Service Manual

C at e r p i l l a r
Service Manual
955L Traxcavator
S/n 64J, 71J & 85J
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 SUCCESSORS
ARE 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.

CT-S-955LTX64J
 3304 & 3306 VEHICLE ENGINES SPECI FICATIONS

INTRODUCTION

The specifications given in this book are on the When the word "permissible" is in the description,
basis of information available at the time the book the specification given is the "maximum or mini-
was written. These specifications give the torques, mum" tolerance permitted before adjustment,
operating pressure, measurements of new parts, repair and/or new parts are needed.
adjustments and other items that will affect the A comparison can be made between the measure-
service of the product. ments of a worn part, and the specifications of a
When the words "use again" are in the description, new part to find the amount of wear. A part that is
the specification given can be used to determine if worn can be safe to use if an estimate of the re-
a part can be used again. If the part is equal to or mainder of its service life is good. If a short service
within the specification given, use the part again. life is expected, replace the part.
NOTE: The specifications given for "use again" and "permissible" are in-
tended for guidance only and Caterpillar Tractor Co. hereby expressly denies
and excludes any representation, warranty or implied warranty of the reuse
of any component. 77200X1

NOTE: For Systems Operation and Testing and Adjusting, make reference to
3304 & 3306 Vehicle Engines, Form No. REG01349.

INDEX

Air Cleaner ................................... . . . . .. 24 Glow Plug Positioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20

Alternators ................................ 53, 54, 55, 56 Governor (Scroll Fuel System) .......................... 14
Alternator Regulator .................................. 57 Governor And Decelerator Control
(Scroll Fuel System) ................................ 16
Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 20 Governor And Decelerator Control
Checking and Adjusting Alignment For the Flexible (Sleeve Metering Fuel System) ........................ 10
Coupling Drive .................................... 51
Connecting Rod ..................................... 42 Oil Breather Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 35
Cooling System Pressure Cap ........................... 39 Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 34, 35
Crankshaft ......................................... 43 Oil Pan ............................................ 35
Crankshaft Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 44 Oil Pump ..................................... 31,32,33
Cylinder Block ...................................... 40
Cylinder Head ....................................... 23 Pistons And Rings .................................... 41
Cylinder Liner ....................................... 40
Radiator .......... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 36
Engine Decelerator Control Rear Accessory Drive Gears ......................... 47,48
(Scroll Fuel System) (980 Wheel Loader) . . . . . . . . . . . . . . .. 17
Engine Design (all engines) ....•.•......•............... 4 Service Meter (Scroll Fuel System) ....................... 15
Engine Mounting Bolts ............ . . . . . . . . . . . . . . . . . . .. 52 Service Meter (Sleeve Metering Fuel System) ............... 9
Exhaust Manifold .................................... 24 Shutoff Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 68
Exhaust Pipes and Muffiers . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 24 Starter Magnetic Switches .............................. 67
Starter Solenoids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 65, 66
Flexible Coupling Drive ............................... 50 Starting Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 62, 63, 64, 65
Flexible Drive Coupling ............................... 49
Flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 44 Tachometer Drive (Scroll Fuel System) ................... 15
Flywheel Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 45 Tachometer Drive (Sleeve Metering Fuel System) . . . . . . . . . . .. 9
Flywheel Housing Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 46 Timing Gears (Scroll Fuel System) .................... 18, 19
- ," 'jfuel Bypass Valve (Scroll Fuel System) ................... 17 Timing Gears (Sleeve Metering Fuel System) ............ 11, 12
Fuel Injection Equipment (Scroll Fuel System) ............. 13 Turbocharger ........................ 25,26,27,28,29,30
Fuel Injection Equipment (Sleeve Metering Fuel System) . . . . .. 4
Fuel Ratio Control (Scroll Fuel System) ................... 16 Valves ............................................. 21
Fuel Ratio Control (Sleeve Metering Fuel System) ........... 10 Valve Cover ......................................... 23
Fuel Transfer Pump (Scroll Fuel System) .................. 15 Valve Rocker Arms And Lifters ......................... 22
Fuel Transfer Pump (Sleeve Metering Fuel System) .......... 9 V-Belt Tension Chart ................................. 36

