CT-S-D8 36A44+

CCaatteerr ppii ll llaarrService Manual

D8 & D8H CrawlerS/n 36A4469-36A5484,46A10725-46A28136,

68A1004-68A4586

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

SA-S Group 10.2

Page 1

SERVICE MA·NUAL

for

CAT'ERPILLAR

DB TRACTOR SERIAL NUMBERS 36A4469-36A5484

AND 46A 1 0725-46A28136

®

E . nglne _________________________________ . _____ .. __________ .. ___ . _______ .. __ ._

Starting Engine ______________ .. _________ . __ .. __ . _____ . _______ . ___ . __ ._

Power Transmission Units ___ . __ ._. __ . ___________ .. ______ . __ . ___ ._.

Track Roller Frame . ____ . ___ ._. __ .. _._. ___ . __ . _________ ._. ___ . _______ ._

Seat, Fuel Tank and Miscellaneous ____ . __ ._ .... ______ .. ______ _

rB CATERPILLAR FORM NO. RE00019

Section

10-

20--....

30---.....

40----~

200-----.....

PRINTED IN U.S.A.

ENGINE TABLE OF CONTENTS

Index

Specifications

Cooling System (36A) - ......

Cooling System (46A)

Water Temperature Regulators

Fan Group (Blower)

Fan Group (Suction)

Water Pump.

Radiator

Lubrication System

Oil Pan

Oil Pump

Oil Coolers (36A)

Oil Coolers (46A)

Oil Filter and Manifold

Fuel System

Fuel Supply Equipment

Fuel Injection Equipment

Accessory Drive & Governor

Air Induction & Exhaust System

Turbocharger (AiResearch TIB)

Cylinder Heads

Valves and Valve Mechanism

Vibration Damper (Two Belt Drive)

Vibration Damper (Three Belt Drive)

Front Support (Two Belt Drive)

Front Support (Three Belt Drive)

Timing Gears

Pistons, Rings and Connecting Rods .

Cylinder Liners

Main Bearings

Crankshaft

Flywheel and Flywheel Housing (36A)

Flywheel and Flywheel Housing (46A)

Diesel Engine Removal and Installation (36A)

Diesel Engine Removal and Installation (46A)

Electrical System

Electrical System . . .......

Alternator

Section

SA-lO

SA-lO

SA-lO

SA-lO

SA-lO

SA-lO

SA-I0

SA-lO

SA-lO

SA-lO

SA-lO

SA-lO

BA-lO

BA-lO

BA-lO

BA-I0

BA-lO

BA-lO

BA-10

BA-lO

12A-1O

BA-I0

BA-lO

BA-lO

BA-lO

BA-lO

BA-lO

BA-lO

BA-lO

BA-lO

BA-lO

BA-lO

BA-lO

BA-lO

BA-lO

BA-lO

8A-10 SA-lO

12A-I0

8A-1O

Group

30.2

40.2

70.3

70.4

100.1

130.4

130.5

140.1

160.3

170.4

lS0.2

190

200.3

200.4

210.6

230

240.2

250.1

260.3

270.4

271

2BO.2

290.1

300.2

300.3

310.3

310.4

320.3

340.1

350

360.1

370

390.2

390.3

400.5

400.6

410.1 410.3

411

Group 20.2

Page I

A

Accessory Drive Housing Accessory Shaft Adjustments:

Accessory Drive Gear and Shalt Aligning Engine Alternator .. Compression Release Decelerator Fuel Injection Pump Lifters Fuel Rack ... Fuel Ratio Control Generator Regulator Generator Polarization .. Governor Starter Pinion Clearance Valve Clearance ................. .

Air Cleaner Air Induction and Exhaust System Air Inlet Manifold ......... . Alternator Altitude Operation

Bearings: Connecting Rod Main

Breather, Crankcase Bypass:

Fuel Oil Filter

Camshaft Gear

B

c

Chambers, Precombustion ......... . Cleaning:

Engine Valves Fuel Injection Valve Pistons Turbocharger .......... .

Clearances and Tolerances ............. . Compression Release Mechanism Connecting Rods and Bearings Cooling System

Core, Radiator .. Crankshalt Crankshaft Pulley

Cylinder Head Cylinder Liners

Damper, Vibration

Decelerator Directors, Water

Electrical System Alternator Battery Circuit Breaker Generator Generator Polarization

D

E

ENGINE INDEX

Group Page

260.3 - 1 260.3 -12

260.3 -13 400.5 - 2 411 - 1 290.1 - 4 260.3 -11 250.3 - 6 260.3 - 5 260.3 - 8 410.3 - 4 410.1 - I 260.3 - 4 410.3 - 3 40.2 - 3

270.4 - 3 270.4 - I 270.4 - I 411 - I 271 - 2

340.1 - 3 360.1 - 1 210.6 - 3

240.2 - 2 210.6 - I

320.3 - 2 280.2 - 2

290.1 - 3 250.1 - 1 340.1 - 2 271 - 5

Generator Regulator

Starter Solenoid Starting Motor

Pinion Clearance Engine Alignment

Engine Removal

Exhaust Manifold

Fan Group (Blower) Fan Group (Suction) Flow 01 Fuel Flow 01 Lubricating Oil Flywheel

Front Support, Engine

Fuel: Bypass Rack Setting Filter Housing Injection:

Equipment Pumps Pump Housing Pump Lifters Valves ...

