CT-S-D3 6N1,79

CCaatteerr ppii ll llaarrService Manual

D3 CrawlerS/n 6N1 & 79U1 & up

Volume 1 of 2

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

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

Serv

ice

Man

ual

(SIN 6N1, 79U1 & UP)

C~TERPILLAR® REG01454-01 July 1973

®W®l@ITi1U@ @~®[f®~O@[fi) U®~O[fi)® ~ ~c9]D(ill~O[fi)® Alternator System (Nippondenso Co. LTD)

NIPPONDENSO ALTERNATOR SYSTEMS

TABLE OF CONTENTS

4N4540 & 6N5460 ALTERNATORS

Specifications .............................................................. 5 Construction ............................................................... 5 Troubleshooting ......................................................... ,... 6

Battery................................................................... 6 Charging System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Component Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Check of Alternator Output ............................................... 9 Check of Rectifier (Diodes) (4N4540 Alternator) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Check of Rectifier and Stator (6N5460 Alternator) .......................... 10 Check of Rectifier (Diodes) (6N5460 Alternator) ............................ 10 Check of Stator Coil. . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . .. 10 Check of Rotor Coil ...................................................... 11 Check of Brush Wear..................................................... 12 Check of Slip Ring........................................................ 12

Disassembly................................................................ 13 Assembly .................................................................. 15

4N5110 REGULATOR (EXTERNAL)

Operation .................................................................. 18 Features................................................................. 18 Handling Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. 19 Principals of Voltage Regulation........................................... 19 Performance Inspection.. . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . .. . . . .. 20

7N4784, 7N6118 & 8N2268 ALTERNATORS (7N5961 INTEGRAL REGULATOR)

Specifications .............................................................. 22 Features ................................................................... 23 Construction ............................................................... 24 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 26

Engine Not Running. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 26 Initial Field Excitation Just After Engine Start-Up. . . . . . . . . . . . . . . .. . . .. . . . . .. 26 Alternator-Generated Voltage Still Lower Than

Regulator-Setting Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 27 Alternator-Generated Voltage Higher Than

Regulator-Setting Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 27 Output Voltage Versus Alternator Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 28 Handling Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 28

Troubleshooting. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. 29 Performance Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 30 Component Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 30

Check of Rectifier ........................................................ 30 Check of Stator Coil. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 31 Check of Rotor Coil ...................................................... 31 Check of Brush Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 31 Check of Slip Ring. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 32 Check of I.C. Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 32

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 33 Assembly .................................................................. 36

CONTENTS

3

ASSEMBLY

4. Install bearing, retainer plate, felt and bearing.

Fill bearing with Denso No. 50 grease.

Install three screws in retainer cover (FIG. 25).

5. Install rotor shaft into drive end frame.

Install pulley and fan (FIG. 26).

6. Install rotor core in a vise. Tighten pulley lock nut (FIG. 27).

Alternator Pulley Nut Torque

4N4540 304.5 to 435.0 lb. in. (34.0 to 49.0 Nom)

6N5460 435.0 to 652.5 lb. in. (49.0 to 74.0 Nom)

CAUTION Do not tighten the vise too much because damage to core could result.

16

4N4540 & 6N5460 ALTERNATORS

FIG. 25 INSTALLING COVER PLATE

FIG. 26 ASSEMBLE THE DRIVE ASSEMBLY

FIG. 27 TIGHTEN THE PULLEY LOCK NUT

Index

Specifications

Specifications ............................................................. 4

Systems Operation

Components ............................................................... 10

Introduction................................................................. 9

Starting Motor Operation ............................................ 12 Component Operation ........................................ 12 General Operation .............................................. 12 Starting Operation .............................................. 14

Testing And Adjusting

Off Machine No Load Test ......................................... 20 On Machine Starting Motor Diagnosis ....................... 18

Diagnosis Procedure .......................................... 19 General Information ............................................ 18 System Voltage .................................................. 19

Starting Motor Component Tests ............................... 23 Armature Tests ................................................... 24 Brush and Brush Holder Checks ........................ 26 Field Winding Tests ............................................ 23 Pinion Drive Checks ........................................... 26 Shunt Coil Tests ................................................. 23

