D3 Crawler S/n 79U4709 & Up

Transcription

1 Parts Manual Parts Manual D3 Crawler S/n 79U4709 & Up THS S A MANUAL PRODUCED BY JENSALES NC. WTHOUT THE AUTHORZATON OF CATERPLLAR OR T S SUCCESSORS. CATERPLLAR AND T S SUCCESSORS ARE NOT RESPONSBLE FOR THE QUALTY OR ACCURACY OF THS MANUAL. TRADE MARKS AND TRADE NAMES CONTANED AND USED HEREN ARE THOSE OF OTHERS, AND ARE USED HERE N A DESCRPTVE SENSE TO REFER TO THE PRODUCTS OF OTHERS. CT-P-D379U4709

2 CONTENTS ALPHABETCAL NDEX OF GROUPS 3 CONVERSON EaUVALENT TABLES NSDE BACK COVER ORDERNG PARTS- auck REFERENCE CHART NSDE FRONT COVER USNG THE PARTS BOOK QUCK REFERENCE GUDE TO MAJOR SECTONS BASC ENGNE LUBRCATON SYSTEM COOL. NG SYSTEM PARTS BOOK 03 TRACTOR POWERED BY 304 ENGNE SERAL NUMBER 79U4709TO LAST BULT (VEHCLE) 45V760TO LAST NSTALLED (ENGNE) REVSON PUBLSHED JULY 98 CATERP LLAR TRACTOR CO. PUBLCATONS DV.-SERVCE G.O. PEORA, LL. U.S.A. NTAKE AND EXHAUST SYSTEM FUEL SYSTEM AND GOVERNOR STARTNG AND ELECTRCAL SYSTEM POWER TRAN- POWER TRANSMSSON UNT STEER NG CLUTCHES AND BRAKES CHASSS AND UNDERCARRAGE HYDRAULC SYSTEM CAB, GAUGES AND ACCESSOR ES SERVCE EQUPMENT AND SUPPL ES

3 N D EX A c Nome Name Accessory Drive Cab Arrangement Air Cleaner... 3 Cab Conversion Arrgt Air Filter Service ndicator Cab Floormat... 4 Alarm-Sack-Up Warning Cab Heater Alternator-40 Ampere Cab liner Alternator Adjusting Sracket Cab Mounting Alternator Change-Over... 48A Ammeter-60 Ampere... 48A Cab Panel - Front Cab Panel - L.H Cab Panel - Rear... 5 Cab Panel - R.H B Cab Wiring Back-Up Warning Bar - Track Cleaner Base - Fuel Filter Battery - Heavy Duty Battery Box Battery & Wiring Battery Cables Battery Holddown Bearing Cap - Cyl. Block... 6 Bearing Caps - Connecting Rod... 8 Bearings - Camshaft... 6 Bearings - Connecting Rod... 8 Bearings - Crankshaft... 7 Belt - Seat - Standard Belt - Seat - Suspension... 3 Belt-Vee... Bevel Gear Blades - Windshield Wiper Bracket - Alternator Adjusting Cable - Stg. Motor Grd Camshaft... 9 Cap - Bevel Gear Filler Tube Cap - Engine Oil Filler... 0 Cap - Fuel Tank Cap - Fuel Tank Protection Cap - Hyd. Tank Cap - Hyd. Tank Protection Cap - Radiator Pressure Relief... 9 Cap - Transmission Filler Tube Case - Steering Clutch Circuit Breaker - 50 Ampere... 4 Clutch - Steering... 7 Connecting Rod & Piston... 8 Control - Governor... 7 Control - Governor Torque... 9 Control - Hyd. Hand Control - Steering Clutch Control - Transmission Cooler - Engine Oil... Counterweight - Front Bracket - Drawbar Mounting... 8 Counterweight - dler Bracket - Governor & Fuel nj. Cover - Valve Mechanism... 0 Pump Housing Support Crankcase Guard Bracket - Oil Filter to Hyd. Tank Crankshaft... 7 Brackets - Cab Mounting Crankshaft Bearing - Oversize rackets - RaPS Mounting Crankshaft Bearing - Standard... 7 Crankshaft Bearing - Undersize... 8 Brake Band & Lining... 7 Crankshaft Pulley... Brake - Steering... 7 Cylinder - Ether... 5 Breather - Bevel Gear Filler Tube Cylinder Block... 6 Breather - Hyd. Tank Relief Valve Cylinder Block & Covers... 4 Breather - Transfer Gear Cylinder Head... 9B Breather - Crankcase... 7 Cylinder Head Fastener... 9B