Ratio Control System Transler Pump

Gauge: Fuel .. . Oil ....... .

Gear: Accessory Drive Camshaft Crankshaft

8A·I0

F

G

Group 30.2 Page 1

Group 'Page

410.1- 1 410.3 - 1 410.3 - 1 410.3 - 2 410.3 - 3 400.5 - 2 400.6 - 2 400.5 - 1 400.6 -·1 270.4 - 2

130.4 - I 130.5 - I 230 - 1 170.4 - 1 390.2 - I 390.3 - I 310.3 - 1 310.4 - 1

240.2 - 1 260.3 - 5 240.2 - 2

250.1 - 1 250.1 - 2 250.1 - 3 250.1 - 6 250.1 - 1 260.3 - 7 230 - 1 240.2 - I

230 - I 170.4 - 2

40.2 - I 290.1 - 4 340.1 - 2 70.3 - 1 70.4 - I

160.3 - I Idler ...................................... .

260.3 -12 320.3 - 2 370 - 1 320.3 - 2 390.2 - 1 390.3 - I 320.3 - 1 320.3 - 1

370 - I 300.2 - 1 300.3 - I 280.2 - 1 350.1 - I

300.2 - 1 300.3 - 1 260.3 - 9 280.2 - I

410.3 - I 411.1 - I 410.3 - 3 410.3 - 2 410.3 - 1 410.1 - I

Ring, Flywheel .

Timing .. Timing Marks

Governor: Adjustments Control Mechanism Operation Seals.

Head, Cylinder Heat Tube Housing:

Flywheel

Fuel Injection Pump

H

Fuel Filter .......................... . Timing Gear .'.

260.3 - 4 260.3 -11 260.3 - 1 260.3 - 2

280.2 - I 270.4 - I

390.2 - 2 390.3 - 2

. . .. 250.1 - 3 240.2 - 2 320.3 - 1

Group 30.2 Page 2

Injection, Fuel Inlet:

Manifold Valve

Lifters:

8A-1O

Fuel Injection Pump Valve

Liners, Cylinder Lubricating System Lubrication:

Governor Piston and Ring Service Meter Timing Gear

Main Bearings Manifolds:

Exhaust Fuel Inlet Oil

Oil: Bypass Valves Cooler

Filters Manifold Pan Pump Pump Drive

Pump Suction Bells Operating Difficulties:

L

M

o

Engine Coolant Overheating

Engine Fuel System Engine Lubricating System

Overheating, Coolant

Pan, Oil Pistons Piston Pin Bearings Piston Rings

p

Power Take-off Drive Shaft, Rear Precombustion Chambers Pressure, Oil ............ .

Gauge Relief Valve

Primary Fuel Filter Pump:

Fuel Injection Fuel Transfer ........ . Oil Water

Radiator R

Raising Ring Ridge in Cylinder Liners Rear Power Take-off Drive Shalt Regulators, Water Temperature Release, Compression

ENGINE INDEX

250.1 - I

270.4 - I 290.1 - 3

250.1 - 5 290.1 - 4 350.1 - I 170.4 - 1

260.3 - I 340.1 - I 260.3 -13 170.4 - 2

360.1 - I

270.4 - 2 230 - 1 270.4 - 1 210.6 - 2

210.6 - I 200.3 - I 200.4 - I 210.6 - 1 210.6 - 2 180.2 - 1 190 - 1 190 - 1 320.3 - 1 190 - 1

70.3 - 1 70.4 - 1

230 - 1 170.4 - 2 70.3 - 1 70.4 - 1

180.2 - I 340.1 - 1 340.1 - 4 340.1 - 2 320.3 - 3 280.2 - 2 170.4 - 2 170.4 - 2 190 - 2 240.2 - 2

250.1 - 2 240.2 - I 190 - 1 140.2 - I

160.3 - 1 350.1 - 2 320.3 - 3 100.1 - I 290.1 - 4

Ring Gear, Flywheel

Rings, Piston Rocker Arms, Valve Rod, Connecting

S Schedule for Initial Operation

After Engine Reconditioning Sealed Pressure Overflow Seals, Liner Service Meter Setting Fuel Pump Lifter Shaft, Accessory Drive Specifications Speed Limiter Spring, Governor Spring, Valve Strainer, Magnetic Suction Bell Support, Engine Front

