Professional Documents
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Ed 246299
Ed 246299
Ed 246299
ABSTRACT
This training manual, the first of two volumes,
comprises the first six blocks in a nine-block in-service training
course for apprentices working in heavy duty mechanics. Addressed in
i
the individual blocks included in this volume are the following
topics: shop equipment and practices; procedures for starting,
moving, and stopping equipment; the principles and theory of
hydraulics; brakes; power trains; and frames, suspensions, running
?vh-, and working attachments (bearings and seals; track machine
&nderzarriages; track machine final drives; track machine steering;
wheel machine Suspensions; tires, rims, and wheels; wheel machine
final drives; wheel machine steering and front suspension; and
working attachments). Each block contains 'a section on parts theory
that gives the purpose, topics, operations, and applications ,f the
parts and systems being discussed; a set of questions on parts
theory; a section on scheduled maintenance and, service repair; a set
of questions on service; and a list of validated tasks to be
completed during the course of daily on-thejoh routines. The manual
is illustrated with photographs and drawings. (MN)
..**********************************************************************
* Reproductions supplied by EDRS are the best that can be made *
* from the original document. *
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Heavy Duty Mechanics
Apprenticeship Training,
Moduie One
VOLUME I
3
ACKNOWLEDGMENTS
We wish to thank the following members of the Heavy Duty Mechanics Trade
Advisory Committee to the Ministry of Labour who were instrumental in
initiating the writing of this manual:
We wish to also extend our thanks to other members of the Heavy Duty
Mechanics Trade Advisory Council for the support they gave to this manual.
1:
4
INDIODUCTION
This is an in-service training manual for ap likely .o be doing in your shop. Another set of
prentices working in heavy duty mechattios questions ft,11)ws the service section. The
shops who wish to complete tA9dulo One, blocks end wi h a list of practical tasks that
Heavy Duty Mechanics Apprenticeship should be done during daily work at your job.
Training in-service. it covers the same Your employer has a Task Check Chart, that
material that is taught in the 14 week training he will complete to vouch that you have done
program for Module One at the vocational all the tasks listed in the manual.
schools. Although you don't have an in-
structor to assist you like apprentices at Following is some advice on how to approach
school. you will receive assistance from your the ceurue:
employer and the journeyman you work with.
it is expected that the program will be
The manual is divided into nine blocks: (1) completed within a three month period;
Shop Equipment and Practi;es, (2) Starting. however, provision is made for up to a
Stopping. Moving Equipment. (3) Hydraulics, three month extension if required. Try
(4) Brake;_;. (5) Power Trains. (6) Frames. to space the blocks out over the time
Suspension. Running Gear and Working At- you set to do the course. There is a lot
tachwrits. (7) Engines. (8) Electricity. and (9) of material here. and if you leave it all
Winches. Hoists and Cables. The material in to the end. you won't get finished.
blocks 1. 2. 6 and 9 is dear. with in a fairly Monitoring of your progress in the
thorough manner as these subjects won't be co'irse is done by your employer and
covered again in your training courses. The by contact with the Apprenticeship
other blocks, blocks 3. 4. 5. 7 and 8. are intro- Branch. Since this is an individualized
ductions that give a basic grounding in their learning package. there is no one
subjects. The topics in these blocks will be standing over you telling you to do so
covered in greater detail in later courses. The much today and so much tomorrow.
main idea behind the depth that subjects are The onus is on you to keep a regular
studied in this manual is to try to relate progress through the course. And it
course material to the work you will actually won't be easy.
be doing in the shop at this level of your ap- Don't skip out a section thinking that
prenticeship. This is the reason. for example, you already know it. There probably
that detailed information is given on frames. will be material in it that you are un-
suspensions and running gear. whereas only certain of. And Desides. if you know
basic information is given on electricity: it is most of th(d material already you'll be
assumed the t you will be doing a lot of work able to go through it quickly.
on suspension and running gear. but little on
electrical systems. Blocks 1.2. 3, 4 and 5 should be done
first. The other blocks can be taken in
Each of the blocks is laid out in the following any order, although it's probably best
pattern: the block begins with a section on to take them in the order in which they
parts theory that gives the purpose, types. come.
operations (how they work) and applications
(where they are used) of the parts and The questions are straightforward;
systems be' ig discussed. A set of questions there are no trick ones. They can all be
follows the parts theory. the answers to which answered from a close study of the
are given at the end of the block. Next is a text. Try to do as many of the questions
section on service that is divided into Daily as you can, without going back to the
Routine Maintenan -e. Scheduled Main- text. If you can't get a question, then
tenance and Service Repair. Daily Routine open the text and seek the answer
Maintenance deals with watchful visual rather than turning to the answers. This
checks and adjustments; Scheduled Main- way you re-read the topic and get a
tenance with scheduled lubrication and more complete understanding of it than
checks; Service Repair with removal. if you just look up the answer.
disassembly, repair or replacement and in- The practical tasks should normally be
stallations. The Service Repair sections in the completed as you work on the material
blocks that are written at a basic level are in each blocks however, this may not be
limited to the types of repair that you are
5
SiliiIMEMEIMENIRM=MINMMI11
7
Washers 173
Cotter Pins 1'74
Lock Wires V75
Flat Metal Locks 1'75
Keys 1.76
Splines V76
Pins 1.77
Rivets 1'79
Questions Fasteners 111
Hoses, Pipes, Tubes. Fittings and Adapters 113
Hose 113
Hose Fittings 116
Good Practices when Installing Fittings 118
Pipes and Tubes 119
Pipe Fittings 1'89
Good Practices for Installing Pipes and Pipe Couplers 111
Tube Fittings 1'91
Good Practices when Installing Tubes and Tube Fittings 116
Questions Hoses, Pipes, Tubes, Fittings and Adapters 117
Lifting and Blocking 118
Types of Lifting Equipment 1:98
Hydraulic Hoists and Jacks 119
Chains 1101
Wire Rope Slings r 1102
Hooks 1105
Shackles 1106
Lifting Eyes 1.106
Spreader And Equalizer Beams 1.107
Blocking and Stands 1108
Lifting Procedures and Precautions 1109
Questions Lifting and Blocking 1111
Welding 1112
Cylinders Handling. Storage and Safety 1112
Hose and Connections 1113
Regulators 1i13
Oxygen and Acetylene Cylinders 1114
Oxygen and Acetylene Gases 1115
Welding Torches 1116
Set Up Oxyacetylene Equipment 1118
Oxyacetylene Flames 1122
Shutting Off Oxyacetylene Equipment 1123
Healing 1123
Flame-Cutting 1123
Cutting Torch Tips 1124
To Prevent Fires and Explosions 1126
Backfires and Flashbacks .1:127
Fusion Welding 1128
We Idfaults 1130
Braze Welding 1133
Questions Welding 1137
Answers Hand Tools. Shop Safety. Service Literature 1139
Answers Air, Electric and Hydraulic Power Tools 1140
Answers Measuring Tools 1141
Answers Fasteners 1.142
Answers Hoses, Pipes, Tubes. Fittings and Adapters 1143
Answers Lifting and Blocking 1144
Answers Welding 1145
Tasks Shop Equipment and Practices 1146
8
.1811301111M1111111111MINIIIMMIIIMIIIMMIMEM11184
BLOCK 2 STARTING, MOVING AND STOPPING EQUIPMENT
Starting, Moving and Stopping Equipment 21
Pre-Start Checks 21
Walk Around Inspection 2.4
Starting and Moving Equipment 2.6
Emergency Shut Down Procedures 2.6
Starting Procedures, Cold Starting Aids. and Stopping Procedures 2.7
Starting Procedures. Including Safe Use of Cold Starting Aids 2.7
Engine Oil and the Battery in Cold Starting 2.8
Detroit Diesel 2.9
Cummins Diesel 2.10
Caterpillar Diesel Engine 211
After Start Checks 212
Moving Vehicles 213
Safety Precautions with Articulated Steering 219
Common Causes of Injury in the Heavy Dui) Field 2:20
Machine Storage 2.22
Questions Starting. Moving and Stopping Equipment 214
Answers Starting. Moving and Stopping Equipment 226
Tasks Starting. Moving and Stopping Equipment 2.27
BLOCK 4 BRAKES
Brakes 4.1
Brake Operation 4.1
Basic Friction Theory Related to Brakes 41
Facts on Braking 4.2
Brake Capacity 4.2
Types of Brake Systems 4.3
Service Brakes 1.3
Standard Hydraulic Brakes 4.4
F)undation Brake 4:5
Drum Brakes 4.5
Disc Brakes 4.7
Multi-Disc Brakes 4:7
Power-Assisted Hydraulic Brakes 4.7
Vacuum-Assisted Brakes 41.9
.Air-Over-Oit Brakes 4.10
Oil-Over-0:1 Brakes 4.10
Air Brakes 4.11
Emergency or Parking Brakes 4:13
Integral Parking Brake 4:13
Drive Shaft Parking Brakes 4.14
Spring Brakes 4.15
Brake Fluid 4.16
Questions - Brakes 4.17
Preveltive Maintenance and Adjustments on Brakes 4.18
Needing Hydraulic Brakes 4.18
Adjulting Hydraulic Brakes 4:19
Acjusting Air Brakes 4.22
Aclusting Parking Brakes 4.24
Questions - Brake Maintenance 4.26
Answers - Brakes 4.27
Answers - Brake Maintenance 4.28
Tasks - Brakes 4.29
10
J
With a Power Shift Transmission 5.33
Lubrication and Maintenance Checks on a Wheel Loader With a
Power Shift Transmission and Standard Drive Axles 5.35
Scheduled Maintenance on Retarders 5.38
Removing Axle Shafts 5.38
Questions - Power Train Maintenance 5.39
Answers - Power Trains 5.40
Answers - Power Train Maintenance 5'41
Tasks - Power Trains 5.42
11
Undercarriage Maintenance and Repair 6.57
Maintenance and Service Life 6.57
Daily. Routine Maintenance Checks on Undercarriages 6.58
Track Tension: Dozers. Loaders. Excavators 6.61
Track Tension: Shovels. Cranes 6.64
Questions Undercarriage Daily. Routine Maintenance 6.66
Scheduled Maintenance 6.67
Undercarriage Wear 667
Measuring Undercarriage Wear 6.69
Alignment 6/9
Track Frame Alignment 6/9
idler Alignment 6.82
Questions Undercarriage Scheduled Maintenance 6.85
Service Repair on Track Machine Undercarriage 6.86
Removal and Inswilation of Tracks 6:86
Undercarriage Repairs 6.91
Installing Components To The Track Frame 6.96
Aligning the Individual Track Sides 6.97
Questions Undercarriage Service Repair 6.98
Answers Track Machine Undercarriages 6.99
Answers Track Undercarriage Daily. Routine Maintenance 6.100
Answers Undercarriage Scheduled Maintenance 6.101
Answers Undercarriage Service Repair 6.102
Tasks Track Machine Undercarriages 6.103
12
Troubleshooting on Steering Systems 6147
Service Repair of Track Machine Steering 6150
Questions Crawler Steering Maintenance and Repair 6156
Answers Track Machine Steering 6157
Answers Crawler Steering Maintenance and Repair 61 55
Tasks Track Multi-Disc Steering System 6159
13
Service of Traction Devices 6.239
Questions - Tires. Rims. Wheels. Maintenance an Repair 6.241
Answers - Tires. Rims and Wheels, Ballast. Traction Devices 6 242
Answers - Tires. Rims. Wheels. Maintenance a.:d Repair 6.243
Tasks - Tires. Rims and Wheels. Traction Devices 6.244
14
WORKING ATTACHMENTS
Crawler Dozers 6.309
Crawler Loaders 6.315
Wheel Loaders 6.316
Hydraulic Excavators . 6'319
Crawler Shovels 6122
Hydraulic Cranes 6.323
Skidders 6.324
Graders . 6:325
Machine Balance and Counterweights 6.327
Canopies 6.329
Maintenance and Service Repair of Working Attachments ... 6:330
Daily. Routine Maintenance 6.330
Service Repair on Working Attachments 6132
Questions Working Attachments 6137
Answers Working Attachments 6138
Tasks Working Attachments 6:339
15
BLOCK
Shop Equipment
and Practices
16
SHOP EQUIPMENT AND PRACTICES 1:1
17
1:2 SHOP EQUIPMENT AND PRACTICES
METRIC CONVERSIONS
In the event metric conversions are required,
refer to conversion tables at the back of this
manual.
SPECIFICATIONS
Service data, fits. and tolerances are listed at
the end of each section or sub-section under
the heading "Specifications". In some cases
reference must also be made to these
"Specifications" for model application and
methods of distinguishing the various design
and construction differences.
Manufacturer's model or part numbers are
18
SHOP EQUIPMENT AND PRACTICES 1:3
TABLE OF CONTENTS
GENERAL INFORMATION
SERVICE 0 OA.
OB.
General Information
Lubrication
MANUAL 1 1A.
1B.
Heating
Air Conditioning
ENGINE
6A. Engine Mechanical
6B. Cooling
NOTE 6 6C. Fuel System
60. Engine Electrical
When reference is made in this 6E. Emission Controls
manual to a brand name. number. or 6F. Exhaust
specific tool, an equivalent product
may be used in place of the recom- TRANSMISSION & CLUTCH
mended item.
7A. Automatic Transmission
7 7B. Manual Transmission
7C. Clutch
SPECIAL TOOLS
Courtesy of General Mows Corporation INDEX
19-
r.
CLARK
L 1PM MT
TS - '7117
INDENTED DESCRIPTION
Indented parts in the description list are a part of the preceding assembly or sub-assembly. The
quantity shown in the "Number Required" column is the number of parts used on a machine except
where parts are indented in descriptive list. In this case the quantity shown is the number required
for the preceding assembly or sub-assembly.
0670160
Issued March, MN
z1
1:6 SHOP EQUIPMENT AND PRACTICES
4. When listing the parts. keep the related (number on bearing) 672181
items together, i.e., don't give a bearing, 1 only hub outer bearing cop
then a gear, then a gasket and back to (number on bearing) 672182
another bearing. This makes the list hard
for a parts person to follow, and increases 1 only axle sna4t (left side)
the chances of missing a part. 1 only sun gear
5. State the quantity of each part required. 1 only internal gear
3 only planet pinion gears
6. When parts are received, check im-
mediately for quantity, correctness and 3 only planet pinion gear shafts
condition of parts. Advise the distributor 6 only planet pinion thrust washers
of any error, and make claims for any ship-
ping damages immediately with the
carrier.
7. There are three situations you can be
faced with when ordering parts:
(a) Parts book is available: this is fairly
straight forward as you lust list the
part numbers from the parts book as
in the example below:
Case Crawler Loader: Model 1150,
Serial #7108999. Parts for a Track
Roller:
1 only #36406 Shaft
2 only #36043 Bushing
2 only #35267 Seals
2 only #30116 Bearing cones
2 only #55807 Bearing cups
4 only #31329 Shims
1 only #36465 Hub double
flange
22
SHOP EQUIPMENT AND PRACTICES 1:7
ENGINE
SERIAL NUMBER
i.'"iEEcill;Ns,
1,3Mli TRANSMISSION SERIAL NUMBER
23
1:8 SHOP EQUIPMENT AND PRACTICES
Service Report
A service report should be short and concise.
A service report written before a repair is
made should contain:
1. What is to be worked on, and what is
wrong with it.
2. List the parts needed.
3. Statement to the effect that with the parts
listed the component can be rebuilt.
A service report written after repair is done
should:
1. List the parts used.
2. Briefly state what work was done.
An example of a service report satement for
the Clarke Skidder mentioned under the sec-
tion, Parts List, is given below (note that the
lists of parts would be included in the report,
in addition to the make. model and serial num-
ber of the machine):
"When the left rear final drive was
disassembled and inspected, the parts
listed were found to be worn or
damaged to the point of needing
replacement.
The spindle. hub. cover and wheel
assembly are all in good condition. In
my opinion it is economical to rebuild
this final drive."
Although service reports are discussed here,
it should be pointed out that the apprentice or
for that matter iourneyperson, in many cases,
will be given a work order and will not have a
say in what work is to be done. However,
when carrying out the work order, always
bring to the attention of your supervisor other
work that you find needs doing. Disregarding
it and following only the work order does not
make a responsible mechanic.
24
SHOP EQUIPMENT AND PRACTICES 1:9
SHOP SAFETY
Most accidents don't just happen: they are
caused by carelessness. Always be con-
cerned with your own safety and with that of
others around you. The following cautions and
illustrations (courtesy of Mack Truck of
Canada Limited) show how ignoring common
safety rules can cause injury. even death.
(1.4)
Courtesy of Mack Truck of Canada Li Gated
(1-5)
Courtesy of Mack Truck of Canada Limited
25
1:10 SHOP EQUIPMENT AND PRACTICES
9. Watch for other floor traffic when moving 13. Keep jack handles up where they won't
material, especially at blind openings. be tripped over
10. Do not use carbon tetrachloride for 14. Stand creepers up when not in use.
cleaning. This fluid can cause serious in-
ternal injury, even death, if its fumes are 15. Keep work areas as tidy as possible.
inhaled (Figure 1-6). Cluttered surroundings can cause ac-
cidents.
11!=
4 1.. FIRE PREVENTION PRACTICES
Carelessness is the major cause 4:4 fire and
explosion in repair shops. Fire prevention
practices are listed below.
Airtzkilt
11181
1. Keep all inflammable fluids and materials
in their proper containers.
2. Heed No Smoking signs. They are there
for a purpose (Figure 1-8).
(1-6)
COUtteSY of Mack Truck of Canada Limited
(1-8)
Courtesy of Mack Truck of
Canada Limited
26
SHOP EQUIPMENT AND PRACTICES 1:11
6. Watch where you point a lighted torch. 11. Gasoline is very volatile; its vapors can
You could injure someone (Figure 1-9), be set off by a spark. When working on
or light the place on fire. or near a fuel system, be very careful not
to do anything that would cause a spark.
12. Clean with non-inflammable solvents.
which are non-toxic and of high flash
point (100°F. or more). Do not use
questionable cleaning fluids in the
vicinity of open flames (such as welding
operations) or high heat sources.
Petroleum-based solvent is most com-
monly used in the trade for washing
parts, although diesel fuel is also used
for this purpose. Hot and cold caustics
(1-9) are also used for washing in some shops;
Courtesy of Mack Truck of they must be used with caution. If your
Canada Limited shop has a caustic wash tank obtain in-
7. Do not overload any one circuit with structions for its proper use.
plugs. Octopus connections (Figure 1-10)
are dangerous
IN CASE OF FIRE
wires have been divided into four main
cAsses: A, 13, C and D. The extinguishers
used to fight these fires are similarly classed
as an A, B, C or 0 Extinguisher.
t_.'t
1'. *....
27
1:12 SHOP EQUIPMENT AND PRACTICES
Locate the fire extinguishers in your shop. All fire occurs. you won't have time to waste
extinguishers have directions for use printed studying directions how to use the ex-
on the cannister. and include the letters tinguisher. The type of extinguishers you are
referring to the type of fire they can be used likely to find in a mechanical shop are
on. Study these directions beforehand so that illustrated in Figure 1-11.
you will be prepared for an emergency. It a
Type Contents Kinds of Fire How to :art Discharge
(15-lb. size)
CLASS A
and for
Solution of CLASS B 21/2 gal.
aluminum size
sulfate and (off,
bicarbonate gasoline. Turn over 30 to 42 feet
of soda grease.
paint) 50 to 55 sec.
28
SHOP EQUIPMENT AND PRACTICES 1:13
(1-14)
Courtesy of Mack Truck of
Canada Limited
Seek
1. Don't overestimate your strength. Many
back strains have been caused by people
lifting something that was too heavy for
them. Get help with heavy objects. or use
a lifting device.
(1-12)
Courtesy of Mack Truck of 2. Lift from a squatting position with the
Canada Limited back straight (Figure 1-15). Never reach
and lift.
3. Push a heavy object: don't pull it.
(1-13)
Courtesy of Mack Truck of
Canada Limited
29
1:14 SHOP EQUIPMENT AND PRACTICES
Hands
Your hands are the most important tools you
have. Protect them. Remember it's hard to
count to ten on your hands when some of the
digits are missing (Figure 1-16).
(1.18)
Courtesy of Mack Truck of
Canada Limited
Ears
Hearing is as important as sight. It's as com-
mon nowadays to see sound muffs being worn
as it is hard hats. When working around
(1.17) machinery, noise levels can reach a level that
Courtesy 01 Mack Truck of
causes shortterm deafness. Continued ex-
Canada Limed posure to these levels can cause long term
deafness. Always wear ear protection when
working in areas of high noise levels.
30
SHOP EQUIPMENT AND PRACTICES 1:15
HAND TOOLS
This section is intended as a basic in-
troduction to hand tools. For more detailed in-
formation. there are several good tool books
on the market. One of these is Peterson's
Tool Book No. 1, Basic Automotive Tools and
How to Use Them.
HAMMERS
Bail Peen Hammers (Figure 1-19): are
frequently used by shop servicemen. The flat
face is for hammering and the ball part is for
rounding off rivets and similar jobs. They are
available in various sizes rated according to
their weight.
Correct Use
1. The proper grip and striking angle of a
hammer are illustrated in Figure 1-21.
(1.20) SOFT HAMMERS
2. If the wedge in the hammer handle starts
Courtesy of John Deere Ltd.
to come out. drive it in again to tighten the
handle. If the wedge is lost, replace it
before using the hammer. Never work with
a hammer having a loose head.
3. Never use a steel hammer on a machined
surface: use a soft hammer.
BALL PEEN
(1-19)
BALL PEEN HAMMER
'FACE
X 2268 Courtesy of John Deere Ltd.
WRONG RIGHT
X 2.2$6
31
4
1:16 SHOP EQUIPMENT AND PRACTICES
WRENCHES
Common wrenches are illustrated in Figure 1 -22.
STRIKING
WRENCH
OPEN END
WRENCH
COMBINATION
WRENCH
SPANNER
WRENCH
BOX
WRENCH
12-POINT
SOCKET
ADJUSTABLE TUBING
WRENCH WRENCH
SOCKET WRENCH
WITH RATCHET TORQUE WRENCH
32
SHOP EQUIPMENT AND PRACTICES 1:17
Box Wrenches: both six and twelve point box Courtesy of John Deere LW,
wrenches (Figure 1-26) are available, but
twelve point are most common. Box wrenches Spanner Wrenches: are usually special toots
are sometimes referred to as 12-point wren- supplied with a machine. Some types of span-
ches. Because of their 12-points, box wren- ners are illustrated in Figure 1-29.
ches can turn with a minimum swing of 15
degrees compared with 30 degrees or 60
degrees for an open-end wrench.
Box wrenches won't slip off a nut since they
completely surround the nut. Combination box HOOK TYPE WRENCH
and open-end wrenches can speed up nut and
bolt installations. The box end is used to
break loose or snug down the nut, while the
open-end is used for greater speed for the rest
of the turning. These combination wrenches
are the most popular hand wrenches
r
COMBINATION OX AND OPEN-END WOO
I30X WRENCH
X 2E82
(1-26) BOX WRENCHES
Courtesy of John Deere Ltd,
33
1:18 SHOP EQUIPMENT AND PRACTICES
SOCKET WRENCHES
Modern socket wrenches have done more to
make a mechanic's job easier and faster than
any other tool. A full socket wrench set con-
tains sockets as well as various accessories
that allow the sockets to be pJt to best ad-
vantage.
) SINGLE HEX
34
SHOP EQUIPMENT AND PRACTICES 1:19
Adapters Multipliers
Adapters are used to change the wrench or Multipliers (Figure 1-34) are socket wrench at-
socket drive size up or down one size. For tachments that give a mechanical advantage.
example, if you have a 1-inch drive flex handle A multiplier consists of a handle, a small
and want to use a socket for a 3/4 drive set, planetary housing and male and female
use a 1-inch to 3/4 inch adapter (Figure 1 -33), square socket adapters. To use a multiplier.
Conversely. if you want to use a 1 inch drive install a flex handle or ratchet into the female
socket on a 3/4 inch drive flex handle, use a adapter and a socket onto the male adapter.
3/4 inch to 1 inch adapter. bold the handle of the multiplier with or.e
hand, and turn the flex handle or ratchet with
/....._,.....r....Z....%
1" the other. The socket is turned at a reduction
...1.1. FEMALE /'44).- , 4,6.3/4" thus multiplying the force applied to the
FEMALE sockets. Multipliers are available in 3/4 inch
and 1 inch drive sizes with a torque
multiplication of 4 : 1.
Cj--3/4" MALE -4- -V' MALE
FEMALE
SOCKET ADAPTER
(1-33) ADAPTERS
HANDLE
4-PLANETARY
HOUSING
TORQUE WRENCHES
On modern machinery, torquing bolts is an im
portant procedure. Uneven torquing can
cause warping, leaks, cracks, and stressed
areas. Under and over torquing also causes
problems. Thus the need for torque wrenches.
Torque wrenches (Figure 1-35), like other
wrenches, tighten or apply torque to a nut, but
there is a difference. With ordinary wrenches
you rely on touch or feel to tell if a nut is tight.
whereas with a torque wrench a scale gives
exactly how much torque has been applied to
the nut. Torque wrenches take the guesswork
out of tightening nuts. You look up in the ser-
vice manual what torque should be applied,
then turn the torque wrench until the scale
reaches the recommended value. Most torque (1-36) TOROUE WRENCH
wrenches have a signalling device: the
desired torque is set on an indicator and when
that torque is reached the wrench gives a
signal. There are a number of good torque
wrenches on the market, and it's a matter of Courtesy of Owatonna Tool Company
personal preference which to buy,
35
I
1:20 SHOP EQUIPMENT AND PRACTICES
1 FOOT
HORIZONTAL
90°
TORQUE w 1 FOOT-POUND
x vf:.:)o 1 POUND
(146) UNITS FOR MEASURING TORQUE
Courtesy of John Deere Ltd
36
SHOP EQUIPMENT AND PRACTICES 1:21
.,1,,
f ter' ------
0 7/
749Y.
37
1:22 SHOP EQUIPMENT AND PRACTICES
Snap Ring Pliers: Snap rings fit into a bore or SINGLE DOUBLE RASP CURVED
casing (internal) or fit on a shaft (external). CUT CUT CUT TOOTH
Snap ring pliers are made tc spread or close
the rings just enough to allow removal or in-
stallation (Figure 1-40). Several types of pliers
are available to work with the different types
of snap rings.
38
SHOP EQUIPMENT AND PRACTICES 1:23
VISES
The size of a vise refers to the measurement
across the jaws. Four to six inch vises are
commonly found in heavy duty shops.
Correct Use
1. Never use a hammer to tighten or loosen a
vise; arm strength is sufficient.
2. Always use a vise big enough for the part
or type of work to be held.
3. When round parts must be held, soft metal
or hardwood jaws can be used to prevent
slipping or damage to parts. Whenever
X 2.302 finished surfaces must be held, be sure to
(1-43) TIGHTENING FILE HANDLE use soft metal jaw covers as shown in
Figure 1-44 so that the finish isn't marred.
4. Use a drill press vise (Figure 1-45) when
drilling small pieces of metal.
PROTECTIVE
JAW COVERS
X4211
X 2.308
(1-44) MACHINIST'S BENCH VISE
Courtesy of John Deere Ltd.
X 2304 _
FILE CARD
.39
1:24 SHOP EQUIPMENT AND PRACTICES
HACKSAWS
bTILT BLADE
FOR MORE CONTACT
(1-46)
SAWING THIN TUBING
X 2.307 Courtesy of John Deere Lid
40
SHOP EQUIPMENT AND PRACTICES 1:25
Taps
Taps are used for cutting internal threads. TAPER
There are many styles of taps; common ones
are taper, plug, bottoming. and machine
screw (Figure 1-47). A taper tap is used to tap
completely through the hole; it has a long PLUG
gradual taper that allows the tap to start
easily. A plug tap is used to tap threels part- 111011WW111!11111
way through. A bottoming tap is use° to cut UMEM *MIMIPPIIPPPPPOPIPPM11
threads all the way to the bottom of a blind
BOTTOMING
hole. A plug tap should precede a bottoming
tap, as the bottoming tap will not start well. A
machine screw tap is good for small diameter,
fine thread jobs. The plug tap is the most Z4213 MACHINE SCREW
widely used tap, and except for running
threads completely to the bottom of a blind (1-47) FOUR KINDS OF TAPS
hole, will cut satisfactory threads for most
jobs. Courtesy of John Deere Ltd.
X4214
41
1:26 SHOP EQUIPMENT AND PRACTICES
_..... 4
ca:Cro
imi= =120
cznto co=
c= 1.-11=1 %,1/4.19 p®
42
SHOP EQUIPMENT AND PRACTICES 1:27
CHISELS PUNCHES
Flat Cold Chisel (Figure 1-50): the most com- Starting Punch (Figure 1.151): used to knock
mon chisel used by the servicemen. They are out rivets and to start or knock out straight or
used for cutting metal. Common uses of tapered pins.
chisels for a mechanic are to break rivets and Pin Punch: used for driving out pins after the
split nuts. starting punch can no longer be used. Don't
use a pin punch to start a pin moving: the slim
Cape Chisel: used for cutting keyways. shank could bend or break.
narrow grooves, and square corners.
Center Punch: used to mark the center of a
Round Nose Chisel: used for cutting semi- hole that is to be drilled. The mark ensures
circular grooves and chipping inside corners that the drill will bite in the right spot and
which have a fillet or radius. won't wander.
Diamond Point Chisel: used for cutting V- Aligning Punch: used to shift parts to line up
grooves and square corners. corresponding holes. Never use an aligning
punch as a center punch.
HANK
LI
t----.... 1
PIN PUNCH
CAPE CHISEL
43
1:28 SHOP EQUIPMENT AND PRACTICES
Drift Punches (Figure 1-52): are long punches Correct Use Of Chisels And Punches
usually between one and two feet in length;
they are used for reaching hard-to-get-at 1. A chisel (or punch) should be held fairly
spots and for lining up. Some drifts are loose, so that the jarring vibrations are not
tapered, while others such as a brass drift are all transmitted to the hand. Also, the hand
a straight rod (Figure 1-53). is less likely to get injured in case of a
miss.
2. Wear safety glasses when using a chisel.
3. A chisel will cut any metal softer than it-
self. Always use a chisel that is big
enough for the job and a hammer that is
heavy enough for the size of the chisel.
This also applies to punches.
4. When grinding a chisel or punch never
hold it against the grinding wheel too
long. Dip it frequently in water or coolant
to keep it cool. Otherwise it will lose its
DRIFT PUNCHES temper and aecome soft
(1-52)
Cot'nesy of Mac Tools
(1-54)
RIGHT
To get at driving jobs where a soft GRIND BACK CHISEL AND PUNCH HEADS
punch is reciuired. 8" long, 3/4" stock.
Courtesy of John Deere Ltd.
(1-53)
Courtesy of Mac Toots
44
SHOP EQUIPMENT AND PRACTICES 1:29
DEAD
MARGIN CENTER
CUTTING
LIP
SHANK
o
THE POINT
LIP CLEARANCE
(1-55)
X 2311 TWIST DRILL
Courtesy of John Deere Ltd.
o
Sharpening Drills
To drill accurately drills must be sharp. Drills
are sharpened by grinding them either
freehand or with a jig that attaches to a grin-
der. It is important that drills be ground ac- o
X 2313
(1 -56) COMMON SHAPE OF DRILLS
Courtesy of John Deere Ltd.
45
1:30 SHOP EQUIPMENT AND PRACTICES
Correct Use
1. For low speed drilling, carbon tool steel
drills can be used.
2. For high-speed drilling, use drills of high-
speed tool steel.
SHANK
3. Always center punch before drilling. X 2260
4. After the drill has enlarged the center (1-56A) COMMON SCREWDRIVER
punch mark slightly and before the whole Courtesy of John Deere Ltd.
point has entered the material. check to
see that the hole is correctly centered. If
the drill is not entering the right spot. it Phillips-Head Screwdriver (Figure 1-60): will
can be drawn over by making a chisel cut
rot slip sideways out of the cross slots of a
on the side to which the drill should be Phillips-head screw. but more force must be
drawn (Figure 1-57). exerted in keeping it in the slots. If the bit gets
damaged, it is not practical to repair it.
5. Always use a lubricant to cool the drill.
Clutch-Head Screwdriver: is used with
CHISEL. screws for sheet metal and trim where a neat
CUT appearance is desired. The tip of the
screwdriver is very strong and stays in the
screw opening with only moderate pressure.
46
1
SHOP EQUIPMENT AND PRACTICES 1:31
o o
PHILLIPS-HEAD
HOW A SCREWDRIVER POOR FIT DAMAGES
SHOULD FIT THE SCREWDRIVER MO
SCREW SLOT SCREW SLOT
X 2261
it
grinding wheel for long periods. Dip the
bit in water to keep it cool.
RIGHT WRONG
X 226 2
(1-59)
GRINDING A SCREWDRIVER BLADE
Courtesy of John Deere Ltd. OFFSET
47
1:32 SHOP EQUIPMENT AND PRACTICES
2.
size iron is most suitable.
Soldering Guns electric soldering guns
are used to solder electrical connections.
The :rigger switch can be turned on and
/
()SURFACES
LAPPED
ARE
off as required.
SEAM IS
3. Torches oxyacetylene torch or a HEATED
propane torch kit can be used to heat TO FUSE
metals for soldering. (A propane torch kit SOLDER\
has a disposable propane cylinder and
soldering tips. as well as other ac- THIN SOLDER HERE X4216
cessories.) Broad areas can be soldered
faster with a torch because it supplies (1-62) SOLDERING COPPER WIRES
more heat. There is a danger with torches,
however of overheating the material and Courtesy of John Deere Ltd.
of damaging nearby parts such as hoses.
Soldering Hints
So Merino Procedures 1. Keep soldering irons or tips smooth by
filing them.
1. Thoroughly clean the work to be soldered,
removing all rust scale and oxidation. A 2. Excessive solder can be removed from a
quick brush over with a wire brush is not tip with a cloth when the iron is hot.
good enough.
3. Don't let irons overheat: turn them off
2. Before using a soldering iron or tip, it when not in use.
must be tinned. To tin an iron. heat it and
apply solder to it. 4. Metal is ready for soldering when the
solder melts freely and sizzles.
3. Heat the pieces to be soldeeed and apply
flux if it isn't included in the solder. 5. When using a propane torch kit for
soldering in an area where nearby parts
4. Always apply solder to the work, not to the could be damaged, heat the tip and then
iron. turn the propane off before using the tip.
48
SHOP EQUIPMENT AND PRACTICES 1:33
DRILL
(1.63)
Courtesy ol Helicoil Products
TAP
1. Drill out damaged or stripped threads
using the drill size specified in the
Helicoil kit. Drill to an adequate depth
right through. or for blind holes. to the bot-
tom.
2. Using the tap supplied with the kit, cut the
threads that will receive the insert.
3. Taking the installation tool supplied
(Figure 1-65). screw the helicoil insert on
the tool. The insert should be screwed far
enough so that the tang (Figure 1-66) is
engaged in the slot at the bottom of the
tool. Now screw the insert into the tapped
hole until it is one-quarter to one-half turn
below the surface of the hole. INSTALL
4, Finally the tang must be removed. Place
the square end of a punch (no bevel) on (1-64) INSTALLING A HELICOIL
the tang and strike it sharply with a ham-
mer. The tang will break off at the notch. Courtesy ol Helmoil Products
49
1:34 SHOP EQUIPMENT AND PRACTICES
STANDARD TYPE
(1-65)
CARBON SCRAPERS
PREWINDER TYPE
long blade
Courtesy of Helicon Producis
Tool No. 1 Type Noodle Imp
HELICOIL STAINLESS STEEL INSERTS 5111 Wood Handle 114'a
TANG
SPH1
SP.
Plastic Handle
Plastic Handle r
1144"
(1-68) SCRAPERS
NOTCH CourlesY of Mac Toots
S"'""IgC:::14
STANDARD SPARK PLUG CSIO
(1-66)
Courtesy Of Neircod Products
FLEXIBLE WIRE
CARBON SCRAPER
coo 10" long, 1" wide.
50
SHOP EQUIPMENT AND PRACTICES 1:35
WBIO
HEAVY-DUTY CARBON
CLEANING BRUSH
W115 End Brush. W diameter with W
shank.
W86 Similar to the WB8. r in diam-
eter. Vi shank.
WB7 Cable Twist 1" diameter with ve ADAPTOR FOR
shank. DRILL CHUCK
CAI W shank. WW4
CA2Adaptor for Drill Chuck. W shank.
CA3Adaptor for Drill Chuck. rh~ shank. STANDARD
OBIS
WIRE WHEEL BRUSH
NYLON BRISTLE (1-69) COMMON BRUSHES
Courtesy of Mac Tools
MOTOR CLEANING BRUSH
CRANKSHAFT OIL HOLE CUMMINS DIESEL BRUSH PW34 Aluminum handle economy
size polypropylene.
BRUSH SET NH1 Stainless steel bristle handle
CSN Set of two Tynex nylon brushes to be used when changing injector while NYLON OIL LINE BRUSH KIT
5/is and 7132 x 2 x 10. in truck. OLK Tynex nylon brushes for: feed
DETROIT DIESEL BRUSH CUMMINS DIESEL BRUSH line, block oil return lines, overhead rocker
001 NH2 Stainless steel bristle cut for feed lines, valve guides, cam and crank-
Stainless steel bristle with handle
to be used when changing injector while power, cleans or polishes entire copper. shaft.
in truck. Best used as a bench tons VALVE GUIDE BRUSH SET
314" PARTS WASH BRUSH VOCK Set includes sizes V4. 5116. "ht.
'3/32, Yu, and 1/2.
SNIPS
Snips are used for cutting sheet metal and
other sheet material like that used for gaskets.
In a repair shop snips are used for such lobs
as cutting shim stock, sheet metal for small
fabrication jobs, and gasket material.
Both straight cutting and circle cutting snips
are available (Figure 1-71).
CIRCLE SNIPS
STRAIGHT SNIPS (1-71)
Courtesy of Gray Tool Company
51
1:36 SHOP EQUIPMENT AND PRACTICES
r--- DRILL
i i
I 1 DRILL
GUIDE
K02043
KD2044
52
SHOP EQUIPMENT AND PRACTICES 1:37
(1.76)
WIRE SPLICER
PULLERS
Three basic pulling problems are illustrated in
Figure 1-77. The solutions to these problems
are shown in Figures 1-78, 1-79 and 1-80.
Examples of pulling jobs are shown in Figure
1-81.
(1-74) USING CHISEL AS EMERGENCY
STUD REMOVER
Courtesy of John Deere Ltd
4--- PULL
STUD PULLER
4111 PUSH
To remove unbroken studs, use a stud puller. pulling
Drop the stud puller over the stud to be something
removed (Figure 1-75). Use a "T" or flex hand- PULL
le to turn the stud out. The puller off a shaft
automatically grips the stud with a knurled ec- Removing a gear, bearing. wheel. pulley. etc . to replace
centric as pressure is applied. One size fits it or get at another Part
almost all studs. In all stud removals, use a
generous amount of penetrating oil.
PULL
pulling
something PULL
out of a hole
Internal bearing cups. retainers or oil seals are usually
pressfitted and are difficult to remove
111. PUSH
1110 PULL
pulling
(1-75) STUD PULLER FOR UNBROKEN STUDS
a shaft out 01 PUSH
Courtesy of John Deere Ltd
of something
A transmission shall or pinion shalt 4 often hard to
remove from a bore or housing.
53
1:38 SHOP EQUIPMENT AND PRACTICES
otzjGet a grip on
the outer
circumterence Puller with bearing pulling
attachment. Provides "knife-
like" edge to get behind
component.
Use a pulling
attachment to
gel behind
,;:mUse threaded
adapters On
threaded studs
Pushpotter with attachments.
Above, matefemale adapters
can thread directly Into tapped
holes on component. Right.
splutter gets behind Component
to prevent damage.
Slide hammer
Get a firm grip
through spokes Special pullers
designed to do
Vr puller with
selected
attachments.
specific jobs.
OE Adapters
Variety used to protect shaft. bridge a hole. thread
Loa Utilize tapped
holes to pull
into tapped holes. assist inStaltatIOn of component.
54
SHOP EQUIPMENT AND PRACTICES 1:39
I li II
- /
When there is a shalt to
bear against. a forcing
screw of proper size may
be used in cOmbination
with an internal pulling
attachment.
.
(1-79) PULLING FROM A HOLE
Courtesy of Owatonna Tool Company
55
1:40 SHOP EQUIPMENT AND PRACTICES
iS3the problem...
the tools to use...
a housing...
the solution...
Female threaded
adapter allovirs you to
thread onto shaft
directly tot pull.