4 D Name Name Dash Dash Lamps Dipstick - Engine Oil Level... 4 Dipstick - Power Train Lubrication.. 53 Dipstick - Transmission Oil Door - Cab - L.H Door - Cab - R.H Drain Cock - Cab Heater Drain Cock - Fuel Tank Drain Cock - Radiator... 9 Drain Plug - Engine Crankcase Oil.. 4 Drain Plug - Fuel njection Pump... 3 Drain Plug - Hyd. Tank Drawbar - Fixed... 8 Drawbar - Swinging... 8 Drum - Final Drive Driven Drum - Driving... 7 Drum - Steering Clutch Driven E Elbow - Exhaust... 4 Elbow - Radiator Top Tank Hose to Front Housing... 0 Electric Horn Element - Fumes Disposal... 7 Element - Primary & Secondary Air Cleaner... 3 Element - Hyd. Filter Enclosure - Engine Engine Arrangement... 3 Engine & Transmission Support... Ether Cylinder... 5 Ether Starting Aid... 5 Exhaust Manifold... 4 Exhaust Manifold' Fastener... 4 Exhaust Pipe - Muffler... 6 F Fan & Guard - Blower Fan - Defrosting Fan Drive... Fan - Blower... 8 Fan - Suction... 8 Fastener - Cylinder Head... 9B Fastener - Oil Pan..... '4 Fasteners - Exhaust Manifold... 4 Filler Spout - Transmission Oil Filler - Engine Oil... 0 Filler - Transmission Oil Filter - Fuel Filter - Hydraulic Oil Filter - Engine Oil... 6 Filter - Transmission & Steering Clutch Final Drive Final Drive Pinion Firewall Flood Lamp Flywheel... 3 F yw h ee H ousmg...., 3 Floormat - Cab... 4 Frame Frame - Track Roller Front Housing... 5 Front dler Front Pull Hook Fuel Filter Fuel njection Lines Fuel Lines Fuel Priming Pump Fuel Tank Fuel Tank Protection Cap Fuel Transfer & Priming Pump Fumes Disposal - Engine Crankcase Breather... 7 Fuse - 5 Amp. Cab Wiring Fuse - 0 Amp. - Electric Horn G Gasket - Bevel Gear Case to Filler Tube Gasket - Cylinder Head to Cylinder Block Gasket - Exhaust Manifold to Cylinder Head... 4 Gasket - Flywheel Housing to Cyl. Block..., 3 Gasket - Fuel Pump Housing to Accessory Drive..., 34 Gasket - ntake Pipe to Cylinder Head... 4 Gasket - Oil Pan to Cylinder Block.. 4 Gasket - Starting Motor... 49