T Testing Temperature Regulators Testing and Adjusting Electrical System Thrust Bearing:

Camshaft Crankshaft

Timing: Engine Gears

Engine Valves Flywheel

Fuel Injection Timing Gears Timing Marks Tolerances Transfer Pump, Turbocharger:

Operation Removal Seals

Valve: Bypass, Fuel Bypass, Oil

Fuel

Fuel Injection Inlet and Exhaust

v

Inspection and Reconditioning Lifters Operation Pressure Relief Rocker Arm Rotators Seat Specifications Stem Bushings Timing

Valves and Valve Mechanism Vibration Damper

w Water:

Directors, Seals and Ferrules Pump:

Seal Replacement Temperature Regulator

390.2 - I 390.3 - I 340.1 - I 290.1 - I 340.1 - I

340.1 - 3 160.3 - 2 350.1 - 1 260.3 -13 250.1 - 6 260.3 -12 40.2 - 1

260.3 - 4 260.3 - 2 290.1 - 1 200.4 - 1 190 - 1 310.3 - 1 310.4 - 1

100.1 - 1 410.3 - 3

320.3 - 3 360.1 - 1

320.3 - I 260.3 - 1 290.1 - 4 390.2 - I 390.3 - 1 250.1 - 7 320.3 - 1 320.3 - 1 40.2 - 1

240.2 - 1

271 - 1 270.4 - 2 271 - 2

240.2 - 2 210.6 - I 250.1 - I 290.1 - 3 290.1 - 3 290.1 - 4 290.1 ,;;; I 190 -'2 290.1 - I

. . . . . 290.1 - I 40.2 - 3

. . . . . . . . .. 290.1 - 3 290.1 - 4 290.1 - 1 300.2 - 1 300.3 - I

280.2 - 1

140.1 - 3 100.1 - 1

SA-lO Group 130.4

Page 2 ENGINE FAN GROUP

7. Remove the fan and fan drive as a unit, being careful not to damage the radiator fins.

REMOVING FAN AND FAN DRIVE

FAN AND PULLEY DISASSEMBLY

I. Remove the eight bolts that secure the fan spider to the fan pulley and remove the fan spider.

DISASSEMBLING FAN DRIVE I-Bracket assembly. 2-Seal. 3-Bearing. 4-Bearing. S-Cover.

6-Bolts (two) and lock. 7-Spacer. 8-Plate. 9-Shaft (Part of bracket assembly). IO-Spacer. ll-Pulley.

2. Slide pulley (ll) and components forward to remove from shaft (9) as a unit.

NOTE

It may be necessary to tap with a soft hammer on the back side of the pulley to remove it from the shaft.

3. Remove bearing (4) by tapping around the inner bore of spacer (10) with a mild steel drift until enough space is obtained to tap the bear­ing out the front end of the pulley.

4. Use a suitable spacer inserted through the front of the pulley, to drive spacer (7), seal (2) and bearing (3) out of the pulley.

5. Install seal (2) with the lip facing bracket (1).

NOTE

Lubricate lip of seal before installing.

6. Inspect bearings (3) and (4) and replace if necessary.

7. Assemble in reverse order of disassembly and lubricate the bearings with ball and roller bear­ing lubricant through the grease fitting in brack­et assembly (1).

FAN BELT ADJUSTING PULLEY DISASSEMBLY

PREPARING TO DISASSEMBLE ADJUSTING PULLEY' I-Bracket assembly. 2-Seal. 3-Bearing. 4-Snap ring.

S-Bearing. 6-Cover. 7-Cotter pin. 8-Nut. 9-Gasket. IO-Shaft (part of bracket assembly). II-Spacer.

l2-Pulley.

1. Slide pulley (12) and components from the shaft.

2. Remove bearing (5) by tapping around the inner bore of spacer (11) with a mild steel drift until space is obtained to tap the bearing out of the front end of pulley (12).

3. Remove spacer (11) and snap ring (4).

4. Drive seal (2) and bearing (3) out the back end of pulley (12).

5. Clean and inspect all parts. A.ssemble in reverse order of disassembly.

6. Replace worn bearings.

7. Install seal (2) with the lip of the seal facing away from bearing (3).

NOTE

Lubricate lip of seal before installing.

8. Lubricate bearings with ball and roller bearing lubricant through the grease fitting in the bracket assembly (1).

12A-IO Group 411

Page 2 ENGINE CHARGING ALTERNATOR

water usage and battery specific gravity checks over a service period of reasonable length will establish the ideal voltage setting for the equipment involved.

