TM 5-3805-248-14&P-2 TECHNICAL MANUAL FOR
Contents
1. seit diced ie a ence 1 9 NS 1 10 TUIDOCN ADO uu u ac Heian cita ea 1 10 Valves and Valve System 1 11 1 16 da 1 16 tte 1 16 Cylinder Block and 1 16 Pistons Rings and Connecting 0 1 16 Vibration Damper u a cacon cc lid cares 1 16 SV SUSI 18 1 14 Coolant for Compress Ofer o ii aaa 1 15 Coolant u LLL ri a 1 15 Engine Alter St 1 14 SyS a iia 1 17 Charging System Components snacks ride 1 17 Electrical System 1 19 Other Components 2 2 a a tas 1 19 Starting Circuit Components u LLULLU ci de 1 18 Winng Ghart A 1 4 Automatic Timing Advance Unit dana 1 8 Fuel Injection Pump 12. 1 1 DISASSEMBLY AND 5 1 76 SPEGIPIGATIONS conan 1 190 PART TWO POWER TRAIN SERVICE MANUAL NERA A 2 1 POWER SHIFT TRANSMISSION TESTING AND ADJUSTMENT 2 DISASSEMBLY AND ASSEMBLY u SPECIFICA TIONS 2 208 VEHICLE SYSTEMS COACH AND CAR AIRDRAULIC SEAT 5 3 1 HYDRAULIC SYSTEM UU u 3 26 SYSTEM ciao u u 5 x 3 113 DISASSEMBLY AND 3 179 ELECTRICAL SYSTEM 5 3 367 MAINTENANGE cctv add 3 369 5 3805 248 148 2 CHAPTER 1 ENGINE SYSTEMS OPERATION TESTING AND ADJUSTING TORQUE SPECIFICATIONS You will find instances in this publication where the manufacturer has used Meter Kilograms or Centimeter Kilograms In page of Newton Meters for the metric torque In these Instances use the following conversion factors to obtain the metric torque in Newton Meters Ib ft x 1 355819 Nem Ib in x 0 1129848 Nem INDEX Air Basic Cooling Electrical Fuel Lubrication Page SYSTEM OPERATION Inlet and Exhaust System ssnin
3. 5 3805 248 148 2 TECHNICAL MANUAL FOR SCRAPER EARTH MOVING MOTORIZED DIESEL ENGINE DRIVEN NSN 3805 01 153 1854 MAINTENANCE HEADQUARTERS DEPARTMENT OF THE ARMY AUGUST 1985 5 3805 248 14 amp P 2 TECHNICAL MANUAL HEADQUARTERS NO 5 3805 248 148 2 DEPARTMENT OF THE ARMY Washington DC 19 Aug 1985 TECHNICAL MANUAL FOR EARTH MOVING MOTORIZED DIESEL ENGINE DRIVEN NSN 3805 01 153 1854 MAINTENANCE REPORTING OF ERRORS pos can help improve this manual If you find any mistakes or if you know of a way o improve the procedures please let us know Mail your letter DA Form 2028 a 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 AMSTA MBP WARREN 48397 5000 A reply will be furnished direct to you TABLE OF CONTENTS General Description and Specifications PART ONE Engine PAGE System operation Testing Adjusting U I n 1 1 Chapter 2 Disassembly A 1 190 PART TWO Power Train Service Manual 011 L n Power Shift Transmission Testing Chapter 3 Disassembly and Assembly n nn nsn ii A 2 208 This technical manual is an authentica
4. ed eh ahd Flywheel and Flywheel HOUSING ccccccccsccssecseesecesecseesecssescsssssessecsassaeesscsaecaeseecusesaecseseesesecsaeecseeneesseeaeees 1 68 Piston RINGS uuu u usa o 1 66 Projection of Cylinder 1 67 Vibration Dampe tencia daa tota 1 71 Syste M o dd s 1 60 Testing the Cooling System Uu aaa da od 1 60 Checking Coolant 1 60 Checking Fan SPp8668d uuu uandaa a Saa agag sanceell 1 63 Checking Radiator Air Flow I rra 1 62 Filler and Pressure Relief Valve 1 63 Gauge for Water Temperature 1 64 Temperature RegulatO k u ul u L u a a 1 65 Vee Tension Chalecos toi a Ra 1 65 Visual Inspection of the Cooling 1 60 qhiswa Battery R S 1 72 Charging 1 72 Starting E 1 73 Rack Shut Off Sole
5. 14 is shown in the position when the force of the governor weights and the force of the governor spring are in balance When there is an increase in engine load there will be a decrease in engine rpm and the rotation of governor weights 12 will get slower The governor weights will move toward each other Governor spring 5 moves valve 14 forward toward the right in picture shown When valve 14 moves forward an oil passage around valve 14 opens to pressure oil Oil now flows through passage 7 and fills the chamber behind piston 15 the rear end of the valve stops oil flow through the rear of the cylinder around the valve This pressure oil pushes the FUEL SYSTEM piston and rack forward to give more fuel to the engine Engine rpm goes up until the rotation of the governor weights is fast enough to be in balance with the force of the governor spring there is a reduction in engine load there will be an increase in engine rpm and the rotation of governor weights 12 will get faster This will move valve 14 backwards toward the left in picture shown This movement stops oil flow from the forward passage through piston 15 and allows the oil behind the piston to go out through a passage at the rear of the piston around valve 14 Now the pressure oil between sleeve 16 and piston 15 pushes the piston and fuel rack backwards There is now a reduction in the amount of fuel to the engine Engine rem goes down un