5 Name Name Gasket - Transmission to Oil Filler Tube Gasket - Valve Mechanism Cover to Cylinder Head... 0 Gasket - Water Elbow nlet to Front Housing... 0 Gasket - Water Pump to Front Housing... 0 Gasket Kits Gasket Solution - Final Drive Gauge - Engine Oil level... 4 Gauge - Hyd. Tank Oil Sight level.. 06 Gauge - Oil Pressure Gauge - Transmission Gauges Gear - Accessory Drive Gear - Crankshaft... 7 Gear - Final Drive Gear - Transmission Oil Pump Drive... 6 Gear - Transmission Oil Pump... 6 Governor Governor & Fuel njection Pump... 9 Governor Control... 7 Governor Spring...,... 9 Grab ron - Cab Grab ron - Firewall Grease Gun Guard - Brush Guard - Crankcase Guard - Defrosting Fan Guard - Engine Guard - Blower Fan... 8 Guard - Front lamp Guard - Hyd. Hand Control... Guard - Radiator... 9 Guard - Radiator Hinged... 9 Guard - Recoil Guard - Track Guiding Guard - Track Roller Guard - Transmission Shifter Control Guard - nstrument Panel Vandalism H Hand Tools Handle - Cab Door L.H Handle - Cab Door R.H: Handle - Hyd. Hand Control... Handle - Gearshift Control Handle - Governor & Transmission Control... 8 Harness - Battery & Wiring Heater -- Cab Heater - Jacket Water... Holddown - Battery Hood & Guard Hook - Front Pull Horn - Electric - Forward Warning.. 33 Hose - Air Cleaner to ntake Manifold Hose - Engine Block to Cooler... Hose - Cooler to Front Housing... Hose - Radiator nlet & Outlet... 9 Hour Meter - Electric Housing - Flywheel... 3 Housing - Front... 5 Hydraulic Arrangement Hyd. Hand Control Hydraulic Tank & Valve dler - Counterweight dler - Front ndicator - Air Filter Service ndicator - Oil Temperature ndicator - Water Temperature nserts - ntake & Exhaust... 9B K Key - Cab Door Kit - Rebuild - Water Pump... 0 Kit - Repair - Hyd. Pump Kit - Repair - Alternator Kit - Repair - Suspension Seat Kit - Repair - Solenoid Switch Kit - Repair - Starting Motor Kits - Gasket Knob - Governor Control... 7 Knob - Transmission Safety Knob - Transmission Shift... 55

6 L Name Name lamp - Dash... 4 lamp - Flood lever - Gearshift Control lever - Governor Control... 7 lever - Governor & Transmission Control... 8 lever - Hydraulic Hand Control... lifters - Valve... 0 lifting Eye - Cyl. Head... lifting Eye - Engine... lighting - RaPS ligthing & Wiring - 3 lamp liner - Seat & Tank... 4 liner - Cab liner - Canopy liner - Firewall lines - Cab Heater lines - Fuel njection lines - Fuel Filter to Fuel nj. Pump lines - Fuel Filter to Fuel Transfer Pump lines - Fuel Tank to Transfer Pump.. 37 lines - Hydraulic Pump... 4 lines - Pump... 6 lines - Rear... 8 lines - Winch Pump lines - Torque Converter Cooler... link - Track - Sealed & lubricated.. 03 link - Track - Sealed Non-lubricated... 0 linkage - Governor & Transmission Control... 8 linkage - Hyd. Hand Control... linkage - Steering Brake... 7 linkage - Steering Clutch Control linkage - Transmission Control M Manifold - Exhaust... 4 Manifold - nlet... 4 Meter - Hour Electric Motor - Starting Mounting - Alternator Mounting - Cab Mounting - RaPS... '80 Muffler... 5 N Nameplate - Planetary Transmission Name Plates & Transfers Name Plates - Front dler Warning.. 96 Nozzle - Fuel Nozzle - Windshield Washer... 6 o Oil Cooler - Engine... Oil Filler - Engine... 6 Oil Filter - Engine... 6 Oil Filter - Hydraulic Oil Level Gauge... 4 Oil Pan... 4 Oil Pan Fastener... 4 Oil Pump - Engine... 5 Operator Protective Cab Arrgt p Padlock & Key-Fuel Tank Cap Padlock & Key-Hydraulic Tank Cap Padlock & Key-Vandalism Guard Panel-R.H. Cab Panel-L.H. Cab Panel-Front Cab Panel-Rear Cab Panel-Dash Pedal-Steering Brake Pipe-Exhaust Pipe-nlet Piston Piston Pump-Slipper A Piston Rings Plug-Bevel Gear Drain Plug-Final Drive Oil Fill Plug-Final Drive Drain Plug-Freeze Cylinder Block... 6 Plug-Fuel njection Drain... 3 Plug-Hydraulic Tank Drain Plug-Hydraulic Filter Drain. 30