Starting Motor Solenoid Tests .................................... 21 Hold-In Winding Test .......................................... 22 Pull-In Winding Test ............................................ 22

Troubleshooting .......................................................... 16 Problem List ........................................................ 16 Problems ............................................................. 16

Disassembly And Assembly

Assemble Starting Motor 1453-016 ........................... 32

Disassemble Starting Motor 1453-015 ....................... 30

Nippondenso Starting Motors 3 Index

ENGINE

6

DISASSEMBLY AND ASSEMBLY

INDEX

Accessory Drive ...................................................................................................... 57-59 Accessory Drive, Disassemble & Assemble ............................ ...................... ......... 60-63 Air Cleaner Housing ..... .............. ......................... ...... ..... ........... ............... ............... ...... 83 Alternator ....................................................................................................................... 11

Camshaft .................................................................................................................. 70-72 Camshaft Bearing ......................................................................................................... 73 Connecting Rod Bearing ..................................................... '.... ....... ..... .......... ......... ....... 37 Crankshaft Front Pulley...... ............................. ............ ...... .......................... .......... ....... 64 Crankshaft Front Seal............ .............. ............... ...... ........ ................ .............. ....... ....... 65 Crankshaft and Gear ................................................................................................ 80,81 Crankshaft Main Bearings .......... ............................ ........ .......................... ................ 38,39 Crankshaft Rear Seal and Wear Sleeve .................. .................................................... 79 Cylinder Head (Direct Injection) ............................................................................... 30,31 Cylinder Head (Precombustion Chamber) .... ............ ............ .................... ............... 32,33 Cylinder Head, Disassemble & Assemble .................. .................................... ......... 34,35

Engine (910) ....................... ................................... ........ ................................. ......... 86,87 Engine (D3, 931) ..................................................................................................... 88-91 Engine Oil Cooler ............ ................... ............. ......... ............ ............ ........ .............. ......... 7 Exhaust Manifold .................................................................... : ..................................... 64

Flywheel ........................................................................................................................ 77 Flywheel Housing .......................................................................................................... 78 Flywheel Ring Gear ...................................................................................................... 78 Fuel Injection Lines ........... ...... .................. ....... ......... ............ ........ ......... ...... ................. 18 Fuel Injection Nozzles ............. ......................... ......... ................ ................. .............. 25,26 Fuel Injection Nozzles, Disassemble & Assemble ...... ...... ............ ............ ...... ....... 26-29 Fuel Priming Pump .............. ....... ............................ ................... ............. ......... ...... ......... 8 Fuel Injection Pump Housing, Disassemble & Assemble ...................... ...... .......... 52-56 Fuel Injection Pump Housing and Governor ........ ........ ........................ ...... ............. 44,45 Fuel Injection Pump Housing and Governor, Separation and Connection ............. 46,47 Fuel Injection Valves ....... ............................ ............. .................... .......................... ....... 20 Fuel Transfer Pump ........ .......... ......... ................... ..... ...... ........... ................... ........ ......... 8 Fuel Transfer Pump, Disassemble & Assemble ........................................................ 9,10

Glow Plugs ............ .......................... ..... ......... .......... ........... ........ .............. .............. ....... 19 Governor, Disassemble & ASl1emble ....................................................................... 48-51

Hood .............................................................................................................................. 82

Muffler ........................................................................................................................... 83

Oil Pan .......................................................................................................................... 31 Oil Pump and Relief Valve ...................................................................................... 68-70

Pistons ......................... ....... .................. ............ ......... ...... ............... ................... ....... 39,40 Pistons (Direct Injection), Disassemble & Assemble ............................................... 41,42 Pistons (Precombustion Chamber), Disassemble & Assemble .................. ............. 42,43 Precombustion Chambers ............................................................................................ 21

Radiator & Guard Assembly................ ................. ............ ........... ............................ 84,85 Rocker Shaft, Disassemble & Assemble .................. .................... ........................... 23,24 Rocker Shaft and Push Rods (Direct Injection) ......................... ........... .............. ..... 22,23 Rocker Shaft and Push Rods (Precombustion Chamber) ....................................... 21,22