CHECKING VOLTAGE SETTING

I. Turn off all accessories and connect a voltmeter from the output terminal to ground.

2. By using a fully charged battery, an ammeter, and a carbon pile resistor, adjust the current flow (amps) to the value given in the topic SPECIFICA TIONS (Voltage regulator). See the schematic diagram in the topic, CHECKING AL­TERNATOR OUTPUT WITHOUT REGULATOR IN CIRCUIT.

3. Operate the alternator at approximately 2500 RPM and note the voltage output. See the topic, SPECIFICATIONS.

4. If necessary, the voltage setting on early models can be changed by removing the voltage ad­justment cover plate and moving the screw (1) into another adjustment hole. The amount of voltage variation is stamped on the case. Al­ways check the voltage output with a voltmeter after making adjustments.

H2300

ADJUSTING VOLTAGE (EARLY MODELS) I-Adjusting screw.

ADJUSTING VOLTAGE (LATER MODELS) 2-Plug.

On later models, remove the plug (2) and care­fully adjust the potentiometer with a screwdriver. Adjust very slowly while observing the voltmeter for correct value listed in the topic, SPECIFICA­TIONS.

CAUTION

Do not allow the voltage to exceed the recom­mended regulator voltage setting listed in the topic, SPECIFICATIONS.

NOTE

If the voltage setting is not steady, or if it can­not be adjusted to a value reasonably close to the listed specifications, trouble in the alternator or regulator components is indicated.

CHECKING ALTERNATOR OUTPUT WITHOUT REGULATOR IN CIRCUIT

I. Disconnect the battery ground strap.

2. Remove the end cover and disconnect the field terminal and AC leads. See the topic, DISAS­SEMBL Y AND ASSEMBLY.

TESTING SCHEMATIC I-Jumper lead. 2-Voltmeter. 3-Ammeter. 4-Carbon pile. S-Field wire (red). 6-Charging alternator. 7-0utput ter­

minal. 8-Ground terminal. 9-Battery.

3. Connect an ammeter between the alternator out­put terminal and the positive post of the bat­tery. Connect the voltmeter between the output terminal and ground. See the testing schematic.

4. Connect a carbon pile load (4) between the positive battery post and the ground. Turn to the "off" position. See the testing schematic.

5. Use a jumper lead (1) to connect the field ter­minal lead (5) to alternator output terminal (7). See the testing schematic.

STARTING ENGINE

TABLE OF CONTENTS

Section

Index ............... . 8A-20

Specifications ........ . 8A-20

Operation ................. . 2A-20

Removal and Installation 8A-20

Lubrication System ............ . 2A-20

Fuel System ........... . 8A-20

Cylinder Head and Valves .. 8A-20

Pistons, Rings and Connecting Rods . 12A-20

Timing Gear Housing ........................... . 2A-20

Magneto (Wico) ..................... . 12A-20

Crankshaft, Flywheel and Main Bearings .. 12A-20

Camshaft ..... . 15A-20

Starting Mechanism 8A-20

8A-20 Group 20.2

Group

30.2

40.1

70

80.2

90

100

110.1

120

130

135

140

150

160:1

Page 1

A Adj ustments :

Anti-Butt Engagement Device Carburetor Governor Starter Pinion Plunger Valve Clearance

Bearings: Connecting Rod Main

Brackets, Support Bushing, Piston Pin Bushing, Valve Guide

Camshaft Carburetor Clearances and Tolerances Clutch Clutch Housing Connecting Rod Bearings Cooling Crank Mechanism, Hand Crankshaft Crankshaft Gear Cylinder Head Cylinders

Data, Engine Drive, Magneto

Flywheel Fuel System

Gear: Camshaft Crankshaft Oil Pump Pinion Drive

Governor

Hand Crank Mechanism Head, Cylinder Housing:

Clutch and Transmission Timing Gear

B

C

D

F

G

H

8A-20

STARTING ENGINE

INDEX

Group Page

160.1 - 7 100 - 2 130 - 3 160.1 - 3 110.1 - 2

120 - 1 140 - 2 80.2 - 1

120 - 2 110.1 2

150 - 1 100 40.1 -

160.1 - 4 160.1 120

70 130 2 140 1 140 110.1 1 120 - 1

40.1 130 - 1

140 - 1 100 - 1

150 - 2 140 1 90 - 2

160.1 130 - 2

130 - 1 110.1 - 1

160.1 -130 - 1

Lifters, Valve Lubricating System

Magneto Adjustment Ignition Timing Maintenance Test Equipment

Magneto Drive Main Bearings

Oil: Pan Pump

L

M

o

Pump Pressure Regulating Valve Operation, Startinq Engine

Pan, Oil Pinion, Starter Pistons Piston Pin Bushings

p

Plunger, Starter Pinion Pressure Regulating Valve, Oil Pump, Oil

Reboring Cylinders Removing Engine Rings, Piston

Screen, Sump Specifications:

