tripper on the tractor WINCH 2 Inspect bearing bore for scoring or wear 3 Inspect bearing surfaces for deep grooving or scoring and refinish if necessary Bearing sur faces may be dressed on a piece of fine abrasive paper held to a true flat surface plate Do not dress enough to remove oil groove 4 Check bearing flats and wedging in their respective covers If bearings wedge in the covers or new bearings are installed proceed as follows Hold the bearings at extreme ends of a discarded gear shaft from which the teeth have been removed and dress the flats lightly against a piece of fine abrasive paper held to a true flat surface plate Dress a little at a time and repeat Check in the cover until the bearings slide into place freely The dearance between the flats when assembled in their cover should not exceed 0 005 to prevent turning of the bearing resulting in lowering the pump efficiency 5 Inspec relief valve ball and seat in cover for grooving e Reassembly 1 Lubricate drive gear jou
119. al 20 Seal 9 Gasket 21 Gasket 10 Gear 22 Shaft 11 Gear 23 Body 12 Shaft 24 Bearing Figure 5 22 Fue tansfer pump 2 Remove the screws 5 and 6 and remove the cover 7 Remove the seal 8 from the cover Remove the cover mounting gasket 9 3 Remove the gear 10 from the shaft 22 Remove the gear 11 and shaft 12 4 Remove the nut 13 Pull the gear 14 from the shaft and remove the key 15 5 Remove the bearing cage 16 Remove the seal 17 ring 18 and the bearing 19 Remove the gasket 21 6 Remove the shaft 22 from the body 23 Press out the bearing 24 d Cleaning Clean all components except bearings with cleaning solvent Fed Spec P D 680 and dry with compressed air Clean bearings as instructed in paragraph 2 6 Inspection and Repair 1 inspect the cover and housing for cracks chips nicks and other damage Check for cracks and rough spots at the mating surface Repair or replace as required 2 Inspect the spring for cracks and weak condition Replace if necessary 3 Inspect the gears for chipped or broken teeth and for wear Repair or replace as required 4 Inspect the drive shaft for dents nicks and scratches and for excessive or uneven wear Repair surface if possible or replace the shaft 5 Inspect the bearings for wear nicks scratches pitting and other damage f Reassembly Assemble the pump in the reverse order of disassembly Observe the following
120. alk sss s Ge Z Sans UNU 102 WAY 2410 233 34 6 81 Steering clutch piston 2 Steering clutch pressure plate Steering clutch spring retainer Figure 6 81 Steering clutch operation b Removal and Installation 1 Remove the fuel tank para 5 14 the rear cross member and brake engaging mechanism para 6 14 2 Rotate the track by placing a hydraulic jack under track grouser and remove the bolts 1 6 82 and bolts 4 INQ IE To prevent the possiblity of the outer drum slipping off the steering clutch driven drum flange 3 fig 6 82 and the inner drum slipping off the steering clutch driving hub 2 causing steering clutch assembly to drop leave two bolts 1 securing the inner drum to the hub until a sling is attached The bolts holding the outer drum to the flange can be removed replaced and torqued through the opening in the side of the steering clutch and bevel gear case after removing the plug Rotate the steering clutch assembly after each bolt is removed to gain access to the next one 6 75 1 2 3 4 Bolts ME 2410 233 34 6 8 Steering clutch driving hub Steering clutch driven drum flange Bolts z 2 Figure 6 82 Preparing to remove steering clutch assembly 3 Attach a suitable hoist and sling to the brake band and pry the outer drum away from the flange 4 Remove the two bolts securing the inner drum to the hub pry the dru
121. allation 2410 233 34 5 50 6 Install a inch 13NC forged eyebolt CAUTION in the flywheel Attach a hoist and remove the Keep the flywheel level during removal flywheel in order to prevent gear from falling off front of flywheel fig 5 5 1 HYDRAULIC DRIVE GEAR ME 2410 233 34 5 51 Figure 5 51 Flywhed and hydraulic pump drive gear 7 Remove the hydraulic pump drive gear 10 Remove the hydraulic pump drive idler from front of flywheel gear retaining bolts fig 5 5P and lock Remove 8 Remove the oil pan plate para 5 24 the idler gear and shaft 9 Remove transmission oil pump TM 5 2410 233 20 5 69 OL S IDLER GEAR RETA NING BOLTS IDLER GEAR SHAFT
122. allation in the HIGH position The bearing that was previously on the right side of the idler will now be on the left and the recess will again be toward the front of the machine 7 11 P COLLAR 1 ae i S et 2410 233 34 7 20 Figure 7 20 Idler bearing in low position Figure 7 21 Repositioning bearings 7 5 Front Idler Yoke Assemby a Removal 1 Separate the track and lay it out flat 7 3 2 Remove front idler para 7 3 Remove recoil rod 2 fig 7 22 after removing bolts 4 and washer 3 Then strike recoil rod 2 with a hammer at rear of yoke 1 to unseat the taper fit in yoke Separate rod and yoke NOTE Yoke L and recoil rod 2 can be assembled for use on either right or ieft side of the tractor Align the ear on washer 447 23 in noteh CL in yoke for use on the right side of the tractor Align ear on washer with notch 2 for the left side Tapped holes in end of recoil rod must be in line with holes in washer and the milled flat tor guard on the Mange at the rear end of the rod must be up 7 12 Front idler yoke assembly 2 ddler recoil rod j Washer 4 Bolts Figure 7 22 Preparing to remove yoke assembly ME 2410 233 34 7 23 5 Notch for right side use Noteh for left side use Bolts 21 Washer 3 4 Figure 7 23 Idler recoil rod alignment b Inspection and Repair 1 Inspect front idler yoke for cracks breaks distortion and ot
123. alled in a similar manner b Removal Refer td paragraph 3 6 and remove the cylinders c Disassembly Disassemble the ripper lift cylinders according to sequence of index numbers assigned to figure 4 41 4 44 CAUTION Extend piston rod out of the cylinder before removing bolts to prevent scoring of the cylinder walls when removing the piston from the cylinder d Cleaning Clean all parts with cleaning solvent Fed Spec P D 680 Dry parts with a lint free cloth e Inspection and Repair 1 Inspect the cylinder for scoring pitting and wear Replace a cylinder which cannot be made serviceable with light honing CAUTION Do not weld on the cylinder assembly as scoring may result from shrinkage 2 Replace all seals packing and wear rings 3 Inspect the rod end bearing for scoring damage and wear 4 Inspect the piston rod for nicks burrs pitting distortion and wear Repair or replace a damaged or distorted rod Remove minor nicks and burrs using a fine emery stone Pitted scored or worn rods may be repaired by metalizing or chrome plating and regrinding to original size A noncorrosive metal will be used to metalize shafts 5 Inspect remaining cylinder parts for wear or damage Replace all defective parts f Installation Refer td paragraph 3 9 and install the ripper lift cylinders on the ripper Key td figure 4 41 1 Bearing 2 Rod 3 Seal 4 Bolt 5 Lockwasher 6 Retainer 7 S
124. alve 2 4 Remove elbows 4 and 6 5 Remove mounting bolts 3 and lift control valve 1 from the bevel gear case 6 Install replacing damaged gaskets c Disassembly and Assembly 1 Remove five bolts 1 fig 6 10 separate the control valve housing 2 from the oil tube 5 fig 6 101 reverse order of removal seals in and and control lever housing 3 2 Remove plungers 6 and 7 valves 5 and springs 4 from housing 2 3 Remove lockring 3 Lfig 6 103 washer 4 and spring 5 from inside of plunger 1 and rem ove blushing 2 from outside of plunger Plunger 1 is identical to plunger 6 tike except for length Disassembly is the same since all parts are the same l 2 3 4 6 84 ME 2410 233 34 6 101 1 Control valve 4 Elbow 2 Check valve 5 Supply tube 3 Bolt Elbow Figure 6 101 Control valve removal ME 2410 233 34 6 102 Valve 2 Plunger Bolts 2 Control valve housing 0 Control lever housing Plunger Spring 2 Figure 6 102 Control valve housing disassembly Plunger Bushing Lockring Washer Spring Valve Slug TP E VR S L Figure 6 103 Plunger and valve disassembly 4 Remove slugs 7 fig 6 109 from both valves 6 5 Replace worn or damaged parts and assemble valves and plungers back into housing in reverse order of removal CAUTION Extreme care should be taken to avoid introducing dirt in
125. and lift the center section out of the turbine housing 8 6 Place the unit in arbor press as illustrated in figure 5 32 Make sure the turbine N geet URBINE WHEEL ME 2410 233 34 5 31 removal and installation wheel will dear base of press during removal Place a pin or dowel on end of shaft hold the turbine wheel by hand press against the pin until shaft is free and remove the turbine wheel shaft 9 and wheel assembly 10 fig 5 30 5 37 PRESS IMPELLER D PRESSING SHAFT FROM UNIT ME 2410 233 34 5 32 Figure 5 32 Pressing turbocharger shaft from turbine wheel 7 Remove the unit from the press and place on bench compressor end down 8 Remove insert retaining ring 11 from bearing housing 26 Install two No 10 24 screws in shaft insert 12 and pull insert out of bearing housing 26 Push out ring 14 and remove seal 15 9 Remove the oil deflector 16 Remove thrust bearing 17 sleeve 18 and ring 19 10 Remove four shaft rings 20 and bearing 22 and sleeve 21 from bearing housing 26 11 Remove retaining ring 23 and shroud 24 from bearing housing 26 12 Remove seal 25 from shaft of wheel assembly 10 d Cleaning 1 Wash all parts except bearings in cleaning solvent Fed Spec P D 680 and dry thoroughly 2 Use a soft brush plastic blade scraper or 5 38 compressed air to remove deposits Do not use a wire brush or steel blade sc
126. and wear Repair or replace a damaged or distorted rod Remove minor nicks and burrs using a fine emery stone Pitted scored or worn rods may be repaired by metalizing or chrome plating and regrinding to original size A non corrosive metal will be used to metalize shafts f Reassembly 1 Place retainer 6 packing rings 9 and head 4 on the piston rod 2 Separate and oil all of the rings in packing 9 Install one ring of packing at a time into head 4 so the open part of the V is facing toward head Be sure rubber pressure ring 11 is located as shown 3 Using retainer 6 tap the packing firmly into place in the head 4 While holding retainer firmly seated against packing measure dearance B fig 4 39 between retainer and head with a thickness gage 5 Remove the head with the packing from the piston rod leaving the retainer on the rod 6 Install shims on the rod with a total thickness of 0 010 inch to 0 01 5 inch less than the measured clearance B This will preload the 4 42 packing properly when retainer is tightened into place CAUTION When installing the head on the rod be careful not to damage the packing 7 Install new backup ring 3 fig 4 38 and preformed packing 2 8 Assemble wear ring 8 on piston 1 and install piston on the rod 9 Install the nut securing the piston to the rod and tighten per nut and bolt torque chart in 10 Install seal assemblies 7 to the piston
127. and wear Replace worn or defective bearings 2 Inspect the bevel gear and pinion for chipped pitted broken or worn teeth Replace a damaged or excessively worn gear set TB ENG 364 may be used as a guide for determining gear replacement 3 Inspect the bearing cages for cracks breaks and other damage Replace defective or damaged bearing cages d Bevel Gear and Pinion Setting 1 General The bevel pinion is free to float in the transfer case of the transmission and seeks its own running position with respect to the bevel gear in forward speeds and is located by the rear bearing in reverse The only adjustments necessary are the bevel gear shaft bearing preload subpara 2 and 3 below and the backlash subpara 4 below between the bevel gear and pinion The correct amount of backlash for each bevel pinion installed at the factory is marked on the end of the bevel pinion If the pinion is not marked refer to table 14 4 After adjusting the bevel gear shaft bearing preload the backlash should be set as described below 2 Bevel gear shaft bearing adjustment transmission removed NOTE It is preferred that the bevel gear shrift bearing preload be set with the transmission removed This permits adjusting the bearings to a definite preload a Install a full shim pack under the bearing cage farther from the bevel gear Tighten all bolts b Install the other bearing cage without shims and tighten the bolts evenly
128. ansmission lubricating system d Torque Divider Reconditioning 1 To obtain maximum service cleanliness must be the rule Be careful to avoid introducing dirt into the torque divider or the fluid system when reconditioning and filling the fluid system 2 Protect all internal parts of the torque divider during reconditioning to avoid bumping burring scratching or damaging 3 Oil all parts before installation and be sure there is oil in the bevel gear sump before starting the diesel engine Run the diesel engine at one half engine speed for several minutes before putting the machine to work CAUTION Whenever a torque converter fails the entire torque converter fluid system must be cleaned thoroughly to remove all metal chips and particles before the converter is returned to operation All lines including those to the gages should be removed and cleaned It is essential that the torque converter cooler be absolutely clean Failure to take these precautions will probably result in a recurrent failure Any foreign material left in the torque converter fluid system will be cir culated through the transmission lubrication valve and into the trans mission lubricant circuit NOTE The torque div ider unit weighs approximately 550 pounds e Removal 1 Drain the oil from transmission and torque divider TM 5 2410 233 20 2 Remove the floor plates Kpara 2 8a seat frame para 2 9 and brake pedal assembly p
129. ants Oils and Waxes Tractor Full Tracked Caterpillar Model D7F W Engine D333CT Color and Marking of Military Vehicles Painting Instructions for Field Use Chemicals and Chemical Products Hard and Soft Water Cleaning Components Welding Theory and Application Operator s Manual D7F Caterpillar Tractor Gears Serviceability Organizational Maintenance Manual DI Caterpillar Tractor Direct and General Support and Depot Main tenance Repair Parts and Special Tool List D7F Caterpillar Tractor The Army Maintenance Management System Accessory 5 26 Adjustment Bevel gear and pinion setting 6 18 Backlash ea 6 18 Final drive bearing 6 28 Front idien uuum RE 7 4 Track adjusting mechanism 7 7 Transmission hydraulic system 6 11 Air cleaner 5 25 Alignment Bevel gear 6 18 Engine Track roller frame with sprocket 6 29 B Bearing cage holder assembly Belts fan Bevel gear transmission Blade assembly Block 5 35 Brake pedal and support assembly Brakes xad ak ok Rx ADR Bulldozer control Bulldozer relief valve 44 C 5 30
130. ar face of the tractor bevel gear case and is driven by a power takeoff shaft from the tractor transmission The winch clutches forward and reverse and the brake are hydraulically actuated A separate hydraulic pump supplies power for clutch and brake operation The control valve is in the winch and is operated by cables which are connected to the two lever control mounted near the operator s seat 3 11 Removal Refer to TM 5 2410 233 20 and remove the winch winch pump and winch controls 3 12 Winch Pump a General The pump contains two steel gears a drive and driven shaft and four bearing assemblies The machined covers support the gear shafts and are provided with oil seal rings When servicing the pump extreme care must be taken to prevent foreign matter from entering the unit and causing damage to the machined surfaces b Disassembly 1 Refer to figure 3 4 Jand remove the eight bolts screws and washers and lift cover from body If cover sticks tap lightly with rawhide mallet 2 Cover bearings may remain in either the body or cover but should be match marked in their respective locations for reassembly 3 Remove relief valve spring and ball from cover 4 Identify gears with match marks for correct reassembly 5 Remove oil seal from body assembly using an arbor press and suitable dowel rod c Cleaning Wash all parts a cleaning solvent Fed Spec P D 680 and dry with filtered com pressed
131. ara 6 30 3 Remove transmission vent line fig 2 3 sheet 4 of 6 transmission oil pump oil outlet line 4 Disconnect the oil temperature sensing unit from the torque converter 5 Disconnect the torque divider oil outlet line from the torque divider and from the oil cooler sheet 3 of 6 and remove from tractor 6 Remove the torque divider oil inlet line sheet 4 of 6 7 Remove the scavenge pump oil outlet line 8 Remove power take off gears oil supply line 9 Remove drive shaft para 6 10 Install two in 11 NC forged eyebolts in top of torque divider Attach a hoist to eyelets 1 Remove the twelve retaining nuts 31 sheet 4 of 6 and install two 3 in 16 NC forcing screws to separate torque divider from flywheel housing Remove the torque divider from the tractor WARNING Secure the planet carrier 8 fig 6 1 to the torque divider housing with a wire to prevent possible serious personal injury as a result of the carrier sliding out of location and falling from the torque divider output shaft 12 Mark the mating teeth of sun gear 4 and flywheel Remove the sun gear retaining ring and remove the sun gear 13 Remove the three springs located behind the sun gear from the flywheel f g 5 50 14 Remove the pilot bearing retaining ring and remove pilot bearing from the flywheel 6 5 9 9
132. arch engines A HREFzhttp www liberatedmanuals com Free Military and Government Manuals lt A gt Sincerely Igor Chudov http igor chudov com
133. are placed can now be removed NOTE Before assembly check the discs for warping and check also the disc assemblies for excessive wear and roughness Inspect for broken springs and excessive wear on retainer E ek D Z 4 Z LS a ME 2410 233 34 6 85 Clutch disc assembly Clutch spring sleeve Clutch spring Clutch driving disc Steering clutch inner drum Clutch spring Steering clutch spring retainer zl E CO H Figure 6 85 Cross section of clutch assembly 6 77 ME 2410 233 34 6 86 Steering clutch pressure plate 2 Plate Figure 6 86 Holding steering clutch spring in compression d Inspection and Repair 1 Inspect the clutch disks for damage and wear The clutch disk stack height of 10 disk assemblies and 9 disks new is 2 536 to 2 802 inches The minimum clutch disk stack height of 10 disk assemblies and 9 disks worn is 2 356 inches Replace the disks and or disk assemblies if worn excessively Replace disk assemblies which have a Chipping on the edge of the disk b Cracks at tbe root of any of the teeth c Worn teeth only when wear has ob viously changed tooth contour d Excessive foreign material imbedded in the face Replace warped disks 2 Inspect the clutch inner and outer springs for damage distortion and proper tension The outer clutch springs should exert 286 t
134. arm movement replace the shaft 2 Check rocker arm bushings for scratches pitting or scoring Replace the bushings if damaged 3 Place each rocker arm in position on the shaft The rocker arm must rest freely on the shaft without side wobble If wobble exists replace the rocker arm 4 Inspect the springs for cracks and weakness Replace springs as necessary 5 Inspect the cylinder head for fretting erosion and warping in excess of 0 005 inch Resurface the bead if necessary 6 Inspect the push rods for straightness cracks and worn ends Replace if bent 7 Using a micrometer measure the valve guide inner diameter The diameter should be 0 3736 to 0 3756 inch and must not exceed 0 3766 inch Replace if wear is excessive 8 Inspect and repair the valves as follows a Inspect the valves for damage If the valve faces are pitted or do not properly contact the valve seats reface the valves Ensure that there is enough metal on the head of tbe valve to prevent dishing Replace the valves if they are excessively damaged or worn b Using a micrometer measure the valve stem diameter at three places Diameter must not be less than 0 3702 inch at any point CAUTION While handling valves be careful not to scratch or nick the area between the valve face and stem A small nick can 5 56 cause the valve head to break off during service d Reassembly and Installation fig 5 40 1 Install the seals 30 an
135. assemblies 101 Removing final drive gear and hub Hub inner bearing cone removal Bearing cone removal tools trends as Mets 3 25 6 106 Removing bearing cage Cama ge be EEE Removing outer race and roller assembly CTO Removing retaining nut pedro det iiie dert et Pob s 22109 Installing sprocket 2 ea Dimensions with sprocket shaft properly installed DESCH Installing retaining nut lockpins GaGa ees ie Preparing to remove final drive Go Removing final drive pinion gear ESCH Installing final drive pinion gear 2 mo Preparing to remove pinion flange 2 4 rz Removing pinion flange er hn Removing outer race and roller assembly Installing pinion flange 2
136. ation Reverse removal procedure and install the fan and adapter assembly onto the fan support assembly coupling 5 5 Fan Belts a Removal 1 Remove engine upper guard assemblies TM 5 2410 233 20 2 Loosen fan belts TM 5 2410 233 20 3 Slip forward belt off the generator and crankshaft pulleys Pass belt over fan blade stationed in expanded portion of fan guard fig 5 11 Rotate fan assembly by hand and slip belt around each blade as it enters expanded cage When fan has been rotated approximately 3 4 of a revolution the belt should drop between the fan blade assembly and the radiator core The belt may be withdrawn by passing below the lowest fan blade Repeat procedure with other two belts pe FAN GUARD EXPANDED PORTION 4 B ME 2410 233 34 5 11 H Figure 5 11 Fan belt removal and installation 5 13 b Installation 1 Place belt over a fan blade within the expanded portion of the fan guard 2 Rotate fan assembly by hand and slip belt around each fan blade as it enters expanded cage When fan belt drops to pulley spindle repeat procedure with other 2 belts NOTE Thefan belts must be replaced as a set c Adjustment Place belts on appropriate pulleys and adjust belt tension TM 5 2410 233 20 5 14 5 6 Water Pump a General The gear driven centrifugal type water pump is mounted on the left front of the timing gear housirig Figure 5 13 shows an ex ploded view of th
137. b leaving ap proximately 1 4 inch clearance be tween the retaining nut and sprocket This will keep the sprocket from jumping off final drive hub 5 during pulling A Yoke Figure 6 118 Removing nut witk yoke installed d Attach the Cylinder Group to the Pump Group Place sleeve assembly 5 fig 6 11 over the sprocket shaft and against final drive gear hub Attach the cylinder group to the sprocket with arms 2 adapters and nuts 4 and pins 3 and pull the sprocket loose from hub e Relieve the pressure on the cylinder group and remove puller arrangement from the sprocket f Attach a hoist to the sprocket and remove retaining nut 2 fig 6 117 and lock 1 g Remove sprocket weight approximately 300 Ib 6 119 as soon as the sprocket has been removed Inspect the splines on hub 5 and splines in the Tie the mating seals together to assure installation sprocket for wear if the sprocket pulls nff easily of the same mating seal surfaces h Remove metal floating ring seals 7 ME 2410 233 34 6 119 1 Retaining nut Arms Pins Adapters and nuts Sleeve assembly 6 Guards 7 Metal floating ring seal Figure 6 119 Sprock amp removal 6 97 2 Inspection a Inspect sprocket and sprocket hub splines for damage and wear If the sprocket is removed easily the splines in one or both may be worn and should be replaced b Inspect the sprocket segments for damage a
138. ble tapered parts dry Before assembling parts with tapered splines be sure the splines are clean dry and free from bum Position the parts together by hand to mesh the splines before applying pressure 3 If parts which are fitted together with tapered splines are not tight inspect the tapered splines and discard if worn f Bolts and Bolt Torque 1 A bolt which is too long may bottom before the head is tight against the part it is to hold The threads can be damaged when a long bolt is removed 2 If a bolt is too short there may not be enough threads engaged to hold the part securely 3 Apply proper torque values to all bolts and nuts when assembling Caterpillar equipment 2 4 When a specific torque value is required the value is listed in the SPECIFICATION section of the Service Manual Tighten all other bolts and nuts for general usage hydraulic valve bodies or taperlock studs to the torque values given in the charts g Locks 1 Flat metal locks must be installed properly 2 5 to be effective Bend one end of the lock around the edge of the part Bend the other end against one flat surface of the nut or bolt head 2 Always install new locks in compartment which house moving parts 3 When installing lockwashers on housings made of aluminum use a flat washer between the lockwasher and the housing OY SHARP BENDS CORRECT CORRECT INCORRECT P A d WV c INCORR
139. blind end The rod end line directs oil to the rod end of the cylinder to retract the rod The head end line directs oil to the head end of the cylinder to extend the rod ME 2410 233 34 2 18 l Rod end 2 Head end Figure 2 18 Hydraulic cylinder rod and head ends b Removal The hydraulic system need not be drained to remove any or all cylinders Only the oil in the lines between the cylinder and its control valve will be lost However the control lever must remain in HOLD position or oil can drain from the tank in some instances Disassembly and assembly Remove and install the bolts securing the cylinder head to the cylinder with the piston rod fully extended d Cylinder head seals The rubber O ring seal 1 2 19 and the backup ring 2 which form the seal between the head 3 and cylinder bore 4 are all assembled as illustrated Note that the toe or lip of all wiper seals 2 2D on all cylinders faces away from the cylinder head KE gt ENS Q e Key ENS OU ME 2410 233 34 2 9 O ring Back up ring Cylinder head Cylinder bore Piston rod CT gt Figure 2 19 Cylinder head seals 2 9 2410 233 34 2 20 Buffer seal 2 U cup seal always installed with lip facing the oil 3 Wiper seal Figure 2 20 Three seal cylinder head e Cylinder head packing adjustment 1 Oil leakage between the rod and the hydraul
140. bling piston head Measuring clearance Removing shims Ripper lift cylinder exploded view Cooling system schematic diagram Hood removal and headlight brackets and radiator top guard Preparing 10 remoye e es die See rox 03 e EROR ee ae Lifting radiator from radiator guard Radiator disassembly Radiator bottom guard removal and installation Fan adapter and fan drive and support assembly coupling Bulldozer lift cylinder hydraulic lines disconnect couplings Radiator and radiator guard removal and installation Lifting radiator guard and radiator from tractor Fan belt removal and installation Water pump removal and installation Water pump exploded view installation Engine oil cooler removal Fan and fan drive disassembly Fuel injector removal and installation Fuel injector disassembly and reassembly Fuel injection pump removal and installation Fuel injection pump exploded view Engine speed governor exploded view Fuel transfer pump removal and installation Fuel transfer pump Fuel tank removal and installation Air cleaner body removal and installation Muffler removal and installation Engine exhaust flow diagram Turbocharger removal and installation installation disesssembly ixekcpRREUR ER ER ED ee OE wed amus PD CMO voa S dedos emt oe EE Page L
141. bly tht ttn 771 Safety and directional valve disassembly 2 22 ttt ttt 6 28 Speed selector valve 00002 hehehe tete nnn EZA Linkage adjustment us usus E EE EEEE E Linkage adjustment top view a tht tn nn Hydraulic pump disassembly 20000 eee tht hn r Torque converter inlet relief valve and directional valve body rz Torque converter inlet relief valve teens Lou Torque converter outlet relief valve removal Ih Number Le Title Qutlet relief valve NC a OY dU quy cass eoe X ouk Check valve removal Check valve disassembly Clutch operation Clutch designation Preparing to remove input shaft front oil seal Removing input shaft front oil seal 1 died de de w M Up a p a pa er celo kia nap ce Preparing to remove transmission case Removing transmission case Checking clutch operation Preparing to remove input shaft Removing input shaft Removal of No 1 and No 2 clutch Removing 1 carrier Removing No 3 clutch housing No 2 carrier removal Removing output shaft Preparing to disassemble input shaft Bearing cage removal Oil seal removal Retainer ring removal Bearing cage disassembly Bearing race and sun gear removal No 4
142. board blade assembly on the bulldozer ME 2410 233 34 3 1 Figure 3 1 Bulldozer blade assembly 3 1 3 3 Push Arms and Braces fig 3 1 a Removal Refer to TM 5 2410 233 20 and remove the push arms ancf braces from bulldozer b Cleaning Scrape wash and clean all parts thoroughly with soap and warm water Remove oily deposits with cleaning solvent Fed Spec P D 680 Inspection and Repair 1 Inspect arm assemblies for broken weldments cracks bends and damage to trunnions Weld broken weldments and cracks TM 9 237 2 Inspect caps bearings and pivots for wear corrosion or damage 3 Inspect the links for cracks distortion and wear 4 Inspect brace assembly for wear bends and dam aged screw threads 5 Replace all defective parts d Installation Refer to TM 5 2410 233 20 and install the push arms and braces on the bulldozer 3 4 Scarifies fig 3 P a Removal Refer to TM 5 2410 233 20 and remove the scarifier housings b Cleaning Scrape wash and clean scarifier housings thoroughly with soap and warm water Remove oily deposits with cleaning solvent Fed Spec P D 680 Inspection and Repair 1 Inspect scarifier housing for cracks distortion or wear 2 Weld minor cracks in housing 3 79 3 according to TM 9 237 3 Replace a defective housing 3 shank 4 tooth 6 or lock rod 1 d Installation Refer to TM 5 2410 233 20 and in stall the scarifi
143. bove 2 Rotate the crankshaft in the direction of engine rotation until the No 1 piston is at top dead center on the compression stroke and the timing marks are matched Refer tg figure 5 45 ACCESSORY B DRIVE ACCESSORY DRIVE IDLER Ges GEAR CAMSHAFT N GEAR CRANKSHAFT DRIVE GEAR Figure 5 45 Timing gears and marks 3 If the timing marks are not properly aligned remove and reinstall the gears as necessary Checking Camshaft Gear Backlash 1 Check the backlash between the camshaft gear and the crankshaft gear by installing a dia indicator Backlash should be 0 001 to 0 010 inch 2 If backlash is excessive check for worn timing gears bearings or camshaft bearings 5 27 3 Compensate for worn timing gears by adjusting the fuel injection pump lifters 11 4 If the backlash measurement is low check for a burr or rough spot on one of the gears and smooth as required 5 30 Cam shaft a Removal and Disassembly fig 5 46 1 Remove the engine from the tractor 2 8 2 Remove the pushrods para 5 27 and lift the valve lifters clear of the camshaft 3 Remove the timing gear cover para 5 29 4 Remove two bolts and the washer and pull the camshaft and camshaft gear from the block Be careful not to damage the camshaft bearings CAMSHAFT GEAR 2410 233 34 5 46 Figure 5 46 Camshaft assembly exploded view 5 Remove four bolts and the lock and pull t
144. c Valve Bolts and Nuts 5 10 13 22 L 60 3 38 24 222 58 118 4 7 16 39 2 Table 1 2 Specific Nut and Bolt Torque Data Item Lb Ft Cylinder head first time s S la SEN ae doe Oe a 115 second time P x Deedee a Ear eh Ses 1754 5 third time bom AIEO X ra AE RE UE DERE RI eus 175 5 Accessory drive retainer nut torque A 2 2 90 110 Camshaft gear retainer bolt torque 14 20 14 20 Connectingrod bolt nuts torque bolt nuts torque 30 30 3 plus additional turn of 90 Main bearing bolt torque torque E UR D RUE E 30 3 plus additional turn of 90 Crankshaft pulley retaining screw torque 1 i 21 Flywheel retaining bolt torque Late 130 170 Fiywheel housing bolt and and nut torque 65 85 Fuel injection injection line nut torque nut torque 25 35 Fuel injection nozzle retaining nut 105 5 Fuel injection precombustion chamber torque 140 160 Fuel transfer pump shaft retaining nut torque 17 27 Fuel injection pump retaining bushing 150 10 10 Timing gear housing bolt orgue 21 31 Turbo charger Torque on housing band 120 ban b in Torque on on impeller nut 1 15 1 Turbocharger to manifold bolt 36 44 Water pum
145. ce Manual TRACTOR FULL TRACKED LOW SPEED DED MEDIUM DRAWBAR PULL OSCILLATING TRACK 78 IN GAGE CATERPILLAR MODEL D7F FSN 2410 177 7283 W RIPPER FSN 2410 177 7284 W WINCH TM 5 2410 233 34 12 October 1971 is changed as follows Page 2 13 raragraph 2 8 1 is superseded as follows 1 Remove the hood para 5 2 side panels and instrument panel supports Drain the cooling sys tem Disconnect the negative battery cable from the batterv Page 2 14 Paragraph 2 8a 7 In line 1 6 bolts is changed to read 5 Page 2 18 Paragraphs 2 8a 23 1 23 2 23 3 and 23 4 are added 23 1 Remove clamps securing tilt cvlinder hoses to engine 23 2 Disconnect lift hoses left side of engine and tie back to clear engine 23 3 Disconnect voltage regulator and remove regulator 23 4 Remove lines from hydraulic and winch pumps Page 5 14 Paragraph 5 60 3 is superseded as follows 3 Remove the four bolts which secure the water pump to the cylinder block and timing gear cover Paragraph 5 65 5 is added as follows 5 Remove by pass line and 1 4 inch line be tween the pump and the block Page 3 32 Paragraph 5 16 is rescinded Figure5 25 is rescinded Page 5 44 Paragraph 5 20 1 is added as follows 5 20 1 Generator Regulator a Inspection and Repair 1 Inspect all resistors capacitors contacts and wiring for burned or defective condition Re place as required 2 Clean regulator