=) Malefemale threaded
adapter threads into
tapped hole of shaft
for direct pull,
ADAPTERS
FEMALE ADAPTERS
Fasten to the male
Or, use a malefemale adapter to engage a threaded end of shalt
.011 to pull while pushing
tapped hole in the end of the shaft. against the housing.
selir
Sometimes. we can push a shaft through a Slide hammer puller MALEFEMALE
housing. rather than pulling it out. In with threaded
ift
ADAPTERS
applications of this type, the puller legs must adaptereither Thread into shalt to
be securely fastened to the housing and the malefemale or putt shaft white pushinc
female. against the housing.
screw may simply bear against the shaft.
56
SHOP EQUIPMENT AND PRACTICES 1:41
57
1:42 SHOP EQUIPMENT AND PRACTICES
(1.83)
58
SHOP EQUIPMENT AND PRACTICES 1:43
QUESTIONS HAND TOOLS, SHOP 9. Snap ring pliers are made for removing
SAFETY, SERVICE LITERATURE either or snap
rings.
1. The three basic pieces of information
that should be in a parts list are: 10. After cutting a piece of tubing with a
tubing cutter. the end should be:
(a) make. color. and size of the
machine (a) filed smooth
(b) type. model. and size (b) reamed
(c) make. model. and serial number (c) left as is
2. True or False? A parts book and a ser- (d) expanded
vice manual are essentially the same.
3. Fires are divided into how many classes?
11. True or False? Use a double flare on
tubing when a double nut is required.
(a) 2
12. The average lip clearance angle of a drill
(b) 4 is from:
(c) 5
(a) 59`' to 65°
(d) 3
(b) 8° to 12°
4. True or False? Fire extinguishers are (c) 118° to 130°
classed according to the type of fire they
will extinguish. 13. If a drill bit runs off center when starting.
it can be brought back by:
5. List the six parts of the body a heavy duty
mechanic can most commonly injure. (a) using a larger drill bit
fb) leaning the drill to one side
6. Which is a properly ground screwdriver.
A or B? (c) making another center punch mark
(d) making a chisel cut on the side to
A which the drill should be drawn
14. The narrow raised rib that runs the
length of the twist drill and finishes the
hole to size is called the:
(a) lip
(b) flute
B
(c) margin
___----_ (d) web
15. The size of a twist drill can be measured
with a micrometer:
(a) over the land
(b) over the flutes
7. Soft faced hammers are used rather than (c) over tho margin
steel hammers because they: (d) over the web
(a) apply softer blows 16. Number drill sizes range from:
(b) are quieter
(a) No. 1 to 80
(c) jar the hand less
(b) No. 1 to 95
(d) protect machined surfaces
(c) No. 1 to 26
8. True or False? Combination pliers are (d) No 1 to 75
intended to be used as substitutes for
wrenches.
59
1:44 SHOP EQUIPMENT AND PRACTICES
17. For general purpose work the cutting lips 23. What precaution must be taken with a
of a drill should be ground to an included reamer not to dull its cutting edge?
angle of:
24. A multiplier is a geared attachment that
(a) 135 gives a mechanical advantage through:
(b) 118
(a) bevel gears
cc) 180 (b) helical gears
(d) 145
(c) planetary gears
18. The difference between a tap and die is:
25. What are four common types of chisels
(a) a tap cuts threads in a hole. and a used in the heavy duty trade?
die cuts threads on a rod
(b) a tap cuts threads on a rod. and a
26. The terms rough. smooth. and dead-
die cuts threads in a hole smooth refer to:
(c) a tap cleans threads. and a die cuts (a) hacksaw Wades
new threads (b) drill tips
19. Three types of taps are: (c) file cuts
(a) taper. pin. and bottoming
27. Name three common types of punches.
(b) taper. plug. and bottoming
(c) taper. bottom. and cape
28. Name four types of screwdrivers.
29. Name four types of material used for
20. A plug tap is used: hammer heads.
(a) to thread a blind hole 30. Name four types of pliers.
(b) after a taper tap
31. The file with the largest teeth is a:
(c) before a taper tap
(a) double-cut file
(d) alter a bottom tap
(b) flat file
21. Which of these taps is referred to as a (c) rough or coarse-cut file
plug?
32. A file that has two series of diagonal
rows of teeth cut across its face is
(a) called:
(a) rasp cut
(b) doubll cut
(c) single cut
(b) jiN10111111111iiii
PPOPPI/PlimPPPwri (d) fine cut
33. What does the term "drawli!e" refer to?
34. What are the minimum umber of
(c) hacksaw teeth that should be in contact
with the work?
35. When culling with a hacksaw. pressure
should be applied to the blade:
22. To remove a broken stud. center punch (a) in both the forward and reverse
it. then' stroke
(a) drill a large hole in the center (b) on the forward stroke only
(b) drill a hole 'art way down (c) on the reverse stroke only
(cl drill a pilot hole
(d) drill it right out to the threads
Go
SHOP EQUIPMENT AND PRACTICES 1:45
36. In reference to hacksaw blades, pitch 46. What is the advantage of a tubing
refers to the per inch. wrench over a standard open-end
wrench?
37. When really tightening a vise, it is ad-
visable to tighten it with: 47. Identify the following socket drive ac-
cessores.
(a) the handle of the vise only
(b) a piece of pipe on the handle to get 2.
leverage .iiiirmakt' i
wo
(c) a hammer to strike the handle and
secure the vise
38. What is the purpose of soft jaws for a
bench vise?
39. Normally, hacksaw blade teeth should
point:
(a) toward the right hand
(b) toward the handle
61=. 5.
(c) away from the handle
40. A typical box wrench has:
48. A torque wrench is recommended to
(a) 10 notches provide:
(b) 8 notches (a) extra leverage
(c) 12 notches (b) adaptability of sockets
(c) safeguard on over stressing parts
41. Wrench sizes are governed by the: (d) "non-slippage" of sockets
(a) thread length
(b) length of the bolt 49. When the torque wrench lever length is
12 inches and the force applied to the
(c) width of the bolt head across the handle is 5 pounds. the torque produced
flats is:
(d) width of the bolt head across the
corners (a) 10 ft.-lbs.
(b) 50 ft.-lbs.
42. What is the main rule when using an ad-
justable wrench? (c) 2 ft. -tbs.
(d) 5 ft.-lbs.
43. Open and box end wrench sizes increase
in steps of: 50. In selecting the right sized puller, it must
have the correct and
(a) 1/8 inch for the job.
(b) 1116 inch
51. For hydraulic pullers. the maximum force
(c) 1/32 inch exerted in tons should be
(d) 1/46 iiicn times the diameter of the shaft in inches:
44. Spanner wrenches are used on nuts with: (a) 1 to 2
(a) 12 points (b) 4 to 5
(b) 6 points (c) 12 to 15
(c) notches (d) 7 to 10
(d) flanges
45. Why is the head of an open end wrench
made with an offset?
61
1:46 SHOP EQUIPMENT AND PRACTICES
11;111;;;;; et I
62
SHOP EQUIPMENT AND PRACTICES 1:47
IMPACT WRENCHES
Impact wrenches are driven by air (Figure 1.
87) or by electricity: they work in either direc-
1" DRIVE IMPACT WRENCH
tion, and come with 3/8" 1/2". 3/4" and heavy
duty 1" drives. Their advantage over hand (1.87) IMPACT WRENCHES
wrenches is that they are much quicker and Courtesy 0 Mac Tools
require less effort to use. The time taken to do BENCH GRINDER
such jobs as loosening or tightening wheel
nuts or U-bolt nuts will be cut in half by using All repair shops have bench grinders (Figure
an impact wrench. A rule of thumb on when to 1-88). They are used for sharpening. cleaning.
use impact wrenches is to use them wherever shaping. wire brushing. buffing. Bench grin-
possible to save time and energy. However. ders have two drives. Often a medium-grit
where torque is critical, do final tightening grinding wheel will be on one side and a fine
with a torque wrench. wheel or wire brush on the other.
Correct Use Correct Use
Some impact wrenches have an adjustment to I The shaft that holds the right-hand wheel
gauge the amount of torque the wrench has right-hand threads, while the shaft
delivers, but most don't. Since it's very easy to that holds the left-hand wheel has left-
overtighten nuts with an impact wrench, it's hand threads. Remember this when
necessary to develop a feel for how much changing grinding wheels
torque the impact wrench puts on nuts. To 2. Tool rests should be approximately 1/16"
help get this feel. tighten a few nuts with an from the wheel and should be at or below
impact wrench and then put a torque wrench the center of the wheel. Rests can be set
on the nut and see how much torque you have at various angles for sharpening tools.
applied. Be alert when using an impact
wrench don't damage parts by overtightening 3. Take the following safety precautions
them. when grinrong: always wear safety
glasses even if the grinder has a shield.
Air impact wrenches require lubrication. See Never wear loose clothing or jewelry.
the maintenance instructions for the wrench Don't have anything near the grinder that
or ask a journeyperson. Three methods of a spark could explode.
lubricating air wrenches are (1) a special
lubricator located in the incoming air line, (2) 4. Place the work on the tool rest when grin-
an oil reservoir in the handle or (3) squirting ding: don't lift it up.
lubrication into the air intake by hand. Electric
impact wrenches are usually lubricated by the
5 Move the work back and forth across the
wheel so that the wheel doesn't develop a
manufacturer on assembly. but should oc-
groove. Don't use a wheel that is cracked
casionally be cleaned and relubricated.
or flawed.
6. Dip the work frequently so that it doesn't
lose its temper.
7. Give a wheel a chance to warm up: don't
start right in heavily grinding on a cold
w heel.
63
1:48 SHOP EQUIPMENT AND PRACTICES
PORTABLE GRINDERS
Hand held. electric and air grinders are also
available. They are made in sizes ranging
from small light-duty models with specially
shaped grinding bits to larger heavy duty ones
suitable for continuous grinding. Many port-
able grinders have accessories that can do
other jobs such as sanding, brushing, buffing.
filing. Portable grinders are used when the
work can't be brought to a bench grinder. or,
in the case of small specialty grinding jobs
when the bench grinding wheel is not the
right shape. Always use two hands on a port 01160
able grinder: never try to operate it with one 1/2" SINGLE SPEED
hand_
ELECTRIC DRILL
The same precautions that apply to bench (1-89) HAND DRILLS
grinders also apply to portable ones. In ad-
Courtesy of Mac Tools
dition. keep the electric cord or air hose free
of the grinding wheel.
Correct Use
HAND DRILLS 1. Select the ccrrect size hand drill for the
Electric and air (pneumatic) hand drills job.
(Figure 1-89) are available in 1/4", 3/8" and 2. Insert drill bits fully into the chuck and
1/2" chuck sizes. Larger sizes are made but tighten the chuck with a key.
they are not very common. Of the three drill
sizes. the quarter-inch drill has the fastest 3. Avoid excessive pressure when drilling. In
speed but the lowest torque. It is made for other words, keep twist drills sharp.
drilling holes in steel up to one-quarter inch in
diameter. Similarly. a 3/8 inch drill (medium 4. When drilling steel keep the twist drill and
speed. medium torque) is used for drilling work cool by using lubricating oil, The oil
holes up to 3/8 inch diameter. and a 1/2 inch will also aid the bit in cutting.
drill (low speed. high torque) for holes up to 5. Don't let hand drills overheat. Remember
1,2 inch. Within each electric drill chuck size. light duty drills are not intended for long
various strengths and qualities of motors are periods of continual use.
made, some for light occasional use and
others for heavy continual use. The motors 6. Air drills, like air impact wrenches, require
and switches on hand drills are either straight lubrication. See the drill maintenance in-
on-off or are variable speed (air drills are all structions or ask a journeyperson. Air
variable speed). Some drills have forward drills also have air strainers that oc-
drive only while others have reverse and for- casionally need cleaning.
ward.
7. When using an electric drill. or any elec-
tric hand tool. make sure it is properly
grounded.
8. If you have to use an electric drill a long
ways from the source of electricity, have
an extension cord of proper size to
prevent voltage drop.
64
SHOP EQUIPMENT AND PRACTICES 1:49
Correct Use
1. Keep the bedplate clean.
2. Use a piece of wood or steel under the
work you are drilling to protect the
bedplate.
3. Use the correct drill speed.
4. Keep drill bits sharp.
5. Clamp the work securely.
6. Don't force the drill.
7. Use ample lubrication for cooling and cut-
ting.
(1-90) DRILL. PRESS
Courtesy of Malkin and 8. Remove the chuck key after removing the
Pinion Industrial Supplies drill.
FEATURES
1. Hinged Steel belt and pulley cover.
2. Ring-lock depth stop for positive depth control.
3. Sall bearing quill.
4. Quill stroke. approximately 31/2".
5. 1/2" capacity 3 jaw key-type belt tension
device for quick speed changes.
7. Machined column.
8. Slotted cast iron worktable. machined surface.
(approximately 9'/2" square).
9. Table tilts 45 degrees right and left. Pointer
and degree scale.
10. Geared table raising-lowering mechanism with
positive lock.
11. Cast base with machined top and ..r slots.
65
1:50 SHOP EQUIPMENT AND PRACTICES
Correct Use
1. A press is used with parts having an in-
terference fit. Always keep in mind that
presses can apply a tremendous force.
Not paying attention when pressing could
cause injury to you or to someone working
nearby and in addition break the parts
2. Press on the correct spot. e.g.. to remove
(1-91) STANDING HYDRAut.le PRESS a bearing on a shaft press on the
bearing's inner race.
Counesy of Owatonna Tool Company
3. Stand to one side white operating the
press.
4. Observe the amount of force being ap-
plied.
5. Wear a face mask in case something
should break.
6. Carefully support Ile part being disassem-
bled.
7. Know flow the pieces come apart before
attempting to apply force.
8. Make sure weight is off the cables and
support pins are fully installed.
66
SHOP EQUIPMENT AND PRACTICES 1151
R.
DOUBLE-
ACTING
-
(1-92)
PULLERS .1.41;k
67
1:52 SHOP EQUIPMENT AND PRACTICES
68
SHOP EQUIPMENT AND PRACTICES 1:53
-
4. What is the advantage of a drill press over
a power hand drill?
5. When using impact wrenches. care must
be taken not to nuts.
6. What should you know about parts before
pressing them apart?
7. What are the three essential parts of a
hydraulic puller assembly?
8. What is the difference between a 3/8" and
a 112" power hand drill?
9. True or False? To start a steam cleaner
first ignite the fuel. then turn on the water.
69
1:54 SHOP EQUIPMENT AND PRACTICES
MEASURING TOOLS
70
SHOP EQUIPMENT AND PRACTICES 1:55
4. Vernier .007
71.
1:56 SHOP EQUIPMENT AND PRACTICES
1 2
7 ci 2 3
3 4
4
illiti.«;10m;Iliri
Answers:
1. 1.025 3. 1.550
2. 2.759 4. 3.735
72
SHOP EQUIPMENT AND PRACTICES 1:57
DZI
BARREL RATCHET
STOP 01==
X 2311.7
FRAME 0:= t
(1-99) OUTSIDE MICROMETER
Courtesy ol John Deere Ltd
121==
X 2330 LARGE INSIDE DIAMETER MICROMETER
(1-101)
Courtesy of John Deere Ltd
M4ORL
73
1:58 SHOP EQUIPMENT AND PRACTICES
Inside and outside micrometers are read in 2. Number of marks beyond one
the same way. Refer to Figure 1-103. Note the tenth (three so 3 x .025 = .075) .075
gradations on the barrel and the thimble: each 3. Thimble reading (3) .003
mark on the datum line on the barrel
represents twenty-five thousandths (.025) of 4. Total .178
an inch, while each mark on the thimble
repreSents one thousandth (.001) of an inch.
On the datum line 4 marks make one-tenth (.1)
of an inch, since 4 x .025 = .1. Therefore, the
0. 1. 2. 3. etc., that you see on the datum line
represent tenths of an inch, e.g.. 3 is .3 of an
inch. The numbers on the thimble. 0, 5, 10,15,
20. represent thousandths of an inch, e.g., lY
is .017 of an inch.
The reading on Figure 1-103 is taken as
follows: (1-104)
1. Highest tenth visible on datum
line (2) .200
2. Number of marks beyond the 2
tenths (one so 1 x .025 = .025) .025
3. Thimble reacting (21. Note if
thimble mark doesn't line up
exactly with datum line read to
the nearest mark). .021
DATUM LINE
74
SHOP EQUIPMENT AND PRACTICES 1:59
'I 2
4
3
Answers:
1. .340 3. .132
2. .125 4. .158
75
1:60 SHOP EQUIPMENT AND PRACTICES
(1-105)
4. Total. .770
Answers:
1. .665 3. .968
2. .612 4. .952
76
SHOP EQUIPMENT AND PRACTICES 1:61
DATUM LINE
3. Do not slide a micrometer back and forth
excessively across the work because this
will wear away the contact surfaces and
make the micrometer inaccurate.
4. To get a more accurate reading, take the
x :::329 BARREL reading, if possible, before removing the
micrometer from the work. If this can't be
(1- 106)MICROMETER WITH VERNIER SCALE done, remove the micrometer very
Courtesy of John Deere Lid. carefully so as not to disturb the setting.
x f.,i,rs
(1-108)
(1-107) METRIC MICROMETER READING CHECKING MICROMETER WITH STANDARD
Courtesy of John Deere Ltd.
77
1:62 SHOP EQUIPMENT AND PRACTICES
78
SHOP EQUIPMENT AND PRACTICES 1:63
(a)
3.
1.13$ 1".01/
3 4310
1 IR ! 41;1
,er,
I 3 'As
, 103
Isi.tt7
1.43v44.1414 fat'
ifinS it wi
:i411$ I hinle
79
1:64 SHOP EQUIPMENT AND PRACTICES
(a) (b)
(c) (d)
(a) (b)
(c) (d)
SHOP EQUIPMENT AND PRACTICES 1:65
(a) (b)
w) (d)
(a) (b)
81
1:66 SHOP EQUIPMENT AND PRACTICES
(c) (d)
82
SHOP EQUIPMENT AND PRACTICES 1:67
X4633 ROOT
(1-113)
Courtesy of John Deere Ltd. BEEE\\\I
4. The size of a bolt is determined by the
diameter of the crest of the threads
(Figure 1-114). The lensoh of a common
bolt is determined by oftisuring from the
RULER ve
bottom of the head to the end of the (1-116) THREADS PER INCH
threads. Courtesy of John Deere Ltd.
COARSE FINE
(1-114) THREAD
(1-117.) THREAD
Courtesy of John Deere Ltd. Courtesy of John Deere Ltd.
83
1:68 SHOP EQUIPMENT AND PRACTICES
7. Bolts and screws normally have right- Note that in the past. NC standing for
hand threads: that is, they are turned to National Course, and NF for National Fint
the right or clockwise when threaded into were used to identify threads he modern
a nut or part (Figure 1-118). In a few ref : system of bolt ider lficatIon has been
cases, bolts. screws and nuts with left- used since 1948.
hand threads are needed. Turnbuckles
(Figure 1-119), for example, have one bolt 9. The Society of Automotive Engineers
with left-hand threads, and some wheel (SAE) has stablished certain standards
nuts have left-hand threads. for gradir bolts and screws based on
their maten., d treatment and on their
tensile strength or as it's sometimes
(CLOCKWE
IS
called, elastic limit. Tensile strength is the
ON)
amount of pull bolts can stand without
Coarse
Fit symbol (1, loose fit: 2, tighter lit: 3.
tightest tit)
r Thread
Length
nto
hread (A. external bolts: S. Internal nut)
I!
1/2-20 UN C - 2A x3
84
SHOP EQUIPMENT AND PRACTICES 1:69
Tensile
Strength
Grade Marking Specification Material
4in.. psi.
SAE-Grade 0 Steel
1.1
SAE -Grade 1 Low Carbon Steel 5:5.000
( )
'Small Size bolls. Larger bolts may have lower values. X4646
0-121) SAE GRADE MARKINGS AND STRENGTH SPECIFICATIONS
Courtesy of John Deere Lid
li
85
1:70 SHOP EQUIPMENT AND PRACTICES
HEX CHAMFER
SOCKET BOTH SIDES (1-126) HEX NUT
HEAD Courtesy of John Deere Ltd
114680
(1-124) Castle nuts and slotted nuts: the top part of a
Courtesy of John Deere Ltd castle nut is smaller in diameter than the body
of the r. . (It should be noted that castle nuts
are no longer recommended for new
machinery.) A slotted nut is simply a hex nut
with slots (Figure 1-127). Both nuts are mated
with bolts having a hole drilled through the
end. When the nut is tightened a cotter pin
(Figure 1-128) is inserted through the slots
USED IN A and hole to hold the nut firmly ln place.
RECESSED HO! E Steering parts are often secured with slotted
USED IN A nuts.
X4661 CONFINED AREA
NUTS
There are literally hundreds of nuts of all
shapes and sizes. The nuts discussed here Plol BEING
PIN BENT
are the ones you are most likely to encounter. INSERTED
TO S!CURE
Nuts have three important dimensions: (1)
thickness. (2) distance across flats. and (3) in- (1-126)
side diameter (ID). Note that the ID of a nut is X4691
the same as the OD of its mating bolt. A COTTER PIN SECURES A CASTLE
OR SLOTTED NUT
Courtesy of John Deere Ltd
88
SHOP EQUIPMENT AND PRACTICES 1:71
Self locking nuts: once tightened stay firmly vibration. Most chemical locks (Figure 1-120)
in place. There are many types of self locking are free-flowing plastic material. Wnen ap-
nuts, having many ingenious means of staying plied to threads. the chemical will fill the
tight The most common ones are called spaces between the threads and harden. i:or
prevailing torque nuts and plastic-insert nuts critical applications a primer caii be sprayed
(often referred to by their trade name Elastic on the threads to clean them and speed up the
nuts) drying time 'a the chemical lock. Chemical
locks are excellent for keeping nuts and bolts
A prevailing-torque nut has a means of grip- tight. and have the advantage that the bond
ping the mating threads. One popular can be broken. if necessary. to remove the
prevailing-torque nut (Figure 1-129) resembles nut.
a castle nut the top is split into sectors bent
inward. When the nut is threaded onto a bolt.
the sectors are forced outward and tightly grip
the bolt. Prevailing- torque nuts can be reused.
Plastic insert nuts (Figure 1-129) which are
actually a special type of prevailing-torque
nut. contain a relatively soft collar of un-
threaded material built into the head. This
collar may be a fibrous material or a plastic
such as nylon. When the nut is threaded onto
a bolt, threads are impressed into the collar.
Being elastic. the collar has a tendency to
return to its original shape when the nut is (1-130) SEALANTS AND PRIMERS FOR
removed. Although plastic insert nuts can be NUTS AND DOLTS
reused. it is usually recommended that they Gourley" of John Deere Ltd
be replaced.
Miscellaneous nuts: are illustrated in Figure
Interference nuts are similar to plastic insert 1-131.
nuts except that the top two threads are bent
in slightly in a few placeS giving an in.
terference that prevents the nut from coming
loose. Once removed these nuts are replaced
414. !.
...
NJ' ..' 87
..-
X4697
(1-134)
STUBBORN
HEAT IS OFTEN HELPFUL BUT USE IT WISELY
NUT
Courtesy of John Deere Ltd
In many cases, because of the high cost of
labor, stubborn nuts and bolts are cut off with
a cutting torch and the bolts and nuts are
replaced. If a torch isn't available stubborn
STRIKING WRENCH
nuts can be cracked off with a nut splitter
(Figure 1-135). If all else fails. use a sharp
chisel or hacksaw (Figure 1-136), but take
(1-132) USING A STRIKING WRENCH TO REMOVE care not to damage other parts.
A STUBBORN NUT
Courtesy of John Deere Ltd
Sometimes hard-to-remove nuts can be
loosened with penetrating oil (Figure 1-133) or
special liquids made for this purpose. Heat
can also be used, and is usually the quickest
(Figure 1-134). However. heat must be used
with caution in areas where it could damage
other parts.
FROZEN
THREADS X9690
(1-135) USING A NUT SPLITTER TO REMOVE
A STUBBORN NUT
PENETRATING Courtesy of John Deere LW
OIL
X968
(1-133) PENS' BATING OIL IS OFTEN HELPFUL
IN REMOVING NUTS
X4699
Courtesy of John Deem LW (1-136) USING A CHISEL OR HACKSAW ''0
REMOVE A NUT
.a1MILIammr 1 .4 -0J
IM'SM1i111=112,
88
_..... .....
RETHREADING
DIE
E E9:1
INTERNAL THREAD
13
CHASERS
LOCK
WASHER LOOSE TIGHT
(WASHER GRIPS)
(1.140)
HAND TAP Courtesy o$ John Deere Ltd
X11:2
'1-1381 OTHER THREAD-RESTORING TOOLS
Col.nesv of John Deere Lid
WASHERS
89
1:74 SHOP EQUIPMENT AND PRACTICES
CORRECT:
BEND PRONGS CORRECT:
BEND PRONGS
EXTERNAL TOOTHED
LOCK WASHER
_
(1-142)
X470$ CASTLE NUT SLOTTED NUT
HOW A TOOTHED LOCK WASHER GRIPS
Courtesy of John Deere Ltd. (1-144) X4709
90
SHOP EQUIPMENT AdO PRACTICES 1:75
?HARP BENDS
91
1:76 SHOP EQUIPMENT AND PRACTICES
SEMICIRCULAR
SLOT
KEY
INSTALLED
BETWEEN
MATING
PARTS
(1-149) A KEY AND THE KEYWAYS IN A
GEAR AND SHAFT
Courtesy M John Deere Lid X$201
92
SHOP EQUIPMENT AND PRACTICES 1:77
PIN
CENTER PUNCH
GROOVED
PINS XS2.11
k \
x6211 (1-154)
STAKING A PIN TO HOLD IT IN PLACE
Courtesy of John Deere Ltd
(1-152) SPRING LOCKING Taper pins: parts that must fit tightly are often
PIN fastened together with a taper pin (Figure 1-
SOME FREQUENTLY USED PINS 155). The taper on the pin helps to line up the
Courtesy of John Deere Ltd. holes in the parts being assembled. The pin is
driven into a specially reamed hole until it is
Clevis or Headed pins: the simplest pin is a fully seated. Taper pins are driven out with a
headed pin, often called a clevis pin because hammer and a punch held against the small
it is used to attach a part to a U-shaped yoke end of the pin (Figure 1-155).
known as a clevis (Figure 1.153). Headed pins .....--.1110--
are usually drilled on the end opposite the 1111%.........
TAPER PIN
CLEVIS PIN
X5212 (1.153)
A CLEVIS PIN USED TO ATTACH
A TURNBUCKLE XS215 (1 DRIVING OUT A TAPER PIN
-155)
Courtesy of John Deere Ltd. A T AVER PIN AND HOW IT IS REMOVED
Courtesy of John Deere Ltd
93
1:78 SHOP EQUIPMENT AND PRACTICES
L1 L
posed to. The dowel pins that lir.e up the TYPE 2 TYPE 3
TYPE 1
timing gear cover and gasket with the engine
cranke:ase are a good examplv) (Figure 1-156).
A dowel pin is d tiny bit larger in diameter
than the hole into which it is to go. and so it TYPE 4 TYPE 5
must be pressed or driven in. Once in place X5228
the press-fit assures that the pin will not come (1-157) TYPES OF GROOVED PINS
out. The outer end of a dowel pin projects
Courtesy of John Deere Lid.
above the surface of the part .ito which it is
pressed and males with other holes in the ad- Convenience Pins
joining parts. Dowel pins are usually per-
manent and need not be replaced unless they Several types of pins are made for quick and
are damaged. easy removal, e.g., spring locking pins and
quiklock pins.
Spring locking pins: often called a hairpin
cotter (Figure 1-158), is used when parts must
be separated for adjusting or for changing
replaceable parts. Usually a spring locking
pin is inserted into a hole drilled through a
clevis pin to hold the parts together.
DOWEL
PINS
X5276
(1.156) HOW DOWEL PINS LINE UP PARTS (1-158) TYPICAL SPRINCi LOCKING PINS
FOR EASY ASSEMBLY .Corptesy 0 John Deere Ltd.
Courtesy of John Deere Lid
Spring pins: often called roll pins, are hollow CluikLock pins: (Figure 1-159) are another
cylinders of spring steel (Figure 1-152). They handy convenience pin. A common use of
are split lengthwise and beveled at each end these pins is to fasten removeable at-
for easy starting. They are used in areas tachments to a machine such as three-point
where loads are not too great. Spring pins ure hitch parts to a loader-backhoe.
made slightly oversize so that when they are
driven or pressed into place. they are com- Ouik-lock pins have a split steel ring. The
ends of the ring fit into two holes drilled in dif-
pressed it is this tension that holds the parts
ferent planes in the pin head. Once the pin is
in place. To remove a spring pin. drive it out of
its hole with a punch lust a little smaller in in place, the steel ring is rotated down and
diameter than the hole. around the end of the clevis pin (Figure 1-
159). The difference in the two planes of the
Grooved pins: are solid, having slots or ring ends develops an over-center spring ac-
grooves cut along all or part of their length tion which holds the ring firmly around the
(Figure 1-157). Their holding power comes clevis pin holding the quik-lock pin in place.
from a tendency to expand when driven into Some quik-lock pins have a short chain which
place. Grooved pins come in standard types. can be fastened to a convenient nearby part
In the past the type designations were letters to keep the pin from getting lost.
A, B. C. etc. but now numbers are used: Type
1. Type 2. etc.
94
UM
BALL PEEN
HAMMER
SPECIAL
TOOL
(:::/ ti RIVET
TUBULAR. SPLIT AND COMPRESSION RIVETS
BLIND RIVETS
X5228
(1-160) RIVETS
Courtesy of John Deere Ltd
it
1
"95
..,,...
SHANK
RIVET
STEM FLARES TO
HOLD RIVET
Az.f..14
96
SHOP EQUIPMENT AND PRACTICES 1:81
97
1:82 SHOP EQUIPMENT AND PRACTICES
9 101
98
SHOP EQUIPMENT AND PRACTICES 1:83
1 2
COVER-.
COVER- RUBBER DR COTTON
-FULMER OR COTTON
SINGLE WIRE BRAID
FABRIC BRAID REINFORCEMENT
REINFORCEMENT
COTTON
INNER BRAID
SYNTHETIC RUBBER
INNER TUBE SYNTHETIC RUBBER
INNER TUBE
100
SHOP EQUIPMENT AND PRACTICES 1:86
Selecting Hose
The following chart will help you to select the proper hose for any pressure application. Find the size
of the hose you need and read across. to the system working pressure nearest your application. If
you find it In column 1. use a single wire braid hose, if in column 2, use a double wire braid hose; or
in column 3. a spiral wire hose.
--
Hose
Size in
Inches
,4,,
3/.0 0
ih
1 Use SINGLE WIRE BRAID
Hose II System Working
Pressure Equals ...
3000 psi
2250 psi
2000 psi
-
2. Use DOUBLE WIRE BRAID
Hose If System Working
Pressure Equals ...
5000 psi
4000 psi
3500 psi
3. Use SPIRAL WIRE Hose
If System Working
Pressure Equals .. -
A
5000 psi
4000 psi
1/2"
34"
1750 psi 2750 psi -.-
1500 psi 2250 psi 3000 psi
1" 800 psi 1875 psi 3000 psi
11/2" 600 psi 1625 psi 3000 psi
1 1/2" 500 psi 1250 psi 3000 psi
2" 350 psi 1125 psi 2500 psi
Note how larger hoses are recommended for lower pressures rather than Smaller
ones of the same construction.
101
1:86 SHOP EQUIPMENT AND PRACTICES
Hose Fittings
Fittings are couplers at the ends of hoses that
connect the hose to a component or to
another line. There are male and female fit-
tings. male fittings have a socket and a nipple
with a hex nut (Figure 1-167), while female Ft-
tings have a socket and a nipple with a swivel
nut (Figure 1-168). Female fittings are
sometimes called swivel ends. Hose fittings
have several methods of sealing the threaded
end (Figure 1-169).
$
?,
(1 -169)
FIVE MAJOR WAYS OF SEALING HOSE FITTINGS
Courtesy 0 John Deere Ltd
102
SHOP EQUIPMENT AND PRACTICES 1:87
NOTCH
SOCKET HEX NUT
A3407
PERMANENT REUSABLE NIPPLE MEDIUM PRESSURE FITTING HIGH PRESSURE FITTING
(1 -170) (1-172) HOSE FITTINGS
/1114111111A.
(1-171)
Courtesy of John Deem Lid
INSTALLING REUSABLE HOSE
FITTINGS 4 For tomato ends. tighten Leave ' in to ' i. on
nipple and Out on assembly clearance between nut and
tool d required Screw nip. socket
Pie Clockwise _socket
03
1:88 SHOP EQUIPMENT AND PRACTICES
104
SHOP EQUIPMENT AND PRACTICES 1:89
Pipe Fittings
Pipe is normally connected by taper threading
its outside diameter with a die and then
screwing it into a taped hole. Sealing com-
(1-173) TUBING pound is applied when the pipe and taped
Courtesy 01 John Deere Ltd hole do not have dryseal or precision cut
threads.
Besides sealing compounds. pipe threads and
connections can also be sealed by using fit-
tings with pipe lock nuts. These fittings have a
free nut with a Teflon seal ring. When
positioned and tightened. the nut forms the
seal and lock the fitting in position. Pipe fit-
tings are available in many differnt styles.
(1.173) PIPE both male and female. They are constructed
Courtesy of John Deere Ltd of three types of material:
105
1:90 SHOP EQUIPMENT AND PRACTICES
. ,
_
I
11 1 I
1/8
Length
1-1/2
, _. 1 8 18
_ _ ___
_
14 I4 I/4 I;4 1.1/2
38 38 3:8 3/8 1 1 /2
1 2 1 2 1 2 1/2 1.1/2
1 /8 2
- 1,'4
(*)
2
_- ._
i. i ---2--
--
__2.1/2
--- _
1
110 1
___
1,1
1/8
- - --__ _ _
2
2.1/2
-
,
_
4
. -
3/8 2.1/2
11-104 Union 1.109 Plug II. t 10 Bushing 1/2 2.1/2
_
1 4 1 4 3 8x1 4 3
38 38 3 8)08
_ __._ _ _
1/2 3
_.
3 03 '8
3. 4x 1 '2
3/8
____
1 /2
---.
3.1/2_--
3.1 12
, 1 [ . AL ,o,,;,, ,1 ,1,11, It
o
1
1 .124
43°
,,,,.. ",s 1.112 1.116 1.121
1.122 Hex Nipple Elbow - Close Nipple Street Elbow Square Need Plug
_
_ --.
Pipe Thread
_ Pipe Thread Pipe Thread Pups Thread
...--..
Pipe Thread
1 8x1 8
1;4 al /4
1/8
1/4
__ 1/8 _..._ _
1/4
-'Y" 1.8
1r 4
__ --..--1/8
1/4
-- -
3'8x3 8 3r9 3.8 318
i2
---1 '2
1 /2 1 '2
106
SHOP EQUIPMENT AND PRACTICES 1:91
107
1:92 SHOP EQUIPMENT AND PRACTICES
INVERTED
FLARED TUBE
FITTINGS
ASSEMBLY OF B-24 CONNECTOR CUT-AWAY OF 8.24 CONNECTOR
COMPLETE WITH B21 NUT COMPLETE WITH B21 NUT
,-
mo
M1,,,,,
11
., aztit WI 'qlfl ,
1.'4 1.'4
_.---.___
1/8 1/4 1/4 1,8 1/4 1/8
---___
1 2
___ .
5,'16
_
3,6
_.
1;4
_._____
1/4
__ 5/16
3/8
1/4
1/4
I 2 3;8
108
SHOP EQUIPMENT AND PRACTICES 1:93
SAE tube fittings (Figure 1-176): are the most SAE flaiod tube fittings are manufactured to
common fittings found on heavy duty equip- the exact specifications of the Society of
ment, They are used not only to connect Automotive Engineers. In making a con-
tubing but also as adapters for replaceable nection with these fittings, first place the nut
hose fittings. For example. the Bob male con- over the tubing end with the large threaded
nector is the adapter fitting used with a hole towards the tube end. then flare the end
female swivel fitting on a hose end. Figure 1- of the tubing. The fitting has a tapered seal
177 illustrates places where adapters (i.e.. and the tubing is held between the tapered in-
SAE flared tube fittings) are used. When or- side of the nut and the beveled face 'A the fit-
dering SAE flared tube fittings, as with in- ting. This makes a very tight seal and secure
verted fittings. the tube size is given first. then joint that will withstand great pressure.
the pipe size.
.11.01.111111-
'4111Lauglemm *Aar'
ASSEMBLY OF B-42 UNION CUT-AWAY ASSEMBLY OF
WITH B-41 NUTS B-48 CONNECTOR WITH B-41 NUT
.1- '
am.
, I
- ____.
._
1-41 Nut
Um Site
iiiT_ _ _ .
1/4
5.16
_
3-4 IS
Short Nut
Tube S3I0
3116
1
$'16
4
_
_ _ _ --
8.42 Union
Tube Site
3/16
I '4
5/16
_.
1.44 Too
Tuba Site
.-._ _ -
__
_-
3/16
14
5/16
_ _
_-
Tube She
3/16
1 :4
14
11.4$
Male Connector
.
SeieeT:Iseed
18
18
1 4
3' 16
14
i4
B-49
Melo Elbow
5/8
......._______,. _ _
S'8 .518
... ___ . _ _ _. __
5/8 _ _ 3/8
__.. _ . _
1 4 38 1 4
---3/8 3/8 38 38
i /2-
1 .1
----i/8
._---- -
1/2
---1 /2
1/2
- 38
12
(1. 176)
./8 1 1/2 5/1-1--- 1 2
3/4 1/2 3/4-- 12
109
1:84 SHOP EQUIPMENT AND PRACTICES
CONNECT LINES
REDUCER (1.177)
BULKHEAD COUPLER
FOUR USES OF HOSE FITTINGS counesy of John Deere lid
Compression fittings: the advantage of com- seat. To assemble these fittings insert the
pression fittings is that a flaring tool is not copper tubing through the nut into the body of
needed to install them. There are two common the fitting as ,ar as the shoulder of the body
types of compression fittings used in the permits. Tighten the nut to the body and the
mechanical trades. double compression fit- assembly is complete The sleeve end of the
tings and solderless compression fittings. nut is wedged by the tapered seat of the body
and bites into the copper tubing to form a
Double compression fittings (Figure 1-178). liquid tight seal. Since it is crimped to the
consist of a nut with an integral sleeve and a tube. the fitting also provides a swivel for
body internally threaded with a machined removing the tube.
DOUBLE
COMPRESSION
1/2 3/8
110
SHOP EQUIPM ENT AND PRACTICES 1:95
1.10 Sleeve B..' Nut 1.62 %den 1.64 Tee 11-11 Elbow
Tube Sue Tube S.te Tube Site Tube She Tube Site
Iii Mole
Connector 1.19 Male Elbow
18 1 13 18 18
3 16 1 8 316 18
14 1 8 14 18
14 1 4 14 14
5 16 18 $16 18
5 16 1 4 5 16 14
38 1 38 i4
38 1 8 38 18
38 3B 38 38
7 16 1 4 12 3.1
12 38 1 1/2
12 12 S8 1/2
/2-
58 3 '4 1,2
34 2
111
111F,
kinked. or wrinkled bends (Figure 1- (1-180) GOOD AND BAD BENDS IN TUBING
180). The bends shouid be accurate
Courtesy of John Deere i.td
and smooth so that they do not
restrict flow. As a general rule. the
radius of the bend should be three to
live times the diameter of the tubing. Installing Tube Fittings
but follow the manufacturer's recom-
mendations.
1. The most important rule for tightening
tube fittings is: tighten only until snug. Do
(b) Avoid routes that interfere with the not over tighten. More damage has been
operator. moving parts. access doors done to tube fittings by over tightening
or controls. Keep the lines from than by any other cause.
protruding if possible.
2. Where necessary. use two wrenches on
(c) Avoid straight-line hookups where the fittings to avoid twisting the lines.
possible (Figure 1-181). They rnake
the line difficult to remove and do not 3. If a fitting starts to leak and appears
allow for enough expansion and con- loose. retighten it only until the leak stops.
traction.
(d) Support long tubing runs with
brackets or clamps. Group lines and
clamp them together for a neater ap-
pearance.
(e) Do not route tubes through
bulkheads or walls if you can avoid it.
However. if it can't be avoided. use
bulkhead connectors.
WRONG WRONG
112
SHOP EQUIPMENT AND PRACTICES 1:97
113
1:98 SHOP EQUIPMENT AND PRACTICES
(1-183)
GANTRY A-FRAME CRANE
4r* JIMI.all.
...----111111)..11Lr.....-
114
SHOP EQUIPMENT AND PRACTICES 1:99
C 47
(1-184) HAND HOISTS (1-185) COME ALONGS
Courtesy of Clark Equipment Co. Courtesy of Clark Equipment Co.