Generators ...................................... 58, 59 Water Pump ........................................ 37

Generator Regulator ............................ 59,60,61 Water Temperature Regulator ........................ 38, 39

2
3304 & 3306 VEHICLE ENGINES INDEX

SYSTEMS OPERATION
Air Inlet and Exhaust System . . . . . • . . . . . . . . . . . . . . • . . . . .. 23 Governor Operation ...................•.......•.... 21
Aftercooler . . • . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . .. 24
Engines With Turbochargers . . . • . . . • . . . . . . . . . . . • . . . . .• 23 Sleeve Metering Fuel System .. ~ •.....................• " 5
Engines Without Turbochargers ••....•..••.•...•.••... 24 Adjustments to the Sleeve Metering Fuel System •.......•. 15
Timing Gears •....•...........••.•••........•..... 25 Fuel Flow After Engine Stops Running .... ~ . . . . . . . . . . .. 12
Turbocharger ..................................... 24 Fuel Flow Using the Priming Pump and Bleed Valve ....... 12
Valves and Valve Mechanisms. . . . . . . . . . • . . . . . . . . . . . . .• 24 Fuel Flow With Engine Running .................. 6,8, 10
Fuel Injection Pump Operation ....................... 13
Basic Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 30 Fuel Priming Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 13
Fuel Ratio Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 19
Cooling System . . . . . . . . . . • . • . . • . . . . . . . . . . • . . . . . . • . . •• 28 Fuel System Operation. . . . . . . . . . . . . . . . . . . • . . . . . . . . .. 15
Coolant for Air Compressor . . . . . . • . . . . . . • . • . . • . . . . . .. 29 Fuel System Timing .............................. " 5
Cooling System Components .. . . . . . . . . . • . . • . . . . . . . . .. 29 Fuel Transfer Pump ................................ 13
Governor ...................................... .• 18
Electrical System .................................... 31 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . • .. 5
Charging System Components .........•..•.•...•.. 31,32 Sleeve Position .................................... 14
Other Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 33, 34 Water Separator ................................. .. 5
Starting System Components . . . . . . . . . . . . . • . . . . . • . . • .. 33
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 4
Fuel Systems (Sleeve Metering & Scroll) ................... 22
Fuel Injection Valve .•............................. , 22 Lubrication System. . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . .. 26
Glow Plugs . . . . . • . . • . . . . . . . . . • . . . . . . • • • . . . . . • • . . .. 22 Lubrication System Components . . . . . . . . . . . . • . . . . • . . .. 26
Oil Flow in the Engine . . . . . . . . • . . . . • . • • • . . . . . • . . . . .. 27
Scroll Fuel System .....•...........••.......•........ 20 Oil Flow Through the Oil Filter and Oil Cooler .••.... . . .. 26
Fuel Injection Pump Operation ............•.•........ 20