6. Fuel rack linkage 4 Pressure chamber 5 Diaphram sesembiy 6 inlet air chamber 7 Valve 8 Small pas sages 9 Large passages 10 drains 13 Valve 5 3805 248 14 amp P 2 SYSTEMS OPERATION When the governor control is moved to increase fuel to the engine with the control activated valve 7 limits the movement of fuel rack linkage 1 in the FUEL ON direction Charged oil pressure chamber 4 acts as a restriction to the movement of valve 7 until inlet air pressure increases As inlet air pressure increases valve 7 moves to the left away from springs 11 and 12 and lets pressure oil from chamber 4 drain through large oil passages 9 past the land of valve 13 through inside of valve 7 and out through oil drains 10 This reduction of oil pressure behind the piston of valve 7 lets spring 12 move valve 7 to the left so that fuel rack linkage 1 can move gradually to increase fuel to the engine The control is designed not to let the fuel increase until the air pressure in the inlet manifold is high enough for complete combustion This prevents large amounts of black exhaust smoke caused by an air fuel mixture with too much fuel AIR INLET PRESSURE PRESSURE OIL WITHOUT PRESSURE 7 107 1 1 AIR FUEL RATIO CONTROL Engine Acceleration 1 Fuel rack linkage 4 Pressure oil chamber 5 Diaphram assembly 6 Inlet air chamber 7 Valve 9 Large oil pas sage
7. 4 Fuel Injection aa 1 5 Governor 1 5 Hydraulic Air Fuel Ratio 1 6 SUM ui Oil Flow im the 1 aa 1 13 Oil Flow Through the Oil Filter and Oil 1 12 Basic Cooling Electrical Fuel 5 3805 248 14 amp P 2 TESTING AND ADJUSTING Page Inlet and Exhaust 1 54 Bridge PC HEISE LESTE da Crankcase Crankshaft Compartment 1 55 Cylinder Head iconos e a dra 1 55 Measurement of Exhaust Temperature l U 1 54 Measurement of Pressure in Inlet 1 54 Restriction of Air Inlet and 1 54 Valve Clearance SM deci Block qu Connecting Rod and Main 1 66 Connecting amp ad 1 66 A ce
8. 4 amp P 2 SYSTEMS OPERATION AIR INLET AND EXHAUST SYSTEM 0002 1 8 AIR INLET AND EXHAUST SYSTEM 1 Exhaust manifold 2 Inlet manifold 3 Engine cylin der 4 Turbocharger wheel 5 Turbocharger compressor turbine wheel 6 intet 7 Exhaust outlet The air inlet and exhaust system components are air cleaner inlet manifold cylinder head valves and valve system components exhaust manifold and turbocharger Clean inlet air from the air cleaner is pulled through the air inlet 6 of the turbocharger by the turning compressor wheel 4 The compressor wheel causes a compression of the air The air then goes to the inlet manifold 2 of the engine When the intake valves open the air goes into the engine cylinder 3 and is mixed with the fuel for combustion When the exhaust valves open the exhaust gases go out of the engine cylinder and into the exhaust manifold 1 From the exhaust manifold the exhaust gases go through the blades of the turbine wheel 5 This causes the turbine wheel and compressor wheel to turn The exhaust gases then go out the exhaust outlet 7 of the turbocharger AIR INLET AND EXHAUST SYSTEM 1 Exhaust manifold 2 Inlet manifold a Turbocharger
9. DRA MECHANICAL GOVERNOR The accelerator pedal or governor control 15 connected to the control lever on the engine governor The governor controls the amount of fuel needed to keep the desired engine rpm The governor has governor weights 12 driven by the engine governor spring 5 valve 14 and piston 15 The valve and piston are connected to fuel rack 18 The pressure oil for the governor comes from the engine oil pump Pressure oil goes through passage 17 and around sleeve 16 The accelerator pedal or governor control controls only the compression of governor spring 5 Compression of the spring always pushes to give more fuel to the engine The centrifugal force rotation of governor weights 12 is always pulling to get a reduction of fuel to the engine When these two forces are in balance the engine runs at the desired rpm governed rpm 2 Ee a lt f d i NAS LDAA MILES y SSS CALA gt 7 SAA GE HYDRA MECHANICAL GOVERNOR Typical Example Shown at Full Load Condition 1 Collar 2 Speed limiter plunger 3 Lever assembly 4 Seat 5 Governor spring 6 Thrust bearing 7 Oil passage Drive gear weight assembly 9 Cylinder 10 11 Spring seat 12 Governor weights 13 Spring 14 Valve 15 Piston 16 Sleeve 17 Oil pas sage 18 Fuel rack exi Governor valve
