TM-5-2410-233-34 Tractor Full Tracked Low Speed DED Medium Drawbar Pull; Oscillating Track 78-In. Gage (Caterpillar Model D7F) Manual

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TM-5-2410-233-34

TECHNICAL MANUAL
Warning
Direct Support and General Support Maintenance Manual
Figure 2-31.1. Preparing to remove engine (w/ROPS) (sheet 2 of 6).
Figure 3-4. Winch hydraulic pump, exploded view.
Figure 3-7. Power take off bearing and brake drum, removal and installation.
Figure 4-1.1. Hydrailic tank removal (w/ROPS).
Direct Support and General Support Maintenance Manual
Voltage Regulator
Figure 5-35.1 Generator regulator (Sheet 1 of 2)
Figure 5-35.1 Generator regulator (Sheet 2 of 2)
ALternator
Figure 5-35.2 Electrical Cheks of Alternator
Figure 5-35.3 Checking Components and transistors
ALternator (Cont)
Figure 5-34.4 Transistor Checking
Figure 5-35.5. Inner race,bearing and seal locations
Table of Contents
Table of Contents (Cont)
List of Illustration
List of Illustration (Cont)
List of Illustration (Cont)
List of Illustration (Cont)
List of Illustration (Cont)
List of Illustration (Cont)
- Blank Page
Chapter 1. INTRODUCTION
Figure 1-1. Electrical System Schematic Diagram
table 1-1. Standard Torques
Table 1-3. Engine Repair and Replacement Standards
Table 1-3. Engine Repair and Replacement Standards (Cont)
Table 1-3. Engine Repair and Replacement Standards (Cont)
Table 1-4. Power transmission Units Repair and Replacement Standard
Table 1-4. Power Transmission Units Repair and Replacement Standard (Cont)
Table 1-4. Power Transmission Units Repair and Replacement Standard (Cont)
Table 1.5 Track Roller Frame Units Repair and Replacement Standards
Chapter 2. DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS
Chart 2-1. Troubleshooting
Section Ill. GENERAL MAINTENANCE
Figure 2-3. Puller assembly.
Figure 2-6. Locked anti-friction bearing.
Figure 2-9. Floating seal installation tool.
Figure 2-12. Heel and toe type seals.
Figure 2-13. ELbow body assembly.
Figure 2-16. Shear-type fitting.
Figure 2-20. Three seal cylinder head.
Figure 2-23. Measuring cylinder head clearance.
Figure 2-26. Compressing seals.
Section IV. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS
Figure 2-31. Preparing to remove engine (sheet 1 of 6).
Figure 2-31. Preparing to remove engine (sheet 2 of 6).
Figure 2-31. Preparing to remove engine (sheet 3 of 6).
Figure 2-31. Preparing to remove engine (sheet 4 of 6).
Figure 2-31. Preparing to remove engine (sheet 5 of 6).
Figure 2-31. Preparing to remove engine (sheet 6 of 6).
Transmission
Figure 2-33. Preparing to remove transmission (sheet 1 of 3).
Figure 2-33. Preparing to remove transmission (sheet 2 of 3).
Figure 2-33. Preparing to remove transmission (sheet 3 of 3).
Blank Page
Chapter 3. REPAIR OF EARTH MOVING EQUIPMENT
Scarifies (fig. 3-2)
Section Il. RIPPER
Section III. WINCH
Figure 3-4. Winch hydraulic pump. exploded view
Figure 3-5. Control valve removal.
Winch Disassembly
Figure 3-7. Power Take Off Bearing Carrier and Brake Drum.Removal and Installation
Brake Shaft Remoual.
Figure 3-10. Bearing and clutch drive gear removal.
Figure 3-12. Intermediate gear and drum pinion removal.
FIGURE 3-16. Hydraulic Clutch
Winch Reassembly
Figure 3-19. Pinion depth.
Installation
Chapter 4. REPAIR OF HYDRAULIC SYSTEM
FIGURE 4-1. Hydraulic tank removal
Disassembly.