Fork Lifts
HYDRAULIC HOISTS AND JACKS
Forklifts (Figure 1-186) have become common
pieces of lift equipment around mechanical Hydraulic hoists lift from above, while
shops mainly because of their mobility and hydraulic jacks push from below. Both have
versatility. Originally intended for moving single acting hydraulic cylinders, and have
loads on pallets from one spot to another, pumps and reservoirs integral to their
forklifts can also do various hoisting jobs in a assemblies A typical mobile floor hoist is
shop. They are, however, limited in reach and shown in Figure 1-187. The lifting reach can
height. Forklifts are available in lifting be changed by extending the boom in or out.
capacity from 2 to 20 tons and more. However, keep in mind that as the boom ex-
tends, the lifting capacity decreases. Note
that the lifting capacities of these types of
mobile hoists are rated wain the lift arm fully
retracted.
(1-1P6)
(1-187) HYDRAULIC FLOOR HOIST
Counesy of Clark Equipment Co Courtesy of Owatonna Tool Company
115
1:100 SHOP EQUIPMENT AND PRACTICES
-z_z--.-
16
TRUCK JACK
TRANSMISSION JACK
.116
SHOP EQUIPMENT AND PRACTICES 1:101
Inspecting Chains
Inspect regularly used chains at least once a
month. Each link of the chain must be
checked. Chain inspecting procedures are:
1. Wash the chain in solvent.
2. Place the chain on a flat surface or
suspend it.
3. Check for elongated or stretched links.
Two signs of this are links that stick
together. or a chain that won't hang
straight. Stretched links are caused by
overloading.
4. Check for worn, twisted. bent links. Also
look for large nicks. cuts. gouges that
could make the chain unsafe. Tables are
available that show the allowable amount
of wear or depth of cuts for chains.
5. Closely .heck for cracks in the links. If
cracks me found. the chain is unsafe to
use. *rid should be discarded.
117
1:102 SHOP EQUIPMENT AND PRACTICES
Standard
Rope Loop Sizes Minimum
Diameter Inches Sling
H Inches
A B
Length
T %
5/16
2
2 Y2
4
S
1'6"
2'
i_ 3 6 2'
7116 3 6 2'6"
1/2 4 8 2'6"
9/16 4 8 3'
5 10 3' (1-191) CHOKER SLING
6
3,6,,
SLING SL % 12 Courtesy of MartonBlack
LEN 3TH % 7 14 4' Wore Ropes Ltd.
1 8 16 4'6"
1% 9 18 5'
1% 10 20 5'6"
1% 11 22 6'
1 1/2 12 24 7'
134 13 26 8'
1% 14 28 8'
17/it 15 30 9'
2 16 32 9'
118
SHOP EQUIPMENT AND PRACTICES 1:103
-1Bh-
A
LENGTH
LENGTH OF
OF SLING
(SL)
SLING
(SL)
2-PART
3-PART
LENGTH
OF
SLING
(SL)
4-PART
Courtesy 01 Marton-Black Were Ropes Ltd
(1 -192) BRIDLE SLINGS
119
1:104 SHOP EQUIPMENT AND PRACTICES
Lifting capacity is an Important consideration 2. Check for kinks and twists Badly kinked
with slings. it depends on wire rope diameter. or twisted ropes should be discarded
sling configurations and lifting angle. Figure
1-193 shows the lifting capacities of single 3. Check the eye for signs of failure at the
slings making both a vertical lift and a basket outer end and at the crimped loin.
hitch lift. Note the greater lifting capacity of
the two part basket hitch. The lilting capacity
of bridle slings depends on the Idling angle of Care and Use Of Wire Rope Slings
the line parts For example. on a half inch. 1. Hang up the slings when not using them.
three part bridle sling. if the lifting angles are
30 degrees from the vertical. the sling's lifting 2 Use shackles to connect sling eyes to lift-
capacity is 9730 pounds. but if the angles are ing eyes.
increased to 60 degrees the lifting capacity is
reduced to 5600 pounds. In other words, the 3 Protect the rope with blocking or pads
greater the lifting angle of the line parts of a when it passes around sharp corners.
bridle sling the less its lifting capacity.
% 1,840 920
% 4,040 2,020
% 7,470 3740
34 11,210 5,600
34 16,160 8,080
% 21,790 10,900
1 28,360 14,180
1% 33,320 16,660
1% 41,480 20740
134 50,680 25,340
1% 61,240 30,620
BASKET HITCH VERTICAL LIFT 134 71,800 35,900
1% 82,330 41,170
1% 96,640 48,320
(1-193) 2 105,520 52,760
CointesY of Marlin-Black Wire Ropes Ltd 4. Don't pull slings from under loads be-
cause this causes unnecessary wear on
Inspecting Wire Rope Slings the rope and can kink it.
Wire rope slings. like chains. should be in- 5. Don't drop loads on slings or run over
spected on a regular basis. although. because them with heavy equipment as crushing
of their construction. they don't require as limits the service life of slings.
careful examination as chains To inspect
wire rope slings. 6. Whenever possible keep the sling lifting
angle from the vertical to 45 degrees or
1 Look for broken outer wires and signs of less. Figure 1.194 shows the effects of
stretching. sling angle on sling load. Note that once
the angle reaches 60 degrees. double the
amount of strain is put on the sling com-
pared to lilting vertically.
120
SHOP EQUIPMENT AND PRACTICES 1:105
RIGGING HARDWARE
HOOKS
Common types of hooks are slip hooks. safety
hooks. grab hooks. and choker hooks An eye
slip hook and a clevis slip hook are shown in
Figure 1-195. Safety slip hooks in solid or
swivel forms are also available (Figure 1-196).
Figure 1.197 shows an eye grab hook and a
clevis grab hook A sliding choker hook is
shown in Figure 1-198).
Slip hooks and grab hooks are generally used
with chains. although sometimes slip hooks
SAFETY HOOK SWIVEL SAFETY HOOK
are attached to the eye of a sling such as on
bridle slings The clevis type of slip or grab (1-196) SAFETY HOOKS
hook is handy as it can be put on or taken off Courtesy of Martin -Black Wore Ropes Ltd
to suit the lob Choker hooks are made to
slide on wire rope.
.
121
1:106 SHOP EQUIPMENT AND PRACTICES
SHACKLES
PACKINGS HOOK
Shackles are used to couple a chain or sling
to a lifting hook or to a load. Two common
types of shackles are bow-type and D-type
(Figure 1-200). The D-type is usually longer,
whereas the bow-type is wider and will fit a
larger lifting hook. Shackles are sized ac-
cording to the diameter of the body of the
shackle rather than pin diameter. Safe
working loads of shackles depend on their
size, e.g., a three-quarter inch diameter forged
alloy steel shackle has a safe working load of
four and three-quarter ions.
WRONG RIGHT
LOAD OFF CENTER LOAD CENTERED
(1-202)
LIFTING EYES.
Lifting eyes are used to lift odd shaped parts.
Components such as transmissions. cylinder
BOW-TYPE D-TYPE
heads and engine blocks often have con-
veniently taped holes for lifting eyes to be
(1-200) SHACKLES threaded into. Lifting eyes are available in a
counesy of Crosby-Laughlin
variety 01 thread sizes but generally only in
Inspection, Care and Use Of Shackles N.C. thread. They are made from forged alloy
steel and are most useful when equipped with
1. Figure 1-201 illustrates the critical in- shoulders or collars. Plain eye bolts (Figure 1-
spection spots on a shackle 203) are okay for vertical hits but when angle
2. Use only forg d alloy steel shackles loaded they are subject to bending and have a
reduced safe carrying toad. A pipe sleeve with
3. Don't use a bolt in place of a shackle pin a thick washer on the top (Figure 1-204) will
as it may be of a lower grade steel and will support a plain eye bolt when a shoulder eye
bend. bolt is not available
4. Discard spread, twisted or bent shackles.
5. Loads must ba centered on the shackle. If (1-203)
PLAiN EYE BOLT Courtesy of Owatonna
need be use washers or spacers to center
a load on the pm (Figure 1-202). II the load Tool Company
AC-754
is lifted off-center, the shackle has
reduced lifting capacity, and it will likely
be damaged. 1 8" THICK
FLAT WASHER
6 Fully install screw pins
7. Lock all round pin shackles with cotter
pins.
122
SHOP EQUIPMENT AND PRACTICES 1:107
Bolt-on lilting eyes made for lifting light loads SPREADER AND EQUALIZER BEAMS
are also available (Figure 1-205). They are
made of forged alloy steel and the link is per- Spreader beams (Figure 1-207) balance long
manently attached. The Mt must be made in loads during lifting. preventing them from tip-
line with the angle of the link ping. laming or sliding. Equalizer beams
(Figure 1-207) equalize the load over the
length of the object lifted.
Spreader and equalizer beams are often made
up in the shop. rather than gurchased. and are
used for jobs such as lifting heavy engines.
Shopmade beams should have the lifting
capacity marked on them. in addition to the
job the beam is intended for.
..- c;
11111111114111111111111111111111MIIIIM1111111111111111[1[111
ci
RIGHT WRONG
PULLING IN LINE AT RIGHT ANGLES (1-207)
(1-206)
123
1:108 SHOP EQUIPMENT AND PRACTICES
T10
A
lie
CY
BLOCKING UNDER
THE SCRAPER
DRAFT TUBE
.. Th1413
111111%;71(1;
(1-209) EQUIPMENT STANDS
Courtesy of Caterpillar Tractor Co
At,
When wood blocking is used. select firm
square blocks, and place them as shown in
Figure 1-210. This arrangement ci! blocks is
called bridging: it provides a wide, solid base
for the machine. In this example note also
how blocks have been placed at the front and
rear of the tires to prevent the machine from
rolling Other examples of blocking are shown
in Figure 1-211
19949
BLOCKING THE FRONT OF
THE TRACTOR
Counesy of Caterpillar Tractor Co
124
SHOP EQUIPMENT AND PRACTICES 1:109
LIFTING PROCEDURES AND PRECAUTIONS 2. If the center of gravity of the object being
lifted is not in line below the hook, the
Lifting procedures and equipment depend on load will shift. In Figure 1-213 the center
four factors:
of gravity of the transmission is not quite
the object to be lifted in line with the hook so a bolt has been in-
its weight stalled through the chain link just un-
derneath the hook. This bolt will prevent
the lifting and blocking material the transmission from shifting. Note the
available lifting eyes and the angle iron lifting
the decision to lift from above or jack bracket that have been installed for this
from below lift. Lifting brackets can be easily made in
a shop (Figure 1-214), or purchased from
Good Practices When Lifting manufacturers or tool companies (Figure
1.215).
1. Find the weight of the object to be lifted;
service manuals are the best source for
this information. The diesel engine shown
in Figure 1-212 could weigh, with all its
accessories, from 2000 to 4000 pounds.
Note the equalizer beam and lifting
brackets.
A
At-
V10005 1. w.
(1-212) LIFTING AN ENGINE
Courtesy of Cummins Engine Co.
"";
0;4 r. .1k9
.' .cgt
,:%440fr
(1-213)
REMOVING OR INSTALLING TRANSMISSION
411=.-- c
Courtesy of Ford Motor Company
125
1:110 SHOP EQUIPMENT AND PRACTICES
,'2
1 lirl
(1-215) LIFTING BRACKET
Courtesy of Owatonna Tool Co
7.
8.
9.
Never walk under a lifted object.
Lift an object only as high as necessary,
then lower it as soon as possible. Never
leave it suspended.
Always keep the load under control. If
necessary tie a tag line on the load to
prevent excessive swinging.
10. Keep your hands clear of sling pinch
points when the sling tightens for the lift.
11. Keep others away from a load that you
are lifting or lowering.
12. Never ride on a load while it is being
raised or lowered.
13. Raise and lower objects slowly.
14. In a situation where lifting brackets or
lifting eyes are not available and a chain
must be wrapped around a component to
lift it, be careful to place the chain so
(1-216) HYDRAULIC JACK that it does not slip and does not apply
Courtesy of Hem-Werner pressure to accessory parts.
3. Before using a hydraulic jack, be sure it
has the capacity to lift the load (Figure 1-
216).
4. When using a hydraulic jack make sure
the threaded jack extension is well within
its limit.
5. Use an equalizer bar to distribute the
load whenever possible (Figure 1-217).
INCORRECT
126
SHOP EQUIPMENT AND PRACTICES 1:111
127
fa)
The purpose of this section is to give the 13. Never roll cylinders or use them as
essential information needed for safe handl- rollers.
ing, set up. and operation of oxyacetylene 14. Keep oil and grease from the cylinder
welding. cutting, and healing equipment. valves.
CYLINDERS HANDLING, STORAGE 15. Store cylinders securely where they can-
AND SAFETY not fall or be struck by mechanical or
other objects. and where they cannot
1. The storage and handling of oxygen and contact salt or corrosive chemicals or
acetylene cylinders are governed by the fumes.
Fire Marshal's Regulations. These
regulations also specify the safety 16. Cylinders should be kept in an upright
precautions that must be taken when position when in use and in storage.
welding and cutting. Although general
precautions for the handling and storage 17. Cylinders should be used in the order
of cylinders vs given here, take the Fire that they are received from the supplier.
Marshal's Regulations as the authority. 18. Cylinders should not be placed in
2. Be sure the cylinders contain the proper locations where sparks or flame from
gas and are stored with like gas cylin- welding or cutting can contact them.
ders. Never mix unlike gas cylinders. 19. Extreme care must be taken to ensure
3. Protect the cylinders against the weather that the arc from an electric welder never
when stored outdoors, particularly touches a cylinder.
against ice, snow, and direct rays of the 20. Cylinders should never come into con-
sun. tact with bare electric wires.
4. Store empty cylinders separately from 21. To prevent serious explosions. oily and
lull cylinders, and mark the empty ones greasy substances must be kept from
so they can be recognized. oxygen cylinders. valves. hoses and ap-
Do not store cylinders close to hot sur- purtenances.
5.
faces such as radiators or stoves. 22. Do not attempt to repair cylinder valves.
6. Be sure cylinder storage rooms are well 23. Make sure the valve is tightly closed
ventilated. when handling the cylinder. Do not
7. Chain or fasten cylinders to a carrier. or remove the key from the valve while the
to a fixed object, when in use. cylinder is in use.
8. Protection caps should be in place on 24. Remove a leaking cylinder into the open
the top of the cylinders when they are in
air at a safe distance from any type of
flame.
storage and when they are being moved
to and from the shop or storage area. 25. Do not tamper with the fusible safely
plug on acetylene cylinders.
9. Always close the cylinder valves when
the equipment is not in use. 26. Keep the top of acetylene cylinders away
from tools and other objects.
128
SHOP EQUIPMENT AND PRACTICES 1:113
VALVE SEAT
INLET PRESSURE Af
FILTER ADJUSTING *...)
QUA ET 0- SCREW
DIAPHRAGM
k 129
1:114 SHOP EQUIPMENT AND PRACTICES
130
SHOP EQUIPMENT AND PRACTICES 1:115
SAFETY
CAP
RECESSED
TOP
VALVE
FUSIBLE PLUGS
POROUS FILLER
WELDED STEEL
SHELL
FINE ASBESTOS
FUSIBLE PLUGS
-____,
(1-221) ACETYLENE CYLINDER
131
1:116 SHOP EQUIPMENT AND PRACTICES
OXYGEN
tv HAND WHEEL
REGULATOR
o
---111:!......,
OXYGE
BRASS COPPER SECTION
TORCH
VALVE MIXING
HANDLE CHAI1/4"3ER
ACETYLENE
HOSE
.
W.44iM 7t7k9rAWA/4M f iriX/MgifiC fA //Wife//0.4
(1-222) OXYACETYLENE WELDING SET-UP
132
SHOP EQUIPMENT AND PRACTfCES 1:117
00 1164 1 1 7
0 1/32 1 1 8
1 1116 1 1 10
2 3/32 2 2 14
3 1/8 3 3 18
4 3/16 4 4 22
5 114 5 5 26
6 5/16 6 6 30
7 3/8 7 7 34
8 1/2 7 7 37
9 5/8 7% 7'et 42
10 3/4 & up 9 9 45
133
1
3 4
ATTACH HOSE TO REGULATORS BE SURE ALL RELEASE REGULATOR ADJUSTING SCREWS
CONNECTIONS ARE CLEAN AND GAS TIGHT. AND OPEN CYLINDER VALVES
TURN JUST ENOUGH GAS TO BLOW OUT HOSE. OPEN NEEDLE VALVES OF TORCH INSERT
OXYGEN HOSE IN TORCH HEAD AND TURN ON A
LITTLE OXYGEN TO BLOW OUT INTERIOR OF
TORCH.
(1-225)
135
1:120 SHOP EQUIPMENT AND PRACTICES
AI
8
7
INSERT TIP IN TORCH HEAD AND TIGHTEN WITH
CONNECT HOSE TO TORCH TAKE CARE TO AT- WRENCH. BE SURE THE TIP IS CLEAN. USE JUST
TACH OXYGEN HOSE TO OXYGEN INLET ON ENOUGH PRESSURE TO MAKE TIP GAS TIGHT.
TORCH MAKE CONNECTIONS CLEAN AND GAS CONSULT MANUFACTURER'S CHART WHEN
TIGHT. SELECTING TIPS.
9 10
OPEN ACETYLENE NEEDLE VALVE AND TURN OPEN NEEDLE VALVES OF TORCH AND TURN
REGULATOR ADJUSTING SCREW UNTIL OXYGEN REGULATOR ADJUSTING SCREW UN-
DESIRED ACETYLENE PRESSURE IS OBTAINED. TIL DESIRED WORKING PRESSURE IS IN-
DICATED THEN CLOSE OXYGEN NEEDLE VALVE.
11
12
IGNITE ACETYLENE WITH TORCH LIGHTER
AVOID USE OF MATCHES OR OPEN FLAME. OPEN OXYGEN NEEDLE VALVE AND ADJUST
FOR NEUTRAL
(1 -228)
136
SHOP EQUIPMENT AND PRACTICES 1:121
137
1:122 SHOP EQUIPMENT AND PRACTICES
Oxyacetylene Flames
Three types of flames (Figure 1-227) are
produced by adjusting the needle valves con-
trolling the amounts of acetylene and oxygen
being burned.
I Neutral Flame this is the ideal flame for
welding or cutting steel. The ratio of
acetylene and oxygen supplied to the
torch is approximately 1 : 1. Melted steel
flows easily and is clear and clean
Main Use Cutting
Fusion welding of
mild steel WHITE PALE BLUE
Copper LUMINOUS OUTER ENVELOPE
CONE
Cast Iron (1-227) NEUTRAL FLAME
Temperature 3260 C. approximately
2. Reducing Flame carburizing, car-
bonizing, excess acetylene.
More acetylene is supplied to the torch
than the 1 1 ratio, producing an inner
cone with a feather. The length of the
feather indicates the amount of acetylene
and is expressed in relation to the inner WHITE
cone. e.g.. "three times reducing" means INNER
that the white feather is three times the WHITE PALE BLUE
CONE
length of the inner cone. When steel is FEATHER OUTER ENVELOPE
melted the puddle is boiling and not clear.
(1-227) REDUCING FLAME
Main Use Aluminum welding.
aluminum brazing. fusion
welding of stainless steel.
silver brazing and hard
surfacing
Temperature 2980 C to 3200 C ap-
proximately
3. Oxidizing Flame excess oxygen
More oxygen is fed to the torch for this
type of flame than the 1 1 ratio of the
neutral flame, producing a shorter, more
bluish cone and somewhat shorter outer
envelope. Melting steel with this flame OUTER ENVELOPE
produces excessive foaming and sparking SHORTER. REDUCED IN SIZE
of the metal. BLUISH INNER CONE
138
SHOP EQUIPMENT AND PRACTICES 1:123
OXYGEN VALVE
VALVE LEVER OXYGEN
TORCH HEAD ASSEMBLY
LEVER PIN FITTING CONNECTION
90 HEAD NUT
TORCH HANDLE
\ . ...i.L JU G WLL4LJULi
,
t. .
f 1: 1. JUL :1..KilttIliltl
ormseemesemoctoonc,
! TIP NUT
If )-- OXYGEN
BODY PREHEAT VALVE
TIP NUT REAR END ----- HOSE
STEM ASSEMBLY FUEL GAS CONNECTION
I. 1 CUTTING TIP VALVE ASSEMBLY GLANDS
FUEL GAS
CONNECTION
(1-228) TORCH WITH CUTTING TIP ASSEMBLY NUT
Courtesy of Air Reduction Canada Limited
139
1:124 SHOP EQUIPMENT AND PRACTICES
CUTTING TORCH TIPS Hold the torch at a very flat angle about
1'4" to 2" away from the surface of the
Cutting tips are interchangeable end pieces metal (Figure 1-230).
for cutting torches that contain openings for
the preheating flame and for the cutting Complete the cut as quickly as
oxygen stream. Tips are supplied in a variety possible to avoid undue melting of the
of sizes and styles to meet different cutting metal.
requirements. Torch manufacturers supply
their own range of tips and charts that I
'Ir..... VA"
.4---- -
Al
CUT
Cutting Procedures
--1..
Factors affecting the quality of a cut:
Size of cutting tip (opening)
Oxygen cutting pressurc
Speed of travel
Material thickness
Type of material (1-231)
Surface condition ARCING TECHNIQUE FOR SHORT LENGTH CUTS
140
SHOP EQUIPMENT AND PRACTICES 1:125
Cutting Rounds
The technique for cutting rounds involves
holding the torch perpendicular to the work
for preheating and then following the outline
of the round (Figure 1-232). A method of star-
ting the cut is to raise a chip in the metal With
a chisel (or by welding on a drop of metal),
and to commence the cut on this raised por-
tion.
EID17Z3 (1-232)
141
1:126 SHOP EQUIPMENT AND PRACTICES
:A
142
.
wry
SHOP EQUIPMENT AND PRACTICES 1:127
AREA
SUSCEPTIBLE
REGULATORS
ITO BACKFIRES
I& SURNBACKS AREA SUSCEPTIBLE TO FLASHBACKS (Includes Regulators) .7
941)
I KIT NEEDLE VALVES
HOSE
TIP
MIXER HANDLE
(1-235) BACKFIRES AND FLASHBACKS
143
1:128 SHOP EQUIPMENT AND PRACTICES
444
SHOP EQUIPMENT AND PRACTICES 1:129
--
APPROXIMATELY 45'
i=
APPROXIMATELY 90
FILLER /
ROO
LEADING EDGE
PUDDLE DEPOSIT
'1505333:Vc
(1-238) DIRECTION OF TRAVEL
BACKHAND TECHNIQUE
145
1:130 SHOP EQUIPMENT AND PRACTICES
2. Lack of fusion:
(a)
(b)
insufficient heat.
Tip too small.
Wrong angle of torch.
=11
(c) Improper manipulation. (b)
(1-241)
146
SHOP EQUIPMENT AND PRACTICES 1:131
3. Poor appearance.
(a) Improper manipulation.
Uneven distance of flame.
Irregular torch and rod movement.
(b) Wrong flame setting
Result of oxidizing or reducing flame.
(c) Insufficient heat.
(d) Dirty surface (oil paint. etc.).
-\=
(a) Improper torch angle.
(b) Excessive heat and/or
insufficient filler material.
(c) Puddle too large
(does not solidify in time). TORCH POSITION
(d) Base metal too hot
(puddle does not solidify in time).
(e) Incorrect torch and rod manipulation.
147
1:132 SHOP EQUIPMENT AND PRACTICES
148
SHOP EQUIPMENT AND PRACTICES 1:133
149
1:134 SHOP EQUIPMENT AND PRACTICES
150
SHOP EQUIPMENT AND PRACTICES 1:135 1
When preparing a joint sharp corners and 2. Sear joint surfaces with strongly
edges should be avoided as they tend to oxidizing flame to remove carbon smear.
overheat and oxidize. Once oxidized they will Do not overheat the work so the ground
not tin properly and the joint will be weak. surfaces are discolored. Sand blasted
surfaces or chipped grooves, are best.
The use of fluted joints will further increase but grinding is more common.
tinning surface, but again avoid sharp edges
(Figure 1-244). 3. Align and tack the work securely.
SHOULDER CLEANED BEYOND 4. Support the work adequately to prevent
THE VEE sagging. Intricate castings should be
totally preheated to a grey color. Even
simple shapes should receive a local
slow even preheat right across the entire
joint area.
5. Slightly carburize the flame (11% times)
to neutral. Hold it back from the work.
and keep it moving to promote even
SINGLE VEE ROOT ROUNDED AND
PREPARATION CLEANED BACK
heating. Bring the joint temperature at
starting point to a red dull.
6. Put a drop of braze (with flux) on the
work and watch the reaction.
(a) If the drop of bronze flows quickly.
evenly, and smoothly, with little or
FLUTED JOINT SURFACES no fuming. the temperature of the
work is approximately right.
(b) If the work is too cold. the bronze
drop sits like a ball. and refuses to
flow. Add further heat around the
drop of bronze till it spreads and
flows evenly. Do not add heat on the
(1-244) JOINT PREPARATION bronze drop as it will burn quickly.
giving off a puff of white zinc-oxide
Braze Welding Cast Iron fumes. which normally would mean
1. Properly prepare the joint. The use of too much heat. In this case.
(r :cers is recommended to help in however. its the bronze drop that is
aligning the parts of odd shaped pieces. too hot. and the work is still too
Since cast iron does not take a per- cold. When good smooth even flow
manent bend belore it breaks. the pieces is established. the tinning tem-
may be fitted back together on the perature has been reached.
breaks and proper alignment is assured
(Figure 1-245). Tracers should be small (c) If the work is too hot when the
enough to tin through. bul not small bronze is added. a puff of white
enough to oxidize or burn. fumes appears. often accompanied
TRACERS ON BOTH by blue flame in the puddle. The
PIECES FITTED bronze flows very quickly and
TOCF YHER
unevenly, leaving islands of oxides
that refuse to tin. The oxides appear
as white spots under the flame. Sub-
SHOULDERS sequent passes of d metal will
CLEANED cover these spots biAt they still are
BACK not tinned and they seriously
weaken the joint. Where
overheating occurs, reclean the sur-
faces. removing the oxides.
ENDS CLEANED
151
1:136 SHOP EQUIPMENT AND PRACTICES
152
SHOP EQUIPMENT AND PRACTICES 1:137
(d) left-hand threads on both lines only 11 True or False? Torches can be safely
hose color is used for identification relit from hot metal.
4 The regulator is a device connected to 12 Before installing regulators on cylinders,
the cylinder that high a good practice is to:
pressure in the cylinder and maintains a oil the threads
(a)
pressure
(b) crack the cylinder valves to blow
5 Pressure in a lull oxygen cylinder is 2200 out dirt
psi at 21 C As the temperature in-
creases (c) Both of (a) and (b) are recom-
mended
(a) the weight and pressure increases
13. Once gauges are installed. open the
(b) the weight stays the same and the cylinder valves first the
pressure increases acetylene. normally turn. then
(c) the weight increases but the oxygen
pressure decreases 14. Briefly explain how to check for leaks
(d) no change takes place in either the once the torch is set up.
weight or pressure
15 For fusion welding. what type of flame is
recommended?
(a) neutral flame
(b) oxidizing flame
(c) reducing flame
(d) fusion flame
153
1:138 SHOP EQUIPMENT AND PRACTICES
154
SHOP EQUIPMENT AND PRACTICES 1:139
. 155
1:140 SHOP EQUIPMENT AND PRACTICES
156
SHOP EQUIPMENT AND PRACTICES 1:141
3. 1. anvil
2. frame
3. spindle
4. lock
5. ratchet
6. thimble
7. barrel
4. (b) between three and four inches
5. (c) 3.187
6. (a) 3.812
7. (a) .812 (b) .770 (c) .665
(d) .875
157
1:142 SHOP EQUIPMENT AND PRACTICES
ANSWERS FASTENERS
1, (a) slash marks
2. The distance from under the head to the
end of the threadeo part.
3. (c) diameter of the bolt or screw
4. (b) number of threads per inch
5. (c) the grade
6. Three slashes indicates grade t..
7. (c) the number of threads per inch
8. (c) nuts
9. (c) screws
10. (d) a cotter pin
11. False
12. (c) across the flats on the head
hex head bolt 3
plow bolt 9
hex socket head 5
12-point head bolt 2
hex nut 6
castle nut 8
lock washer 10
lock nut 4
flat washer 1
slotted nut 7
158
SHOP EQUIPMENT AND PRACTICES 1:143
159
1:144 SHOP EQUIPMENT AND PRACTICES
160
SHOP EQUIPMENT AND PRACTICES 1:145
28. True
7. Upright.
8. (b) weight
29. ... thickness ...
9. An explosion.
10. (d) tip cleaners or tip drills
11. False
12. (b) crack the cylinder valves to blow
out dirt.
13. ... slowly.... half a turn ... all the way.
14. Turn on the cylinder valves. set the
working pressures. turn the cylinder
valves off. If there's a pressure drop on
the high pressure gauge. there's a leak.
15. (a) neutral flame
16. acetylene
17. squealing or hissing noise from inside
the blowpipe
sparks coming out of the nozzle
heavy black Smoke coming out of the
nozzle
18. close the blowpipe oxygen valve
close the blowpipe acetylene valve
close the oxygen regulator
close the acetylene regulator
19. ... melted ...
20. ... melt ....
21. faulty seat conditions between tip and
mixer
too little gas flow
tip too hot from being too close to the
work
dirty tip
161
1:146 SHOP EQUIPMENT AND PRACTICES
TASKS SHOP EQUIPMENT 13. Using a small hammer. snips. and hole
AND PRACTICES punches. make:
3. Clamp in a vise a piece of mild steel. e.g.. Using the indicated precision measuring in-
x 2", and cut a 3" piece with a strument, take the following measurements:
hacksaw. 1. With an outside micrometer. measure the
4. Clamp the 3" piece of steel with the cut throw on a crankshaft for taper and out
end up. and square the end with a file. of round to within .001" (.025 mm) of
manufacturer's specifications.
5. Select the correct size drill bit for %" NF
thread, and using a drill press, drill a 2. Using an inside micrometer. measure the
hole through the flat of the metal. bores on an engine for taper and out of
round to within .001" (.025 mm) of
6. Using a taper and then a plug tap, thread manuisc:turer's specifications.
the hole to V:" NF.
3. With a depth micrometer. measure the
7. Using a vise and hacksaw, cut a piece of counter bore depth on an engine block
1/4" round stock 6" long. to within .001" (.025 mm) of manufac-
turer's specifications.
8. Clamp the 6'' piece of round stock ver-
tically in a vise. taper its end with a file, HOSES, TUBES, PIPES,
and thread it with a '4" NF die for 2". FITTINGS AND ADAPTERS
When complete, the rod should thread in
the tapped hole (made in Task 6) with Hose and Fittings
ease.
1. Matching the correct size and type of
9. Locate a broken stud which has broken hose with replaceable fittings, make up a
at or below the surface. Using the low, a medium. and a high pressure hose.
correct drill and stud-removing equip- using the correct procedures and hose
ment, remove it without damaging the make-up tool kit or hand tools.
threads of the tapped hole.
Tubing and Fittings
10. Locate a worn hole in a casting
(preferably aluminum) and using a thread 1 Using a tubing cutter. cut a 10" piece of
restorer kit install a thread restorer 'he 5/16" copper tubing from a roll Ream
same size as the original. the ends in preparation for flaring.
11. Clean and flux two pieces of 20 gauge 2. Using a flaring tool kit. flare one end of
metal, then with a torch and solder make the tube with a single I:are. Then put two
a lapped joint. 5/16" SAE flare tube nuts onto the tube
from the end not yet flared. Make sure
i2. With a soldering iron and rosin core the nuts face the right way. Now double
solder. clean and solder two pieces of 12 flare the other end of the tube. The flares
gauge wire to form a good connection. must be straight and square with the
tubing. and be large enough to support
the fittings yet not so large that they in-
terfere with the nut or won't fit inside the
nut.
3. When the flaring is complete bend the
tubing.
162
SHOP EQUIPMENT AND PRACTICES 1:147
163
ellmMt,
BLOCK
Moving and
Stopping Equipment
164
STARTING, MOVING AND STOPPING EQUIPMENT 2:1
Starting. moving and stopping equipment is There are also some good publications such
part of a heavy duty mechanic's job. The as the Construction Industry Manufacturer's
mechanic must know: Association (CIMA) Mantwts that deal with
general procedures and safe practices to
1. What to check prior to starting a machine follow when moving or working on heavy
(pre-start checks). equipment. Some examples of CIMA Manuals
2. How to start a machine under varying are.
climatic conditions. Motor Grader Safe 'anual for Operating
3. How tc safely move a machine. and Maintenance Personnel
4 How to shut down a machine for both Crawler Tractor/Loader Safety Manual for
overnight and extended periods. Operating and Maintenance Personnel
(Figure 2-1)
One of the best sources of information on the
operation of equipment is manufacturer's Hydraulic Excavator Users Salety Manual
Operating Manuals. Some manufacturers
have information for the operator and the
maintenance man in one manual. where as
others supply two manuals: an Operator's
Manual and a Lubrication and Maintenance
Manual.
CRAWLER TRACTOR/LOADER
Safety Manual
FOR OPERATING AND MAINTENANCE PERSONNEL
(2-1)
c011 1 le,'Sy (A C 01151 rtti:Ito m industry
Adlailli IA, WHIM ASSW;I:111, fil $(,IMA I
165
2:2 STARTING, MOVING AND STOPPING EQUIPMENT
Obviously it is not possible to be familiar with Fasten the safety bar on machines with
the operation of all heavy duty machines. articulated steering.
However. you should acquire and read
Operator's manuals for each piece of equip- Stop the wheels from rolling by putting
ment that you service in your shop. Find out blocks against the tires (if applicable).
all you can about the machines you work on;
the knowledge will make your job easier, and
will make you a better mechanic. This is the SAFETY ALERT
Initial experience moving a machine should SYMBOL You will see it
used throughout service and
be done under the guidance of a qualified per-
operator's manuals
son.
PRE-START CHECKS
A pre-start check is a systematic series c!
checks on engine di iven equipment prior to
starting. The checks are intended to see that To do a Pre-Start Inspection. also called a
the machine is in good. safe running con- Daily Walk Around Inspection. refer to the
dition before it goes out to do its day's work manual for the machine you are working on
Besides protecting people from injury and the Although pre-start checks vary from machine
machine from negligent damage, pre-start to machine. there are checks common to most
checks are part of a good maintenance machines. These include:
program. Any minor problems on the machine
will be noticed and can be repaired before 1. Record the service hours or miles.
they become major ones. 2. Locate. check and top up. if necessary. all
Generally. pre-start checks are the respon- fluid levels including coolant. fuel. battery
sibility of the operator. However. the policy of electrolyte. tube oil. Keep records of fluid
some companies is to have mechanics do pre- additions.
start checks to prepare the machine for its 3. It is best to fill the fuel tank at the end of a
daily shift. In any case. you should be aware
shirt to reduce condensation. Drain a
of pre-start procedures since they are'part of
small amount of fuel from the tank at the
machine maintenance. In addition. you will start of a shift to remove any water and
have to move machines. and even though you
wouldn't do as thorough a pre-start check to
sediment. Also check the water trap.
move a machine as you would to prepare one 4. Check the condition and tension of drive
for a shift. you will still make some of the belts.
checks
5. Drain air reservoirs (if so equipped).
Before beginning pre-start checks put the although this is also best done at the end
machine in the service position: of a shift.
Put all the attachments on the ground 6. Do a walk around inspection to review the
and put an hydraulic controls in machine's general condition (Figure 2-2).
neutral
visually inspect the undercarriage,
Apply the parking brake and the trans- frame and suspension for loose bolts
mission neutral safety lock. and missing parts.
Turn the ignition key to the off position. check to see that mountings of hang-
(and pull the engine stop handle if the on components are tight.
machine is equipped with one).
check for fluid leaks: lube oil. hydraulic
Remove the ignition key from the oil. coolant, fuel.
ignition switch and open the master
switch -- examine pipes and hoses for damage
or leaks and gasket joints for leaks.
Fasten a red warning flag to the canopy
upright or attach a DO NOT START check tire pressure and wheel studs.
TAG to the steering wheel
166
STARTING, MOVING AND STOPPING EQUIPMENT 2:3
Or ;A1
or
(2-2)
,
0
..-
.....
Courtesy of Construction Industry
Manufacturers Association (LIMA)
Some companies will make up Pre-start Check Lists for their own machines. An example is shown
below
Date
--
Model Hour Meter
11
Drain air tanks
visually ...
.....
....
OK
OK Replace
--
---
_
12 Check for loose nuts and bolts .. . OK Loose
167
2:4 STARTING, MOVING AND STOPPING EQUIPMENT
Z:701!
HYDRAULIC SYSTEM C Mil COOLING SYSTEM
Inspect leaks, worn Inspect for teaks, worn
hoses or damaged lines. riff uses and trash build-up.
%"---"'."-.1 . Observe coolant level.
COVERS AND GUARDS - U 4
r.
J.
M..
OPERATOR'S COMPARTMENT
Inspect for loose items and
cleanliness.
BUCKET
Inspect for wear
or damage. BUCKET TEETH
Inspect for worn,
damaged, or missing
teeth.
168
STARTING, MOVING AND STOPPING EQUIPMENT 2:5
ITEM SERVICE
EVERY 10 SERVICE HOURS OR DAILY
C) Radiator Observe coolant level
® Air Cleaner Precleaner Inspectclean
C) Engine Crankcase Inspect oil level
® Fuel Tank Drain moisture and sediment
® Warning Systems Test
OFF-HIGHWAY TRUCK
(Wabco)
.t
[Ji
BODY
FENDERS
NOT SHOWN
169
2:6 STARTING, MOVING AND STOPPING EQUIPMENT
8. Mr Starter Lubricators Fill to oil level. Stopping a diesel engine can be more dif-
Type Oil SAE-WW. ficult. A diesel fires its fuel by the heat of com-
pression (see Block 7. Engines). Once the
9. Turbo-Chargers Check for leaks. engine is cranked and fuel is supplied to the
vibration or unusual noise combustion chamber (assuming temperature
10 Crankcase Check oil level Capacity conditions are right). the engine will start. The
with fillers 40 gal : without filters 37 gal. only way the engine can be stopped is (1) by
shutting off the fuel (2) by cutting off the air or
11. Fuel Filter Drain condensation from (3) by de-compressing the cylinders (on some
filter engines).
12 Fuel Strainer Drain condensation The speed of a diesel engine is controlled
from filter. strictly by the amount of fuel delivered to it.
All diesel engines have a governor that sen-
$3. Air Reservoirs Drain condensation ses engine RPM's and controls. through
from all reservoirs. linkages. the amount of fuel delivered to the
14 Air Cleaner Check service indicators cylinders. thus preventing the engine from
on dash panel. Service filters if indicator over speeding. The governor limits the
shows red when engine is shut down. maximum RPM's to an amount safe for the
engine. The throttle position controls the
RPM's within the governor setting.
STARTING AND MOVING EQUIPMENT
For normal engine shut down. either the throt-
Once pre-start checks have been made. the tle is moved to the No-Fuel position or the fuel
engine can be started. The points below are is shut off by an electric solenoid control
common to starting and stopping all heavy valve. In either case there should be no
duty vehicles and are discussed in order in problem in stopping the engine. However.
the rest of th's block. should a fuel system malfunction during start
Emergency shut down procedures. up or while the engine is running. excessive
fuel feeding could cause an uncontrolled
Starting procedures to include the safe speed increase in the engine. Such an RPM
use of cold starting devices. increase can happen in seconds, and if
emergency procedures are not taken im-
After start checks. checking
e.g.. mediately. the engine will over speed to
gauge readings and warning devices destruction. If the malfunction is in the gave:
and testing brakes. nor. it may not be possible to cut off the fuel
Safely moving the machine and safely supply. The other alternatives left are to cut
operating the working attachments. off the air supply or to decompress the cylin-
ders.
Stopping and Safe parking.
Some engines, for example Detroit Diesel.
Procedures for extended shut-down or have an emergency shut down device that
storage. cuts ol the air supply to the engine. A flapper
valve ;Figure 2-5) is located in the air inlet of
Safe practices when working on or the engine and is operated by a cable at-
around machines with articulated tached to the control panel. Pulling the con-
steering
trol reeeases a catch. allowing spring pressure
to close the flap and shut off the air supply. If
EMERGENCY SHUT DOWN PROCEDURES
the engine has reached a runaway speed. the
Before you start a machine. know how to stop flap may not stop the engine but will slow it to
it. A gasoline engine can be stopped by sim- a point where you can safely get near and
ply turning off the ignition switch. Since the disconnect the fuel line. Note that the flapper
engine is fired by spar ignition and the valve is to be used for emergencies only and
ignition switch controls current flow that not for normal shut down: regular use of it can
creates the spark. turning the switch off slops damage seals within the scavenge blower.
the engine
170
STARTING, MOVING AND STOPPING EQUIPMENT 2:7
171
2:8 STARTING, MOVING AND STOPPING EQUIPMENT
(50 F.). compression may not be able to 3. Applying an ether starting kit (Figure 2-7).
bring the cool air to a high enough tem- The kit has mounted on the control panel
perature to ignite the fuel. a hand operated pump that injects ether
vapor directly into the intake manifold.