10. Ratio Control 1 53 Installation of Injecti n PUMP 1 39 Measuring Fuel Injection Pump Timing Dimension n nn bebe Removallot Injection PUMP uu uuu u aces cede lidia 1 38 Set Point CHECK a iia Setting the Injection Pump Timing Dimension OM ENQING aiid uu tle PR Le ee el 1 49 Test Sequence Direct Injection DI Fuel 1 35 Syste Mis uuu is ds ls 1 58 Increased Oil 2 22 2 1 59 Measuring Engine Oil Pressure n s n s L 1 58 Pressure is High oad eps u O tsakuwaqssyakas5l 1 59 Oil Pressure is LOW 1 59 Too Much Bearing Weal a canine 1 59 Too Much Oil 1 58 Troubleshooting cirio ai 1 20 1 3 FUEL SYSTEM 5 3805 248 14 amp P 2 SYSTEMS OPERATION FUEL SYSTEM A21330 1X1 10 11 FUEL SYSTEM 1 Injection valve 2 Anti siphon block 3 Injection pump housing 4 Priming pump 5 Plug 6 Secondary filter 7 Return line to tank 9 Fuel tank 10 Primary filter 11 Transter pump This engine has a pressure type fuel s
11. a full stroke The force of springs 5 hold the lifters 8 against the cams of the camshaft FUEL SYSTEM Fuel from fuel manifold 1 goes through passage 2 in the barrel and then into the chamber above plunger 4 During injection the camshaft cam moves plunger 4 up in the barrel This movement will close inlet passage 2 and push the fuel out through the fuel lines to the injection valves The amount of fuel sent to the injection valves 15 controlled by turning plunger 4 in the barrel When the governor moves fuel rack 7 the fuel rack moves gear 6 that is fastened to the bottom of plunger 4 2 WSS L lo ISS ESAS sS 55 Sy NANNI S INN SAAN EY S 7 9825402 CROSS SECTION OF THE HOUSING FOR THE FUEL INJECTION PUMPS 1 Fuel manitold 2 intet passage in pump barrel 3 Check valve 4 Pump plunger 8 Spring 6 Gear 7 Fuel rack 8 Lifter 9 Camshaft FUEL INJECTION VALVE Fuel under high pressure from the injection pumps is sent through the injection lines to the injection valves The injection valves change the fuel to the correct fuel characteristic spray pattern for good combustion in the cylinders The fuel injection valves are installed in an adapter The adapters are installed in the cylinder heads 1 5 5 3805 248 14 amp P 2 SYSTEMS OPERATION HY
12. is 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 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 symbol 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 instructions 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 stability 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 TM 5 3805 248 14 amp P 2 Never let the machine hang on a hoist put blocks or stands under the weight When using a hoist follow the recommendation 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 operation measurements adjustments and other items change at any ti
13. me 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 within the specification given use the part again When the word permissible is in the description the specification given is the maximum or minimum tolerance permitted before adjustment 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 WARRANTY STATEMENT The Caterpillar 6218 Tractor Scraper warranted by Caterpillar Tractor Co for 15 occurs first The warranty starts on the date found on the DA form 2408 9 in the log Report defects in material or workmanship to your supervisor who will take appropriate action through your organizational maintenance shop 1 or 1500 hours of operation whichever HAPTER 2 HAPTER CHAPTER 4 CHAPTER 1 CHAPTER 2 CHAPTER 3 CHAPTER 4 CHAPTER 5 CHAPTER 6 5 3805 248 14 amp P 2 TABLE OF CONTENTS PART ONE ENGINE Page SYSTEMS OPERATION TESTING AND ADJUSTING LLL dad cda a