Section Il. HYDRAULIC CONTROL VALVES AND HYDRAULIC PUMP
Figure 4-4. Bulldozer and Ripper Control Valves (sheet 1 of 2)
Figure 4-4. Bulldozer and Ripper Control Valves (sheet 2 of 2)
Figure 4-4. Bulldozer and Ripper Control Valves (sheet 2 of 2) (Cont)
Figure 4-5. Valve spool removal.
Figure 4-6. Valve Spool Disassembled
Check Valve Removal.
Figure 4-7. Check Valve Removal.
Makeup Valves.
Figure 4-8. Makeup Valve body Removal
Figure 4-9. Makeup Valves Disassembled
Control Lever.
Figure 4-10. Control Lever Assembly (sheet 1 of 2)
Figure 4-10. Control Lever Assembly (sheet 2 of 2)
Figure 4-11. Control Lever Disassembly
Reassembly.
Removal.
FIGURE 4-14. Relief Valve Disassembly
Ripper Control Valve
Inspection and Repair.
Figure 4-16. Blade tilt manifold and valve removal.
Disassembly.
Figure 4-17. Tilt control valve disassembly.
Figure 4-18. Tilt control lever removal.
Hydraulic Pump
Figure 4-19. Cover and cartridge removal, small pump section.
Figure 4-20. Cartidge disassembly.small pump section
Figure 4-21. Cover and cartridge removal, large pump section.
Figure 4-22. Cartridge disassembly , large pump section.
Section III. HYDRAULIC CYLINDERS
Figure 4-24. Disconnecting piston rod.
Figure 4-26. Preparing to Disassemble Cylinder
Figure 4-27. Disassembling piston and head.
Figure 4-30. Piston rod bearing disassembly.
Reassembly.
Hydraulic Tilt Cylinder
Figure 4-35. Tilt cylinder removal.
Figure 4-36. Preparing to disassemble cylinder.
Inspection and Repair.
Figure 4-38. Disassmbling piston head.
Figure 4-39. Measuring clearance.
Figure 4-41. Ripper lift cylinder,exploded view
Chapter 5. REPAIR OF THE POWER PLANT
Figure 4-2. Hood headlight brackets and radiator top guard, removal and installation
Figure 5-3. Preparing to remove radiator.
Figure 5-4. Lifting radiator from radiator guard.
Figure 5-5. Radiator disassembly.
Radiator and Radiator Guard
Figure 5-6. Radiator bottom guard, removal and installation.
Figure 5-7. Fan adapter and fan drive and support assembly coupling.
Figure 5-8. Bulldozer lift cylinder hydraulic lines disconnect couplings
Removal.
Figure 5-9. Radiator and radiator guard, removal and installation.
Fan
Fan Belts
Water Pump
Figure 5-12. Water pump, removal and installation.
Engine oil Cooler
Figure 5-14. Engine oil Cooler. removal and installation
Fan and Fan Drive Assembly
Figure 5-15. Fan and Fan Drive Assembly
Section II. FUEL SYSTEM
Fuel Injection Pump
Figure 5-18. Fuel injection pump, removal and installation.
Figure 5-19. Fuel injection pump, exploded view.
Inspection and Repair.
Engine Speed Governor
Figure 5-20. Engine Speed Governor. Exploded view
Inspection and Repair.
Fuel Transfer Pump
Fuel Tank
Section III. AIR INDUCTION AND EXHAUST SYSTEM
Figure 5-24. Air Cleaner body, removal and installation
Muffler
Figure 5-26. Engine exhaust flow diagram.
Figure 5-27. Turbocharger, removal and installation
Disassembly.
Figure 5-30. Turbocharger, disassembly and reassembly
Figure 5-31. Turbocharger retaining nut, removal and installation.
Inspection and Repair.
Figure 5-33. Turbocharger clearance check, between spacer block and housing face.
Exhaust Manifold
Figure 5-34. Exhaust Manifold, removal and installation
Section IV. ELECTRICAL SYSTEM
Figure 5-35. Generator disassembly.
Inspection and Repair.