2 The diesel fuel itself is less volatile in cold The ether capsule in the kit is good for
weather and therefore harder to start several starts and then must be replaced.
Two common types of starting aides are used
with diesel engines:
1. Ether
2 Pre-Healer or Glow Plugs
ETHER
CAUTION, ETHER CAN BE DANGEROUS
Never handle ether near an open flame
Do not breathe the fumes
Do not use excessive amounts of ether.
Too much ether will cause unusually high
pressures and detonation which can
severely damage engine parts. Use ether
sparingly.
Ether must never be used when the electric
Glow Plug 's on (Manifold Type).
Ether is used as a starting aid because it is Air Box Fiteng 4 Piercing Tool
very volatile and readily combustible. It is 2 Capsule 5 Cap
taken into the combustion chambers with the 3 Tubing 6 Pump
air. Three methods of using ether are.
(2-7) ETHER-STARTING KIT
1. Pouring a small amount of liquid ether on
Courtesy of Detroit Diesel. General Motors Corporation
a rag and holding it near the air cleaner
inlet while the engine is turned over (takes PRE-HEATER AND GLOW PLUGS
two persons).
A pre-heater in the intake manifold (used in
2. Spraying a small amount of ether into the relation with a pump and atomized fuel) or
air cleaner intake while turning the key to glow plugs in precombustion chambers heat
the start position (Figure 2.6). the air that is taken into the combustion
chambers to aid in starting.
CAUTION: Never use ether with a pre-heater
or glow plugs because severe in-
jury can result from the ether ex-
172
STARTING, MOVING AND STOPPING EQUIPMENT 2:9
173
2:10 STARTING, MOVING AND STOPPING EQUIPMENT
Whenever the emergency stop control has starting fluid is used with the
been used. it is necessary to manually reset glow plug hot. Do not use
the emergency stop cable latcharm (Figure starting fluid in any form with
2.9) at the engine air intake a preheater.
SHUTTING DOWN THE ENGINE
For the same reasons mentioned with a
Detroit Diesel. idle a Cummins Diesel for three
EMERGENCY STOP to five minutes before shutting it down. The
CABLE pre-shut down idle is especially important
LATCH with turbo-charged engines. The turbo-
charger contains bearings and seals that are
subject to the high heat of combustion
exhaust gases. While the engine is running
this heat is carried away by oil circulation but
if the engine is stopped suddenly. the turbo-
charger temperature may rise as much as
LEVER ARM 47 C (100'F). The results of this temperature
increase in the turbo-charger may be seized
TSI0177 bearings or loose oil seals.
411IMI
t2 -91 RESETTING THE LATCH HANDLE Note on idling an engine: As was just stated.
Counesy of Clark Equipment Co idling an engine for up to five minutes prior to
shut down is a good practice. However, long
CUMMINS DIESEL periods of idling are not good for an engine
because temperatures in the combustion
NORMAL STARTING chamber drop so low that the fuel may not
burn completely. Carbon from the unburnt fuel
Cummins normal start procedures are the will clog the infector spray holes and the
same as those listed for a Detroit Diesel.
piston rings. and may cause the valves to
COLD WEATHER STARTING
stick. Also. if the engine coolant temperature
becomes too low. raw fuel will wash
Cummins Diesels are not equipped with cold lubricating oil from the cylinder walls and
weather starting aides. The following cold dilute the crankcase oil Diluted crankcase oil
starting aide procedures are recommended. means that other moving parts of the engine
will suffer from poor lubrication. II the engine
I Pour three tablespoonfuls of ether on a is not being used. shut it down.
Cloth. One man holds the cloth close to
the air cleaner intake while a second man To shut down a Cummins Diesel that has an
cranks the engine. electric shut down valve. turn the switch key
to the off position. The key controls the elec-
2. Or spray a small amount of ether into the tric shut down valve and will stop the engine
air cleaner intake while cranking the unless the override button on the valve has
engine An alternative cold starting aide is been locked in the open position. In this case
a preheater. available as optional equip- to stop the engine the override button will
ment for a Cummins engine This equip- have to be manually turned clockwise. The
ment consists of a single glob. lug moun- engine can always be stopped. under normal
ted in the intake manifold, and a hand conditions. by turning this button.
priming pump to force atomized fuel into
the manilold. Depressing a glow plug CAUTION. Never leave the switch key or the
switch heats the glow plug igniting the override button in the valve open
fuel that has been pumped into the position when the engine is not
manifold thereby heating the intake air en- running. if this is done. fuel from
tering the combustion chamber. See the overhead tanks will drain into the
service manual for directions on how to cylinders causing hydraulic lock.
use the preheater. To stop a Cummins engine without an electric
CAUTION Since primary ignition takes shut down valve. turn the manual shut down
place within the manifold. valve knob.
serious damage may result if
174
STARTING, MOVING AND STOPPING EQUIPMENT 2:11
.,
6 Depress accelerator just past 7 Turn HEAT-START switch to
detent. START Release switch when
engine starts.
41111111160MIX.
I Place speed a direction con-
trol in NEUTRAL
&
6. Depress accelerator lust past 7 Turn switch to START. Re-
detent and turn switch to HEAT lease switch when engine starts.
for indicated time. It may be necessary to return
.4 Switch to HEAT until engine
runs smoothly
Starting Aid Chad
lk
The "Heat" mentioned is provided by glow
plugs. The Cummins Diesel just discussed
had a single glow plug in the intake manifold.
This plug ignites atomized fuel pumped in by
hand, and the burning fuel heats the air that
goes to the combustion chambers. A Cater-
pillar Diesel has a glow plug for each cylin-
der. The plugs are located in precombustion
chambers and heat the air prior to it going to
the combustion chamber.
U111111111104 .
175
2:12 STARTING, MOVING AND STOPPING EQUIPMENT
-
past detent. HEAT for indicated time.
O
4. Turn disconnect switch OFF
and remove key.
(2-12)
A
Counesy of Catatonia' TraCtor Co.
_ -1
A ,
9. Push in and turn switch to 10. When engine starts. it may
START. and spray starting fluid be necessary to return switch AFTER START CHECKS
sparingly into precleaner while to HEAT until engine runs
cranking. smoothly. After starting the engine. some routine checks
should be made. Warm-up chetics are virtually
WARNING
use starting fluid sparingly. F4liow manufacturer's instructions carefully. the same for all engines, no matter what the
make. Below are two examples of warm -up
Never switch to HEAT when engine Is warm and running.
checks taken from Operator's Manuals.
(2-11)
Counesy of Caterpillar Tractor Co Example 1:
WARM-UP CHECKS
(Clark Equipment Company)
STOPPING THE ENGINE
Hold the engine at idle speed for ap-
proximately two minutes after starting-, then,
while the engine continues to warm-up for the
next few minutes. perform the following
checks (refer to the section. Under 250 Hours
Operations. for warm-up procedures):
1. Engine Oil Pressure Gauge 10 to 25
psi at engine idle. If less than 10 psi is
registered after 15 seconds of running.
AVvIr 1 ill shut down the engine and refer to your
t. Before stopping the engine, 2. Reduce engine speed to low engine Service Manual to correct
operate at reduced load for 5 idle for 30 seconds.
minutes and stop loader. 2. Ammeter high rate of charge to the
battery at engine start: charging rate will
decline as the charge is restored in the
batteries.
176
STARTING, MOVING AND STOPPING EQUIPMENT 2:13
3 Mr Cleaner Indicator Check that the charger reduces oil available for bearings.
red flag indicator is not at its top position. Watch engine oil temperature or pressure
or a new filter or cleaning of this filter is gauge for a warming trend before increasing
required. Refer to the section. Under 500 engine idle RPM.
Hour Operations. for cleaning in- After a couple of minutes of idling at 600 RPM,
structions.
increase engine speed to 900 or 1000 RPM
4 Converter and Transmission Oil Tem- and continue warm-up. This procedure allows
perature Gauge 130 to 200 F is the oil to warm up and flow freely while
operating temperature. pistons, liners. shafts. and bearings expand
slowly and evenly. Idling the engine too slowly
5. Engine Water Temperature Gauge- does not allow sufficient splash lubrication of
170 to 185 F is operating temperature. cylinder walls and may result in excessive
6. Converter and Transmission Fluid wearing of pistons and liners. Idling too fast
Level checked at operating tem- during warm-up will cause too rapid and
perature as per instructions in the section. uneven expansion and also excessive wear.
Under 8 Hour Operations. Continue the warm-up until temperature
reaches at least 130 °F. (54"C), when part
Visually check for leaks at the drain and fill throttle operation is permissible. Do not
plugs in the axle assemblies. torque converter operate at full throttle until temperature is at
and transmission. and at all hose couplings least 160 'F. (71'C).
and fittings in the hydraulic. luel. air intake,
brake and cooling systems. Correct all MOVING VEHICLES
leaking conditions. and repair or replace the
gauges that are not functioning bele e con- Before attempting to operate any machine,
tinuing the operatic I of the machine. read the operator's manual and become
familiar with the purpose and use of all
Example 2: operating ontrols. Ask an experienced per-
son to show iou how to move the machine.
BEFORE DRIVING VEHICLE Then ask him to observe while you put the
(Kenworth Truck Company) machine through a trial run of its operations.
ENGINE WARM -UP When operating or moving heavy equipment.
After engine start:. let it idle while you check you shout(' be guided by some fundamental
oil pressure. air pressure and generator cwt. rules of safety that will protect you, your
put. The engine should be brought up fellow workers. and (he machine. The
following d - 'ngs taken from C.I.M.A. (Con-
operating temperature gradually while o.i
struction Industry Manufacturers Association)
films are re- established between pistons and
liners. ehafts and bearings. Safety Manuals. illustrate safe and unsafe
operating rules for heavy equipment.
In colder areas, where temperature is often
below 32°F (0°C). the warm-up period for Before mounting the machine walk cr.lm-
plelely around it making sure that there is no
turbo-charged engines is especially im-
one nearby (Figure 2-13).
portant. The chilled external oil lines leading
to the turbo-charger will tend to slow oil flow
until the oil warms up Slow oil flow to turbo- Courtesy of Consiruction Industry
Manufacturers Association (CNA)
-,..-1..
177
0.
Mount the machine carefully. Always use the Know that the area is safe for vehicle
steps and grab rails provided (Figure 2-14). Do operation. If it is necessary to start an engine
not grasp the steering wheel or other controls- within an enclosed area. provide adequate
Don't get on the machine or operate it with ventilation. Remember, exhaust fumes can kill
wet or greasy hands or with muddy shoes (Figure 2-16).
(Figure 2-15). Never try to mount a machine in
motion. If someone else has been operating
the machine, check the seat adjustment.
Stay seated while operating a vehicle. If the
machine has a roll-over structure. you should
use a seat belt (if equipped). Also. make sure
the seat is adiusted correctly.
(2-16)
Courtesy of Construction Industry
Manufacturers Association (CIMA)
(2-17)
Counesy 01 Construction Incwstry
manuitiolurors Association (CimA)
401 %simile
(2-15)
Courtesy of Construction Incttbstry
Manufacturers Association (CIMA I
17&
STARTING, MOVING AND STOPPING EQUIPMENT 2:15
During warm-up check all gauges carefully. Test the engine speed control (Figure 2-20).
Don't operate a vehicle if gauges aren't
working (Figure 2-18).
i,
(2-18) (2-20)
Courtesy of Conetr-ction tqductry
Manufacturers Association (CIMA)
Courtesy 01 Construction Industry
Manufacturers Association (CIMA)
1.
(2-21)
179
. ..
2:16 START'i'G, MOVING AND STOPPING EQUIPMENT
(2-25)
WRONG
(2-26)
Besides obstructing the vision, carrying tne
load high also makes the machine top-heavy
(Figure 2-27).
(2-23)
(2-24)
- (2-27)
Courtesy of Construction Industry
Manufacturers Association (COM)
1.80
STARTING, MOVING AND STOPPING EQUIPMENT 2:17
When operating a machine that has limited V it is necessary to move equipment through
vision sound the horn before making any areas where other machines are working. be
moves It is also a bystander's responsibility to courteous Give loaded equipment the right of
an operator to stay clear of a moving machine Way (Figure 2-30).
(Figure 2.28)
(2-30)
(2-31)
181
2:18 STARTING, MOVING AND STOPPING EQUIPMENT
(2-32)
(2-34)
182
STARTING, MOVING AND STOPPING EQUIPMENT 2:19
-"14111111111111r
Machines with articulated steering present a there while the machine was turning. he
particular safety problem When the machine would be crushed. Most articulated machines
hinges or articulates to turn. the two frame will have an Area Warning Decal. like the one
sections of the machine come close together below. on each side of the front frame. Be ab-
in the pivot area on the side nearest the direc- solutely sure when the engine is running or
tion of turn There is no clearance for a person when you're moving an articulated machine
in this pivot area If someone happened to be that no one is in the pivot area.
WARNING
NO ROOM FOR A MAN IN THIS AREA
WHEN MACHINE IS TURNED.
DO NOT STAND OR WORK IN THIS
AREA WHEN ENGINE IS RUNNING.
USE SAFETY LINKS WHEN SERVICING
MACHINE.
183
2:20 STARTING, MOVING AND STOPPING EQUIPMENT
All articulated machines are equipped with a To lock the two frames in a full turn position
safety bar which will lock the two sections of some machines use the bar (Figure 2-38).
the machine in a straight ahead position or in whereas others just insert the pin between the
a lull turn position. Never make any checks or two frames (Figure 2-39).
do any service on an articulated machine
without first installing this safety bar Before
locking a safety bar. shut off the engine,
relieve the hydraulic pressure. and attach a .-: -- r-
00 NOT OPERATE TAG on the steering
wheel. The safety bar is stored alongside the
frame (Figure 2-36). 40
., F ..{ 4. ...,
AA&
....--
(2 -38) FRAME LOCKING BAR IN
ARTICULATED POSITION
Courtesy of Fiat -Albs Construction
Equipment Inc.
-_F o
(2-39) PIN ONLY IN FULL TURN
LOCK POSITION
Courtesy of internalsonal Harvester
184
STARTING, MOVING AND STOPPING EQUIPMENT 2:21
most common causes of injury to those 4 Unexpected violent shocks or pars to the
working on or arouad heavy equipment. machines
1 Repairing and servicing equipment in 5 Uncontrolled traffic involving other
dangerous positions vehicles.
2 Sink png other persons or vehicles with the 6 Hazards from limbs of trees or overhead
machine obstructions
3 Unexpected violent tipping of the equip- 7 Leaving earth-moving or other equipment
ment in dangerous positions unattended.
WOW SAFELY
---'021VE
1
SAFE Y
2:22 STARTING, MOVING AND STOPPING EQUIPMENT
186
STARTING, MOVING AND STOPPING EQUIPMENT 2:23
GENERAL PROCEDURES
I Lubrication Completely lubricate the
i nit according to instructions.
2 Batt' ries Install batteries being sure
they have a rull r:harge and the wale
level IS J/8" if) 1/z" above plates.
3 Tires infiato tires up to the proper
level
4 Air Tanks Check drain cocks to en-
sure that they are closer'
5 Fuel, Hydraulic and Steering Cylin.".er
Tanks - Drain sumps. fill tanks to
proper level. remove breather covers and
install air breathers Be sure breathers
are cleaned before installation
187
2:24 STARTING, MOVING AND STOPPING EQUIPMENT
6 Referring to the walk around inspection 19. When using ether as a cold starting aid.
diagram for the Caterpillar excavator. use it ____ to avoid
what should the track be checked for? damaging internal engine parts.
7 Referring to the pre-start checks for the 20. Why is it a good practice to idle an
Haul-Pack off-highway truck. what type engine three to five minutes before
of brake fluid is used at above 0 F tem- shutting it down?
peratures to top up the brake reservoirs/ 21. If the emergency stop is used on a
8 What is the most important thing to know Detroit diesel. what must be done before
before starting an engine? restarting the engine?
(a) how many speeds the transmission 22 Why are long periods of idling not
has recommended for diesel engines'
OA of all the lights are working properly 23 How should an engine be brought up to
operating temperature?
(c) where the starter switch is located
(dl how to stop the engine 24 Should the electric solonoid fuel shut-off
on a Cummins engine fail. how can the
9 List the three wuys diesel engines can be engine be started or stopped/
stopped
25 The glow plugs discussed for Caterpillar
10 True or False') The main purpose of an engines are located in
engine governor is to prevent the engine
from overspeeding. (a) the intake manifold
(b) the intake ports
11 If vie emergency stop is used regularly
to slop a Detroit diesel engine. what (ci combustion chamber
damage is likely to occur? (d) pre-combustion chamber
188
STARTING, MOVING AND STOPPING EQUIPMENT 2:25
189
2:26 STARTING, MOVING AND STOPPING EQUIPMENT
ANSWERS - STARTING, MOVING AND 22. When idling for long periods of time the
STOPPING EQUIPMENT temperature of the combustion chamber
drops so tow that fuel does not burn com-
1. ... manufacturer's operating rianuals. pletely causing carbon build-up.
2 A pre-start chec:. is a systematic series clogging of injector spray holes.
of checks on engine driven equipment clogging of rings and even sticking of
prior to starting, the valves.
3. To ensure that the machine is in good, 23. By gradually increasing the idling speed.
safe running condition before beginning
its shift. 24. By pushing the manual override button
on the solonoid.
4. (e) all of the above
25. (d) pre-combustion chamber.
5. (b) condensation in the tank is :educed
26. Walk completely around the machine to
6. Broken or missing shoes and bolts. ensure that all persons are clear.
7. SAE J1703 27. Use one or more signal men to guide the
operator.
8. (d) how to stop the engine
28. - park on the flattest ground possible
9. 1. shut off the fuel
- lower all attachments
2. cut off the air
- set parking brakes
3. de-compress the cylinders
- shut engine down and neutralize all
10. True. hydraulic controls
11. Using the emergency stop on a regular 29. To keep the frames parallel when ship-
basis will damage the scavenge blower ping the machine.
seals.
30. To protect the machine so that there is
12. True. minimum cost and time delay when it
returns to work.
13. Remove the air intake and have a piece
of smooth plywood ready to cover the 31. Remove all vents and breathers and plug
inlet. the openings with pipe plugs. If this is
not possible. seal the vents and
14. 1 The engine overheating breathers with waterproof tape.
2. Low oil pressure
3. The engine over-speeding
15. 1. Ignition of the fuel is accomplished
by heat of compression. Cold air
when compressed may not reach a
high enough temperature to ignite
the fuel.
2. Diesel fuel is less volatile in cold
weather.
16. ether and pre-heaters or glow
plugs.
17 False
18 (b) 30 seconds
19 . sparingly .
120
STARTING, MOVING AND STOPPING EQUIPMENT 2:27
191
BLOCK
3
Principles and Theory
of Hydraulics
192
PRINCIPLES AND THEORY OF HYDRAULICS 3:1
193
3:2 PRINCIPLES AND THEORY OF HYDRAULICS
The reasons for the popularity of hydraulic 1. Liquids have no shape of their own; a
systems can be seen by looking at their ad- liquid takes the shape of its container
vantages: (Figure 3-2).
1. Hydraulic systems are simple in con-
struction. A few basic hydraulic com-
ponents will replace complicated
mechanical linkages. With less moving
2.
3.
parts. there are fewer points of wear.
Since hydraulic systems are controlled by
relief of safety valves, vital parts of the
system are protected from damage.
Hydraulically operated parts move very
smoothly.
X 1071
se
(3-2) Liquids Have No Shape of Their Own.
4. Hydraulic systems give a wide range of
Courtesy of John Deere Ltd
speed and force.
5. Hydraulic force is multi-directional; it can
push, pull or rotate. Having the property of shapelessness, oil
in a hydraulic system will flow in any
Of course. no system is without some disad- direction and into a passage of any size or
vantages: shape.
1. Hydraulic systems are subject to leaking. 2. Liquids will not compress. For example, if
When a hydraulic system is working. it is the cork of a tightly sealed jar was pushed
submitted to high pressures. shock down, the liquid in the jar would not com-
loading and heat, and leaks can occur. press. The jar would shatter first. For ob-
2. Heat from friction in a hydraulic system vious safety reasons. Ws not recom-
causes some loss of efficiency. mended you try this experiment (Figure 3-
3).
3. Hydraulic systems have to be kept clean.
They must be protected against rust,
corrosion. dirt. and oil contamination. any
of which can ruin their precision parts.
directions. X 1072 4 4
Liquids provide great increases in work (3-3) Liquids Will Not Compress
force. Courtesy of John Deere Ltd
Liquid displaced is equal to liquid gained.
NOTE: to be totally accurate it should be
pointed out that liquids will com-
press slightly under pressure (1/2
to 1% at 1000 lbs. per sq. in.). In
the present discussion. however,
fluids will be considered in-
compressible.
194
PRINCIPLES AND THEORY OF HYDRAULICS 3:3
3. Liquids transmit applied pressure in all The first cylinder has a surface area of
directions. The experiment in (2) shattered one square inch and the second has a sur-
the glass jar and also showed how liquids face area of ten square inches- A force of
transmit pressure in all directions when 1 pound is put on the piston in the smaller
they are put under compression. Here is cylinder. Once again the one pound per
another experiment: square inch pressure is spread throughout
the oil. Since the larger cylinder haS, 10
Take two cylinders of the same size (one square inches at its surface. each one of
square inch) and connect them by a tube those 10 square inches exerts a force of 1
(Figure 3-4). Fill the cylinders with oil to pound. Together they exert a force of 10
the level shown Place in each cylinder a pounds. the force needed to balance a 10
piston which rests on the columns of oil. pound weight. In this way the fluid has
Now press down on one cylinder with a greatly increased the work force: an input
force of one pound. This pressure is force of 1 pound has given an Output force
created throughout the system, and an of 10 pounds.
equal force of one pound is applied to the
other piston. balancing the 1 ib. weight A work force increase made hyOraulically.
put on the second cylinder. as in the above example. is similar to a
work force increase that can be achieved
by mechanical leverage. In the following
diagram the 1 pound force acting at 10"
from the fulcrum will balanCe a 10 pound
force acting at 1 inch from the fulcrum.
- (3.4)
T
1.,
195
3:4 PRINCIPLES AND THEORY OF HYDRAULICS
1
(b) When the cylinders are of unequal PRESSURE, FORCE AND AREA
size. the smaller piston will move far-
ther than the larger one. In the exam- The words pressure. force and area were used
ple below the 1" diameter piston above when describin3 the experiments that
moves 10 inches while the 10" demonstrated the basic principles of
diameter piston moves 1 inch. The hydraulics. Given here is 4 definition of these
fluid lost from the first cylinder, hydraulic words and a formula that shows the
though. is equal to the fluid gained relationship between the two.
141- '''41
14-- 10"-01
by the second (Figure 3-8). Force
Area
a push or a pull measured in
units of weight (lbs.).
the surface space on which a
I force is applied. Measured in sq.
ins.
1"
Pressure a force applied to a certain area.
I
the force is measured in lbs..
T and the area it is applied to in
square inches. Pressure is
measured in pounds per square
10" inch (F.S.I.); r.e., if 30 lbs. of
pressure were applied to 10
square inches, the pressure
would be 30 ÷ 10 = 3 lbs. per
square inch.
The following relationships exist between
pressure force and area.
Pressure = Force ; P=F
i
.i,rea A
(3.8)
Force = Pressure x Area; F = PxA
Note the factor of piston speed here.
Since the fluid is displaced by one cylin- Area = Force ; A=F
der and gained by the other at the same Pressure P
time, the smaller piston travels 10" in the
same time it takes the larger piston to An easy way to remember these formulas is by
travel 1". The smaller piston therefore using the following triangle.
travels much faster (10 times fastee).
In points 4 and 5 above. fluid was confined be-
tween two interconnecting cylinders. In point
4 force was transmitted by the fluid; in point 5
motion was transmitted. Now combine the two
points and you have force and motion applied
to one cylinder (:vaster cylinder) transmitting To understand how it works, look at the
a force and motion to the other cylinder triangle as you read the formulas:
(working cylinder). The amount of force and
motion transmitted to the working cylinder F = PxA P =F A=F
depends on the relative sizes of the two cylin- K -1:7
196
PRINCIPLES AND THEORY OF HYDRAULICS 3:5
(3.9)
J.97
3:6 PRINCIPLES AND THEORY OF HYDRAULICS
= 100 P.S.I.
F=PxA
. WO x 2
P=F = 200 lbs.
A
= 100 (3-12/
5
= 200 PS.I. 100 lbs. 400 lbs.
(3-10)
i 4
sq. in.1 4 sq. ins.
2 Conversely. if the size of the cylinder in- L--I1
I100 P.S.I.
100 lbs. 100 lbs.
T 100 P.S.I. lir 50 P.S.I.
P=F
(3-11) A
= 100
2
= 50 P.S.I.
198
-211114:4 iiiMMINIXIIMEMIPM1574:3,is__01
PRINCIPLES AND THEORY OF HYDRAULICS 3:7
t
_
199
3:8 PRINCIPLES AND THEORY OF HYDRAULICS
. ... ............................
RELIEF
VALVE
PUMP
CONTROL
VALVE
CYLINDER
200
PRINCIPLES AND THEORY OF HYDRAULICS 39
tTHIS OIL
\t
RETURNS
TO RESERVOIR
O
PRESSURE /ar
OIL RAISES
VALV! IS PISTON AND
SHIFTED. LOAD
DIRECTING
OIL AS SHOWN
(3-16)
Courtesy of John Qeere Lid.
Extend
Rkago
I DOUBLE - ACTING
CAPACITY OF RESERVOIRS
A reservoir should be compact. yet large OIL
enough to: LEVEL
GA('GE BAFFLE INTAKE DRAIN
1. Hold all the oil that can drain back into FILTER
the reservoir by gravity flow. :::. (3-18) Reservoir SCREEN
2. Maintain the oil level above the suction Courtesy of John Deere Ltd.
line opening.
3. Dissipate excess heat during normal 4. Outlet and Return Lines are designed
operation. (See also "Oil Coolers". which to enter the reservoir at points where air
follows.) and turbulence are least. They can enter
4. Allow air and foreign matter to separate the reservoir at the top or sides, but their
from the oil. ends should be near the bottom of the
tank. If the return is above the oil level. the
return oil can foam and draw in air.
FEATURES OF RESERVOIRS NOTE: Be careful when placing extra
To serve its purpose. the reservoir (Figure 3- returns from auxiliary equipment
18) must have several features. in the reservoir. if not placed
correctly, they can cause foaming
1. Filler Cap should be air tight when of return oil.
closed. but may contain an air vent which
5. Intake Filter is usually a screen used in
filters air entering the reservoir to provide
a gravity push for proper oil flow. The air series with the system oil filter which may
vent filter must be kept clean to prevent also be installed in the reservoir.
partial vacuums which restrict gravity flow 6. Drain Plug allows all oil to be drained
from the reservoir. from the reservoir. Some drain plugs are
NOTE: Ideally, a system may be designed magnetic to help remove metal chips and
with a sealed reservoir and no air burrs from the oil.
vent. However. since most systems The location of the reservoir depends upon
have changing oil levels and tem- the design of the machine. the available
peratures and different piston space and the size of the reservoir (Figure 3-
sizes. air venting is needed. 19).
2. Oil Level Gauge gives the level of oil in
RESERVOIR IN SEPARATE TANK
the reservoir without opening it. Dipsticks
are still widely used, however.
3. Baffle helps to separate return orl from
that entering the pump. This slows the cir-
culation of oil. gives the return oil time to
settle. and prevents constant reuse of the
same oil. However. no baffle is needed in
many modern systems because the same
separation of inlet and return oil is
achieved by placement of lines and filters
202
PRINCIPLES AND THEORY OF HYDRAULICS 3:11
203
3:12 PRINCIPLES AND THEORY OF HYDRAULICS
VANE PISTON
GEAR (3-22) Three Types of Hydraulic Pumps Courtesy of John Deere Ltd
4. The shoft is
mechonically linked
S. Fluid is discharged
I,cre of tow pressure
and routed back to the
3. This motion in turn
rotates the attached
shaft. r to the work load and
provides rotary mech.
anical motion.
pump.
Nif.;:....
204
PRINCIPLES AND THEORY OF HYDRAULICS 3:13
Like hydraulic pumps, there are gear, vane Pressure Control Valves are used to limit or
and piston hydraulic motors. The motors are reduce pressure, unload a pump, or set the
rated by motor horsepower, a combination of pressure at which oil enters a circuit.
force and speed. Horsepower = Force x Pressure control valves include relief valves.
Speed. pressure reducing valves. pressure sequence
valves, and unloading valves.
Directional Control Valves control the
CONTROL VALVES direction of oil flow within a hydraulic system.
They include check valves, spool valves, and
Valves are the controls of the hydraulic rotary valves.
system. They regulate the pressure, direction,
and volume of oil flow in the hydraulic circuit. Volume Control Valves regulate the
volume of oil flow. usually by throttling or
Valves can be divided into three major types: diverting it. They include compensated and
non - compensated flow control valves and flow
1. Pressure Control Valves divider valves.
2. Directional Control Valves Some valves are variations on the three main
3. Volume Control Valves types. For example, many volume control
valves use a built-in pressure control valve.
Figure 3-25 shows the basic operation of the
three types of valves. Valves can be controlled in several ways:
manually, hydraulically. electrically, or
pneumatically (compressed gas). In some
modern systems. the entire sequence of valve
operation for a complex machine can oe
made automatically.
Hydraulic valves may or may not be ad-
justable. depending on their location and pur-
pose.
Generally speaking if the hydraulic systfn is
kept clean. valves will give little trouble.
(3-25) TheThreeTypesolValves
,..
205
3:14 PRINCIPLES AND THEORY OF HYDRAULICS
HYDRAULICS While most accumulators can do any of these
ACCUMULATORS four functions, their use in a system is usually
limited to one of them.
A hydraulic accanulator is basically a cylin-
der with a piston that is opposed by a spring Accumulators which Store Energy are often
or compressed gas. Fluid from the hydraulic used as "boosters" for systems with fixed
system enters the cylinder and pushes against displacement pumps. The accumulator stores
the piston. The piston in turn pushes against pressure oil during slack periods and feeds it
the spring or the compressed gas. Thus the back into the system during peak periods of
piston. with the compressed spring or the oil usage, The pump recharges the ac-
compressed gas exerting a force against it, cumulator after each peak. Sometimes the ac-
becomes a source of potential engergy. This cumulator is used as a protection against
potential energy could be used. for example, failure of the oil supply, for example, on power
in a brake system to apply the brakes if, for brakes on larger machines. If the system oil
some reason, the hydraulic system pressure supply fails. the accumulator feeds in several
failed. charges of oil for use in emergency braking.
Besides storing energy for the hydraulic
system. accumulators can absorb shocks,
build pressure gradually, and maintain a con-
stant pressure (Figure 3-26).
4 4
206
PRINCIPLES AND THEORY OF HYDRAULICS 3:15
Accumulators which Absorb Shocks take in range it must at least keep the oil under
excess oil during peak pressures and let it out 250 F. Beyond 250°F a chemical change
again after the surge is past. This reduces takes place in the oil. causing it to oxidize at a
vibrations and noise in the system. The ac- high rate.
cumulator may also smooth out operation
during pressure delays. as when a variable TYPES OF COOLERS
displacement pump goes into stroke. By
discharging at this moment. the accumulator Air-to-Oil Coolers use moving air to dissipate
takes up the slack. heat from the oil (Figure 3-27). On mobile
machines. the cooling system (radiator) fan
Accumulators which Build Pressure may supply the air blast. The cooler has fins
Gradually are used to soften the working which direct the air over long coils of oil tubes
stroke of a piston against a fixed load. as in a which expose more oil to the air. The cooler
hydraulic press. By absorbing some of the may also have a tank to store a reserve of
rising oil pressure the accumulator slows cooled oil. A bypass valve is also sometimes
down the stroke. used as a safety valve in case the cooler oil
tubes become clogged.
Accumulators which Maintain Constant
Pressure are always weight-loaded which OIL
COOLING
places a fixed force on the oil in a closed cir- OUT
FINS
cuit. If the volume of oil changes from leakage ...-'''' w- _ ' "-
or from heat expansion or contraction. this ac-
cumulator keeps the same gravity pressure on
the system.
.=='----
Pneumatic or Gas Loaded are the most com- 1)
mon types of accumulators used on mobile
hydraulic systems. Gas loaded accumulators OIL --.4"
.,,-----------' I A1R
use the principle that gas will compress while IN AIR-TO-OIL COOLERS FAN
fluid will not. In an accumulator gas and oil (3 -27) Courtesy of John Deere Lid
occupy the same container, but are usually
separated by a diaphram or a piston. The Water-to-Oil Coolers use moving water to
cylinder is charged with an inert gas, dry carry off heat from the oil (Figure 3.28). The
nitrogen (not oxygen), to a specified pre- water flows through many tubes and the oil
charge When the oil opposes the compressed circulates around the cooling tubes as shown.
gas, the gas will compress !tut' providing a On mobile machines, water from the engine
static pressure over the entire system. The radiator is often used for cooling.
compressed gas also acts as a cushion for the
system.
OIL OUT OIL 1N
Pressurized systems can be dangerous.
Always bleed down a system that uses a gas
charged accumulator, before working on it. To WATER
discharge the accumulator. shut down the WATER TUBES
engine and move all the hydraulic controls OUT
through all their operating positions. 41.- WATER
IN
OIL COOLERS
On modern high-pressure hydraulic systems. WATER-T0-01L COOLER
cooling the oil can be a problem. Often nor-
mal circulation of the oil in the system will not (3-28) Courtesy of John Deere Ltd
provide adequate cooling. Thus the need for
oil coolers. Air-to-oil coolers such as the one shown are
usually mounted in front of the engine
The purpose of the oil cooler is to keep the oil radiator, making use of the fan's air blast.
at an ideal operating temperature, 180° to Other coolers can be mounted in a variety of
200°F. If under extreme conditions the cooler locations, but are usually placed near the
cannot keep the oil temperature within this reservoir or the engine cooling fan.
207
3:16 PRINCIPLES AND THEORY OF HYDRAULICS
HYDRAULIC CYLINDERS
A double acting hydraulic cylinder is shown in
Figure 3-29. Cylinders will vary in their
diameter and stroke length.
BLEED VALVE
PISTON
ROD STOP
BLEED (ADJUSTABLE)
HOLES
OIL Stop Valve Arm
OUTLET STOP VALVE
5. Briefly explain the terms velocity and (c) Maintain a constant pressure.
flow rate. (d) All of the above.
6. The teem viscosity is the measure of 16. The purpose of an oil cooler in a
in hydraulic oils. hydraulic system is to:
Viscosity Index reflects the way viscosity
changes with (a) Keep the oil as cold as possible.
With respect to additives the most (b) tool the oil and ict as additional
desirable oils for hydraulic service con- reservoir.
tain high amounts of Keep the oil at an ideal operating
(c)
temperature.
7. What are the five basic parts required to
(d) Filter and cool the oil.
makeup a hydraulic system?
17. There are two basic types of cylinders
8. The function of filters in a hydraulic used in a hydraulic system:
system is to catch and hold
that get into the acting and
oil. acting.
209
3:18 PRINCIPLES AND THEORY OF HYDRAULICS
210
PRINCIPLES AND THEORY OF HYDRAULICS 3:19
SAFETY PRACTICES ON A
HYDRAULIC SYSTEM
1. Shut down the engine.
2. Unless stated otherwise in the service
manual. lower all implements to the
3.
ground, and level them if necessary.
Apply the parking brake and chalk the
DO NOT
wheels on wheeled /elides.
4. Bleed off pressure in the system so that
you don't get showered with hot oil.
Pressure in a hydraulic system comes
OPERATE
from three sources:
(a) Resistance to pump flow.
(b) Accumulators. (3-30)
CourtosY of Ji Case
2.11
3:20 PRINCIPLES AND THEORY OF HYDRAULICS
212
PRINCIPLES AND THEORY OF HYDRAULICS 3:21
!WA-- WRONG
'11------(A MKT
D. AVOID LOOPS
WRONG
D. AVOID TwISTINO
213
3:22 PRINCIPLES AND THEORY OF HYDRAULICS
REFILL TANK
5 WITH RECOMMENDED
GRADE OF SERIES 3 OIL.
DRAIN THE TANK
RAISE THE BUCKET. EXTEND
2 ALL CYLINDER RODS, DRAIN
THE HYDRAULIC OIL. THEN
ALLOW BUCKET TO LOWER
BY GRAVITY FOR MAXIMUM
DRAIN.
(3.32)
6 FLUSH SYSTEM
SLOWLY CYCLE
CYLINDER OR PAIR OF
EACH
CLEAN TANK
3 REMOVE BOTTOM OR SIDE
IF POSSIBLE AND CLEAN
THOROUGHLY.
214
PRINCIPLES AND THEORY OF HYDRAULICS 3:23
QUESTIONS MAINTENANCE OF
HYDRAULIC SYSTEMS
1. List the things that would be done to a
hydraulic system during scheduleo main-
tenance.
2. Before doing a daily maintenance check
on a machine's hydraulic system. what
safety practices must be carried out?
3. Premature hose failure can occur after in-
stallation because of:
(a) Improper length and twisted.
(b) Being too close to moving parts.
(c) Too near a heat source.
(d) All of the above.
4. What is the most important thing to know
when disconnecting a hydraulic hose? Ex-
plain why.
215
3:24 PRINCIPLES AND THEORY OF HYDRAULICS
ANSWERS - HYDRAULIC THEORY 11. If the line size is decreased. the velocity
of the fluid will increase. When fluid
1, 1. brakes travels at higher speed. greater friction
2. steering and thus heat is created in the lines.
3. working attachments 12. With the smaller lines. the velocity of the
4. transmissions fluid will increase. but it won't increase
5. propel
enough to maintain the flow rate. With
less flow. the implement will operate
2. Advantages. more slowly.
1. Simple in construction 13. A pump drives the fluid while a motor is
2. Gives a wide range of speed and driven by the fluid.
force. 14. pressure control valve
3. System is protected against damage volume control valve
by relief valves.
directional control valve
Disadvantages:
15. (d) All of the above.
1. Subject to leaks from high pressure,
shock loading and heat.
16, (c) Keep the oil at an ideal operating
temperature.
2. Heat from friction causes some lc 4s
of efficiency. 17. ... single ... double
3. Need for cleanliness, must be kept The single acting cylinder can be
clean. powered only in one direction (in ex-
tension), whereas the double acting
3. (b) Non-compressible: transmits ap- cylinder can be powered in two direc-
plied pressure in all directions tions (extension and retraction).
throughout the liquid.
18. The output force will be greater because
4. (d) Dividing the force by the area _F there will be a greater area for the
A pressure to act against. The speed of the
piston. however, will be decreased.
5. 1. Velocity is the average speed of a
fluid past a given point. 19. The smaller cylinder will act with greater
speed.
2. Flow rate is the measure of the
volume of fluid that passes a point in 20. (d) both (b) and (c)
a given time.
21. An accumulator is a safety device in a
6. fluidity hydraulic brake system which supplies
temperature enough fluid to stop the vehicle should
the system fail.
anti-wearing compounding
7. 1. a reservoir
2. a pump
3. a relief valve
4. a control valve
5. a cylinder
8. insoluble contaminants
9. (d) positive displacement pumps
10. (b) gallonage at a specific r.p.m. and
pressure
216
PRINCIPLES AND THEORY OF HYDRAULICS 3:25
ANSWERS MAINTENANCE OF
HYDRAULIC SYSTEMS
I. changing filters
cleaning screens
cleaning breathers
adding or changing oil
Replacing damaged hoses and fittings
and repairing leaks. Checking hydraulic
rams for scores or burns and leaks.
Sometimes flushing.
2. I. Shut off engine.
2. Lower all implements to the ground
and level them.
3. Apply parking brake or block wheels.
4. Neutralize or bleed off all pressure by
operating all controls and open vent
on reservoir.
3. (di All of the above.
4. Know what you are disconnecting. A head
of oil and/or pressure in the line when
disconnected could prove messy or even
harmful.
217
3:26 PRINCIPLES AND .THEORY OF HYDRAULICS
TASKS HYDRAULICS
218
BLOCK
Brakes
I
219
BRAKES 4:1
10 lb.
11:1111; 2 lb.
100 lb
mmilligb. 20 lb.