146. ce and snapring properly installed 2 Recheck the backlash and gear mesh of the bevel gear set This is best done by painting the gears with white lead and obtaining a gear pattern as shown in figure 3 19 3 After the correct gear pattern is obtained move the bevel ring gear away from pinion to obtain 0 005 0 014 blacklash 3 14 ME 2410 233 34 3 19 Figure 3 19 Pinion depth 3 16 Installation Refer to LO 5 2410 233 12 and fill winch gear case Refer to TM 52410 23320 and install the winch with oil winch pump and winch controls on the tractor CHAPTER 4 REPAIR OF HYDRAULIC SYSTEM Section 4 1 General The hydraulic system consists of the hydraulic tank and valves a two section pump two lift cylinders a bulldozer blade tilt cylinder and the hydraulic lines necessary for bulldozer operation It also has provisions for hydraulic operation of a rear mounted ripper attachment 4 2 Hydraulic Tank a Removal 1 Remove guard from around the bottom of the hydraulic tank 2 Drain the hydraulic tank Refer to TM 5 2410 233 20 3 Remove bolts 1 4 T and disconnect hydraulic lines 3 fig 411 and 6 below tank 4 Remove bolts 2 and 4 and drain line 5 HYDRAULIC TANK 5 Refer to paragraph 6 30 Jand follow a 1 through 4 6 Disconnect hydraulic lines 6 7 8 9 and 11 7 Disconnect hose from elbow assembly 10 8 Disconnect bulldozer con
147. ches deep into the sprocket shaft A fig 6 138 Place the lockpin the hole and install the lockring to hold it in place ME 2410 233 34 6 13R A 0 368 in drill 0 56 in deep in shaft Figure 6 138 Installing retaining nut lockpins d Checking Sprocket Shaft Check the final drive sprocket shaft to determine if it is straight NOTE If the sprocket shaft is bent more than the allowable tolerance shaft should be removed and a new shaft installed 6 27 Final Drive Pinion Group a Removal and Installation 1 Remove the steering clutch as outlined in 2 Remove bolts 1 fig 6 139 3 Insert a bolt 3 fig 6 140 in one of the steering clutch to pinion flange dearance holes and attach a hoist for support l Bolts 7 Figure 6 139 Preparing to remove final drive pinion 1 Cage 2 Flange 3 Bol Figure 6 140 Removing final drive pinion gear 4 Using a suitable pry bar remove final drive pinion flange 2 bearing cage 1 inner bearing and final drive pinion as a unit from the steering clutch and bevel gear case 6 111 5 At installation insert a 1 2 inch 13 NC guide pin 2 ffg 6 amp 341 to position the bearing cage 1 Gasket 2 Guide pin Figure 6 141 Installing final drive pinion gear 6 Replace gasket 1 7 Attach a hoist for support and install the final drive pinion bearing cage and final drive pinion flange in reverse order of removal Position bearin
148. clamp and the compressor 10 Install the bolts securing the cylinder head to the cylinder with the piston rod fully ex tended Tighten the bolts to the torque value in the SPECIFICATIONS 9 Cylinder installation Before installing a hydraulic cylinder apply FED SPEC TT A 580 Anti Seize Compound to the cylinder pins and pin bores to aid in future removal After the cylinder has been installed start the engine and operate the cylinder to remove air from the hydraulic system When the system is functioning properly check the level of the oil in the hydraulic oil supply tank 2 12 CAUTION Under no circumstances should welding be done on the wall of the cylinder except the welded area at the head end of the cylinder Welding on the cylinder wall can cause enough bore distortion to cause interference between the piston and the cylinder wall and can result in severe scoring of the cylinder wall 10 Vane type pumps a Before disassembling a pump mark the pump body and cover to insure correct assembly with respect to port relationship ME 2410 233 34 2 27 Inserta 2 Vanes 3 Pressure plate 4 Ring 5 Rotor Wear plate Figure 2 27 Pump cartridge 2410 233 34 2 28 A Passage in ring Sharp edge of vane Passage in rotor Figure 2 28 Ring rotor and vane installation b Assemble the vanes 2 fig 2 27 and inserts 1 in the rotor 5 and the rotor into the ring 4 The sharp edges
149. contact points with a fine riffler file Do not use sandpaper or emery cloth to clean contact points CAUTION When a regulator has been removed from the vehicle or leads disconnected from the regulator the generator must be polarized after leads are connected but BEFORE THE ENGINE IS STARTED To polarize the gen erator insert the special test harness TM 5 2410 233 20 Disconnect T 2 and 3 also disconnect the battery cable from the regulator Momentarily touch a jumper lead between T 3 of the harness and the prong of the battery cable This allows a surge of current to flow through the generator field windings in the proper direction Failure to do this may result in severe damage since reversed generator polarity causes vibra tion arcing or welding of cutout relay con tact points b Adjustments fig 5 35 1 1 Cutout relay Three checks and adjustments are required on the cutout relay air gap point open ing and closing voltage Air gap and point opening are checked with the battery disconnected a Air gap Measure the air gap between the armature and the core not between the brass piu in the armature and the core with the contact points barely touching If both sets of points do not close together it will be necessary to realign the lower contact bracket slightly or to bend the spring fingers on the armature until points do meet simul taneously Adjust air gap by loosening the two screws att
150. contact surface wear or flange wear exceed 74 inch or the roller is otherwise damaged it will be replaced 2 Inspect the roller bearings for corrosion roughness and wear Replace bearings which are pitted rough or worn excessively 3 Inspect the metal floating ring seals for dam age and proper wear pattern Replace seals which are pitted grooved scratched across the seal surface or which show an uneven wear pattern Seals must be replaced in sets 4 Replace all toric sealing rings Do not reuse toric seal rings Reassembly and Installation 1 Heat the bearing 6 fig 7 12 and install it on the shaft so that the inner race seats the raised section of the shaft 2 Install the bearing outer races 4 in the roller 3 Install the shaft in the roller heat the bearing cone 7 and install it on the shaft and install the spanner nut 4 Tighten the nut 5 until all bearing end clearance is removed and a slight drag can be felt on the bearings when the shaft is rotated then back off the nut until the nearest aligning hole aligns with the slot in the shaft and install the lockring 8 5 Install the end cover preformed packing if it is damaged CAUTION Before installing the end cover remove any burrs from the bore of the roller to prevent damage to the preformed packing during installation CAUTION Before installing the end cover remove any burrs from the bore of the roller to prev
151. ct drive pinion and idler pinion outer race and roller assemblies 6 fia 6 129 for ex cessive wear 3 Remove both pinion outer race and roller assemblies from the final drive case after removing plugs 1 fig 6 129 and dowels 2 4 Using inch 20 NC bolt remove dowel 2 and remove pinion outer race and roller assembly as a unit Remove both pinion outer race and roller assemblies in a like manner NOTE All outer race and roller assemblies with snaprings are to be assembled with snap rings next to the gear teeth 6 103 V ME 2410 233 34 4 129 1 Plug 2 Dowel Figure 6 129 Removing outer race and roller assemblies 5 Attach a hoist to support final drive gear 2 and final drive gear and hub off the sprocket shaft WARNING Support idler pinion 3 during removal of final drive gear 2 and hub 1 The idler pinion is supported only by the idler pinion inner bearing and is free to fall 6 104 1 Hub 2 Final drive gear 3 Idler pinion Figure 6 130 Removing final drive gear and hub 6 Separate gear 2 from hub 1 after removing the bo
152. d 4 in each of the shafts 3 and 1 Two bearings 8 and two washers 10 one on either side of each planet gear are provided with each planet gear in the carrier Three planet gear shafts are removed from each end of the carrier The No 2 outer planet gears 5 and No 1 planet gears 6 can be removed after removing the planet gears 73 5 6 Inspect all gears bearings washers and shafts in the carrier and replace any that are worn or damaged 7 Inspect the support bearing in the carrier for wear or damage and replace it if necessary by pressing it from the carrier using a piece of pipe 4 inches in diameter and approximately 5 inches long disassembly 8 Assemble each planet gear the notch in the A 15 rs Figure 6 58 the carrier in the reverse order of making certain the ball is in place in shaft and correctly aligned with carrier No 4 sun gear Bolts and locks Plates No l carrier No 4 sun gear removal d up 2410 233 34 6 58 6 51 6 52 Figure 6 59 No 1 carrier disassembly ME 2410 235 34 cr Ui Key to figure 6 59 1 Planet gear shaft 2 Ball 3 Planet gear shafts 4 Ball 5 No 2 outer planet gear 6 No 1 planet gear 7 No 3 planet gear 8 Planet gear bearings 9 No 2 inner planet gear 10 No Washer i No 2 Carrier Disassembly and Assembly 1 Position the No 2 carrier 1 Eig 6 60 as shown 2 Pull the
153. d 31 onto the precombustion chambers 29 2 Coat the chamfered portion of the cylinder head and the rubber seals 30 with liquid soap Install the precombustion chambers in the cylinder head and tighten to a torque of 140 to 160 foot pounds 3 Install the dowels 27 in the block Install a new gasket 20 Install the plug 32 4 Install the valve lifters 28 5 Press the valve guides 24 into the cylinder head using an arbor Resurface the valve seats after installing in the cylinder head Lap valves and seats together to obtain a proper seal 6 Shrink the valve seats 20 in dry ice and install in the head Drive into place with a suitable driver 7 Lubricate the valves 25 with clean engine oil and install 8 Install the valve springs 23 and retainers 22 Compress the springs and install the retainers 9 Coat the push rods 16 with clean engine oil and install in the block 10 Install the cylinder head 19 and secure with the washers 18 and bolts 17 Coat the threads of the bolts with a sealant Refer to figure 5 41 and tighten as follows a Step 1 Tighten bolts in numerical order to 115 foot pounds b Step 2 Retighten bolts in numerical order to 170 to 180 foot pounds c Step 3 Retighten bolts in numerical order band torque only to 170 to 180 foot pounds d Step 4 Tighten bolts in alphabetical order to 22 foot pounds e Step 5 Retighten bolts in alphabetical order t
154. d increasing clearance at 10 and 15 f Remove shims 3 to allow the track roller dearance at 10 and 15 and increasing the frame to move closer to the machine decreasing the dearance at 12 and 14 6 115 6 116 VZ SSS rS gt 222222222 VG t e 22 FP V ME 2410 233 34 6 147 er assembly 9 assembly Nut 3 Shims x t g Sien E w Dim z x f k Sac it Ze gee r Llockrin Final dr ive sprocket m Aligning track roller frame with sprocket Figure 06 117 6 30 Brake Pedal and Support Assembly a Removal 1 Remove the seat TM 5 2410 233 20 seat frame para 2 9 and floor plates 2 Disconnect brake lock rod fig 6 148 at foot pedal end 3 Disconnect steering dutch rods fig 2 31 sheet 5 at both ends and slide forward to dear brake support assembly fig 6 148 4 Remove brake control rods 5 Remove four bolts and attach hoist and remove brake and support assembly from tractor 6 117 811 9 prem TN 11 Figure 6 118 Brake pedal and support assembly removal aud installation b Inspection 1 Inspect ratchet and pawl for wear rounded or missing teeth Check action of ratchet and pawl to see that pawl engages ratchet teeth prop
155. d the clutch hub The nut is installed to decrease the possibility of personal injury or damage when the clutch hub is pulled loose from the shaft ME 2410 233 34 6 97 Retaining nut 2 Puler 3 Puller adapter 4 Bolt 5 Push puller Figure 6 97 Pulling hub 7 Fasten the puller 2 to the clutch hub using four inch 11 NC bolts approximately 3 inches long 8 Using puller adapter 3 a puller 5 with two 34 inch 10 NC bolts 4 9 inches long pull the hub loose from the shaft 9 Remove the puller tools and the nut and remove the hub b Inspection and Repair 1 Inspect the hub for cracks breaks and worn seal ring travel areas Replace a damaged or worn hub 2 Inspect the clutch piston for nicks scoring and wear Replace a damaged or worn piston 3 Inspect ring seals for damage and wear Replace worn or damaged ring seals c Installation 1 Place the hub on the clutch shaft 6 81 2 Align the locating dowel in the retainer washer 1 with the dowel hole in the hub Install the washer 3 Assemble bolt adapter 3 to the hydraulic puller and install the adapter 3 on the clutch shaft 4 Place the spacer 2 over the adapter as shown 5 Press the hub onto the shaft to the pressure given table 1 4 Measure the distance 6 98 from the shoulder on clutch shaft to the face of the clutch hub Refer to table 1 4 for the correct dimension 6 Install the
156. d within the hydraulic tank and for the scraper circuit which is controlled by an external valve The small pump section powers the blade tilt circuit through a control valve mounted in the tank b Removal Refer to TM 5 2410 233 20 and remove the hydraulic pump from the tractor Disassembly 1 When disassembling the oil pump avoid introducing dirt or foreign material into the pump 2 Before removing the small section cover mark both section covers with match marks so the covers can be installed in the same position This will insure the proper relationship between the inlet and outlet ports of the pumps 3 Small pump section a Remove bolts 1 fig 4 19 and cover 2 b Remove O ring seal 3 wave washer 4 and cartridge 5 CAUTION Vanes 11 fig 4 20 and insert vanes 12 are free to slide out of the rotor and ring and may be damaged if drop peal c Refer to figure 4 20 and disassemble the cartridge Pump rotation is counterclockwise when viewed from the drive spline end Correct pump assembly requires that the leading chamfered edge of vanes 11 arrow 6 on ring 5 and the arrow on rotor 13 all point in the direction of pump rotation CAUTION Tighten bolts 1 only after large sec tion cover bolts have been tightened ME 2410 233 34 4 19 1 Bolts 2 Cover 3 O ring seal 4 Wave washer 5 Cartridge Figure 4 19 Cover and cartridge removal small pump section 4 29 0
157. detaching the regulator from the heat sink the heat sink mounting screws and the generator output terminal Note the round insu lators under the heat sink mounting screws and the flat insulator located behind the heat sink The sili cone grease on both sides of the flat insulator pro vides the necessary heat transfer between heat sink and end frame Reapply silicone grease during assembly tighten the heat sink mounting screws loosely securely tighten the output terminal then securely tighten the heat sink screws To replace a diode in the heat sink support the heat sink and use an arbor press or vise to push the diode out When installing a diode use a suitable tool which will fit over the outer diode edge to push the diode in Support the heat sink on end frame with a suitable tool CAUTION Do not strike the diodes as shock may age it and the other diodes Use only those diodes listed in the parts list for these units Never use substitutes 2 Stator check Use a 110 volt test lamp or an ohmmeter If the lamp lights or if the meter read ing is low when connected from any stator lead to the ground the windings are grounded See figure 5 35 2 If the lamp fails to light or if the meter read ing is high when successively connected between each pair of stator leacs the windings are open A short circuit in the stator windings is difficult to locate without laboratory test equipment due to the low resistance of t
158. e 5 22 Disassembly Refer tq figure 5 19 NOTE Clean the fuel injection pump housing with cleaning solvent Fed Spec P D 680 thoroughly before disassembly 1 Remove the cap 1 and the felt washer 2 sch 2 t gt 17 18 Cap Washer Bushing Retaining ring Bonnet Barrel Check valve lt 19 20 21 22 8 9 10 11 12 13 14 Figure 5 19 Fuel injection pump Spring Plunger Keeper Spring Fuel rack Bearing Bearing 15 Spacer 16 Lifter 17 Bolt 18 Lock 19 Retainer 20 Spring 21 Ring gear exploded view ME 2410 233 34 5 19 Spacer Camshaft Bearing Bearing Gasket Gasket Housing 5 23 2 Remove the fuel injection pump retailing bushing 3 from the housing 3 Using an extractor remove the fuel in jection pump from the housing NOTE Components of the fuel injection pumps cannot be interchanged Tag parts for assembly with the same parts and installation in the same bore in the fuel pump housing 4 Remove the retaining ring 4 and Separate the bonnet 5 from the barrel 6 5 Remove the check valve 7 and spring 8 from the bonnet 6 Remove the plunger 9 keeper 10 and spring 11 from the barrel 6 7 Remove the fuel rack 12 from the housing 8 Remove the bearing 13 from the housing 9 Scribe two marks on the housing above the groove on the bearing 14 and in line with the lubrication passage Remove the bearing 10 Remove
159. e 7 and the pressure differential valve 8 These valves act in combination to limit the maximum pressure of the system control the rate of pressure rise in the system and insure the proper sequence of clutch engagement 5 The differential valve 8 allows the selected speed clutch to become engaged before any oil is directed to the directional clutches This arrangement provides smooth engagement and allows most of the load to be taken up by the directional clutches No 1 or No 2 The pressure relief valve 7 maintains the proper pressure in the system and by passes the oil to the torque converter inlet relief valve 6 The safety valve 6 is a spring loaded spool valve that shifts the selector lever into the neutral position whenever the oil pressure drops below 100 psi and remains for approximately 15 seconds This valve also blocks the oil passage leading to the directional valve when the selector lever is in neutral 7 The directional spool valve 5 is con tained in the same housing 4 as the safety valve The directional valve is positioned by the control linkage to direct oil to one of the directional clutches No 1 or No 2 8 The gear selector lever is located at the left side of the operator s seat Mechanical linkage connects the lever to the speed selector spool valve and to the directional spool valve Speed shifts are made by moving the selector lever forward or back ward and direction is selected by m
160. e bearing 24 Ensure that the bearings are flush with the face of the housing 2 Install the camshaft 23 in the housing 3 Install the spacer 22 ring gear 21 spring 20 spring retainer 19 lock 18 and bolt 17 4 Install the valve lifter 16 and sparer 15 5 Install the bearing 14 so that the hole in the hearing aligns with the marks made on the housing before removal Install the bearing 13 6 Install the fuel rack 12 7 Install the spring 11 keeper 10 and plunger 9 in the barrel 6 8 Install the spring 8 and check valve 7 in the bonnet 5 9 Secure the bonnet 5 to the barrel 6 using retaining ring 4 Install the barrel and bonnet assembly in the fuel pump housing Align the notches in the bonnet and barrel with the mark 180 from the gear center tooth Align the notches with the guide pins in the housing bore Align the pump gear center tooth with the fuel rack center notch 10 Press down on the barrel and bonnet assembly and install the retaining bushing 3 flush with the top of the housing If the bushing cannot be properly installed remove the barrel and bonnet realign and reinstall Tighten the bushing to a torque of 140 to 160 foot pounds 11 Install the felt washer 2 and the cap 1 g Installation Install the fuel injection pump in the reverse order of removal Tighten bolts and fittings securely Check and adjust timing subpara h i or j and fuel
161. e bevel gear to give approximately the amount of backlash indicated on the end of the bevel pinion or in table 1 4 b Install the other bearing cage without shims or lockwashers and tighten the bolts evenly while slowly rotating the bevel gear until a definite preload is noticeable on the bevel gear shaft bearings c Evenly back off the bolts on the bearing cage without shims until approximately 0 002 inch end clearance has been reached on the bevel gear shaft being sure there is backlash between the bevel gear and pinion NOTE To determine end clearance pry against the ends of the bevel gear shaft 6 88 d Use a thickness gage to determine the clearance between the flange of the bearing cage and the face of the bevel gear case at each bolt location making sure the clearance is the same all around the cage e Remove the cage and install the shims with a total thickness the same as the clearance determined in subpara 4 less 0 015 inch to give the required preload to the bevel gear shaft bearings NOTE THe 0 015 inch shim removal includes 0 002 inch end clearance as left in c above plus the 0 013 inch normal preload f Again install the cage and lockwashers and securely tighten the bolts 4 Backlash adjustment a Mount a dial indicator with a universal attachment on one of the pinion gear teeth as shown in figure 6 110 b Block the bevel gear c Move the pinion as far forward as possible and roc
162. e converter The pressure of this oil is held to 40 44 psi at stall speed by a torque converter outlet relief valve Refer t paragraph 6 11 for the correct testing and adjusting procedure Oil leaves the torque converter through outlet port in the carrier From here it flows through the oil cooler and returns to the transmission lubrication system 5 The energy imparted by the impeller 5 transmits torque to the turbine 10 and con sequenty the output shaft 7 Under normal operating conditions the oil passes through the converter easily and quickly striking each blade at a very slight angle When a load is encountered the speed of the turbine is reduced and the oil strikes the turbine blades at a sharper angle This multiplies the torque delivered to the output shaft of the torque divider c Lubrication 1 Oil for lubrication of the torque divider bearings and planetary system is furnished from the supply used for operation of the torque converter The bearings 15 are constantly running in oil The bearings and gears in the planetary system 4 and the pilot bearing 15 receive lubrication through drilled passages in the output shaft 7 The output shaft rear bearing 17 receives lubrication from normal oil leakage past a piston ring type seal 2 Normal oil leakage past the bearings and piston ring type seals falls to the bottom of the torque divider housing and is picked up by the scavenge pump and returned to the tr
163. e kept in matched sets The floating ring seals 2 should always be installed in pairs that is two new seals together or two seals that have previously run together Never assemble one new seal and one used seal together or two seals that have not previously run together 7 5 ME 2410 233 34 7 9 1 Bracket 2 Bolt 3 Roller 4 Nut 5 Lockring 6 Cover Figure 7 9 Removing nut ME 2410 233 34 7 10 1 Seal support 2 Metal floating ring seals 3 End collar 4 Lock ring Figure 7 10 Removing metal floating ring scab 4 Install two 5 16 inch 18 NC bolts approximately 3 inches long into the seal support and attach a puller with a step plate and remove the seal support 1 5 Using a puller and a spacer press ths shaft from the roller 6 Remove the shaft 2 fig 7 11 and bearing 1 and bearing 3 from the roller 7 The bearing races can be removed from the roller with a bearing cup pulling attachment and a puller ME 2410 233 34 7 11 1 Bearing 2 Shaft 3 Bearing Figure 7 11 Removing bearings Cleaning 1 Clean all parts using cleaning solvent F ed Spec P D 680 and wipe dry with lint free cloth 2 Remove all dirt and rust from the floating ring seal mounting grooves Grooves must be dean smooth and dry 3 Wash protective coating from new ring seals with cleaning solvent d Inspection and Repair 1 Inspect the carrier rollers for damage and wear When the
164. e resistor Cut away sealing compound with sharp blade 3 Transistor TR2 a Step 1 Should get one low reading and one high reading If not replace transistor b Step 2 Same as step 1 c Step 3 Both readings should be very high If not replace transistor NOTE The replacement transistor may be a red dot and a flat side When assembled the flat side should face towards diodes D1 D2 and D3 See fig 5 35 3A 4 Diode D4 Should get one low and one high reading If not replace diode 5 Diode D1 D2 and D3 Check each diode separately Sh 1ld get one low and one high reading If not replace diode being checked 6 Transistor TR1 see fig 5 85 4A a Step 1 Both readings should be very high If not replace transistor b Step 2 Should get one low and one high reading c Step 3 Same as step 2 7 Capacitor C1 Visually inspect for broken leads f no defects have been found replec plete regulator assembly g lf regulator was repaired reussemuie lows 1 If heat sink is reused burn away with sol dering iron old epoxy separating heat sink from pane board Apply new epoxy at all four 4 locations on old or new heat sink fig 5 35 3B NOTE Keep opposite side of heat sink except under tap switch perfectly clear and free of epoxy and rubber seal fig 5 35 3B 2 Using 4 insulators assemble heat sink panel board and transistor TR1 Use silicone grease available commerciall
165. e rings in packing 11 Install one ring of packing at a time into head 6 so the open part of the V is facing toward head Be sure rubber pressure ring 12 is located as shown 5 Using retainer 5 tap the packing firmly into place in the head 6 While holding retainer firmly seated against packing measure dearance A fig 4 31 between retainer and head with a thickness gage 7 Remove the head with the packing from the piston rod leaving the retainer on the rod 8 Install shims on the rod with a total thickness of 0 010 inch to 0 015 inch less than the measured clearance A This will preload the packing properly when the retainer is tightened into place CAUTION When installing the head on the rod be careful not to damage the packing PISTON ROD ME 2410 233 34 4 31 Figure 4 31 Measuring clearance 9 Install new backup ring 7 fig 4 27 and preformed packing 8 on the head 10 Install inserts 3 and 4 with the milled end pointing away from the piston surface and positioned as shown NOTE The bores in piston 1 which contain inserts and plungers must be free of dirt or foreign matter 11 Chill the inserts before installing Install one insert into the piston until it is flush with the piston surface Turn the piston over and place plunger 2 into the piston Position and press the other insert into the piston until it is flush with the piston surface Check the plunger for moving free
166. e the running clearance A f Measure diametral clearance at four equidistant points Use the highest clearance when determining if the components are within the allowable limits g Position impeller 3 as shown and place steel rods 5 on the impeller h Position stator 1 into impeller 3 and on rods 5 i Clamp the dial indicator to bolt j Move stator 1 from side to side in line with the dial indicator stem and record the total movement reading on the dial indicator This reading is the total diametral clearance twice the running clearance B K Measure the diametral clearance at four equidistant points using the highest clearance when determining if the components are within the allowable limits h Installation Reverse removal procedure and 6 22 install the torque divider on the engine Refer to LO 5 2410 233 12 and fill transmission and torque divider to specified level CAUTION Install the universal joint before starting diesel engine to prevent hydraulic pressure from forcing the torque divider output shaft to the rear and causing a rapid loss of oil 6 4 Transmission Hydraulic Controls a General fig 6 2D 1 The transmission hydraulic control system is composed of a pump filter series of valves and a Control lever and linkage mechanism The hydraulic control system directs oil to the clutches in the transmission Bypass oil from the hydraulic control pressure relief valve 7 i
167. e tool arrangement used to disassemble the clutch assembly and tighten the retaining bolts 11 Remove the compressor tools and guide pins and install the remaining bolts Torque all the bolts to 600 800b and bend the metal locks 12 Using a suitable lifting hook remove the steering clutch assembly 1 fig 6 92 from the outer drum Invert the outer drum remove the forcing screws 3 and replace the outer drum on the steering clutch assembly 13 Install the brake band ME 2410 233 34 6 90 1 Installing clutch dise assemblies Figure 6 90 Installing clutch disc assemblies 6 79 6 16 Steering Clutch Driving Hub a Removal 1 Install two 5 16 inch 18 NC bolts approximately 3 inches long in the steering clutch piston 1 fig 6 93 Remove the piston by pulling toward the outside of the tractor 2 Straighten the lock 11 6 94 securing the hub retaining nut 3 fig 6 9 3 Remove the retaining nut 3 NOTE To facilitate nut removal with both steering clutches removed install two inch 11 NC bolts 1 fig 6 95 approximately 3 inches long into the opposite clutch hub clearance holes and insert a bar to retain the steering clutch shaft 2 4294 Using the wrench 2 LI1g 8195 remove the retaining nut This procedure can be used when installing the retaining nut after placing the opposite clutch hub on the shaft temporarily and inserting the bolts 1 to retain the
168. e water pump b Removal 1 Drain the cooling system TM 5 2410 233 10 2 Disconnect the water inlet and outlet hoses 5 10 3 Remove the bolts which secure the water pump to the cylinder block and timing gear cover 4 Remove the water pump from engine and dean gasket material from water pump and gear housing Figure 5 12 Water pump removal and installation 5 15 c Disassembly 1 Remove the bolts 1 fig 5 13 and lock washers 2 and remove the cover 3 from the wa ter pump Remove the seal 4 2 Remove the bolt 5 and washer 6 3 Using a suitable puller remove the Bolt Lockwasher Cover Seal Bolt Washer Bearing Spacer Bearing Bolt Lockwasher Cover O00 0U RUN hearing 7 from the impeller shaft Remove the spacer 8 and hearing 9 4 Remove the bolts 10 and lockwashers 11 Remove the cover 12 from the body Remove the seal 13 seal 14 and dowel 15 T ME 2410 233 34 5 13 13 Seal 14 Seal 15 Dowel 16 Bolt 17 Washer 18 Impeller 19 Spring 20 Body 21 Gear 22 Seal 23 Key 24 Impeller shaft Figure 5 13 Water pump exploded view 5 Remove the bolt 16 and washer 17 Remove the impeller 18 and spring 19 from the impeller shaft 6 Remove the impeller shaft from the body 20 7 Remove the gear 21 seal 22 and key 23 from the impeller shaft 24 c Cleaning Clean all components except bearings i
169. ears 5 65 99 4 USE SUITABLE TOOL TO REMOVE DRIVE GEAR BEARINGS FLYWHEEL HOUSING THRUST WASHERS ME 2410 233 34 5 49 Figure 5 19 Removing power takeoff drive gear bearings b Cleaning Clean all components in cleaning solvent Fed Spec P D 680 Dry with com pressed air or with soft lint free cloths c Inspection and Repair 1 Inspect power take off cover for chips cracks and other damage and for distortion Repair or replace as required 2 Inspect the drive gears for broken or missing teeth excessive or unevern wear and cracks chips and other damage Repair or replace as required 3 Inspect the bearings and thrust washers for excessive or uneven wear cracks pitting or other damage Replace all defective parts d Installation Reverse removal procedure and install the power takeoff drive gears and bearings in the flywheel housing 5 32 Flywheel and Flywheel Housing a Remoual and Disassembly 1 Remove the engine from the tractor 2 8 and block in position 2 Remove the starting motor as instructed in TM 5 2410 233 20 3 Remove power takeoff drive gears bearings and cover para 5 31 4 Remove torque divider para 6 5 Remove all but one of the flywheel retaining boltBE fig 9 50 Install 18NF guide bolt in the crankshaft a inch 5 67 89 S Figure 5 50 Flywheel removal and inst
170. el gear shaft ME 2410 233 34 6 107 Oil tube Bolts Bearing cage Forcing screws Ct Figure 6 107 Removing bearing cage 7 Attach a suitable hoist to support the bevel gear shaft 8 Remove bolts 2 and remove bearing cage 3 using two 13 NC forcing screws 4 as shown 9 Slide the bevel gear 1 fig 6 104 and the bevel gear shaft 5 out of the left bearing cage far enough to permit removal of bolts 4 securing the bevel gear 1 to the flange on the bevel gear shaft 5 10 Move the bevel gear shaft into the right steering clutch compartment and lift out as shown in figure 6 108 11 Lift out the bevel gear d ME 2410 233 34 6 108 Figure 6 108 Removing bevel gear shaft 12 Install the bevel gear and shaft in the reverse order of removal Adjust the bevel gear and pinion backlash as described in subparagraph d below b Disassembly and Reassembly 1 Remove the bearing cones from the shaft with a hydraulic puller a puller a bearing pulling attachment and a step plate 2 Heat the bearing cones in oil prior to reassembly 3 Remove the cups from the bearing cages using a puller two adapters and a bearing cup pulling attachment with an adapter 4 Chill cups in prior to reassembly c Inspection and Repair 1 Inspect all bearings for corrosion roughness