TESTING AND ADJUSTING

Air Inlet and Exhaust System . . . . . . . • . . . . . . • . . . . . . . . . . .. 77 Oil Pressure is Low . . . . . . . . . . . . . . . . . . . . . • • . . • . . . . . .. 82
Checking Inlet Manifold Pressure At Torque Too Much Bearing Wear ..............•.•........•. " 83
Converter Stall Speed ...........•...•.•.......... 77 Too Much Oil Consumption. . . . . . . . . . . • . . . . . • . • • • • • •• 82
Crankcase (Crankshaft Compartment) Pressure ........... 78
Cylinder Condition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 78 Scroll Fuel System .......•............•.•.....•••.•.. 67
Cylinder Head .................................... 80 Accessory Drive Shaft Timing ............•.•...•.•... 71
Measurement of Exhaust Temperatures ................. 78 Check Fuel Injection Pump Lifter
Measurement of Pressure in Inlet Manifold. . . . . . • . . . . . . .. 77 Washer and Pump Plunger .............•..••.•..... 67
Precombustion Chamber Position. . . . . • . . . • . . . . . . . . . . .. 80 Checking Fuel Injection Pump Timing; On Engine . •. 69, 70, 71
Restriction of Air Inlet and Exhaust ................... 77 Checking Fuel Injection Valve . . . . . . . . . . . . . . . . . • . . • . .. 67
Valve Clearance Setting .....................•.... 79, 80 Deceleration Control Adjustment ...................... 76
Fuel Bypass Valve ................................. 69
Basic Block ........................................ , 89 Fuel Injection Adjustments ...................•....•. 69
Connecting Rods and Main Bearings. . . . . . . . . . . . . . . . . . .. 89 Fuel Injection Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 68
Connecting Rods and Pistons ...........•........... " 89 Fuel Injection Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 68
Cylinder Block . . . . . . . . . . . . . • . . . . . . . . . • . . . . . . . . . . .. 90 Fuel Injection Pump Installation ...................... 68
Cylinder Liner Projection ........•................... 89 Fuel Injection Pump Timing Dimension Setting; Off Engine . 71
Flywheel and Flywheel Housing .............. 90,91,92,93 Fuel Injection Service. . . . . . . . . . . . . . . . . . • . . . . . . . . . . .. 68
Oil Pump Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 93 Fuel Injection Valve ................................ 68
Vibration Damper ................................. 93 Fuel Rack Setting ............................... 72, 73
Fuel Ratio Control Setting ........................... 74
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 84 Fuel System Adjustments .......................... " 69
Checking Coolant Temperatures .................. " 84, 85 Governor Adjustments .............................. 74
Checking Fan Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 86 Governor Cont.rol and Deceleration Linkage Adjustments ... 75
Checking Pressure Cap or Relief Valve .................. 87 Locating Top Center Position for No.1 Cylinder .......... 69
Checking Radiator Air Flow. . . . . . . . . . . . . . . . . . . . . . . . .. 86 Testing Fuel Injection Equipment ..................... 67
Gauge for Water Temperature ........................ 88 Visual Inspection .................................. 67
Testing the Cooling System .......................... 84
Visual Inspection of the Cooling System ................ 84 Sleeve Metering Fuel System .......................... " 54
Water Temperature Regulator ........................ 88 Checking Balance Point (Full Load Speed) ............. " 60
Checking Timing by Fuel Flow Method . . . . . . . . . . . . . . . .. 58
Electrical System .................................... 95 Checking Timing by Timing Pin Method ................ 56
Alternator Regulator ............................ 96, 97 Finding Top Center Compression Position
Battery .......................................... 95 for No.1 Piston ........................•........ 55
Charging System ................................... 95 Fuel Pump Calibration .. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 64
Shutoff Solenoid ................................. 101 Fuel Ratio Control Setting .......................... , 64
Starting System ................................... 97 Fuel System Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . .. 56
Fuel System Inspection ............................. 54
Flexible Drive Coupling ............................... 94 Fuel System Setting ................................ 61
Checking Flexible Drive Coupling Alignment . . . . . . . . . . . . . 94 Governor Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 59
Testing Fuel Injection Equipment ..................... 54
Lubrication System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 82
Oil Pressure is High ................................. 83 Troubleshooting .................. . . . . . . . . . . . . . . .. 35·53

3
SLEEVE METERING TESTING AND ADJUSTING
FUEL SYSTEM

5. The point where an increase in load on the

engine puts the engine in a lug condition (a
condition in which a small increase in load
makes the engine speed get much less).

