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TM_5-3805-263-14_P-2..

1. Disassembly and Reassembly Chapter 4 Specifications This technical manual is an authentication of the manufacturers commercial literature and does not conform with the format and content specified in AR 310 3 Military Publications This technical manual does however contain available information that is essential to the operation and maintenance of the equipment TM 5 3805 263 14 amp P 2 11 vg a 3 9200 27 s 0 4m TM 5 3805 263 14 amp P 2 TECHNICAL DATA VEHICLE CHARACTERISTICS NAME GRADER ROAD MOTORIZED INC 05701 WHEEL QUANTITY 6 DRIVE WHEEL QUANTITY 4 STEERABLE WHEEL QUANTITY 2 FRONT WHEELS FRONT WHEEL TYPE LEANING PRIMER MOVER TYPE DIESEL ENGINE ENGINE MANUFACTURER S NAME CATERPILLAR TRACTOR CO ENGINE MODEL NUMBER MODEL NUMBER 3304DIT BLADE OVERALL LENGTH THE DIMENSION MEASURED ALONG THE LONGITUDIAL AXIS WITH TERMINATION POINTS AT THE EXTREME ENDS OF THE ITEM 12 FT MINIMUM CLEARANCE BETWEEN CUTTING EDGE AND GROUND AT MAXIMUM BLADE ELEVATION 17 25 IN BLADE MAXIMUM BANK CUTTING ANGLE IN DEGREES 90 RIGHT OR LEFT BLADE CONTROL METHOD HYDRAULIC CONTROL AUTOMATIC BLADE CONTROL NOT INCLUDED BLADE PULL RATING 18 000 LBS AT 2 MPH 0 1 LB WITH A LIMIT OF 15 SLIPPAGE STEERING CONTROL METHOD HYDRAULIC VEHICULAR TURN RADIUS 24 FT SPECIAL FEATURES ROLL OVER PROTECTIVE STRUCTURE SCARIFIERS LIFTING ATTACHMENT BLACKOUT LIGHTS FRONT AND REAR TOW PINS CAB MANUF
2. V Belt Tension lt antas venda Visual Inspection of the Cooling 55 Warning Light For Water Temperature 00eeeee sree eee eee Water Temperature Regulators sneresesssessesnnereeressseseeessuessreese Electrical System seewew ewer nau canas 1 75 ley i RS ds DE a a SES T ae arg n SEM Starting E rrr PTT rere 1 71 Fuel System sssssssesressresrsreeererreeseeseerenes ns sara a eee 1 37 Checking Engine Cylinders Separately s ssnsecsccesennnneene pride 1 37 Checking Engine Timing With 6V3100 Diesel Engine Timing Indicator Group cccreccecerrernenmanececerterererceeso Por Checking the Plunger and Lifter of an Injection Pump eee e Checking Timing by Fuel Flow Method Checking Timing by Timing Pin Method Fuel Injection Lines s ssseseseseressereseessseseseserresseseresereeerere Fuel System Inspection s sssessssersererseressesseeseereresreesesesseererto 1 4 TM 5 3805 263 14 amp P 2 INDEX Governor Adjustments Locating Top Center Compression Position for No 1 Piston Measuring Engine Speed Rack Setting Removal and Installation of Fuel Injection Pumps Testing 8N7005 Fuel Injection Nozzles
3. bottom of the stroke fuel at transfer pump pressure goes into inlet passage 2 around pump barrel 4 and to bypass closed port 5 Fuel fills the area above the pump plunger After the pump plunger begins the up stroke fuel will be pushed out the bypass closed port until the top of the pump plunger closes the port As the pump plunger travels farther up the pressure of the fuel increases At approximately 690 kPa 100 psi check valve 1 opens and lets fuel flow into the fuel injection line to the fuel injection nozzle When the pump plunger travels farther up scroll 9 uncovers spill Port 10 The fuel above the pump plunger goes through slot 7 along the edge of scroll 9 and out spill port 10 back to fuel manifold 3 This is the end of the injection stroke The pump plunger can have more travel up but no more fuel will be sent to the fuel injection nozzle 1 2 FUEL INJECTION PUMP Check valve 2 Inlet passage 3 Fuel manifold 4 7 Pump barrel S Bypass closed port 6 Pump plunger Biot 8 Spring 9 Scroll 10 Spit port 11 Lifter 12 Fuel rack 13 Gear 14 Cam When the pump plunger travels down and un covers bypass closed port 5 fuel begins to fill the area above the pump plunger again and the pump is ready to begin another stroke The amount of fuel the injection pump sends to the injection nozzle is changed by the rotation of the Pump plunger Gear 13 is attached to the