7 Name Name Plug - Oil Pan Drain... 4 Plug - Pressure Manifold... 4 Plug - Pressure Radiator... 9 Plug - Timing - Flywheel... 3 Plug - Transmission lub. Pressure Plug - Transmission Oil Drain Plunger - Fuel Tank Power Take-off Drive Power Train Schematic... 5 Precleaner - Air Cleaner... 3 Prescreener... 4 Protection Cap - Fuel Tank Protection Cap - Hydraulic Tank Pulley - Auxiliary Drive... Pulley - Fan Drive... Pump - Engine Oil... 5 Pump - Fuel njection... 3 Pump - Fuel Transfer & Priming Pump - Hydraulic Gear... 0 Pump - Piston - Backhoe... 5 Pump - Transmission Oil... 6 Pump - Water... 0 Pump - Winch Gear Push Rods... 0 R Radiator... 9 Radiator Cap... 9 Radiator Guard... 9 Radiator Hinged Guard... 9 Rear Window... 5 Ring - Piston... 8 Rocker Arms - ntake & Exhaust... 0 Rod & Piston... 8 Rods - Push... 0 Roll-Over Protective Structure - Open Roll-Over Protective Structure - Arrgt. - Enclosed Roll-Over Protective Structure Mounting s Screen - Transmission Oil Control... 6 Seal - Cab Glass Seal -- Crankshaft... 7 Seal - Duo Cone - Final Drive Seal - Duo Cone - Front dler Seal - Duo Cone - Track Carrier Roller Seal - Duo Cone - Track Roller '".0 Seal - Fuel Filter lines to Gov. & Fuel nj. Pump Seal - Fuel Transfer Pump Seal - Hydraulic lines to Tank... 6 Seal - Hydraulic Pump lines to Hydraulic Oil Filter... 6 Seal - Hydraulic Pump lines to Hydraulic Oil Pump... 6 Seal - Steering Clutch Control to Control Valve Seal - Transmission to Flywheel Housing Seals - Fuel Pump Housing Seat - Standard Seat - Suspension Seat Belt Seat Belt - Suspended Seat... 3 Shaft - Bevel Gear Shaft - Rocker... 0 Solenoid Switch - Starting Motor Sound Suppression Arrgt Specifications Spring - Governor... 9 Spring - Front dler Recoil Spring - Valve - ntake & Exhaust... 9B Sprocket - Final Drive Sprocket & Rim Replacement Starting - Ether... 5 Starting Motor - Electric - Volt Steering Brake... 7 Steering Brake Pedal Steering Clutch... 7 Steering Clutch Case Steering Clutch Control Steering Clutch Driven Drum Support - Engine... Support - Hyd. Control... 3 Support - Transmission... Support & Seat Support - Undercarriage... 8 Suspension Assem. Seat Sweep... 6 Swinging Drawbar... 8 Switch - Cab Heater Switch - Defroster Switch.- Ether Flow..., 5