Cylinder Reboring General

Springs: Governor Valve

Starter Pinion Starting Mechanism

Timing Gear Housing Tolerances Transmission

Valve: Clearance Adjustment Lifters Pressure Regulating

R

S

T

V

Group 30.2 Page 1

Group Page

110.1 - 2 90 - 1

135 - 1 135 - 5 135 - 6 135 - 5 135 - 5 130 140 2

90 - 1 90 - 2 90 2 70 - 1

90 160.1 120 - 1 120 - 1 160.1 - 3

90 - 2 90 - 2

120 - 1 80.2 1

120 - 1

90 - 2

120 - 1 40.1 -

130 3 110.1 - 2 160.1 - 1 160.1 1

130 - 1 40.1 1

160.1 - 3

110.1 - 2 11 O.l 2

90 - 2

21B-30

POWER TRANSMISSION UNITS

TABLE OF CONTENTS

Section Group

Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 21B-30 30

Specifications ......................................... 21B-30 40

Hydraulic Control System Testing and Adjustment (36A4469-36AS484) ....................... 2lB-30 43

Hydraulic Control System Testing and Adjustment (46AlO72S-46A21068)

Hydraulic Control System Testing and Adjustment (46A21069-46A28136)

Introduction (36A4469-36AS484) ... _ .................... .

Introduction (46A1072S-46A28136) .............. _ ....... .

Universal Joint (36A4469-36AS484) ..... _ ............... _ .

Universal Joint (46AI0725-46A28136) ....... _ .. _ . _ ....... .

Flywheel Clutch (36A4469-36AS484) ..................... .

Torque Divider Troubleshooting Guide (46AI072S-46A28136) .. .

Torque Divider Removal (46AI072S-46A28136) __ ........... .

Torque Divider (46AI072S-46A28136) ... __ ...... _ ..... _ .. .

2lB-30

21B-30

2lB-30

21B-30

21B-30

2lB-30

2lB-30

2lB-30

21B-30

2lB-30

43.1

43.2

6S

6S.1

70

70.1

80

89

90

100

Transmission Hydraulic Controls (46AlO72S-46A21068) . . . . . . . . 21B-30 lOS

Transmission Hydraulic Controls (46A21069-46A28136) . . . . . . .. 2lB-30 10S.1

Gearshift and Interlock Mechanism (36A4469-36AS484) . . . . . . . . 21B-30 llO

Transmission Troubleshooting Guide (46AI072S-46A28136) .... 21B-30 ll8

Transmission Removal (36A4469-36AS484) ....... _ . . . . . . . . .. 21B-30 119

Transmission Removal (46AI072S-46A28136) . . . . . . . . . . . . . . .. 2lB-30 ll9.1

Transmission (36A4469-36AS484) ... _ ..... _ ...... _ . . . . . . . . 21B-30 120

Transmission (46AI072S-46A28136) .... _ . __ . . . . . . . . . . . . . .. 21B-30 120.1

Transmission Lubrication System (36A4469-36AS484) _ . . . . . . .. 21B-30 130

Transmission Lubrication System (46AI072S-46A28136) ....... 21B-30 130.1

Bevel Gear (36A4469-36A5484) _ ........ _ . . . . . . . . . . . . . .. . . 2lB-30 140

Bevel Gear (46AI072S-46A28136) ..................... _ . . . 2lB-30 140.1

Hydraulic System (36A4469-36AS484) ..................... 21B-30 145

Hydraulic System (46AI072S-46A28136) ......... _. . .. . . ... 21B-30 14S.1

Brakes ......... _ . _ ...... _ ......... _ .... _ ........ _ . . .. 21B-30 ISO

Steering Clutches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 21B~30 160

Steering Clutch Hydraulic Control ......................... 2lB-30 170

Final Drive ........................................... 21B-30 180

Group 20

Page 1

I

21B-30 Group 30 Pagel

POWER TRANSMISSION UNITS INDEX

A Group Page Adjustments:

Bevel Gear Backlash

Bevel Gear Bearing ......................... .

Bevel Gear and Pinion Setting ........ , .....•..

Brake. Flywheel Clutch ..................... . Brake. Steering Clutch ...................... . Clutch Control Valve ..•..................... Final Drive Bearing ..............•.......•.. Flywheel Clutch (Direct Drive) ............... . Gearshift and Interlock Mechanism ....••....... Hydraulic Control System Testing and

Adjustment ......•......................

