CT-S-955KTX31J

CCaatteerrppii ll llaarrService Manual

955K TraxcavatorS/n 31J, 48H,

51A, 53H & 61H

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

SERVICE MANUAL

955K TRAXCAVATOR

SERIAL NUMBERS 61Hl - UP

53Hl - UP

48Hl - UP

31Jl - UP

~ diesel engine valve clearance.

Check and adjustment must be made with engine stopped.

• If equipped with gas start attach­ment, compres­sion release must be at RUN.

• Valve must be seated and push rod at its lowest point. •

• Turn adjusting screw to obtain clearance .015" (0,38 mm) for inlet valves and .025" (0,64 mm) for exhaust valves.

• Tighten locknut. • • and recheck adjustment.

• Check compression release clearance. Should be • 060" (1,5 mm). If not correct, see your Caterpillar dealer.

~--~-.-.---.------------------------------------------------------------

......• '\

CAeck starting engine valves with engine cold. Clearance for both inlet and exhaust valves is .010" (0,25 nun).

• Remove air cleaner, carburetor and valve cover ..

Loosen loclmut and turn adjusting screw to obtain correct clearance.

@ CAeck starting engine spark plugs •

• And check gap with plug gauge ••

• Valve closes and pushrod is at its lowest point. •

• Repeat procedure for each valve •

• Replace valve cover, carburetor and air cleaner.

Bend outer electrode to maintain .030" (0,76 mm) gap.

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~ _____________________________________ 11IiJj~'la.~.l.,;.1,11!/:

INDEX TO TOPICS

Periodic Maintenance Service Index

10 Service Hours .•

60 Service Hours .

125 Service Hours

250 Service Hours

1000 Service Hours

2000 Service Hours

Safety Precautions •

General Instructions

Service Meter ••••••

Air Cleaner Elements

Fuel Injection Valves ..

Glow Plugs •••

Generator ..••.

Electric Starter. .

Rollers and Idlers

Lift Arm Support .

Wiring Diagrams • . . •

As a member of the National Safety Council, we are privileged to use the Green Cross for Safety to designate not only our interest in Safety, but to em­phasize and call attention to the safety precautions in this book.

INDEX

TO TOPICS

~ .

2

4

10

16

18

20

30

33

34

34

34

36

37

38

38

39

39

40

• \II.

_._---------------------------------------------- - ---

INDEX TO TOPICS

Periodic Lubrication Service Index.

10 Service Hours.

60 Service Hours

125 Service Hours •

250 Service Hours • •

500 Service Hours •

1000 Service Hours

2000 Service Hours

Safety Precautions •

General Instructions • •

Lubricating Oils

Grease •

Fuel Oil

Hydraulic System

Cooling System

Starting Engine Fuel. •

Lift Arm Support

Capacities ••••

Location of Serial Numbers

As a member of the National Safety Council, we are privileged to use the Green Cross for Safety to designate not only our interest in Safety, but to em­phasize and call attention to the safety precautions in this book.

INDEX

TO TOPICS

2

4

8

12

14

20

24

28

33

34

35

36

36

37

37

40

41

43

43

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955K TRAXCAVATOR SYSTEMS OPERATION 2-1

Table of Contents

ENGINE

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Fuel System .................................................... .

Air Induction and Exhaust System ................ .

2-20

2-30

Engine Timing Components ................................ 2-40

Cooling System ................................... 2-50

Lubrication System ........... . . . . . . . . . . . . . . . . . . . . . . . . . 2-60

Electrical System ............................................... .

Starting Engine ............................................... .

POWER TRAIN

General Information

Transmission ........................................... .

Transmission Hydraulic Control ...

Transmission Lubrication System

Steering Clutches. Brakes and Final Drive ....... .

CHASSIS

Undercarriage ............................ .

LOADER PORTION

Loader Hydraulic System

2-70

2-80

2-100

2-110

2-120

2-130

2-150

2-210

2-310

955K TRAXCAVATOR SYSTEMS OPERATION 2-70

Engine

ELECTRICAL SYSTEM The electrical system is a combination of three

separate electric circuits: the charging circuit, the starting circuit and the lighting circuit. Each circuit is dependent on some of the same components. The battery (batteries), disconnect switch, circuit breaker, ammeter, cables and wires from the bat­tery are common in each of the three circuits.