Figure 5-36. Starter motor, exploded view (sheet 1 of 2).
Figure 5-36. Starter motor, exploded view (sheet 2 of 2).
Figure 5-36. Starter motor, exploded view (sheet 2 of 2). (Cont)
Disassembly of End Bell and Brush Holder Plate
SECTION V. ENGINE LUBRICATING SYSTEM
Figure 5-37. Oil pump, removal and installation.
Figure 5-38. Oil pump, exploded view.
Oil Pan and Oil Pan Plate
Figure 5-39. Oil Pan and Oil Pan Plate, removal and installation
Section VI. DIESEL ENGINE
Figure 5-40. Cylinder head and valves, exploded view.
Inspection and Repair.
Accessory Drive.
Figure 5-42. Accessory drive shaft, removal and installation (sheet 1 of 2).
Figure 5-42. Accessory drive shaft, removal and installation (sheet 2 of 2).
Installation .
Figure 5-44. Timing gears and cover, exploded view.
Checking Camshaft Gear Backlash.
Cam shaft
Figure 5-47. Power takeoff cover, removal and installation.
Figure 5-48. Power takeoff drive gears.
Figure 5-49. Removing power takeoff drive gear bearings
Flywheel and Flywheel Housing
FIGURE 5-50. Flywheel.removal and installation
Figure 5-51. Flywheel and hydraulic pump drive gear.
Figure 5-52. Hydraulic pump idler gear,removal and installation
Remoual and Disassembly.
Figure 5-5.3 Flywheel Housing,removal and installation
Inspection and Repair.
Figure 5-55. Checking Flywheel Runout.
Pistons, Connecting Rods and Cylinder Liners
Figure 5-56. Piston and connecting rod, exploded view.
Crankshaft and Main Bearings
Figure 5-57. Crankshaft and main bearings.
Cylinder Block
Chapter 6. REPAIR OF DRIVE TRAIN
Figure 6-1. Torque divider.
Figure 6-2. Cross sectional view of transmission
Universal Joint
Removal.
Figure 6-4. Preparing to remove sun gear
Figure 6-5. Pilot bearing and retainig ring. removal and installation
Figure 6-6. Planet carrier, removal and installation.
Figure 6-7. Planet carrier, disassembly and reassembly.
Figure 6-8. Torque divider housing, removal and installation.
Figure 6-9. Removing output shaft bearing
Figure 6-10. Scavenge pump exploded view.
Figure 6-11. Removing stator.
Figure 6-13. Carrier disassembly.
Figure 6-14. Ring gear removal
Torque Divider Disassembly and Assembly.
Figure 6-15. Turbine, flange assembly and rotating housing removal
Figure 6-16. Flange Assembly
Inspection and Repair.
Figure 6-18. Torque converter clearances.
Figure 6-19. Checking torque converter clearances.
Transmission Hydraulic Controls
Figure 6-20. Hydraulic control (schematic)
Hydraulic Control Removal
Figure 6-21. Hydraulic Control Removal
Figure 6-22. Disassembly of pressure control value.
Figure 6-25. Pressure relief valve disassembly.
Figure 6-27. Safety and directional valve disassembly.
Figure 6-29. Linkage adjustment
External adjustment .
Figure 6-30. Linkage adjustment ( top view )
hydraulic Pump
Figure 6-31. Hydraulic pump disassembly
Torque Converter Inlet Relief Valve
Figure 6-33. Torque converter inlet relief valve.
Figure 6-34. Torque conuerter outlet relief value removal.
Transmission and Steering Clutch Control Check Valve
FIGURE 6 -37. Check Valve disassembly
Transmission
Transmission Case Removal.
Checking Transmission Clutches With Air.
Input Shaft Remoual and Installation.
Removal and Installation of Clutches and Carries
Figure 6-49. Removing No.3 clutch housing
Figure 6-50. No. 2 carrier removal.
Figure 6-53. Bearing cage removal.
Figure 6-55. Retainer ring removal.