Procedure for Checking Balance Point

1. Connect a tachometer which has good accura-
cy to adapter (1) on the end of the fuel injec-
tion pump.

LOCATION OF IDLE ADJUSTMENT

SCREWS
1. High idle adjustment screw. 2. Locknut. 3. Cover. 4.
Low idle adjustment bolt.

slower. Turning the screw out makes the en-

gine run faster. Hold screw (1) and tighten CHECKING BALANCE POINT
locknut (2) after adjustment procedure is 1. Adapter.
done.
2. Connect a continuity light (2) to the brass ter-
3. To make an adjustment to the low idle rpm, minal screw (3) on the cover for the load stop.
tum bolt (4). Turning the bolt in makes the Connect the other end of the light to a place
engine run faster. Turning the bolt out makes on the fuel system which is a good electrical
the engine run slower. Grooves in cover (3) connection.
hold bolt (4) and keep it from turning after
adjustment is done and the cover is installed. 3. Start the engine.
4. After each idle adjustment is made, move the
governor lever to change the rpm of the en-
gine. Now move the governor lever back to the
point of first adjustment to check the idle
adjustment. Keep doing the adjustment
procedure until the low idle and high idle rpm
are the same as given in RACK SETTING
INFORMATION.

Checking Balance Point (Full Load Speed)

Checking the Balance Point of the engine is a
fast way to make a diagnosis of engine
performance.
CHECKING BALANCE POINT
The balance point for the engine is:
2. Continuity light. 3. Brass terminal screw. 4. Tachometer
1. At full load speed. drive shaft.

2. The point where the load stop pin is against 4. With the engine at operating temperatures, run
the load stop or torque spring. the engine at high idle.
5. Make a record of the speed of the engine at
3. The point where the engine gets the maximum high idle.
amount of fuel.
6. Add load on the engine slowly until the con-
4. The point where the engine has the most tinuity light just comes on. This is the balance
horsepower output. point.

60
ENGINE DISASSEMBL Y AND ASSEMBLY

INDEX
PAGE NO.

Adapter Housing and Levers .................................................... 52, 53

Air Cleaner Housing ............................................................. 16
Alternator .................................................................... 17

Balancer Shafts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 94
Balancer Shaft Bearings ......................................................... 106

Camshaft ..................................................................... 92
Camshaft Bearings ............................................................. 103
Connecting Rod Bearings ......................................................... 13
Crankcase Guard ............................................................... 6
Crankshaft ............................................................... 104, 105
Crankshaft Front Seal ........................................................... 88
Crankshaft Main Bearings ...................................................... 14, 15
Crankshaft Pulley ............................................................... 87
Crankshaft Rear Seal ........................................................... 101
Cylinder Head .............................................................. 73-75
Cylinder Liners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 80-82

Engine .................................................................... 94-96

Engine Oil Cooler ............................................................ 24, 25
Exhaust Manifold ............................................................ 45,46

Fan and Alternator Belts ......................................................... 18

Fan and Fan Drive ........................................................... 20, 21
Fan Drive, Disassemble & Assemble .............................................. 22,23
Flywheel ................................................................. 97-100
Flywheel Housing .............................................................. 102
Fuel Check Valve and Bypass Valve ................................................. 62
Fuel Filter Base ................................................................ 28
Fuel Injection Lines ............................................................. 36
Fuel Injection Pump Housing, Disassemble & Assemble .................................. 70
Fuel Injection Pump Housing and Governor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 47-49
Fuel Injection Pump Housing and Governor, Separation and Connection ................. 54·57
Fuel Injection Pumps ............................................................ 63
Fuel Injection Pumps, Disassemble & Assemble ..................................... 64,65
Fuel Injection Valves ......................................................... 36,37
Fuel Priming Pump .............................................................. 28
Fuel Ratio Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 50
Fuel Ratio Control, Disassemble & Assemble ....................................... 50,51
Fuel Transfer Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 66-69

Governor, Disassemble & Assemble .............................................. 58-61

Hood ........................................................................ 16

Oil Filter Base .............................................................. 26, 27

Oil Filter Base, Disassemble & Assemble ............................................. 27
Oil Pan... .... . . .... .... .. . . .. .. .... ... ..... . ..... ..... . ... .. ........... .... .. 6
Oil Pan Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7
Oil Pump..................................................................... 8
Oil Pump, Disassemble & Assemble ............................................... 9-12

Pistons ....................................................................... 76
Pistons, Disassemble & Assemble ................................................... 77
Precombustion Chambers ......................................................... 38

4
ENGINE DISASSEMBL Y AND ASSEMBL Y

INDEX
PAGE NO.