14. n TM 5 3805 248 14 amp P 2 SYSTEMS OPERATION HYDRAULIC AIR FUEL RATIO CONTROL The hydraulic air fuel ratio control automatically controls the amount of travel of the fuel rack in the FUEL ON direction until the air pressure in the inlet manifold is high enough to give complete combustion The hydraulically operated fuel ratio control has two valves 7 and 13 A hose assembly connects inlet air chamber 6 to the inlet manifold Air pressure from the inlet manifold works against diaphragm 5 which moves valve 13 to control oil pressure against valve 7 Engine oil pressure works against valve 7 to control movement of the fuel rack When the engine is stopped there is no pressure on either of the valves Springs 11 and 12 move both valves to the ends of their travel In this position there is no restriction to fuel rack movement Also in this position oil outlet passage 2 is open to let oil away from valve 7 WITHOUT PRESSUPE 23 4 5 6 18242642 cl 0 enn Z 1 8 1 W 1 13 ATSTOX2 AIR FUEL RATIO CONTROL Engine Stopped 1 Fuel rack linkage 2 Oil outlet 3 iniet 4 Pressure chamber 5 Diaphram assembly 6 Inlet air cham ber 7 Valve 8 Small oil passages 9 Large oil pas sages 10 Oil drains 11 Spring 12 Spring 13 Valve When the engine is started engine oil flows through oil inlet 3 into pressure oil chamber 4
15. noid sssi uu 1 75 DOV SUGIM dor 1 33 Adjustment of Hydraulic Air Fuel Ratio 1 53 Camshaft Timing for the Fuel Injection Pump iii it 1 42 Checking Engine Timing and Timing Advance With 6V3100 Diesel Engine Timing Indicator Group Dynamic O c10 Checking Low and High Idle 1 51 Checking the Plunger and Lifter Washer of an u u A A eee Engine Cylinders Checked ed 1 33 Finding Top Center Compression Position TOF NOs 1 PISTON erica 1 41 Flow Checking Fuel Injection Pump 1 45 NECESI 1 2 5 3805 248 148 2 Fuel Injection LINGS 1 41 A Fuel Setting 1 44 Fuel System Adjustments Fuel System Adjustments On 1 42 Fuel System Inspeccion ivan di adan Hydraulic Air Fuel
16. s 10 Oil drains 11 Spring 12 Spring 13 Valve These movements of the control take a very small amount of time No change in engine acceleration rate at which speed increases can be felt FUEL SYSTEM AUTOMATIC TIMING ADVANCE UNIT The automatic timing advance unit is installed on the front of the drive shaft 6 for the fuel injection pump and is gear driven through the timing gears The drive gear 5 for the fuel injection pump is connected to the drive shaft for the fuel injection pump through a system of weights 2 springs 3 slides 4 and a flange 1 Two slides that are fastened to the flange fit into notches made on an angle in the weights As centrifugal force rotation moves the weights outward against spring pressure the movement of the notches in the weights causes the slides to make the flange turn through a small angle in relation to the gear Since the flange is connected to the drive shaft for the fuel injection pump the fuel injection timing is also changed The automatic timing advance unit is held in place on the drive shaft 6 by four bolts 1 8 5 3805 248 14 amp P 2 SYSTEMS OPERATION AUTOMATIC TIMING ADVANCE UNIT 1 Flange 2 Weight 3 Springs 4 Slide 5 Drive geer 6 Drive shaft The unit advances the timing 2 1 40 between approximately low idle and 1100 rpm No adjustment can be made to the automatic timing advance units AIR INLET AND EXHAUST SYSTEM 5 3805 248 1
17. through large oil passages 9 to inside of valve 7 and out small oil passages 8 to oil outlet passage 2 outlet passage 2 prevents oil pressure against valve 7 until air pressure from the inlet manifold is high enough to move valve 13 to close large oil passages 9 The control will not activate until there is some boost inlet air pressure available from the inlet manifold This boost is made by the turbocharger when a load is applied during engine acceleration 1 6 S FUEL SYSTEM AJA PRESSURE PRESSURE OIL 07777 222 9 41 13 475109 1X1 AIR FUEL RATIO CONTROL Engine Started 4 Pressure chamber 5 Diaphram assembly 6 inlet chamber 7 Valve 9 Large oil passages 11 Spring 13 Vaive As the inlet air pressure increases it causes diaphragm assembly 5 to move left against spring 12 Valve 7 connected to diaphragm assembly 5 also moves left to close large oil passages 9 With these passages closed chamber 4 is now charged with pressure oil and valve 7 is pushed to the right against spring 1 control is now activated and will continue to operate until the engine is stopped In the activated position excess oil will go out pressure oil chamber 4 through large oil passages 9 past the land of valve 13 and then out through oil drains 10 1 4 5 8 WITHOUT PRESSURE AY016853 AIR FUEL RATIO CONTROL Control Activated 1