CAUTION-The disconnect switch must be ON to allow any part of the electrical system to work. Some charging circuit components will be damaged if the engine is operated with the disconnect swikh OFF.

The charging circuit is in operation when the diesel engine is operating. The electricity produc­ing (charging) unit is a generator. A generator regulator in the circuit senses the state of charge in the battery and regulates the generator output to keep the battery fully charged.

The starting circuit operates only when the disconnect switch is ON and the start switch is actuated.

The starting circuit for the gasoline starting engine includes a magneto. The magneto generates and distributes electricity to the spark plugs in the engine. The start switch in the circuit is also the magneto switch. When the start switch is placed in the START position, the starting motor rotates the flywheel to start the engine.

When the start switch is released to the RUN position, the electric circuit to the starting motor opens and the starting motor stops. The OFF posi­tion on the start switch is a ground for the starting engine magneto. A grounded magneto cannot pro­duce electricity.

The direct electric diesel engine starting circuit includes a glow plug for each engine cylinder. Glow plugs are small heating elements in the precom­bustion chambers which promote fuel ignition when the engine is started in Jow temperatures.

BRUSH ASSEMBLY

ARMATURE

This is a cutaway view of a generator.

The lighting and charging circuits are both con­nected on the same side of the ammeter. The

starting circuit connects to the other side of the ammeter.

SYSTEM COMPONENTS Generator

The generator is belt driven by the diesel engine. The generator keeps the battery charged and sup­plies current to operate the electrical components.

Generator Regulator

This is a generator regulator with the cover removed.

The generator regulator controls the output of the generator. The regulator incorporates three controls: the output relay. the voltage regulator and the current regulator. Each control has contact points which are operated by electromagnets.

Springs hold the cutout relay points open and the voltage regulator and current regulator contact points closed. The spring tension for each unit is a force opposing the force of electro-magnets.

The cutout relay prevents the battery from motorizing a generator that is not producing enough voltage. Generator voltage approximately equal to battery voltage will close the cutout relay points. This closes the circuit between the genera­tor and the battery. The generator can now supply the battery and the components of the electrical system with power.

The voltage regulator prevents the generator from producing damaging high voltage. Generator voltage slightly higher than battery voltage opens the regulator points causing the generator output voltage to lower. Low generator voltage allows the spring to close the regulator points and generator voltage is again high. The action of the voltage regulator points, opening and closing, controls the output voltage of the generator. The points can open and close as often as 200 times per second.

The current regulator limits the current produced by the generator to allow the generator to con­tinue producing voltage equal to battery voltage.

1

955K TRAXCAVATOR

ENGINE

TESTING AND ADJUSTING 3-1

Table of Contents

Problem Solving. . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-10

Fuel System ..................................................... 3-20

Air Induction and Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-30

Cooling System .................................................. 3-50

Electrical Systems ................................................ 3-70

Starting Engine .................................................. 3-80

POWER TRAIN

Problem Solving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-100

Transmission ..................................................... 3-11 0

Steering Clutches and Brakes. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-150

LOADER PORTION

Loader Hydraulic System 3-310

955K TRAXCAVATOR SPECIFICATIONS 5-1

Table of Contents

Engine 5-10

Power Train ..................................................... 5-100

Chassis .......................................................... 5-200

Loader Portion ................................................... 5-300

1

955K TRAXCAVATOR DISASSEMBLY AND ASSEMBLY 4-1

Table of Contents

General Instructions ............................................. 4-3

ENGINE

Service Guide

Engine Removal and Installation ................................. .

Fuel System ............................................ ' ....... .

Air Induction and Exhaust System ............................... .

Timing Components ............................................ .

Cooling System Components .................................... .

Lubrication System Components ................................. .

Electrical Systems .............................................. .

Starting Engine Removal and Installation ......................... .

Crankshaft, Pistons and Connecting Rods ......................... .