4. the weight When using a hoist follow the recommenda tion in the manual Use correct lift tools as shown in illustrations to get the correct balance of the component you lift This makes your work safer at all times The specifications torques pressures of opera tion measurements adjustments and other items can change at any time These changes can effect the service given to the product Get the complete and most current information before you start any job When the words use again are in the description the specification given can be used to determine if a part can be used again If the part is equal to or with in the specification given use the part again When the word permissable is in the descrip tion the specification given is the maximum or minimum tolerance permitted before adjust ment repair and or new parts are needed A comparison can be made between the measurements of a worn part and the specifications of a new part to find the amount of wear A part that is worn can be safe to use if an estimate of the remainder of its service life is good If a short service life is expected replace the part STATEMENT The Caterpillar 130 G Motor Grader is warranted by Caterpillar Tractor Co for 15 months or 1500 hours of operation whichever occurs first The warranty starts on the date found on the DA form 2408 9 in the log book Report all defects in material or workmanship to your super
5. ACTURER S MODEL NUMBER FOR THIS GRADER 130G iii TM 5 3805 263 14 amp P2 INTRODUCTION This publication has instructions and pro cedures for the subject on the front cover The information and specifications in this publica tion are on the basis of information that was current at the time this issue was written Some photographs in this publication show details that may be different from your machine Also for some photographs guards or covers may have been removed for illustrative purposes Correct operation maintenance test and repair procedures will give this product a long service life Before starting a test repair or rebuild job the serviceman must read the respective chapters of the Service Manual and know all the components he will work on Your safety and the safety of others is at all times very important When you see this sym bol A in the manual you must know that caution is needed for the procedure next to it The symbol is a warning To work safely you must understand the job you do Read all in structions to know what is safe and what is not safe It is very important to know the weight of parts Do not lift heavy parts by hand Use a hoist Make sure heavy parts have good stabili ty on the ground A sudden fall can cause an accident When lifting part of a machine make sure the machine has blocks at front and rear WARRANTY Never let the machine hang on a hoist put blocks or stands under
6. EE RD aunts eee Valve Clearance siccnsastaeecons iene sessenta e a pica es eas sa eee res Os eU Os CU enero as cosa a Basic 1 tise UC Ce Rar pees gee a nada Connecting Rod and Main Bearings sssssesesssrsrereesosereeeresrpreeres Connecting Rods and PistOns c ce cece cece tenn eee tenet eee ence te eneenenene Cylinder Block ssscesesessastacam accede E Cylinder Liner Projection sesssrssesesesserssrsrrerereesererrres Flywheel and Flywheel Housing sseeeeeee cree eee e cree erte eee eeen ener ees Oil Pump Installation Piston Ring Grooves Cooling System ia gaan eames Checking Coolant 8 eee Checking Fan Speed oo sicccceccceecueetede cscs an eseesedeee seeasanee eres ee Checking Radiator Air FIOW cece ee enee eee eee e een ete eneene n Filler Cap and Pressure Relief Valve cece eee eee e cece eee ete Testing Radiator and Cooling System For Leaks in 1407 Testing the Cooling System 0 cece seen eee cence eee eeenenee T
7. Lubrication System Oil Pressure Oil Pressure is Too Much Bearing Wear Too Much Oil Consumption Troubleshooting rocedure LG a e en a Page GENERAL INFORMATION SYSTEMS OPERATION TM 5 3805 263 14 amp P 2 ENGINE DESIGN BOE na a 4 5 in 120 7 mm wees donee eae NR ee enue 6 0 in 152 4 mm Number of Cylindera E aci Red a se Ta a die Sosa T AU DOU 4 Cylinder Arrangement we sl Mei SSSA in line Firing Order Injection 1 3 4 2 Direction of Flotation when seen from flywheel end Counterclockwise No 1 Cylinder Is Opposite Flywheel End EXHAUST VALVES ARTIKI INTAKE VALVES CYLINDER AND VALVE IDENTIFICATION 1 5 FUEL SYSTEM TM 5 3805 263 14 amp P 2 FUEL FUEL FLOW SYSTEMS OPERATION SYSTEM 8384421 7 8 10 11 12 FUEL SYSTEM SCHEMATIC 1 Fuel tank 2 Fuel return line 3 Priming pump 4 Fuel injection nozzle 5 Fuel injection line 6 Fuel injection pump 7 Primary fuel filter 8 Check valves 9 Fuel transfer pump 10 Secondary fuel filter 11 Constant bleed valve 12 Fuel injection pump housing Fuel is pulled from fuel tank 1 through primary fuel filter 7 and check valves 8 by fuel transfer pump 9 From the fuel transfer pump the fuel is pushed through secondary fue