18. til the centrifugal force rotation of the governor weights is in balance with the force of the governor spring When these two forces are in balance the engine will run at the desired rpm governed rpm When engine rpm is at LOW IDLE a spring loaded plunger in lever assembly 3 comes in contact with a shoulder on the adjustment screw for low idle To stop the engine pull back on the governor control This will let the spring loaded plunger move over the shoulder on the low idle adjusting screw and move the fuel rack to the fuel closed position With no fuel to the engine cylinders the engine will stop After the engine has stopped spring 13 moves valve 14 and piston 15 to the full load position This moves the rack to full travel position and gives full fuel flow through the fuel injection pump when starting the engine Oil from the engine gives lubrication to the governor weight bearing The other parts of the governor lubrication from splash lubrication oil thrown by other parts Oil from the governor runs back into the housing for the fuel injection pumps A small force from spring 13 moves fuel rack 18 to give a little more fuel for engine start With the engine running the rotation of governor weights 12 will put spring 13 in compression and cause fuel rack 18 to move back Spring 13 is extended only when the engine is stopped or at start When the engine is running spring 13 is in compressio
19. tion 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 9 8 2946 Overall 11 4 Width 3450 mm 10 5 3175 4971 872 9088 9 NL 5 3805 248 14 amp P 2 TECHNICAL DATA VEHICLE CHARACTERISTICS 1 2 8 9 10 11 12 13 14 15 16 17 18 NAME SCRAPER EARTH MOVING MOTORIZED DESIGN TYPE WHEELED WHEEL QUANTITY 4 TIRE PNEUMATIC SCOOP OPERATION METHOD HYDRAULIC SCOOP CUT WIDTH 119 3022 mm SCOOP MAXIMUM CUT DEPTH 13 4 340 mm SCOOP STUCK CAPACITY 14 cu yds 10 7 cu SCOOP BOWL TYPE OPEN MAXIMUM SPREAD DEPTH 18 457 mm HAULING GROUND CLEARANCE 20 6 523 mm PRIME MOVER TYPE DIESEL ENGINE ENGINE MANUFACTURER S NAME CATERPILLAR TRACTOR ENGINE MODEL NUMBER 3406 STEERING CONTROL METHOD HYDRAULIC VEHICULAR TURN RADIUS 183 or 5 56 m BOWL CAPACITY 15 3 cu mor 20 cu yds MANUFACTURER S MODEL NUMBER FOR THIS SCRAPER 621B INTRODUCTION This publication has instructions and procedures for the subject on the front cover The information and specifications in this publication are on the basis of information that was current at the time this issue was written Some photographs in th
20. ystem There is a single injection pump and injection valve 1 for each cylinder The injection pumps are in the pump housing 3 on the left side of the engine The injection valves are in the precombustion chambers or adapters under the valve cover The transfer pump 11 pulls fuel from the fuel tank 9 through the primary filter 10 and sends it through the base of the priming pump 4 and the secondary filter 6 through the anti siphon block 2 and to the manifold of the injection pump housing When priming pump 4 is not used the position of fuel line 7 and plug 5 are reversed The fuel in the manifold of the injection pump housing goes to the injection pumps The injection pumps are in time with the engine and send fuel to the injection valves under high pressure 1 4 Some of the fuel in the manifold is constantly sent back through the anti siphon block 2 and through the return line 8 to the fuel tank to remove air from the system Orifices in the anti siphon block control the amount of fuel that goes back to the fuel tank The priming pump 4 is used to remove air from the fuel filter fuel lines and components The transfer pump has a bypass valve and a check valve The bypass valve lower side gives control to the pressure of the fuel The extra fuel goes to the inlet of the pump FUEL INJECTION PUMP OPERATION Injection pump plungers 4 and lifters 8 are lifted by cams on camshaft 9 and always make
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