Figure 6-56. Bearing cage disassembly
Removal and Installation of Clutches and Carries (Cont)
Figure 6-57. Bearing race and sun gear removal
No. 1 Carrier Disassembly and Assembly.
Figure 6-59. No. 1 carrier disassembly.
No. 2 Carrier Disassembly and Assembly.
Figure 6-60. No. 2 carrier disassembly.
Clutch Disassembly and Assembly
Figure 6-62. Transfer gear removal.
Figure 6-64. Separating cages.
Transfer Gear Disassembly and Assembly.
Figure 6-65. Removing cover.
Figure 6-66. Removing bevel pinion.
Figure 6-67. Bearing outer race removal.
Transmission Hydraulic System Testing and Adjustment
Figure 6-69. Transmission hydraulic control system schematic (First forward).
Steering Clutch Control Tests
Figure 6-70. Hydraulic control system pressure tap locations.
Table 6-2. Transmission and torque divider hydraulic control test
Figure 6-71. Transmission control linkage, exploded view.
Section Il. STEERING CLUTCHES, BRAKES AND BEVEL GEAR
Figure 6-72. Brake Operation
Removal and Installation.
Figure 6-75. Brake engaging mechanism disassembly.
Figure 6-76. Brake lever bearings.
Figure 6-78. Disassembling clutch cover brake linkage.
Figure 6-79. Adjusting brake engaging mechanism.
Steering Clutches
Figure 6-82. Preparing to remove steering clutch assembly.
Disassembly.
Inspection and Repair.
Figure 6-88. Assembling springs and sleeves to retainer.
Figure 6-91. Compressing steering clutch springs.
Figure 6-96. Steering clutch hub assembly (exploded view).
Steering Clutch Hydraulic Controls
Figure 6-99. Steering clutch hydraulic control (side view)
Removal and Installation.
Figure 6-104. Control lever housing disassembly.
Bevel Gear
Disassembly and Reassembly.
Figure 6-109. Measuring clearance.
Section III. FINAL DRIVE
Figure 6-111. Final drive.
Track Roller Frame Outer Bearing
Bearing Cage Holder Assembly
Figure 6-114. Bearing cage holder removal.
Disassembly.
Floating Duo-Cone Seals
Figure 6-117. Removing outer bearing cone.
Figure 6-119. Sprocket removal.
Inspection.
Figure 6-121. Sprocket installing tools
Sprocket Segments.
Final Drive Gear Case
Figure 6-126. Final drive case removal.
Final Drive Gear, Idler Pinion, and Bearings
Figure 6-129. Removing outer race and roller assemblies.
Figure 6-131. Hub inner bearing cone removal.
Figure 6-132. Bearing cone removal tools
Removal.
Figure 6-133. Removing bearing cage.
Sprocket Shaft
Figure 6-136. Installing Sprocket Shaft
Final Drive Pinion Group
Figure 6-141. Installing final drive pinion gear.
Inspection and Repair.
Aligning Track Roller Frame With Sprocket
Aligning Track Roller Frame With Sprocket (Cont)
Figure 6-147. Aligning Track Roller Frame With Sprocket
Brake Pedal and Support Assembly
Figure 6-148. Brake Pedal and Support Assembly removal and installation
Inspection.
Chapter 7. REPAIR OF TRACK ROLLER FRAME AND TRACKS
Section II: TRACKS AND SUSPENSION
Figure 7-4. Relief valve and fill valve.
Inspection and Repair.
Track Carrier Rollers
Figure 7-9. Removing nut.
Track Rollers
Disassembly.
Front Idler
Figure 7-17. Preparing to remove guide plate.
Cleaning.
Front Idler Yoke Assemby
Recoil Springs
Figure 7-26. Removing tension from recoil spring stops.
Disassembly.
Installation.
Carrier Roller Support Assembly
Section Ill. EQUALIZER BAR AND TRACK ROLLER FRAME
Track Roller Frame
Appendix A: REFERENCES
INDEX
INDEX (Cont)
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TM-5-2410-233-34
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DISTRIBUTION:
Distribution:
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Blank PAge
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Distribution
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