8. TM 5 3805 263 14 amp P 2 TECHNICAL MANUAL UNIT DIRECT AND GENERAL SUPPORT MAINTENANCE MANUAL FOR GRADER HEAVY ROAD MOTORIZED TYPE I NONSECTIONALIZED NSN 3805 01 252 0128 TYPE II SECTIONALIZED NSN 3805 01 251 8252 HEADQUARTERS DEPARTMENT OF THE ARMY APRIL 1989 TECHNICAL MANUAL TM 5 3805 263 14 amp P 2 NO 5 3805 263 14 amp P 2 HEADQUARTERS DEPARTMENT OF THE ARMY Washington DC 14 April 1989 UNIT DIRECT AND GENERAL SUPPORT MAINTENANCE MANUAL FOR GRADER HEAVY ROAD MOTORIZED TYPE I NONSECTIONALIZED NSN 3805 01 252 0128 TYPE II SECTIONALIZED NSN 3805 01 251 8252 REPORTING OF ERRORS You can help improve this manual if you find any mistakes or if you know of a way to improve the procedures please let us know Mail your letter DA Form 2028 Recommended Changes to Publications and Blank Forms or DA Form 2028 2 located in the back of this manual direct to Commander US Army Tank Automotive Command ATTN AMSTA MB Warren MI 48397 5000 A reply will be furnished direct to you TABLE OF CONTENTS General Description and Specifications PART ONE Engine Chapter 1 Systems Operation Testing and Adjusting Chapter 2 Disassembly and Chapter 3 Specifications ho PART TWO Power Train Systems Operation Testing and Adjusting Power Shift Transmission Test and Adjust
9. e saison Other Components E a Starting System Components Fuel SyStettl ssavdscd cecal env aeaedaed ddan cade dc edd da dd edd ida dad dinanan Fuel Flow 0c ccc ccc cee cc eee cence eee Fuel Mieco INGZ 71 hd ced deckddodeokeaeeragkeeontaeheaeaaendacecagncans Fuel Injection Nozes son a Bmw mR NON a ORR A RON Fuel Transfer Pump eed amp Oil Flow for Fuel Pump and Engine Design RR gee Save See Lubrication System teen eet renan aero 1 15 Oil Flow In The ENNE 60324 tap ES E SEES 1 16 Oil Flow Through The Oil Filter and Oil Cooler 0c ce eee cence cence eee nes 1 16 5 3805 263 14 amp 2 INDEX Page TESTING AND ADJUSTING Air Inlet and Exhaust System Compression ecra ses dada e e sa a e Ra Snape acta Crankcase Crankshaft Compartment Pressure een eeeeeees Cylinder Head eia Peas easurement of Exhaust Temperatures Measurement of Pressure in Inlet Manifold Procedure for Measuring Camshaft Lobes Restriction of Air Inlet and Exhaust ccccecccese nec cc case eee ese enngeneees Turbocharger P
10. iameter 8 of valve 7 When the pres sure of the fuel that pushes against diameter 8 becomes greater than the force of spring 3 valve 7 lifts up When valve 7 lifts the tip of the valve comes off of the nozzle seat and the fuel will go through the nine 0 20 mm 008 in orifices 6 into the combustion chamber The injection of fuel continues until the pressure of fuel against diameter 8 becomes less than the force of spring 3 With less pressure against diameter 8 spring 3 pushes valve 7 against the nozzle seat and stops the flow of fuel to the combustion chamber 1 7 FUEL SYSTEM TM 5 3805 263 14 amp P 2 The 8N7005 Fuel Injection Nozzle can not be disassembled and no adjustments can be made FUEL TRANSFER PUMP MINLET FUEL PRESSURE FUEL FUEL TRANSFER PUMP SCHEMATIC UP STROKE 1 Bypass valve 2 Pumping spring 3 Small piston 4 Outlet 5 Inlet check valve 6 Push plate 7 Pumping check valve 8 Outlet check valve 9 Large piston 10 Push rod SYSTEMS OPERATION The fuel transfer pump is a two piston pump that is moved by a cam eccentric on the camshaft for the fuel injection pump The transfer pump is located on the right side of the fuel injection pump housing When the camshaft turns the cam lifts push rod 10 up The push rod lifts large piston 9 push plate 6 and small piston 3 As the pistons move up inlet check valve 5 and outlet check valve 8 close Pump