Radiator and Guard .......................................................... 83, 84

Radiator Core ............................................................... 85, 86
Rocker Shaft and Push Rods ...................................................... 72
Rocker Shaft, Disassemble & Assemble .............................................. 73

Starting Motor .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17

Timing Gear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 89-91

Timing Gears and Plate ........................................................... 93
Turbocharger .................................................................. 39
Turbocharger, Disassemble & Assemble ........................................... 40-44

Valves ........................................................................ 78
Valve Cover ................................................................... 71
Valve Guides .................................................................. 80
Valve Lifters ................................................................... 75
Valve Seat Inserts ............................................................... 79

Water Directors ................................................................ 79

Water Pump ................................................................ 29, 30
Water Pump, Disassemble & Assemble ............................................ 31-35
Water Temperature Regulator ..................................................... 19

DISCONNECT BATTERIES
BEFORE PERFORMANCE
OF ANY SERVICE WORK

5
ENGINE DISASSEMBLY AND ASSEMBLY

RADIATOR CORE
REMOVE RADIATOR CORE 1353-11
start by:
a) remove hood

1. Drain the coolant from the radiator.

2. Remove the left and right fan guards and

remove top shields (4).

3. Disconnect hose (1) and water line (2).

4. Remove two bolts (3) from each side of the

core.

5. Remove the front section of the crankcase

guard and disconnect oil line (7) from under
the radiator.

6. Disconnect lower pipe (6) and remove lower

left shield (5) from the radiator.

7. Remove bolts (9) and lockwashers from

lower right shield (8).

8. Remove two bolts (10) from each side of

the radiator, that hold the bar to the core.
Remove bolts on each side of the radiator
that hold bracket (II) to the radiator
guard.

9. Pull the bracket and the bar out of the way

before the removal of the core.

10. Install two 3/8"~16 NC forged eyebolts in

the top of the core and fasten a hoist to the
eyebolts.

II. Remove radiator core (12). Weight of core

is 325 lb. (147.4 kg).

85
POWER TRAIN DlSASSEMBL V AND ASSEMBL V

INDEX
PAGE NO.

Bevel Gear and Bevel Pinion Shaft Settings ........................................ 97, 98

Bevel Gear Shaft, Disassemble & Assemble ......................................... 90,91
Bevel Pinion Shaft ........................................................... 92·96
Brake Actuating Mechanisms, Disassemble & Assemble ... . . . . . . . . . . . . . . . . . . . . . . . . . . .. 70-75
Brake Actuating Mechanisms, Adjustment of .......................................... 63

Connection of Tracks ......................................................... 18, 19

Crankcase Guard (Rear) ......................................................... 104

Final Drive Cases, Gears, Idler Pinions and Bearings .................................. 47-53
Final Drive Pinions and Flanges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 99-103
Flexible Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 105
Front Idlers ................................................................ 20, 21
Front Idlers, Disassemble & Assemble ............................................ 23-27
Front Idlers, Adjustment of ....................................................... 22
Front Idler Yokes ............................................ '.' ................. 28
Fuel Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 56, 57

Hydraulic Track Adjusters ..................................................... 29,30

Hydraulic Track Adjusters, Disassemble & Assemble ................................. 31,32

Pump Drive, Disassemble & Assemble .......................................... 126-128

Recoil Springs ................................................................. 33

Recoil Springs, Disassemble & Assemble .......................................... 34, 35

Seat Frame and Floor Plates .................................................... 58, 59