171. elow to check the clearance The measured distances are total diametral clearances which are twice the actual running clearances A and B figure 6 18 Refer to table 1 4 for correct diametral clearances a Equally space steel balls 4 figure 6 1 19 between blade ends in turbine flange as illustrated b Position stator 1 in turbine 2 being careful not to move steel balls 4 7 A AA SE OCH Ki SA 2 BEE SE di ME 2410 233 34 6 18 Stator 2 Turbine 3 Impeller A Dimension to be checked clearance between stator and turbine Dimension to be checked telearance between out side of flange on stator and inside of flange impeller Figure 6 18 Torque converter clearances 2410 233 34 6 19 Stator M Outside diameter of stator Turbine N Inside diameter of turbine Impeller X Outside diameter of stator inner flange Steel balls 4 1 16 in dial Y Inside diameter of impeller flange Steel rods 2 in dia 20 in long Figure 6 19 Checking torque converter clearances 6 21 c Rotate stator 1 slightly until the smooth surface of the turbine is resting on steel balls 4 d Clamp dial indicator to turbine 2 Move the stator 1 from side to side in line with the dial indicator stem and record the total movement reading on the dial indicator This reading is the total diametral clearance twic
172. embly hub and a step plate pull bearing cage 2 and cup 3 as a unit 5 Remove bearing cage holder gasket 4 and seal 5 if replacement is necessary 6 Using a puller an adapter and a bearing cup pulling attachment remove the cup 3 from the bearing cage 6 94 ME 2410 233 34 6 115 Nut 2 Metal floating ring seal 3 Holder assembly Figure 6 115 bearing cage holder assembly ME 2410 233 34 6 116 1 Holder assembly 2 Cage 3 Cup 4 Gasket 5 Seal Figure 6 116 Removing bearing cage CAUTION At assembly align the milled slot in bearing rage with the dowel in hearing cage holder assembly 1 fig 6 116 This is not a press fit and can be assembled by using a soft hammer Insert the assembly to see that hearing cage 2 has bottomed in the bearing cage holder Inspection and Repair 1 Inspect bearings for corrosion pitting and wear Replace corroded rough or worn bearings 2 Inspect holder assembly 2 fig 6 114 for cracks breaks and other damage Replace a defective or damaged holder assembly d Reassembly and Installation Reverse disassembly and removal procedure and assemble and install the bearing cage holder assembly on the final drive assembly 6 22 Floating Duo Cone Seals a Removal To remove the outer metal floating ring sea
173. emo ed after the lev ers are remo ed 3 Remove covers 1 and 4 4 Remove tube 2 and tube from under cover 1 5 Inspect ring seal 3 and preformed parking at other end of tubes Replace if damaged 6 Remove lubrication valve 5 nuts and lockwashers 7 7 Remove transmission cover 8 8 Remove the transmission hydraulic controls 6 H 9 Remove bolts 9 nuts and bolts 10 10 Install two 3 4 inch NC eyebolts and lift off the transmission Casel fig 6 4B 11 Install the transmission case the reverse order of removal 12 Tighten the transmission case to transer gear housing retaining nuts and bolts 10 fig 6 42 to the torque value given in tabIe 1 2 ME 2410 233 34 6 42 Cover 2 Tube 3 O ring seal 4 Cover 5 Lubrication valve 6 Control shafts Nuts and lockwashers 8 Transmission cover 9 Bolts 10 Nuts and bolts Figure 6 42 Preparing to remove transmission case g ME 2410 233 34 6 43 Figure 6 43 Removing transmission case d Checking Transmission Clutches With Air 1 After assembly of a power shift trans mission prior to installation of the transmission case each clutch piston can be checked with the aid of a simple tool setup and compressed air This preliminary check points out assembly problems which can be easily corrected at this stage but are very difficult to repair once the unit is installed in
174. emoval of the generator c Disassembly 1 Remove nut 29 flat washer 30 and collar 35 2 Remove screw 44 nut 42 and cover band 43 3 Scribe marks across end frames and housing for use in aligning parts in reassembly 4 Remove six hex head bolts 6 and lock washers 7 securing commutator end frame 8 to housing 5 Remove assembled washer screws 15 and remove lead 10 Mark leads and brush holders to assure correct connections are made in reassembly 6 Remove assembled end frame 8 and brush plate assembly 10 7 Remove six hex head bolts 6 and lock washers 7 securing drive end frame 34 to housing Remove end frame 8 Remove armature 40 bearings 5 and 30 and inner bearing retaining plate 37 9 Remove brushes 14 Remove four Screws 46 nuts 2 lockwashers 1 and separate brush plate assembly 10 from end frame 10 Remove four springs 13 electric contact arms 12 and flat washers 11 from brush plate assembly 10 11 Remove four screws 3 and remove end frame plate 4 12 Remove six screws 31 lockwashers 32 and remove retaining plate 33 from drive end frame 34 5 42 13 Remove dowel pins 9 only if they require replacement 14 Remove screw 45 Remove four screws 21 receptade connector 22 and leads 27 and 2 Remove leads only if they require replacement 15 Remove four screws 23 elbow 24 and elbow spacer 26 1
175. ent damage to the preformed packing during installation 6 Drive the seal support 3 into the roller until it seats in the bore Lubricate the preformed packing on support 3 with liquid soap to facilitate installation Replace the NOTE Be sure the dowel in the support 3 lines up with the milled slot in the roller 7 Install the floating ring seals in the end collar 2 and seal support 3 as outlined in 8 Replace the preformed packing on the shaft install the end collar on the shaft and install the retaining ring NOTE Lubricate the preformed packing on the shaft 1 with liquid soap before installing the end collar 2 9 Lubricate the carrier roller 10 Reinstall the carrier roller and adjust the track TM 5 2410 233 20 ME 2410 233 34 7 12 Shaft End collar Seal support Outer races Nut Bearing cone Bearing cone Lockring DAOU bb Figure 7 12 Assembling carrier roller 7 3 Track Rollers a Removal 1 Loosen the tracks as outlined in paragraph 7 1 2 Place a block approximately 12 inches high in front of the track and drive the tractor over the block until the block is beneath the front roller 3 Place a block approximately 12 inches high against the track in back of the sprocket and back the tractor until the track is resting on the block under the sprocket and the block under the idler 4 Push brake pedals down and apply brake lock 5 Remove the bolts from the e
176. ent seal and packing damage 16 Inspect walls of cylinder bore for scoring marks Any scoring marks which cannot be removed with a minimum of light honing will require replacement of cylinder assembly CAUTION Under no circumstances should welding be done on cylinder Welding on cylinder may cause enough shrinkage to cause interference between piston and cylinder wall and result in severe scoring of cylinder walls and piston d Cleaning Clean all parts with cleaning solvent Fed Spec P D 680 Dry parts with a lint free cloth ME 2410 233 34 4 35 1 Tilt cylinder 2 Bolts 3 Cap 4 Shims 5 Cylinder oil lines 6 Pin Figure 4 35 Tilt cylinder removal 4 40 a 1 huge i adt PES ME 2410 233 34 4 36 3 Bolts 1 Cylinder head 2 Piston rod 4 Bearings Figure 4 36 Preparing to disassemble cylinder 4 41 ME 2410 233 34 4 37 Nut 2 Piston rod Flats on piston rod Figure 4 37 Removing nut e Inspection and Repair 1 Inspect the cylinder for scoring pitting and wear Replace a cylinder which cannot be made serviceable with light honing CAUTION Do not weld on the cylinder assembly as scoring may result from the bore shrinkage 2 Replace all seals packing and wear rings 3 Inspect the rod end bearing for scoring damage and wear Replace as required 4 Inspect the piston rod for nicks burrs pitting distortion
177. eplacement is necessary remove the lockring 7 and press out the bearing 9 Remove No 1 sun gear 1 fig 6 5 lockrings 2 and 3 and bearing race 4 if necessary 10 The bearing race 4 can be removed if worn or damaged by using a puller and step plate 11 Inspect the bearing race 5 for wear or dam age The bearing race can be removed after removing the lock ring 3 Pull the bearing race using a bearing pulling attachment a puller and a hydraulic puller NOTE Heat the bearing races 4 and 5 in oil to facili their installation Chilling the bearings 3 and ETRA 56 will permit easier installation into the bearing cages 12 Assemble the input shaft in the reverse order of disassembly 6 49 ME 2410 233 34 6 57 1 No 1 sun gear 4 Bearing race 2 Lockring 5 Bearing race 3 Lockring Figure 6 57 Bearing race and sun gear removal 6 50 h No 1 Carrier Disassembly and Assembly 1 Position the No 1 carrier 4 f g 6 54 with the No 4 sun gear 1 on top 2 Remove No 4 sun gear 1 bolts and locks 2 and plates 3 3 Position the No 1 carrier on its side 4 pull the planet gear shaft l fig 6 5p part of the way out of the carrier and remove the No 2 inner planet gear 9 washers 10 and bearings 8 5 Pul the shaft 1 from the carrier remove the No 3 planet gears 7 complete with bearings and washers NOTE Use care to avoid loss of the balls 2 an
178. er head and valves para 5 27 10 Service the engine lubricating system and cooling system Refer to TM 5 2410 233 10 5 34 Crankshaft and Main Bearings a Remoual and Disassembly 1 Remove the engine from the tractor Refer to paragraph 2 8 Place the engine on a suitable work stand 2 Remove the water pump para 5 Remove the timing gear cover para 5 2D and the flywheel and housing 5 32 3 Place the engine on its side and remove the oil pan and oil pan platd para 5 2b and the oil pump para 5 2 4 Remove the connecting rod bearings and caps para 5 33 Push the piston and rod assemblies upward into the cylinders to clear the crankshaft 5 Wrap a heavy cloth around the number two and five connecting rod bearing sufaces on the crankshaft 6 Place a cable around the cloth and attach a hoist to the cable Tighten the cable just enough to prevent the crankshaft from moving when the main bearing caps are removed 7 Remove the bolts and washers that secure the bearing caps to the block Refer to figure 5 5 5 77 BEARINGS P WASHER CAP BOLT ME 2410 233 34 5 57 Figure 5 57 Crankshaft and main bearings 8 Grasp the bearing cap at the recessed portion and pull outward Tap the cap lightly with a soft hammer to aid in removal NOTE Mark the upper and lower caps for location 9 Place a main bearing removal tool in the drilled oil hole of the crankshaft journal
179. er on the bulldozer 3 2 ME 2410 233 3H 3 2 Lock rod Lock pin Housing Shank Pin Tooth Hinge pin Figure 3 2 Scarifier Section 3 5 The ripper is rear mounted and is hydraulically operated by a control the operator s seat General lever located to the right of TM 5 2410 233 20 ripper has three detachable teeth One two or three teeth may be used as working conditions permit The hydraulic pump supplied chapter h power for ripper raising and lowering operations 3 6 Removal and Disassembly a Refer to TM 5 2410 233 20 and remove the ripper from the tractor b Attach a hoist to cylinder assembly c Pull pins fig 343 far enough to allow cylinder remoal and still support beam assembly d Remove the pins on the opposite ends of link arm and beam assembly removed in a above e Remove partially removed pins and remove the link arm and beam assembly from ripper RIPPER PIN RETAINING BOLT ME 24 10 233 303 3 Figure 3 3 Hydraulic cylinder link arm and beam assembly removal and installation 3 3 3 7 Cleaning Clean all parts with soap and warm water Remove oily deposits with cleaning solvent Fed Spec P D 680 3 8 Inspection 1 Inspect ripper surfaces for cracks breaks excessive wear and damage 2 Inspect hydraulic hoses for breaks cracks Sect ion 3 10 General The power shift winch is a single drum unit that mounts on the re
180. er removal ect T ME 2410 233 34 6 51 Bolts and locks 2 Output shaft 5 Openings 4 Transfer gearcase Figure 6 51 Removing output shaft 6 45 11 Inspect and replace all worn parts before assembling the transmission At the time of assembly tighten the No 2 carrier to bearing cage retaining bolts 2 3 to the torque value listed in table 1 2 12 All worn damaged or warped clutch plates and disc assemblies should be replaced when installing the clutches CAUTION When installing the clutches install the clutch housing first then install the ring gear followed by a disc assembly and plate alternately subpara j below for the correct number of disc assemblies and plates for each clutch Make certain the clutch reaction pins are in their proper location and the springs are seated correctly The ring gear for the No 5 clutch should be installed with the face having the smaller outer diameter toward the input end of the trans mission The clutch housing for the No 1 dutch is installed inverted with respect to the other clutches In stallation of the clutch housings can be facilitated by using three of the long retaining bolts as guide pins 13 Complete the installation in the reverse order of removal and tighten the clutch housing retaining bolts 1 fig 6 47 to the value given in 0 Input Shaft Disassembly and Assembly 1 Remove bolts lock and retainer 1 fig 6 52 and input flange 2
181. er with track rollers Removing guards Removing tension from recoil spring stops Removing recoil spring stops Recoil recoil spring assembly Assembling recoil 8 SW s ik ee saca gua RR RE Pe RE RA dem EMER S e Sod OE Geb pub ese or ce AA Q Spring bolt guide Installing seal and ring Preaparing to remove cylinder Removing seal and ring Cylinder assembly nr 8 dis e appe he ira Kaba Oink EE i Relief valve and fill valve Preparing to remove support assembly Removing outer bearing cap Removing diagonal brace bearing Removing track roller frame Bearing cap assembly Hydraulic flow schematic diagram os e CHAPTER 1 INTRODUCTION Section 1 1 Scope This manual contains instructions for the use of direct and general support maintenance personnel maintaining the Caterpillar Model D 7F Tractor as allocated by the Maintenance Allocation Chart It provides information on the maintenance of the equipment which is beyond the scope of tools equipment personnel or supplies normally available to organizational level maintenance personnel 1 2 Maintenance Forms and Records Maintenance forms records and reports which are to be used by maintenance personnel at all Section Il 1 4 Description A general description of the Model D 7F tractor and plates is contained in TM 5 2410 233 10 A more detailed description of specific components and assembl
182. eral The alternator is a 24 volt belt driven 3 phase self rectifying brushless unit with a built in microminiature voltage regulator The only mov able part in the assembly is the rotor mounted on a ball bearing at the drive end and a roller bearing at the rectifier end b Removal Refer to TM 5 2410 233 20 for the re moval of the alternator c Disassembly 1 Remove the cover plate 2 Remove cover and gasket 3 Remove the drive end frame from the recti fier end frame d Cleaning Clean the armature and field coils of any dirt or magnetized particles To remove any grease and oil apply a light coat of cleaning solvent Fed Spec P D 680 with a brush Wipe clean and then use compressed air to remove any remaining dirt film e Inspection and Repair 1 Diode Check Check each of the six diodes by removing each diode lead from the stud and connect ing an ohmmeter using the lowest range scale to the diode lead and the case Then reverse the ohm meter lead connections to the diode case If both readings are the same replace the diode A good diode will give one high and one low reading See figure 5 35 2 CAUTION Do not use high voltage such as 110 volt test lamps to check diodes Before replacing a diode in the rectifier end frame the end frame must be separated from the drive end frame Also before replacing a diode in the heat sink or end frame it is necessary to remove the heat sink from the end frame by
183. erly Replace a defective or damaged ratchet 2 Inspect brake rods and levers for bends cracks or excessive wear clevis pin holes elongated Replace defective or damaged parts 3 Inspect support assembly for cracks breaks distortion or other damage Replace a defective or damaged support assembly c Installation Reverse removal procedure and install the brake pedal and support assembly d Adjustment Refer td paragraph 6 14 eand adjust the brake linkage 6 119 CHAPTER 7 REPAIR OF TRACK ROLLER FRAME AND TRACKS Section The track roller frame assembly 11 fig 7 1 provides a mounting for the track rollers 7 track carrier rollers 2 hydraulic track adjusting mechanisms 10 front idlers 3 recoil springs 9 and equalizer bar 6 The weight of the tractor is GENERAL frame maintains correct track roller frame alignment This construction allows each track frame to operate independently and to move up and down relative to one another by pivoting at the sprocket shaft Figure 7 2 shows cut away view of carried through the frame to the rollers 7 The track pin and bushing diagonal brace 5 welded to the inside of the Outer bearing cup Frack carrier rollers Front idler Diagonal brace bearings vU X Lie Diagonal braces 6 Equalizer bar Track roller 8 Track 9 Recoil spring IO Hydraulic track adjusting mechanism Il Track roller frame Figure 7 1 Tractor roller frame
184. ers 18 spring lie Zeg In x ME 2410 233 34 5 40 Bolt 9 Bushing li Bolt 25 Valve Washer 10 Bracket 18 Washer 20 Seat Locknut ll Rocker arm 19 Cylinder head 27 Dowel Adjusting screw 12 Washer 20 Gasket 28 Valve lifter Ring 13 Spring 21 Retainer 29 Precombustion chamber Washer 14 Washer 22 Retainer 30 Seal Spring 15 Rocker arm shaft 23 Spring 31 Seal Rocker arm 16 Push rod 24 Guide 32 Plug Figure 5 40 Cylinder head and valves exploded view 5 55 12 Install two 3 4 10 forged eyebolts and attach a hoist to the cylinder head 19 and remove from the tractor Discard the cylinder head gasket 20 13 Using a spring compressor compress the springs 23 Remove the retainers 21 Release the spring compressor and remove the retainers 22 springs 23 and guides 24 14 Remove the valves 25 and valve seats 26 Remove the locating dowels 27 15 Using a wire about 15 inches long with a hook at one end remove the valve lifters 28 from the block 16 Remove the precombustion chambers 29 and seals 30 and 31 17 Remove the plug 32 from the cylinder bead b Cleaning Remove all traces of carbon and other deposits with a clean cloth dampened with cleaning solvent Fed Spec P D 680 Blow out oil and coolant passages with compressed air C Inspection and Repair 1 Inspect the rocker arm shaft for scoring or wear If the shaft has been damaged by rocker
185. es 2 Refer to TM 5 2410 233 20 and drain the transmission lubrication system 3 Disconnect the junction block outlet line fig 6 68 and the inlet line CAUTION Cover all openings to prevent the entry of dirt or other foreign matter into the hydraulic system 4 Remove the junction block 5 Replace all damaged or worn parts 6 Install in the reverse order of removal 6 61 TRANSMISSION OIL LINE ME 2410 233 34 6 68 Figure 6 68 Junction block removal 6 11 Transmission Hydraulic System Testing and Adjustment General The hydraulic control system oil supply and 6 70 is common to the entire system Tests and adjustments can be performed using individual pressure gages or a hydraulic test box pressure taps use inch 27 NPT plugs except the transmission oil pump pressure tap E fig 6 69 and 6 70 on the filter B and the transmission lubricating oil pressure tap C Use adapter assemblies when making connections to these taps 6 62 CAUTION Al tests and adjustments must be made with the oil in the hydraulic control system at normal operating tem perature The low and high idle engine speeds for this machine are 660 rpm and 2210 rpm respectively It is important that the transmission hydraulic control linkage is properly adjusted before making any tests Refer to paragraph 6 4 for linkage adjustments
186. eservoir with oil and install pipe plug 3 If sleeve bearing was removed press a new bearing in end bell and install expansion plug 4 Assemble brush holder plate and end bell in the reverse order of disassembly but do not install brushes h Starter 1 If during disassembly install wicks and plugs following same instructions specified for end bell subparas g 1 and 2 above 2 If bearings were removed press new bearings into housings 3 Assemble starter in reverse order of disassembly with the following exceptions and addictions 4 fied windings were removed coat threads of pole shoe screws with a suitable thread sealer before installation Varnish inside of frame Assembly wicks were removed Section V ENGINE 5 23 General The engine lubricating system consists of the oil pump oil cooler and filter oil pan and lubricating passages within the engine block The oil pump provides pressurized oil to lubricate the engine components and draws the oil back to the engine oil pan 5 24 oil Pump a Reoval 1 Lower the front section of the crankcase and winding assembly Leave 0 38 inch from end of frame free of varnish 5 Partially install lever housing lever and solenoid plunger before installing drive clutch With frame in vertical position and lever housing upward install non metallic washer 95 and install drive clutch Tilt clutch to engage lugs on shift lever Seat housing making su
187. estionable Wash used parts Use a wire brush to dean dirt or rust from the bore of the seal retainers to assure they are clean and smooth Remove all oil or the protective coating from floating ring seals and retainers with a nonflammable cleaning solvent Be sure the ramp on the retainers and on the floating ring seals are dry e Check the ramps for tool marks and nicks on used parts remove dirt or rust deposits from the ramps Smooth the surface with emery cloth f Install new toric sealing rings or floating ring seals Scat the toric sealing ring uniformly in the relief of the ring seal Be sure the toric sealing ring is not twisted It must set straight against the lip which keeps it from falling off the floating ring seal g Floating seal installation tools are available for various size seals A typical in stallation tool is shown in figure 2 9 ME 2410 233 34 2 9 Figure 2 9 Floating seal installation tool h If an installer tool is not used install the toric sealing ring and floating ring seal as an assembly by pressing on the toric sealing ring 2 10 Use finger pressure only Be sure the toric scaling ring is seated uniformly in the recess of both the floating ring seal and the retainer Make sure it sets in the bore straight and against the lip that keeps it from falling out of the retainer DO NOT USE A SCREWDRIVER OR STICK TO ASSEMBLE THE TORIC SEALING RING IN THE RETAINER i Before assemblin
188. etween the control levers and the transmission 53 Nut 34 Lockwasher 35 Nut 36 Nut 31 Lever 38 Key 30 Washer 40 Nut 4 End 42 Nut 435 Lockwasher 44 Nut 55 clamp 45 Bolt 56 46 End 57 Washer 4 Nut 58 Seal 48 Bolt 59 Bearing 49 Lever 60 Bearing 50 Key 61 Seal 5l Bolt 62 Washer 32 Lockwasher 63 Shaft 53 Bolt 64 Fitting 51 Lockwasher 65 Support ME 2410 233 34 6 71 Figure 6 71 Transmission control linkage exploded view 6 67 Section Il 6 13 General This section contains information on the brakes steering clutches steering clutch hydraulic controls and bevel gear 6 14 Brakes a General Two contracting band type brakes which operate independently of one another are used to supplement the action of the steering clutch or to stop the tractor Either or both brakes can be held in the locked position by the brake lock pawls 7 These pawls are actuated by a single hand lever The operation of both brakes is the same When the brake pedal 8 is depressed the brake control linkage moves the brake control lever 5 forward The brake shaft 4 and brake lever 3 rotate and pull up on the brake link 9 This flattens the brake toggle links 16 and causes the brake strut support lever assembly 10 and the 6 68 STEERING CLUTCHES BRAKES AND BEVEL GEAR brake lever assembly 14 to rotate about the brake lever shafts 11 and 12 The struts 15 and 17 are forced against the l
189. eup valve body 3 c Remove bolts 1 and 6 and remove covers 2 and 5 d Remove springs 3 99 4 9 and valves 4 1 Bolts 31 2 Cover 3 Valve body 4 Bolts 3 5 Cover 6 Bolts Figure 1 8 Makeup valve body removal ME 2410 233 34 4 8 4 13 2410 233 34 4 9 4 Makeup valves Preformed packing 2 Cover 5 Valve body 3 Springs 6 Cover Figure 4 9 Makeup valves disassembled e Control Lever 1 Removal a Remove the hydraulic tank from the tractor and remove the tank assembly from bottom plate para 4 P b Remove and inspect pin 1 fig 4 10 c Loosen bolt 3 and remove lever 4 d Remove bolts 5 and remove lever assembly 2 e Remove key 2 fig 4 11 and washer 1 f Remove lever 3 and adapter 4 91 Figure 4 10 Control lever assembly sheet 1 of 2 ME 2410 233 34 4 10 T 1 Pin 2 Lever assembly 3 Bolt 4 Lever 5 Bolt 4 Figure 4 10 Control lever assembly sheet 2 of 2 4 ME 2410 233 34 4 10 2 8r VIEW Washer 5 Housing Key 6 Bearings Lever 1 Lip type seal Adapter 8 Bearing Figure 4 11 Control lever disassembly ME 2410 233 34 4 11 f Cleaning Clean all parts with cleaning solvent Fed Spec P D 680 and dry with clean com pressed air or wipe dry using a lint free cloth g Inspection and Repair 1 Inspect valve body and
190. ever 4 fig 4 10 on control lever 3 4 11 until it is snug but not tight against washer 1 then tighten bolt 3 fig 4 10 Check for binding 2 Reassemble make up valves and springs Torque bolts 1 and 6 Figure 4 8 to 60 2 ft 165 Torque bolts 4 to 60 2 ft lbs 3 Reassemble the check valve using Tfigure 7 as a guide Install valve in housing 4 Reassemble and install the control valve usinf figures 4 and 4 6 as guides To obtain the correct thickness of shims required assemble and install the valve spool Install housing without shims Tighten bolts 5 figure 4 12 until the shoulder in the housing just contacts retainer 2 and starts to compress the spring Hold spacer 3 figure 4 12 tight against the valve body and measure dearance A between housing 2 and spacer 3 with a thickness gage Install shims 4 with a thickness equal to this measurement ME 2410 233 34 4 12 S pool Housing Spacer Shims Bolts 2 Clearance to be measured PUBWNE Figure 4 12 Measuring clearance i Installation Reverse removal procedure install bulldozer control valve and torque bolts 3 7 8 and 12 figure 4 4 0 60 2 ft lbs 4 4 Bulldozer Relief Valve a General The bulldozer relief valve 1 fig 4 13 mounted on the bottom plate of the hydraulic tank prevents excessive pressures from being imposed on the large section of the two section pump and other com
191. ever Distance between front face of seat support and rear face of brake pedal 17 61 17 81 in Final drive Flange to final drive press fit tons 35 41 Dimension between face of flange and th shoulder of the pinion shaft when pressed on to 35 40 tons 0 124 Sprocket to hub press fit tons 60 6 Dimension bet ween face of sprocket and the en of the splines on the final drive hub whe pressed on to 60 65 tons 0 44 in Sprocket shaft to case press fit tons 55 6 Sprocket shaft must straight within 0 125 in Continued Manufacturer s dimensions andtolerancesin inches 0 860 0 820 Desired clearance Maximum 0 900 0 940 Maximum allowable wear and clearance 0 006 1 9 Table 1 5 Track Roller Frame Units Repair and Replacement Standards Component Track roller frame Inner bearing clearance Minimum thickness of wear strip for front idler 0 125 in Clearance between yoke and wear plate Track rollers Shaft clearance End clearance Permissible bend in shaft 0 005 in Track carrier rollers Adjustment Tighten nut until resistance is felt then back off to nearest locking position End clearance Front idlers and recoil springs Shaft clearance End clearance Recoil spring outer free length Recoil spring free length Recoil springs from rear face of front pilot to front face of rear pilot assembled length 24 50 in Recoil springs from rear face of front pilot to front face of rear pi
192. ever housing until housing and attached parts are free Remove preformed packing 48 9 Remove clutch assembly 94 and non metallic washer 95 10 Remove inspection plug 13 and gasket 12 Place solenoid plunger into relay to prevent plunger from rotating and loosen hex locking nut 5 47 87 Remove nut and guide and pull plunger and attached parts from lever housing 11 Using retaining ring pliers remove retaining ring 80 retainer 79 lever spring 78 retainer ring 77 bellows 76 and flat washer 75 from plunger 74 12 Remove retaining ring 80 and remove lever shaft 89 and lever 90 Remove seals 88 and 91 from shaft 13 Disassemble lever housing only if parts require replacement Remove oil seal and press out sleeve bearing in lever housing Remove pipe plug 85 and wick 86 14 Remove hex nut and lockwasher securing connector to solenoid switch 72 Remove four assembled washer screws 73 securing relay to frame and slide relay out of connector 15 Remove hex nut 1 lockwasher 2 connector 3 hex nut 1 flat washer 4 two non metallic washers 5 and bushing 6 16 Do not remove field coil assembly unless inspection indicates coils are defective Remove two pole shoes screws 14 from each of the six pole shoes 11 Remove field coil assembly 9 ter minal screw and bushing Unsolder terminal screw from coil assembly 17 Remove commutator end insulator
193. fixture plate installed 3 Remove the small cover from the front of the timing gear housing fig 5 42 Remove the accessory drive gear retaining nut and washer 4 Separate the gear from the accessory drive shaft 5 Rotate the accessory drive shaft as necessary to permit installation of the timing fixture plate 6 Insert the shaft through the gear Tighten the gear retaining nut to a torque of 90 to 110 foot pounds and remove the timing plate Install the fuel injection pump housing para 5 11 5 29 Timing Gears and Cover a Removal and Disassembly fig 5 44 1 Remove the engine from the tractor 2 8 and block in position 2 Remove the water pump para 5 6 and generator as instructed in TM 5 2410 233 20 Remove the fan belts para 5 b 3 Loosen the bolt 1 approximately five turns 4 Using a hydraulic puller pull the crankshaft pulley assembly from the crankshaft 16 Bolt Washer DBolt Lockwasher Vibration damper Pulley Dolt Lockwasher Support Bolt Lockwasher Oil pan Bolt Washer Lockwasher Timing gear cover Gasket e lt lt SE lt l x to ty te ty te 121201212 ME 2410 233 34 5 44 Seal Nut W asher Cover Gasket Nut Accessory drive gear Washer Retainer Bolt Lock Accessory drive idler gear Plate Spacer Bolt Lock Camshaft gear Figure 5 44 Timing gears and cover exploded view 5 61 5
194. flywheel housing TM 5 2410 233 20 8 Install the engine in the tractor para 2 B 5 33 Pistons Connecting Rods and Cylinder Liners a Removal and Disassembly fig 5 56 1 Drain the engine lubricating oil and coolant TM 5 2410 233 10 2 Remove the cylinder head and valves para 5 2 3 Remove carbon deposits from the inside top surfaces of the cylinder liner 4 Remove the cylinder block inspection covers or the oil pan to gain access to the connecting rod bearings 3 and 5 Turn the crankshaft until the nuts 1 are accessible 5 Remove the nuts 1 from the bolts 4 and remove the cap 2 and bearing lower half 3 Rotate the crankshaft and remove the bolts 4 and upper bearing half 5 5 75 2410 233 34 5 56 Nut 9 Piston 2 Cap 10 Bearing 3 Bearing lower half 11 Piston ring 4 Bolt 12 Piston ring 5 Bearing upper half 13 Liner 6 Retaining ring 14 Ring Piston pin 15 Block 8 Connecting rod Figure 5 56 Piston and connecting rod exploded view 5 76 6 Rotate the crankshaft to place the piston to be removed at top dead center Push the con necting rod upward until the piston rings are out of the cylinder Lift out the piston and connecting rod assembly 7 Remove the piston pin retaining rings 6 from the piston pin 7 and press out the piston pin Separate the connecting rod 8 from the piston 9 Remove the bearing 10 from the connecting rod 8 if replacement i
195. frame by swinging the front end of the roller frame away from the tractor and guiding the track carrier roller support 4 off of the equalizer bar 2 9 Inspect the bearings fig 7 40 for damage or excessive wear Replace if necessary NOTE When replacing the bearings align the dowel holes in the bearings with the dowels contained in the bearing cap and diagonal brace b Inspection and Repair Inspect the track inner bearing for scoring pitting and wear The specified bearing clearance is 0 012 0 015 inch The maximum allowable clearance is 0 040 inch Replace excessively scored pitted or worn bearings c Installation 1 Install the track roller frame in the reverse order of removal 2 Install and adjust the track subpara 7 7 e DOWELS ME 2410 233 34 7 39 1 Track roller frame outer bearing 2 Equalizer bar 3 Track roller frame 4 Track carrier roller support BEARINGS MENO C ME 2410 233 34 7 40 Figure 7 39 Removing track roller frame Figure 7 40 Bearing cap assembly 7 19 1 Fire Protection 5 4200 200 10 A 2 Lubrication C91001L LO 5 2410 233 12 1 2 and 3 A 3 Painting TB 746 93 1 TM 9 213 A 4 Cleaning C68001L SB 725 7930 1 A 5 Welding TM 9 237 TM 5 2410 233 10 A 6 Maintenance TB ENG 364 TM 5 2410 233 20 TM 5 2410 233 34 TM 38 750 APPENDIX A REFERENCES Hand Portable Fire Extinguishers Approved for Army Users Fuels Lubric