Starting Motor .................................................................................................................. 7 Timing Gear Cover ........................... ............. ............. ..... ..... .................. .................. 66,67 Timing Gears and Plate .......................................................................................... 74-76

Valve Cover (Direct Injection) ............... ....................... ................ ....... .......................... 18 Valve Cover (Precombustion Chamber) ... ...... ............... ........ ........... .................. .......... 19 Valve Lifters .... ......... .................... ... .... ............ .............. ..... .... .... ...... .... .... .............. ....... 36

Water Pump ... ........ ........................ .............................. ......... .............. ........ .................. 12 Water Pump, Disassemble & Assemble .................................................................. 13-17 Water Temperature Regulator ...................................................................................... 11

& WARNING

DISCONNECT BATTERIES BEFORE PERFORMANCE OF ANY SERVICE WORK.

ENGINE

CRANKSHAFT AND GEAR

REMOVE CRANKSHAFT AND GEAR 1201 & 1204-11

Tools Needed A

887548 Puller Assembly

8H684 Ratchet 80x Wrench

887560 Step Plate

887551 8earing Puller Attachment

start by: a) remove flywheel housing b) remove timing gear cover c) remove pistons

1. Tum the crankshaft until the "C" mark on the crankshaft gear is in alignment with the "C" mark on the camshaft gear as shown.

NOTE: The main bearing caps are installed with the part number toward the front of the engine. Each cap has a number on the bottom of the cap, which is the same as the number on the camshaft side of the cy linder block.

2. Remove the three center main bearing caps and thrust bearing.

3. Install one of the flywheel bolts in the end of the crankshaft. Fasten a hoist.

4. Remove the two end caps.

CAUTION Be extra careful not to cause damage to the crankshaft journals when the crankshaft is re­moved.

5. Remove the crankshaft. The weight is 100 lb. (45 kg).

6. Remove the crankshaft main bearings from the cylinder block and from the main bearing caps.

7. Install tooling (A) and remove the gear from the crankshaft.

80

DISASSEMBLY AND ASSEMBLY

3204 VEHICULAR ENGINE SPECIFICATIONS

INTRODUCTION

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

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

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

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

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

77200X2

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

NOTE: For Systems Operation and Testing and Adjusting, make reference to the 3204 Vehicular Engine, Form No. REGO 1222.

INDEX

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

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

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

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

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

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

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

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

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

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

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

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

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

01 ...................... '" .. .. ... .... ...... ..... ... 11 PC ................................................. 11

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

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

3204 VEHICLE ENGINE INDEX

SYSTEMS OPERATION

Air Inlet and Exhaust System............................ 16 Valves and Valve System Components................. 17

Basic Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 25 Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 25 Connecting Rods ..................................... 25 Crankshaft ........................................... 25 Pistons and Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 25

Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 23

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

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

Fuel System, New Scroll ................................ 6 Fuel Flow............................................. 6 Fuel Injection Pump. . .. .. . . .. .. . . ... . . . . .. .. . . . . . .. . .. 6 Fuel Injection Nozzle.. .. .. .. ... . . .. ... .. .. ... . . .. . .. . . 7 Fuel Transfer Pump. . . .. . .. . . . .. .. ... . . . . .... .. . .... .. 7 Governor............................................. 8 Oil Flow for Fuel Pump and Governor.................. 10

Fuel System............................................ 12 Fuel Injection Pump.. . . . .. .. .. . . .. . .. . . . . . .. . . . . .... .. 13 Fuel Injection Valves (Nozzles) ........................ 13 Governor (Hydra-Mechanical) ......................... 14

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

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

TESTING AND ADJUSTING

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

Basic Block ............................................. 123 Connecting Rod and Main Bearings .................... 123 Con necti ng Rods and Pistons ......................... 123 Cylinder Block ........................................ 123 Flywheel and Flywheel Housing ....................... 124 Piston Rings .......................................... 123

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

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

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

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

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

(Cont. next page)

3

3204 VEHICLE ENGINE INDEX

TESTING AND ADJUSTING (Cont.)