11. icated by oil leakage from the servo and the oil is thrown by parts in rotation The flyweight carrier thrust bear ing gets oil from the passage at the rear of the camshaft Oil from the governor returns to the oil pan through a hole in the bottom of the front governor housing and through passages in the support and cylinder block GOVERNOR The governor controls the amount of fuel needed by the engine to maintain a desired rpm The governor flyweights 8 are driven directly by the fuel pump camshaft Riser 10 is moved by flyweights 8 and governor spring 1 Lever 7 connects the riser with sleeve 2 which is fastened to valve 3 Valve 3 is a part of governor servo 5 and moves piston 4 and fuel rack 6 The fuel rack moves toward the front of the fuel pump housing to the right in the illustration when moved in the FUEL OFF direction 1 9
12. ing check valve 7 in the large piston opens and fuel goes through the holes in the bottom of the large piston and fills the passages and chamber between the bottom of the large piston and outlet check valve 8 As small piston 3 moves up the pressure of the fuel above the piston increases and flows out of the pump through outlet 4 As the camshaft continues to turn the cam lowers push rod 10 down Pumping spring 2 pushes small piston 3 push plate 6 and large piston 9 down When the piston moves down inlet check valve 5 and outlet check valve 8 open Pumping check valve 7 in the large piston closes and the pressure of the fuel below the check valve increases Fuel now flows through the outlet check valve A part of the fuel goes through outlet 4 and the remainder goes to the area above small piston 3 As the large piston moves down fuel from the fuel tank is pulled through inlet check valve 5 into the area between the large and small piston The pump is now ready to start a new cycle Bypass valve 1 controls the outlet pressure of the fuel If the fuel pressure goes beyond 170 to 280 kPa 25 to 40 psi the bypass valve opens and fuel flows to the inlet of the pump OIL FLOW FOR FUEL PUMP AND GOVERNOR Oil from the side of the cylinder block goes to support 9 and into the bottom of front governor housing 4 The flow of oil now goes in three differ ent directions A part of the oil goes to the rea
13. l filter 10 and to the fuel manifold in fuel injection pump housing 12 A bypass valve in the fuel transfer pump keeps the fuel pressure in the system at 170 to 280 kPa 25 to 40 psi Constant bleed valve 11 lets a constant flow of fuel go through fuel return line 2 back to fuel tank 1 The constant bleed valve returns approximately 34 liters 9 gal per hour of fuel and air to the fuel tank This helps keep the fuel cool and free of air There is also a manual bleed valve that can be used when the fuel priming pump is used to remove air from the system Fuel injection pump 6 gets fuel from the fuel manifold and pushes fuel at very high pressure through fuel line 5 to fuel injection nozzle 4 The fuel injection nozzle has very small holes in 1 6 the tip that change the flow of fuel to a very fine spray that gives good fuel combustion in thecylinder FUEL INJECTION PUMP The fuel injection pump increases the pressure of the fuel and sends an exact amount of fuel to the fuel injection nozzle There is one fuel injection pump for each cylinder in the engine The fuel injection pump is moved by cam 14 of the fuel pump camshaft When the camshaft turns the cam raises lifter 11 and pump plunger 6 to the top of the stroke The pump plunger always makes a full stroke As the camshaft turns farther spring 8 returns the pump plunger and lifter to the bottom of the stroke FUEL SYSTEM When the pump plunger is at the
14. ms in place of Newton Meters for the metric torque In these instances use the following con version factors to obtain the metric torque in Newton Meters Ib ft x 1 355819 Nem Ib in x 0 1129848 Nem INDEX Page CHAPTER 1 SYSTEMS OPERATION TESTING AND ADJUSTING bs eae CHAPTER 2 DISASSEMBLY AND ASSEMBLY n 1 80 CHAPTER 3 SPECIFICATIONS cenie cia apes PECUS eee 1 221 1 1 TM 5 3805 263 14 amp P 2 CHAPTER 1 ENGINE Systems Operation Testing and Adjusting INDEX Page SYSTEMS OPERATION Air Inlet and Exhaust System aid di dadas Air Inlet and Exhaust System gs Timing GEARS asse ae ka kama ka be da a ka be be ra a a Da a pur aw bis Ui DOC ACC dores el aa died a a eani aai Valves and Valve Mechanism qem o rnc Cylinder Head and NAS ass sie a ce Ge oe Ghee ee es Basic Block E se Crankshalt LE CCR Cylinder Block pras es a aa 8 8 Pistons Rings and Connecting SR RE PPA ace sau nouns Coolin System eens Coolant for Air Comp esse seas Electrical Systemi 1 211 Charging System Components Electrical System Sehemati