Courtesy of Don
Friction Materials UM
(4.1)
220
4:2 BRAKES
O Engine Clutch
Hoist Clutch Hoist Brakes
co
(4-4) THE LOCATION OF FRICTION Hoist Clutch Hoist Brakes
MATERIALS IN A SHOVEL
O Crowd Blake
Retract
Crowd Clutch
8 O Swing Clutch
4 7
1 23 5 6 O Tripper Clutch
9 O Swing Brake
FACTS ON BRAKING
1. To give an example of the tremendous for- 3. Speed has an even greater effact on
ces involved in braking a commercial braking power than does weight. A
vehicle consider the following: vehicle will need 5 times as much stop-
ping power at 70 km/h, and 9 times as
The average truck having an engine much at 100 km/h as it needs at 35 km/h.
capable of developing 100 horsepower
requires about one minute to accelerate to 4. Other factors affect braking power such
a speed of 60 miles per hour, whereas the as brake shoe leverage. number of tires
same vehicle should be capable of easily and road surface deceleration: these will
stopping from 60 miles per hour in not be discussed in a ,ter course.
more than six seconds. Ignoring the
unknown quantities such as rolling fric- BRAKE CAPACITY
tion and wind resistance which admittedly
play a part in all stops. the brakes must Brakes are classified according to their stop-
develop the same energy in six seconds ping power or horsepower absorption
as the engine develops in 60 seconds. In capacity. Brakes have a limit to the amount of
other words. the brakes do the same horsepower they can absorb without damage
amount of work as the engine in one-tenth to themselves other than normal wear on the
the time. This means that they must brake linings and drums. No control. however.
develop approximately 1,000 horsepower is built into brakes as to how much horse-
during the stop. power they will absorb. If called on to absorb
more horsepower than they are built for.
2. Braking power is directly proportional to brakes will do so and destroy themselves in
vehicle weight. For example a 10,000 the process. It is very important. therefore.
pound vehicle would need twice as much when brakes are designed for a vehicle that
braking power to stop it as would a 5.000 they be of adequate capacity to absorb the
pound vehicle travelling at the same horsepower that a vehicle of a given engine
speed. size. weight and travelling speed will produce.
221
BRAKES 4:3
TYPES OF BRAKE SYSTEMS Service Brakes slow or slop the vehicle. They
are designed to have a braking capacity suf-
Generally a vehicle or machine will be equip- ficient to stop the vehicle when travelling
ped with two types of brakes: within a speed and load limit. If the speed and
1. parking brakes load limit are exceeded, service brakes will
not perform satisfactorily.
2. service brakes
Figure 4-5 shows a typical automobile or light
Parking Brakes secure a vehicle when stop- truck brake system. Note that this vehicle has
ped. Parking brakes can be used in an disc brakes on the front and drum brakes on
emergency should the service brakes fail, but the rear.
if they are applied when the vehicle is
travelling fast or is heavily loaded, they will
burn out, Parking brakes will be looked at in
greater detail later on in this section.
POWER BRAKE
MASTER CYLINDER
BRAKE PEDAL
z BRAKE HOSE
PARKING BRAKE
METERING VALVE
BRAKE WARNING
LIGHT SWITCH
\
I
PROPORTIONING VALVE
DRUM BRAKE
DISC BRAKE (REAR)
(FRONT)
(4-5) TYPICAL MODERN BRAKE SYSTEM
Courtesy 01 Elendoi Corporation
222
vf
4:4 BRAKES
DUAL
MASTER PRIMARY RESERVOIR
CYLINDER (FRONT BRAKE SYSTEM)
MECHANICAL
STOP LIGHT
SECONDARY RESERVOIR SWITCH
(REAR BRAKE SyS QM)
WARNING LIGHT
BRAKE
IGNITION PEDAL
SWITCH REAR DRUM BRAKES
FRONT DISC
BRAKES SELF ADJUSTING
DIFFERENTIAL/PROPORTIONING
METERING VALVE
HIOSSI
(4-6) HYDRAULIC BRAKE SYSTEM
MANUAL BRAKES
Courtesy of Ford Motor Company
223
BRAKES 4:5
ADJUSTER CABLE
ADJUSTER LEVER
SPRING
I OJUSTER
LEVER
PARKING
PIVOT
BRAKE STRUT
ADJUSTING NUT
ADJUSTING SCREW
There are two main types of drum brakes. Duo- On a duo-servo brake, the shoe toward the
Servo and Non-Servo. front of the vehicle is called the primary shoe,
and the shoe toward the rear is called the
DUO-SERVO BRAKES secondary shoe. The primary shoe normally
has a shorter piece of lining than the secon
The distinguishing feature of a duo-servo dary,
drum brake is that a single anchor holds the
shoes at their upper ends and the shoes are
linked together at the bottom ends by an ad-
justing screw.
The duo-servo brake obtains its name from
the servo principle of brake action which was
introduced in the late twenties. During a brake
application, each shoe serves the other. and
the motion of the vehicle actually helps to ap-
ply the brakes.
224
4:6 BRAKES
(4 -9)
NON-SERVO BRAKES
225
BRAKES 4:7
DISC BRAKES
Disc brakes are becoming more common on
modern automobiles and trucks. There are
two main types of disc brakes: caliper disc
brakes and multi-disc brakes.
CALIPER DISC BRAKES
Caliper disc brakes (Figure 4-10) have:
a disc or rotor that is secured to and
rotates with the wheel hubs.
a caliper assembly that squeezes the
rotor on both sides to give the braking
action. There are three designs of
calipers: fixed. floating and sliding (4-101 TYPICAL FIXED CALIPER DISC BRAKE
calipers. Coulter, of Swint Corporation
hydraulic wheel cylinder(s) or air to ac-
tivate the caliper.
226
4:8 BRAKES
Why are power-assisted brakes necessary? booster is frame mounted away from the
master cylinder; its control valve is operated
1. Large vehicles require greater braking by hydraulic pressure from the master cylin-
forces than manually operated brakes can der.
supply.
POWER BOOSTER OPERATION
2. Vehicles travelling at higher speeds
require power brakes for a similar reason. An integral booster consists of a power sec-
tion. a master cylinder section. a vacuum line
3. Power brakes are easier to operate from the intake manifold and a brake pedal to
requiring less effort from the driver. operate it. as shown in Figure 4-11.
All three types of power-assisted brakes The power section is a vacuum chamber (the
operate according to a hydraulic principle vacuum is created by the intake manifold)
similar to standard hydraulic brakes. The dif- divided into two by a piston or a diaphragm. In
ferelce between the two is that power- the centre of the piston is a control valve. In
assisted brakes have an additional released position the control valve is open
mechanism that increases the braking force. and a vacuum exists on both sides of the
piston. A slight movement of the brake pedal
VACUUM-ASSISTED BRAKES closes the control .valve. Atmospheric
pressure (air) is then fed into the rear of the
Vacuum-assisted brakes use a vacuum brake piston. Since the pressure in air is greater
booster to increase the braking force of a than in a vacuum, the air will force the piston
conventional hydraulic brake system. into the vacuum. Thus the piston is pushed by
Boosters are standard equipment on all large the atmospheric pressure trying to take up the
trucks with hydraulic brakes and on many vacuum. The piston in turn pushes on the
light trucks and automobiles. Truck boosters master cylinder which activates the wheel
are commonly referred to as Multiplier cylinders. What has happened is that 4 slight
boosters (Hydrovacs), and automobile force on the brake pedal has resulted in a
boosters as integral boosters. strong force being applied to the brake
Integral and multiplier boosters operate master cylinder. The actual force on the
similarily, but are mounted differently. The In- master cylinder would be equal to the at-
tegral booster is firewall mounted directly to mospheric pressure on the booster piston
the master cylinder; its control valve is times the surface area of the rear of the piston
operated by the brake pedal, The multiplier (Force = Pressure x Area).
me-FIREWALL
VACUUM HOSE
INTAKE D
"4"".'-BRAKE PEDAL
) --.)
POWER SECTION VALVE ROD
0.24613749
227
BRAKES 4:9
CLEAR
NER 111
0. MARINO LIGHT
oottco
sotto
OIF I faEldnAu
MoRORTscR000r AMER
4111MEME1
VALVE
111011%
hi
YAMPA
U II
Cola
VALVE
VVEAHEC"ALCICVE
U VACUUM
ROOSTERS 11
DIAPHRAGM VACUUM
POPPET
ATMOSPHERE
POPPET
4....--ATMOSHPERE
TUBE
PORT TO
WHEEL BRAKES
228
4:10 BRAKES
0 t
P25247CC
/ (4-15)
NYDROBOOST HYDRAULIC SCHEMATIC
..&-:,... Courtesy of Bendix Corporation
9Iblial..
,
lr.
MOUNTINGb.
BRACKET ,...1.
HYDRAULIC
(4-14)POWER CLUSTER WITH HYDRAULIC OUTLET
CYLINDER AND AIR CYLINDER POWER SECTION OIL-OVER-OIL BRAKES
Power clusters are capable of producing a With the help of a booster assembly equipped
pressure ratio increase of 15 : 1. For example. with an accumulator. oil-over-oil brakes corn-
100 P.S.I. air pressure applied to the air cylin- bine hydraulic pressure from a power steering
der will create 1.500 P.S.I. master cylinder out- system with a conventional hydraulic brake
put. system. The accumulator is a safety system
that supplies enough fluid to stop the vehicle
Air-over-hydraulic systems differ in the num- when the engine stalls, Figure 4-15 shows an
ber of power clusters and differ. as do most oil-over-oil brake system.
hydraulic systems. in the number of wheel
cylinders size of lining and diameter of brake Pushing the brake pedal. opens a control
drums. valve in the power booster and pressurized oil
from the steering system enters the booster.
Airover-hydrauliC brakes are often prelerred This oil pushes the piston in the booster
to air brakes on larger off-highway vehicles which in turn applies force to the master cylin-
such as trucks and loaders because the air- der. The master cylinder then sets the
_ _____ovel-Ctil _brakes are less. .vu In erable to rough
terrain. Air brakes have a number of relatively
hydraulic system in motion to apply the brake
shoes. Note that there is no mixing of steering
large exposed parts that would be subject to fluid and brake fluids. The oil from the
damage by the uneven. rocky ground that off- steering system stops at the power booster: it
highway vehicles work in. Air over hydraulic does not mix with the brake fluid from the
brake& on the other hand. are more compact: hydraulic brake system.
229
BRAKES 4:11
Power boosters in oil-over-oil brakes, like If the spring is compressed. it then has poten-
power clusters in air-over-hydraulic brakes. tial energy which can be put to work. Com-
are capable of producing a high increase in pressed air has a similar work potential
force with a minimum effort from the operator. (Figure 4-17).
Oil-over-oil brakes should not be confused
with straight hydraulic brakes such as those
found on a cat loader. These brakes may ap-
pear to be power-assisted but they are not;
they use pressure from the machine's
hydraulic system in graduated amounts to ap-
ply the brakes,
The common name for oil-over-oil brakes is
hydro-boost brakes. Hydro-boost brakes are
used by General Motors on some of their light p.
to mid-weight trucks. Larger trucks that use
oil-over-oil brakes have an emergency system
other than an accumulator in case the truck
engine stalls An electric motor will cut in and
run a hydraulic pump. allowing the vehicle to
be safely braked. (4-17) Courtesy of Bendix CorPoratton
AIR BRAKES
Air brakes are the most common brakes used
on both on-highway and off-highway trucks
and trailers. Many types of construction
equipment too numerous to mention also use
air brakes. Air brakes transmit force and
motion through compressed air. Compressed
air is defined as air that is forced to occupy a
space less than it normally would in the at-
mosphere. Atmospheric air pressure at sea
level is 14.7 P.S.I. Compressed air is measured
in P.S.I. above atmospheric pressure. For
example. a compressed air measurement of 50
P.S.I. means 50 P.S.I. above standard at-
mospheric pressure of 14.7.
A standard air brake system (Figure 4-18), is 6. Brake Chambers receive the gradu-
made up of the following components. ated amounts of compressed' air and con-
vert it into the mechanical force and
1. Compressor pumps air under pressure movement needed to apply the brakes.
into the reservoir. It is driven, cooled and
lubed by the main engine. 7. Slack Adjuster part of the mechanism
that applies the force from the brake
2. Reservoirs receive and store the com- chamber to the brake shoes. Slack ad-
pressed air. justers also provide the means to adjust
3. Governor controls the air in the reser- air brakes to compensate for normal run-
voirs. ning wear.
SAFETY VALVE
FRONT
BRAKE CHAMBER
00 0
HANO VALVE
COMPRESSOR
EMERGENCY
covcmcH
TEE OR QUICK
TEE OR QUICK RELEASE VALVE
RELEASE VALVE
FRONT OF
TRACTOR
BRAKE
VALVE
REAR
TRACTOR BRAKE CHAMBER TRAILER
Courtesy of Grey Rock. Division of
Raybestos Manhattan Inc.
231
BRAKES 4:13
SLACK ADJUSTER
BRAKE DRUM*.
4: :"
4: eNt' 4
ADJUSTING NUT
BRAKE CAM
0 CAM ROLLER
AXLE
--BRAKE SHOE
RETURN SPRING
Courtesy of Grey Rock. Division of
(4-20) Raybestos Manhattan inc.
232
4:14 BRAKES
P24607.43
18 3
19 4
S
--
-
6 17 4,1
16
4 6
14 7
.7
11
8
7
10 9 8
9
Return Springs 7 Brake Shoe 13 10
12 11
2 Anchor Pin Link 8 Plate Bolt
3 Camshaft 9 Adjusting Screw 1 Brake Band 11 Lock Nut
4 Control Lever Spring 2 Cams 12 Lock Washer
5 Link 10 Adjusting Screw 3 Links 13 Brake Linings
6 Relay Lever 11 Support Plate
4 Clevis Pins 14 Release Springs
5 Cam Shoe 15 Brake Drum
(4.23) INTERNAL EXPANDING BAND 6 Lock Nut 16 Adjusting Bolt
PARKING BRAKE 7 Adjusting Nut 17 Anchor Bar
8 Locating Bolt 18 Anchor Screw
Courtesy of General MOrtOrS Corpoation 9 Washer 19 Lock Wire
10 Adjusting Nut
233
BRAKES 4:15
3. Disc and pads (Tru Stop) (Figure 4-25). (4-26) HOW THE SPRING BRAKE WORKS
Note the disc 12 between the two brake
shoe friction pads (9) and (10). This disc
and pad construction is a very effective
parking brake and is used on many
vehicles.
1
trso
of
44 e .-
3
4
01(4(7quiliii6o6
-
16 14
16
a k fr
17
le no
1 Brake Suppon 8 Brake Shoe Pin
Bracket 9 Front Brake Shoe
2 Parallel Adjusting 10 Rear Brake Shoe
Screws 11 Front Lever Arm
3 Front Lever Arm Pin 12 Brake Disc Service Brake Application
4 Pin Retaining Screw 13 Tension Spring
5 Brake Cable Clews 14 Spring Air pressure from the service brake system
6 Brake Lever 15 Rear Lever Arm acts on the diaphragm applying the brakes.
7 Brake Shoe Pin 16 Adjusting Nut
Retainer 17 Tie Rod
(4-25) TRU-STOP TYPE PARKING BRAKE
Courtesy of General Motors Coroorairon
SPRING BRAKES
Vehicles with air brakes may have a drive
shaft parking brake. but they are more likely
to have spring brakes. Spring brakes could be
referred to as integral parking brakes be-
cause they work on the service brake shoes.
There are a number of types of spring brakes
but they all operate on the basic principle of
spring applied and air released. Once applied, Parking Brake Application
the brakes cannot be released until sufficient
air pressure is fed into the chamber to retract Exhausting the air from the chamber releases
the spring. Spring brakes are very positive the piston, allowing the spring to force it and
and very safe. Operation of a typical spring the push rod forward, applying the brakes.
brake is illustrated in Figure 4-26. Courtesy ot the Government ot &dish Columbia
Artbrake Manual
234
4:16 BRAKES
the following 1. Keep the brake fluid clean. Do not get any
Brake fluid must possess
characteristics: foreign material in the fluid.
235
BRAKES 4:17
236
4:18 BRAKES
REAR BRAKE
BLEEDER HOSE
GLASS JAR
(4.28) MANUAL BLEEDING
P251620
Courtesy of Berdix Corporation
237
BRAKES 4:19
REAR BRAKE
238
4:20 BRAKES
Some self adjusters may require an initial Figure 4.32 shows a large wheel assembly
adjustment. or may have to be adjusted that has a star wheel brake adjuster.
manually if they are not self adjusting Probably there is another adjuster located
properly. They can be adjusted by holding 180 from this one.
the internal adjusting lever away from the
star wheel. and then turning the wheel
with a hook shaped tool. The method of WHEEL
holding the adjusting lever away from the CYLINDER BOLTS
wheel will depend on where the access
hold or adjusting slot is located (Figure A JU TII
4-31). TOOL
4..
BACKING PLATE
BLEEDER VALVE
ADJUSTING TOOL
CONNECTOR
TUBE
ADJUSTER
LEVER
STAR WHEEL
SCREWDRIVER
P.24607.26
ADJUSTER (4 -32)
LEVER Courtesy of General Motors Corporation
HOOK
TOOL
P.24607.26
239
BRAKES 4:21
The wheel assembly in Figure 4-33 uses a lid. This practice will prevent dirt from get-
stud adjuster. The direction that the stud ting into the fluid. Figure 4-34 shows
is turned to adjust the shoes will vary (see various types of reservoir filler caps and
service manual). Note there are two studs. lids. FILLER CAPS
one for each shoe.
WHEEL CYLINDER
BOLT
LEED
VALVE
COPPER (4-34)
GASKETS
,
CONNECTOR
TUBE
REAR SHOE
ADJUSTING STUD (4-34)
1.2938 RESERVOIR 1124607-43
DIAGHRAGM RESERVOIR COVER
(4-33)
RETAINER COVER
Counesy of General Motors Corporation
240
4:22 BRAKES
fluid level as it goes down in the reservoir. or slightly greater. as shown in Figure 4-
The membrane keeps air away from the 35. When the angle is less than 90° there
fluid, but still allows a normal atmosphere is too much push rod travel and the slack
pressure above the fluid. adjuster should be adjusted.
Brake fluid can be topped up. if low with ANGULAR ADJUSTMENT
the approved brake fluid. However. if very (Brake Applied)
much fluid is needed. it's quite possible
there is a leak. Normally. little brake fluid .1P.,,,,
has to be added and it shouldn't have to
be added very often. -, (4-35)
(c) Adjust the brake until the wheel is CHECK BELT TENSION
tight and then back it off enough to
get the shortest possible push rod if the compressor is a belt drive. check the
stroke without the brakes dragging. belt tension.
as illustrated in Figure 4-37). 1. Use a V-Belt Tension Gauge to check belt
Shed As Paula.
tension (Figure 4-39).
Without Brakes Dragging
Applied
Position
/
V -BELT TENSION
GAUGE
(4-37)
Courtesy of General Motors Corporation
242
4:24 BRAKES
200 F (93 C) or for use between the vehicle 1. install the hose so that it lies naturally.
frame and moveable axle housings where the without twist
brake chambers are located. Because nylon
can be used only on certain lines. never 2. guard hose that is near heat
replace a metal line with a nylon one unless it 3. support long lines
is in an approved nylon location. When a num-
ber of nylon lines run alongside one another. After any air line has been installed. carefully
tape them together for added support and check the connections for leaks. One com-
protection. mon way to look for a leak is to put soapy
water on the connection and when the brakes
The fittings (Figure 4-40) for nylon tubing are are applied check for bubbles.
easy to install, requiring no special tools. Sim-
ply cut the line to the required length and in- ADJUSTING PARKING BRAKES
stall the fitting. Avoid tight lines or lines that
are longer than they have to be. Figure 4-41 Since parking brakes are mechanical and
shows a cut away of a nylon line connection. usually not too difficult to get at. they are
generally easy to adjust. Check the service
NUT FITTING SLEEVE INSERT NUT TUBE manual for the method of adjustment on any
dlOileeze.r......m..'
(4-40) NYLON AIR LINE FITTINGS
Courtesy of General Motor's Corporation
TUBING NUT
SLEEVE
BODY
..--/ j/s"v...evvvvv. cl,
i
SYNFLEX TUBE INSERT
NYLON TUBE
(4.41) MOM
Courtesy of Bendix Corporation
(4-42)
Courtesy of General Motors Corporation
Flexible hose. or more specifically, wire braid
hose. is used for air lines between the brake
chambers and the frame and axle housings.
and for trailer connections. Flexible hose. like
nylon tubing. has also replaced some lines
that used to be metal. Wire braid hose is
available in a variety of sizes. #4. #6. #8. etc.
When making up flexible hose. be sure the fit-
tings are compatible with the hose. Follow the
same make up procedures mentioned for
hydraulic hoses with replaceable fittings:
243
BRAKES 4:25
V
t ------",-41
7
6
-
244
,..
4:26 BRAKES
245
BRAKES 4:27
ANSWERS BRAKES
1. (c) Heat energy
2. coefficient of friction.
3. over/ceding the vehicle and braking at
high speeds
4. standard hydraulic brakes, power-
assisted hydraulic brakes, full air-brakes
5. (c) a confined fluid
6. When the force on the master cylinder
piston is released. springs return the
wheel cylinder piston to its non-applied
position and in doing so push the oil
back to the master cylinder.
7. Vacuum
Air-over-oil
Oil-over-oil
8. The multiplier vacuum-assist brake is
frame mounted and the control valve is
operated by pressure from the master
cylinder. It is generally used by trucks.
The integral vacuum-assist brake is
firewall mounted and the control valve is
operated directly by the foot pedal. It is
used by automobiles and light trucks.
9. The two shoes on a duo-servo brake
have a single anchor and they have an
interrelated action against the drum. The
two shoes on a non-servo brake have
separate anchors and the shoes act in-
dependently against the drum.
10. (c) air cylinder or power cluster
11. cooled
12. Disc or rotor, caliper, hydraulic wheel-
cylinder.
13. Power steering oil pressure.
14. (b) compressed air
15. (b) spring applied and air released
16. No. Brake fluid is a composite of
glycerine, alcohol and performance ad-
ditives.
17. Forcing fluid through the entire hydraulic
system after working on it to remove the
air.
246
4:28 BRAKES
24 7
BRAKES 4:29
VACUUM POWER-BRAKES
Routine Maintenance Check
1. To check the operation of vacuum power-
brakes pump the broke pedal several
times with the engine 4topped, and then
hold your loot on the pedal and starl the
engine. The brakes are working properly if
the pedal moves down slightly when the
engine is started.
248
BLOCK
Power Trains
249
POWER TRAINS 5:1
10 6 5 4
General Arrangement
250
5:2 POWER TRAINS
6 7
1Transmission hydraulic controls. 2Universal joint. 3 Diesel engine. 4Steering
clutches. 5Final drive. 6Range transmission. 7Torque divider. 8Track.
(5-2) CRAWLER DOZER POWER TRAIN
Courtesy of Caterpillar Tractor Co
25.1
POWER TRAINS 5:3
As long as the discs are not touching. one can gear with 24 teeth. When the small gear has
spin without affecting the other. But if the made one complete revolution. it has gone a
discs are moved together when one is spin- distance equivalent to 12 teeth. The larger
ning, the other begins to turn and almost in- gear also turns through 12 teeth but this
stantly both shafts rotate as one unit. in an ac- represents only one-half a revolution.
tual disc clutch (Figure 5-4) the discs are for- Therefore. in this gear arrangement. the
ced together by strong springs. and are smaller gear makes two revolutions for every
separated by pushing down on the clutch one of the larger. In other words. the smaller
pedal. gear travels twice as fast as the larger.
FLYWHEEL CLUTCH PRESSURE PLATE SPRING COVER
DISK
TO DRIVE
FROM ENGINE WHEELS
SHAFT
CLUTCH
'AY"- PEDAL
DOWN TURNING
4 CLUTCH
m"- PEDAL
TURNING TURNING UP
NOT TURNING
FLYWHEEL
7.
CLUTCH D1SeNGAGED CLUTCH ENGAGED
(5-4) DISK CLUTCH IN OPERATION Courtesy of John Deere Ltd
252
5:4 POWER TRAINS
RING GEAR
(5-7) GEARS
Courtesy 01 John Mere LW
r
ANION GEAR 3. Fluids (the water wheel principle)
(5-7) FLUIDS
(5 -6) RING GEAR AND PINION FOR REAR AXLE Courtesy of John Deere Ltd
Courtesy of John Deere Ltd
FRICTION DRIVES
Not seen in Figure 5.6 are other differential
gears that are needed to permit the wheels to Friction drive is the result of bringing tegether
travel at different speeds when cornering. two surfaces made from materials that will
These gears are discussed later in this sec- transmit motion from one surface to the other.
tion. Slippage between the surfaces is a matter of
design and for now will be assumed to be
HOW POWER IS TRANSMITTED negligible. The engine clutch is a prime exam-
ple of a friction drive.
Earlier it was shown that clutches use friction
to transmit power. whereas transmissions and A simple form of useful friction is obtained
differentials use gears. A third way of trans- when a rubber-tired wheel contacts the
mitting power is by fluids, as in automatic ground (Figure 5-8). The friction between the
drives. These three basic ways of transmitting wheel and the ground causes the wheel to
power are illustrated in Figure 5-7. move forward when it is rotated by hand.
WHEEL MOVES
FORWARD
FRICTION HERE
401°.
FRICTION (5.8) FRICTION BETWEEN WHEEL AND GROUND
X3309
(5-7) Courtesy of John Deere Ltd
Courtesy of John Deere Lid
253
POWER TRAINS 5:5
to%
Ili
ail
254
5:6 POWER TRAINS
Picture A is a disc connected to a rotating slower. Thus. as gear torque increases, there
shaft. The discs contain vanes which are filled is a corresponding decrease h. gear speed
with fluid. In B the disc is rotated at high (Figure 5-14).
speed and centrifugal force causes the fluid
to move out as shown. In C a second disc is
placed above and close to the first disc. Fluid
now flows into the second disc as shown. The
force of the fluid on the second disc will
cause it to rotate in the same direction as the
first. forming a fluid coupling which transmits
power. When the discs are seated and the
fluid is under pressure. a solid coupling is for-
LARGE GEAR SMALL GEAR
med. Fluid drives. such as torque converters DRIVING SMALL DRIVING LARGER
and fluid clutches. operate according to this GEAR GEAR
basic principle. MORE SPEED
BUT LESS TORQUE
LESS SPEED
BUT MORE TORQUE
GEARS
(5-14) HOW TORQUE VARIES WITH GEARS
The basic elements of almost all conventional Courtesy of John Deere Lid
power trains are gears. Gears are simply a
means of applying twisting force. or torque. to The gears in a transmission are selected to
rotating parts. The amount of torque obtained give the operator a choice of both speed and
from a source of power is proportional to the torque.
distance from the center at which it is applied.
(The larger the distance the greater the Lower gear range = less speed but more
torque.) torque.
The principle of leverage can be used to ex- Higher gear range = less torque but more
plain gear torque. A lever (Figure 5-13) has speed.
more torque as the distance from the fulcrum
to the line of force increases (i.e.. the radius of GEAR RATIO
the applied force increases).
Gear ratio is a measure of the changes in
speed and torque in meshed gears. The for-
LEVER mula for gear ratio is:
OBJECT
8
ratio = number of teeth of driven gear
'TORQUE number of teeth of drive gear
1
In Figure 5 -15 the top gears are the drive
FULCRUM gears.
FULCRUM CLOSER TO OBJECT EQUALS
MORE TORQUE FOR LEVER
BUT LEVER MUST MOVE FARTHER RATIO 2 TO 1
RATIO 1 TO 1
(5.13) HOW TORQUE VARIES WITH LEVERS
Courtesy of Jahn Deere Ltd
15 SPEED
i15 TEETH
The radius of the applied force on the lever is TEETH 100 RPM
analogous to the radius of the driven gear.
The torque output of the gear increases as the
radius of the gear increases. In other words.
the larger the driven gear. the greater its
torque. SPEED
50 RPM
Gear torque can't be discussed without also 30
discussing gear speed. As a driven gear gets TEETH
larger the distance that the teeth must travel (5-15) GEAR RATIOS
for one revolution increases. Since this
Courtesy of John Deere Ltd
distance is greater. the gear will have less
revolutions per minute. i.e., it will travel
255
POWER TRAINS 5:7
The gear ratio of the first set is _1 = _.1 or There are many different types of gears, each
15 1 having its own application. The four most
1.1 (read: ratio of 1 to 1). A gear ratio of 1:1 common you will encounter at this stage of
means that both gears turn at the same speed training are:
with the same torque. The gear ratio of the
1. Straight Spur Gears (Figure 5-17)
second set is) = _2 or 2:1 which means that These gears have straight teeth cut
15 1
parallel to the axis of rotation. Normally.
the drive gear travels twice as fast as the mating gears have two pairs of teeth
larger driven gear, but that the driven gear engaged at all times. These gears are
has two times more torque. 'noisy and are used mainly for slow
Consider another example: a 10 tooth gear speeds. At higher speeds spur gears tend
drives a 60 tooth gear. The gear ratio would to vibrate.
be: Uses: Straight spur gears are used in
driven gear = 60 = 6 or 6:1 devices such as hand or powered
winches. Sliding gear bans-
drive gear 10 1
missions also use spur gears for
The smaller drive gear travels six times as fast speed changes because the shape
as the larger driven gear, but the driven gear of the teeth allows a sliding gear
has six times more torque. These three exam- to easily mesh and demesh with
ples of gear ratios demonstrate the law of stationary gears.
gear operation that states: any reduction in
gear speed gives an equal increase in gear STRAIGHT SPUR
torque. (5-17)
Further information on gear ratio and torque
can be found in the first part of Chapter 47,
"Gears ". in Automotive Mechanics, Seventh
Edition.
TYPES OF GEARS
Courtesy of John Deere Ltd
Gears are normally used to transmit torque
from one shaft to another. The shafts may be 2. Helical Spur Gears (Figure 5-17) The
in line or they may be parallel or be at an teeth of helical spur gears are cut
angle to one another. obliquely across the perimeter of the gear
instead of straight across. Engagement
Gears that mesh must have teeth of the same between two teeth starts at the tooth tip of
size and design. and must have at least one one gear and rolls down the teeth to the
pair of teeth engaged at all times. Some gear trailing edge. This angular contact tends
teeth are designed to have contact between to cause side thrusts which the bearings
more than one pair of teeth. Gears are nor- must absorb. However. helicat spur gears
malty classified by: are quieter in operation, and have greater
strength and durability than straight spur
1. Type of teeth. gears because their contacting teeth are
2. Surface angle on which teeth are cut. longer.
Figure 5-16 shows two categories of gear Uses: Helical spur gears are widely used
teeth. in machine transmissions because
they are quieter at high speeds
and are durable.
HELICAL SPUR
(5-17)
STRAIGHT
CUT
25? ?
5:8 POWER TRAINS
SUN
GEAR
PLANET RING OR
CARRIER INTERNAL
GEAR
(5-18)
257
POWER TRAINS 5:9
The ring gear has teeth on its inner Two main advantages of planetaries are:
diameter which mesh with the teeth on the
planet pinions. The planet pinions are (a) the load is spread over several gears
held by the carrier and in turn mesh with reducing the stress and wear on any
the sun gear. The type of teeth used on one gear.
these gears may be straight spur or (b) a high reduction can be obtained
helical spur (as in the diagram). within a limited space.
To obtain a power flow through a planetaries are very common gear sets
planetary gear set: found on both track and wheeled
machines. Transmissions, drive axles,
(a) Hold one gear by a brake or clutch. final drives, and wheel reductions for
or by solidly anchoring it. large machines are just a few areas where
(b) Drive one gear. planetary gear sets are used.
(c) The third gear will be driven (power
output). BACKLASH IN GEARS
These three gears all remain in constant Backlash is the clearance or play between
mesh and give many speed changes and two gears in mesh. Too much backlash can be
torque outputs depending on which gear caused by worn gear teeth. by an improper
is held and which gear is powered. It is meshing of teeth or by bearings which do not
possible to get four forward speed ratios. support the gears properly. Extreme backlash
two reverse speed ratios. as well as direct can result in severe impact on the gear teeth
drive and neutral from a planetary gear from a sudden stop or reverse of the gears.
set. However. on any given planetary only Figure 5-20 shows both normal gear mesh.
one or two ratios would be used. A com- and gear mesh that permits too much
mon combination of planetary gears is backlash.
illustrated in Figure 5-19. The sun gear is
driven and the ring gear held. causing the PITCH DIAMETERS
planet pinions and thus the carrier to walk
around the inside of the stationary ring
gear. The result is a speed reduction to
the carrier. This gear combination is often
used to give a gear reduction in a final
drive.
RING GEAR
RESTRAINED
X2042
NORMAL GEAR MESH
POWER
OUTPUT
(5-20) BACKLASH IN GEARS
258
5:10 POWER TRAINS
------------ CLUTCH
BRAKE
INTERMEDIATE
INTERMEDIATE PRESSURE PLATE FLYWHEEL RING DRIVE PIN SET
PLATE DRIVE PM AND PRESSURE SCREWS
PLATE ASSEMBLY 4121112-A
(5-22) DOUBLE DISC CLUTCH
Both single and double disc clutches require
Courtesy Fora Motor Co adjustment to compensate for running wear.
A
1
POWER TRAINS 5:11
I
Clutch packs generally run in oil and therefore
must use a type of lining material not affected
by oil. Unlike single and double disc engine
Clutches. clutch packs are not adjustable.
Figure 6-24 shows a steering clutch with the
outer drum removed. This assembly is spring
applied and hydraulically released.
r-
i
(5 -24)
STEERING CLUTCH OPERATION
1Piston. 2Pressure plate. 3Retainer.
Courtesy of Caterpi liar Tractor Co T3 41)$ I
260
5:12 POWER TRAINS
R.H.
SHIFTER
FORK
'NE
261
."ffiffimiMMINNINEEINNI=IMMIENIIMI
POWER TRAINS 5:13
irA71`1
l I
B
I
.)
C D
FLUID LIES BOWL IS SPUN TORQUE IS
LEVEL IN BOWL AND FLUID TRANSMITTED TO
SPILLS OUT UPPER BOX BY
A
FORCE OF FLUID
FLUID (5-28)
COUPLING
As the pump is turned by the engine, cen- The combined action of the two oil flows will
trifugal force causes oil to be forced radially transmit torque but not increase it. Here is
outward and because the housing is curved where the torque converter goes beyond the
the oil crosses over and strikes the vanes of basic fluid coupling: the converter can
the turbine causing the turbine to rotate in the multiply torque.
same direction. Thus the power is coupled.
A torque converter (Figure 5-30) looks much
Two types of flow are produced in the like the fluid coupling above. The main dif-
revolving coupling (Figure 5-29). The circular ference is that the converter has, in addition
flow of oil between the pump and turbine is to the driving pump and the driven turbine, a
called vortex flow. The f It i around the pump third member: a wheel of blades or vanes
and turbine that forms the coupling is called called a stator. The stator is mounted on a one
rotary flow. way clutch. When the turbine is slow or stop-
ped the stator wheel is stationary. In this
position the stator vanes change the direction
Droviag
Member
of oil flow after it has gone through the tur-
(Pump) Driven bine and sends the flow back to the pump.
Member
(Turbine)
The velocity of this returned flow is added to
the velocity already existing in the pump.
Thus. the pump velocity or output is in-
creased. In this way the converter multiplies
the torque.
Torque is increased as long as the turbine is
turning slower than the pump. This occurs
when the machine first starts to move. But as
the machine speeds up, the turbine, which is
directly splined to the transmission. also
speeds up. causing the vortex flow of oil in the
converter to decrease and the rotary flow to
increase. As the turbine approaches pump
speed. the stator free-wheels (in the same
direction) and there is no longer a torque in-
crease. Total rotary flow has been reached.
X 2199
The torque converter now acts as a single
fluid coupling sending the same torque it
(5.29) VORTEX AND ROTARY FLOW IN A receives onto the drive wheels.
FLUID COUPLING
CounesY of John Deere Lld
262
A
5:14 POWER TRAINS
Number of speeds
Number of countershafts
Location and number of transmissions
used (there are main transmissions.
auxiliary transmissions and transfer
cases).
1. The number of transmission(s) speeds will
depend on the size of the vehicle and the
C To kind of work it does.
Nye
Wheels
Light duty machines may have Three or
four speeds whereas heavy duty machines
may use one or two transmissions that
give 15 or more speeds.
2. in the past transmissions had single coun-
tershafts and this design is still used on
automobile and light trucks. However.
many heavy duty vehicles now have trans-
missions with two or even three coun-
(5-30) TORQUE CONVERTER tershafts.
Courtesy of John Deere Lid
The advantage of the multi-countershaft
The torque converter is able to automatically. design is that the torque is divided evenly
reduce or increase torque in infinitely small over two or more shafts. Dividing the
steps to match the needs of the machine and torque reduces the load on the gears.
its driver. The converter has the same effect shafts and bearings. thereby allowing the
as shifting speeds in a gear transmission ex- overall size and weight of the trans-
cept that it is done smoothly and mission to be reduced.
automatically while on the go-. Figure 5-31 shows power flow through a
The above is only a basic explanation of how single countershaft transmission. This is a
a torque converter works. simplified figure: an actual transmission
would have many more gears.
Many variations of converters are made to MAIN SHAFT
meet the demands of different machines. CLUTCH SHAFT DRIVE GEAR AND
GEAR
STANDARD MECHANICAL TRANSMISSIONS
A mechanical transmission is a train of gears
that transfers and adapts the engine power to C
the drive wheels of the machine. Usually the
transmission is located to the rear of the
engine and clutch. and in front of the dif-
ferential or ring gear. COUNTERSHAFT AND GEARS
The transmission does two jobs: (541)
Courtesy of Eaton Corporhon
selects speed-torque ratios
reverses the direction of the machine The clutch shaft drive gear turns the coun-
For information on the operation of a basic tershaft gears: the countershaft gears turn
transmission. read pages 457 to 461 (Chapter the mainshaft gears.
471 in Automotive Mechanics, Seventh
Edition.
TRANSMISSION CHARACTERISTICS
There are a number of mechanical trans-
missions. The types can be classified ac-
cording to the:
263
POWER TRAINS 5:15
(5-32)
Courtesy of Eaton Corporation
ENERGIZED SYNCHRCNIZER
IN NO ANO 3RD GEAR
\mown SPLINES
FOR DRIVE YOKE
LARGE DIAMETER
BEARING RETENTION BOLT
(5-34)
COutIOSY Oa Eaton Corporation INPUT SHAFT
SLIDING
REAR ORIvE
AND GEAR LOw
CLUTCH
REAR ORM
OUTPUT SHAFT
---L401--11XER GEAR
IDLER SHAFT
L
FRONT ORWF
LOW
FRONT DRIVE
OUTPUT, SHAFT
C21134.
265
POWER TRAINS 5:17
266
5:18 POWER TRAINS
FORWARD
REVERSE
INPUT
(5-38)
SPUR GEAR POWER SHIFT
OW
IGH
UTPUT
DRIVING SPIDER
DRIVE LINES
YOKE
The drive line transmits the driving torque DRIVEN YOKE
from the transmission(s) to the drive axle(s). A
drive line may have one drive snatt or it may
have multiple shafts. depending on the size
and drive axle arrangement. Each drive shaft
has a universal joint at either end which TRUNIONS
allows the shaft to hinge. Being able to hinge
makes the shaft flexible and enables it to
transmit power at an angle. A universal joint is (5-39) SIMPLE UNIVERSAL JOINT
a double hinged joint consisting of:
1. two "Y" shaped members called "yokes".
2. a cross shaped member called the
"spider".
3. Four arms on the spider called "trunions".
LOCK
4. bearing caps and needle bearings in- PLATE
stalled on the ends of the trunions. BEARING
CAP
Two illusrations of universal joints are given
in Figures 5-39 and 5-40. The first is a sim-
plified view. The second is more detailed
(note that only one yoke is shown).
LOCK
PLATE
267
POWER TRAINS 5:19
INTER-
TRANSMISSION
SHAFT
/ MAIN DRIVE SHAFT REARWARD REAR AXLE
COUPLING
FORWARD
SHAFT REAR AXLE
(5-41)
2B8
5:20 POWER TRAINS
DIFFERENTIAL PINION
ONLY ONE SHOWN
DIFFERENTIAL
CASE DRIVE PINION
SIDE BEVEL
GEAR
RIGHT AXLE
SHAFT
(5-43)
A problem can occur with differentials when ferential to the wheels is a live axle Live axles
one wheel looses traction and starts spinning. are also referred to as floating axles
Various devices have been made to prevent
this spinning and a differential equipped with Dead axles can be made of either tubular or
one is called a locking differential. These solid steel. Live axles are constructed of solid
locking devices may be mechanical. steel capable of withstanding the twisting
hydraulic. or automatic: the automatic is most stress of the torque that the axle transmits.
common today. Essentially. the locking device One end of a live axle is splined to fit into the
locks out differential action in poor traction differential gears. The other end can be con-
conditions but allows normal action under nected to the wheal in various ways such as a
good ground conditions. bolted flange. a ...plined end :hat fits into 3
flange cap. or a splined end that fits into the
TYPES OF DRIVE AXLES sun gear of a planetary gear set.