Steering Clutch and Transmission Hydraulic Tests

Transmission Idler Gear ..........•........... Transmission Hydraulic Control Linkage .....•.•.

B

Bevel Gear

140 3 140.1 - 3 140 2 140.1 - 2 140 - 2 140.1 - 2 80 -12

150 - 4 80 - 6

180 -12 80 -12

110 - 5

43 43.1 -43.2-

43 3 120 9 105 9 105.1 - 6

43.1 - 4

140 140.1 -

Bevel Gear and Pinion Setting ................... 140 2 140.1 - 2

Brake Band Removal ..•...••...•...•.•.......• 150 5 Brake Engaging Mechanism .......•............. 150 3 Brakes. Steering Clutch ........•..••........•.. 150

Parking.. . . . • . . •• . . . . . . • . . . . •. . . . . . . . . . . .. 150

C

Check Valve. Steering Clutch and Brake Hydraulic Control ......................... .

Checking Hydraulic Control Pressure •...•.•.•..•.•

Checking Torque Converter Clearances •.•.••.•••.• Clearances and Tolerances ..•••..••..•....••••. Clutch Designation ..•.....•.•...•.•.....•..... Clutch. Flywheel ...............•..•.......... Clutches. Steering •......•.•••..••••...•..•... Clutches. Transmission ..••.••..•.....•..••...•. Control. Flywheel Clutch Hydraulic .•...•...•.•.. Controls. Steering Clutch Hydraulic ........••...•. Control System Testing and Adjustment.

Hydraulic •..••.•..•.....••.....•.••.•....•

Controls. Transmission HydrauliC

D

Data Divide'r . ~~br;~~ti~~: T~;q'~e' .................... . ............................... Divider. Torque Divider Removal. ~~rq' ~~ .....•.•.•........•..•..

.... -................... .. Drive. Final ...................................................

145.1 - 4 105 5

43.1 - 1 43.2 - 1

100 7 40 1

120.1 - 1 80

160 120.1 - 1 80 2

170

43 43.1 - 1 43.2-

105 105.1 - 1

40 100 100 90

180

F Group Page

Filter. Oil

Final Drive ...•.•..•.•••....................•. Bearing Adjustment .••......••.........•.... Duo-Cone Floating Seals ..................•.. Gear .........••.......................... Pinior;l .................•................. Sprocket ...•............................. Sprocket Shaft .......•....•................ Support ....•.•.........•..•......•....•..

Flywheel Clutch ...........................•.. Fork. Shifter ..........•....•..•.............

G

Gear: Bevel

Final Drive .•...•...........•.........•.... Gearshift and Interlock Mechanism ..........•..•. Guide. Power Shift Transmission

Troubleshooting .•....•................•.... Guide. Torque Divider Troubleshooting ••...•......

H

Hydraulic Booster. Brake ...•..........••.•..... Hydraulic Control. Flywheel Clutch ..••.......•.. Hydraulic Control Safety Valve ...•...•......•••.

Hydraulic Control. Steering Clutch .............. . Hydraulic Control System Testing and

Adjustment .............................. .

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

Hydrauljc Oil Pump ..•....•.......•.•....•. , •.

Hydraulic System .......•.•.•......•.....•....

J

Joint. Universal

L

Linkage. Hydraulic Control

Lubrication: Final Drive ..•.•••...•.•.•..••..•..•.....•. Flywheel Clutch ~ •....••..•.•.•..•..•..•.... Torque Divider .......................•...•. Transmission (Direct Drive) ....•.•...•...•..•. Transmission (Power Shift! ..•.•......•.•.....

M

Magnetic Strainer

145 3 145.1 - 3 180 - 1 180 -12 180 - F 180 - .. ", 180 -10 180 - 5 180 -9 180 4

80 110

140 - 1 140.1 - 1 180 6 110

118 89

150 1 80 6

105 6 105.1 - 4 170

43 43.1 -43.2-

105 1 105.1 - 1 145 2 145.1 - 2 145 1 145.1 - 1

70 70.1 -

43.2 - 4

180 -1

80 1 100 130 130.1 -

145 2 145.1 - 2

21B-30 Group 30 Page 2 POWER TRANSMISSION UNITS

INDEX

o Group Page

Oil Filter ................•...•......•.......

Oil Pump: Final Drive .•.•.•••.......•.••............. Flywheel Clutch ..•.•....••...•..•.......... Steering Clutch, Brake and Transmission

Hydraulic Control ..............••••.•....

Torque Divider Scavenge and Torque Converter Recirculating .•.•.•...•.••.......

Operation: Brakes .••...•........••.•..••.•.•..•..••. Final Drive ..•..........•..•.•••...•.•....• Flywheel Clutch ........•..•......•..••..... Hydraulic System .......••...•.•.•.•.•......