8 Name u Switch - Heat- Start... 4 Switch - Horn Switch - Light... 4 Switch - Pressure - Horn " Switch - Pressure - Hour Meter Switch - Safety Transmission... 6 Switch - Solenoid Switch - Temperature... 5 Switch - Transmission Switch - Wiper T Tank - Fuel Tank - Hyd Tappets Thermostat - Water Temperature... 0 Tools - Hand Torque Control... 9 Torque Converter..., 54 Torque Converter Cooler Lines... Track - Sealed & Lubricated Track - Sealed Non-Lubricated... 0 Track Carrier Roller Track Cleaner Bar Track - Guiding Guard Track Link - Sealed & Lubricated Track Link - Sealed Non-Lubricated.. 0 Trock Roller... 0 Track Roller Frame T rack Roller Guard T rack Shoe... 0 Transfer Gear Transfers Transmission Arrgt Transmission - Planetary Transmission Control Transmission Oil System Control... 6 Tube - Fumes Disposal... 7 Tube - Front Housing Vent... 0 Tube - Fuel Pump to Transfer Pump Tube - Fuel Transfer & Priming Pump to Fuel Filter Tube - Steering Clutch Control to Bevel Gear Case Tube - Transmission Filler Tubes - Fuel Tank to nj. Pump Nome Undercarriage Support Universal Joint - Power Take-off... 6 v Valve-Bank-Main Relief... 7 Valve-Bank... 5 Valve-Breaker Rellef-Hyd Valve-Fuel Check-Fuel njection Pump... 3 Valve-Front dler Relief Valve-Front dler Fill Valve-Hydraulic Control... 3 Valve-Lift Control... 9 Valve-Lift Control-Check... 0 Valve-Relief... 7 Valve-Relief-Ripper Cyl Valve-Ripper Control... 8 Valve-Servo... 7 Valve-Steering Clutch Control Valve-Ti t Control... 7 Valve-Transmission Hydraulic Selector & Pressure Control Valves-Fuel Tank Drain & Shut-Off Supply Valves-ntake & Exhaust Valve Mechanism... 0 Valve Mechanism Cover... 0 Vandal ism Arrangement Vandalism Guard-nstrument Panel Vee Belt-Fan, Alternator & Crankshaft... w Water Heater... Water Lines... 0 Water Pump... 0 Winch Drive Arrgt Winch Pump & Lines Windshield Washer... 6 Wiper - Windshield Wiring - Cab Wiring Diagram... 4

9 BASC ENGNE 8A C NDCATES CHANGE REF. NO. PART NUMBER DESCRPTON C 6N40 PSTON GROUP std. ) L936 R' ~G ASSEM oil) L99 R NG compression )---- C 4 6N4340 PSTON GROUP in. 0.5 mm) oversize 5 9L9673 RNG ASSEM L9674 R NG C 7 6N4350 PSTON GROUP in.. 0 mm) oversize 8 9L933 RNG ASSEM L946 R NG J6473 RNG N8 ROD ASSEM L838 BEAR NG L85 BOLT NUT N9 BEAR NG std. ) N4707 BEAR NG <.00 in mm) undersize 4N473 BEAR NG in mml undersize 6 9L9889 P N BEARNG GROUPS AVALABLE: i 4N4705-BEARNG GRP std. bearings) N4706-BEAR NG GRP in mm) undersize 4N474-BEARNG GRP in mm) undersize 9L96-P STON RNG GROUP std. ) Complete set of Rings for one Std. Piston) OTY 4N9 CONNECTNG ROD AND PSTON GROUP-4 Required-Field nstallation Engine Serial No. 45V760 to 45V765 inclusive Part of 8N988 Cylinder Block Group listed on 6A 9' cj 0 C j Cj Cj / CA CA CA CA CA REF. NO C 3 4 PART NUMBER 8N5537 9L633 9L936 W N58 9L9673 lw5796 9N578 9L933 7N9803 8N794 8N6308 W3906 W38 W38 8N8753 9N508 9N DESCRPTON OTY. PSTON GROUP--- (standard) ncludes) R NG--(standard-compression R NG--(Standard - oi\) PSTON BODY mml 0 in. )oversize R NG------(Oversize - compression R NG---(Oversize - oi\) PSTON BODY mm(.(J4 in. )oversize R NG---(Oversize - compression)-- R NG---(Oversize - oil) PN RET A NER BEAR NG---( standard) BEAR NG--l. Z7mm(. 05 in. ) U. S. - BEARNG--.54mm('0 in.) U.S. - BEARNG--.5Omm(.0 in.) U.S.-- ROD AS SEM ( ncludes) BEAR NG BOLT NUT j NOT PART OF 8N4079 CONNECTNG ROD AND P STON GROUP C NDCATES CHANGE 837 8N4079 CONNECTNG ROD AND PSTON GROUP-4 Required Engine Serial No. 45V766-Up Part of W549 Cylinder Block Group listed on 6C