196. g cage 1 fig 6 140 with oil drain hole at bottom b Disassembly and Assembly 1 Position the final drive pinion assembly as shown in figure 6 142 2 Remove the nut 1 bolt 3 and lock 2 6 112 ME 24102 233 34 60 142 Nut 2 Lock 3 Bolt Figure 6 142 Preparing to remove pinion flange CAUTION Before attempting to remove flange 2 fig 6 143 install nut 1 flush with the end of the pinion gear shaft 4 to prevent the pinion flange from becoming damaged while being removed under hydraulic pressure 3 Using a hydraulic puller and a puller with two 34 inch 10 NC bolts approximately 7 inches long remove flange 2 fig 6 143 NOTE The final drive pinion flange can be removed with the pinion installed using the same tool group 1 Nut 2 Flange 3 Cage 4 Pinion gear shaft Figure 6 143 Removing pinion flange 4 Remove bearing cage 1 fig 6 144 outer race and roller assembly 2 and seal 3 as a unit 5 Using a Ya inch 20 NC bolt remove dowel 4 and remove outer race and roller assembly Cage 2 Metal floating ring seal 3 Outer race and roller assembly 4 Dowel Figure 6 144 Removing outer race and roller assembly NOTE Chill the outer race and roller assembly before in stallation When installing align the hole in the outer race and replace dowel 4 6 Remove mating seal in pinion flange using a seal installer tool 7 When installing the final dri
197. g floating ring seals together wipe faces of seals with lint free tissue to remove any foreign material and fingerprints Place one drop of oil on the cleaning tissue and coat the sealing surfaces of the seals Be careful to prevent any oil from contacting the toric sealing ring or its mating surfaces ME 2410 233 34 2 10 1 Metal floating ring seal 2 Toric sealing ring Figure 2 10 Floating seals installed with metal floating ring seal and toric sealing ring properly positioned 2 Lip type seals a Generally the toe or spring loaded lip of an oil seal faces the oil being sealed or the oil having the higher pressure The toe or lip of a grease seal faces away from the lubricant being sealed Unless otherwise specified use the preceding rules for installing lip type seals fig 2 11 HEEL SEALING ELEMENT GARTER SPRING FLEX SECTION LIP SHAFT CONTACT EDGE TRIM SURFACE GARTER SPRING GROOVE BOND AREA CASE ME 2410 233 34 2 11 Figure 2 11 Lip type seal b The main parts of a lip type seal are the case sealing element and garter spring The picture illustrates the construction of a simple lip type seal The cross sections show the terms heel 2 12 and toe used to identify the sides of various types of seals ME 2410 233 34 2 12 Figure 2 12 Hed and toe type seals Lubricate the lips of lip type seals before installation Use the same type lubricant in which
198. ge pump Bearings Pilot bearing Output shaft bearing Bolt Bolt 1 d sel Jp q i 5 NL n Si 7 224 N RASEN E YYY mm Y Se NE B p PERS 2 Gei s Ge GE SE Bee M S i o REN in 22274 Ip z 222 MAAS SF A 1 S LIC LQZ SSS S Z SE eg I X Ike ps 2 SSS 222 E 722222 See A Ed 4 es E EED J r 3 K fe PV k k EXEEZZ SH 2 220 Zzzz73 M 4 q f 11 NI 9 2 aoe NS 3 MES WWW 2 Com lt N ra SW N SEE d E ey S S SCH z Wees N T 14 NUIT 1 NS iS AES SS Z2 SAAS Ai meest NS NU el 4 L H J 222222222222222 1 22222222222222 0 2410 233 34 6 2 Transfer case Upper compartment of transmission case 1 2 3 Transmission input shaft 1 Transmission output shaft Transfer gear D Bevel pinion Figure 6 2 Cross sectional view of transmission 6 2 Universal J oint a Removal 1 Remove the floor plates para 2 8a and the brake pedals a
199. ghten the bolt on each tool to compress seal washers Spacers will be flush with inner face of links when seal washers are properly compressed 7 Force the track together until the spacers and seal washers are held in place by the track links NOTE If master pin is to be driven in with a sledge hammer move the machine forward and drive the track together until the spacers and seal washers are held in place by the track links 8 Remove the holding tools Align the holes and install the master pin 9 Install the bolts in the track shoes Refer to table 1 2 for track shoe bolt torque NOTE Install the track shoe bolt nut with end having the 0 156 inch corner radii against the track link 10 Adjust the track para 7 7 7 2 Track Carrier Rollers a Removal 1 Loosen the track as outlined inrparagraphi 7 1 2 Lift the track to provide clearance for removal 3 Remove the bracket fig 7 8 and roller as an assembly by removing the 4 bracket to frame mounting bolts Figure 7 8 Preparing to remove carrier rollers b Disassembly 1 Remove the cover 6 7 9 lockring 5 and nut 4 from the roller 3 2 Loosen the damping bolts 2 and drive a suitable metal wedge into the slot of bracket 1 to free the carrier roller shaft and remove the bracket 3 Remove the lockring 4 fig 7 10 end collar 3 and metal floating ring seals 2 CAUTION Tape the seals 2 together so they will b
200. gure 5 28 Turbocharger mounting fixture and adapter plate 2 Note and mark related positions of parts as illustrated i 8 COMPRESSOR HOUSING 1 RELATED POSITION MARKS FOR REASSEMBL Y 6 NUTS 2 2 RELATED POSITION MARKS FOR RE ASSEMBLY 4 CLAMP 3 NUTS 2 a ENEE 5 TURBINE HOUSING A MARKING RELATION OF PARTS ME 2410 233 34 5 29 Figure 5 29 Matchmarking turbocharge parts rdation 3 Remove nut 1 and clamp 2 4 Remove nut 5 while holding turbine securing compressor cover 3 and remove the wheel 9 as illustrated in figure 5 31 housing and packing 4 5 35 96 65 24 TI Figure 5 30 Turbocharger disassembly and reassembly ME 2410 233 34 5 30 Kev to 5 30 Nat 2 V clamp 3 Cover 4 Preformed packing 5 Nut 6 Nut Clamp 8 Turbine housing 9 Turbine wheel and shaft 10 Wheel assembly 11 Retaining ring 12 Insert 13 Preformed packing IMPELLER RETAINING NUT D 4 E gel 14 Dirt deflector ring 15 Seal 10 deflector 17 Thrust bearing 18 Retainer 19 Ring 20 Shaft ring 21 Sleeve 32 Bearing 23 Retaining ring 24 Shroud 25 Seal ring 20 Bearing housing WRENCH d WRENCH gt trap aram V lt Figure 5 31 Turbocharger retaining nut 5 Remove nut 6 fig 5 30 expand clamp 7
201. he wires in position 2 Turn the crankshaft one complete revolution 3 Remove the bearing cap and measure the thickness of the compressed wire using a micrometer Clearance should be 0 0030 to 0 0059 inch Replace bearings if the proper clearance is not obtained f Crankshaft End Clearance Check 1 Push the crankshaft as far as it will go to one end of the cylinder block 2 Using a thickness gage measure the clearance between the machined face of the crankshaft flange and the flange of the lower half of the rear main hearing End clearance should be 0 0025 to 0 0145 inch 5 35 Cylinder Block a Removal and Disassembly 1 Remove the engine from the tractor para 2 8 2 Remove the water pump para 5 6 generator TM 5 2410 233 20 and fuel transfer pump para 5 3 Remove the fuel injection pump para 5 1 11 transmission oil cooler TM 5 2410 233 20 oil pump para 5 24 and oil pan and oil pan plate para 5 23 4 Remove the timing gears and cover 5 29 flywheel and flywheel housing 5 32 cylinder head and valves para 5 27 pistons connecting rods and cylinder liners para 5 3B crankshaft para 5 32 and camshaft para 5 3p 5 Remove the inspection covers from the block b Cleaning Steam clean the block Wipe with a cloth dampened with solvent Remove all corrosion and scale from water jackets and passages using high pressure water and steam Flush oil passages w
202. he current regulator setting it is necessary to keep the voltage regulator from operating so that the generator out put can increase to the value for which the current regulator is adjusted and thus cause the current regulator to operate Regardless of the method used disconnect battery cable from the regulator anc connect an accurate ammeter in series between these junctions The three methods of preventing voltage regulator operation are CAUTION Never use the cranking motor for more than 30 seconds at a time without pausing to allow the cranking motor to cool 1 Battery discharge method Partly dis charge the battery by cranking the engine for 30 seconds with the lights and accessories turned on Start the engine and allow the generator output to increase to its maximum Since the battery voltage recovers very quickly this method requires prompt action 2 Load method If a load approximating the current regulator setting is placed across the battery during the time that the current regulator setting test is made the voltage will not increase sufficiently to couse the voltage regulator to oper ate This load may be provided by a carbon pile or other suitable resistance 3 Jumper lead method If the regulator cover is removed and a jumper lead placed across the volt age regulator contact points the voltage regulator cannot operate Consequently the generator output will increase to its maximum as determined by the current reg
203. he gear from the camshaft 6 If camshaft bearings are to be removed remove the flywheel housing para 5 31 and press the bearings out of the block b Cleaning 1 Clean the camshaft thoroughly with cleaning solvent Fed Spec P D 680 Blow out the oil holes with compressed air Dry with clean lint free cloths or with compressed air 2 Clean bearings as instructed in paragraph 2 6 Inspection and Repair 1 Using a magnetic particle technique inspect the camshaft for cracks Replace if any cracks are detected 2 Inspect the camshaft for roughness scoring scratches grooves or wear Replace if worn or damaged Measure the camshaft bearing sur faces using a micrometer If any diameter is less than 1 40 inches replace the camshaft 3 Inspect the camshaft bearings for wear and surface damage Repair if possible or replace bearings as required 4 Inspect the camshaft gear for broken teeth cracks scratches scoring and wear Repair or replace as required d Reassembly and Installation 1 Install the camshaft bearings in the cylinder block Align the oil holes in the front bearing with the oil hole in the block Install the front and rear bearings so that there is a l inch clearance between the cylinder block and the bearing 2 Install the flywheel housing if removed 3 Install the gear to the camshaft Secure with the lock and four bolts 4 Install the camshaft and camshaft gear in the bl
204. he windings If all other electrical checks are normal and the generator fails to supply rated output shorted stator windings are indicated To replace the stator separate drive end frame from rectifier end frame and pull leads and grommet through hole Place grease on grommet and pull into hole during assembly 3 Regulator replacement or repair fig 5 35 2 NOTE Some 24 and 32 volt regulator models have a permanently connected separate transis tor mounted onto the rectifier end frame The installation of the regulator is the re verse of removal Disconnect the three identically colored regulator leads Then regulator may be replaced by removing the attaching screws and disconnecting the regula tor lead from the heat sink See fig 5 35 3 NOTE Some 24 and 32 volt regulator models have a permanently separated transistor mount ed onto the rectifier end frame Regulators may differ in appearance but the various types are completely interchangeable CHECK FOR GROUNDS CHECK FOR SHORTS OHMMETER Geet AND OPENS CHEC OHMMETER OHMMETER OHMMETER OHMMETER CHECK FOR OPENS CHECK FOR GROUNDS OHMMETER P i LM ME 2410 233 34 5 35 2 Cl Figure 5 35 2 Electrical checks of alternator DIODE D4 CAPACITOR CI RESISTOR R5 TAP SWITCH AND TRANSISTOR TR2 HEAT SINK ASSEMBLY R4 UNDERNEATH DIODES D1 D2 D3 TRANSISTOR TRI UNDERNEATH A PANEL BOARD ASSEMBLY QPP IDE OF KEER
205. heck valve Bolts Oil supply line woe Figure 6 36 Check value removal 4 Install the relief valve in the reverse order of removal using new preformed packings b Disassembly and Reassembly Refer td figure 6 37 to disassemble and reassemble check valve 6 37 ec Figure 6 37 Check valve disassembly ME 2410 233 34 6 37 Inspection and Repair 1 Inspect valve housing and valve for nicks burrs pitting and wear Examine the valve seat and valve for damage and proper seating If wear or damage replace the assembly 2 Inspect the check valve spring for damage and proper tension The check valve spring should exert 5 75 0 50 pounds of force when compressed to 2 00 inches Free length after test should be 3 281 inches Spring diameter is 0 50 inch Replace defective or weak spring NOTE The m inimum operating pressure for the steering clutch control valve clutch disen gaged engine at low idle is 20522 15 psi exists complete valve 6 9 Transmission a General 1 The power shift transmission planetary gearing and five hydraulically actuated clutches to provide three forward and three reverse speeds 2 The five transmission clutches are of the multiple disc type and are contained in separate housings surrounding the ring gears of the trans utilizes mission The clutches have alternate discs 5 Lfig _ 6 38 and plates 3 The discs 5 have internal teeth which mesh with external
206. her damage 2 Repair by welding TM 9 237 or replace part c Installation Reverse removal procedure and install the front idler yoke Adjust front idler ac cording to subparagraph d below d Front Idle Adjustment 1 Install shims 1 fig 7 24 and 3 between collars 2 and bearings 8 to align the idler with the track rollers and keep clearance B between the yoke and the plate with tolerances given in NOTE Removing shims 1 or 3 from one end bearing will tilt the top of the idler away from that bearing Adding shims to one end bearing will tilt the top of the idler toward that end bearing 2 Install enough shims 4 and 5 between bearings 8 and guide plates 6 and 7 to provide clearance A between guide plates 6 and 7 and the frame 9 Refer to for correct clearance 3 Shims 4 and 5 are used to shift tbe idler from side to side to align idler and track properly 4 5 SASSY ES we 6 __ Wy 1 A B S Ni Y A 2 2 2 2 2 2 2 2 2 2 2 2410 233 34 7 24 Shims Collars Shims Shims Shims Guide plate Guide plate End bearings Frame Dimension to be checked Dimension to be checked gt 2 ei Z d Q L i Figure 7 24 Aligning idler with track rollers 7 6 Recoil Springs a Removal WARNING Be certain the hydraulic pressure in the track adjusting mechanism is com pletely relieved and the cyli
207. hese stresses on eyebolts 3 Some removals require the use of lifting fixtures to obtain proper balance and to provide safe handling 4 If a part resists removal check to be certain all nuts and bolts have been removed and that an adjacent part is not interfering INCORRECT ME 2410 233 34 2 1 Figure 2 1 Lifting beam c Disassembly and Assembly When assembling a machine complete each step in turn Do not partially assemble one part and start assembling some other part Make all adjustments as recommended Always check the job after it is completed to see nothing has been overlooked d Service Tools 1 Puller assembly 2 or 3 arm Two or three arm puller assemblies figs 2 and 2 4 can be used to remove gears bearing cages hubs bearings shafts etc 1 8 IN MM THICK FLAT WASHER ME 2410 233 34 2 2 Figure 2 2 Lifting ede PULLER ME 2410 233 34 2 3 Figure 2 3 Puller assembly 2 Bearing pulling attachment Bearing pulling attachments fig 2 4 can be used with forcing bolts to remove shafts bearings gears etc They can be used with Push Pullers to provide a variety of pulling combinations BEARING PULLING ATTACHMENT FORCING BOLTS ME 2410 233 34 2 4 Figure 2 4 Bearing pulling attachment e Pressing Parts 1 When pressing one part into another use Fed Spec TT A 580 Anti Seize Compound to lubricate the m sting surfaces 2 Assem
208. him 8 Shim 9 Packing 10 Screw 11 Lockwasher 12 Head 13 Packing 14 Washer 15 Seal assembly 16 Piston 17 Ring 18 Nut 19 Fitting 20 Oylinder assembly St t Figure 4 41 Ripper lift cylinder exploded view ME 2410 233 34 4 41 CHAPTER 5 REPAIR OF THE POWER PLANT Section l COOLING SYSTEM 5 1 General Cooling system components are the radiator water pump water temperature regulator oil cooler and lines fittings and passages Coolant pumped from the outlet side of the water pump flows directly into the front of the cylinder block and to the oil cooler The coolant passes through the oil cooler returns to the block and flows around the cylinder liner walls to the precombustion chambers The coolant then flows to the water temperature regulator When the WATER PUMP WATER RADIATOR ENGINE OIL COOLER THERMOSTAT coolant becomes sufficiently warm the regulator opens to permit the coolant to return to the radiator The coolant is cooled by air forced through the radiator core The cooling system is pressurized to permit safe operation at tem peratures higher than the normal boiling point prevent cavitation in the water pump and reduce the possibility of air pockets in the coolant passages Refer to figure 5 1 for the cooling system schematic diagram WATER DIRECTOR TRANSMISSION OIL COOLER ENGINE BLOCK ME 2410 233 34 5 1 Figure 5 1 Cooling system schematic diagra
209. houlder of the relief valve will contact the underneath side of the guard Grease should then escape through slot 4 in the lower section of threads ME 2410 233 34 7 4 l Relief valve 2 Vent holes 3 Fill valve 4 Slots A and B Unthreaded sections Figure 7 4 valve and fill valve 6 Loosen fill valve 3 until the unthreaded section B is exposed above the flange of the hydraulic cylinder The hexagonal shoulder of fill valve 3 will contact the underneath side of the guard Grease should then escape through slot 4 in the lower section of the threads NOTE Detailed information concering the hydraulic track adjusting mechanism can be found paragraph 7 7 7 Position the master pin above and slightly behind the front carrier roller 8 Install the tools 7 9 and press the master pin from the links NOTE An alternate method for master pin removal is as follows Place a block approximately 12 inches high in front of the track and drive the machine forward so the track shoe below the master pin rides on the block then using a suitable drive and a sledge hammer drive the master pin out of the links REMOVAL TOOLS 5 m d TRACK LINK y n FRONT CARRIER MOR RoLLER Figure 7 5 Master pin removal group 7 3 9 Separate the track and remove fig 7 6 and coned disc seal washers from links 10 Back the machine slowly allowing the trac
210. hreads are disengaged c When assembling safety valve apply 6 28 Liquid Lock on threads of valve stem 5 install valve stem into valve 4 and tighten to torque value listed in table 1 2 Do not hold valve 4 by finished lands 5 Speed selector valve Speed selector valve stem 1 fig 6 28 can be removed from valve housing 2 if necessary d Linkage Adjustment e Valve stem 2 Valve housing Figure 6 28 Speed selector value 1 Internal adjustment a When hydraulic controls are installed in transmission control linkage should be adjusted to position directional valve stem 5 6 29 safety stem 3 and speed selector valve stem 2 properly in their selective housings b With levers 1 and 4 in positions shown adjust threaded drag links in ends of valve stems so end of first land of each valve is flush with machined face of valve housing the end of first land of valve stem 2 must be flush with surface A 3 with surface B and 5 with surface C 2 External adjustment WARNING Do not adjust linkage with engine running 2 3 4 Qu W are Sep D 2 en 3 g PM e H W DW v a AS 11 2410 233 34 6 29 Loosen clamp bolt in lever 6 fig 6 3 b Loosen bolts in clamps 2 and 4 a
211. hrough an inlet port from the fuel filter The pump plungers and lifters are actuated by lobes on the pump camshaft The lifters are held against the cam lobes by springs 3 Each pump measures the amount of fuel to be injected into the cylinder and delivers it to the fuel injection nozzle in the precombustion chamber 4 The amount of fuel pumped per stroke is varied by the turning of the plunger fig 5 19 in the pump barrel 6 The plunger is turned by governor action through the circular rack 12 which turns the gear segment on the bottom of the pump plunger 9 b Removal Refer td figure 5 18 1 Disconnect the linkage at the governor control lever 2 Disconnect the fuel injection lines at the housing Cap or plug openings 5 21 eg e E se o LINE GOVERNOR MOUNTING 25 FUEL INJECTION LINES I FUEL 8 i 3 a FUEL INJECTION PUMP MOUNTING BOLTS IK MF 24 10 7233 34 5 18 Figure 5 18 Fue injection pump removal and installation 3 Disconnect the oil line at the housing Cap or plug openings 4 Remove the bolts which secure the fuel injection pump housing to the bracket Remove the fuel injection pump housing and governor as an assembly 5 Remove the bolts securing the governor housing to the fuel injection pump housing and Separate the housings Remove the gasket from the mounting fac
212. ic cylinder packing can be the result of worn cut and or distorted packing Leakage can often be stopped by removing shims 2 fig 2 21 located between retainer 1 and the cylinder head this will allow the packing to be compressed against the rod when the retainer is tightened 2 Remove the bolts securing retainer to the cylinder head Move the retainer away from the cylinder head to allow the shims to be cut and removed 3 Remove one shim 2 install retainer 1 and operate the cylinder If leakage is still apparent repeat the procedure If the cylinder leaks after removing two shims remove and disassemble the cylinder and replace the packing NOTE Remove only the shims which measure 0 010 in 2 54 mm in thickness The thicker shims should not be removed to adjust the packing 2 10 ME 2410 233 34 2 21 Retainer 2 Shims Figure 2 21 Removing cylinder head shims a Place retainer 3 fig 2 22 on rod 6 Separate and oil all the rings of packing 2 Place the packing on the rod so the open part of the V will be facing toward head 1 when the head is installed Be sure rubber pressure ring 4 is located as shown 4 5 2410 233 34 2 22 Head 2 Packing 3 Retainer 4 Rubber pressure ring 5 Shims 6 Piston rod Figure 2 22 Packing and shims installed b Place the head on the rod and insert one ring of packing at a time into the head c Tap packing firmly into the head
213. ies is contained in the applicable sections of this manual Detailed descriptions of the components of the Model D 7F tractor are provided in the applicable maintenance paragraphs of this manual 1 5 Differences Between Models This manual D7F Tractor M odel covers only the Caterpillar Model No known differences exist for the covered by this manual 1 6 Tabulated Data a Identification The major identification plates of the tractor are described in TM 5 2410 233 20 GENERAL maintenance levels are listed in and prescribed by TM 38 750 1 3 Reporting of Errors Reporting of errors omissions and recom mendations for improving this publication by the individual user is encouraged Reports should be submitted on DA Form 2028 Recommended Changes to Publications and forwarded direct to Commanding General U S Army Mobility Equipment Command ATTN AMSME MPP 4300 Goodfellow Blvd St Louis Mis souri 63120 DESCRIPTION AND DATA b Nut and Bolt Torque Data Tables 1 1 and 1 2 list the standard and specific nut and bolt torque data for the D7 F tractor c Repair and Replacement Standards Tables 1 3 1 4 and 1 5 list manufacturer s dimensions tolerances clearances and the maximum allowable wear clearance d Electrical System Schematic Diagram Figurd 1 1 shows the schematic wiring diagram for this tractor e Hydraulic System Circuit Diagram F 0 1 Located in back of manual shows the hydraulic fl
214. ig 6 14 down flush with the face of the flange assembly ME 2410 233 34 6 13 Bearing outer race 1 2 Carrier 3 Ring seals Figure 6 13 Carrier disassembly SI 9 Figure 6 14 Ring gear removal ME 2410 233 18 Compress the retaining ring and remove the ring gear 19 Remove the retaining ring 20 Remove turbine retaining ring 64 15 21 Heat the rotating housing and turbine assembly fig 6 15 in oil at a temperature of 280 F 3000 F for ten minutes CAUTION Do not exceed 300 F or damage to the turbine may result 22 Immediately after heating the rotating housing and turbine assembly turn 180 and install two in 16 NC forcing screws in the flange assembly separate the turbine spacer and flange assembly from rotating housing LT 9 Figure 6 15 Turbine flange assembly and rotating housing removal ME 2410 233 34 6 15 23 Remove the bearings fig 6 1b from flange assembly BEARING FLANGE ASSEMBLY ME 2410 233 34 6 16 Figure 6 16 Flange assembly 24 Remove the seal ring from carrier on the 26 Turn the housing over and drive the flange assembly bearing assembly and retaining ring ont of housing 25 Remove the bearing assembly retainer 27 Remove the retaining ring from bearing mounting bolts fig 6 17 and remove retainer assembly 6 18 ROTATING HOUSING
215. ine wheel forcing it and the impeller to rotate The gases then exhaust through the outlet opening Refer to figure 5 26 for an exhaust flow diagram EXHAUST MANIFOLD INTAKE MANIFOLD ENGINE CYCLINDER INLET OPENING AFTERCOOLER TURBINE OUTLET IMPELLER OPENING ME 2410 233 34 5 26 Figure 5 26 Engine exhaust flow diagram 3 Air drawn through the air cleaner enters around the center of impeller through the inlet opening The rotating impeller compresses the air and forces it to the intake manifold and cylinder head b Removal 1 Remove the hood para 5 2 and the engine upper right guard assembly TM 5 2410 233 20 2 Remove air cleaner body para 5 1b 3 Remove turbocharger oil supply line fig 5 27 and oil drain line 4 Remove the turbocharger air outlet pipe 5 Install a inch 16NC eyebolt in top of turbocharger 6 Attach a hoist and remove the four tur bocharger mounting bolts and nuts and remove the turbocharger 5 33 GL Figure 5 27 Turbocharger removal and installation Sid gt ji d Gg oe C Disassembly 1 Mount the turbocharger in the holding fixture 5 28 5 25 R 1312 5 16 DRILL 3 69 R 3 8 16 TAP 50 PLATE 4 72 R 2 HOLES 4 25 R Lx AR WELD IN PLACE 2 5 8 4 1 2 x 5 RODS 406 DRILL 2 HOLES FIXTURE ADAPTER PLATE ME 2410 233 34 5 28 Fi
216. ing inner 4 Recoil spring bolt 5 Guide pin 6 Recoil spring rear pilot 7 Recoil spring bolt sleeve Figure 7 29 Assembling recoil spring assembly 7 15 1 25 DIA 1 2 13 NC STUD ME 2410 233 34 7 30 8 00 JB Figure 7 30 Spring bolt guide pin e Installation 1 Install the recoil spring assembly in reverse order of removal NOTE When installing 2 fig 7 31 in cylinder 3 the beveled edge is placed toward the cylinder Align the flat on the cylinder flange with the flat or guard on the idler recoil rod flange ME 2410 233 34 7 31 Seal Antiextrusion ring l 3 Cylinder Figure 7 31 Installing seal and ring 2 After recoil spring stops 1 g 127 have been installed loosen recoil spring bolt nut 668 7 28 releasing the recoil spring tension against the stops continue turning nut 6 until the end of the nut extends 16 inch beyond the end of the recoil spring bolt Install bolt 1 and washer 2 to lock nut 6 in place 7 7 Vraek Adjusting Mechanism a Removal WARNING Be certain the hydraulie pressure track pletely relieved and the cylinder can be in the adjusting mechanism com moved to the rear into the recoil spring front pilot before attempting to separate the track or remove the track adjusting mechanism On tractors that have badly 7 16 worn track it is possible for the hydraulic track to be adjusted forward
217. ings 11 Place adjusting screw 1 6 77 in as low a position as is necessary to remove wedge support 4 and brake adjustment wedge 5 12 Remove adjusting screw 1 bolt 3 which secures wedge support 4 to brake lever 2 and adjusting wedge 5 13 Remove bolt 6 and adjusting screw spring 7 from adjusting wedge 14 Remove bolt 5 securing the brake lever 6 to the brake shaft 1 in steering clutch cover 8 15 Slide the lever 6 along the shaft 1 6 72 toward the needle bearing 7 Remove the key 10 16 Pull the brake control lever 2 shaft 1 and key 13 as a unit and lift out the lever 6 and washer 11 Inspect the needle bearings 7 and 12 for damage or excessive wear Replace if necessary NOTE A suitable drift pin can be used for needle bearing removal and installation after removing the plug 9 Drive in the new needle bearings from the stamped end to the dimensions show Fill the needle bearing compartments with an approved ball GAA grease Stake the plug 9 in three places to secure it to the steering clutch cover at assembly 17 Reassemble in reverse order of disassembly NOTE Refer to subparagraph e below for adjustment of brake engaging mechanism prior to installation in the steering clutch and bevel gear case VIEW VIEW B ME 2410 233 34 6 77 Adjusting screw Brake lever Bolt Wedge support Adjusting wedge Bolt Adjusting wedge s
218. intenance personnel with general repair instructions applicable to the Caterpillar D 7F tractor The following instructions will prove helpful to disassemble and assemble the tractor components 2 6 Genera Instructions a Cleanliness 1 Whenever hydraulic fuel lubricating oil or air lines are disconnected clean the point of disconnection and the adjacent area As soon as the disconnection is made cap plug or tape the line or opening to prevent entry of foreign material The same recommendations for cleaning and covering apply when access covers or inspection plates are removed 2 Clean and inspect all parts Be sure all passages and holes are open Cover all parts to keep them clean Be sure parts are clean when installed Leave new parts in their containers until ready for assembly b Removal and Installation 1 Unless otherwise specified all removals should be accomplished using an adjustable lifting beam All supporting members chains and cables should be parallel to each other and as near per pendicular as possible to the top of the object being lifted 2 1 2 When it is necessary to remove com ponent on an angle remember that the capacity of an eyebolt diminishes as the angle between the supporting members and the object becomes less than 90 Eyebolts and brackets should never be bent and should only have stress in tension A length of pipe and a washer can be used fig 2 p to help relieve t
219. ith water and dry with compressed air Inspection and Repair 1 Inspect threaded holes for damage Chase with a tap or die if damaged 2 Inspect the block thoroughly for cracks wears signs of strain or other damage Replace block if damage cannot be repaired by welding or minor machining 3 Inspect gasket surfaces for warpage nicks or burrs Smooth by grinding Replace block if excessively warped d Reassembly an Installation Assemble the engine in the reverse or er of disassembly Install in the tractor para 2 5 79 CHAPTER 6 REPAIR OF DRIVE TRAIN Section 1 TORQUE DIVIDER AND TRANSMISSION 6 1 Genera a Power from the diesel engine is transmitted by the flywheel 3 to the torque divider where it travels through two separate paths An internal coupling gear on the engine flywheel drives the rotating housing 2 which delivers a larger portion of the diesel engine torque through torque con verter Another coupling gear drives the sun gear 6 on a planetary gear set to mechanically transmit a lesser portion of the torque to the planet carrier 8 which is splined to the torque divider output shaft 7 Since the ring gear 4 is driven by the turbine of the torque converter this torque is also applied to the output shaft through the planet carrier 8 b From the torque divider output shaft 7 torque is transmitted through the universal joint to the transmission input shaft 3 fig 6 P The
220. k and place tool on wheel Make sure wheel is starting squarely on shaft press against tool until wheel bottoms Remove tool and place unit in vise 15 Apply a film of grease to threads and back face of nut 5 fig 5 30 Install nut and torque to 30 ft Ibs fig 5 31 16 Recheck for 0 0019 to 0 022 in clearance between compressor and housing as illustrated Recheck end play 17 Position damp 7 fig 5 30 over bearing housing 18 Install packing and compressor cover on bearing housing Earlier models have no groove for preformed packing Align assembly marks fig 5 29 and position clamps on flanges 19 Lubricate clamp threads and face of nut Install damp nut and torque to 10 ft lbs 5 40 g installation Reverse removal procedure and install the turbocharger on the engine 5 18 Exhaust Manifold a Removal 1 Remove air cleaner para 5 1b muffler 5 16 and turbocharger para_5 1 2 Remove the crankcase breather pipe fig 5 34 3 Remove 6 capscrews and remove the turbocharger air outlet pipe 4 Remove the fuel injection lines 5 Remove the turbocharger oil lines 6 Remove the muffler support bracket mounting bolts and remove the support brackets from engine 7 Remove the exhaust manifold retaining nuts washers and locks Remove exhaust manifold from engine and remove exhaust manifold gaskets 0 9 TURBOCHARGER ag Dit i
221. k the pinion gear back and forth The backlash between the bevel gear and pinion will be the difference in readings on the dial in dicator Figure 6 110 Measuring backlash d Check the backlash at four around the bevel gear to determine the point of least backlash Be sure the pinion is held forward while rocking it back and forth to take the backlash readings NOTE The correct amount of backlash is marked at the end of the bevel pinion if installedn the machine a factory If the bevel pinion is not marked refer t 1 4 e the reading is too great at the point of least backlash remove shims from the bearing cage on the right side and install them on the left side NOTE THe preload on the bevel gear shaft bearings will not be changed by moving shims from one side to the other if the same total number of shims is maintained f To increase the backlash move shims from the left side to the right side Section Ill 6 19 General fig 6 111 The final drive group consists principally of the final drive pinion idler pinion final drive gear final drive gear hub sprocket shaft and sprocket The final drive group is contained by tapered and FINAL DRIVE straight roller bearings sup ported by the steering clutch and bevel gear case and final drive case The final drive group is enclosed in the final drive case 6 89 1577 EL Sea 0 7 6 90 amp God L 10