Fuel System (Earlier & Later) ......... . . . . . . . . . . . . . . . . . .. 62 Governor Adjustments ................................ 84

4

Adjustment and Cleaning of 9L6969 Fuel Injection Nozzles ................................... 69

Adjustment and Cleaning of 9N3979 and 1W5829 Fuel Injection Nozzles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 77

Checking Engine Cylinders Separately.. .. .. . . . . . . . . . .. 62 Checking Engine Timing with 6V3100

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

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

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

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

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

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

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

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

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

Injection Pump (Install) (Earlier) .. .. . . . . . . .. . . .. .. . . . .. 99 Injection Pump (Remove) (Earlier) ................ . . . .. 98 Injection Pump (Install) (Later) ........................ 87 Injection Pump (Remove) (Later) ...................... 87 Setting Fuel Injection Pump Timing

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

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

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

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

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

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

Electrical System ....................................... 127 Alternator Regulator .................................. 129 Battery ............................................... 128 Charging System ..................................... 128 Starting System ....................................... 129 Test Tools For Electrical System ....................... 127

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

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 30

SPECIFICATIONS

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

c

c

D3 POWER TRAIN SPECI FICATIONS

?

INTRODUCTION

The specifications given in this book are on the basis of information available at the time it was written. The specifications torques, pressures of operation, mea­surements, adjustments and other items can change at any time. These changes can effect the service given to the product. Get the complete and most current infor­mation before you start any job. Caterpillar Dealers have the most current information which is available. For a list of the most current modules and form numbers available for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE REG 1139F.

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

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

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

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

NOTE: For Systems Operation and Testing and Adjusting, make reference to D3 TRACTOR POWER TRAIN, Form No. REG01262.

INDEX

Bevel Gear and Pinion. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .. 10, 11 Bevel Gear and Pinion Shaft Free Movement (Backlash) ...................... 12 Brake Adjustment. . . . . . . .. . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 14 Brake Drum Alignment...................................................... 13 Carrier Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 18 Control Group for Transmission Oil System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Control Linkage for Transmission ........................................... 9 Control Valve for Steering Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Final Drive................................................................. 17 Final Drive Bearing Installation.............................................. 16 Front Idler and Recoil Spring................................................ 18 Hydraulic Controls.......................................................... 7 Lubrication Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Oil Pump for the Transmission. . .. . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Plugs for Steering Clutch Case. . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . .. . . . .. 17 Pressures for the Hydraulic Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Roll-Over Protective Structure (RaPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . .. 19 Steering Clutch .................. :.......................................... 15 Steering Clutch Adjustment................................................. 15 Torque Converter. . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . .. . . . .. . . . . . 6 Track...................................................................... 21 Track Adjustment. . . .. . . . . . . . . . . .. . . . . . . . . . . .. . . .. . . . . . . . . . . . . . . . . . . .. . . . . .. 20 Track Rollers ......... :. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 19 Transfer Gears ............................................................. 5 Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Transmission and Governor Control (Attachment) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Universal Joint ............................................................. 8 Undercarriage Support. . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 19 Winch Drive................................................................ 19

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

77200X2

03 POWER TRAIN

SYSTEMS OPERATION

Lubrication System for the Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11

Power Flow ................................................................ 5

Steering Clutches, Brakes and Final Drive.................................... 15

Torque Converter and Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Planetary Transmission ................................................... 6

Torque Converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Transmission Hydraulic Controls............................................ 12

TESTING AND ADJUSTING

Back-up Alarm ............................................................. 23

Bevel Gear and Pinion (Adjustment) ........................................ .

Adjustment for the Amount of Free Movement (Backlash) .................. .

Bearing Preload of Bevel Gear Shaft ...................................... .

Bevel Pinion Assembly ................................................... .

Bevel Pinion Location .................................................... .

Final Drive Installation ..................................................... .

Power Shift Transmission Testing and Adjusting ........ See Form No. REG01307

Problem Solving............................................................ 18

Check List During Operation.............................................. 18

Checks During Operation............................................ ..... 18

Visual Checks............................................................ 18

Steering Clutches and Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20

Brake Adjustment ........................................................ .