POWER TRAIN

Service Guide

Flexible Coupling Drive ......................................... .

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

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

Transmission Lubrication System Components ..................... .

Bevel Pinion ................................................... .

Steering Clutch and Brake Controls ............................... .

Steering Clutches, Bevel Gear and Final Drive ..................... .

Service Guide

Undercarriage

CHASSIS

4-5

4-10

4-20

4-30

4-40

4-50

4-60

4-70

4-80

4-90

4-100

4-105

4-110

4-120

4-130

4-140

4-150

4-155

4-200

4-210

Seat, Fuel Tank and Miscellaneous .... ' . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-220

LOADER PORTION

Service Guide .,. . .............. ,"" .... ' ..... ', ... ,', .. ,.""

Hydraulic System Components

Hydraulic Lines and Cylinders

Bucket, Bucket Control and Frame

4-300

4-310

4-330

4-340

"

DISASSEMBLY AND ASSEMBLY 4-70

Engine

Starting Motor Solenoid Removal

NOTE-Whenever the solenoid is removed, the pinion clearance should be adjusted. The ad­justment should be made with the starling motor removed.

l-Connector from MOTOR terminal on solenoid to motor 2-Ground wire. 3-Bolts (four). 4-Solenoid.

Pinion Clearance Adiustment

Bench test and adjust the pinion clearance at installation of solenoid as follows:

1. Install the solenoid without connector from the MOTOR terminal on solenoid to the motor.

Specific points related to the circuit connections for checking pinion clearance are: I-Connector from MOTOR terminal on solenoid to motor. 2-SW ter­minal. 3-Ground terminal.

2. Connect a battery, of the same voltage as the solenoid, to the terminal marked SW.

2

955K TRAXCAVATOR

3. Connect the other side of battery to ground terminal or to solenoid frame.

4. MOMENTARILY flash a jumper wire from the solenoid terminal marked MOTOR to the frame or ground terminal. The pinion will shift into cranking position and will remain there until the battery is disconnected.

This schematic shows the circuit for checking and acijusting pinion clearance. 2-SW terminal. 3-Ground terminal. 4-Ground flashing point.

5. Push pinion towards commutator end to elim­inate free movement.

6. Pinion clearance should be .36 in. (9,14 mm).

7. Adjust clearance by removing plug and turning shaft nut.

This illustrates the points where pinIon clearance checking and adjusting are made. 5-Pinion. 6-Pinion clearance. 7-Shaft nut.

/

/

955K TRAXCAVATOR .. DISASSEMBLY AND ASSEMBLY 4·1

Table of Contents

General Instructions ............................................. 4-3

Tool Supplement ................................................ 4-4

ENGINE

Service Guide .................................................. . 4-5

Engine Removal and Installation ... : .............................. . 4-10 ;.."

Fuel System ................... i; • ....•..•..•.••..•.............. 4-2.0 ..~ .

Air Induction and Exhaust System ............................... . 4-30

Timing Components ............................................ . 4-40

Cooling System Components ......................... : .......... . 4-50

Lubrication System Components ................................. . 4-60

Electrical Systems .............................................. . 4-70

Starting Engine Removal and Installation .......................... . 4-80

Crankshaft, Pistons and Connecting Rods ......................... . 4-90

POWER TRAIN

Service Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . 4-100

Flexible Coupling Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-105

Transmission and Torque Converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-110

Transmission Hydraulic Controls .. , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-120

Transmission Lubrication System Components ..................... .

Bevel Pinion ....................................... .

Steering Clutch and Brake Controls .................... .

Steering Clutches, Bevel Gear and Final Drive .......... .

CHASSIS

Service Guide .................................................. .

Undercarriage ................................................. .

Seat, Fuel Tank and Miscellaneous . . . . . ...................... .

LOADER PORTION

Service Guide ............................... .

Hydraulic System Components .. . ...... .

Hydraulic Lines and Cylinders ............... .

Bucket, Bucket Control and Frame ........... .

4-130

4-140

4-150

4-155

4-200

4-210

4-220

4-300

4-310

4-330

4-340

?l·: ::'""