222. k to ride over the carrier rollers and off the sprocket Figure 7 6 Track seal washers and spacers b Inspection and Repair 1 Inspect the track links and grousers for cracks breaks and distortion Repair or replace broken or damaged links and grousers 2 Refer to table 1 5 for track pin and bushing wear tolerances 3 Inspect the track links for wear When the links are worn from 4 57 to 4 38 inches in height they will be repaired by welding an overlay on the wear surface Links worn 4 38 inches or less in height will be replaced Link height new is 4 75 inches NOTE Pin boss clearance new is 0 69 inch Acceptable pin boss clearance is 0 35 inch 4 Inspect the grousers for wear Grousers worn from 1 93 1 00 inches height will be repaired by installing applicator bars Grousers worn to a height of less than 1 inch or grousers uneconomical to repair will be replaced New grouser height is 2 56 inches Applicator bars will be installed one time only c Reassembly and Installation 1 Back the tractor until the sprocket is just ahead of the last link of the track 2 Attach a hoist to the outside link and raise the track as the tractor is driven forward NOTE Ifa traveling hoist is not available it may be necessary to block the track and reposition the hoist to complete the installation 7 4 3 Carry the track high enough to dear the rollers 4 Stop with the end of the track slightly behind the f
223. ks On used parts remove all dirt or rust deposits from the ramps with a scraper or wire brush and smooth the surface with emery cloth 3 Always install new rubber toric sealing rings 1 on floating ring seals 2 Never install a used toric sealing ring on a new or used floating ring seal NOTE Use seal installer fig 2 9 to install metal floating ring seal 2 fig 2 9 and toric sealing ring 3 into seal mounting groove 4 Be sure not to bump the floating ring seal when removing the installer tool 4 Install toric sealing ring 3 so it seats uniformly in the relief of floating ring seal 2 Be sure the toric sealing ring is not twisted and that it sets straight and against the lip that keeps it from falling off the floating seal fig 2 1D 5 If the installer tool is not used install the toric sealing ring 3 fig 2 8 and floating ring seal 2 as an assembly into groove 3 by pressing on the toric sealing ring at location 3 Be sure the toric sealing ring is seated uniformly in the recess of both the floating ring seal and the groove Make sure that it sets in the bore straight and against the lip that keeps it from falling out of the retainer fig 2 10 CAUTION If installer tool is not used do not use a screwdriver or stick to assemble the toric sealing ring in the groove Use finger pressure only 6 Instal the floating ring seal to a uniform depth in the groove The dimension 1 fig 2 8 mu
224. l it is necessary to remove the track roller frame 7 10 outer bearing 6 20 holder and outer bearing adjusting hub outer bearing cage holder and outer bearing adjusting nut para 6 20 The sprocket must be removed to service or replace the inner metal floating ring seal para 6 23 b Cleaning 1 Wash off all dirt accumulation from used parts using deaning solvent Fed Spec P D 680 t may be necessary to use a wire brush to clean the accumulations of dirt or rust from the bore of the seal mounting grooves to assure they are clean and smooth 2 Remove all oil or the protective coating from the floating seals with cleaning solvent Inspection Inspect the metal floating ring seals 8 and 9 fig 6 114 for damage Replace the seals if there are scratches across the sealing bands or if contact is not clearly defined around the outer edges If either floating ring seal is damaged both must be replaced CAUTION To obtain maximum service cleanliness must be the rule Avoid introducing dirt into the parts during installation or filling w ith oil d Installation 1 Handle all parts with care to avoid nicks in critical areas File smooth any parts other than the sealing faces that have nicks that may make assembly difficult or questionable 2 Be sure the ramps on the seal mounting grooves and on the floating ring seal are dry and with no oil present Check the ramps for rough tool marks and nic
225. l housing LO 5 2410 233 12 3 Remove cross sheet guard from bottom of fuel tank 5 2410233 20 shut off fuel supply line 5 23 4 Disconnect radiator water outlet line hose from the water pump fig 2 31 sheet 1 and disconnect top radiator hose from radiator 2 Figure 2 31 Preparing to remove engine sheet 1 of 6 5 Remove the 8 fan adapter mounting bolts 5 7 and lay the fan and adapter inside the radiator guard 6 Loosen fan belts TM 5 2410 233 20 and remove the fan belts from engine para 5 b 7 Remove 6 bolts and remove the fan drive assembly para 5 8 8 Disconnect the fuel supply line fig 5 21 from the accessory drive housing 2 14 9 Disconnect starter ground cable from the starter TM 5 2410 233 20 10 Disconnect the positive cable from the starter and pull the cable through to the left side of tractor 11 Remove capscrews 2 31 sheet 2 and remove the floor plates 12 Disconnect the transmission oil cooler oil inlet line fig 2 31 sheet 3 13 Disconnect the power take off drive gears lubrication line from oil inlet line fig 2 31 sheet 4 ME 2410 233 34 2 31 Figure 2 31 Preparing to remove engine sheet 2 of 6 Figure 2 31 Preparing to remove engine sheet 3 of 6 2 16 Dk SrEERING CLUTCH CONTROL VALVE OIL SUPPLY LINE TRANSMISSION VENT LINE TORQUE DIVIDER
226. l lip is toward or next to the bear ing 5 Lubricate collar then install collar and retainer plate Press against inner race only to n stall the new bearing onto the shaft against the collar 8 The remaining assembly procedure is the reverse of disassembly fb Rectifier and Pall the press the new inner race onto figure 5 35 5 A CHECKING TRANSISTOR FOR SHORTS A CHECKING TRANSISTOR TRI PROPER GT EDITUM OF WN POSITIVE GROUND CLIP LOCATED KEEP CLIPS PERFECTLY CLEAN AND FREE OF RUBBER SEAL AND EPOXY B RUBBER SEAL APPLIED ME 2410 233 34 5 35 4 C1 Figure 5 3 Transistor checking ME 2410 233 34 5 35 4 Cl 5 64 A INNER RACE LOCATION B BEARING LOCATION C SEAL LOCATION 2410 233 34 5 35 5 Figure 5 35 5 Inner race bearing and seal locations ME 24 10 233 34 5 35 5 2 Discard the old seal and push the old bleed to the bearing Press the cover into the housing bearing out of the housing from inside toward the 5 Add lubricant to seal lip and fill the cavity outside with lubricant between the rubber lip and steel case 3 Push against the race only to install the of the sexi Install the seal with the lip toward the new bearing to the dimension shown in figure 5 35 5 bearing See figure 5 35 5 To facilitate the installation h pend frame in an WF This wi amp Reassembly procedeces ore oven to 200 to 300 F This wi ui lator
227. late and a wrench ME 2410 233 34 6 8 l Bolt 6 Scavenge pump 2 Flange 7 Bolts 3 Bolt 8 Carrier assembly Outlet relief valve 9 Torque divider housing 5 Figure 6 8 Torque divider housing removal and installation 6 10 Bearing 2 Output shaft Figure 6 9 Removing output shaft bearing ME 2410 233 34 6 9 4 Remove bolts 3 and remove the torque converter outlet relief valve from torque divider housing 9 5 Remove bolts 5 and remove the scavenge pump 6 from torque divider housing 9 6 Disassemble the scavenge pump as follows a Remove cotter pin 1 fig 6 10 and nut 2 b Invert nut and install flush with shaft threads to make a flat surface c Pull gear 3 from scavenge pump shaft d Remove woodruff key 4 and bolts 5 e Remove end cover 6 f Remove gears 7 and 8 and shafts 9 and 10 g Remove bearings 11 if replacement is required Cotter pin 2 Nut 3 Gear 4 Woodruff key 5 Bolts D End cover ME 2410 233 34 6 10 Gear 8 Gear 9 Drive shaft 10 Idler shaft ll Bearings 12 Pump body Figure 6 10 Scavenge pump exploded view 6 12 7 Remove the 8 torque converter carrier to cover mounting bolts 7 fig 6 8 8 Install two in 16 NC forcing screws and separate the housing 9 from carrier assembly 8 9 Remove the forcing screws and install two 3 4 in 16 NC forged
228. lding reinforcing strips and radiator core to the top tank 2 Remove bottom tank in similar manner PRESSURE RELIEF VALVE FILLER CAP UME 2410 233 34 5 5 Figure 5 5 Radiator disassembly c Cleaning 1 Clean the radiator core of all ac cumulation of debris between the fins and tubes with water or compressed air 2 Clean the inside of the radiator core bottom tank and top tank using a steam cleaner Flush steam cleaner solvent from core and tanks with fresh water d Inspection and Repair Assemble radiator core and tanks Cap openings and test radiator under water with 8 to 10 pounds air pressure Note source of air bubbles and solder the leaks Be sure to wash off the acid after soldering as the acid will corrode the tubes Be careful not to bend the fins and straighten any that may be bent e Installation Install radiator in reverse order of removal procedure f Rdief Valve Test 1 Tighten the radiator cap to seal the cooling system Install a pressure gage capable of indicating 25 psi into the radiator tank top using appropriate fittings Connect an air pressure regulating valve and an air source CAUTION Do not apply a pressure greater than 16 psi 5 5 2 Slowly pressurize the radiator top tank The highest pressure gage indication is the relief valve opening pressure Indication should be 10 to 16 psi 3 If relief valve fig 5 5 does not open within the specified limits replace
229. ll the preformed packing 2 on the bushing 1 and remove any burrs from the roller to prevent damage to the preformed packing NOTE White lead should be used on the outside diameter of the bushing assembly when pressing it into place 2 Install the shaft before pressing in the second bushing 3 Install the metal floating ring seals 3 in the roller and collars as outlined apace 4 Install the preformed packing 4 on the track roller shaft and lubricate it to facilitate in stallation of the end collar 5 Remove any burrs smooth the chamfer in the bore of the end collar and install the end collar and the retaining ring 5 6 Lubricate the roller f Installation 1 Install the track roller with notched end collar toward the center of the tractor 2 Place the roller assemblies on the track in the proper relative locations and follow the reverse order of removal in completing the installation 3 Place the wedge shaped lock strip in the notch in the end of the shaft and in the notch of tbe end collar and securely tighten the bolts which hold the end collars to the track roller frame Some clearance will remain between the track roller frame and the end collars to insure that the ends of the track roller shaft will be held securely against the track roller frame 7 4 Front Idler a Removal 1 Separate the track and lay it out flat 2 Remove the guard 1 fig 7 17 bolts 2 and guide plate 3 NO
230. ll the rocker arm cover TM 5 2410 233 20 5 28 Accessory Drive a Removal 1 Remove the fuel transfer pump para 13 and fuel filter housing 2 Remove the fuel injection pump housing and governor para 5 11 3 Remove the accessory drive gear cover located on the front of the timing gear cover 42 NOTE The accessory drive shaft can be removed without removing the timing gear cover 5 57 ACCESSORY DRIVE KR GEAR COVER GEAR COVER NUTS 233 34 5 42 QD ME 2410 sheet 1 of 2 tallation Ins ive shaft removal and Accessory dr 42 5 Figure 5 58 6S S TIMING GEAR COVER ACCESSORY DRIVE GEAR Figure 5 42 ACCESSORY DRIVE GEAR RETAINING NUT Accessory drive shaft removal and installation sheet 2 of 2 4 Position the accessory drive gear to allow access to the bolts which secure the accessory drive housing to the timing gear plate Remove the bolts and locks CAUTION Do not allow the bolts or locks to fall into the timing gear housing 5 Remove the accessory drive gear retaining nut 6 Install puller and push the accessory drive shaft until the gear comes off the shaft and the accessory drive is removed from the timing gear housing 7 Pull the bearing from the shaft 8 Discard the housing mounting gasket b Cleaning Inspection and Repair 1 Clean the shaft cover and gear in solvent and dry with clean lint free cloths or with com
231. lot installed length 25 00 in Clearance between frame and guides Clearance between yoke and plate assembly Track Wear external bushing and pitch increase on pins and bushings permissible before turning see text Measured across 4 track links 33 84 0 08 in Track adjustment sag 1 1 1 in Limit of adjusting track measurement between stops on shaft assembly and back of equalizer bar support not to exceed 0 062 in 1 10 Manufacturer s dimensions and tolerancesin inches Desired clearance Maximum allowable wear and Maximum clearance 0 015 0 040 0 032 0 012 0 050 0 029 0 050 0 030 0 050 2 DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS Section l REPAIR PARTS SPECIAL TOOLS AND EQUIPMENT 2 1 Special Tools and Equipment The special tools required to perform direct and general support maintenance on the Caterpillar Model D 7F Tractor are listed in appropriate TDA of the organization performing the maintenance 2 2 Maintenance Repair Parts Repair parts and equipment required to perform direct and general support maintenance of the D 7F tractor are listed and illustrated in TM 5 2410 233 34P Section TROUBLESHOOTING 2 3 General This section provides information useful in diagnosing and correcting unsatisfactory operation or failure of the tractor and its components 2 4 Troubleshooting Malfunctions which may
232. lts and lockwashers 9 fig 4 17 securing housing 12 to valve body 5 2 Remove plug 1 with a inch 16 NC eyebolt 3 Remove spring 3 and check valve 4 4 The check valve 4 must slide freely in its bore in valve body 5 Inspect chamfered seating surface of check valve 4 and mating seat 6 in valve body for nicks or burrs 5 Inspect O ring 2 and replace if necessary 6 Remove bolt and lockwasher 10 washer 11 spacer 13 spring 14 and spacer 15 from spool 16 CAUTION Valve body 5 and spool 16 are machined to close tolerances To avoid distortion of spool 16 leave spool in valve body when loosening or tightening bolt 9 7 Remove bolts and lockwashers 18 and cover 17 8 Remove sleeve 19 spring 21 and pilot valve 22 Remove shims 20 from between spring 21 and sleeve 19 Be sure to install same number of shims 20 as were removed The total thickness of shims determines the pressure at which the relief valve opens 1 975 25 psi 9 Dump valve 26 spring 25 and seat 23 are retained in control valve body 5 by friction of O ring 24 To remove insert a inch diameter rod 10 inches long into check valve bore until it contacts dump valve 26 Push against dump valve compressing spring 25 until dump valve contacts seat 23 While holding dump valve firmly against seat tap against rod forcing seat spring and dump valve out of control valve
233. lts which hold the two together 7 Inspect hub inner bearing cone 5 131 8 Using puller assembly 4 fig 6 132 three arms 1 spacer 3 cylinder group 1 fig 6 131 a pump group and an adequate spacer 3 remove bearing cone 5 from the final drive hub NOTE Heat bearing cone 5 in oil at installation 1 Cylinder group 2 Arm 3 Spacer 4 Spacer 5 75 in diameter 5 Bearing cone 6 Puller assembly Figure 6 131 Hub inner bearing cone removal 6 105 901 9 Figure 6 132 Bearing cone removal tools ME 2410 233 34 6 132 9 Attach a puller to the idler pinion and remove 10 Inspect idler pinion outer race and roller assembly 11 Using a puller a bearing pulling at tachment a hydraulic puller a pump group and a spacer remove inner race The idler pinion inner bearing inner can be removed in like manner NOTE Heat bearings races to facilitate removal 12 Remove the bolts and locks Olga 6 133 13 Drain the oil in the steering dutch compartment before removing the idler pinion inner bearing cage 3 14 Using two 1 2 inch 13 forcing Screws 5 remove bearing cage 3 Inspect the bearing cage to steering dutch case gasket 15 Using a 1 4 inch 20 NC bolt remove dowel 2 6132 6 134 and remove outer race and roller assembly 1 NOTE When installing bearing cage 3 fig 6 133 in tbe steering clutch and bevel gear case position dowel to
234. ly Install remaining inserts and plunger in a similar manner 4 37 12 Assemble wear ring 3 fig 4 27 to piston 10 13 Install piston 10 washer 2 and nut 1 on the piston rod Tighten nut 1 to 750 850 lb ft 14 Install the rubber inner ring of seal assembly 9 into the groove on the piston 10 15 Place the outer sealing ring of the seal assembly on the expander assembly 1 fig 4 33 16 Stretch until point A is slightly above the 4 75 mark B which is the diameter of the ring 17 Back point A to the 4 75 mark B and try to lift the seal ring from the expander assembly 1 If the seal ring will not slip off easily rotate the seal ring 900 and stretch as before When ring will slip off the expander assembly easily with point A set at the 4 75 inch mark B the ring can be assembled on the piston over the rubber inner ring CAUTION Do not over stretch the seal ring 18 oil the piston wear ring seal assembly and the inside of the cylinder and install the seal compressor 3 and damp assembly 2 over the seal assembly Compress the seal assembly until it is equal to the od of the piston 10 Install the piston assembly into the cylinder allowing the seal compressor to shoulder against the cylinder and be forced off the seal assembly as the piston is pushed into the cylinder 20 Tighten the cylinder head bolts with the piston rod fully extended Refer to table 1
235. ly is installed on the fitting body a Lubricate the sleeve and the threads on presetting tool and nut b Place the nut on the tube with the threaded end of the nut toward the end of the tube c Place the sleeve onto the tube so the short tapered heavy end faces the presetting tool as illustrated d Bottom the tube end against shoulder of the tool e Assemble the nut to the tool finger tight Then tighten the nut until the threads on the tool are no longer visible f Remove the tube from the presetting tool Check to be certain sleeve does not move longitudinally The sleeve can rotate on the tube g When the tube assembly is assembled onto the fitting body tighten the nut until the threads on the body are no longer visible Refer to 5 a above for the installation of the fitting bodies 2 8 ME 2410 233 34 2 14 Tube 2 Nut 3 Sleeve 4 Presetting tool 5 Shoulder of tool 41 Figure 2 14 Sleeve type fitting 2 Type B a Place the nut sleeve fig 2 15 onto the tube Install the sleeve so the thick end faces away from the body b Install the insert into the tube c Bottom the tube and insert the body as illustrated d Tighten the nut 105 turns past finger tight ME 2410 233 34 2 15 Nut Tube Li Sleeve Insert gt Fitting body Figure 2 15 Sleeve and insert type fitting 3 Type C a With the nut and sleeve installed loosely in the body
236. m 5 2 Radiator a Removal 1 Drain the cooling system TM 5 2410 233 10 and remove engine upper right guard assembly TM 5 2410 233 20 2 Remove the hood headlight brackets al 5 2 and radiator top guard 5 1 Us 2 EXHAUST PIPE 1 EXHAUST PIPE MOUNTING CLAMP 4 AIR CLEANER 3 AIR CLEANER MOUNTING CLAMP 12 RADIATOR 9 HEADLIGHT BRACKET TOP GUARD MOUNTING BOLTS 10 HEADLIGHT BRACKET 11 RADIATOR TOP GUARD MOUNTING BOLTS SSE MOUNTING BOLTS x P i ME 2410 233 34 5 2 Figure 2 2 Hood headlight brackets and radiator top guard removal and installation 3 Remove two capscrews 1 fig 5 3 and 6 Rotate bracket 7 away from the radiator remove elbow 2 core after loosening bolt 5 4 Remove four bolts 3 and six bolts 4 7 Remove bolts 11 and disconnect elbow 5 Remove bolts 6 8 0 233 34 5 3 Capscrew 1 Bracket 2 Elbow 8 Elbow 3 Bolts 9 Bolts 4 Bolts 10 Bolts 5 Bolt HI Bolts 6 Bolt Figure 5 3 Preparing to remove radiator 8 Attach a hoist fig 5 4 and remove the 9 Tilt the radiator sideways so the bottom radiator approx weight 425 165 tank will pass the top tank mounting pads HOIST EYEBOLT RADIATOR RADIATOR GUARD Figure 5 4 Lifting radiator from radiator guard 5 4 b Disassembly 1 Remove top tank fig 5 b by removing TOP TANK BOLTS the bolts ho
237. m away from the hub and remove the steering clutch assembly as shown in Tizure 6 83 CAUTION Keep the steering clutch assembly level since the clutch is free to slide out of the outer drum 6 76 ME 2410 233 34 6 83 Figure 6 83 Removing steering clutch assembly 5 Before installing the steering clutch assembly inspect the splines of the outer drum and the teeth of the discs for roughness and excessive wear Replace if not reusable NOTE The following procedure will permit the flange on the pinion shaft and the steering clutch outer drum to draw together without binding at the time of in stallation 6 Install one bolt that secures the outer drum to the flange but do not tighten the bolt too tight 7 Rotate the steering clutch 180 by moving the machine or the sprocket 8 Install a second bolt that secures the outer drum to flange Tighten this bolt securely 9 Complete the installation in reverse order of removal Torque the bolts aL fig 6 82 and 4 to the value given in table 1 2 10 Refer to paragraph 6 14 and adjust the brakes c Disassembly NOTE Position the steering clutch assembly on blocks allowing at least 5 inches of clearance 1 Remove the brake band 1 6 84 from the outer drum 2 2 Remove the outer drum from the steering clutch assembly NO
238. mage and wear Replace worn damaged or questionable ring seals n Inspect the carrier bearing for scoring pitting and wear Replace a scored pitted rough or excessively worn hearing Inspect the turbine for damage and wear The desired stator to turbine clearance is 0 012 to 0 018 inch The maximum allowable clearance is 0 030 inch Replace a damaged or worn turbine See subpara 3 below for measuring procedure p Inspect the turbine bearing for scoring pitting and wear Replace a scored pitted rough or excessively worn bearing 6 20 q Inspect the flange ring seals for damage and wear Replace damaged worn or questionable ring seals Inspect the flange inner sleeve bearings for scoring damage and wear The desired shaft to bearing clearance is 0 002 to 0 005 inch The maximum allowable clearance is 0 015 inch Replace scored damaged or excessively worn sleeve bearings r Inspect all gears for chipped pitted broken or excessively worn teeth Replace defective or excessively worn gears s Inspect the torque divider and rotating housings for cracks breaks and wear Repair or replace as dictated by the extent of damage 3 Checking torque converter clearance T o maintain efficiency of the torque converter it is necessary that maximum wear limits between certain components be observed and used as a guide when determining parts replacement At the time of reassembly use the procedure listed b
239. n diameter the seal is expanded sufficiently ME 2410 233 34 2 25 Expander assembly A Indicated piston diameter Figure 2 25 Seal on expander 2 11 4 Place seal on the expander Turn the crank on the expander until the inside face of the movable block is slightly past point A Then return to point A Rotate the seal 90 on the expander and expand again Check to see if the seal will slip off the expander If not repeat the procedure expanding the seal farther each time until the seal will slip off the expander when block is returned to point A 5 Lubricate the outer seals and place them on the piston Install and lubricate the wear ring 6 Select the applicable compressor 1 fig 2 26 and install the clamp 2 on the compressor Place the compressor loosely over the outer seals fig 2 26 Place the compressor on the piston so the rolled side of the compressor will be facing the cylinder when the piston is installed in the cylinder ME 2410 233 34 2 26 Seal compressor 2 Clamp assembly Figure 2 26 Compressing seals 7 Slowly turn the handle on the clamp and force the seals into their grooves Be certain the seals are being settted in their grooves as they are being compressed 8 Place the piston assembly into the cylinder bore as illustrated be certain the piston is square in the bore 9 Drive on the piston rod until the entire piston assembly is in the cylinder bore Remove the
240. n P D 680 cleaning solvent and dry with compressed air Clean bearings as instructed in d Inspection and Repair 1 Check the housings for cracks at the mounting flanges Repair or replace as required 2 Inspect the impeller for dents nicks cracks chips and bent or broken splines Repair or replace as necessary 3 Inspect the bearing for scoring wear scratches pitting and other damage Replace as required 4 Replace all seals and gaskets Reassembly Assemble the water pump in the 5 16 reverse order of disassembly Grease the seals before installing and use a seal installation tool to insert the seals Tighten the impeller bolt 16 fig 5 15 to a torque of 27 to 29 foot pounds f Installation Reverse removal procedure and install the water pump on the engine 5 7 Engine oil Cooler a Removal 1 Drain cooling system TM 5 2410 233 10 2 Loosen the water inlet bonnet hose clamps TOES and slide the hose back on the bonnet 3 Remove oil filters TM 5 2410 233 20 4 Remove the oil level gauge guide clamp mounting bolt 5 Remove the oil cooler to elbow assembly mounting bolts 6 Remove the two support bracket mounting bolts and remove the engine oil cooler and oil filter base as a unit 7 Separate the oil filter base from oil cooler LTS Figure 5 14 Engine oil cooler removal and installation b Cleaning Inspection and Repair NOTE If oil cooler has exeessive
241. n all components with cleaning solvent Fed Spec P D 680 and dry with com pressed air d Inspection and Repair 1 Inspect the housing and cover for breaks cracks and rough mating surfaces Repair by welding 2 Inspect control levers for cracks breaks and worn bores Inspect pins for wear and damage Replace worn parts 3 Inspect springs for cracks and other dam age Replace weak or damaged springs 4 Inspect rollers and bushings for wear Replace bushings if worn or loose Replace rollers if worn or out of round 50 Shaft assembly 51 Guide 52 Key 53 Pin 54 Gasket 55 Plug 56 Washer 57 Plunger 58 Spring 59 Plug 60 Spacer 61 Packing 62 Piston and valve assembly 63 Bolt 64 Locking plate 65 Ring 66 Cylinder 67 Weight assembly 68 Ring 69 Bearing race 70 Bearing 71 Seat 72 Spring 73 Washer 74 Pin 75 Pin 76 Seat 77 Ring 78 Washer 79 Spring 80 Plunger 81 Pin 82 Spring 83 Plunger 84 Bolt 85 Lockplate 86 Lever assembly 87 Band assembly 88 Housing assembly 89 Bolt 90 Locking plate 91 Spacer 92 Retainer 93 Spacer 94 Spacer 95 Contact 96 Spring 97 Bar e Reassembly fig 5 2D 1 If the guide was removed press a new guide into position in the housing 88 Form the guide against the chamfer in the governor housing Install the band assembly 87 2 Install the spring 82 plunger 83 and pin 81 to the lever 86 Install the lever assembly in the ho
242. n the track adjusting mechanism is pletely relieved and the cylinder can be moved to the rear into the recoil spring front pilot before attempting to separate the track or remove the track adjusting mechanism On tractors that have badly worn track it is possible for the hydraulic track adjuster to be adjusted forward to the limit of its travel and the stop will be against the equalizer bar support The hydraulic cylinder could have high oil pressure in it even though the track is loose enough to remove the master pin without relieving the hydraulic track adjusting pressure 1 Remove guards 7 25 2 Separate the track and iay it out flat para 7 1 3 Raise the front of the tractor until equalizer bar 3 fig 7 38 is against roil bar 2 Use blocking to support the front of the tractor 4 Remove bolts 4 5 Attach a hoist to and remove track carrier roller 1 carrier roller bracket 6 and support assembly 5 as a unit 7 17 b Disassembly Refer to paragraph 7 2 and remove the track carrier roller from support assembly c Inspection and Repair 1 Inspect track carrier roller para 7 2 2 Inspect carrier roller support for cracks breaks distortion or other damage Repair minor cracks by welding TM 9 237 Replace a damaged carrier roller support d Installation Install in reverse order of removal ME 2410 233 34 7 36 1 Track carrier roller 2 Roll bar 3 Eq
243. nd on selector lever control shaft and using a thickness position support 3 to obtain dimension A listed gage between washer 5 and lever position lever to in table 1 4 obtain dimension given in table 1 4 Tighten clamp With the connecting link disconnected bolt position lever 8 in forward detent Key td figure 6 30 Selector lever Clamp Support Clamp Washer Lever 7 Shaft assembly 8 Lever 9 Lever L ON 6 30 Ea 3RD 22222 vad 1 We Ly 9 IST ME 2410 233 34 6 30 A Dimension between centerline of transmission control shafts and left face of lever 6 Figure 6 30 Linkage adjustment top view 9 d With the connecting link disconnected position lever 9 in NEUTRAL detent Position lever 1 in center of neutral slot f Adjust length of short rod to enter ends of levers 6 and 9 g Place selector lever 1 in position of forward slot h Adjust length of longer rod to enter the ends of levers 1 and 8 NOTE The chamfered side of the nuts which retain the conne eti ng links to the levers should alw ays face the ball section on the sw ivel ends NEUTRAL 6 5 hydraulic Pump a General The steering clutch and trans mission hydraulic pump is a single section gear type pump which is bolted to the front of the rear power takeoff housing 6 32 b Removal and Installation Refer to TM 5 2410 233 20 and remove or
244. nd collars 2 fig 7 13 at each end of the roller to be removed and remove the roller To facilitate removal of the front or rear rollers the second roller from either end should be removed and rolled back on the rails out of the way CAUTION Do not extend any part of body legs or arms between the track and rollers or between ground and track during removal of lower track rollers ME 2410 233 34 7 13 1 Ring 2 Collar 3 Metal floating ring seals 4 Plug 5 Preformed packing Figure 7 13 Track roller disassembly b Disassembly 1 Remove the ring 1 2 Remove the collar 2 the metal floating ring seals 3 the plug 4 and the preformed packing 5 CAUTION The two metal floating ring seals 3 should be taped together so they will not become intermixed with seals from other rollers 3 The other end of the roller is disassembled in the same manner 4 Remove the bolts which secure the bushing assembly fig 7 14 to the roller 5 The bushing assembly can be pressed out of the roller by supporting the roller and pressing on the end of the shaft The bushing assembly can then be removed from the shaft Insert the shaft back into roller and repeat the procedure to press the bushing assembly from the opposite end BUSHING ASSEMBLY ROLLER SHAFT n 2410 233 34 7 14 Figure 7 14 Bushing assembly removal 7 8 6 The bearing fig 7 15 can be pressed out
245. nd support para 6 30 2 Remove oil supply line fig 2 38 sheet 2 and oil pressure line 3 Rotate the universal joint 2 31 sheet 4 of 6 as necessary and remove the bolts securing the bearing caps to the transmission input shaft flange and torque divider output shaft flange 4 Pry the universal joint bearing caps loose from each flange and remove the universal joint NOTE Do not cut the metal straps securing the bearing Caps to the spider If they are cut or missing tem porarily fasten the bearing caps to the wniversal joint to prevent them from sliding off or dirt entering the bearings l Bearing D Seal 3 Retainer b Disassembly 6 1 Remove the bolts which bearings to the spiders 2 Remove the strap 4 from bearings 1 3 Remove the bearing 1 seal 2 and retainer 3 from the spider 5 secure the C Inspection 1 Inspect the spider journal bearing surfaces for roughness or needle bearing grooves 2 Carefully inspect each bearing for wear and for broken or missing needle bearings 3 Replace the spider and bearing assembly if either the spider or the bearings show excessive wear 4 Light brineling of the spider bearing area is not harmful d Reassembly and Installation Reassemble the universal joint in the reverse order of disassembly ME 2410 233 34 6 3 4 Strap 5 Spider Shaft Figure 6 3 Universal joint disassembly 6 3 Torque Divider
246. nd wear Segments with teeth having considerably more wear on one face than the other may be switched from one side of the tractor to the other If sprocket segments faces are worn 3 16 inch or more replace sprocket To prevent ac celerated wear the sprocket segments must be replaced in sets only Inspect guards 6 fig 6 119 for corrosion cracks breaks distortion or other dam age Replace a defective or damaged guard 3 Installation a Install the metal floating ring seals para 6 22 b Before installing the sprocket 120 make sure the splines are dean dry and free of burrs Set the sprocket on the hub with the splines in the sprocket meshing with the splines on the hub and push the sprocket on as far as possible by hand 6 98 1 ME 2410 233 34 6 120 1 Cylinder group Figure 6 120 Installing sprocket c Install adapter 2 fig 6 121 on cylinder group and extend the ram to its limit with the pump group d Assemble head 1 to cylinder group e Install adapter 3 onto the sprocket shaft 66 9 Su P gt w L rs Figure 6 121 Head Adapter Adapter Coupling pin Sleeve Ring Sprocket installing tools ME 2410 233 34 6 121 f Place ring 6 and sleeve 5 over adapter Quadr and hib 3 fig 6 122 and connect adapter 2 fig 6 121 and adapter 3 with pin 4 g Place the pump control in the pulling position and apply a slight