Brake Drum Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 23

Brake Noise. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 23

Brake Pedal Kickback. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 22

Rough Brake Operation .................................................. , 22

Slow Operation of Steering Clutches ...................................... 20

Steering Clutch Adjustment .............................................. .

Track Adjustment .......................................................... .

Transmission Control Linkage .............................................. .

Transmission and Governor Control ........................................ .

'See SPECIFICATIONS, Form No. REG01263

SPECIFICATIONS

NOTE: For Specifications with illustrations, make reference to the POWER TRAIN SPECIFICATIONS FOR D3 TRACTOR, Form No. REG01263. If the Specifications in Form REG01263 are not the same as in the Systems Operation and the Testing and Adjusting, look at the printing date on the back cover of each book. Use the Specifications given in the book with the latest date.

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

INDEX

3

POWER TRAIN

6

DISASSEMBLY AND ASSEMBLY

INDEX

Battery And Frame Assembly .................................................... 105 Bevel Gear and Pinion ....................................................... 55-60 Bucket (931) ................................................................. 106

Dash Panel (D3) ............................................................. 93,94 Drive Shaft ................................................................. " 43 Drive Shaft, Disassemble & Assemble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 43

Engine, Torque Converter And Transmission (D3) .. Engine, Torque Converter And Transmission (931) ....

61,62 63-67

Final Drive Pinions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53, 54 Front Idlers ............................................................... 23,24 Front Idlers, Disassemble & Assemble .......................................... 25-29 Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 95

Hydraulic Control Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 96 Hydraulic Control Valves, Disassemble & Assemble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 97-100 Hydraulic Oil Pump ............................................................ 101 Hydraulic Oil Pump, Disassemble & Assemble .................................... 102, 103 Hydraulic Tank ......................................................... " 108 Hydraulic Track Adjuster Seals .......................................... 30,31

Recoil Springs .............................................................. 32, 33 Roll-Over Protective Structure (ROPS) Canopy ....................................... 104

Seat Assembly ................................................................ 104 Sprockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 36-38 Sprocket Shaft, Gear And Cover ................................................ 39-42 Steering Clutches ............................................................ 45,46 Steering Clutches, Disassemble & Assemble ........................................ 47-50 Steering Clutch Control Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 44 Steering Clutch Control Valves, Disassemble & Assemble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 44 Steering Clutch Hub Couplings And Pinion Flanges. . . . . . . . . . . . . . . . . . . . . . . ........ 51,52

Tilt and Lift Cylinders .......................................................... 107 Torque Converter And Transmission ............................................. 69-72 Torque Converter And Transmission, Disassemble & Assemble ......................... 78-89 Torque Converter And Transmission, Remove And Install From Case. . . . . . . . . . . . . . . . . . . . .. 77 Torque Converter And Transmission, Remove And Install From Engine. . . . . . . . . . . . . . . . . . .. 68 Tracks, Separation And Connection .............................................. 21, 22 Track Carrier Rollers ........................................................... 7,8 Track Carrier Rollers, Disassemble & Assemble ...................................... 9-11 Track Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 14-16 Track Rollers, Disassemble & Assemble ........................................... 17-20 Track Roller Frames .......................................................... 34,35 Track Roller Guards .......................................................... 12,13 Transfer Gears ........................................................... . .. 90.92 Transmission Control Valve, Disassemble & Assemble .................................. 75 Transmission Oil Pump, Disassemble & Assemble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 76 Transmission Oil Pump And Control Valve ........................................ 73, 74

I!::::. WARNING

DISCONNECT BATTERIES BEFORE PERFORMANCE OF ANY SERVICE WORK.

D3 TRACTOR HYDRAULICS

SYSTEMS OPERATION

Control Assembly ........................................... 6 Make-up Valve ............................................. 13 Relief Valve ............................................... 13 Ripper Hydraulics .......................................... . Valve Section for RAISE and LOWER ............................ .