Magnetic Strainer .....•...•...•..•••........

Steering Clutches ........•......•....•.•...• Steering Clutch Hydrllulic Controls •.•.••.•..•.. Steering Clutch and Brake Hydraulic

Control Clock Valve •....•• , .•••••••••....• Torque Converter Outlet Relief Valve .....•.•... Torque Divider ..••.•..••..•...••••.••...... Transmission (Direct Drive) .................. . Transmission (Power Shift) ...........•.......

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

Hydraulic Pump ...•....•..........•.••.....

14S - 3 14S.1 - 3

180 80 S

14S 2 145.1 - 1

145.1 - 6

lS0 180 80

14S 14S.1 - 1 145 - 1 145.1 - 2 160 1 170 - 1

14S.1 - 4 145.1 - 5 100 1 120 1 120.1 - 1 120.3 - 1 105 - 2 105.1 - 2 14S - 2 14S.1 - 2

Safety Valve .....•.••...•....•....••••••... lOS 5 105.1 - 3

P

Pinion, Final Drive. .. .•.•..•. . . .. . .•. . • . . •. ... 180 -10 Planet Carrier (Torque Divider) .•.....•..•....... 100 - 2 Planet Carrier (Power Shift Transmission) .•.....•.. 120.1 - 8 Pressure Control Valve .••...•••....••••.•...•.. lOS - 6

105.1 - S Pressure Relief Valve:

Clutch ••.•....•. ,;....................... 80 - 6 Steering Clutch Cf;'A Bro::ke

Hydraulic Controls •.....•.••.....••.••...• 14S - 4 Transmission ....•...•..•....•..•.•••..••.• 130 1

130.1 -Pumps:

Final Drive Oil •.••...•.•.••.•••...•.•••.... 180 Hydraulic Oil ••.•....•..•......•..•••...... 145 2

14S.1 - 2. Torque Divider Scavenge and Torque

Converter Recirculating Oil •.•..•....•...•.. 14S.1 - 6

s

Safety and Directional Valve .•••.•...•...•..••.• lOS - 6 105 - 8 10S.1 - 3 105.1 - 6

Seals, Final Drive Duo·Cone Floating. . . . .. .. •. . . .. 180 Seals, Turbine and Impeller ...•.••..•.. '~ ,. ';.... . .. 100 Shifter Fork ........•......••.•.....••. :..... 110 Specifications, Tolerances and Clearances ......... . 40 Speed Selector Valve ........................... lOS

6 6 1 1 7

10S.1 - 4

Group Page

Sprocket, Final Drive ••...••.....•..•...•...... Sprocket Segments ......•••...•..•..•..•...... Sprocket Shaft, Final Drive ....••....•.......... Steering Clutch ............•.....•.•...•..... Steering Clutch and

Transmission Hydraulic Tests .•..••••.....••... Steering Clutch and

Brake Hydraulic Control Check Valve ...•...•..• Steering Clutch Brake ......•.•...........••... Steering Clutch Hydraulic Control •...........•... Strainer, Magnetic .......••.•.........•...•...

T

Torque Divider ......••.•..•••••.............. Torque Divider Lubrication .••.••.•••.••...••••. Torque Divider Removal •....•.......•.......•. Torque Divider Troubleshooting Guide ............ . Transmission ..••.......................•...•

Clutches .................•••.....•......•. Front Carrier .•..........••.•..•......••.•. Gearshift and Interlock Mechanism •..•....••••. Hydraulic Controls .......•.........•...•....

Input Shaft .......••.......•..........•... Lubrication ......•••.•..•..........•••..•.

Output Shaft .•.....•.................•.... Removal ........•.•..•..............•.•...

Transfer Gear ...•..••.•.•.•.............••... Troubleshooting Guide,

Power Shift Transmission •...........•.......• Troubleshooting Guide, Torque Divider ..••••.••••.

U

180 - S 180 -12 180 9 160 1 '

43 3

14S.1 - 4 lS0 1 170 1 145 2 14S.1 - 2

100 100 90 89

120 120.1 - 1 120.1-1 120.1 - 8 110 1 lOS - 1 10S.1 - 1 120.1 - 6 130 - 1 130.1 - 1 120.1 - 9 119 - 1 119.1 - 1 120.1 -12

118 89

Universal Joint ............•••....•..•••..•.•• 70 70.1 - 1

V

Valve: Brake Cooling and Lubricating Oil

Pressure Relief •.•••.••••••..•••••.•..•••• 14S - S 14S.1 - 6

Flywheel Clutch Pressure Relief ••.....•.••..••. 80 - 6 Pressure Control •••.•..•.••.•...••..•.•.••.• lOS - 6