269
POWER TRAINS 5:21
the full weight of the vehicle and absorbs all Semi-Foating Axles
stress or end thrust caused by turning. skid-
ding. etc. The axle shaft only transmits the Semi-floating axles (Figure 5-45) fit into the
torque from the engine and is said to float in differential and turn within the axle housing
the axle housing. The most common full- the same way as full-floating axles. However.
floating axle is splined at the differential and there is a critical difference in the two axles.
has a flange at the other end. The flange is With a full-floating axle. the wheel and hub
bolted to the outside of the wheel hub. On turn on the axle housing and the axle shaft
machines with planetary final drives the axle just transmits drive torque. On the other hand.
will be splined at both ends. with a semi-floating axle the wheel and hub
are attached to the outer end of the axle.
Full-Floating Axle Courtesy of John Deere Lid Therefore. the axle shaft supports the
vehicle's weight as well as transmitting drive
DRIVE
WHEEL
WHEEL HUB torque. It must take all the weight and all the
AXLE HOUSING stresses caused by road impact. turning. and
AXLE SHAFT ONLY TAKES FULL WEIGHT skidding.
TURNS WHEEL OF VEHICLE
The outer end of a semi-floating axle is sup-
ported by one bearing that is pressed onto the
axle shaft and fits into'the axle housing. Two
types of bearings are used: tapered roller
bearings or ball bearings. Where tapered
roller bearings are used. an adjustment for
axle shaft end play is provided. The ad-
justment is made with shims or a nut located
at one end of the axle housing. In order to
transmit equally shaft end thrust to the
bearings at both ends of the axle housing. a
thrust bloc or spacer is located between
SLEEVE NUTS
RETAIN BEARING the inner ends of the two axle shafts within
WHEEL HUB SUPPORTED the differential carrier.
BY BEARINGS ON
I 4: AXLE HOUSING
Semi-floating axles are commonly used in
(5-44) FULL-FLOATING AXLE SHAFT automobiles and light trucks. The outer ends
of the shaft may be flanged or tapered as
shown below. When the shaft is tapered. the
wheel hub is keyed to the shaft and locked in
place with a nut.
Beonng
Axle
Shoff
Acliustmg Axle
Shims Sho It
I 7 TAPERED ROLLER BEARINGS AND SHAFT x ':is-4 B -L BEARINGS AND FLANGED SHAFT
270
111W....111l.INIIIMM11
5:22 POWER TRAINS
RETARDERS
A retarder (Figure 5.46) supplements the main
braking system of a vehicle. A retarder cannot RETARDER
stop a vehicle by itself. Rather, it assists the VAN
TRANSMISSION W.A. LAr
brakes in stopping the vehicle. From outward
appearance, a retarder looks similar to a
torque converter. In actual fact though, the
retarder performs an opposite function to a
converter. absorbing torque rather than trans-
mitting P.
Hydraulic retarders are mounted in the power
train at one of three locations:
1. In the engine behind the flywheel. 4 IMPELLER
CONVERTER
CONTROL
VALVE HOUSING
2: In the transmission between the converter
and the transmission.
a Within the drive line. (5.46) TRANSMISSION RETARDER
,w!,721 Courtesy of General Motors Corporation
A retarder consists of three bask. oarts: a
housing. rotor. and stator (Figure 5-47).
(5-47) a
OIL COOLER
oil
system
1
OIL
CONTROL
VALVE
27i
5,
In a retarder the housing is the stationary The degree of retarding effect produced by a
component and the rotor is the moving one. retarder is controlled by the operator through
The rotor is driven by the engine. transmission a foot or a hand controlled valve. When using
or drive line. The internal surface of the the retarder. the operator should keep in mind
housing has fins on one or both sides of the that the retarder is only meant to assist the
rotor The rotor may also have fins on one or brakes not to replace them. and that the
both sides, depending on how the housing is engine RPM's should be kept up to provide
made. The rotor runs with a very close sufficient air flow for the retarder cooler.
tolerance to the housing.
GREASE AND OIL
When the retarder is in the unapplied position. I
oil freely circulates within the retarder Before getting into preventive maintenance
housing, causing little or no drag on the rotor on power trains a discussion on grease and
(i.e.. the drive train). When the retarder is ac- oil is necessary.
tivated by applying air pressure to the oil, the
pressurized oil is churned and sheared be- Grease
tween the closely tolerated housing and rotor. Grease consists of an oil of a certain viscosity
causing a strong resistance which slows the range (viscosity is the resistance of a liquid to
rotor and thus the drive train. By resisting flow) combined with a thickening agent such
drive train motion. the retarder helps slow as soap. Additives are included to give
down the vehicle. stronger wear and performance qualities to
Friction in the retarder creates heat that must the grease:
be dissipated. This is done by circulating GREASE = OIL + SOAP + ADDITIVES
through a cooler and back into the retarder
(Figure 5-49). The following additives go into grease (and
into oil):
The source of a retarders oil depends on its
location An engine retarder uses engine oil oxidation. corrosion and rust inhibitors.
and a transmission retarder uses transmission extreme pressure and anti-score agents
oil. A drive line retarder. not having an im-
mediate source of oil. has its own oil supply. Types of Grease
Some common types of grease are:
2 72
5:24 POWER TRANS
273
POWER TRAINS 5:25
4/
/Am SPAC(
7-7 w.
PORERFUL
remota
CREATED
/
AS SPACE
REDUCED OIL AND AIR IN
BARREL EXPAND
0CLEAA OlLy WHEN WARM.
SOME OF AIR
/DELIVERED/ ABOVE OIL
ESCAPES.
1 4 A
WATER
PREVENTION
VI 4.
274
5:26 POWER TRAMS
275
POWER TRAINS 5:27
PREVENTIVE MAINTENANCE SERVICE ches can go thousands of miles and not need
OF POWER TRAINS adjustment. Under very stressful conditions
#he clutch may need adjusting (Jai. Another
Preventive maintenance service of Power factor affecting clutch adjustments is the
Trains on a daily basis should consist of a operator. Some drivers or operators are hard
thorough visual check of all the drive com- on clutches and their clutches will need more
ponents from the engine out. Look for: frequent adjustment.
1. Loose parts Power train components Clutch adjustment vane, 'h the type of
involve many moving parts that carry clutch. A push clutch (i.e.. the release bearing
heavy torques and stresses. These parts is pushed to disengage) is used on smaller
can work loose Check especially the vehicles. This type of clutch has an adjusting
areas where power is transmitted from a mechanism such as a threaded rod located
stationary part to a moving one. i.e.. trans- externally on the linkage. Larger vehicles
mission and drive shaft. generally use a pull clutch (the release
2 Oil leaks There are a number of oil bearing is pulled to disengage) which is ad-
compartments. and in some cases con- justed internally or inside at the pressure
necting hoses, in power trains. Under plate Clutch brakes are used in conjunction
stress and heat, leaks will develop. Make with pull clutches. A clutch brake slows down
any minor repairs. and report major ones. the transmission input shaft on un-
Oil level checks will be made on a synchronized transmissions to aid in shifting.
scheduled basis. Clutch brakes are applied with the clutch
3 Faulty adjustment To compensate for pedal when the pedal is approximately one
running wear. adjustments need to be inch from the floor boards. Adjustment to
made on belts, chains. clutches. Adjusting clutch brakes are made externally on the
clutches will probably be the most com- linkage.
mon adjustment a first year apprentice will Clutch Clearance
do. and is detailed below.
Clutch clearance is the amount of clearance
CLUTCH A:.aJUSIMENT between the reloase bearing and the release
levers. point #1 in Figure 5-51 showing a sim-
A major factor in clutch adjustment is working plified view of a push clutch.
conditions. Under ordinary conditions clut-
PR ESSURE PLATE RELEASE LEVER
(or Release Fingers)
SPRING
FREE CLEARANCE
BEARING RETURN
RELEASE
EASE
SPRING
The correct clearance prevents the release 3. The proper clutch pedal free travel is ap-
bearing from riding constantly against the proximately 1t/2". The gradual reduction
release fingers of the pressure plate. As wear from this amount is a normal condition
occurs on the disc lacir.gs. the release levers caused by facing wear.
move towards the release bearing taking up
the clearance If the movement of the release 4. If inspection indicates clutch pedal free
levers is not compensated for. the pressure travel is less than V2". immediate ad-
against the release bearings will cause the justment should be made to restore the
clutch to slic. under load proper 11/2" travel. This 11/2" of free travel
normally results in Vs" clearance between
The clutch adjustment for this push clutch the release bearing and the release
would be a threaded rod located outside the levers. Figure 5-53 shows a correctly ad-
clutch housing. Adjusting the threaded rod justed push clutch.
would pull the release bearing back on the
release sleeve making a gap (ttl) between
the bearing and the release levers of the
pressure plate. This gap has to be wide
enough to let the release bearing be free of
the release levers when the clutch is fully
A
engaged. but narrow enough to allcw the PEDAL FREE TRAVEL
1 FREE PLAY
Below is a typical section from a service
manual on clutch adjustment. The clutch
referred to is a basic push clutch. (5-53)
Clutch Pedal Adjustment
Courtesy of lipe.R011way Corporation
1. The clutch must be kept in proper ad-
justment by frequent inspection of clutch
free travel, the first easy movement of the Below is a typical adjustment procedure for a
clutch pedal. puti clutch equipped with a clutch brake. Ad-
2. Check the clutch pedal free travel by hand justment to the clutch is made internally: the
(Figure 5-52) and be sure that the free release bearing assembly is reached by
travel IS a result of actual release bearing removing a cover on I"' nderside of the
clearance and is not caused by worn flywheel. Note: The clutcn or.ke may also
linkage or faulty hydraulic cylinde's, have to be adjusted (it is adjusted externally).
depending on what has previously been done
to it.
Clutch Adjustment
111PIPT"-- 1. Unlock sleeve locknut "D" (Figure 5.64).
., 2. Turn slotted spanner adjusting nut "E" for
proper clearance.
4.'1:F1.3rWW:4"P7.- 7/16" for 14"-2PT
1/2" for 1512"-212T
gtir 3. Lock sleeve locknut "D"
Fa PON
NM's* IracH
oc,
0SLEEVE LOCHNUT
f--CorttoOrsass
ESLOTIE0 ADJUSTING NUT Ito's. loRa
Trachoma
tadFULTIC FOR sr4 Elsonce WP
RELEASE TRAVEL
Strong tomoa
Courtesy of Ljoe-Rollway Corporation
cooler
Figure 5-55 shows a properly adjusted pull aelmol RN.
IRS Osinaglarmiecit
IracaP
Oa hat otala
lea
wdl may rascal**
NalsocattosworrMw
Lubricating Release Bearings
Lubrication of the release bearing is very im-
portant on large equipment. (Release
bearings for clutches in smaller vehicles are
prene.;ked). An example of lubrication in-
structions are shown below:
Milton Vaa calico erattv I. The release bearing housing has not been
pre-packed with grease! it must be
lahmessa lubricated when the clutch is installed in
Front IIMMS WP
the vehicle or Premature failure will occur.
haat Man Pad
Yea Cisaraset-ka
2. Only high temperature greases should be
a-rr-o-itsltaes tarsi
ca far Ta
Vs far TO .21, used. Chassis lube or all purpose
Ira for IS LP lubricants are not recommended.
'SRI Chsten Dna/ tr pd rood ab sperm:clad taitmishaa1-0*
Musa cm atust IM Nast 0115105 trautoat 4 be artariallat,
riternins PooSsolcaCaP.
3. Add lubricant at each chassis lubrication
period or more often if service is extreme.
(5-55) Only a small amount is required.
Courtesy of LopeRoilway Corporation 4. To assure adequate distribution of the
grease throughout the bearing, the engine
fshould he running while grease is being
adried.
278
...---.r.-.
5:30 POWER TRAINS
279
POWER TRAINS 5:31
SAE 30
Temperature
Above 4. 10.
type meeting MILL2104B specificaiions.
MIL11210413 SA E 30 below + 10F.
Mineral gear oil inhibited against rust. oxidation and Mineral Gear Oil SAE90 Above + 107.
foaming. Il and 0 Type SAE 80 Below tor.
Mild E.P. Oil, except SAE90 Above + 10F.
Extreme preSTure oils under some condilions might form
Sulforchlorinelead type SAE 80 Below + 10.F.
carbon deposits on gears, shafts, bearings and sYnchro Mil210g
niter discs, and may also glaze friction surfaces of
synchronize, discs conditions which will result in OFFHIGHWAY AND MINING EQUIPMENT
transmission matfanction and premature failure. It is
Heavy Duty Engine Oil SAE 30 Above + 10T.
suggested that if these conditions exist, and E.P. oil is MILL2104B SAE30 Below + 10F.
being used, a change should be made to mineral oil or
Special Recommendation For extreme told weather
hcavy-duiy engine oil as recommended.
where temperature is consistently below O'F.
280
5:32 POWER TRAINS
2,91
POWER TRAINS 5:33
Lubricating Grease
Use Multipurpose-type Grease, NLGI No. 2
Grade is suitable for most temperatures. Use
NLGI No. 0 or No. 1 Grade for extremely low
temperatures. Wipe all fittings, caps and
plugs before servicing.
Lubricating Oils
Superior Lubricants (Series 3): API Engine
Service Classification CD: Additive type oils
that meet rigid, high quality standards and are
certified for use in Caterpillar diesel engines.
Must contain zinc dithiophosphate when used
in a hydraulic system.
NIL-L-2104A Oil. API Engine Service
Classification CA; or MIL-L-2104B Oil, API
Engine Service Classification CC: Additive
type oils, but milder than Superior Lubricants
(Series 3).
Multipurpose-type Gear Lubricant (MIL-L-
2105B): AN Gear Lubricant Designation, GL-
5: Used in gear compartments where gear
loads and speeds are factors. In extremely
cold temperatures consult your oil supplier for
special Arctic Lubricants.
Your oil supplier is familiar with the oils
meeting those requirements.
"SAE 10W ea may be used in The diesel engine even if daytime ambient f*roperthwe rims to 70.1 (WC), Below 10F (23C)it
may be necessary to warm the enghe oil so tha engine an be stinted and the oil will circulate freely.
140,041in industriel4ype Hydraulic Oils may be used at arkornely low temperatures. Consult your oil supplier for oil moiling this re.
gvirement.
"SAG 140 musr not be used when the ambient ton:potato* k below 32F (VC).
"Consult your oil supplier for special Amtic Lubricants.
232
5:34 POWER TRAINS
IMM=.11.
ITEM
i SERVICE
WHEN REWIRED
Clutches Require periodic maintenance that
cannot be given a definite service
hour interval. Maintenance information
is given in the service manual.
KEY TO LUBRICANT
S3 Superior Lubricants (Series 3) only.
HYD Superior Lubricants (Series 3) containing zinc dithiophosphate. MIL-L-2104A. M`L-L-
21048 or approved industrial-type Hydraulic Oil.
MPG Multipurpose-type Grease
MPL Multipurpose-type Lubricant
283
M
1.1.111.1.1!1IN
TEXT HOUR
SYS1EM OPERATION LOCATION INTERVALS
,§
Clean Breathers
284
5:36 POWER TRAINS
HOURS KEY
TEXT
DRIVE LINE LUBRICATION LOCATION
80 i7
50 012 §2
LUBE'r:AllON KEY
EPGL Extreme Pressure Gear Lube (* * SCL Type) SAE 75. SAE 90. or H090
+ Sequence Tested
* *"SCL" Signifies Sulfo-Chloro-Lead type. Factory fill i' Tiede with SCL type tube and it is recommended
that the same type be used when adding or refillin.
Courtesy of Clarke Moment Co
285
POWER TRAINS 5:37
(5-59)
286
5:38 POWER TRAINS
288
5:40 = POWER TRAINS
289
POWER TRAINS 5:41
290
5:42 POWER TRAINS
2. Check to ensure there are no leaks. 3. Inspect the reservoir. cooler. retarder and
related hoses for leaks or damage and
POWER SHIFT TRANSMISSION report to a journeyman if a suspected
AND TORQUE CONVERTER problem or an unsafe condition exists.
SCHEDULED MAINTENANCE
1. Drain the oil. remove and clean the filter
housing' and install a new filter. Refill the
transmission with the correct type and
amount of lubricant (see service manual).
2. Start the engine and ensure there are no
oil leaks.
DRIVE LINE
ROUTINE MAINTENANCE CHECK
1. On a truck Or tractor truck check and
tighten any loose dr ee line bolts or com-
ponents. Also check the drive line for
wear at the universal joints. splines.
steady bearings and mountings. Report
any suspected unsafe operating con-
ditions to a journeyman.
291
1
BLOCK
O
Frames, Suspension,
Running Gear and
Working Attachments
292
BEARINGS AND SEALS 6:1
ANTIFRICTION BEARINGS
TRUCK
REAR
REAR
WHEEL AXLES
FULL
FLOATING
001.181REDOCTION
AXLE CENTER
MULTI.
COUNTERSHAFT PINION OIFFERENTIAL
TRANSMISSION CROSS SHAFT
FORWARD REAR
COUNTERSHAFT
43P
or
AXLE CENTER AXLE CENTER
di
INPUT OUTPUT HIM TAIL II DIFFERENTIAL
DODEILEDDCEON
SHAFT ly*-SHAFT SHAFT RAFT PINION
IOLER th AXLE CENTER
OIFFERENTIAL
COUNTERSHAFT SHAFT CROSS 11
PINION
th SHAR DIFFERENTIAL
PINION
1114
294
6:2 BEARINGS AND SEALS
OUTSIDE
OUTSIDE DIAMETER
DIAMETER
INNER RING
I
BALL RACE
BORE CONE
CAGE
295
BEARINGS AND SEALS 6:3
RADIAL LOADS
SHAFT
LOADING
NOTCHES
(6-5)
AXIAL LOADS LOADING
BEARING GROOVE BEARINGS
296
6:4 BEARINGS AND SEALS
297
BEARINGS AND SEALS 6:5
Bearing Fit
Ball and roller bearings are usually installed
with either the inner ring or the outer ring a
tight fit. If the inner ring is a tight fit it means
that the bore of the ring is slightly smaller
than the shaft diameter and some force is
298
6:6 BEARINGS AND SEALS
REMOVAL OF BEARINGS
(6-61
Where there is enough space behind a
bearing or bearing ring to admit a puller
always be sure that the puller is adtusted so
that it will not slip over the inner ring when
pulling pressure is applied U this happens
bearing parts can be severely damaged
(6-6)
299
BEARINGS AND SEALS 6:7
Removing Bearings With Arbor and Improvised Tools For Removing Bearings
HYdraulic Presses
Using proper care. bearings can be removed
Figure 6-7 shows the right and wrong methods quite safely with improvised methods when
of removing a bearing with an arbor or the right tools are not available (Figure 6-9).
hydraulic press. The press ram is pushing
down against the shaft on which the bearing A vise will do instead of an arbor press and a
inner ring is tightly fitted. The stripping is drift will take the place of the press ram. If the
being done by the support blocks under the shaft is held in the vise, protect its surface
nngs. The blocks must be the same size and with copper sheet or by hardwood blocks.
squared on all sides. When using a tube, drive alternately on one
Note. as shown in the wrong method that if the side and then the other to keep the bearing
support blocks are spaced too far out the from cocking.
pressure will be against the outer ring or If it becomes necessary to remove a bearing
shield. Damage will result as a heavy stress is by pressure not directly applied to the tight lil-
put on the balls or rollers which can injure ting ring, do not pound it off: use a puller or
them and cause indentation of both races. pry it off exerting even pressure.
Keep the press table and the blocks clean and Sometimes a separable inner ring is installed
square. Provide some means to keep the shaft against a shoulder of equal diameter so that
from falling to the floor. If the shalt and there is no way to get hold of it. Leave the
bearing are very large and the shaft end can- bearing ring on if it is usable. II not. cut it off
not be squared up with the press ram. turn up with a torch. Burn it part way through in order
two steel blocks to make a self-aligning fix- not to harm the shaft. It may loosen enough to
ture between the ram and the shaft. Protect pull off. If not. crack it through the rest of the
the end of the shaft with a pad of lead. copper way with a hammer and cold chisel, using
or other soft metal. precautions to prevent personal injury by
flying parts.
I
4.."
. .k
4 4..
ClItOTHER 0.
SOM MEM
MOLLER
SEARING SORE
A
$
TAPE OR
TO MANY
BLOCKS 1Amate6 cur
- n4cm.oaeR
WRONG Blocks RIGHT Blocks con. otos
contact the bearing tact inner ring - or 7 i-d
outel ring only both rings it bearmy is
flush faced
(6-7)
:4-144E,41:6'
"
To drive shall out of bearing. use a soft metal
slug which will not mar the 'bail
(69)
5
BEARING REPLACEMENTS
As a rule when bearings are taken out they
are discarded and new ones installed. It is
more economic& to replace a bearing while a
machine is down than to reinstall the used
one, even though the used bearing may still
be serviceable. The reasoning is simple: a
new bearing contains more serviceable hours
than a used one Another consideration is that
it makes more sense to replace a bearing than
to risk damage due to bearing failure to the
more expensive part the bearing supports.
Note: Save the used bearing to compare it
with the new one so that you can be ir
roZt
sure you are installing the right f 7v-
bearing. Never pound directly on a bearing or ring. It
will likely damage both shaft and bearing.
When removing a bearing that has failed, take (6-9)
a half a mi:ute to examine the bearing for the
cause of failure. Some of the signs to look for
are:
1. metal fatigue bearing has worn out: it
ran over its serviceable life.
2. scored or scratched rolling elements
and/or races dirt contamination
possibly suggesting poor preventive main-
tenance. or metal chip contamination in-
dicating internal damage.
3. darkened or burned molal overheating tr. t:.
caused by lack of lilt- cation. If ring has been cut to remove. squeeze in
4. roller taper bearings worn on small vise and strike smartly at points indicated to
fracture it Be careful of shaft.
diameter the bearings were adjusted
too loose. (6-9)
roller taper bearings have darkening or
excessive wear on large diameter the
bearings were adjusted too tight.
5 rust, corrosion the bearings were not
lubricated properly.
30j
BEARINGS AND SEALS 6:9
INSTALLATION OF BEARINGS
(i;
_--r NEVER DO
THIS
OR
THI
Never use a hammer di, ocl on any Be Sure blocks will clear threads before A tough hardwood block used like
bearing it will result in damage forcing shaft into bearing this is 0 K protects end of tube
(6-1 1 I (6 -11) (6-1 1)
302
6:10 BEARINGS AND SEALS
seo°41
IQ
303
BEARINGS AND SEALS 6:11
4,
Don't scratch or nick bearing surfaces.
Handle bearings with clean hands and use
,t,
Get the habit of wiping tools and work
clean tools. Handle bearings as little as benches. Clean tools are half the battle in
possible. Finger marks are hard to wash keeping bearings clean.
off and perspiration starts corrosion
(6-13)
6. Don't take new bearings apart. They were
assembled correctly in the first place.
7. Don't spin any bearings with compressed
air.
Keep bearings in their original boxes and Never wash the grease Oil out of new
wrappings until they are to be mounted bearings. It is carefully selected and put
(6-13) there for bearing protection.
(6-13)
,
304
6:12 BEARINGS AND SEALS
305'
...
BEARINGS AND SEALS 6:13
BEARING ADJUSTMENT
Tapered roller bearings must be adjusted to
give the bearing the correct running
clearance or pre-load and then must be
locked into position. Below are some common
bearing adjusting devices. The list is intended
to give a general idea of bearing adjustments.
Service manuals will give the exact
procedures for how to adjust specific
bearings. Always use a torque wrench to get
an accurate adjustment.
306
6:14 BEARINGS AND SEALS
30 7
BEARINGS AND SEALS 6:15
QUESTIONS BEARINGS
1. Name three main purposes of anti-
fric lion bearings.
2. What are the two load forces acting on
bearings? Describe them.
3. What are three basic types of anti-
friction bearings? Give the type of load
each will carry.
4. II the stamped number is not readable on
a used bearing, how would you go about
ordering a new one?
5. The genera: rule is to
bearings when they are taken out.
6. What are the three factors that govern
the capacity of a bearing?
7. How do tapered roller bearings differ in
their load carrying ability from straight
roller or ball bearings? Give two exam-
ples where tapered roller bearings are
commonly used.
8. What three functions must a lubricant
perform for bearings? Where would
grease be used instead of oil to lubricate
a bearing?
9. Referring to tapered roller bearings. what
does the term pre-load mean? Why is it
necessary?
10. What tools are commonly used to remove
bearings in a shop? In the field?
11. Where should the stripping blocks be
placed when removing a bearing with an
arbor press?
12. If a bearing is press-fit on a shaft, at what
point would you apply pressure to
remove it?
(a) the outer race
(b) the inner race
(c) either the inner or outer race: there
is no difference
13. True or False? Grease bearings liberally;
extra grease won't hurt them.
14. A small amount of ______ on a
bearing seat makes mounting the
bearing easier and helps prevent shaft
scoring.
15. True or False? It's an acceptable prac-
tice to spin dry bearings with com-
pressed air.
308
6:16 BEARINGS AND SEALS
309
BEARINGS AND SEALS 6:17
) I
)
I
) I
REAR
STEERING CRONY REAR POWER WHEEL
SEALS CRANK CRANK TAKEOFF (INNEMOUTER)
SEALS SEALS SEALS SEALS
(6-15)
CourteSy of C R Industries
310
6:18 BEARINGS AND SEALS
Courtesy 0 C R Industries
au
BEARINGS AND SEALS 6:19
A lip seal can be bonded. its flexible sealing Lip Seal Operation
material formed and bonded onto a metal
case. or it can be assembled. its parts made A radial lip seal is press fitted into a housinV
separately and then assembled and crimped bore The lip of the seal contacts the shaft
to an outer case (Figure 6-17). thus retaining the fiuid contained within and
helping to prevent dirt from getting into the
system. Note that complete sealing is not
desired. What is wanted is a slight leakage
which leaves a thin film of oil on the shaft that
lubricates and helps to cool the moving parts.
The tension of the lip contact is usually set by
a spring in the seal. This spring tension is very
important to the correct operation of the seal.
Excessive tension would cause too much fric-
tion. loss of oil WM, premature failure of the
seal and even wear on the shaft. Insufficient
X2997 tension would allow excessive leakage.
BONDED SEAL ASSEMBLED SEAL Exclusion Seals
Courtesy of John Deere Lid
Exclusion seals are used to exclude or
prevent entry of dirt and other unwanted con-
Lip seals are classed by the type of lip. Single taminants that would damage the moving
lip not spring loaded. single lip spring loaded. parts. For example. an exclusion seal is
and double lip are three of the most common needed to prevent scoring of a piston rod on a
lip types (Figure 6-18). hydraulic cylinder. Figure 6-19 shows a typical
radial exclusion seal.
SEALING EDGE It
CONTACT
1. LIP HEIGHT
PRESSURE
CONTACT
WIDTH LIP
BORE
312
6:20 BEARINGS AND SEALS
Types 01 Exclusion Seals
Wipers sealing is done by a wiping action
of a stationary leather or rubber lip, often on
reciprocating shafts.
Scrapers stationary metal lip scrapes
heavy clinging material off reciprocating SEALING POSITION
shafts (Figure 6-20).
(6-22) STEP SEAL RING
Counesy of John Deere Ltd
t
SEALING POSITION
CONICAL SCRAPER RING SCRAPER
PUSH ROD
$tr
tkat
:5'
X 2862 mmoiwn
(6-23) SPLITING SEALS ON
AN ENGINE PISTON
(6-21) Counesy of John Deere Ltd
Courtesy of Bendix Corporation
313
BEARINGS AND SEALS 6:21
SEALING RINGS
SEALING SURFACES
(6-24) Courtesy 0$ J I Case
SEAL CONTACT AREA Tne two mated seal rim?) s of metallic face
seals are precisely lapped to one another. In
operation the sealing faces have a narrow
contact at the outside diameter (Figure 6-25)
and the remainder of the faces are tapered
back slightly. As the seals wear the area of
contact increases. moving across the width of
the seal.
314
6:22 BEARINGS AND SEALS
STATIC STATIC
SEAL SEAL
METALLIC PACKINGS
X3018
ROTATING (6-27) STRING PACKINGS
SHAFT
Courtesy of John Deere Ltd
HOuSING Molded. compressed pack ings are circular
(STATIONARY)
rings made of various materials compressed
into definit "U" or "V" cross - sectional pat-
terns. The compressed rings come in various
sizes depending on the shaft bore they are to
fit. Several of these molded rings are used
with metal back up rings on either side. one of
which may be spring loaded. Figure 6.28
shows molded "V" packings (with back up
STATIONARY ROTATING rings) used to seal a reciprocating shaft.
SEAL RING SEAL RING
X30 IS
(6-26) ADJUSTING NUTS
Courtesy of John Deere Ltd
Compressed Packings
Placed in a stuffing box next to a moving shaft
or rod. packing material is compressed to
form a seal against the shaft or rod. For exam-
ple. packing is used to seal rotating shafts in
pumps. or to seal reciprocating shafts such as
a piston or a piston rod in a hydraulic cylinder.
4FEMALERING
SUPPORT
FABRIC PACKINGS
The size of compression packing is very im-
portant. If too small. it will require too much
(6-27) compression to seal. If too large. it will cause
Courtesy of John Deere Ltd
315
r=MNid
CUT
INCORRECT: TOO-LARGE RING
4 FORCE
316
6:24 BEARINeS AND SEALS
BASIC FLANGE
MER_
METAL-TO-METAL
ELL
THREADED
(6-30) COMMON TYPES OF GASKETED JOINTS Flange finish a rough flange surface
COMESY of John Deere Ltd. requires greater stress for the gasket to con-
form than does a smooth flange surface
The joints between two stationary. mated sur- would.
faces is only as good as its gasket. Gaskets
must be of suitable material to seal the sur- 0-Rings (Static)
faces and they must be installed correctly.
Gasket fit refers to the term "minimum stress A static 0-ring is a type of gasket that seals
required". the minimum amount of stress it the movement of fluids across two mated sur-
takes to make the gasket material conform to faces. Figure 6-32 shows two static 0-ring in-
the irregularities of the flange faces and thus stallations.
for a seal (Figure 6-31).
FLANGE
GASKET
1.--;LANGE
NO CONFORMATION FULL CONFORMATION
Bad Good
(6-32)
X3033 NON-METALLIC STATIC 0-RINGS
X3031 IN FLANGE JOINTS
(6-31) CONFORMATION OF GASKET TO FLANGE (TWO TYPES OF RECTANGULAR
GROOVES SHOWN)
Courtesy 01 John Deere Lid
Courtesy of John Deere Ltd.
327
BEARINGS AND SEALS 6:25
Like dynamic 0-rings. static 0-rings fit in a 3. Be sure the seal. the shaft. the seal bore
groove and are squeezed or compressed by or groove is absolutely clean on assembly.
about 10% of their thickness. It is important to
install the correct size 0-ring as one too large 4 If a seal is leaking don't just replace the
will squeeze out between the flange, and one seal take a quick look for the cause of
too small will not have sufficient tension to the leak.
seal. As well as normal frictional wear. possible
Sealants causes could be (Figure 6-34):
Sealants perform a job similar to that done by worn shaft support bearings allowing
(a)
gaskets. Where a gasket is a set shape and excess movement of the shaft.
size though. a sealant is applied in liquid or
paste form. Sealants are generally applied to (b) plugged vent creating excess
a joint that has less pressure and lower tem- pressure within the housing.
perature than a joint where a gasket would be (c) worn or scored shaft seal surface
used. Sealants are also used to provide a high temperature.
(d)
protective coating, to reduce noise and to aid
in sealing gaskets. Sealants can be applied by (e) what looks like a seal leak could be
brush, tube. or spray (Figure 6-33). In fact a loose bolt. a cracked
housing. or a worn gasket.
O e..
318
6:26 BEARINGS AND SEALS
...
319
BEARINGS AND SEALS 6:27
Removal
Installation
FIG 1 Clean the packing bore. the shaft. the
gland. and back up rings with solvent and
blow them dry. File or emery smooth any
burr or nicks on the shaft. bore or gland.
Replace worn or damaged parts.
FIG C
2. When installing packing rings:
INSTALLING FLOATING RING SEAL Lubricate liberally each ring of a new
AND TORUS SEAL packing.
iTorus seal 2Floating rir.g seal. 3Location
to press on seal X-Dimension Install the packings with the "V" point-
to be checked ing toward the gland.
(6-36) Stagger the diagonal split joints of the
packing rings.
320
6:28 BEARINGS AND SEALS
Removal
Removal of 0-rings is a straight forward
procedure.
321
BEARINGS AND SEALS 6:29
QUESTIONS SEALS
1. What are the two basic types of seals
and what is each used for?
2. Name three jobs a seal may be required
to do.
3. When installing a lip seal. is it desirable
to have a slight leakage? Explain.
4. When installing a lip seal. which way
should the lip go?
5. Which has more positive sealing action.
a lip seal or a metallic face seal? Under
what type of conditions are metallic face
seals used?
6. Should compression packings allow a
slight leakage when adjusted correctly?
Explain.
7. What effect does gasket material have
on minimum stress required to make the
gasket conform to the irregularities of
the flange faces?
8. When an 0-ring is used as a static seal.
how much should it compress? What
would happen if an 0-ring that is too
large is used?
9. Bores. shafts. and flange surfaces should
be before installing a new
seal or gasket.
10. Which is the accepted rule when an old
seal is removed?
(a) Carefully inspect it. and. if not too
badly worn. reinstall it.
(b) Replace it with a new one.
11. A tool should
be used when installing a lip seal.
12. Can metallic ring seals be reused? What
about the toric or tension 0-rings?
.. 322
6:30 BEARINGS AND SEALS
ANSWERS SEALS
1. Static seal seals stationary parts.
Dynamic seal seals moving parts.
2. Retain a fluid
Exclude dirt
Hold pressure
Hold a vacuum
3. Yes. a slight leakage lubricates the
moving parts and helps to cool them as
well.
4. Towards the fluid it will seal.
i
5. A metallic face seal. Metallic face seals
are used in severe conditions that
require a strong. positive seal (e.g.. track
rollers).
6. Yes. for the same reason as lip seals: to
lubricate and cool the moving part.
7. A soft material conforms easier than a
harder one and therefore less stress is
required to form a seal with a gasket of
soft material.
8. About 10%. Too large an 0-ring will
squeeze out between the flange faces.
9. . .. cleaned ...
10. (b) Replace it with a new one.
11. . . . seal installation . . .
SEALS
1. Remove front wheel seal. and install a
new seal using the correct size seal
driver.
324
TRACK MACHINE UNDERCARRIAGE 6:33
GROUSERS
TRACK
SHOES IDLER
PINS a
aUSHINGS
TRACK ROLLER
FRAME
TRACK ROLLERS \MP' LINKS
BASIC UNDERCARRIAGE COMPONENTS
32g
6:34 TRACK MACHINE UNDERCARRIAGE
Carrier rollers
Final
drive case
Links
Sprocket
Idlers
Track roller frame
327
TRACK MACHINE UNDERCARRIAGE _ 6:35
...-...a.L...../11111a_ _-,Mllur-_
Ia DIAGONAL BRACES
(6.41) ,.,
Courtesy of Caterpillar Tractor Co
.: 328
6:36 TRACK MACHINE UNDERCARRIAGE
329
TRACK MACHINE UNDERCARRIAGE 6:37
CENTER GUDGEON
AND VERTICAL
HYDRAULIC
FINAL PROPEL SHAFT
STEERING COMPONENTS
DRIVE CRAWLER
GEAR ASSEMBLY
CASE CARBODY
":-
PROPEL
GEAR CASE
Courtesy of Harnistifeger Corporation POI
1. Front Idler
2 Carrier Roller
3. Recoil Cylinder
4. Final Drive Assembly
5 Track Chain Assembly
6. Track Roller
7. Track Roller Frame
8 Track Shoe
C rurleey of Tere* General Molars Corporation
IF;te 33o
6:38 TRACK MACHINE UNDERCARRIAGE
Track Frames
Track frames provide a housing onto which all
the other undercarriage components are
mounted. The frames are drilled and tapped or
have bolting strips to mount the various com
ponents. Track frames are usually made of
channel or box shaped steel (Figure 6-45). OPEN CHANNEL
BOX-SECTION SOLID STEEL
Box shaped is used on large machines as it is
more resistant to cracks and bends. Solid (6-45) CAT
steel is also used on some large machines. Courtesy ol Caterpillar Tractor Co
Dozers with oscillating (moving up and down) Some manufacturers attach the frame ahead
track frames require some way of keeping the of the sprocket centerline and they may or
frames in alignment. One way is to weld a may not use a diagonal brace. To further aid
diagonal brace to the inside face of the track frame alignment dozers have a guide roller or
frame. thus allowing the frame to be attached bar towards the front of the machine. The
to the rear of the tractor at two points along guide rollers in Figure 6-47 are located just
the sprocket centerline, points A and B in behind the equalizer bar.
Figure 6.46.
DIAGONAL BRACE
A
SPROCKET
SHAFT-0.
(PIVOT SHAFT)
WI nil IlDiLiTKR PAIN
1.111-11 iff in 111- ni ire II
(6-46)
11
ftk...,A,
TRACK MACHINE UNDERCARRIAGE 6:39
On machines using springs as a recoil The hydraulic track adjuster (Figure 6-49) con-
mechanism the springs are compressed to a sists of a piston (6) installed in a cylinder.
specific length Then they are held by a Grease is forced into the cavity (3) to push the
through-bolt and positioned between stops recoil rod. yoke and idler outward to tighten
welded or bolted to the track frame. Recoil the track. Venting the cavity will slacken the
springs on some crawlers are submersed in track. Figure 6-50 shows a more detailed view
oil within the frame. of a hydraulic track adjuster cylinder.
integrated with the recoil mechanism is a Caution: the adjuster cylinder is under high
hydraulic track adjuster. a device that pressure. Therefore. venting the
tightens or slackens the tracks. Many track cylinder to slacken the track must
adjusters are located between the recoil be done with care.
spring and the front idler (Figure 6-43). The
adjuster may be part of the recoil rod or it may
be fitted into the front spring seat to act
against the recoil rod. Other track adjusters
are positioned within the springs (Figure 6-
49).
173134
RECOIL MECHANISM
YOKE '
(6-48)
.332
6:40 TRACK MACHINE UNDERCARRIAGE
7 8 13
=
14e.--IIIL
1941:41re-0-11- =
18
_ 7-7
16 15
(6-51)
LINKS RIDE HERE
1. Poston Rod
2 Giant Grease Fitting
3. Rod Guide
4. Bearing
5. "0" Ring
6. Backup Ring
7. "0" Ring
8. Retainer Plate INTERNAL
9. Screw GUSSETS
10. Bushing
11. Backup Rings
12. "0" Ring
13. Nut
14. Charging Valve
15. Piston
16. "0" Ring
17. Cylinder
18. Bleed Valve CENTER FLANGE
19. Seal
(6-52) FRONT IDLER
*.
artCr. 3.3J
TRACK MACHINE UNDERCARRIAGE 6:41
(6-53)
SPOKE SPROCKET
III 111111
(6-52)
on
4 ' 0.r 1.
r
r, ii;
334
. fj V
6:42 TRACK MACHINE UNDERCARRIAGE
(6-55)
335
TRACK MACHINE UNDERCARRIAGE 6:43
-ft
'176:,
IA 1
Aft.
(t$1.
DRIVE TUMBLER
Ills Sprocket Is Behind DRIVE SPROCKET
The Tumbler)
SHOES (6-57) Courtesy of Massey Ferguson Inc
1" DRIVE CHAIN 1" SHIMS
;"'.
r7-7:744-i,\
41111.ii
Inn
117?;:u
,C*Z-
ti,17,
, . 1,#),
336
6:44 TRACK MACHINE UNDERCARRIAGE
Flanges aid in keeping the track on the rollers Oil is forced into this passage and into a
and thus in line. If the roller has outer flanges cavity between the roller shell and the
only. it is called a single flanged roller. if it bearings. With the roller in a horizontal
has both outer and Inner flanges. it is balled a position the oil is fed in with a special nozzle
double flanged roller. Figure 6-58 shows a screwed into the end of the shaft. As the oil
double flanged roller. enters. the vented nozzle allows air to escape.
Once filled to a point where oil comes out the
TRACK ROLLERS nozzle. a plug is inserted into the shaft to seal
it. The oil filled passage and cavity act as a
reservoir for the roller.
700.4011.'"'