F LOA T Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........ . HOLD Position ............................................. . LOWE R Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . RAISE Position .......................................... .

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

RAISE Position .......................................... . Valve Section in ANGLE LEFT Position ............................ . Valve Section in ANGLE RIGHT Position .......................... . Valve Section in HOLD Position ................................ . Valve Section in TI L T LEFT Position .............................. . Valve Section in TI L T RIGHT Position ............................ .

TESTING AND ADJUSTING

14 9

12 10 11 11 15 16 16 8 9 7 9 8

Checking Pump Efficiency ..................................... 17 Test on the Bench ......................................... 18 Test on the Machine ....................................... 18

Performance Test List ..................... . . . . . . . . . . . . . . . . . . .. 17 Relief Valves ............................................... 18 Relief Valve for Bulldozer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 19 Relief Valve for Ripper ....................................... 19 Test for Drift of Cylinder Rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 18

Lift Cylinders, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 18 Visual Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17

SPECI FICATIONS

NOTE: For Specifications with illustrations, make reference to the D3 TRACTOR HYDRAULICS SPECIFICATIONS, Form No. REG01265. If the Specifications in Form REGO 1265 are not the same as in the Systems Opera­tion and the Testing and Adjusting, look at the printing date on the back cover of each book. Use the Specifications given in the book with the latest date.

INDEX

3

D3 TRACTOR HYDRAULICS

head end and rod end of cylinder (6). Relief valve ( 1) is in the passage to the head end of cylinder (6). The relief valve opens at approximately 3700 psi (260.1 kg/cm2 ).

Relief valve (1) in the hydraulic system is a pro­tection for the tooth groups of ripper assembly (11). Ripper assembly (11) can move the rod up into cylinder (6), which opens relief valve (1), if the tooth group comes against material that can not be moved.

SYSTEMS OPERATION

RIPPER

6. Ripper cylinder. 11. Ripper assembly.

Valve Section for Ripper in HOLD Position

The pump oil from the other valve sections of the contwl assembly goes into passages (2), (4) and (6). When valve spool (5) is in HOLD position the oil in passages (2) and (4) goes around the valve spool and through passage (3). The oil in passage (3) goes to the end section of the control assembly and then through passage (1). Passage (1) is to the passages through all of the valve sections and the oil goes to the filter and tank.

The HOLD position of valve spool (5) stops the

PUMP OIL TO TANK

STOPPED OIL

6-__ ~:L6

7

oil in passages (7) and (9) to the cylinders. The cylinders can not move until the control lever for the ripper is moved to another position.

When the ripper, in the ground, comes against a piece that will not move, the ripper moves up. As the ripper is moved up, the pressure of the oil in the head end of the cylinder gets an increase. Re­lief valve (10) opens to let the oil run out of the head end of the cylinder when the pressure of the oil is approximately 3700 psi (206.1 kg/cm2 ).

73194XI

VALVE SECTION IN HOLD POSITION

1. Passage to tank. 2. Passage from pump. 3. Passage to end section. 4. Passage from pump. 5. Valve spool. 6. Passage from pump. 7. Passage to rod end of the cylinder. 8. Check valve. 9. Passage to head end of the cylinder. 10. Relief valve. A. LOWER position. B. HOLD position. C. RAISE position.

15

TABLE OF CONTENTS

Introduction 3

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

Preparation of System for Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3

System Test (Chart A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Troubleshooting

Pump Test (Chart B) ......................................... 5

6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7

Pump Test for Aeration and Cavitation ........................... 7 Troubleshooting .......... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7

Blocked Cylinders Test (Chart C) ................................. 8 All Cylinders Blocked ....................................... 8

Troubleshooting .......... ,............ . . . . . . . . . . . . . . . . .. 9 Right Side Cylinders Blocked ................................. 9

Troubleshooting ., . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10

GLOSSARY

aeration: Air mixed with the oil.

block, blocking, blocked: To close off a passage; to stop or prevent movement.

cavitation: Air present at the inlet of the pump.

data: Specific information.

flow differential (flow loss): The difference between two oil flows.

stick, sticking, stuck: To prevent free movement; keep open or closed.

tip, tipping, tipped: To move from a vertical position; to slope.

viscosity: The property of a fluid that resists internal flow by releasing counteracting forces.