10S.1 - S Pressure Relief ..•.••....••..•••...•.••..•.• 130 1

130.1 - 1 Safety and Directional •.••••..•.•.•.•.......• lOS - 6

10S.1 - 3 lOS - 8 10S.1 - S

Speed Selector ..•.......•..•.•••••...•..•.• lOS 7 10S.1 - 6

Steering Clutch and Brake Hydraulic Control Check ...•.........•..•.•.......• 145.1 - 4

Steering Clutch and Brake Hydraulic Controls Relief .................. 14S 4

Torque Converter Inlet Relief .......•......•.. 14S.1 - 4 Torque Converter Outlet Relief •.....•.....••.. 145.1 - 5 Transmission Lubrication Regulator .........•.. 130

130.1 -

TRACK ROLLER FRAME

TABLE OF CONTENTS

Section

Index ............................................... . 21B-40

Specifications ........................................ . 21B-40

Tracks .............................................. . 21B-40

Track Carrier Rollers and Track Rollers ................. . 21B-40

Front Idler, Recoil Spring and Equalizer Bar ............. . 2IB-40

Track Roller Frame Removal .......................... . 21B-40

------ _._ .... -. '"" .. <,---.

21B-40

Group

30

40

80

90

100

120

Group 20 Pagel

I

r1;

21B-40 Group 30 Pagel

TRACK ROLLER FRAME

INDEX

Jl Group Page Adjustments:

Front Idler Track Adjusting Mechanism ............... . Track .................................. . Track Roller Frame

B

Bar. Equalizer ............................ . Bushings, Track Pins and ................... .

C

Carrier Roller Support Assembly ............ . Carrier Rollers, Track ...................... . Clearances and Tolerances ................. .

E

Equalizer Bar ....... _ ..................... _ . Equalizer Bar Support ..................... .

F

Floating Duo-Cone Seals, Installation ........ . Frame Removal. Track Roller ................ . Front Idler .......... _ ......... _ ....... _ ... .

I

Idler, Front ............ _ .................. . Installing Floating Duo-Cone Seals .......... . Installing Track ........................... .

L

Links, Track .............................. . Lubrication:

Front Idler . . . . ........... _ ........ _ .... _ . Track Carrier Rollers ..... __ ... _ . _ ........ . Track Rollers ......... '. _ ................ .

100 - 4 100 - 8

80 - 4 120 - 1

100 -11 80 -4

100 -10 SO - 1 40 - 1

100 -11 100 -11

90 - 5 120 - 1 100 - 1

100 - 1 SO -5 80 -2

80 - 1

100 - 1 90 - 1 90 - 3

M Group. PQge

Master Pin ................. -........... ... .. 80 - 1 Mechanism, Track Adjusting .. . ... ........ . . .. 100 - 8 Metal Floating Ring Seal Installation . .. ...... 90 - 5

P

Pins and Bushings, Track .. . . . . . . . .... ... . .. 80 - 4

R

Recoil Spring . . .... . .... . ............. . . .. . 100 - 4 Removing Recoil Rod and Yoke As A Unit . . .. 100 - 9 Rollers:

Carrier, Track ..... . ..... . . . ......... - ... . . 90 - 1 Track .. . . . .... . . . . .. ........ . ..... .. , -. SO - 3

Roller Frame Removal. Track - .... ... .. . ' . . . 120 - 1

S

Seals. Floating Duo-Cone . . . . . . . . . . . . . . . SO - 5 Specifications ................ ............. 40 - 1 Spring. Recoil . . . . . . . . . . . . . . . . . . . . . . . . .. 100 - 4

Tolerances and Clearances Track:

T

Adjusting .............................. . Adjusting Mechanism .................... . Carrier Rollers ........................ . .. Installing ............................... . Links .................................. . Pins and Bushings . . ..................... . Rollers .................................. . Separating ............................ ..

Track Roller Frame Removal ................ . Tracks ................................... .

40 - 1

80 -4 100 -'8 90 - 1 80 - 2 80 - 1 80 -4 90 3 80 1

120 1 80 1

'";;. ~".: ",~

:t

:~~ :.~.

•

21B-200

SEAT, FUEL TANK AND MISCELLANEOUS

TABLE OF CONTENTS

Section Group

Seat and Seat Frame Removal ....................... . 21B-2QO 70

Fuel Tcoik Removal .................................. 21B-200 70

Dash Removal ...... '.' .... , ... ... . . . ... . ... .. . . . . ... 21B-200 70

Fender Removal ..................................... 21 B-200 70

~bar Removal ................................... 21B-200 70

Track Roller Guards ................................. 21B-200 70

Cab Glass Installation .. 21B-200 70

Group 20

Page 1

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