15. pump plunger and is in mesh with fuel rack 12 The governor moves the fuel rack according to the fuel needs of the engine When the governor moves the fuel rack and the fuel rack turns the pump plunger SYSTEMS OPERATION TM 5 3805 263 14 amp P 2 scroll 9 changes the distance the pump plunger pushes fuel between bypass closed port 5 and spill port 10 opening The longer the distance from the top of the pump plunger to the point where scroll 9 uncovers spill port 10 the more fuel will be injected To stop the engine the pump plunger is rotated so that slot 7 on the pump plunger is in line with spill port 10 The fuel will now go out the spill port and not to the injection nozzle FUEL INJECTION NOZZLE The fuel injection nozzle goes through the cylinder head into the combustion chamber The fuel injec tion pump sends fuel with high pressure to the fuel injection nozzle where the fuel is made into a fine spray for good combustion FUEL INJECTION NOZZLE 1 Carbon dam 2 Seal 3 Spring 4 Filter screen 5 inlet passage 6 Orifice 7 Valve 0 Diameter 9 Passage Seal 2 goes against the cylinder head and pre vents leakage of compression from the cylinder Car bon dam 1 keeps carbon out of the bore in the cylinder head for the nozzle Fuel with high pressure from the fuel injection pump goes into inlet passage 5 Fuel then goes through filter screen 4 and into passage 9 to the area below d
16. r camshaft bearing in fuel pump housing 5 The bearing has a groove around the inside diameter Oil goes through the groove and into the oil passage in the bearing surface journal of camshaft 7 A drilled passage through the center of the camshaft gives oil to the front camshaft bearing and to the thrust face of the cam shaft drive gear Drain hole 6 in the front of fuel pump housing 5 keeps the level of the oil in the housing even with the center of the camshaft The oil returns to the oil pan through the timing gear housing FUEL SYSTEM ASS a AYDIN DA 2 a C 10 YAGI SRS ANNAN SYSTEMS OPERATION TM 5 3805 263 14 amp P 2 PREUR ONL EB castor FUEL PUMP AND GOVERNOR 1 Deleted 2 Servo 3 Rear governor housing 4 Front governor housing 5 Fuel pump housing 6 Drain hole 7 Cam shaft 8 Drain hole 9 Support Oil also goes from the bottom of the front governor housing through a passage to the fuel pump housing and to governor servo 2 The governor servo gives hydraulic assistance to move the fuel rack The remainder of the oil goes through passages to the rear of rear governor housing 3 and into the compartment for the governor controls Drain hole 8 keeps the oil at the correct level The oil in this compartment is used for lubrication of the govern or control components and the oil is the supply for the dashpot The internal parts of the governor are lubr
17. visor who will take appropriate action through your organizational maintenance shop iv TABLE OF CONTENTS CHAPTER 1 CHAPTER 2 CHAPTER 3 CHAPTER 1 CHAPTER 2 CHAPTER 3 CHAPTER 4 CHAPTER 1 CHAPTER 2 CHAPTER 3 CHAPTER 1 CHAPTER 2 PART ONE ENGINE INDEX SYSTEMS OPERATION TESTING AND ADJUSTING 0 cece e eect eee eeees DISASSEMBLY AND ASSEMBLY eee eeee SPECIFICATIONS ees eR A PART TWO POWER TRAIN INDEX GU q GAS gone SYSTEMS OPERATION TESTING AND ADJUSTING POWER SHIFT TRANSMISSION TESTING AND ADJUSTING lt 0005ssecseeeeeees ees rena sa assess DISASSEMBLY AND ASSEMBLY sees SPECIFICATIONS Rae doa eur PART THREE VEHICLE SYSTEMS INDEX ee meee ee eee eer ace SSE eae ey AIR SYSTEM ensaio aaa ia a soul a ads DISASSEMBLY AND ASSEMBLY eee ececeeceeetet eee eeeees PART FOUR OPERATORS STATION INDEX esase papi aa ae ha eae cand af ES lean a acne es OPERATORS STATION AND ELECTRICAL SYSTEM DISASSEMBLY AND ASSEMBLY PART FIVE MAINTENANCE TM 5 3805 263 14 amp P 2 v vi Blank TM 5 3805 263 14 amp P 2 PART ONE ENGINE TORQUE SPECIFICATIONS You will find instances in this publication where the manufacturer has used Meter Kilograms or Centimeter Kilogra

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