10 POWER TRAN-POWER TRANSMSSON UNT 55 REF. PART NO. NUMBER DESCRPTON OTY 5 9 BOLT B 4SD6 LOCKWASHER S4087 GUARD ASSEM M 706 KNOB S 3849 lever S PLATE C 5 4B 80 SCREW S889 LOCK ASSEM S 445 5HAFT COlTER PN K347 PN B46 COlTER PN C 0 6S903 lever ASSEM ( ncludes) 9 H 400 BEARNG S 3903 BRACKET AS5EM (ncludes) 3 4 K465 8 STUD ! C 6S 999 WASHER ~L--36 C C C TRANSMSSON CONTROl,- --- ' \... " -@' HAFT T883 WASf:R (use as required) lever A5SEM ~ !ncludes) 9H400 BEAR NG ~ L487 ROO la885 NUT H364 ROD ENO BOLT NUT ---~ B4505 LOC KWASHER ~ ~ lever ~ ROO BOLT S 389 SHAFT ASSEM M8908 KNOB S 69 lever ASSEM NUT S PR NG S 695 ROD B4607 COlTER PN B476 WASHE R S3848 SHAFT C 6S903 BLOCK ASSEM (ncludes) 4H60 BEAR NG C 34 6S90 lever ASSEM (ncludes) 35 9H400 BEAR NG H3956 P N C 37 H554 BOLT ~ C 38 5K3546 PLUG C NDCATES CHANGE 76 6S3535 TRANSMSSON CONTROL GROUP Serial No. 79U4709 to 79U484 inclusive

11 HYDRAULC SYSTEM REF. PART DESCRPTON QTY NO. NUMBER 9J587 OUTLET SECTON ASSEM (J neludesl 9S483 PLUG SEAL S48 PLUG M8485 SEAL J73 VALVE GROUP (Separate llustrationl 5 H445 SEAL J3 ROo NUT J 703 ROo NUT J0 HOUSNG J 78 VALVE GROUP J 75 ~ALVE GROUP (Separate llustrationl J583 BANK VALVE GROUP Part of Control Valve Group shown on 3, 9J78, 9J73 and 9J75 Valve parts are shown on s 7 and 9. AN ATTACHMENT REF. PART NO. NUMBER DESCRPTON QTY 9J 74 ROD <8405 NUT J587 OUTLET SECTON ASSEM (ncludes) 3 9 S483 PLUG SEAL S48 PLUG M8485 SEAL J8 ~ALVE GROUP J 75 WALVE GROUP J0 tjalve GROUP J73 ~ALVE GROUP (Separate llustration) 9 9J04 ROo NUT H445 SEAL J0 HOUS NG J7 VALVE GROUP (Separate llustrationl 3 9J709 PLUG ASSEM (J neludes) SEAl Jl7 R NG J5309 SEAL J585 BANK VALVE GROUP Part of Control Valve Group shown on 3 9J78, 9J73, 9.70, 9J77 and 9J75 Valve parts are shown on s 7, 8 and 9 AN ATTACHMENT 55600

12 66 SPEC FCA TONS (SUBJECT TO CHANGE WTHOUT NOTCE) Weight, shipping (approximate)... 0,00 bs. DMENSONS Length (without Bulldozer)... 9' Height (without Stack) ' 4.4" Width (over Final Drive)... "..,... 6' 0.5" Gauge (center to center tracks)... 56" Ground Clearance " Drawbar Height... " 3.7" ATT ACHMENTS Additional equipment such as Front Pull Hooks, Lighting System, Swinging Drawbar, Suction Fan, Seat Belt, Operator Protective Cab, Defrosting Fan, Windshield Washer and Wiper, etc., are available at extra cost. Consult your Caterpillar Dealer. MACHNE SERAL NUMBER PLATE LOCATON Serial number plate is located on the right-hand side of the cylinder block, on the right-hand outside of the dash assembly and on top of the bevel gear case under the seat.