Such a lubricated roller is referred to as
kA 404gre". lifetime lubricated. although it can be topped
up if required. Generally though, if a roller is
leaking. trouble is indicated and the roller
,should be removed and repaired. Individual
rollers can be removed without having to take
off the track frame. as is shown in Figure 6-
ti 57).
(6-58)
Courtesy of Caterpillar Tractor Co
6
1409 3
Crawler dozers. loaders. and excavators TRACK ROLLER LUBRICATION
usually have an equal number of rollers. 1- Shaft. 2-Metal floating ring seals. 3-Passage. 4-Plug.
starting with a double at the front of the 5-011 passage. a-Reservoirs. 7-Passage.
machine and ending with a single at the (6-59)
sprocket. If there is any variation in this pat- Courtesy of Caterpillar Tractor Company
tern it will occur at the front of the machine
because a single flange roller always comes
next to the sprocket. The number and size of Shovels and cranes generally use a different
track rollers will vary from machine to type of track roller. It has a solid center flange
machine.
which runs in a groove in the track (Figure 6-
60). However. if a shovel or crane is equipped
Track rollers for dozers. loaders and ex- with tractor-type tracks. it will use single and
cavators have a forged steel shell with double flange rollers like those used on
replaceable anti-friction bearings or bushings. dozers.
Most manufacturers favor the bushing be- SEAL
cause it has greater :oad carrying capacity. is
cheaper. and takes less space. The rollers
turn on a stationary shaft held by end caps
bolted to the tracx frame.
Rollers are sealed and lubricated on assem-
bly. Most manufacturers use a metal face seal
(floating ring seal). one pair on each side of
the roller. because it's the most durable type
of seal for the severe conditions under which
rollers perform. The shaft is drilled lengthwise
part way. and then cross drilled (Figure 6-59). (6.60) SHOVEL TRACK ROLLER
Courtesy of Bucyrus Erie Co.
'337
TRACK MACHINE UNDERCARRIAGE 6:45
6 7 8 9
End collar Seal support. 0-ring. End cover.
(6-61) CARRIER ROLLER CROSS-SECTION
Courtesy 0 Caterpillar Tractor Co
TRACKS
Tractor tracks are made of a chain with shoes
bolted to it. The continuous chain (with the
master pin inserted) travels an elliptical route
from the sprocket, over the carrier roller(s),
around the front idler. under the track rollers
and back around the sprocket. providing a
running surface for the machine to travel on
(Figure 6-62).
(6-62) 41PP
-7041111piir
Courtesy of Caterpillar Tractor CO
V 338
6:46 TRACK MACHINE UNDERCARRIAGE
Track Chains Track chain seals are two conical washers in-
stalled back to back in the link counter bore.
Track chains for a crawler dozer. loader and The seals are compressed. one against the
excavator are virtually the same. differing link counter bore. the other against the
mainly in their size A track chain consists of bushing end. as shown in Figure 6-63. When
two rows of links pined together by pins and the chain bends. the two seal washers turn
bushings. The pins and bushings have a against one another forming a seal.
clearance fit with one another. but are press-
fit into the links (Figure 6-62). The track chain just described is called a
sealed track and is common among many
The links are drilled on the top surface to ac- manufacturers. The latest development in
cept the shoe and are flat on the bottom lo tracks from the Caterpillar Tractor Company
provide a running surface for the track rollers. is the sealed and lubricated track.
The links are paired left and right and in-
terlock with one another. One end of the link
has a large hole to fit the bushing (with pin in-
side) and the other end has both a counter
bore to fit the bushing and seals. and a
smaller hole to accept the part of the pin ex-
tending beyond the bushing. Since the pins
and bushings are slightly oversized in relation
to the link bores. they must be pressfit into
the bores. This press-fit both holds the chain
together and allows it to be flexible. i.e..
hinge.
....:- .
(6-62) TRACK CHAIN LINK SEALS SEALS NOT COMPRESSED SEALS COMPRESSED
Courtesy 01 Caterpillar Tractor Co
(6-63)
Courtesy of Caterpillar Tractor Co
SHOE
BOLT HOLES
BUSHING
SEALS
RUNNING SURFACE
PIN LINK
COUNTER BORE
330
0
9,..
TRACK MACHINE UNDERCARRIAGE 6:47
The sealed and lubricated track (Figure 6-64) identified by the way it is retained. e.g.. a snap
uses the same link-pin-bushing arrangement ring. lock pin or machined step on one side of
as the sealed track. but the pins are lubricated the pin. The master bushing. too. differs from
and the seals are more positive (i.e.. they give the other bushings in that it is shorter to per-
a more complete sealing action). mit joining the track.
SEAL ASSEMBLY Figure 6-65 shows a master pin being in-
stalled. Note on this particular pin the
machined flat and the matching hole in the
master link.
CROSS ,)0
HOLE
ffrl.
THRUST RING s ''
T$4347
(6.641
(6-65) INSTALLING MASTER PIN
Coonesy of Caterpillar Tractor Co (Track Shoes Removed for Better Illustration)
ALink. B-- Master pin. CMaster link.
Couriesv of Caterpillar Tractor Co
The pin IS the same size and length as before
but harder for added strength needed be-
cause of the hole drilled through its center.
This hole is the oil reservoir. A cross hole
provides a passage for oil to gravity feed to
the pin and bushing contact area. Alter the
seals are installed in the counter bore the
lubricant (90EP) is added and the passage
plugged with an expandable stopper. This
rubber material at me end of the pin is a visual
indicator of lubricated tracks.
The bushing is shorter than that of the sealed
track to allow room for the wider seal. The
ends of the bushing are lapped (smooth) for
the 'seal to ride Against. A two stepped
bushing is used on larger machines, thicker in
the center to give added strength.
Track chains, in general. are made to lengths
that fit specific machines. Chains will also
vary in the size of the link and in the pitch
length. the distance pin center to pin centei.
Pitch lengths will depend on the pitch of the
sprocket that drives the chain.
Tracks need to be coupled and uncoupled. A
master pin is the most common method of
separating tracks. The master pin is slightly
smaller than the other pins and can easily be
340
6:48 TRACK MACHINE UNDERCARRIAGE
Large Caterpillar machines are now using a Contact area (width of shoe)
master link (Figure 6-66) in place of a master Bending resistance
pin This master link simplifies removal and
installation in that the link has only to be un- Self-cleaning action
bolted to be disconnected The link saves Wear
time. and thus money. needed to service the
tracks Most machines have a standard shoe width.
but narrower and wider shoes are available.
The rule of thumb to follow regarding shoe
width is to use the narrowest shoe that
provides flotation and. at the same time.
allows full penetration of the grouser in
average conditions. The width of the shoe is
(6-66) * Rc54*
critical because the wider the shoe the
greater the load on the other undercarriage
Courtesy 0 Caterorliar Tractor Co components. This point is illustrated in Figure
6-67: two different sized shoes walk over a
Track Shoes rock on the outside of the shoes. The longer -
shoe has a greater lever arm, and therefore
Track shoes are bolted to the track chain The greater force is imposed on its roller flange.
shoes distribute the machines weight over
the broad surface area where the shoes con-
tact the ground. There are many different
types of track shoes. each suited to a par-
ticular machine. job and terrain.
It IS important that a crawler machine have the
right shoes for the job to assure maximum
track shoe life and minimum wear on the other
components. Terrain is probably the most im-
portant factor In selecting track shoes. Three
broad terrain conditions are dirt. rock. and ice
or snow A dozer will work on everything from
flat. soft soil to steep rocky slopes. A loader.
on the other hand. will generally work on level
compact matenal. Excavators and cranes
work in much the same conditions as loaders.
but they require a different type of shoe. The
excavator shoe is broad and flat (traction is
not a main concern) to give the heavy
machine good stability and flotation because
the upper works revolve 360 Other factors to
consider in selecting the correct shoe are:
Flotation
Traction
Penetration
S.
341
TRACK MACHINE UNDERCARRIAGE 6:49
AFFECTED AREAS_.
Grouser Shoes
Grouser shoes are a flat steel plate with one
or more vertica: oars (grousers) that vary in
height end width. The purpose of the grouser
is to penetrate the ground to give traction and
mobility. Figure 6.68 illustrates the heat treat-
ment in a single grouser shoe. The light area
is very hard while the darker area is softer.
The soft area is necessary to allow the shoe to
flex to prevent it from cracking.
(6-68)
Courtesy of Caterpillar Tractor Co , ... '
342
$ %.
6:50 TRACK MACHINE UNDERCARRIAGE
a1; ::'.
3.43
TRACK MACHINE UNDERCARRIAGE 6:51
;
1, X 'to:'
%Is. *.
344
6:52 TRACK MACHINE UNDERCARRIAGE
.a4;i411
(6-74) "TRACTOR TYPE" TRACKS
Courtesy of 8ucyrusErie Co.
.4ealillidtillik`").
,.. Ar.
-
-
.- 4-4
., -
'
..';'.. . ..1,15.,.___aaliak-
tis
4,ft
AR.
6
.t2
a.. 345
TRACK MACHINE UNDERCARRIAGE 6:53
, .,
4,
-
(6-77) Courtesy of BucyrusErie Co.
SHIMS
346
6:54 TRACK MACHINE UNDERCARRIAGE
4ad.. Lal_swalw
(6-79)
Ash.
Large diameter swing circles are fully en-
closed anti-friction ball bearings. They
are sealed to exclude dust and other
foreign material
(6-80)
Courtesy of BucyrusErie Co.
(6.81)
Courtesy of BucyrusErie Co.
347
TRACK MACHINE UNDERCARRIAGE 6:55
UNDERCARRIAGE GUIDES
AND GUARDS
Track guides and guards (Figure 6-82)
generally apply to crawler dozers and loaders.
(6-82)
Courtesy of Caterpillar Tractor Co
348
6:56 TRACK MACHINE UNDERCARRIAGE
349
TRACK NW-NINE UNDERCARRIAGE 6:57
I
350
6:58 TRACK MACHINE UNDERCARRIAGE
l'i 1. 351
.to. .,`
TRACK MACHINE UNDERCARRIAGE 6:59
AFTON MINE, KAMLOOPS
DATE: MECH:.
1900 AL SHOVEL Hr. Reading: 301___ 302__ 303 301 302 303
Dipper teeth. caps pins
Generator bearings
Magnetorque lubrication
COMMENTS/PARTS USED'
2
6:60 TRACK MACHINE UNDERCARRIAGE
GIBRALTAR MINES
"- 353
-,
...b '
TRACK MACHINE UNDERCARRIAGE 6:61
4. Inspectthe guards and covers for Loose tracks (Figure 6.84) will not stay
damage. and for loose or missing bolts. aligned. accelerating wear on the idler and
roller flanges. At high speeds a loose track
5. On shovel tracks. check the track pins will slip and damage the links, idler and roller
and keepers and the track tension. flanges. On a side hill or in adverse conditions
Any minor problems should be repaired and loose tracks have a tendency to jump off. A
major problems reported. loose track is also hard on the sprocket. In
reverse the track will bunch up at the back of
Also note that track undercarriages should be the sprocket (Figure 6-85). causing sprocket
cleared ol debris at the end of the day. a job jumping which puts extreme stress on the
usually done by the operator. This cleaning is teeth.
particularly important if the weather is cold
and if the machine is working in mud or in
material that compacts. Left overnight. the
debris could freeze solid in the tracks.
TRACK TENSION:
DOZER% LOADER% EXCAVATORS
Track tension is the most important running 4
adjustment to be matritained on any track
machine. There are several reasons why
tracks require frequent adjustment. One is TOO LOOSE
that material. such as clay. builds up on the (6 -84) LOOSE TRACKS
sprockets and track chain, and the track must Courtesy of Caterpillar Tractor Co
be adjusted to make allowance for it. Another
reason is that the track stretches due to wear
on the pins and bushings. Track stretch is
discussed in detail later.
Tight tracks (Figure 6.83) accelerate wear on
all undercarriage parts pins and oushings. V. I
links. sprockets. rollers. idlers and reduce 6.
the tractor's horsepower because of in
-1,1!
.4
(6.85) ';1,1e,Fa".M.
I +: 354
6:62 TRACK MACHINE UNDERCARRIAGE
CORRECT
(6.85) i1:--
Counesy of Caterpillar Tractor Co aLr-".-1 -
[
355
TRACK MACHINE UNDERCARRIAGE 6:63
356
6:64 TRACK MACHINE UNDERCARRIAGE
ti
(6-91)
Courtesy of Massey Ferguson Inc
-
b( mos (1.0.C._ttg!!_(..). P oz=b- (:47111Iiiks
C;f'
#r9
1114
IDLER END
DRIVE END (6-92)
357
TRACK MACHINE UNDERCARRIAGE 6:65
SHIMS (6)
SHIMS (A)
DRIVING
/
TUMBLER
wi-01-"WW.1r
'0I I WijitrIA ri 1,,,at
14Im 111111.._iii HYDRAULIC
40;k---.....-w-7._.\.. JACK
AIIIMIII.'
tlir
__.._
,
7/1....o....,
.......
-_,.....7_
_ ......_,,,
w,
.
-r &
.......... As,..
TAKE UP
SHAFT HYDRAULIC PUMP
2229
301,
6:66 TRACK MACHINE UNDERCARRIAGE
GUESTIOta UNDERCARRIAGE
DAILY, ROUTINE MAINTENANCE
1. What is the best source of information for
the daily, routine maintenance checks
that Should be carried out on a machine?
2. Why are maintenance checks necessary?
List at least four things that should be
checked during a daily walk around in-
spection of the undercarriage.
3. What is a common method used to
measure track tension?
4. Briefly explain why correct track tension
is important.
5. On a hydraulic track adjuster grease is
added to ___ hie track and
to loosen it. On a gas-
charged combined recoil mechanism and
track adjuster grease is _____ to
slacken the track and vented to
it.
6. What precautions must be observed when
slackening a track equipped with a
hydraulic track adjuster?
7. Some shovels and canes have two
"chains" on each side. a drive chain and a
track chain. If both needed adjusting.
which one must be adjusted first? What is
the usual method of adjustment?
359
f
NEW LINK
PIN
ASSEMBLY JOINT
BUSHING
PRESS Fit BUSHING WEARS PIN
(No movement between SPROCKET WEARS
link and bushingSr,.. BUSHINGS
BUSHING WEAR
4
CENTERLINE OF PIN 111- l oeCENTERLINE OF BUSHING
AMOUNT OF TRACK LENGTH
INCREASE PER LINK
(6-95) PIN AND BUSHING WEAR Courtesy of international Harvester
360
6:68 TRACK MACHINE UNDERCARRIAGE
< >
Track s-t-re-t-ches
.0
361
TRACK MACHINE UNDERCARRIAGE 6:69
362
,;(4,.. ,
6:70 TRACK MACHINE UNDERCARRIAGE
Rebuildabie? Lifetime?
Rerliorned?
Lifetime? Rebuildoble? MEM
Anal drive leaks? Chipped?
Leeks?
Crocks?
Crocks?
Bolt on ? Reinforced?
TRAtZ ROLLERS SOURCE
Tread diameter Ls.? 1 mewl GENERAL torts reposentativa
Front Substitute parts Service department
Rear Track odjustment Machine salesman
Other Mechanical or hydraulic Mobile track press
Flange condition Tension spring condition Track Si roller shop
Inter/101 condition Alignment Used parts
Quantity; SF Frame cracks
DF Visible reinforcement
Condition of:
L if. time? Rock guard
Roby ihlable? Equalizer spring/bar
Leaks? Weer stripe & guides
Dote Howe Links Pitch Bushing Shoes Sprockets Idler. C/Rollere T/Rollers Howe Call
___ Left Beck
--,,--
_.
363
TRACK MACHINE UNDERCARRIAGE 6:71
O 96 6.12 ' 0 5.69 0 41.04 0 3.37 0 3.44 0' 3.44 0 .88 0 0.62 t 0' 10.62 07. 10.62 0
10.2s- 4.00 27 5.60 25 41.15 23 3.34 25 2.80 26 2.90 28 .96 29 8.46 25 10.42 22 10.46 22
5.88 63 5.50 52 41.30 54 3.31 50 2.20 51 2.40 54 1.04 52 8.30 51 10.18 49 10.26 49
5.78 76 5.42 75 41.40 75 3.28 75 1.60 75 2.00 74 1.14 76 8.10 76 9.94 75 10.06 76
5.6 1.4 ii 11 LI 1.00 00 0 .. i.s . 100 9.62 100 9.87 OQ
09 t26 1 6 644264
240421.24 % 724444 % I 2 1426 % % Da / 423.24 %
9.03"
5.25 0 36.04 0 3.19 0 3.06 0 3.06 0 .90 0 8.432 0 lom 1 0
5.16 27 36.15 Z3 3.16 25 2.50 27 2.60 29 .96 29 8.46 25 10.46 23
5.06 51 36.30 54 3.13 50 2.00 51 233 49 1.04 52 8.30 51 10.26 52
5.00 75 36.40 75 3.10 75 1.50 76 1.90 74 1.14 76 6.10 76 10.10 75
4.90 100 38.52 100 3.07 100 1.00 100 1.93 100 1.24 100 7.87 100 9.93 103
364
6:72 TRACK MACHINE UNDERCARRIAGE
Measuring Tools
Plastic track wear gauges (Figure 6-99) are
available for many machines. Gauges are not
always the most accurate measuring tool. but
they are handy and easy lto use. A ruler. depth 0
gauge. tape measure. and set of outside
calipers (Figure 6-100) will give reasonably foimpotisvie
accurate measurement of undercarriage com-
ponents in the field. (6-100)
38
6.4.1.7Of
1001,004
72" STEEL TAPE MEASURE
Courtesy 01 Caterpillar Tractor Co.
(6-99)
Courtesy of Caterpillar Tractor Co To perform a track measurement inspection,
move the machine to level, firm ground. clean
any accumulated material from around the
tracks. and do a walk around check. Before
measuring the tracks Check the top part of the
, bushing with your finger to make sure the pins
ipproirrir ,
and bushings have not already been turned.
BUSHINGS
(External
0
(6-101)
(6-100) Ii
WIDE BASE DEPTH GAUGE
(Lufkin 509E depth gauge Shown here)
Courtesy of Caterpillar Tractor Co
365
TRACK MACHINE UNDERCARRIAGE 6:73
Internal Pin and Bushing Wear Divide the measurement by four. the number
of links included. to get a figure for the
To take up the slack in the track. place a present track pitch. Look up this figure on the
block of wood or a steel pin in a sprocket wear chart to find the percentage the pitch is
tooth and then reverse the tractor. Measure worn. Note that some wear charts such as the
from the side of one pm to the same side of one shown give a four link measurement. and
the fifth pin away. This measurement will in- so it is not necessary to divide by four.
clude four links (Figure 6-102). The pins
measured should not be within two of the The same measurement procedure should be
master pin. and should be taken on a section repeated on the master track section to deter-
of the track that is not on the ground. mine whether the master pin and bushing
should be replaced. The master pin and
bushing always wear faster than the others
because there is a greater clearance between
them, necessary for breaking and connecting
the track. Of course. the second measurement
would not be applicable where a master link is
used rather than a master pin.
U the track pitch is not beyond wear limits and
if the bushings are not cracked. the pins and
bushing can be pressed out and turned 1130`..
Turning the pins and bushings will greatly ex-
tend track service life. Figures 6-103 and 6-
104 show the effects of rotating the pins and
bushings.
CENTERLINE OF SPROCKET PITCH
N./ lAk..CENTERLINE
OF WORN
TRACK PITCH
BEFORE TURNING
XVO9 (6-104)
CENTERLINE OF BOTH TRACK
AND SPROCKET PITCH
RE-ESTABLISHED
AFTER TURNING
(6-104)
Rotating Worn Pins and
Bushing 180 Degrees
excessive wear causes stretch between bushings; Courtesy 01 John Deere Lid
bushings then tide up on sprocket teeth
(6-103)
366
6:74 TRACK MACHINE UNDERCARRIAGE
It should be pointed out that not all machines number of hours before turning and after turn-
will have their pins and bushings turned. ing. For example. if by using method one you
Some abrasive working conditions wear parts have 800 hours before turning. 1100 hours af-
very quickly and make turning uneconomical. ter and 1900 hours total. the next time you
Also. some companies have a policy of sun- should try turning at 1000 hours You will
ning the undercarriage to destruction doing probably get 1000 hours after turning for a
little or no repair. total of 2000 plus hours.
The third method involves turning the Pins
and bushings at one half the expected link
life. Method three assumes that from past ex-
When To Turn Pins and Bushings perience you know what link life will be and
also assumes that the machine is working in
Correct timing of turning pins and bushings is similar conditions. This method will not
important.
usually work if link life exceeds pin and
bushing life by more than 50 percent.
WHEN DO YOU TURN PINS AND BUSHINGS?
Better late It's better tot Example Problems For Method Three:
than never. turn too early
'flan too") 1. Normal link life 3000 hours
Normal pin and bushing life
(without turning) 2000 hours
Solution: Turn at 1500 hours pins and
bushings should last 1500
hours after turning to give a
total of 3000 hours.
2. Normal link life 3000 hours
Normal pin and bushing life
(no turning) 1600 hours
i
Solution: In general replacing pins and
bushings at 1500 hours rather
than turning would be best.
367
TRACK MACHINE UNDERCARRIAGE 6:75
Link Wear
Links form the surface or rails that a machine
runs on. They are rugged parts that take a lot
of abuse especially if the tracks are allowed
to run loose. or if the machine is run at high
speed. Normal link wear is caused by the links
contacting the rollers and idlers.
Types of link wear are (Figure 6-106):
Rail tread wear
Rail side wear
Rail inside gouged
Pin boss worn
Bolt holes wallowed oul or elongated (6-107)
(shoes run loose)
Worn counter bore. Track Shoe Wear (Grouser Heighth)
Rest the crossbar of a depth gauge. or a steel
rule, across two grousers (Figure 6-108).
vieasure from the bottom of the crossbar o'
rule to the shoe plate to determine the grouser
height. Grouser wear is the difference be-
tween this height and the height when new.
RAIL
SIDE WEAR
WORN
COUNTER BORE
(6-106)
Courtesy 01 CaleMillar Tractor Co
'.
(6-108)
ass
6:76 TRACK MACHINE UNDERCARRIAGE
Shoes should nut be allowed to wear too much ll rock guards are installed roller diameter
if rebuilding is intended. As the grouser cannot be measured with a caliper. Here is an
wears. the shoe loses its beam strength and alternate method (Figure 6-110
will bend Also, once worn beyond the depth
of the hardening. the grouser will wear Measure vertically from the shoe to the center
rapidly Check the worn chart for the grouser of the roller shaft to get "B". Subtract link
rebuild limit height "C" to get roller radius "A ". Cocking or
tilting the shoe. or a bent shoe. will cause
Track Roller Wear inaccuracy. Take three or more
measurements and average them. Example: If
Roller diameter is calculated by calipering the the roller shaft center to shoe height. "B" is 9
roller tread (Figure 6- 109). The worn diameter. inches and rail height. "C" is 5 inches. then
when subtracted from the new roller diameter. roller radius. "A'S will be 4 inches. Taking this
gives the amount of surface tread wear. radius and doubling it will give the worn
Check the worn chart for the track roller diameter of the roller. 8 inches.
rebuild limit. Track roller wear is shown in
Figure 6-110. ROLLER RADIUS
(on machine with roller guards installed)
ROLLER DIAMETER
(6-1 11)
1.
R
A
Side hill operation caused this Contact ith link rails caused
roller flange wear. this roller tread wear ...
(6 -110)
Courtesy of Caterputfer Trocie Co
369
TRACK MACHINE UNDERCARRIAGE 6:77
IDLER TREAD
rag.
s'474os °
t
(6-112)
:Eutaw/A
(T75449)
(6.113) CHECKING SPROCKET TPC:re WEAR
Courtesy of FiatAnn Construction
Machinery Ltd
370
6:78 TRACK MACHINE UNDERCARRIAGE
Wear Gauges
Gauges for specific machines are available to
check the wear on various undercarriage
components (Figure 6-114). Wear gauges ap-
ply only to the machine they were made
they can't be used on others.
PIN AND BUSHING WEAR CARRIER ROLLER WEAR TRACK ROLLER WEAR
f. _
itiediro_n
(AK WEAR SHOE (GROUSER) WEAR DRIVE SPROCKET WEAR FRONT IDLER WEAR
AZ 558
3n
,MIIMmob
TRACTOR CENTENLINE
PERFECTLY MACHU,
FRAME 19 PARALLEL
MTN TRACTOR
FRONT OF TRACTOR ........ CENTERLINE
1,/
J
a
ROLLER FRAME CENTERLINE
REAR ROLLER FRONT ROLLIR
SHAFT SHAFT 119317
THE RECOMMENDED MAXIMUM TOE AT THE IDLER SHAFT CENTERLINE IS .2510
(.635 CM.). THE MAXIMUM COMBINED TOE FOR 80TH FRAMES IS .50n (1,27 CM.).
: 372
6:80 TRACK MACHINE UNDERCARRIAGE
'.... ...11.
A
..
,:r
Z
3
ROLLER FRAME CENTERLINE
.MI
1.,..1
...-.'
.
,,,
...
z
.,
., TRACTOR CENTERLINE
......
..
,..
..
..,
--.-
'RENT OF TRACTOR
0
...
ROLLER FRAME CENTERLINE.
4.0
REAR ROLLER FRowi. ROLLER
SHAFT SHAFT
(6-117)
373
t.k
TRACK MACHINE UNDERCARRIAGE 6:81
ROLLER
SHAFTS
REAR
=1
2nd 3rd 4th 51h 6th 7th
FRONT OF
B TRACTOR
TRACTOR CENTERLINE
TRACTOR CENTERLINE
DIFFERENCE IN LENGTH
INDICATES FRAME IS
TOEDOUT
.
REAR 2nd 3rd
T 5 14 94 4in 5th nth 7th
(6-119)
374
6:82 TRACK MACHINE UNDERCARRIAGE
IDLER ALIGNMENT
Idler misalignment is one of the most common
undercarriage problems. Located at the front
of the machine. the idler takes the brunt of the
shocks hitting the front of the track. Figure 6-
120 shows wear patterns of aligned and
misaligned idlers. To check idler alignment.
measurement must be taken for ideal till
lateral position and toe-in and toe-out.
1
I
FRONT TRACK ROLLER
1 Heavy Contact (Cutting If ToeIn Is 1/4 or
More) On Idler Outer Flange
2 Moderate Contact On Idler Inner Flange
3 Heavy Contact (Cutting If Toe-in Is 1,4" Or
Morel On inner Side 01 Outer Side Links
4 Heary Contact On Outer Side Of Inner Side
Links
5 Heavy Crntact On Inner Flanges
(6-120) WEAR PATTERN OF TOED-IN IDLER
enuolpsy of Foal Allis Construction IVIachinery Int.
FRONT TRACK ROLLER 1
2
I Light Even Contact On Each Side Of Idler
Flange ,..\<-
2 Light Even Contact On Both Sides Of Side
.....)
Links
3 Light Even Contact On All Flanges 01 Track
Rollers
(6-120) WEAR PATTERNTRACK AND
IDLER PROPERLY ALIGNED
Courtesy of FiaiAuts Construction MaChinery hu,
PA-32715.A
.
IDLER.,
i I 11
A-32714A
il! II
.141I II -
(6-121) VERTICAL ALIGNMENT CHECK AT
BOTTOM OF FRONT IDLER IDLER
Courtesy of International Harvester
BRACKET
1
11111 11
FRAME
1 II/0 II
III
LL Y
(6-123) IDLER NOT CENTERED
Courtesy of John Deere Ltd
376
6:84 TRACK MACHINE UNDERCARRIAGE
(6-124)
Cu4riesy of Caiespoihr Tractor Co
377
TRACK MACHINE UNDERCARRIAGE 6:85
QUESTIONS UNDERCARRIAGE
SCHEDULED MAINTENANCE
1. List four stress factors that can cause ac-
celerated undercarriage wear.
2. Name the two types of wear that occur
on the track pins and bushings. and
briefly explain the damaging effects tha.
occur as the wear increases.
3. What are the advantages of sealed and
lubricated tracks over sealed tracks?
4. What will a Percentage Worn Chart tell
you?
5. Refer to the Percentage Worn Chart
given in this section to answer these
questions.
(a) If a track roller on a D9 was
calipered and found to be 10.1 inch.
what would be its percentage worn?
(b) If the links on a D8 (158839-40)
measured 4.3 inches. should the
links be rebuilt?
6. Briefly explain how to measure pin and
bushing wear.
7. What does turning pins and bushings
achieve?
8 if a sever elyworn sprocket is used with a
new track chain. would it cause
problems? Briefly explain.
9. Track alignment involves keeping the
and
aligned with one another
and parallel to the centerline of the trac-
tor
10. What is an obvious sign of misalign-
ment?
11. What is the most common cause of idler
misalignment?
12. In what three ways may an idi.e; be
misaligned?
13. Briefly explain how to tell if two track
frames are parallel.
3 78
6:86 TRACK MACHINE UNDERCARRIAGE
REMOVAL AND INSTALLATION OF TRACKS The position in which the master pin or link is
put prior to removal is largely a matter of
Removal of a crawler machine undercarriage. preference. Depending on what service is to
although not highly technical. is a major job in be aone on the machine. one positron may be
that you are removing large. heavy pieces of more advantageous than another. For exam-
equipment Suitable jacking and lifting equip- ple. if work is to be done on the final drive a
ment is required. and solid blocking position toward the rear would be more con-
necessary to support the machine. Since venient.
working with heavy machinery is always
PotentlE 'If dangerous. safety must be Removing The Master Pin
foremost in mind when removing or installing
troilerca cage components. Safety Precaution to prevent injury to your
feet. before removing the pin place a block in
A track machine's service manual has step- front of the track to support the track when it
by-step procedures showing how to remove or is released. Always keep hands and feet clear
install the tracks. track frames and track when separating or joining tracks.
frame components. Until familiar with a
machine. you should have the martual in front The way master pins are held in position
of you and follow the steps. When the job be- varies Irom machine to machine. but the
comes routine the manual will no longer be as method of removal is similar A hydraulic pin
important. but you will always know where to press (Figure 6-126) is the accepted tool for
find any procedure you are uncertain of. removing pins When a press is not available.
a large hammer and drift may do the job
The relationship between this book and ser- (Figure 6-127). Master pins on large machines
vice manuals should be pointed out hare This however. can be very difficult to remove with a
book is not a substitute for service manuals. it hammer and drift. Caution: when hammering
will not present detz.led. step-by-step service out a pin use eye protection because of the
and repair procedures The material in these danger of flying metal chips.
pages is intended to supplement service
manuals. to indicate what service repair is
done on a component. to summarize service
procedures. to stress a certain procedure or a
safety Precaution. and generally to provide
helpful practical Service tips and information
not usually found in the manuals.
3 79
TRACK MACHINE UNDERCARRIAGE 6:8T
(6-128)
2. Without elevating the machine: once the
track has been separated at the front of
the machine start the machine and back it
(6-127) up until it reaches the end of the track.
Courtesy of Massey Ferguson Inc Place at the end of the track. a plank that
is approximately the same width and
height as the track and about the same
length as the machine. Back the machine
onto the plank (Figure 6-129).
.ee
(6.130)
380
..-
6:88 TRACK MACHINE UNDERCARRIAGE
r. , a
444,t1,111.; , V=.7,
(6 -132)
Courtesy of Massey Ferguson Inc
(6-134)
Courtesy of Caterpillar Tractor Co
382
6:90 TRACK MACHINE UNDERCARRIAGE
= 383
TRACK MACHINE UNDERCARRIAGE 6:91
:,
(6-138)
,r,41114 HuLLER, IDLER AND LINK
WITH BUILT UP TREAD SURFACE
PARTS WITH TREAD SURFACES
BUILT LIP
Courtesy 01 Terex General Motors Corportion
Recoil Mechanisms
The recoil mechanism generally requires little
repair. It is usually removed from the track
frame. visually inspected and reinstalled. If
11AI. veil"-
Mir'
any damaged or broken parts are found.
though. they should be replaced. Each type of
recoil mechanism coil spring. disc and
conical spring, or gas charged cylinder haS
w..
384
1
6:92 TRACK MACHINE UNDERCARRIAGE
385
TRACK MACHINE UNDERCARRIAGE 6:93
Sealed Tracks
To turn pins and bushings on sealed tracks.
the track must be removed and taken to a
shop equipped with a track press (Figure 6-
141). Each pin and bushing is pressed out.
one at a time, rotated 180 degrees and
pressed back into the links. New sealing
washers are installed during the process.
SADDLE
I
ELEVATING
CONTROLS
TABLE
X2670
386
6:94 TRACK MACHINE UNDERCARRIAGE
Sprockets
(6-142)
Sprocket Removal
Courtesy of Caierpiiiag Tractor Co
BOLT
DiAMETER THREADS
(INCHES) PER INCH TORQUE POUNDFOOT
387
TRACK MACHINE UNDERCARRIAGE 6:95
4.
1110-s t
Pitot-
(
z
Pivot bracket
911 Tr"'
(6-146)
REMOVING PIVOT BRACKET ASSEMBLY
Courtesy of International Harvester
-Spam.
(6-145)
Courtesy of Caterpillar Tractor Co
388
6:96 TRACK MACHINE UNDERCARRIAGE
I
Sprocket Installation
-4.
.11
Consulting the service manual. reverse the
removal procedures. Be sure everything is
clean. the seals are in good condition and in
Place. and the splines are free of burrs. Press
on the sprocket (Figure 6-148). applying the
specified pressure. Sixty-five tons or more
may be needed. Tighten the retaining nut and
/
install the lock.
3$9
TRACK MACHINE UNDERCARRIAGE 6:97
14
15
112134 (6-145) 16
QUESTIONS UNDERCARRIAGE
SERVICE REPAIR
1. List steps required to remove a track.
2. Does it matter which way a track is in-
stalled on a crawler dozer?
3. If you are separating the track at the
front of the machine, what safety
precaution should be taken?
4. Running surfaces on various un-
dercarriage components can be built up
with This is done by a
391
TRACK MACHINE UNDERCARRIAGE 6:99
392
6:100 TRACK MACHINE UNDERCARRIAGE
393
TRACK MACHINE UNDERCARRIAGE 6:101
394
6:102 TRACK MACHINE UNDERCARRIAGE
ANSWERS UNDERCARRIAGE
SERVICE REPAIR
1. (a) Slacken the track.
(b) Position the master pin or master
link for removal. and separate the
track.
(c) Back the machine off the track onto
a plank or raise the machine and
pull the track clear of the machine.
2. Yes. The track must be installed so that
the grouser bar leads the track towards
the front idler.
3. Place a block to support the track when
it is released.
4. .... weld. ... welding machine.
5, Around the carrier rollers.
6. Back off the sprocket retaining nut
just enough to allow about 114 inch
clearance between the sprocket face
and the mit; this will prevent the
sprocket from flying off when pulled
free.
Use correct adapters with the putter
and pull only against the hub. not
against the dead axle.
7. Yes. Clean the bolting surface of drive
disc and segments so that they are free
of dirt. paint or rust. Torque the bolts
evenly and to the recommended
pressure.
8. Clearance between:
(a) The sprocket sides and rear roller
flange,
(b) The diagonal brace and the rear
housing on the pivot shall (if the
track frame has a diagonal brace).
Shim the track frame in or out.
9. Tie a piece of string onto the outside of
the sprocket and stretch the string to the
front of the idler center flange. Check to
see that the sprocket. carrier rollers. and
idler center flange all touch the string.
10. .... tension ...
395
TRACK MACHINE UNDERCARRIAGE 6:103
SERVICE REPAIR
1. Following procedures outlined in the ser-
vice manual, slacken the track And
position the master link or master pin for
convenient removal. Taking safety
precautions. remove the master link or pin
and with the correct lifting equipment lay
the track flat on the ground.
396
BLOCK
Track Machine
Final Drives
397
TRACK MACHINE FINAL DRIVES 6:105
PURPOSE OF TRACK
FINAL DRIVES
As was seen if, elm< 5. Power Trains. several
assemblies are needed to transmit power from
an engine to the tracks. Power from the
engine's flywheel is transmitted through a
torque converter. transmission. a bevel gear
assembly, steering clutch. final drive, and
finally to a sprocket which drives the track.
A final drive is basically a reduction gear
assembly that converts engine horsepower
into powerful torque capable of pulling very
heavy loads. The question might be asked,
why are final drives necessary? Couldn't a
transmission provide this speed reduction and
torque increase? The answer is that the trans-
mission would have to be very large to provide
the required torque. Also. the tremendous
(6-151)
torque or twisting load would have to be
Courtesy of Calerptilar Tractor Co
carried by all the other power train com-
ponents from the transmission out. It is much The final drive pinion meshes with the large
more practical to provide the final reduction final drive gear. Although ifs not clear in
at the sprocket where the torque is needed. Figure 6-151. the sprocket is pressed onto a
Final drives have the advantage of giving hub which is either part of the final drive gear
torque increase while allowing the other or is bolted onto it. Thus. as the final drive
power train component: to carry lighter loads. gear turns. the sprocket turns.
TYPES OF TRACK Some machines have a solid hub. while others
FINAL DRIVES have a hollow hub that fits over what is called
the sprocket or pivot shaft (Figure 6-152). This
There are three types of final drives used on shaft is a non-moving "dead" axle pressed
crawler dozers and loaders: into the final drive housing. The final drive
Single reduction final drives gear. hub and sprocket assembly. supported
by inner and outer bearings. all turn on the
Double reduction final drives sprocket shaft.
Planetary final drives (outboard and
inboard)
SPLINES
(6-152)
Courtesy o! International Harvester
398
6:106 TRACK MACHINE FINAL DRIVES
PA- P t2
399
TRACK MACHINE FINAL DRIVES 8:107
Double Reduction final Drive Lubrication for double reduction final drives
can be either a splash or a pressure feed
The torque requirements for large tractors system. depending on the size of machine and
with greater horsepower are such that they the manufacturer. !n the pressurized system,
need a double reduction in the final drive, The oil is picked up through a screen at the bot-
double reduction provides a greater torque to tom of the housing by a gear pump driven by a
the sprocket tnan a single reduction can give slot at the end of the idler gear. The oil then
in the same space. Figure 6-155 shows a sim- flows through a full flow filter and is fed to all
plified view and an actual view of a double the vital areas requiring lubrication. In-
reduction final drive. formation about the specific flow pattern,
ANAL DRIVE PINION pump location. filters and check valves. can
IDLER GEAR AND PINION be found in the service manual.
STEERING Planetary Final Drive
CLUTCH
Planetary final drives are found on many trac-
tors. small and large. A planetary gear system
has the advantage of:
performing a high reduction within a
limited space. and
FINAL DRIVE GEAR
allowing the first reduction gears to
carry less load and thus to be lighter
(reduced gear width).
The planetary final drive is actually a double
reduction unit. It uses a pinion-to-bull-gear
(6-155) DOUBLE REDUCTION arrangement for the first reduction and a
Courtesy of Caterpillar Tractor Co planetary gear set for the second reduction.
The gear combination used to obtain power
flow through the planetary final drive is to
hold the ring gear. power the sun gear and the
carrier is driven at a reduction. Power is sup-
plied to the sprocket from the carrier. Figure
6-156 shows an outboard planetary. outboard
meaning located outside the sprocket. There
are also inboard planetaries.
I
iftotvz-
(6-155) Courtesy of Caterpillar Tr:Ator Co
The gear arrangement is essentially the same
as in the single reduction except that there is
an additional pair of gears, an idler gear and
pinion. Sometimes referred to as an in-
termediate gear and intermediate pinion.
these gears are joined together to form a pair
or cluster. Power is transmitted from the drive
pinion to the idler gear, and then from the
idler pinion to the final drive gear, giving two
reductions. 1. Drive Gear 7. Sun Gear
Guilt Shaft 8. Drive Shaft
A double reduction final drive Is assembled 3. Driven (Bull) Gear 9. Planetary Pinions
simllarily to a single reduction except that the 4. Gear Cover 10. Ring Gear
double reduction requires extra support for 5. Sprocket It Sprocket Hub
the idler gear and pinion. The bearings have 6. Planetary Housing
to be adjusted for the final drive gear once the (6 156) FINAL DRIVE POWER TRAIN
sprocket is installed. Courtesy of Terex. General Motors Corporation
4^P
6:108 TRACK MACHINE FINAL DRIVES
401
TRACK MACHINE FINAL DRIVES 6:109
29-
28
27
16 26
25
17 24
1$ 23
is 20 2122 DRIVE CASE
REF. SW.I-I
402
A
6:110 TRACK MACHINE FINAL DRIVES
SPROCKET
-7-
HORIZONTAL PROPEL SHAFT
(6-159)
HORIZONTAL PROPEL SHAFT ViEWED Courtesy of Bucyrus Etie CO
FROM THE BOTTOM OF THE MACHINE
LOOKING UP
403
TRACK MACHINE FINAL DRIVES 6:111
HYDRAULIC
FINAL DRIVE PROPEL MOTORS
HOUSING (6.161)
Courtesy of Caterpmar Tractor Co.