247. nder can be removed to the rear into the recoil spring front pilot before attempting to Separate the track or remove the track adjusting mechanism On machines that have badly worn track it is possible for the hydraulic track adjuster to be ad justed forward to the limit of its travel and the stop will be against the equalizer bar support The hydraulic cylinder could have high oil pressure in it even though the track is loose enough to remove the master pin without relieving the hydraulic track adjusting pressure 1 Remove guards 7 25 Install drawbar pin or hardwood block between tbe sprocket and the track and back up the machine slightly to com press the recoil spring When all the tension is rem oved from recoil spring stops remove locking bolt and washer 4 fig 7 26 and screw recoil spring bolt nut 1 tight against rear pilot 2 Remove the drawbar pin or hardwood block 2 Separate the track and lay it out flat par 7 1 3 Move cylinder 5 to the rear as far as possible into front pilot 2 separating tbe cylinder from idler recoil rod 4 Move the idler rod to the front as far as possible 4 Attach a hoist to and remove the recoil spring assembly 5 Inspect antiextrusion ring 2 fig 7 31 and seal 1 7 13 F E 4 us y U P EN 25 uc 3 2 SE i 4 E j 13 i S 2
248. ne rpm at torque converter stall 755 885 Converter type single stage Con verter size 21in Clearance between torque converter stator and turbine see text for correct method of measuring 012 0 018 0 030 Clearance between torque converter stator and impeller see text for correct method of measuring 009 0 015 0 024 Torque Converter Inlet Relief Valve Mounting location Directional valve housing within transmission BENCH TEST ONLY Set to bypass 4 6 gpm At pressure of 135 145 psi Inlet relief valve spring Test force 476 558 lb When compressed to 48 in Free length after test 89 in Spring diameter 300 in Torque Converter Outlet Relief Valve Mounting location Upper rear face of torque divider housing Set to bypass 19 21 gpm At pressure of when converter is stalled 40 44 psi Outlet relief valve spring Pounds force 36 38 42 70 When com to 2in Free length after test 2 98 in Spring diameter 880 in Scavenge and Circulating Pump Type Gear Capacity scavenge 3 2 gpm Based on speed of 500 rpm Pressure 120 psi Transmission Hydraulic EEEN Safety valve spring 3 fig 6 27 Pounds force 36 44 When compressed to 5 74 in Free length test 8 20 in Spring diameter 1 44 in Check valve spring Tig 6 26 Pounds force 38 5 45 1 When compressed to 3 19 in Free length a test 4 38 in Spring diameter 81 in Pressure control valve spring 17 fig 6 25 Pounds force 22 5 26 9 When compre
249. ng to help determine the point of contact Table 5 1 Lifter Setting Lifter number Timing plate degrees 179 30 59 30 299 30 119 30 239 30 359 30 5 Position the rack setting gage from the zero position until it contacts the rack Total rack travel should be 0 650 inch 6 To adjust the rack loosen the locknut 37 fig 5 20 and turn the adjusting setscrew 38 to obtain the desired setting Tighten the locknut 5 12 Engine Speed Governor a Removal Remove the engine speed governor with the fuel injection pump Refer to paragraph 5 11 b Disassembly Refer tq figure 5 20 and disassemble the governor according to sequence of index numbers assigned to figure 5 25 Ga 9 90 89 22 23 Figure 5 20 Engine speed governor exploded view 2 ME 2410 233 34 5 20 Key td figure 5 20 1 Bolt 2 Washer 3 Gasket 4 Bolt 5 Washer 6 Cover 7 Gasket 8 Bolt 9 Cover 10 Gasket 11 Nut 12 Washer 13 Bolt 14 Clamp 15 Capscrew 16 Lock washer 17 Ring 18 Seal 19 Plate assembly 20 Spring 21 Pin 22 Roller 23 Spring 24 Bolt 25 Cover 26 Gasket 27 Screw assembly 28 Pin 29 Screw 30 Spring 31 Spacer 32 Screw 33 Packing 34 Screw 35 Packing 30 Bolt 37 Nut 38 Setscrew 39 Collar 40 Collar 4 Spring 42 Nut 43 Lockwasher 44 Washer 45 Insulator 46 Screw 47 Washer 48 Insulator 49 Shaft assembly c Cleaning Clea
250. nsion Replace a defective ring 11 Discard and replace all seal rings and packing Replace all defective parts f Reassembly The turbocharger must be assembled in accordance with the following procedures Measure all clearances accurately Lubrication unless otherwise specified will be a dean light oil OE 10 1 Clamp the turbine housing 8 fig 5 30 in a vise or fixture 2 Place turbine wheel and shaft assembly 9 with shaft upright in housing Place seal ring 25 over shaft 3 Install shroud 24 in bearing housing 26 and secure with retaining ring 23 with flat side of ring resting against plate 4 With the compressor end of housing 26 up install shaft ring 20 with flat side of ring facing up Lubricate and install bearing 22 and second ring 20 the third ring 20 bearing 22 and fourth ring 20 NOTE Use pliers to install retaining rings Compress rings sufficiently to prevent their ends from scoring bore Make sure retaining rings are secure in grooves 5 Lubricate shaft and rings Place clamp assembly 7 over turbine housing 8 Install bearing housing assembly 26 over shaft and lower to assembly position 6 Align assembly marks and clamp fig 3 29 over flanges on both housings Apply a graphite base grease to clamp threads and face of nut Install and torque clamp nut to 10 ft lbs 7 Lubricate bearing 17 and compressor end bore and install ring 19 and sleeve retainer 1
251. nspection Inspect the sprocket shaft for dam age and distortion Shaft must be straight within 0 12 inch Replace a defective sprocket shaft c Installation 1 Attach a hoist to sprocket shaft and position it for installation 2 Position sprocket shaft retaining nut and lockring 3 Instert sprocket shaft in the steering clutch and bevel gear case far enough to install the sprocket shaft retaining nut and lockring 4 Place the retaining nut and lockring on the shaft and install the sprocket shaft as far as possible into the steering clutch case 5 Install adapter 3 plug 1 and coupling pin 2 as shown 6 Press the sprocket shaft into the steering dutch and bevel gear case with a pressure of 55 60 tons Press until dimensions A or fig 6 137 is attained 6 109 011 9 Plug Coupling pin Adatper w Is Figure 6 136 Installing sprocket shaft ME 2410 233 34 6 136 A Cy STEERING CLUTCH Ce CASE n N li ME 2410 233 34 6 137 A 22 938 in 23 062 in dimension B 23 485 in 23 609 in dimension Figure 6 137 Dimensions with sprocke shaft properly installed 7 Maintaining the 55 60 tons pressure on theshaft tighten retaining nut with a spanner wrench 8 When the retaining nut is securely tightened lock it in the following manner 9 none of the notches in the retaining nut drill a 0 368 inch diameter hole through the nut and 0 56 in
252. nts barelv close then measure the air gap Do not measure the gap with the flat spring that supports the contact screw raised up off the fiber mounting plate To ad just loosen the ocknut and turn the contact screw The most convenient method of performing this operation is to insert the gage press the armature down against it to hold it in place and then turn the contaet screw until the contacts barelv touch Ad just the air gap to a 0 084 inch measurement b Voltage setting Disconnect battery cable from regulator and connect voltmeter between regulator battery terminal and ground screws in the end of the regulator With the generator operat ing at approximately 3 000 RPM and the regulator at operating temperature note the voltage setting Adjust by turning the adjusting serew at the base of the unit thereby changing the spiral spring tension Increasing the spring tension increases the voltage setting After each change of adjustment reduce generator speed until cutout relay opens then return to speed and read voltage Voltage should be between 27 5 to 29 5 volts Adjust to 28 2 volts 3 Current regulator Two checks and adjust ments are required on the current regulator air gap and current setting 2 a Air gap The AIR GAP and not the POINT OPENING is checked and adjusted Adjust the air gap to obtain a 0 115 inch measurement using the same procedure as for the voltage regulator b Current setting To check t
253. o 27 to 37 foot pounds f Step 6 Retighten bolts in alphabetical order hand torque only to 27 to 37 foot pounds C 25 19 17 15 2 24 6 B E M c B B 2 b M 12 1 3 9 4 10 4 2 7 ME 2410 233 34 5 41 om Cu cc Cum Figure 5 41 Cylinder head bolts torque sequence 11 Install the washer 14 5 40 spring 13 washer 12 rocker arm 11 bracket 10 rocker arm 8 bushing 9 spring 7 washer 6 and ring 5 on the rocker arm shaft 15 Install the adjusting screw 4 and locknut 3 12 Secure the rocker arm assembly to the cylinder head using the washer 2 and bolt 1 13 Adjust the valve lash as instructed in TM 5 2410 233 20 and tighten the adjusting screw locknut 3 14 Install the glow plugs and the fuel in jection lines para 5 10 15 Install exhaust manifold para 5 18 muffler para 5 18 air cleaner para 5 15 and exhaust pipe and hood 5 p 16 Service the cooling system as instructed in TM 5 2410 233 10 17 Start the engine TM 5 2410 233 10 Ensure that the rocker arms receiving lubricating oil 18 Operate the engine for approximately one hour uner load if possible to thoroughly warm up the engine and seat the head gasket 19 Shut down the engine and retighten the cylinder head bolts tabTe 1 2 Check and readjust the valve lash TM 5 2410 233 20 20 Insta
254. o 316 pounds of force when compressed to 3 90 inches The inner clutch springs should exert 185 to 205 pounds of force when compressed to 3 71 inches Replace damaged distorted or weak clutch springs 3 Inspect the clutch spring retaining bolts sleeves and retainer for damage and wear Replace defective parts as required 4 Inspect the clutch inner drum for cracks 6 78 breaks and worn lug recesses Repair or replace as dictated by the extent of 5 Inspect drum for cracks breaks and worn splines Repair or replace as dictated by the extent of damage Refer to paragraph 6 14 for inspection of drum braking surface damage clutch outer e Assembly NOTE To prevent the first clutch assembly from dropping below the end of the splines on the outer drum 1 insert three inch 11 NC forcing screws 2 in the bolting flange of the outer drum until they touch the splines ME 2410 233 34 6 87 Steering clutch driven drum outer drum 2 Forcing screws Figure 6 87 Preparing to assemble clutch assembly 1 Place the outer drum 1 fig 6 81 on blocks as a guide to assemble the di assemblies and discs onto the inner drum 1 2 Install two 5 8 inch 11 NC guide pins 2 fig 6 88 into the clutch spring retainer 6 3 Insert the bolt through the plate and place the retainer on the plate and over the bolt Place this assembly into the outer d
255. occur are listed in Chart 2 1 Each malfunction stated is followed by a list of probable causes of the trouble The corrective action recommended is described opposite the probable cause Refer to TM 5 2410 233 20 for initial troubleshooting Any trouble that is beyond the scope of direct and general support main tenance must be reported to depot maintenance personnel Chart 2 1 Troubleshooting Malfunction 1 Engine fails to start b Fuel transfer pump defective c Slipping fuel d Engine improperly timed a Valves not seating properly b Worm pistor rings injectiong nozzle 2 Irregular firing of engine Defective fuel Probable Cause a Worn injector pump injector pump drive Corrective Action a Replace injector pump para 5 11 b Check pump pressure para 5 1p if below 10 psi replace fuel transfer pump 5 1B c Remove fuel transfer pump Opara 5 13 crank engine and observe if shaft rotates If shaft rotates remove the small cover fig 5 4 from the front of timing gear cover and tighten the accessory drive gear retaining nut If tightening eliminates the slip ping retime fuel injector pump and 5 28 Retime engine para 5 2D Recondition valves 5 7 Replace piston rings 5 38 Locate misfiring cylinder by momentarily loosening each fuel line not on injection pump Replace defective fuel injection nozzle of misfiring cyinder
256. ock and secure with the washers and two bolts 5 Check the camshaft gears backlash paral 5 29 6 Check the camshaft end clearance subpara e 7 Install the timing gear cover para 5 2B and the pushrods para 5 27 8 Install the engine in the grader para 2 8 e Checking Camshaft End Clearance 1 Push the washer forward against the cam shaft gear 2 Using a thickness gage measure the distance between the washer and the end of the camshaft bearing journal The clearance should be 0 004 to 0 010 inch and must not exceed 0 025 inch 5 31 Power Take Off Drive Gears and Bearings a Removal 1 Remove transmission oil pump winch hydraulic pump and bulldozer hydraulic pump TM 5 2410 233 20 2 Remove bolts fig 5 47 and remove cover from flywheel housing Remove the thrust washers from the cover assembly 5 63 Figure 5 47 Power takeoff 3 Remove two drive gears fig 5 4B from flywheel housing pull each gear shaft from flywheel housing bearing 4 Remove the bearings from cover assembly fig 5 49 and the bearings and thrust washers from the flywheel housing 5 64 FLYWHEEL HOUSING BOLTS 16 42 COVER 2410 233 34 5 47 cover removal and installation NOTE idler gear and drive gear on crankshaft are to be removed it will be necessary to remove the flywheel para 5 32 Figure 5 48 Power takeoff drive g
257. on 15 Inspect pistons 6 l0 Stop and 15 to make certain orifices are open Check B Lia drain hole in stop 9 to be sure it is open Install 19 Spacers new preformed packings when assembling control 30 Bolts valve Figure 6 26 Pressure control value assembly 6 27 3 Pressure control valve reassembl y a Install plunger 14 fig 6 24 spring 13 and retainer 12 into piston 15 and secure in place with retainer ring 11 b Install slug 10 into piston 15 c Install pistons 2 and 15 and stops 1 9 and 16 into housing 3 Secure stops in place with pins d Install piston 6 retainer 5 and piston 18 into housing 7 NOTE Install spacers 19 inside piston 18 With springs 4 and 17 in their proper location fasten housings 3 and 7 together with bolts 20 through cover 8 4 Safety and directional valve a Safety valve 4 f a 6 7 and direc tional valve 1 can be removed from valve housing 2 for inspection b Screw center stem out of valve 4 to remove spring 3 Ce cH S j E A 2 m lt yp 9 e ME 2410 233 34 6 27 Directional valve Valve housing Spring Safety valve Stem Ve UE Figure 6 27 Safety and directional valve disassembly CAUTION Valve stem 5 may be thrown with considerable force by spring 3 when t
258. on the larger diameter pistons and one seal compressor 3 Measure the diameter of the piston to select the correct seal compressor Compressors are marked for nominal ranges The actual usable range can be calculated by reducing the low figure 1 16 in 1 5 mm and increasing the high figure 3 16 in 4 7 mm NOTE Be certain all hydraulic tylinder components have been inspected and new components installed where necessary before installing the seal assemblies The installation of the seal assemblies is the last step before the piston is installed in the cylinder 1 For ease of seal installation remove the 1 fig 2 20 2 Install the inner expansion rings 4 on the piston 3 wear ring LI Z IMP ME 2410 233 34 2 24 Wear ring Solid plastic outer seals Piston Solid rubber inner expansion rings 2 b i Figure 2 24 Solid seal assemblies installed on piston 3 Measure the diameter of the piston to determine the diameter to which the seal must be expanded The outer seals of the seal assembly must be expanded to a diameter slightly larger than the diameter of piston to allow the seal to be placed over the piston Be careful not to over expand the seals or they can be ruined NOTE The bars of the expander 1 00 22225 are graduated representing piston diameters If the seal can be slipped off the expander when the inside face of the mov able block is at point A indicated pisto
259. outlet relief valve 2 Replace any damaged or worn part 3 Reassemble the outlet relief valve in the reverse order of disassembly NOTE The orifice in valve 3 must be open and the valve installed in the body as illustrated 6 36 7 ZU Z ww ses EGGS ME LESS QS 7 Dd 9 H RB ME 2410 233 34 6 35 1 Bolts 6 Bolt 1 Cavity 2 Cover 7 O ring seals 12 Washers 3 Valve 8 O ring seals 13 O ring seal 4 Cavity 9 O ring seals 14 Bleed passage 5 Cover 10 Spring 15 Valve housing Figure 6 35 Outlet rdief valve assembly Inspection and Repair 1 Inspect the valve housing and valve for nicks burrs pitting and wear Light scratches or a light grey wear appearance are not harmful to the valve Examine the valve land edges for wear If wear or damage exists the complete valve assembly must be replaced 2 Inspect outlet relief valve spring for damage and proper tension The outlet relief valve spring should exert 39 54 3 16 pounds of force when compressed to 2 00 inches Free length after test should be 2 98 inches Spring diameter is 0 88 inch Replace defective or weak spring 6 8 Transmission and Steering Clutch Control Check Valve a Removal and Installation 1 Refer to TM 5 2410 233 20 and drain the transmission and steering clutch hydraulic system 2 Disconnect oil supply line 3 fig 6 36 3 Remove bolts 2 and check valve 1 C
260. oving the selector lever to the left or right 6 24 b Hydraulic Control Removal The trans mission hydraulic controls can be removed from the transmission case without removing the transmission from the tractor 1 Remove the seat cushion and backrest TM 5 2410 233 20 floor plates para 2 8a floor plate framework and the seat frame 24 9 2 Clean the transmission case to remove accumulations of dirt and grease that could enter the case when the cover is removed 3 Remove transmission oil filler spout and top cover from transmission case para 6 B 4 Remove spring 4 fig 6 21 5 Loosen locknut 5 and screw eyebolt 6 out of speed selector valve 6 Loosen locknut 13 and screw eyebolt out of directional valve 7 Loosen clamp bolt of lever 2 and pull shaft 3 from case Remove lever 2 8 Remove cover at front of transmission case and slide safety valve 9 out of valve housing through hole in case 9 Remove bolts 14 holding pressure control valve housing 15 to safety and directional valve housing 8 and lift pressure control valve housing from transmission 10 Remove torque converter inlet pressure relief valve and pry tube 1 16 forward until it clears valve housing 8 11 Disconnect inlet pressure line from filter at transmission case and pry tube 10 forward until it clears speed selector valve housing 1 12 Remove bolts holding two valve housings 1 and 8 to
261. ow schematic diagram for this tractor 1 1 LEGEND NOMENCLATURE LEGEND NOMENCLATURE LEGEND NOMENCLATURE ELE FLOOD LIGHT FRONT CB2 CIPCUIT BREAKEP SW SWITCH FL R FLOOD LIGHT REAR ST STARTER PL PANEL LIGHTS INSTRUMENT PS PRESSURE SWITCH LS LIGHT SWITCH BI GL GLOW PLUG CB CIRCUIT BREAKER TEMPERATURE LIGHT INDICATOR 50 SOLENOID GE GENERATOR TT TEMPERATURE SENDING UNIT CIRCUIT BREAKER RE PEGULATOR MS MAGNETIC SWITCH 54 0255 54 CB 4a 2m CB4 153 1 53 CB3 at339 CB3 152 0 52 CB2 aC 3 CB2 FL F n FL F FL F e FL F TT T4 LT Bi Bit 51 eL 1 CB latim CB I FL R e FL R FL R m FL R 3 PL sif 3 5i co 6 soc ioe so FL R FL R FL F FL F FL I EL GE so 50 x u RE B A 50 Bs PS B GL e GL GL GL GL 5 5 EES Ge B SW tod SW SW ST O N ME 2410 233 34 1 1 Figure 1 1 Electrical system schematic diagram Table 1 1 Standard Torques Bolts and Nuts Size Torque Size Torque inches ft lbs inches ft lbs A 9 23 3 4 265 35 5 16 18 225 7 8 420 60 3 32 55 1 640 gt 80 10 50 10 1418 800 100 Vo 15 10 1 1000 120 6 110 15 1 1200 150 58 150 a 20 1 1500 200 Taper lock Studs 7 9952 110 15 5 10 3 1 8 170 20 20 3 1 260 30 1 10 30 5 11 8 390 30 40 5 114 400 40 9 16 60 10 1 480 40 58 75 10 1 550 50 Hydrauli
262. p impeller retaining bolt torque 21 29 Torque divider Scavenge pump Drive gear to shaft retaining nut torque 2 36 44 Transm hydraulic controls Control valve to transmission retaining bolt 32 38 Safety valve to directional valve torque installed using liquid lock 35 45 Pressure control valve cover to body retaining bolts torque 32 38 Transmission Clutch retaining retaining bolts 80 90 Transmission case to transfer gear case retaining nut 70 80 Bearing cage to No No l carrier retaining bolt 37 43 Bearing cage to cage to No 2 carrier carrier retaining boalts 31 43 Table 1 2 Specific Nut and Bolt Torque Data Continued Item Bevel gear Hub to to drum bolts bats Hub to beveltobevel gearshaftretainingnut DM ipper Mounting bracket stud nut Hydraulic cylinder piston rod Steering clutch Steering clutch hub to steering clutch inner drum bolt torque Glow plu plug 6 Steering clutch outer drum flange bolt torque Final drive Track roller frame outer bearing retaining nut torque Finaldrive case to steering clutchand bevel gear Final drive drive flange drum screw Track rollers mounting boat Lubrication plug torque plug torque Front idlers and recoil spring
263. pection and Repair 1 Inspect the commutator for roughness high mica loose winding burrs or pits Smooth the commutator with 00 sandpaper or undercut on a lathe Replace the armature if the commutator bars are less than 1 16 inch thick after undercut Undercut the mica between the bars to a depth of 1 32 inch CAUTION Do not widen commutator slots by removing metal from bars when un dercutting Use only solder with a rosin core flux 2 Inspect the armature shaft for wear pits bends corrosion or breaks 3 Place the armature ends in V blocks and measure the commutator for out of round with a dial indicator Turn down if in excess of 0 001 inch out of round 4 Inspect for windings grounded to core with a continuity tester Touch one probe of the tester to the armature shaft and the other to each commutator riser An indication of continuity indicates the armature is grounded CAUTION Do not touch the probes to the com mutator bars or shaft bearing surfaces as arcing may score the smooth surface 5 Inspect for open windings with a test lamp Touch the probes to a pair of adjacent commutator risers Failure of the lamp to light indicates an open winding 6 Inspect for shorts with a growler and steel strip The steel strip will vibrate against the ar mature over a shorted area as the armature is turned 7 Inspect the field windings for worn or frayed insulation defective connections opens and field cur
264. pilot 7 fig 6 96 lock 11 nut 4 and piston 2 in reverse order of removal 2410 233 34 6 98 Retainer washer Spacer Adapter Dimension to be checked gt Zei L Figure 6 98 Installing hub 6 82 6 17 Steering Clutch Hydraulic Controls a General 1 Filtered oil is delivered by the steering clutch hydraulic oil pump to the steering clutch control valve housing 2 The steering clutch control levers are connected through mechanical linkages to levers on the shafts 1 fig 6 99 When the control levers are pulled to release the steering clutches the shafts 1 and 2 are rotated causing the levers 3 and 4 to contact the plungers 5 and move them to the rear The plungers operate the control valves which direct oil to the control pistons 1L fig 6 10 in the steering clutch hubs The oil behind the piston moves them toward the steering clutches com pressing the steering clutch springs 2 and moving the pressure plate 3 out of contact with the clutch discs ME 2410 233 34 6 99 ch hydra Figure 6 99 Steering clut ol side view ulic contr RAS N id AN PT MM ME 2410 233 34 6 100 Piston 2 Spring 3 Pressure plate Figure 6 100 Control piston operation b Removal and Installation 1 Remove the fuel tank para 5 14 2 Disconnect steering clutch control rods para 2 8 3 Disconnect supply and remove check v
265. ponents of the bulldozer circuit 4 19 ME 2410 233 34 4 13 1 Relief valve assembly 2 Manifold 3 Bolts 4 Bolts Figure 4 13 Bulldozer rdief valve removal b Removal 1 Remove the hydraulic tank from the tractor para 4 2 2 Remove the blade tilt control valve mounting plate and manifold 2 4 3 Remove bolts 3 and 4 NOTE Bolts 3 secure the relief valve discharge tube on inside of tank to the tank bottom plate c Disassembly 1 Remove bolts and lockwashers 6 fig 4 1 14 and cover 7 2 Remove bolts and lockwashers 13 to remove pilot valve body 14 3 Remove shims 10 from between cover 7 and spring 11 The total thickness of the shims determines the pressure at which the relief valve opens 1 975 25 psi 4 Remove spring 11 and pilot valve 12 Use a small magnetized rod to remove the pilot valve NOTE The seat 15 for pilot valve 12 is a press fit in body 14 If replacement is necessary remove plug assembly 17 and press the seat downward removing it through the opening for the plug assembly Chill the replacement seat before installing it in body 14 5 Remove bolts 1 and cover 2 Use a Ye inch 20 NC eyebolt to remove plug 4 beneath cover 2 6 Partially remove bolts 19 securing cover 18 to dump valve body 5 7 Insert a inch diameter rod 10 inches long into the plug opening until the rod contacts dump valve 23
266. primer pump The transfer pump draws fuel from the fuel tank and delivers the fuel through the primary and secondary fuel filters to the fuel injection pump The injection pump delivers the fuel under high pressure to the injection valves where it is sprayed into the engine precombustion chambers The accessory drive shaft drives the governor fuel injection pump camshaft service meter and fuel transfer pump 5 10 Fuel Injectors and Glow Plugs a Removal and Disassembly 1 Disconnect the fuel line fig 5 16 at the fuel injectors Cap or plug openings 2 REMOVE FUEL LINE 6 FUEL INJECTOR BODY FUEL INJECTOR NOZZLE NUT 5 REMOVE 1 REMOVE GLOW PLUG PRECOMBUSTION CHAMBER CYLINDER HEAD ME 2410 233 34 5 16 Figure 5 16 Fua injector removal and installation 2 Tag and disconnect electrical lead and remove glow plug from precombustion chamber 3 Remove the nut securing the nozzle and body in the precombustion chamber 4 Lift out the nozzle 5 fig 5 17 and body 1 and discard the two seals 2 and 4 5 Unscrew the nozzle 5 from the body 1 b Cleaning Clean the fuel discharge hole in the nozzle Remove any carbon deposits c Repair Inspect the nozzle for an ac cumulation of carbon eroded orifice and plugged screen Replace the nozzle if necessary d Testing Test fuel injector for proper operation by mounting injector in test fixture examining the
267. pring VU d Zei Li rs 2 l Figure 6 77 Brake adjusting mechanism ME 2410 233 34 6 78 Brake shaft 2 Brake control lever 3 Washer 4 seal 5 Bolt Brake lever Needle bearing 8 Steering clutch cover 9 Plug 10 Key Washer 12 Needle bearing 13 Key Figure 6 78 Disassembling clutch cover brake linkage d Inspection and Repair 1 Inspect all supports links levers and pins for cracks breaks distortion and wear Repair by welding straightening or replace the part 2 Inspect all needle bearings for corrosion roughness and wear Replace damaged or ex cessively worn bearings 3 Inspect all sleeve bearings for damage and wear Sleeve bearing to pin clearance new is approximately 0 003 to 0 005 inch The maximum allowable clearance is 0 015 inch Replace damaged or excessively worn bearings or pins 4 Inspect the brake linings for damaged or worn condition Replace the linings if damaged or worn to within 3 32 inch of rivet heads 5 Inspect the brake dam age and wear Replae a scored or excessively worn drum drums for scoring damaged badly NOTE Steeering brake drums which are not scored cracked or otherwise damaged may be considered serviceable from the wear standpoint if the following conditions is met after installing new brake linings at least one half of the band adjustment travel must remain If one half or more of the adjustment travel does
268. r 51 Nut 52 Lockwasher 53 Nut 6 Remove six hex head bolts 39 and lock washer 40 securing commutator end bell assembly to frame Using a screwdriver pry end frame away from frame 7 Pull commutator end bell assembly at tached brush holder assembly and armature 8 from frame Remove flat washer 7 and pull ar mature from bearing Remove spacer 81 Remove preformed packing 48 from end bell Remove seal 82 and bushing 83 as necessary Refer to d below for disassembly of end bell and brush holder assembly 54 Washer 55 Insulator 56 Bushing 57 Plate 58 Strip 59 Terminal 60 Stud 61 Stud 62 Nut 63 Terminal assembly 64 Gasket 65 Spring 66 Contuct assembly 67 Screw 68 Case and coil assembly 69 Screw 70 Clip 71 Connector 72 Switch assembly 73 Screw assembly 74 Plunger assembly 75 Washer 76 Bellows 77 Ring 78 Spring 79 Retainer 80 Ring 81 Spacer 82 Seal 83 Bushing 84 Housing assembly 85 Plug 86 Wick 87 Nut 88 Seal 89 Shaft 90 Lever assembly 91 Seal 92 Pinion 93 Spring 94 Clutch assembly 95 Washer 96 Gasket 97 Bolt 98 Lockwasher 99 Screw 100 Screw 101 Plug 102 Wick 103 Bushing 104 Housing assembly 105 Gasket 106 Adapter 107 Gasket 8 Remove five hex head bolts 39 and lock washers 40 securing lever housing 84 to frame Using a block of wood tap housing until loose Work end of bellows 76 free from solenoid relay and pull outward on l
269. r bent idler shaft 4 Inspect the metal floating ring seals for damage and proper wear pattern Replace seals which are pitted grooved scratched across the seal surface or which show an uneven wear pattern Seals must be replaced in sets 5 Replace all toris sealing rings Do not reuse toric seal rings 6 Inspect bearings guides and collars for cracks breaks or other damage Repair by welding and grinding smooth or replace the part e Reassembly 1 Reassemble in the reverse order of disassembly 2 Install floating seals 2 using a metal seal installer assembly Follow procedure outlined in NOTE At assembly tighten the nuts on the tapered pins to the initial torque given in table 1 2 05 a hammer punch to seat the tapered pins and then tighten the nuts to the final torque value 3 Lubricate the idler f Installation 1 Install the idler in the reverse order of rem oval 2 Align the idler with the track rollers paral 7 5 g Repositioning Front Idler NOTE The idler can be positioned from the HIGH to LOW or LOW to HIGH position 1 Remove the idler Note the location of the recess with the bearing in the LOW position 20 2 Rem ove the bolts raise collars and revolve bearings and shaft 180 so recesses are toward the rear of tbe machine fig 7 21 Install the bolt 3 Rotate the idler 180 in the direction indicated by the arrows This will position the idler properly for inst
270. rack setting subpara h Checking Fud Injection Pump Timing On Engine Using a Timing Set 1 Remove the rocker arm cover 2 Install a timing indicator set in the precombustion chamber of the pump to be tested Follow instructions included with the indicator set Disconnect the fuel line to the precombustion chamber Cap or plug openings 3 Move the governor control to the full load position 4 Maintain a 10 to 15 psi fuel pressure with the fuel priming pump or shop air CAUTION If shop air is used connect a relief valve which will release pressure above 15 psi Open the fuel shutoff valve 5 Rotate the crankshaft in its direction of normal rotation from 30 before top dead center until the inlet port doses At this point fuel flow is reduced to 6 to 12 drops per minute Zero the dial indicator 6 Rotate the crankshaft until the indicator reaches maximum value At this point the piston is at top dead center 7 At proper timing the indicator reading should be 0 1091 40 0040 inch i Checking Fud Injecion Pump Timing On Engine Using a Gage 1 Locate the top dead center compression position for the No 1 piston 2 Remove the No 1 fuel injection pump subpara cabove Insert a timing gage into the fuel pump bore 3 Ensure that the higher step of the pump plunger is slightly above the top surface of the gage body and that the lower step of the plunger is just below the top surface of the gage body
271. raper to clean trubocharger components NOTE Make sure the wheels are thoroughly cleaned Deposits left on these parts will affect their balance Inspection and Repair 1 Inspect wheel assembly and compression wheel for cracked bent or damaged blades CAUTION Do not attempt to straighten wheel blades 2 Refer to table 1 3 and inspect bearing journals and shaft for excessive wear 3 Inspect seal groove walls for scoring or scratches 4 Inspect bearings for wear looseness corrosion and binding Replace a defective bearing 5 Refer to fable 1 3 and inspect housing bore for scratches or excessive wear Replace housing if bearing bores are excessively scratched or worn beyond the maximum allowable wear limits 6 Inspect dirt deflector ring 14 5 3D for wear or other damage to seal grooves or deflector is damaged 7 Inspect sleeve 18 thrust bearing 17 and ring 19 for excessive wear or damage Replace parts if faces are mutilated Replace thrust bearing if worn beyond maximum allowable wear limits listed table 1 3 The small drilled oil holes in the thrust bearing must be clean and free of obstruction 8 Inspect oil deflector 16 for excessive wear or scoring Replace a defective oil deflector 9 Inspect shaft insert 12 for wear or scoring Replace if bore is scored or worn beyond maximum allowable wear limits listed in table 1 3 10 Inspect retaining ring 11 for proper spring te
272. re bellows is not crimped 6 If new brushes are being installed cover commutator with No 00 sandpaper temporarily install armature brushes and end bell subpara 7 below and turn in brushes Disassemble remove sandpaper and clean armature and brush holder plate assembly 7 Install spacer 81 on armature shaft and install preformed packing on end bell Install frame assembly 45 with assembled brush holder assembly 18 on commutator and install brushes Install flat washer on armature shaft and install armature and end bell as a unit into frame i Adjusting Drive Clutch Pinion Clearance 1 Remove plug 2 With starter pinion in engaged position press clutch inward toward lever to take up slack 3 Adjust hex self locking nut 87 until clearance between outer face of pinion and inner face of housing overhand is 23 64 inch 1 32 inch 5 22 Wiring and Wiring Harness Repair a Replace or repair broken frayed or cracked insulation b Resolder or replace broken terminals c Repair shorted connections d Replace broken wires and connections e Clean corroded terminals with abrasive cloth or replace as necessary f Replace defective wiring harness 0 Replace broken or defective battery cables LUBRICATING SYSTEM guard TM 5 2410 233 20 and drain the engine lubricating oil TM 5 2410 233 10 2 Remove the oil 5 2b 3 Disconnect oil lines to the oil pump fig 5 37 Cap or