Separation of Tracks ............................................................ 17
Sprocket Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 40-46
Sprocket Segments ............................................................... 4
Sprocket Shafts ............................................................. 54,55
Steering Clutches and Bevel Gear Shaft ........................................... 80-82
Steering Clutches, Disassemble & Assemble ........................................ 83-89
Steering Clutch Case Cover, Steering Clutch Control Linkages, and
Brake Actuating Mechanisms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 60·63
Steering Clutch Control Linkages, Disassemble & Assemble. . . . . . . . . . . . . . . . . . . . . . . . . . .. 76-79
Steering Clutch Control Linkages, Adjustment of ...................................... 64
Steering Clutch Control Pump .................................................... 169
Steering Clutch Control Pump, Disassemble & Assemble '" . . . . . . . . . . . . . . . . . . . . . . . .. 170-173
Steering Clutch Hydraulic Mechanism ............................................... 65
Steering Clutch Hydraulic Mechanism, Disassemble & Assemble ........................ 66-69
Steering Clutch Oil Filter ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 182

Torque Converter and Pump Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 114-118

Torque Converter, Disassemble & Assemble ...................................... 119-125
Track Carrier Rollers ............................................................. 5
Track Carrier Rollers, Disassemble & Assemble ...................................... 6-10
Track Rollers ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 11, 12
Track Rollers, Disassemble & Assemble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 13-16
Track Roller Frames ........................................................ " 36-39
Transmission ................................................................. 137
Transmission, Disassemble & Assemble ......................................... 138-159
Transmission and Torque Converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 106-113
Transmission Control Linkages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 160-162
Transmission Hydraulic Controls .............................................. 129,130
Transmission Hydraulic Controls, Disassemble & Assemble. . . . . . . . . . . . . . . . . . . . . . . . .. 131-136
Transmission Lubrication Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 178
Transmission Mounting Adapter and Transfer Gears ................................... 163
Transmission Mounting Adapter and Transfer Gears, Disassemble & Assemble ........... 164·168
Transmission Oil Filter and Screen ................................. : . . . . . . . . . .. 179-181
Transmission Pump ............................................................ 173
Transmission Pump, Disassemble & Assemble .................................... 174-177

DISCONNECT BATTERIES
BEFORE PERFORMANCE
OF ANY SERVICE WORK

3
 POWER TRAIN DISASSEMBLY AND ASSEMBLY
;.
STEERING CLUTCHES
7. Put brake drum (7) in position on the plate
assembly as shown.

8. Install discs and disc assemblies (8) in the

drum in the correct order.

NOTE: For the best wear distribution, the discs

and disc assemblies must be installed so the discs
and disc assemblies that were on the top of the
steering clutch unit are installed on the bottom
with the same faces up. New discs can be installed
with any face up.

9. Install drum (9) in the steering clutch

assembly.

10. Put the two springs and the retainer on each

stud in the plate assembly. Install tooling
/ (D) as shown. Put the springs under com-
pression until two locks (10) can be in-
stalled on each stud. Remove tooling (D).
Remove the brake drum.

CAUTION: Make sure the eight studs are in

alignment with the holes in the 7S8431 Plate when
the spring is put under compression.

WARNING: To make sure the locks are in

place, hit each stud with a hammer. Keep
back from the steering clutch when the
studs are hit.

88
955L LOADER HYDRAULIC SYSTEM SPECIFICATIONS

I NTRODUCTI ON

The specifications given in this book are on the When the word "permissible" is in the description,
basis of information available at the time the book the specification given is the "maximum or mini-
was written. These specifications give the torques, mum" tolerance permitted before adjustment,
operating pressure, measurements of new parts, repair and/or new parts are needed.
adjustments and other items that wiII affect the A comparison can be made between the measure-
service of the product. ments of a worn part, and the specifications of a
When the words "use again" are in the description, new part to find the amount of wear. A part that is
the specification given can be used to determine if worn can be safe to use if an estimate of the re-
a part can be used again. If the part is equal to or mainder of its service life is good. If a short service
within the specification given, use the part again. life is expected, replace the part.
NOTE: The specifications given for "use again" and "permissible" are in-
tended for guidance only and Caterpillar Tractor Co. hereby expressly denies
and excludes any representation, warranty or implied warranty of the reuse
of any component. 77200X1

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

955L LOADER HYDRAULIC SYSTEM, Form No. SENR7372.