03 AND 931 BACKHOE INDEX

SPECIFICATIONS

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

Pump, Hydraulic (3G2873, 3G4096) ........ .... ... ............... ............. 10 Control Valve (3G646) ........ .... ..... ...... ....... ........... ......... ..... ...... .... 13 Pump, Hydraulic (8J4515, 3G5386) ............................................ 12 Control Valve (3G5634) ................................................................ 14 Cylinder for Boom ......................................................................... 15 Servovalve (3G3710) .. ... ............. ..... .... ........ ......... ......... ............... 11 Cylinder for Bucket . .... .... ....... .... ..... ..... ........ .............. ....... .... ........ 16 Servovalve (3G7421) ............................................................. ;...... 11 Cylinder for Stabilizer (Fixed Pivot) . ....... ..... .... .......... ....... ..... ....... 17 Cylinder for Stabilizer (Side Shift) ................................................ 17 Torque Chart ................................................................................... 7

SYSTEMS OPERATION

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

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

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

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

TESTING AND ADJUSTING

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

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

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

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

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

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

DISASSEMBLY AND ASSEMBLY

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

5

D3 AND 931 BACKHOE DISASSEMBLY AND ASSEMBLY

INDEX

Backhoe Stabilizers .......................................................................................................................... 77 Boom and Boom Cylinder ................................................................................... ......................... 42-46 Boom, Disassemble & Assemble ................................................................................................. 47,48 Bucket (Backhoe) .............................................................................................................................. 39 Bucket Cylinder ............................................................................................................................ 49,50 Bucket Linkage ................................................................................................................................. 40

Console ....................................................................................................................................... 78-81

Frame ...................... ...... ....... ..... ..... ............. .... .... ..... ............................. .... ..... ..... ............. ............ 88,89

Hoe Stick ................... ...... ................................................................................... ............................... 41 Hydraulic Control Valves ............................................................................................................. 82-87 Hydraulic Cylinders, Disassemble & Assemble .................................. .............. .......................... 56-62

Piston Hydraulic Pump ....................................................................................... ......................... 90-93 Piston Hydraulic Pump, Disassemble & Assemble .................... ...................... ......................... 94-104

Stabilizer Cylinder ........................................................................................................................ 54,55 Stick Cylinder .............................................................................................................................. 51-53 Swing Actuator ............ ................................................................................................................. 63-64 Swing Actuator, Disassemble & Assemble ................................................................................. 65-72 Swing Frame ................................................................................................................................ 73-75 Swing Frame, Disassemble & Assemble ......................................................................................... 76

Tips and Sidecutters ......................................................................................................................... 38

37

03,910 & 931 HYDRAULICS SPECI FICATIONS

INTRODUCTION

The specifications given in this book are on the basis of information available at the time the book was written. These specifications give the torques, operating pressure, measurements of new parts, adjustments and other items that will affect the service of the product.

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

When the words "use again" are in the description, the specification given can be used to determine if a part can be used again. If the part is equal to or within the specification given, use the part again.

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

2

NOTE: The specifications given for "use again" and "permissible" are in­tended for guidance only and Caterpillar Tractor Co. hereby expressly denies and excludes any representation, warranty or implied warranty of the reuse of any component.

NOTE: For Systems Operation and Testing and Adjusting, make reference to:

D3 Tractor Hydraulics, Form No. REG01264. 910 Loader Hydraulic System, Form No. REG01225. 931 Loader Hydraulic System, Fonn No. REG01328.

INDEX

Control Lever Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11

Control Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8

Cylinders .:...................................................... 9, 10

Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6, 7

Lines, Plugs and Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4

Assembly of Fittings With Straight Threads and O·Ring Seals . . . . . . . . . . . . . . . .. 4

Line Installation ................................................... 4

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

Torque for Other Fittings ............................................ 5

Oil Filter ............................................................ 11

Relief Valve Adjustment ............................................... 8

Tilt Levers .......................................................... 11

77200X1