273. releasing pressure in the hydraulic track adjuster cylinder 1 Pin 2 Segment 3 Segment 4 Nuts 4 5 Bolts Figure 6 124 Preparing to remove segment c Move the machine backward until pin lifts track and all of segment 2 is visible d Remove nuts 4 fig 6 124 and lift segment 2 away as shown i e Bolts 1 can be removed if hub is rotated backward far enough so the bolts will not interfere with the final drive cover 1 Bolt 2 Signment Figure 6 125 Removing segment 3 Inspection Refer to subparagraph 6 23 a 2 4 Installation Install in reverse order of removal 6 24 Final Drive Gear Case a Removal 1 Remove the final drive case metal floating ring seal para 6 22 2 Rem ove the bolts securing final drive case 1 fig 6 126 to the steering clutch and bevel gear case 3 Install three 1 2 inch 13 NC forcing screws 2 in the tapped holes Force the final drive case away from the steering clutch case 6 101 4 Remove the center forcing screw install a 1 2 inch 13 NC forged eyebolt Attach a hoist to the final drive case weight approx 350 Ib 5 Guide final drive case 1 off dowels 4 Take care not to damage splines of final drive gear hub 3 NOTE Inspect the sump area of the final drive case for dirt and other foreign materials Dirt in the sump area is an indication that the final drive seals are leaking Clean entire area thoroughly before case ins
274. removal and installation r Flywheel and hydraulic pump drive gear Hydraulic pump idler gear removal and installation r Flywheel housing removal and installation r Checking flywheel housing runout DZ Checking flywheel runout LU eue aisi I MR M LE E Piston and connecting rod exploded i view p Crankshaft and main bearings r Torque divider Hr 6 7 Cross sectional view of transmission r Universal joint disassembly 2 2 2 22 222 22 2 2 22 r Preparing to remove sun gear Pilot bearing and retaining ring removal and installation r Planet carrier removal and installation Planet carrier disassembly and reassembly r Torque divider housing removal and installation ca Removing output shaft bearing r Scavenge pump exploded view r Removing stator cruce Impeller disassembly r Carrier disassembly m Ring gear removal rm Turbine flange assembly and rotating housing removal EI Flange assembly eer Ee r Rotating housing bearing ege retainer LEE Torque converter clearances EA Checking torque converter clearances pel Hydraulic controls schematic LRL Hydraulic control removal re Disassembly of pressure control valve recu Differential valve removal Er Pressure relief valve removal e Pressure relief valve disassembly tht htt 55 Pressure control valve assem
275. rent draw 8 Inspect end frames for cracks and damaged or worn bearing surfaces 9 Inspect brush plate for cracks and loose rivets Inspect insulated brush holders for grounds 10 Inspect brush springs for tension and signs of breaks or other damage Replace brushes 11 Inspect the ball bearings for smooth operation Inspect for exessive side play and damaged surfaces 12 Inspect the generator field frame for breaks cracks and damaged threads 13 Inspect all hardware for threads 14 Replace or repair all defective parts as necessary f Assembly Reassemble generator in direct reversal of disassembly Seat brushes using a seating hone or sandpaper wrapped around commutator Clean commutator thoroughly and complete assembly 5 21 Starting Motor a General This electrical component is a heavy duty 24 volt submersion proof fungus and corrosion resistant solenoid operated enclosed shift lever type engine starter with eight brushes retained in four brush holders The drive clutch is a heavy duty overrunning type and the pinion clearance is adjustable The principal components of the starter are the frame armature commutator end plate assembly brush holder assembly brushes drive clutch assembly drive housing shift lever and solenoid plunger b Removal Refer to TM 5 2410 233 20 Starter Disassembly 1 Scribe marks across drive housing 1041 fig 5 36 lever housing 84 frame assembly 4
276. rnal with HDO 10 oil before installing through shaft seal 2 Discard all rubber seal rings 3 Press a new seal assembly into the body with an arbor press taking care that seal enters at right angles to the body recess and does not damage the body 4 Insert body bearings in their previously match marked positions 5 Insert drive gear into body bearing 6 Insert driven gear into body bearing at the same position from which it was removed Do not invert driven gear 7 Slide cover bearings on gear journals in previously match marked positions 8 Insert seal ring in body recess 9 Insert relief valve bail and spring body topping lightly to insure seating 10 Secure cover to body with the eight screw torqued to 28 32 foot pounds bearing for their nN w mt T C20 d NS NS an e Lr e Sei 10 IR 18 Bolt Capscrew Lockwasher Washer Cover Seal Bods Bearing Gear Kos Gear Bearing Figure 3 6 Winch hydraulic pump exploded view ME 2410 233 34 4 17 Gasket Spacer Seal Cover Seal Gasket Bracket Gasket Setscrew Coupling Ring 3 13 Winch Control Valve a Removal 1 Remove valve cover setscrews 1 5 and loosen push pull cable locknuts on the valve spools 2 Remove cables from handlever bracket on tractor and unscrew the cable ends from the valve spools by turning the free end
277. ront carrier roller and raise the other end of the track up around front idler until the master links 4 fib 7 7 and links 5 are ap proximately 1 inch apart and install coned disc seal washers 2 and 3 and spacers 1 in master links 4 NOTE If the master pin is to be driven in with a sledge hammer block under the first shoe and drive forward until master links 4 fig 7 2 and links 5 ap proximately 1 apart and install coned disc seal washers 2 and 3 and spacers 1 in master links 4 25 64 39 DRILL 3 8 FLAT WASHER 1 25 Seege 3 8 16 NC BOLT 3 1 2 LONG 3 8 16 NC NUT CENTERED ON 25 64 HOLE AND TACK WELDED 375 625 6 625 FLAT PIECES 50 THICKNESS ME 2410 233 34 7 7 Spacers 2 L Master link 2 Coned dise seal washers 24 5 Track link 5 Coned dise seal washers 19 Figure 7 7 Installing seal washers and spacers 5 Install each set of coned disc seal washers with one outside diameter facing the counterbore in link 4 and one outside diameter facing spacer 1 with inside diameters against each other Install spacer 1 with beveled edge toward the centerline of the track NOTE Coned disc seal washers 2 and 3 and spacers 1 can be held in place in the counterbores of master links 4 with the use of two holding tools Fabricate the tools to the dimension given in figure 7 7 6 Assemble the tools on master links and ti
278. rs are hardened steel with a slight dish built into them as shown in figure 3 15 f Drum Shaft Removal 1 Unscrew drum shaft nut 2 Remove bearing retainer shown in Eigure 3 1 13 BEARING RETAINER STRAIGHT EDGE Figure 3 13 Bearing retainer removal CLUTCH SEPARATOR PLATE 3 Remove place bolts in drum gear 4 Rethread nut on shaft 5 Sling shaft using nut 6 Pull shaft straight up as shown in figure 3 14 Figure 3 15 Clutch separator plates NOTE NOTE LL THE HYDRAULIC CLUTCH MUST BE SERV Place pan under drum shaft to catch oil that is in the ICED IN A CLEAN AREA The clutch pack drum Be sure to add two quarts of oil to drum at contains two parts The clutch 00 fig 3 16 1 reassembly friction discs and separator plates and the dutch spider 2 The two parts are not fastened together and may be separated by sliding them apart as shown The clutch is held together by six flathead capscrews that are locked on the back side by six setscrews 3 11 capscrews 1 the drive hub Clutch 2 Spider Figure 3 16 Hydraulic clutch I E 3 12 m Valve bods Plate Hub Plates 6 Piston Discs Spring Figure 2 17 Hydraulic clutch exploded view clutch discs 6 10 E 2 Remove the setscrews 12 fig 3 17 3 Turn clutch over and remove flathead remove end plate 2 exposing the and return springs
279. rtion Replace all defective parts e Repair Weld minor cracks and broken welds per TM 9 237 Paint welded and other barren areas per TM 9 213 f Reassembly and Installation Reverse disassembly and removal procedure and reassemble and install the hydraulic tank on the tractor Replace all damaged gaskets and seals VALVES AND HYDRAULIC PUMP b Valve Spool Removal 1 Remove and inspect plug assemblies 2 4 5 for broken springs The bane encased in the end of the plugs engage detent 1 Lfig 4 5 to hold valve spool 4 fig 4 3 in the FLOAT position 2 Remove bolt and lockwasher 5 CAUTION Valve body 3 and spool 4 are machined to close tolerances To avoid distortion of spool 4 leave spool in valve body when loosening or tightening bolt 5 4 Disassemble spool as shown in figure 4 6 GP Figure 4 4 Bulldozer and ripper control valves sheet 1 of 2 ME 2410 233 34 4 4 T 2410 233 34 4 4 2 12 Figure 4 4 Bulldozer and ripper control valves sheet 2 of 2 Key toLfigure 4 41 Pump suction line 2 Bulldozer control valve 3 Bolts t Rod 5 Pressure oil line from bulldozer control valve to ripper control valve 6 Bottom plate Bolts 8 Bolts 9 Bolt I 0 Elbow Elbow 1 2 Bolts I 3 Rod 14 Bolt 15 Bolt 10 control valve VIEW 5 X i N X 4 VIEW B ME 2410 233 34
280. rum on blocks about 2 inches lower than the outer drum 4 Insert the clutch spring sleeves 5 into the smaller clutch springs 4 and then place the small springs and sleeves into the large clutch springs 3 5 Place the springs and sleeves over the bosses on the retainer ME 2410 233 34 6 88 Steering clutch driven drum outer drum Guide pins Large clutch spring Small clutch spring Clutch spring sleeve Clutch spring retainer On 4 amp gt L Figure 6 88 Assembling springs and sleeves to retainer Steering clutch inner drum Figure 6 89 Installing inner drum 6 Place the inner drum 1 6 89 on the guide pins and over the spring and sleeve assem blies as shown 7 Install the clutch discs starting with a clutch disc assembly 1 fig 6 90 followed by a clutch driving disc Alternate from one to the other until all are installed NOTE If new driving discs are installed no precaution is necessary as to which face is up If the same discs are installed they must be replaced with the same face up and the top discs should be switched to the bottom of the stack 8 Place plate 2 fig 6 91 over the clutch discs Use the two guide pins 1 to align the holes in the plate with the tapped holes in the retainer 9 Install as many of the retaining bolts 3 and locks as possible to serve as guides for the spring and sleeve assemblies 10 Compress the springs with the sam
281. s Taper lockpins bolt torque Initial to seat parts Hammer lock pins into place then tighten to torque value of Lubrication plug torque iss oe debes duae e d COH E Fill valve torque valve check valve torque Relief valve torque Track Track shoe bolt torque Minim torque after 120 Lb Ft 200 20 100 100 1500 1600 120 180 220 120 24 lb in 180 220 500 600 200 220 180 220 550 50 110 140 65 50 10 110 140 20 30 20 30 20 30 180 260 plus additional 120 420 Table 1 3 Engine Repair and Replacement Standards Manufacturer s dimensions Component andtolerances in inches ACCESSORY DRIVE SHAFT Backlash between accessory drive and accessory drive idler gear Backlash between accessory drive and idler gear and camshaft gear CAMSHAFT Bearing journal diameter Bearing clearance End clearance CONNECTING ROD Connecting rod bearing clearance measured vertically Center to center distance Piston pin bearing should be machined to ID of CRANKSHAFT Main journal diameter Main bearing clearance End clearance Connecting rod journal diameter Permissible journal wear Permissible out of roundness journal CYLINDER BLOCK Main bearing original bore dimension Camshaft bearing bore 0 002 0 014 0 002 0 014 2 3105 2 3115 9 594 1 7009 9 596 1 7015 3 499 3
282. s fig 2 33 sheet 3 15 Remove the transmission from tractor b Installation Reverse removal procedure and install the transmission in tractor Fill transmission with oil to specified level LO 5 2410 233 12 TRANSMISSION MOUNTING NUTS ME 2410 233 34 2 33 Figure 2 33 Preparing to renove transmission sheet 3 of 3 2 23 CHAPTER 3 REPAIR OF Section 3 1 General The bulldozer group includes the bulldozer blade assembly braces push arm assembly and trun nions The bulldozer blade assembly includes the mold board cutting edge and end bits Scarifies are mounted on the back of the mold board The bulldozer hydraulic system chapter furnishes lift and tilt control for the bulldozer 3 2 Moldboard Blade Assembly fi 3 1 a Removal Refer to TM 5 2410 233 20 and remove the mold board blade assembly h Cleaning Scrape wash and clean moldboard LIFT CYLINDER BLADE ASSEMBLY MAOLDBOA RD EARTH MOVING EQUIPMENT AND WINCH BULLDOZER thoroughly with hot water Rem ove oily deposits with cleaning solvent Fed Spec P D 680 c Inspection 1 Inspect moldboard for broken weldments cracks wear and distortion Weld minor cracks TM 9 237 or replace an excessively damaged moldboard blade assembly 2 Inspect the attaching hardware for breaks or dam aged threads Replace all defective hard ware d Installation Refer to TM 5 2410 233 20 and install the mold
283. s directed to the torque converter inlet relief valve to aid in charging the torque converter 2 A hydraulic oil pump 3 is located on the front of the rear power takeoff housing The pump delivers oil to the full flow oil filter 2 located near the left main frame If the filter element becomes clogged a filter bypass valve opens and allows the oil to flow unrestricted to the hydraulic control valve ECH j J of lt lt T WM 2276 A Tap amr nee n x SX titi p J SASALI SALLA ei SSN st 2 SS NE WAS TCT E lt lt 77h Ze ME 2410 233 34 6 20 l Speed selector spool val 6 Safety valve 2 Filter Pressure SE valve 3 Pump 8 Di ffer ial valve 4 Safety and directional valve housing 9 Pr ntrol valve housing 5 Directional spool valve Figure 6 20 Hydraulic control schematic 3 From the filter oil is directed to the control valves in the top compartment of the transmission case The first valve the oil contacts is the speed spool selector valve 1 The valve is a four position spool valve which is positioned by mechanical linkage to direct oil to one of the three speed clutches No 3 No 4 or No 5 A parallel passage in the speed selector valve housing directs the oil flow to the pressure control valve housing 9 4 The pressure control valve is composed of two valve systems the pressure relief valv
284. s necessary 8 Using a piston ring expander remove the piston rings 11 and 12 from the piston 9 CAUTION Cover the crankshaft and main hearings before removing the sleeves Sediment from the block could damage the crankshaft and bearings 9 Using a liner puller assembly and an adapter plate remove the liner 13 from the block 15 Discard the rings 14 b Cleaning Clean all components except pistons with cleaning solvent Fed Spec P D 680 and dry with clean lint free cloths Remove carbon deposits from pistons with fresh cold water Soak the pistons in water overnight and allow to dry in sunlight Ensure that ring grooves are clean Cc Inspection and Repair 1 Inspect connecting rod bearings for burrs and rough spots Light scratching will not impair operation Smooth minor roughness with a soft hone or crocus cloth Replace very rough bearings If one bearing must be replaced replace all bearings if possible 2 Replace bent connecting rods 3 Press the piston pin into position into the bearing Measure the clearance Replace the pin and bearing if clearance exceeds 0 004 inch 4 Inspect tbe piston pin for cracks score marks or pitting Discard the pin if surfaces are dull rough or checked by acid corrosion 5 Inspect the bearing liners for wear scratches pitting and metal failure Replace as required 6 Inspect the piston for grooves scoring pitting and other damage and for wear Replace
285. s of the cables B 3 Remove the pump supply hose 3 and nipple 4 4 Remove the valve cover 5 Detach tube assembly 5 and remove tee 6 6 Disconnect the clutch and brake hoses 7 7 Remove socket head capscrews attaching valve 8 to winch 8 Remove valve 8 from winch Remove or secure the preformed packing that seals between the valve and the winch Be sure preformed packing is replaced when reinstalling valve on winch to avoid seepage around base of control valve 9 Reverse above procedure for valve in stallation and check for proper stroke adjustment between the push pull cables and spools 8 E Se ME 2410 233 34 3 5 Setscrew 2 Cable 3 Hose 4 Nipple 5 Tube assembly 6 Tee 7T Hose 8 Valve Figure 3 5 Control valve removal b Disassembly and Reassembly 1 Selector spool removal NOTE This may be accomplished without removing the valve body 29 ZZS from the support 30 a Remove the snap ring 12 washer 11 and spring 10 3 6 b Remove the plug 23 spring 24 and ball 25 c Remove the spool 7 by pushing the rod end through the valve body as shown CAUTION Do not pull the rod end of the spool after the ball 25 has been removed or the preformed packing 8 on the spool will come in contact with a dump port and be damaged 2 Selector spool stallation a Inspect for nicks on the spool Light nicks may be removed by lapping but if
286. semblies Springs Springs Figure 6 47 Removal of No 1 and No 2 clutch 3 Remove No 1 clutch ring gear 2 plate assembly 5 clutch reaction pins 6 No 1 clutch plates and disc assemblies 9 4 Remove No 2 clutch plates and disc assemblies 8 and springs 10 and 11 5 Install inch 16 NC eyebolts and remove the No 1 carrier fig 6 48 6 Remove bolts locks and plates fo 6 49 and No 2 clutch ring gear 2 7 Install 1 2 inch 13 NC eyebolts and lift off the No 3 clutch housing 3 disc assemblies and plates as a unit NOTE The No 4 and No 5 clutch housings 4 and 7 can be removed in the same manner as the No 3 clutch housing 3 Figure 6 48 Removing No 1 carrier 6 43 vv 9 Bolts locks and plates No 2 clutch ring gear No 3 clutch housing No 4 clutch housing Springs Clutch reaction pins No 5 clutch housing cl E gt whe Figure 6 49 Removing No 3 clutch housing ME 2410 233 34 6 49 8 Remove the No 2 carrier 1 fig 6 50 bolts 2 and bolts and locks 3 9 Remove bolts and locks 1 fig 6 5 10 Install 3 4 inch 16 NC eyebolts in the tapped holes provided and remove the output shaft 2 NOTE Cover the openings 3 when installing the carriers and cl utc hes to prevent the loss of parts into the transfer gear case ME 2410 233 34 6 50 No 2 carrier 2 Bolts 3 Bolts and locks Figure 6 50 No 2 carri
287. si 37 47 psi 135 145 psi Adjustment None Add spacers 5M9622 5M9623 5M9624 located inside piston in the pressure control valve assembly Spacer Chg in psi 5M9622 15 0 5M9623 8 5 5M9624 2 5 None None Add or remove washers from valve Adding 4B5270 washers adds 6 psi Note If engine is below tbe listed values check engine performance If engine speed is above the listed values the torque divider may have to be disassembled and causes for loss of efficiency determined Bench test Supply oil at the pump port at 280 10 psi ratio valve by pass to drain when pressure exceeds 140 5 psi 6 12 Transmission Control Linkage a Removal and Installation Refer to figure 6 71 to remove and install transmission control linkage parts as required b Inspection Inspect parts for breaks cracks distortion damage or excessive wear Key to et 1 Bolt 1 Spring 2 Lock 2 Nut 3 Pin 3 Lockwasher 14 Clevis 4 Serew 15 Knob 5 Knob 6 Bushing 6 Lever assembly 7 Spacer Nut 18 Lever assembly 8 Lockwasher 9 Nut 9 Nut 20 Lockwasher l0 Screw 210 Nut 6 66 22 Bolt 23 Nut 24 Bolt 25 Lever 26 Key 27 Washer 28 Nut 29 Nut 30 End 3 End 32 Rod c Repair The transmission control linkage parts are to be repaired by replacement only Replace worn or defective parts d Adjustment Refer to palagraph 6 4 land adjust the transmission control linkage b
288. ssed to 3 728 in Free length after test 4 11 4 89 in Spring diameter 184 816 in Control linkage adjustment Dimension between washer and lever on selector lever control shaft text for correct method of adjusting 002 022 in Table 1 4 Power Transmission Units Repair and Rep Standards Continued Manufacturer s dimensions Maximum Component andtolerances ininches Desiredclearance allowable wear and Control linkage adjustment Continued Dimension between centerline of transmission hydraulic control shafts and face of lever on selector lever control shaft see text for correct method of adjusting 1 98 in Transmission Transmission clutches Nos 1 3 and 4 clutches Overall width of 3 new disc assemblies and 2 new plates 1 172 1 202 in No 2 clutch Overall width of 4 new disc assemblies and 3 new plates 1 650 1 692 in No 5 clutch Overall width of 2 new disc assemblies and 1 new plate 694 712 in Clutch piston release springs Nos 1 and 2 clutches Pounds force 28 60 33 60 in When compressed to 4 0937 in Free length after test 5 0937 in in Spring diameter 5625 in Clutch release springs Nos 3 4 4 and 5clutches Pounds force 26 45 31 05 When compressed to 1 837 in Free length after test 2 469 in Spring diameter 563 in Clutch reaction pins Nos 1 and 2 clutches Len 5 181 in Clutch reaction pins Nos 3 4 and 5 clutches Length 8 25 in Shafts gear outside diameter 1 3877
289. st be uniform around the entire circumference of the floating ring seal 7 Always install the floating ring sealsl fig 2 1 10 in pairs that is two new seals together or two seals that have previously run together Never assemble one new seal and one used seal or two seals that have not previously run together 8 Before assembling floating ring seals together wipe faces of seals with lint free tissue to remove any foreign material and finger prints 9 Place one drop of light oil on the cleaning tissue and coat the sealing surfaces of the seals Be careful not to let any oil come in contact with the toric sealing ring or its mating surface 6 23 Sprocket and Sprocket Segments a Sprocket 1 Removal a Remove floating ring seal 3 as described in paragraph 6 22 b Bend lock 1 securing retaining nut 2 6 96 ME 2410 233 34 6 117 1 Lock 2 Bearing nut 3 Metal floating ring seal 4 Bearing cone 5 Final drive hub Figure 6 117 Removing outer bearing cone Using spanner wrench back off retaining nut 2 approximately 7 8 inch Turn the nut back toward the sprocket and install yoke fig 6 118 between the nut and bearing cone as shown Remove hearing cone by unscrewing nut 2 fig 6 117 with the yoke in place CAUTION After the outer bearing cone has been forced off install sprocket retaining nut 2 on the final drive hu
290. sun gear removal No 1 carrier disassembly No 2 carrier disassembly Clutch disassembly Transfer gear removal Removing transfer gear outer bearings Separating cages Removing cover Removing bevel pinion Bearing outer race removal Junction block removal Transmission hydraulic control system schematic first Hydralic control system pressure tap locations Transmission control linkage exploded view Brake operation Preparing to remove brake engaging mechanism Brake engaging mechanism removal Brake engaging mechanism disassembly Brake lever bearings Brake adjusting mechanism Disassembling clutch cover brake linkage Adjusting brake engaging mechanism Adjusting brake linkage Steering clutch operation Prepaing to remove steering clutch assembly Removing steering clutch assembly Removing outer drum Cross section of clutch assembly Holding steering clutch spring in compression Preparing to assemble clutch assembly Assembling springs and sleeves to retainer Installing inner drum Installing clutch disc assemblies Compressing steering clutch springs Removing steering clutch assembly from inter drum Removing steering clutch piston Preparing to remove hub retaining hub foward Removing hub retaining nut j poe e EE TEE EE EE Steering clutch hub assembly exploded view Pulling hub Installing hub Steering clutch hydraulic control side view Control pis
291. t 1 r r rr rz Goa Lr LLL LE ru r LL Ll LL Ll r Dm Lm r LE r r L23231 Coa L Gao p LL LL L4 CH Number Title Page r Turbocharger mounting fixture and adapter pnlate ossis EEKE CZI Matehmarking turbocharger parts relation LL Turbocharger disassembly reassembly Kees Turbocharger retaining nut removal and installation LE r Pressing turbocharger shaft from turbine wheel r oo Turbocharger clearance eheck between spacer block and housing face pus p Exhaust manifold removal and installation z D Generator disassembly A p Starter motor exploded view Sheet 1 of 21 D 39 Starter motor exploded view Sheet 2 of 2 BEES rm Oil pump removal and installation ru r Oil pump exploded view cH Oil pan and oil pan plate removal and installation rpm Cylinder head and valves exploded view rum Cylinder head bolts torque sequence CLE Accessory drive shaft removal and installation Sheet 1 a 2 Accessory drive shaft removal and installation Sheet 2 of 21 Timing fixture plate installed Timing gears and cover exploded view Timing gears and marks r Camshaft assembly exploded view r Power takeoff cover removal and installation TIT Power takeoff drive gears 2 rr r Removing power takeoff drive gear bearings oo Flywheel
292. tallation 1 Final drive case 2 Fordng screws 3 Final drive gear hub 4 Dowels 5 nner races 6 Outer race and roller assemblies ME 2410 233 34 6 12 Figure 6 126 Final drive case removal 6 102 b Inspection Inspect gear cases covers bearing cages and flanges for cracks breaks and damaged threads Repair cracked or broken cases covers or cages by welding and grinding smooth or replace the part Repair thread damage by installing helical inserts c Installation stall two 5 8 inch 11 NC guide pins 2 attach a hoist align pinion outer bearing inner races 5 fig 6 126 with pinion outer race and roller assemblies 6 and install the final drive case 2 Install the bolts securing the final drive case to the steering clutch case Tighten the bolts to the torque value given in paragraph 1 4 3 Remove dirt guard 1 fig 6 127 and clean thoroughly so dirt will not fall on the floating ring seals when the sprocket is installed 4 Install metal floating ring seal 1 fig 6 128 using installer tool 2 as shown para 6 22 ME 2410 233 34 6 12 1 Dirt guard 2 Guide pins Figure 6 127 Final drive case installation ME 2410 233 34 6 120 1 Metal floating ring seal 2 Seal installer Figure 6 128 Installing meal floating ring seal 6 25 Final Drive Gear Idler Pinion and Bearings a Removal 4 Remove the final drive gear case as described in paragraph 6 24 2 Inspe
293. tance between the front face of the seat support and the rear face of the brake pedal 17 63 to 17 87 inches 6 73 B See a j N e SN t a 2 SHIMS y STOP BRAKE LEVER SUPPORT ASSEMBLY Nh WOOD BLOCK BRAKE LEVER VIEW lt BRAKE LINK MILLED FLAT VIEW B ME 2410 233 34 6 79 Figure 6 79 Adjusting brake engaging mechanism 6 74 ME 2410 233 34 6 80 Parking brake lever Brake pedal Brake linkage Parking brake linkage Zei L Figure 6 80 Adjusting brake linkage 6 15 Steering Clutches a General 1 The multiple disc oil type steering clutches are held in engagement by springs and are disengaged hydraulically 2 The steering clutch disc assemblies have teeth on the outer diameter which mesh with splines in the outer drum The steering clutch driving discs have lugs on the inside diameter which interlock with the tapered recesses of the inner drum 3 The steering clutches are disengaged by oil pressure acting behind the steering clutch piston 1 fig 6 8 which causes the piston to move outward against the steering clutch spring retainer 3 This moles the steering clutch pressure plate 2 out of contact with the discs to disengage the clutch A 222 CLL lt LE 2 AY I S 8Z EN gt A Es S 1227 SC 7 ss ll ZZ dt n lt SA ees S
294. teeth on the ring gear 6 The plates 3 are notched to fit around pins in the clutch housings which prevent the plates from turning 3 The clutches are held disengaged by springs 2 which act between the clutch housing 4 and piston 1 To engage the dutch oil is directed into the space behind the piston 1 hydraulic pressure then moves the piston outward pressing the plates 3 and discs 5 together and preventing the ring gear 6 from turning 4 The two front clutches No 1 and No 2 fig 6 39 are directional clutches determining forward or reverse direction and the three rear cluthes No 3 No 4 and No 5 are speed clutches providing second third and first speed respectively 5 Two clutches must be engaged in order to transmit power through the transmission The following chart shows the combination of clutches engaged for each forward or reverse speed Speed Clutches engaged First forward 15 Second forward 1 3 Third forward 1 4 First reverse 25 Second reverse 2 3 Third reverse 2 4 2 SSS SS SSSSNNNNN NS SS e d OSS SAA 22 72 SpA AH Ay LLB aos aad 7 KANNAAAAAAAAAAAAAAAAA 5 Wee Kack 4 2 6 5 ME 2410 233 34 6 38 Piston 2 Spring 3 Plates 4 Clutch housing 5 Dises 6 Ring gear Figure 6 38 Clutch operation Figure 6 39 Clutch designation b Transmission Reconditioning 1 Before disassembling
295. ternal lines Leakage within transmission Pressure relief valve in hydraulic control valve stuck open Check valve stuck in bore Differential valve sticking closed f Safety valve improperly adjusted g Torque divider failure Obstruction preventing directional clutch from releasing Control linkage improperly ad justed Speed and safety valve improperly adjusted Defective relief valve in hydraulic control Improper relief valve setting Defective relief valve in hydraulic control Worn cylinder piston rod packing and seals Broken brake spring Sticking or damaged piston in winch control valve Corrective Action Align engine mounts para 2 and tighten all mountin bolts securely b Tighten pulley mounting bolt para 3 29 c Replace defective pulley or damper para 5 29 d Refer to 1 above e Remove fan belts for short duration If vibration is no longer evident replace fan para 5 1 a Replace piston rings para 5 39 b Recondition valves and seats paral 5222 a Replace valve 5 27 b Clean carbon from pistons 33 c Tighten bolts or replace bearing para 5 33 a Replace bearing 5 34 b Replace pump gears 5 21 c Repair or replace a defective pressure regulating valve para 5 24 Disassemble starter and replace armature para 5 21 d Disassemble generator and replace armature para 5
296. the adjusting nut lock and damping bolt removed tighten the adjusting nut 1 in a counterdockwise direction to the torque value of 1200 1500 Ib ft b Continue to tighten the nut until the lock can be installed in one of the recesses in the retaining nut c Insert the damping bolt and tighten to lock the retaining nut in position ME 2410s 233234 6 146 Retaining nut Figure 6 146 Adjusting final drive bearings 6 29 Aligning Track Roller Frame With Sprocket a When installing track roller frame 6 go 6 1 147 the center of the track rollers should be centered with final drive sprocket 8 so the track will lead straight off of rear roller 5 onto the final drive sprocket and not rub against either the sides of the sprocket or the rims of the track roller b Final drive sprocket 8 should be centered in the recess of rear track roller 5 so clearances 10 and 12 between the outer face of the sprocket and the inner edge of the track roller are equal c When this properly adjusted diagonal brace 13 should be checked to see there is some clearance at 14 and 15 in the recess in steering dutch case 16 d To make this adjustment remove cap 1 from outer bearing assembly 4 and remove lockring 7 nut 2 and retainer assembly 9 e Add shims 3 between retainer assembly 9 and holder assembly 11 to move the track roller frame out decreasing dearance 12 at the roller and at diagonal brace 13 an
297. the crankshaft gear for cracks broken teeth burrs scoring and wear Remove burrs and light scoring with a soft hone or crocus cloth or replace the gear if necessary d Reassembly 1 Position the key in the crankshaft Using a hydraulic pump press the crankshaft gear onto the crankshaft 2 Install the crankshaft in the block Align the crankshaft gear as instructed in buscan 5d 29 3 Install the bearing liners and lubricate the inside surfaces of the bearings Rotate the upper bearings into position in the reverse order of removal Ensure that bearings are installed in the same positions they were removed from 4 Install the lower bearing caps and secure with nuts Tighten the nuts to a torque of 155 foot pounds 5 Check the bearing clearance subpara e and the crankshaft end clearance subpara f 6 Install the oil pump para 5 24 and oil pan and oil pan piad oar 5 15 Install the flywheel and housing 5 32 and timing gear cover para 5 29 Install the water pump 6 7 Install the engine in the tractor 2 8 e Main Bearing Clearance Check NOTE If bearing clearance is checked while the crankshaft is installed and the engine is upright hold the crankshaft against the upper halves of the bearings 1 Place a soft lead wire between the lower bearing half and the crankshaft Coat two 1 inch lengths of the wire with grease and place them diagonally on the bearing The grease will hold t