INDEX

Cylinders ................................................. 10
Hydraulic Pump .......................................... " 8
Lift and Tilt Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6
Lines, Plugs and Fittings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4, 5
Loader Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9
Master Valve for the Bucket Positioner .......................... 8
Oil Filter ................................................. 9
Orifice Valve .............................................. 9
Relief Valve for Main Pressure ................................. 6

Tilt Relief Valve for Head Ends ..... . . . . . . . . . . . . . . . . . . . . . . . . . .. 7

Tilt Relief Valve for Rod Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7

2
VEHICLE SYSTEMS DISASSEMBLY AND ASSEMBLY

INDEX
PAGE NO.

Baffle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 43-46

Baffle Assembly, Dissassemble & Assemble ........................................ 47-51
Bucket ....................................................................... 71
Bucket Positioner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 72
Bucket Positioner Master Valve .................................................... 73
Bucket Positioner Master Valve, Disassemble & Assemble ............................. 74-78

Front Links and Levers ..................................................... 106-110

Hand Control Levers and Lift Kickout Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 52

Hand Control Levers and Lift Kickout Controls, Disassemble & Assemble. . . . . . . . . . . . . . . .. 53-58
Hydraulic Oil Filter Housing and Baffle Assembly .......... . . . . . . . . . . . . . . . . . . . . . . . .. 43-46
Hydraulic Oil Filter Housing and Baffle Assembly, Disassemble & Assemble ............... 47-51
Hydraulic Oil Pump .......................................................... 59,60
Hydraulic Oil Pump, Disassemble & Assemble ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 61-70
Hydraulic Tank ............................................................... 5-9
Hydraulic Tank Valve Group ................................................... 18,30
Hydraulic Tank Valve Group, Disassemble & Assemble.. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10-42

Lift Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 90-94

Lift Cylinders, Disassemble & Assemble .......................................... 95-101
Lift Kickout Controls ............................................................ 52
Lift Kickout Controls, Disassemble & Assemble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 53-58

Rear Levers .............................................................. 111-115

Swivel Joints ................................................................. 102

Swivel Joints, Disassemble & Assemble ......................................... 103-105

Tilt Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 79-82

Tilt Cylinders, Disassemble & Assemble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 83-89

DISCONNECT BATTERIES
BEFORE PERFORMANCE
OF ANY SERVICE WOR K

4
/ CONTENTS
!,

Schematic Page No.

Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5

Electrical System ..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3
Safety .......................................................................................... 3

Maintenance Recommendations ................. ................................ 5

Walk-Around Inspection ............................................... ............... 7

Fuel and Lubricant Specifications ........ ....................................... 8

Lubrication and Maintenance Chart ............................................ 9

Every 10 Service Hours or Daily............................ .................... 11

Every 50 Service Hours or Weekly ................. ............................ 13

Every 100 Service Hours or 2 Weeks .... ............ ........................ 15

Every 250 Service Hours or Monthly... ... ..... .......... ......... ............ 16

Every 500 Service Hours or 3 Months ....................................... 19

Every 1000 Service Hours of 6 Months ...................................... 24

Every 2000 Service Hours or 1 Year .......................................... 26

When Required ........................................................................... 31

Refill Capacities .......................................................................... 40

Serial Number Locations ............................................................. 40

2
® TRANSMISSION

~ WARNING
Use caution when draining oil. Hot
oil can cause personal injury.

Machine level, parking brake and 1. Remove filter housing drain plug. 2. Remove floor plate.
transmission safety engaged, oil
warm and engine stopped .

. 3. Remove cover and filter element. 4. Remove used elements and install 5. Inspect seal. Use new seal if
new element. TIghten filter retainer necessary. Install filter.
nuts to 10 ± 2Ib.ft. (13.6 ± 1.7 N·m).
6. Clean and install filter housing
drain plug.

CAUTION
Do not drop or rap magnets
against hard objects.

7. Remove cover. 8. Remove washer, screen and tube

assembly.

22