298. the rh bearing retainer 6 bevel gear shaft 4 Loosen bearing nut 2 enough to permit 12 Pull shaft Slowly as shown in figure 3 11 removal of snap ring 4 5 Replace bearing retainer 3 for support If drum is to be removed remove Ih drum shaft HOIST nut 6 Turn winch on its left side 7 Remove the top side frame cover and disconnect the hydraulic line 8 Remove bearing nut 2 fig 3 9 9 Slide roller bearing and the spacer washer 1 from the shaft 10 Remove the internal snap ring 4 NUT retaining the bearing and clutch drive gear as BEVEL GEAR shown in figure 3 10 ME 2410 233 34 2 11 uu k Figure 3 11 Bevd gear shaft removal 13 Do not pound or drive on the ends of the E bevel gear shaft d 14 Slide the shaft completely away from the unit freeing all component parts on the shaft e Intermediate Shaft Removal 1 Remove bearing retainer 2 Insert puller screw in shaft 3 Pull shaft 4 Remove intermediate gear and drum pinion shown in figure 3 12 WINCH HOUSING OME 24104233 34 73 0 Ss Figure 3 14 Drum shaft removal Figure 3 12 Intermediate gear and drum pinion removal g Clutch Disassembly 1 Overheating due to slipping or lack of cooling oil will cause most damage to the discs and separator plates Overheating causes both parts to warp which causes clutch drag The clutch discs are flat The separato
299. the seal will be operating Do not use grease on any seal except a grease seal d If during installation the seal lip must pass over a shaft that has splines a keyway rough surface or a sharp edge the lip can be easily damaged Shim stock or other such material can be formed around the area to provide a smooth surface over which to slide the seal m Hydraulic Systems 1 Cleanliness a When removing components of a hydraulic system cover all openings in both the component and the machine b If evidence of metal or rubber particles are found in the hydraulic system flush the entire system c Disassemble and assemble hydraulic components on a clean surface Clean all metal parts in a nonflammable cleaning fluid Then lubricate all components to aid in assembly 2 Safety Before servicing the hydraulic system NEUTRALIZE THE HYDRAULIC PRESSURE PROCEDURE a Lower components to the ground In some instances a removal procedure may require the component to be blocked in a certain position b With the engine shut off move the hydraulic control levers to all positions to insure there is no pressure in the system c Place all control levers in HOLD position NOTE When attached hydraulic equip ment is removed from machine which w ill continue to be used the hydraulic sy stem lines must be securely blocked High pressure protective covers are av ailable One O ring seal is required w ith each protective co
300. to the housing when assembling the plungers and valves 6 Remove lever and key 1 fig 6 104 and loosen bolt 2 7 Tap end of shaft 5 to remove spacer 6 and bearing 7 from control lever housing 12 8 Remove snapring 4 9 Remove washer 3 lever 8 and key 11 while pulling shaft from housing 10 Remove pin 9 and roller 10 11 Remove seal and bearing from control lever end of housing NOTE Seal should be installed with lip facing inward 77 ME 2410 233 34 6 104 1 Lever and key 2 Bolt j Washer 4 Snapring 5 Shaft 6 Spacer T Bearing 8 Lever 9 Pin 10 Roller ll Key 12 Control lever housing Figure 6 104 Control lever housing disassembly ME 2410 233 34 6 105 1 Rings 2 Control valve housing 3 Plugs hidden Figure 6 105 Plug removal 6 85 12 Assemble housing in reverse order of disassembly and bolt the two housings together 13 Valves and plungers can be removed from control valve housing 2 fig 6 105 by removing rings 1 and plugs 3 14 Inspect preformed packings plugs before assembly d Inspection and Repair 1 Inspect the valve housing and valves for nicks burrs scoring pitting and wear Light scratches or a light grey wear appearance are not harmful to the valve Examine the valve land edges for wear If wear or damage exists the complete valve assembly must be replaced 2 Inspect valve bushings for damage and wear Repl
301. ton operation Control valve removal age inae PUO s doin RUE EU RACE RC EE eo EO a oan pO Ree RET Control valve housing disassembly Page Ln Leal Lo 4 6j DCH DCH Number Title Page P unger and valve disassembly 35 Control lever housing disassembly DE Plug removal EE Preparing to remove bevel gear and bevel gear shaft eror Ee Removing bearing cage RR eth nui Removing bevel gear shaft pea Measuring clearance 58 Measuring backlash E Final drive EE 6 90 Outer bearing removal 2291 Outer bearing installation LE Bearing cage holder removal H TP reu Bearing cage holder assembly eee tenes ru LE 6 96 Ll 6 9 Removing bearing cage Removing outer bearing cone Removing nut with yoke installed Sprocket removal Installing sprocket Sprocket installing tools EE i wa qoe usa arde qur ora da d Mop a cU de der d Checking sprocket location 2 0 0 0 liiis e singe nea wr Installing retaining mut e 000 Preparing to remove segment Ba Removing segment 2 0 0 0 0000 eR DESCH Final drive case removal kien t yer Ae ew RR 6 107 Final drive case installation LETT Installing metal floating ring seal lisse elei sees Removing outer race and roller
302. transmission clutch housings 13 Remove clip 12 from tube 11 and slide tube 11 into speed selector valve housing 1 until tube clears housing 8 14 Lift valve housings up to clear tubes below them and remove valve housings from case 15 Replace transmission top cover while hydraulic controls are out of transmission 60 9 GA SL gig Wn a i m9 d g ns NT oen Lane EAR 12 14 15 16 ME 2410 233 34 6621 fm Spe e elector valve housing 5 Locknut 9 Safety valve 13 Locknut 2 Lev 6 Eyebolt 10 Tube 14 Bolts 3 Sh er vebolt 11 Tube 15 Pressure control valve housing 4 Spring 8 Safety and directional valve using 12 Clip lo Tube Figure 6 21 17 ic contro remova L c Hydraulic Control Disassembly and Assembly 1 Pressure control valve disassembl y a Remove bolts 1 fig 6 22 and cover 2 b Separate housing 3 from housing 10 c Remove springs 4 and 7 d Remove retainer 5 e Remove pistons 6 and 9 and spacers 8 NOTE Spacers 8 in piston 9 are used for pressure ad justment Keep these spacers together since they will be needed at time of assembly f Remove pin 1 fig 6 23 stop 2 and piston 3 g Remove pin 1 stop 2 slug 3 relief valve piston 4 and stop 5 2410 233 34 6 22 Bolts Cover assembly Housing Spring Retainer Piston Spring 8 Spacers 9 Piston
303. trol linkages 14 15 and ripper control linkage 16 TM 5 2410 233 20 NOTE The fuel tank and the cross members that support the seat frame and floor plates have been removed for better illustration only 9 Install an eyebolt in the hole provided in the top of the tank and attach a hoist to the eyebolt 10 Remove bolts 12 and 13 and remove the hydraulic tank from tractor 4 1 cv Figure 4 1 Hydraulic tank removal H I 1 10 233 34 4 1 to Bolts 2 Bolts 3 llvdraulie lines Bolts 5 Drain lines 6 Hydraulie lines 2 Hydraulie lines 8 Hydraulic lines Hedraulie lines lO Elbow assembh ll Hadraulie lines 12 Bolts 13 Bolts 21 14 Bulldozer tilt control linkage 15 Bulldozer control linkage lo Ripper control linkage h Disassembly 1 Remove bolts 2 4 2 and remove mounting plate 3 and manifold 6 as a unit weighs approx 70 Ib 2 See paragraph 4 4 for the removal of pressure relief valve 5 3 Remove bolts 2 securing line 1 to filter 3 At assembly it may be necessary to loosen hose clamp 4 to align bolt holes 4 Remove all bolts securing tank assembly 1 4 2 to bottom plate 4 5 Install a 13 NC forged eyebolt in top of tank assembly 1 and attach a hoist Remove tank assembly 1 which weighs ap proximately 300 pounds 6 Refer to TM 5 2410 233 20 for filter cap and filter
304. ttach a hoist and remove outer recoil spring 4 Remove inner recoil spring 5 ME 2410 233 34 7 28 Bolt Washer Recoil spring front pilot Idler recoil spring outer Idler recoil spring inner Recoil spring bolt retainer nut Recoil spring rear pilot Recoil spring bolt sleeve Recoil spring bolt gt A Er RI Figure 7 28 Recoil spring assembly C Inspection Inspect recoil springs for damage and distortion Free lengths are Outer 31 1 7 32 23 inches inner 21 50 22 50 inches Replace a distorted or damaged spring d Reassembly 1 Position rear pilot 7 over the choke in the press bed 2 Install recoil springs 4 and 5 3 Install sleeve 7 in inner recoil spring 3 and install front pilot 1 4 Fabricate guide pin 5 as illustrated in figure 7 30 bnd screw it into the recoil spring bolt 4 5 Insert bolt 4 through front pilot 1 sleeve 7 and rear pilot 6 6 Center the recoil spring assembly beneath the press ram and compress the assembly to assembled length measured from the rear face of the front pilot to the front face of the rear pilot table 1 5 7 Remove guide pin 5 Install retaining nut 6 7 28 NOTE Install bolt 1 and washer 2 to lock retaining nut 6 after the recoil spring assembly has been installed in the machine A above ME 2410 233 34 7 29 1 Recoil spring front pilot 2 Idler recoil spring outer 3 Idler recoil spr
305. ualizer bar 4 Bolts 5 Support assembly 6 Track carrier roller bracket Figure 7 36 Preparing to remove support assembly Section Ill EQUALIZER BAR AND TRACK ROLLER FRAME 7 9 Equalizer Bar Inspection Inspect equalizer bar 2 fig 7 39 for cracks breaks distortion or other damage Report any damage or defects of the equalizer bar to depot maintenance personnel 7 10 Track Roller Frame a Removal 1 Separate the track and lay it out flat 7 1 2 Remove sprocket guard and rear track roller frame guard 3 Remove outer hearing cap fig 7 37 and brace bearing cad fig 7 38 i 4 Raise and support the front and rear of the tractor to allow the track rollers to clear the track rails E BEARING CAPR WARNING Support front of tractor under center of equalizer bar 5 Attach a suitable sling and hoist around the track carrier rollers to support the track roller frame 3 fig 7 39 The track roller frame weighs approximately 4350 pounds Figure 7 37 Removing outer bearing cap 7 18 Adjust the hoist sling to position the front of the track roller frame slightly higher than the rear 6 Raise the track roller frame to transfer the weight of the track roller frame from the equalizer bar 2 to the hoist 7 Rock the track roller frame to separate it from the track roller frame outer bearing 1 and to Separate the diagonal brace from the sprocket shaft 8 Remove the track roller
306. ube end of the body will vary in design depending upon the application However the installation procedure of the fitting body into its mating boss will be the same If the tube end of the fitting body is as illustrated either elbow fig 2 18 or straight body 2 14 a presetting procedure is necessary to assemble the sleeve onto the tube before connecting the tube to the end See b below 2 Place the nut washer and seal as far back on the fitting body as possible Hold the components in this position and screw the fitting into its boss until washer just contacts the face of the boss 3 Place the fitting assembly in its correct angular position by turning the body out coun terclockwise a maximum of 359 Tighten the nut finger tight 2 7 NOTE M the fitting is connector straight fitting the hex on the body takes the place of the nut Install this type fitting by tigh tening the hex against the face of the boss 4 Install the assembled tube onto the tube end of the body finger tight Tighten the nut positioning the body Then tighten the nut on the tube assembly ME 2410 233 34 2 13 l End of fitting body connects to tube 2 Fitting body 3 Locknut 4 Backup washer 5 O ring seal 6 End of fitting screws into mating boss Figure 2 13 ELbow body assembly b Assembly of sleeves onto tubes 1 A is necessary to preset this type of sleevel fin 2 18 onto the tube before the tube assemb
307. ue converter inlet relief valve Directional valve body 4 CS N Fe Figure 6 32 Torque converter inlet relief valve and directional valve body d Inspection and Repair 1 Inspect the valve housing and valve for nicks burrs pitting and wear Light scratches or a light grey wear appearance are not harmful to the valve Examine the valve edges for wear If wear or damage exists replace valve assembly 2 Inspect inlet relief spring for damage and proper tension Replace a defective or weak spring e Reassembly and Installation Reverse disassembly and removal procedure and assemble and install the torque converter inlet relief valve 3 8 7654 9 ME 2410 233 34 6 33 D Spring l Bolt and washer 2 Cover x Plunger 3 Slug Spool assembly A Ring 9 Directional valve body 5 Stop Figure 6 33 Torque converter inl amp rdief valve 6 7 Torque Converter Outlet Relief Valve 2 Refer to TM 5 2410 233 20 and drain the torque converter hydraulic system 3 Disconnect oil lines 3 4 fig 6 31 4 Remove bolts 1 and outlet relief valve a Removal and Installation 1 Remove the left front and center floor plates 2 6 35 Bolts 1 2 3 4 Torque converter outlet relief valve Torque divider to oil cooler line Torque converter oil temperature bulb and gage line Figure 6 34 Torque conuerter outlet rdiet value removal b Disassembly and Reassembly 1 Refer to figure 6 35 dnd disassemble the left
308. ugs on the brake band 18 causing the band to contract on the steering clutch outer drum When the brake pedal is released the spring 2 returns the brake pedal linkage and brake hand to the unapplied position The parking brake is engaged by depressing either or both brake pedals and pushing the parking brake lever 1 down This moves the parking brake linkage 6 forward engaging the pawl 7 with the ratchet 13 The brakes are held in the applied position by the pawls that hold the brake linkage in the engaged position CAUTION The brake pedals should be depressed before the lever 1 is pulled upward to release the brakes This will prevent damage to the ratchet teeth or the pawl Key to firure 6 32 l Parking brake lever 2 Spring 3 Brake lever 4 Brake shaft 5 Brake control lever 6 Parking brake linkage 7 Brake lock pawl 8 Brake pedal 9 Brake link 10 Brake lever assembly 11 Brake lever shaft 12 Brake lever shaft 13 Ratchet 14 Brake strut support lever assy 15 Brake band strut 10 Brake toggle link l7 Brake band strut 18 Brake band H B 14 ME 2410 233 34 6072 Figure 6 72 Brake operation 6 69 b Removal and Installation 1 Remove the fuel tank para 5 14 2 Remove rear support l fig 6 78 3 Remove bolts 3 and cover 2 4 Disconnect the brake rod attached to the brake control lever 4
309. ulator setting Lights and accessories should be turned on during the test to prevent exces sive voltage To adjust the current regulator setting turn the adjusting screw at the base of the unit thereby changing the spiral spring tension Increas ing the tension will increase the current setting After each change of adjustment reduce generator speed until cutout relay opens then return to speed and read current Higher residual magnetism result ing from uncontrolled voltage during this test will cause the voltage to regulate at an abnormally low voltage after the jumper is removed To restore proper operation the generator must be cycled that is stopped and restarted Do not attempt to check voltage regulator after using jumper lead metho until this condition has been corrected Current should be 38 to 42 amperes Adjust to 40 am 2 Refer to figure 5 85 1 21 for pr instrument eonnections ADJUSTING SCREW TURN TO ADJUST CLOSING VOLTAGE CONTACT BRACKET ATTACHING SCREWS LOOSEN TO ADJUST AIR GAP CUTOUT RELAY SHUNT H E CHECK POINTS JUST TOUCHING 4 Ak HUT A CONTACT SCREW 4 LOOSEN TO SET AIR GAP TURF TO SET AIR 5 ADJUSTING SCREW TURN TO ADJUST AIR CAP VOLTAGE SETTING CURRENT VOLTAGE REGULATOR REGULATOR FIELO CURRENT SHUNT Ke WINDIN C g SERIES WINDING GENERATOR ME 2410 233 34 5 35 1 1 Figure 5 35 1 Generator regulator sheet 1 of 2 M
310. upport plate 35 e Cleaning 1 Clean all metal nonelectrical parts in an approved cleaning solvent and dry with compressed air 2 Clean field coils thoroughly with a clean cloth dampened with an approved cleaning solvent Be careful not to damage protective insulation coating Dry thoroughly with compressed air 3 Remove loose particles from armature with compressed air and wipe with a clean cloth dampened in an approved cleaning solvent Clean commutator lightly with No 00 sandpaper and remove all traces of dust with low pressure com pressed air 4 Clean solenoid relay insulation plates and non metallic washers with a clean cloth dampened with an approved cleaning solvent and dry with corn pressed air 5 Clean brushes with a dry clean cloth only Do not permit solvent to contact brushes f Inspection and Repair 1 Inspect housings and frames for cracks and distribution Inspect threads in tapped holes for damage Replace defective parts 2 Inspect sleeve bearings for wear gouges and grooves Replace bearing if defective Check for looseness in housing or end bell Replace worn or defective bearings If new bearing is loose in bore replace housing or end hell 3 Inspect wicks for tests fraying or wear Replace wick if defective 4 Inspect armature for gounds with a test light by touching one probe to armature core and other to commutator risers If test light glows the armature is grounded and
311. using and secure with the lock plate 85 and bolt 84 3 Install the governor control shaft 49 and seal 18 4 Install the low idle stop plunger 57 spring 58 washer 56 and plug 55 Install the plug 59 5 Install a new gasket 26 Install the low 5 27 idle adjusting screw 34 high idle adjusting screw 29 and spring 30 6 On the face of the fuel injection pump housing install the packing 61 piston and valve assembly 62 servo cylinder 66 locking plate 64 and bolts 63 7 Install the weight assembly to the servo cylinder 66 and secure with the snap ring 65 8 Install the ring 68 bearing races 69 bearing 70 spring 72 and seat 71 Install the washers 73 and full load stop pin 74 Install the seat 76 and secure with pin 75 Install the spring washer 78 spring 79 and plunger 80 9 Install the adjusting screw 38 and bolt 36 in the collar 39 Install the locknut 37 Install the cover 9 with the bolts 8 10 Complete reassembly of engine governor by reversing disassembly procedure f Installation Install the governor in the reverse order of removal Check and adjust the idle speed settings subpara as necessary g Adjustment 1 Using a tachometer known to be accurate check engine speed with the governor set in thelow idle rpm position Tachometer indication should be 650 rpm 2 If necessary remove the governor cover
312. val 1 Lower the bulldozer blade to the ground and remove the cylinder oil line guard 2 Attach a hoist to cylinder UU fig 4 35 and remove the bolts 2 securing cap 3 to the blade 3 Disconnect cylinder oil lines 5 Cover the openings in the oil lines and cylinder to prevent dirt from entering system 4 Remove pin 6 and lift off the cylinder c Disassembly 1 Drain both ends of the cylinder 2 Remove bolts 3 securing the head 1 to the cylinder CAUTION Extend the piston rod 2 out of the cylinder before removing bolts 3 This will prevent possible scoring of the cylinder walls when removing the piston from the cylinder 3 Remove the head piston rod and piston 4 Inspect bearing 4 and mating pin 5 Remove retaining ring and pin securing nut OI fig 4 37 to the piston rod 2 6 Remove nut 1 with a wrench as shown NOTE When removing or installing nut 1 secure piston rod 2 with a wrench on flats A 7 Remove piston 1 fig 4 38 8 Remove wear ring 8 9 Expand the outer ring of seal assemblies 7 and remove the outer and inner rings 10 Remove preformed packing 2 and backup ring 3 11 Remove head 4 12 Remove bolts 5 securing retainer 6 to head 4 13 Remove packing rings 9 and seal 10 14 Inspect all parts replacing worn or dam aged parts 15 Remove marks or rough spots on the piston rod with crocus or fine emery cloth to prev
313. ve engine sheet 6 of 6 2 19 25 Attach a suitable hoist and remove the engine fig 2 3 NOTE Engine weighs 2700 Ibs 2410 233 34 2 32 Figure 2 32 Engine remoual b Installation Reverse removal procedure and install the engine Fill cooling system TM 5 2410 233 20 Fill transmission with oil to specified level LO 5 2410 233 12 c Engine Alignment 1 Place the quantity of shims required between the engine supports and the tractor frame in order to align the universal joint as closely as possible 2 After installation of the engine and universal joint is complete a visual check of the alignment can be made while rotating the universal joint 2 20 3 If universal joint wobbles perceptibly closer alignment is needed d Misalignment 1 Normally misalignment can be corrected by adding or removing shims as necessary between the frame and the engine supports 2 If it is necessary to shift the engine from one side to the other in the frame loosen the holddown bolts and shift the engine accordingly 3 If the holes for the holddown bolts are enlarged dowels should be installed to hold the engine in the proper location after it is bolted down 4 Extreme misalignment is probably the result of bent main frame channels in which case they should be replaced Extreme wear in the engine front support will also cause misalignment 2 9 Transmission e Removal 1 Remove the
314. ve pinion flange make sure the splines are clean dry and free of burrs Set the pinion flange on the pinion shaft with the splines in the flange meshing with the splines on the shaft and push the flange on as far as possible by hand 8 Install adapter 2 fig 6 145 on the threads of the pinion gear shaft Place bolt 3 through hydraulic puller and screw it into adapter 2 Insert sleeve 1 over the adapter c Inspection and Repair 1 Inspect all bearings for corrosion pitting and wear Replace corroded rough or worn bearings 2 Inspect all gears for chipped pitted cracked or excessively worn teeth Replace damaged or excessively worn gears TB ENG 364 may be used as a guide for determining gear replacement 3 Inspect the metal floating ring seals for damage and proper wear pattern Replace seals which are pitted grooved scratched across the seal surface or which show an uneven wear pattern Seals must be replaced in sets 4 Replace all toric sealing rings Do not reuse toric seal rings 6 113 bref ME 2410 233 34 6 145 1 Sleeve 2 Adapter 3 Bolt D Dimension to be checked 0 094 in 0 154 in Figure 6 145 Installing pinion flange 6 114 6 28 Final Drive Bearing Adjustments a After the final drive has been assembled and the track roller frame outer bearing installed and aligned adjust the bearing preload on the sprocket support bearings With
315. vements You can help to improve this manual If you find any mistakes or if you know of a way to improve the procedures please let us know Mail your letter or DA Form 2028 Recommended Changes to Publications and Blank Forms direct to Commander US Army Tank Automotive Command ATTN DRSTA MBP Warren MI 48090 A reply will be furnished to you Page 1 4 table 1 2 Add the following nut and bolt torque data between Ripper and Steering Clutch Roll over Protective Structure Heavy duty fender support 16 9004100 Tractor frame support 8 350 50 Plate side mounting bolts 00004 210430 Page 2 13 paragraph 2 8a Sub subparagraph 1 1 is added as follows 1 1 Remove roll over protective structure TM 5 2410 233 20 Page 2 15 Figure 2 31 1 sheet 2 of 6 is added Page 2 20 paragraph 2 9a Sub subparagraph 1 1 as follows is added as follows 1 1 Remove roll over protective structure TM 5 2410 233 20 Page 3 4 paragraph 3 12b Delete subparagraph 3 Figure 2 31 1 Preparing to remove engine w ROPS sheet 2 of 6 Page 3 5 Figure 3 4 is superseded as follows BOLT CAPSCREW LOCKWASHER WASHER COVER SEAL BODY BEARING GEAR 10 KEY 11 GEAR 12 BEARING Q 13 SPACER 15 16 SEAL 18 19 20 21 22 23 GASKET SEAL COVER GASKET BRACKET GASKET SETSCREW COUPLING RING TA 17065
316. ver 3 Sealing elements Inspect all sealing elements O rings gaskets etc when disassembling and assembling hydraulic system components Install new elements if necessary 41 Hydraulic lines a When installing metal tubes tighten all bolts finger tight Then in this order tighten the bolts at the rigid end the adjustable end and the mounting brackets After the tubes are mounted install the hoses Connect both ends of the hose with all bolts finger tight Position the hose so it does not rub the machine or another hose and has a minimum of bending and twisting Tighten bolts in both couplings b Due to manufacturing methods there is a natural curvature to a hydraulic hose Install the hose so any bend is with this curvature In case of replacement hoses with angled stem and reusable fittings the hose curvature must be taken into consideration when assembling and positioning the angled stems c After the hoses are installed follow this procedure With the diesel engine running move the appropriate control levers to move the com ponent to every possible position Observe the hoses during the cycle Then lower the component to the ground Shut off the diesel engine and eliminate any twisting rubbing and or excessive drooping of hoses by rotating the stem of the hoses 5 Hydraulic fittings a Fitting bodies with straight threads and O ring seals 1 This type of fitting is used in several applications The t
317. wear surface Rollers worn to a diameter of 8 00 inches or less or rollers uneconomical to repair will be replaced The diameter of a new roller is 8 75 inches 2 Inspect the roller sleeve bearings for pitting roughness and wear The specified shaft to bearing clearance is 0 008 0 012 inch The maximum allowable shaft to bearing clearance is 0 050 inch The specified shaft end clearance is 0 011 0 029 inch The maximum allowable shaft end clearance is 0 050 inch Replace pitted rough or excessively worn bearings 3 Inspect the roller shaft for pitting roughness wear and distortion The maximum allowable bend in roller shaft is 0 005 inch Replace a damaged excessively worn or bent roller shaft 4 Inspect the metal floating ring seals for damage and proper wear pattern Replace seals which are pitted grooved scratched across the seal surface or which show an uneven Wear pattern Seals must be replaced in sets e Assembly NOTE Care should be taken when pressing tbe bushing assembly 1 into place to see that the bolt holes in the bushing flange are held in alignment with the holes in the roller hub This can be done by screwing three studs 120 apart into the roller hub to act as guides MF 2410 233 34 7 16 l Bushing assembly 2 Preformed packing 3 Metal floating ring seal 4 Preformed packing Retaining ring Figure 7 16 Assembling track roller 7 1 1 Insta
318. while slowly rotating the bevel gear until a torque given in table 1 4 is required to rotate it c Rotate the bevel gear shaft bearings several times before making the final adjustment d To determine the torque required to rotate the shaft weld a strap of metal across a steering clutch hub retaining nut and weld a small nut on the strap then thread the retaining nut onto the bevel gear shaft and apply a torque wrench to the small nut e Use a thickness gage as shown in figure 6 109 to determine the clearance between the flange of the bearing cage and the face of the bevel gear case at each bolt location making sure the clearance is the same all around the cage 6 87 Figure 6 109 Measuring clearance f Remove the cage and install shims with a total thickness the same as the measured clearance Install the cage and tighten the bolts g Recheck the torque required to rotate the bevel gear shaft h After the transmission is in place adjust the backlash as described in 4 below moving the shims from one cage to the other as required but not changing the total number of shims 3 Bevel gear shaft adjustment transmission installed NOTE If the transmission is in placeand it is not feasible to remove it the bevel gear shaft bearings can be preloaded in the following manner An approximate adjustment for backlash can be made at the same time a Install enough shims behind the bearing cage nearer th
319. with the retainer 3 d Hold retainer 3 firmly against the packing and measure clearance fig 2 23 between the retainer and the head with a thickness gauge Sufficient shims must be installed between the retainer and head to obtain a total thickness of 010 in to 015 in 2 54 to 3 81 mm less than the measured clearance B The shims will preload the packing properly when the retainer bolts are tightened ME 2410 233 34 2 23 Head 3 Retainer B Clearance to be measured between head and retainer Figure 2 23 Measuring cylinder head dearance e Remove the head 1 fig 2 22 and contained packing 2 from the rod 6 Install the correct amount of shims 5 and reinstall the head CAUTION Be careful not to damage packing 2 when reinstalling head 1 on the rod 8 Solid seal assemblies a Each solid seal assembly consists of a solid rubber inner expansion ring and a solid plastic outer seal Since these seals are continuous rings no split joint special tools and procedures are required for installation b The following is a typical installation procedure for the solid seal assemblies This procedure can be used for all hydraulic cylinders which use the solid seal assemblies A piston may have one or two seal assemblies c The tools needed to install the outer seals of the piston seal assemblies are one Expander Assembly 1 4 33 one Clamp Assembly 2 two clamp assemblies are required
320. worn washers Minimum allowable thickness is 0 065 inch d Inspect the planet carrier for cracks breaks and distortion Replace a defective carrier e Inspect the carrier thrust washers for damage and wear Replace the thrust washer if damaged or if considerable wear is indicated f Inspect the planet sun gear for chipped pitted broken or worn teeth Replace the sun gear if damaged or worn excessively g Inspect the sun gear positioning springs for breaks or damaged condition Replace defective springs h Inspect the pilot bearing for scoring pitting and wear Replace a scored pitted rough or cxcessively worn bearing i Replace the output shaft rear seal Install the seal with the lip facing the torque divider j Inspect the output shaft bearings for scoring pitting and wear Replace defective bearings Examine the shaft splines for distortion and wear Replace a defective shaft Replace a damaged or questionable ring seal Inspect the impeller for damage and wear The desired impeller to stator clearance is 0 009 to 0 015 inch The maximum allowable clearance is 0 023 inch Replace a damaged or worn impeller see 3 below for pleasuring procedure I Inspect the stator for damage and wear Replace a damaged or worn stator m Inspect the carrier inner bearing for scoring pitting and wear Replace a scored pitted rough or excessively worn bearing Examine the carrier ring type seals for da
321. y drive gear 24 on the accessory drive shaft Align the timing mark on the gear with the timing mark on the idler gear 28 Refer to subparagraph e Install the retaining nut 23 and tighten to a torque of 90 to 110 foot pounds 4 Install a new mounting gasket 17 Install the timing gear cover 16 to the engine block and plate and secure with bolts 13 washers 14 and lockwashers 15 5 Install the bolts 10 and lockwashers 11 which secure the oil pan 12 to the timing gear cover Tighten the remaining bolts which secure the oil pan to the cylinder 6 Install a new seal 18 in the timing gear cover 16 if the old seal was removed Using a sleeve to protect the seal install the seal with the spring loaded lip toward the cylinder block 7 Install the front support 9 securing with four bolts 7 and lockwashers 8 8 Press on the pulley 6 and secure with the bolt 1 and washer 2 Tighten the bolt to a 5 62 torque of 210 to 250 foot pounds Tap the pulley with a soft hammer and retighten to the same torque 9 Install the vibration damper 5 to th pulley 6 and secure with six bolts 3 and lock washers 4 10 Install the cover 21 and a new gasket 22 and secure with four nuts 19 and washers 11 Install the water Pump 5 6 fan belts 5 5 and generator TM 5 2410 233 20 12 Install the engine para 2 8 d Timing Mark Alignment 1 Remove the timing gear cover subpara a a
322. y on both sides of mica insula tor located between transistor and heat sink 3 Apply sealing compound as shown in figure 5 35 4B around components using Dow Chemical RTV Silastic 732 silicone rubber seal or equivalent available at hardware drug and paint stores Keep metal clips perfectly clean and free of rubber seal h Test regulator to see if it works If okay re turn to service If defective replace complete regula tor assembly 4 Bearing replacement and lubrication Bear ings normally will operate between engine over haul periods without attention At time of engine overhaul the bearings and seals should be replaced and a fresh supply of lubricant added to the reser voirs a Drive end bearing replacement 1 Remove the shaft nut washer pulley fan slinger and the four retainer plate bolts 2 Remove the rotor and bearing assembly from the end frame 3 Pull the bearing from the rotor shaft separate retainer plate and collar from shaft and discard seals in retainer plate and end frame 4 Add lubricants so each reservoir be tween the bearing seal after assembly will be only three quarters full Arrange the lubricant so at least a portion will contact the bearing after as sembly otherwise the oil in the lubricant will not bleed to the bearing Add lubricant to each seal lip and fill the cavity between the rubber lip and steel case of each seal with lubricant The seals must be as sembled so the sea

Download Pdf Manuals

Related Search

Related Contents

OSs-Micrium-Learning Centre-Application Notes  syllabus l3 socio 2014-2015 - Centre universitaire Jean  Enhanced Support Facility 2.6 ユーザーズガイド - ソフトウェア  Humminbird Wide 2000 User's Manual    SEI Rota CDR-S  servicemanuals.net click here  

Copyright © All rights reserved. Failed to retrieve file