PROPEL
t BRAKE
HORIZONTAL
PROPEL SHAFT CRAWLER
DRIVE SHAFT
...-...,
STEERING
JAW CLUTCH
PROPEL
BRAKE PROPEL
STEERING PROPEL MOTOR TRANSMISSION
JAW CLUTCH
CRAWLER 77*
FINAL REDUCTION DRIVE SHAFT (6-162) PROPEL MACHINERY
PINION
404
6:112 TRACK MACHINE FINAL DRIVES
405
TRACK MACHINE FINAL DRIVES 6:113
406
6:114 TRACK MACHINE FINAL DRIVES
407
TRACK MACHINE FINAL DRIVES 6:115
I/
(6-165)
148341 1 2 40
(6-166)
Courtesy a International Harvester REMOVING FINAL DRIVE CASE
1Steering clutch case 2Ferial drive case.
Courtesy of Caterpillar Tractor Co
(6-166)
REMOVING SPROCKET
8Guards. 9Metal floating ring seals T44303
Courtesy 01 Caterpiilar Tractor Co (6-166)
PLANET CARRIER REMOVAL
1-8M4856 Sleeve
Courtesy 0 Caterpillar Tractor Co
408
6:116 TRACK MACHINE FINAL DRIVES
Removing and Installing Sprocket Shaft broken a thorough inspection for potential
failure spots should be made. A magnaflux
A hydraulic press is needed to remove a dead machine or similar crack testing equipment is
axle that is bent beyond allowable tolerances the most reliable way of checking gears if
(Figure 167). To install a new shaft, a threaded such testing equipment is not available. a
adapter is screwed onto the shaft. and then visual inspection may be sufficient. By ac-
the shaft is driven with a sledge hammer tight cumulating knowledge and experience of
on its taper in the housing (Figure 168). The gear wear, it's possible to tell by sight when a
shaft is then retained by whatever means the gear is worn to the point that it has to be
particular manufacturer uses. replaced. The apprentice should seek the
help of a journeyperson in judging whether a
gear can be reused.
Two factors should be kept in mind when
deciding whether to reuse or to replace gears:
1. Final drive gears have to carry extremely
heavy loads.
2. It is very expensive to have to repair a
final drive that breaks not long alter it
goes back into service.
Types of Gear Wear
(6.169) SPALUNG
Spelling Spalling is a common wear con-
dition which starts with fine surface cracks
and eventually results in large flakes or chips
leaving the tooth face. Case-hardened teeth
are most often subject to this kind of damage
rri9455 due to the brittle nature of the metal. Spalling
may occur on one or two teeth but the chips
(6-168) INSTALLING SPROCKET SHAFT may cause other damage to the remaining
1-5F9879 Adapter. teeth.
Courtesy of Caterpillar Tractor Co
(6-169) CRACKING
410
6:118 TRACK MACHINE FINAL DRIVES
411
TRACK MACHINE FINAL DRIVES 6:119
412
6:120 TRACK MACHINE FINAL DRIVES
. 413
TRACK MACHINE FINAL DRIVES 6:121
414
6:122 TRACK MACHINE FINAL DRIVES
SCHEDULED MAINTENANCE
Scheduled maintenance procedures from the
service manual for final drives include the
following:
1. Drain the final drive housing. inspect the
oil for metal chips and signs of moisture.
Report any chips or moisture detected,
making recommendations for needed
repairs.
2. Replace the drain plug and refill the
housing with the correct type and amount
of lubricant.
SERVICE REPAIR
This task must be done when the track
machine is raised and has the track. track
frame and sprocket removed.
Using the correct tools, equipment and
procedures outlined in the service manual:
1. Take a suitable size container and drain
the oil from the final drive housing.
2. Clean the housing and remove the final
drive housing and gears.
3. Disassemble. clean. inspect the gears.
bearings and seals for wear and damage.
Write a service report or parts list and
repair or replace any parts that are not
serviceable.
4. Disassemble, clean, inspect and replace
non-serviceable parts in the final drive
lubrication system.
5. Practising cleanliness. prelubricate and
install the final drive gears and housing.
6. Install the sprocket, and adjust the
bearings.
7. Fill the final drive unit with the correct
type and amount of oil and ensure there
are no leaks.
415
Track Machine Steering
416
TRACK MACHINE STEERING 6:123
HOW TRACKS ARE TURNED Operating controls (pedals or hand levers) for
steering clutches and brakeb vary with the
To turn a crawler. machine power has to be machine Some machines use separate clutch
cut to one track and then the driven track will and brake controls. whereas others combine
turn the machine in the direction of the track them Steering and braking controls are
that has lost power. Most crawlers interrupt discussed in greater detail later in this sec-
the flow of power to a track by means of tion.
steering clutches. There are three basic types
of steering systems: multi-disc clutch.
MULTIPLE DISC STEERING CLUTCHES
planetary gear. and jaw clutch.
Before looking at multiple disc steering, the
Another method of Interrupting power flow to
most common track steering system. it will be
a track is by the use of hydrostatic steering. helpful to give a brief review of the material
Hydraulically propelled machines. such as on clutches covered in Block 5. Power Trains.
hydraulic excavators. have a hydraulic drive
train component that controls power to the Clutches transmit power by friction. Engine
tracks. As well as transmitting power for clutches have three basic parts: a drive mem-
straight ahead travel. this component can cut ber. a driven member and a release
power to either track and thus provides a mechanism. Power is transmitted only when
means of steering the machine. Hydrostatic the driven member is held firmly against the
steering is a trend in modern crawlers; (or drive member. Clutch holding power or
example. John Deere is now using it on one of capacity can be increased by adding more
its crawler dozers. driving and driven plates. The capacity of an
engine clutch is increased for heavy duty ser-
Crawler steering is related to the type of vice by adding both an intermediate pressure
crawler and in some cases to the manufac- plate. driven by lugs in the flywheel, and a
turer. For example. International Harvester is friction disc splined onto the transmission
the main user of planetary clutches. Crawler shaft. For powershift transmissions still more
dozers or loaders use multi-disc or planetary plates are added to form what is called a
steering clutches. shovels and cranes use jaw clutch pack.
clutches; hydraulic excavators use
hydrostatic steering. A multiple disc steering clutch is a clutch
pack. In consists of e:
STEERING CLUTCHES AND BRAKES
1. Sp lined inner drum (the drive member) at-
Steering clutches are usually located in com- tached to a bevel gear shaft.
partments at the (ear of the machine. between
the bevel gears and the final drive assemblies. 2. Sp lined outer drum (the driven member)
There is one steering clutch for each track. In- connected to the final drive pinion shaft.
corporated with each steering clutch is a
brake. Besides providing braking for a
machine. this brake is also used as an aid in
making a turn. Cutting the power to one track
leaves one track driving and the other in
neutral (i.e.. free to move with the momentum
of the other track). The result is that the
machine makes a slow turn towards the track
in neutral. On the other hand. when a com-
bination clutch-brake turn is made (clutch
disengaged. brake applied same side). the
track without power will not be able to roll
freely but instead will slow down or com-
pletely stop depending on how much brake is
applied. Slaking the track causes the
machine to make anything from a gradual turn
to an abrupt sharp turn. This combination 1
417
6:124 TRACK MACHINE STEERING
we
STEERING CLUTCH OPERATION
1Piston. 2Pressure plate. 3 Retainer.
4Uiscs. 5Steering clutch
04, -`11L.&&10`' driving drum. 6Bevel gear shaft.
(6-172)
Courtesy of Caterpillar Tractor Co.
41&
. .
TRACK MACHINE STEERING 6:125
BRAKE APPLY
PISTON
CLUTCH APPLY
PISTON
STEERING CLUTCH
PACK
BRAKE CLUTCH Operation Of A Single Speed Planetary
PACK Steering Clutch
419
.
6:126 TRACK MACHINE STEERING
STEERING BRAKE
PADS
..«
I
SUN GEAR
mo
1
PIVOT BRAKE
,I1WL-0.(MULTI-DISC)
SPROCKET DRIVE PINION
SHAFT GEAR
(Note: runs on inside of
planet gear cluster)
BEVEL GEAR & CARRIER 1..."STEERING BRAKE DISC
PLANET CARRIER
(3) Small cluster gears (2) Large gears in gear
drive sprocket drive cluster walk around
pinion shaft gear, (6-175) stationary sun gear.
:& 420
TRACK MACHINE STEERING 6:127
BEVEL GEAR
0111761 1°1! (6-177)
SHAFT
.DRIVEN
SHAFT
D B
A Sun Gear
B Large Planet Cluster
C Small Planet Cluster
0 Sprocket Drive Pinion Shalt Gear
(6-176) PLANETARY SYSTEM. SHOWING THE LINE OF POWER IN THE
1
HIGH RANGE POSITION Cotinesy of International Harvester
421
6:128 TRACK MACHINE STEERING
As shown in Figure 6-178. shovels use two jaw The brakes used with jaw clutches are ex-
clutches. one on either side of the bevel gear ternal contracting bands located toward the
on the horizontal propel shaft. outside of the clutches. When applied. the
bands grip a drum attached to the propel
The shift yokes operate the movable jaws On shaft. These brakes shown here are spring-
this model shifting is accomplished by air applied and air-released. Jaw clutch and
cylinders connected to the linkages The air brake controls will be discussed in detail later
cylinder controls are in the operator's com- in this block.
partment. SHIFT
YOKES HYDROSTATIC STEERING
If ....*S.}. Ar_241;-
was
The basic principles of hydrostatic steering
are dealt with here; it is covered in more
detail in later training.
Hydrostatic drive is an automatic fluid drive
using fluid under pressure to transmit engine
power to the drive wheels or tracks. In this
sytem mechanical power from the engine is
converted to hydraulic power by a pump and a
motor. The hydraulic power is then converted
back to mechanical power to drive the
machine (Figure 6-179).
(6-178)
Courtesy of Bucyrus Ene Co
CONNECTING
OIL LINES
PUMP
DRIVE
MOTOR WHEEL
CONTROL
X 2211 ENGINE
(6-179) HYDROSTATIC DRIVE IN A COMPLETE Courtesy ol John Deere Ltd
POWER TRAIN
9
422
TRACK MACHINE STEERING 6:129
CYLINDER FIXED
PISTONS OUTPUT
BLOCK SWASH PLATE
INPUT WHEEL
DRIVE
SHAFT
VARIABLE
SWASH PLATE
SWASH PLATE
ANGLE CONTROL
PUMP MOTOR
(VARIABLE DISPLACEMENT) (FIXED DISPLACEMENT)
.0
423
6:130 TRACK MACHINE STEERING
DRIVE SHAFT
INLET PORT
Hydrostatic Motor
A hydrostatic motor is shown in Figure 6-182. As stated earlier. swash plates in motors can
Oil from the pump is forced into the cylinder be fixed or variable. A variable swash plate
bores through the inlet port. The force on the means that the displacement of the motor is
pistons at this point pushes them against the variable and thus its speed-to-torque ratio can
swash plate. They can move only by sliding be changed. When the plate is at maximum
along the tilted swash plate to a point further angle. the displacement is maximum because
away from the cylinder barrel. In so doing. the pistons travel maximum length. The motor
they cause the cylinder barrel to rotate. The runs slow but with lots of torque. As the angle
cylinder barrel is splined to the drive shaft is reduced piston travel shortens and the
(the shaft passes through a hole in the swash displacement is decreased. The motor speeds
plate). and so the shaft must turn too. up but it has less torque. Thus. by changing
the angle of the swash plate on the motor. a
The transfer of motion that occurs at the hydrostatic drive can give a broad range of
-motor is exactly opposite to what happens at speed-to-torque ratios.
the pomp: incoming hydraulic pressure is
converted to reciprocal motion in the pistons
and then to rotary motion at the output drive
shaft.
424
TRACK MACHINE STEERING 6:131
FILTER
RESERVOIR COOLER
CHARGE
PUMP
I
PUMP MOTOR mom HIGH-PRESSURE OIL
LOW-PRESSURE OIL
=PRESSURE-FREE OIL
X$896
42
6:132 TRACK MACHINE STEERING
VII
.0_2t,P1-
(6-184)
. 426
TRACK MACHINE STEERING 6:133
(6-185) STEERING
CONTROL
Hydrostatic drive keePS the machine moving LEVER
straight ahead even when ifs corner loading
the blade during a heavy cut. Resistance on
the loaded side can be counteracted to give
uniform traCtion to both tracks.
Courtesy of John Deere Ltd
(6-186)
(6 -185) Courtesy of Caterpillar Tractor Co
With hydrostatic drive the tracks Can Counter
rotate allowing the machine to spot turn in
tight quarters.
Courtesy or John Deere Ltd
427
6:134 TRACK MACHINE STEERING
Hydrostatic drives are not only found on ex- linkages that connect the clutch control lever
cavators. Many agricultural wheeled vehicles in the cab with the clutch and connect the
use a hydrostatic drive. And. as was men- brake pedal with the brake bands Manual
tioned earlier. John Deere manufactures a controls are being phased out today and are
crawler dozer and a crawler loader that have used only on some small loaders and dozers
hydrostatic drive. They will also be found on older machines.
Controls For Multi-Disc, Planetary, and Machines with manual controls have two
Hydrostatic Steering steering clutch levers. one left and one right.
both held forward in the engaged position by
The following types of controls are used on springs. The clutches are disengaged by
crawler steering: pulling the levers fully back. Manually con-
trolled machines also have two brake pedals
manual which operate independently and are applied
boosters (manual and hydraulic) by depressing against spring tension These
full hydraulic brakes may be applied and held for parking by
a lock lever.
electric pneumatic
electric hydraulic Figure 6-187 illustrates simple manual con-
trols for one clutch and one brake. Remember
All early crawler machines had manual con- the machine will be equipped with two clutch
trols. Over the years demands for ease of con- levers and two brake pedals. Note the lock
trol. especially on larger machines. and for lever on the brake pedal. Threaded adjusters
less maintenance. have resulted in the are located within the linkage to compensate
development of the other four types of for normal running wear. Adjustment will be
steering controls. covered in the Service Repair Section.
(6-187)
TYPICAL MANUAL CONTROL LINKAGE FOR BRAKE
Counesy of International Harvester
428
TRACK MACHINE STEERING 6:135
Clutch Boosters are located on the bevel gear case above the
steering clutch compartments. A separate
Mechanical and hydraulic boosters can be ad- hydraulic booster is used for each brake.
ded to manual controls to reduce the effort
required to disengage the clutch or apply the Oil is delivered to the boosters through a flow
steering brakes. Boosters are generally found divider. Regardless of their pressure
on large machines. but like manual controls requirements. the flow divider piston equally
they are being replaced by full hydraulic ac- divides the flow of oil to both of the brake
tuating mechanisms. hydraulic boosters. Thus, even though one
Mechanical clutch boosters are an over cen- brake is being applied for a turn. there is stilt
ter. spring-loaded assembly attached to the full pressure available at the other brake so
lower end of each steering operating lever that the machine can be safely stopped.
(Figure 6-188). The booster consists of a Oil from the flow divider is delivered by lines
spring-loaded plunger within a cylinder: to the hydraulic boosters and enters the
movement of the control lever causes the booster housings at the inlet port (3) in Figure
plunger to expand under spring pressure to 6-189.
assist in disengaging the clutch.
STEERING OPERATING LEVER
\ YOKE ASSEMBLY
\) BOOSTER ASSEMBLY
BOOSTER BOOT (6-189)
NOSE CLAMP HYDRAULIC BOOSTER OPERATION
CONTROL ROD PIVOT EYE BOLT
YOKE PIN
1Stop 2Valve. 3Inlet port. 4Booster piston.
5Passage. 6Lever. 7 Belicrank.
Courtesy of Caterpillar Tractor Co
429
6:136 TRACK MACHINE STEERING
(6-190)
FLOW OF OIL
1 Brake booster 2Booster piston, 3Pressure rebel valve 4Flow divider 5Line.
6-- Steering clutch hydraulic control 7Orifice. 8Filter 9Filter by-pass valve. 10Pump
11Oil cooler 12Steering clutch pressure relief valve 13Suction line
14Screen 15Piston. 16Line
Courtesy of Caterpillar Tractor Co
4 .3 0
TRACK MACHINE STEERING 6:137
2 Terex, also uses hydraulically controlled 3. international Harvester uses several types
multi-disc clutches. but instead of band of steering controls. The controls
brakes they use multi-disc brakes (See described here are their newest design
Figure 6-174). The disc brakes are spring- used on a TD2OE single speed steering
applied when the machine is stopped. On drive.
start-up. hydraulic pressure applies the
clutches and releases the brakes. The single speed steering drive contains
Movement of one of the steering clutch one drive clutch pack and one brake
control levers dumps oil from the steering clutch pack for each side of the machine
clutch to release it. Further movement of (Figure 6-191). The drive clutch packs are
the same lever will direct oil to the multi- hydraulically applied and spring released
disc brake to apply the steering brakes. whereas the brake clutch packs are
The amount of brake application is spring-applied and hydraulically released.
proportional to the amount of lever If a hydraulic failure occurs or the engine
movement. When the machine is shut is stopped, the steering drive will
down, oil pressure is released from the automatically apply the brakes.
brake spring caging piston cavity and the When the steering levers are in the drive
brakes are automatically applied by position. the drive clutch pack is held
spring pressure. engaged and the brake clutch pack is
Terex steering brakes (the brakes applied held disengaged by hydraulic pressure.
to either track to aid in steering the Power to the tracks is transmitted from the
machine). it has just been seen, are ac- pinion shaft to the bevel gear and through
tivated by the same lever that disengages the engaged drive clutch pack to the out-
the clutches. The brakes also can be ap- put shaft and sprocket.
plied together by a brake pedal. The brake When a steering lever is moved to the
pedal also has another function. On the brake position. the hydraulic pressure to
initial part of its travel an engine the clutch packs on one side of the
decelerator pedal is simultaneously steering drive is released. As the pressure
depressed. decelerating the engine before drops. springs engage the brake clutch
the brakes are applied. Further movement pack and disengage the drive clutch
of the brake pedal applies both brakes to pack. The brake clutch pack then locks
slow or stop the machine when working the output shaft with the steering drive
on steep grades. housing. thereby stopping rotation of one
track chain. The machine can be stopped
BRAKE DISCS BEVEL GEAR by moving both steering levers to the
STEERING DISCS brake position.
When the foot brake is applied, hydraulic
SPLINED HUB oil pressure to troth brake clutch packs is
released. As the pressure drops. springs
engage both brakes simultaneously.
However. the hydraulic oil pressure to the
drive clutch packs is not released and the
torque converter slips. The toot brake will
hold the machine stationary with the
transmission in second or third gear but
not in first gear at high idle.
431
6:138 TRACK MACHINE STEERING
BRAKES BRAKES
LEFT MOTOR RIGHT MOTOR
REVERSES REVERSES
LEFT MOTOR
r;
11 1%
1
I
RIGHT MOTOR
%
REVERSE it 1, 1 I FORWARD
PEDAL I
t...-,
I " PEDAL
ft,....;
..1 STEERING (1
LEVER
TRAVEL
PEDALS
(6-192)
432
TRACK MACHINE STEERING 6:139
PROPEL . O O O
FORWARD I=E
"to
LEFT HAND
CONTROLLER
0
0.
FORWARD
A
40.-7RIGHT
BRAKE
RELEASED
LEFT .
BRAKE
SET
LEFT RIGHT
STEERING STEERING
CLUTCH CLUTCH
DISENGAGED ENGAGED
-0
433
6:140 TRACK MACHINE STEERING
ENGINE CLUTCH
ENGINE THROTTLE
AIR PRESSURE
REGULATOR
WRIST
HOUSE LOCK
DIG
SWING
BOOM HOIST
PROPEL
(6-194)
BASIC LUBRICATION AND COOLING The oil received by the flow divider (6) is
OF STEERING SYSTEMS divided equally between the brake boosters
(1). When the boosters are disengaged. oil
Most modern wet steering clutches and flows through a passage in the booster
brakes are lubricated and cooled by oil that is pistons and is dumped into the steering clutch
part of a larger reservoir system that also sup- compartments When the boosters are
plies oil to the torque converter. transmission. engaged. oil pressure is forced against the
and bevel gear compartment. This oil system
booster pistons. Two relief valves in-
will have one or more hydraulic pumps driven corporated in flow divider (6). prevent
from the back of the engine or by the torque pressure from becoming excessive and
converter impeller. Pumps can be single or damaging the brake mechanism.
double section models. Often the double sec-
tion models have a large section that delivers The valves in the steering clutch hydraulic
oil to the transmission and torque converter control valve (14) direct oil to the steering
and a smaller section that pumps oil to the clutch pistons (11) in the steering clutch hubs.
bevel gear and steering clutches and brakes. These pistons move to disengage the steering
clutches. If the valves should stick. the
A description of the circulation of oil through pressure relief valve unseats and the oil
the oil system that includes steering clutches bypasses the steering clutch hydraulic con-
is given below The numbers refer to Figure 6- trols. v n the steering clutches are engaged
195. oil flows around the control valves to the
OPERATION torque converter inlet relief valve (12). A small
amount of oil is bled off through an orifice to
3 4 lubricate the control valve operating
mechanism and the bevel gear and beve'1ear
shaft bearings. Oil supplied to the torque con-
verter inlet relief valve (12) charges the torque
converter portion of the torque divider com-
ponents. The scavenge pump (17) returns
leakage oil from the torque divider housing (8)
to the sump in the transmission case (16).
Discharge oil from the torque converter
passes through the torque converter oulet
relief valve (7) to the oil cooler (10) on the
=SUPPLY OIL IIII PRESSURE OP. right side of the diesel engine. From the
666 I. 6 =RETURN OIL CI LUBRICATION OIL cooler. oil returns to the transmission
(6-195) FLOW OF Oil. SCHEMATIC lubrication regulator valve (13) where a por-
Courtesy of Caterproar Tractor Co
tion of the oil is supplied to the transmission
lubricating system. Oil not used for trans-
mission lubrication is directed from the valve
Oil is picked up by the pump (15) from the (13) to the inlet of the hydraulic pump (4).
sump in the transmission case (16). Before en-
tering the pump. the oil is drawn through the
magnetic strainer (19). The oil. under pressure
from the pump. is forced through the oil filter
(18) to the flow control and relief valve (2). if
the filter is clogged. a bypass valve in the
filter housing allows oil to bypass the filter
element.
The flow control relief valve (2) separates the
flow of oil. directing some to the steering
clutch hydraulic control valve (14) and the rest
to the flow divider (6). If the oil flow becomes
restricted. the relief valve will open and allow
the oil to return to the torque converter inlet
relief valve (12).
435
6:142 TRACK MACHINE STEERING
QUESTIONS TRACK MACHINE STEERING 14. Briefly list the changes of motion that
take place in a hydrostatic pump and
1. List the four main steering systems used
motor.
on crawler machines and give an exam-
ple of the type of machine where each 15. On a machine that has manual or
would be found. booster-assisted controls, which of the
following combinations of the two clutch
2. Briefly explain how a steering clutch is levers and two brake pedals is used to
used to steer a crawler machine, make a pivot turn to the right?
3. What function do the brakes serve in (a) Both levers pulled back and left
crawler steering? brake applied.
4. What are two types of brakes used for (b) Left clutch lever pulled back and
crawler steering? right brake applied.
5. List the major parts that comprise a (c) Right clutch lever pulled back and
multi-disc clutch pack, left brake applied.
6. What advantages do wet clutches have (d) Right clutch lever pulled back and
over dry clutches? right brake applied.
7. How does a single speed planetary 16. Booster controls are used to
steering system differ from a basic (a) Give a faster release.
planetary? In a steering planetary what
combination of gears is used to transmit (b) Allow bigger clutches to be used.
power? (c) Reduce the effort needed for con-
trol.
8. By what mechanism is the sun gear held
in planetary steering? (d) Give smoother clutch operations.
9. What is the main advantage of two 17. On multi-disc clutches with hydraulic
speed planetary steering over single controls, what are the two combinations
speed planetary or multi-disc clutch used for clutch apply and release?
steering? 18. What is the function of a flow divider for
10. Why do shovels use jaw clutches for hydraulic brake boosters?
steering rather than multi-disc clutches 19. A machine with hydrostatic drive has
or planetaries? steering lever and
11. How is a machine with hydrostatic drive direction control pedals.
steered? 20. List the three types of power controls
12. Which is the most common pump-motor used for jaw clutches on modern shovels
combination used on crawler machines and cranes.
with hydrostatic drive? 21. Most modern crawlers with wet clutches
(a) Fixed displacement pump driving a and brakes share a common oil supply
fixed displacement motor. with:
(b) Variable displacement pump driving (a) Torque converter and final drive.
a fixed displacement motor. (b) Bevel gear compartment and final
(c) Fixed displacement pump driving a drive.
variable displacement motor. (c) Torque converter, transmission, and
(d) Variable displacement pump driving bevel gear compartment.
a variable displacement motor. (d) Torque converter, transmission, and
final drive compartment.
13. True or False, in a hydrostatic pump or
motor the swash plate rotates and the
circular block of pistons is held
stationary.
436
TRACK MACHINE STEERING 6:143
437
6:144 TRACK MACHINE STEERING
3 free
govern....a
Band Brakes (Manual Controls)
When brake pedal free travel becomes ex-
cessive. brake bands require adjustment for 1,
efficient and safe operation. One manufac-
turer. for example, recommends adjusting t,
ti, '
when free travel exceeds three inches. (6-198)
STEERING BRAKES ADJUSTMENT
c)
®
110415 C
-. --Ari:
e".
I
I
t$w
.1
. 2 4# - . 40........
Woos
438
TRACK MACHINE STEERING 6:145
PIVOT BRAKE
ADJUSTING SCREW
()
LOW RANGE
ADJUSTING SCREW'
e .0
a.toite
439
6:146 TRACK MACHINE STEERING
ITEM SERVICE
(33) Transmission. bevel gear and steering Change oil and breather S3
Clutch compartment wash suction screen
Key to Lubricant
S3 Superior Lubricants (Series 3) only
rlY0 Superior Lubricants (Series 3) containing zinc dithiophosphate.MIL-L-2104A. MIL-L-21048 or
approved Industrial-type Hydraulic Oil
MPG -- Multipurpose -type Grease
MPL Multipurpose-type Lubricant.
Fiat-Allis Crawler Loader (only steering and braking service shown)
OCLEAN. CHECK ANDIOR ADJUST b HYDRAULIC CIRCUIT OIL OPRESSURE GUN LUBRICANT
OENGINE CRANKCASE OIL * REGULAR GEAR OIL
SERVICE NO. OF TYPE OF
INTERVAL DESCRIPTION OF SERVICE POINTS LUBRICANT
Each 10
hours Steering and brake linkage lubricate 4 D
or Daily
Each 100 hours
or 2 weeks Bevel gear. steering clutches and
(Also perform brakes -- check oil level 1
10 and 50 hour
services,
Each 500 hours
or 3 months
Brakes and steering clutches hydraulic 0
(Also perform 1
10. 50 and 250
system -- clean filler
hour services)
Each 1.000 hours
or 6 months
(Also perform
10, 50. 100. 250.
Bevel gear. steering clutches and
brakes change oil
*
and 500 hours
services . .
i.
o
TRACK MACHINE STEERING 6:147
441
6:148 TRACK MACHINE STEERING
to;
P
.16-7re..L-4111111.,
/MI 410
C
4
iimg
Dr
is
(6-201)
ON MACHINE PRESSURE TAP LOCATIONS
A Len steering clutch oil pressure tap 8Transmission oil pump pressure tap. CRight steering clutch
oil pressure tap. D-- transmission lubrication oil pressure tap.
Courtesy of Calerprilar Tractor Co
442
TRACK MACHINE STEERING 6:149
KtarylexcereAle-xx#21,.. Acco:ex:ex;..
10 11
9
(=SUPPLY OIL PRESSURE OIL
-ere.
X 0...1 1=IRETURN OIL , VA. LUBRICATING OIL
(6-202)
TRANSMISSION AND STEERING CLUTCH OIL SYSTEM SCHEMATIC
1 Magnetic strainer 2 Oil pump 3-011 filter 4Flywheel clutch housing. 5Transmission lubrication
regulator v,Ive 6 Relief valve (steering clutch hydraulic control) 7Steering clutch hydraulic control valve.
8 -Right steering clutch piston 9 -Transmission case 10-0d cooler. 11Screen ALeft Steering clutch oil
pressure tap B -Transmission oil pump pressure tap. C Right steering clutch oil pressure tap.
DTranSmission lubricating oil Pressure tap.
CourteSy of Caterpillar Tractor Co
443
6:150 TRACK MACHINE STEERING
Operational Checks For Steering Problems 4. Broken steering clutch spring retaining
bolts.
Below are checks that Caterpillar recom-
mends to troubleshoot steering problems on 5. Worn serrations on driving and driven
one of their machines having multidisc clut- steering clutch drums causing plates to
ches with contracting brake bands. "hang up ".
With the engine running. move the trans- Problem: Sluggish Steering
mission speed selector lever to all positions.
The detents should be felt in each position. Probable Cause
Operate the machine in all speeds. Listen for
unusual noises and determine their source. 1. Incorrectly adjusted. worn or broken
Lock the brakes and stall the torque converter linkage.
in each speed. If the universal joints turn, the 2. Worn brake lining.
transmission clutches are slipping. An
operational check list for steering problems 3. Low pump output.
follows.
4. Worn serrations on driving and driven
Problem: Machine Will Not Turn In One steering clutch drums causing plates to
Direction. hang up.
444
TRACK MACHINE STEERING 6:151
A..
position.
445
6:152 'RACK MACHINE STEERING
..%.....,
*1
tt 9.f.
4-7
86. e 11: i-Cl&Nalp
11. # 8.
Courtesy of International Harvester
446
TRACK MACHINE STEERING 6:153
clutches must have their springs com- 2. Inspect the brake band: 4 may require
pressed before they can be disassem- relining.
bled. The clutches are set into a steering
clutch stand (Figure 6-209) or blocked. 3. A measurement is taken of the clutch
and then disassembled with the aid of a pack to determine its remaining service
compressor tool or a hydraulic press. life. The distance "A" (the stacked
height) in Figure 6-210 is taken and com-
pared to minimal standards in the service
manual. Even if the clutch pack is within
specifications, the discs should be
checked for warping or wear on the
splines. Keep the discs in the same or-
der. Note that individual discs are not
usually replaced on clutch packs, rather
the pack is replaced as a whole.
9 10 11 12
17976X2
Mir
T 41701 13 14 (6-210) 15
CROSS-SECTION OF STEERING CLUTCH
ASSEMBLY
9Disc Assembly. 10Sleeve. 11Inner Spring.
12Disc. 13Retainer. 14Outer Spring.
15Inner drum. ADimension to be checked.
Courtesy of Caterpillar Ttaelor CO
T 411117
4. Make the following inspections:
(6-209)
(a) Check the splines on the inside of
COMPRESSING STEERING CLUTCH SPRINGS the brake drum and the outside of
Courtesy of Cateroinar Tractor Co the drive hub, and replace ihem if
thay are worn.
(b) The outside of the brake drum can
be turned on a lathe. Since turning
requires a special lathe and an ex-
perienced hand. the drums are
usually sent out to be done. The im-
portant point to remember about
turning drums is to be sure that they
can be turned by checking minimal
drum thickness requirements in the
service manual. Don't make down-
time longer by sending out drums
411122 that are worn too thin to be turned.
(6-209) STEERING CLUTCH SPRING COMPRESSOR
TOOL
Courtesy of Catefoillar Tractor Co
447
6:154 TRACK MACHINE STEERING
(c) Remove springs (Figure 6-211) and (b) Hydraulically released: the piston in
check them for cracks, free height the clutch hub should be removed,
and compressed height (see service the bore checked and the seal
manual). replaced. The piston can be pulled
from the hub with a two-jaw puller
using reverse jaws.
6. Hydraulically applied clutches and
brakes are generally found on modular
steering systems. Unlike the previously
discussed spring-applied clutches which
could be repaired in the field, hydraulic
applied clutches are usually disassem-
I bled and repaired in a shop. Special
A C._
tools and a clean place to lay out the
numerous parts are necessary when
overhauling one of these units. Once it's
I MIA 5
i apart. the kinds of repairs required on a
hydraulically applied clutch pack are
similar to the repairs on a spring-applied
(6-211) clutch pack.
1Adapters 2Sleeve. 3Spring. 4Spring.
5Retainer. 7. One repair that may be needed on large
Courtesy of Caterpillar Tractor Co tractors with two speed single disc
planetaries and caliper brakes is to
5. Check the clutch controls: replace the linings on the caliper brake
shoes. This job can be done without
(a) Manual: the release bearing and its draining the oil. The rear main cover is
related parts release pin removed to get at the brake assemblies
bushings, pivot bushings, release and they're removed from the machines.
collar thrust bearing (Figure 6-212) Figure 6-213 illustrates removing the
must be inspected and replaced
/
caliper shoes with a mallet and drift.
(if necessary).
.
PIVOT BRAKE
FORK :BRAKE FORK
BRACKET
RELEASE
FORK
RELEASE PIN N
RELEASE BUSHINGS FORK PIN
(OUTER)
COLLAR emme,maji-FORK PIN
WA-.1712A (CENTER)
RELEASE FORK (6-213) REMOVING THE PIVOT BRAKE FORK
PIVOT
Courtesy of International Harvester
A-32626
',448
TRACK MACHINE STEERING 6:155
PIVOT BRAKE
SHOE PIN PIVOT BRAKE
BRAKE SHOE
GUIDE PIN
PIVOT BRAKE
WA3M/ SHOES
449
6:156 TRACK MACHINE STEERING
450
TRACK MACHINE STEERING 6:157
451
6:158 TRACK MACHINE STEERING
...
452
TRACK MACHINE STEERING 6:159
TROUBLESHOOTING
If a machine is available with a clutch or
brake problem. under the assistance of a jour -
neyperson, perform troubleshooting
procedures outlined in the service manual to
locate the problem.
SERVICE REPAIR
Using the correct tools. equipment and
procedures as outlined in the service manual:
1. Clean and remove the housing cover and
remove the steering clutch and steering
brake unit of a crawler loadi or dozer.
2. Disassemble. clean. inspect the clutch
and brake parts for wear and damage.
Writ', a service report and pa^ "at, and
repair or replace parts that E..: t ser-
viceable.
3. Reassemble the steering clutch and the
steering brake.
4. Install and adjust (if applicable) the brake
and clutch.
5. Check the dive train hydraulic oil level
and fill to the required level with the
recommended oil. Change the filter (if
equipped).
6. Test V : . in of the brake and clutch
cont si Ispect the unit to ensure it
has :. .
453
BLOCK
Wheel Machine
Suspension
454
WHEEL MACHINES 6:161
455
r
1 Grille
2 Main Irame rear section.
3. Main Irame -- front section.
4 Ladder.
5. Handrail
6. Frame locking bar MOM
6
7. _(.4ster Courtesy o International Harvester
(6-214) MAIN FRAME ASSEMBLY
Each main frame has many smaller sections which is attached to the rear frame section at
welded to it and is called a fabricated frame two points by pins and bushings. The purpose
assembly. This particular model has a grill of the bolster is to allow an up and down see-
bolted or welded to the rear section. Note the saw movement (oscillation of the rear axle in
frame locking bar (6) used to lock the two order to give full wheel contact with the
frame halves together when the tractor is ser- ground when the machine is working uneven
viced or transported. terrain (Figure 6-216). This rigid suspension
system used by wheel loaders gives the
To complete the suspension assembly. one machine more strength and stability than
axle (Figure 6-215) is bolted to the front frame could be obtained from spring suspension.
section. and one is bolted to a bolster or as
ifs sometimes called. a walking beam (7).
REAR HOUSING
PIVOT POINT
.0.-- ---....
FRONT HOUSING
BOLSTER
(6-215)
0,
Courtesy of Clarke Equipment Company
456
I
WHEEL MACHINES 6:163
61116'
/4 it
w.Lt11:1".4v NI,
(6-216)
Courtesy 01 Terex. General Motors Corporation
An alternate system to the bolster for axle
oscillation is an oscillating trunnion (Figure 6-
217) used by Caterpillar, The large trunnion
extends from the articulation hinge into the
rear frame and is supported by two tapered
roller bearings. The trunnion allows the
frames to move independently of one another
and still be hinged for steering.
1,4
(6.217) (6.217)
Courtesy of Caterpillar Tractor Co. Courtesy of Calerpillar Tractor Co.
1, 457
6:164 WHEEL MACHINES
Skidder
Like the frame on a loader, a skidder frame
(Figure 6-218) is made of fabricated steel and
is joined by a pin(s) and bushing(s) at the
hinge point between the two frames. However,
the skidder differs from the loader in that the
long section with the engine and transmission
is forward and the short section is at the back.
Also. the bolster or walking beam on a skidder
is attached to the front frame.
(6-218)
458
WHEEL MACHINES 6:165
'It
3 (6-219)
AGRICULTURE TRACTOR
FRONT AXLE PIVOTS
AT THE CENTER
Courtesy 0 J1Case
6 b 11
10
8 (6-220)
7
Courtesy of Champion Road Machinery Limited
459
6:166 WHEEL MACHINES
'6 -221)
Courtesy N Champion Road Machinery Limited
(6-222)
The grader front axle is the steering axle Courtesy A Champion Road Machinery Limited
Besiecs turning, grader wheels an also lilt. a
feature that improves handling on rough
ground and gives sharper turns. Note in
Figure 6-221 that. although the axle is
oscillated the wheeis are perpendicular; they
have been tilted to offset the angle of
oscillation. Grader steering is discussed in
greater detail further on in this section.
A number of manufacturers now offer. as an
option. an articulated grader frame (Figure 6- ARTICULATED TURN
222). The frame is basically the same as the
one described above but with a pivot point (6-223)
part way down the rear section. The ar- Courtesy 01 Cateroltor Tractor Co
ticulated frame is used in combination with
front axle steering to improve the machine's
manoeuverability (Figure 6-223). Suspension
-,/
so°
SPRING SUSPENSION
Frame
A spring suspension frame. like a rigid
suspension frame. is the backbone of the
vehicle. All other suspension parts are at-
tached to it. Truck frames are constructed of
basically two parts: side rafts and cross mem-
bers The rails carry the load and the cross
members stabilize the rags. The entire frame
must be stiff enough to support the load it
carries. yet it must be flexible enough to ab-
sorb and distribute the stress placed on it.
Figure 6-224 shows a typical on-nighway truck
frame.
400
WHEEL. MACHINES 6:167
REAR AXLE
CROSS MEMBER
(REAR)
REAR AXLE
CROSS MEMBER
(FWD) .
(6-225)
461
6:168 WHEEL MACHINES
(6-227)
) ..1--' -a
.0 0
BUMPER
0,, ../
z..k
----- SPRING SHOCK ABSORBER
% .
I ft,
..r.......
t._ _ --....,
EYE-BOLT SPACER SHACKLE LINK
TOW EYE-.1
AXLE A4051
U.B-OLT
1
(6-228) Courtesy 0 General Motors Corporation
462
WHEEL MACHINES 6:169
SLIPPER
CAM BRACKET
ACTION
LOADED
UN-LOADED (6-229)
(6-229) Courtesy of loternatronal Harvester
Councsy of International Harvester A number of manufacturers specialize in
building single and tandem axle suspension
Both constant and progressive rate springs assemblies. and these assemblies are referred
are used for front suspensions. but generally to by the manufacturers name. For example.
progressive rate springs are used for rear Hendrickson. Rockwell and Reyco are a few
suspensions because they provide a softer of the common suspension assemblies. Truck
spring when the vehicle is unloaded and a manufacturers often give a buyer an option as
stiffer spring when the vehicle is loaded. to what type (or manufacturer) of suspension
he wants. Thus. even though two trucks have
different names. e.g.. Kenworth. White.
G.M.C.. Ford. etc.. they could have the same
suspension. On the other hand. some truck
manufacture's such as Mack build their own
suspension assemblies and these assemblies
463
6:170 WHEEL MACHINES
are referred to by the name of the truck Another type of single-axle, leaf spring assem-
manufacturer. bly (Figure 6-232) uses a torque rod rather
than an eye and pin to attach the spring to the
Rear Suspension frame brackets. This particular assembly also
has an auxiliary spring.
Front suspension on trucks is almost always
leaf spring and is quite similar from truck to TANDEM DRIVE SUSPENSION
truck. However, differences do occur in rear
suspension. Tandem drive axles require a special suspen-
sion which will hold the axle housings in line
Single Axle Rear Suspension with one another and with the frame and will
allow independent oscillation of each wheel
Figure 6-231 shows a typical single-axle. leaf or axle housing. Tandem axle suspension
spring rear suspension. The spring has a must withstand rugged usage and give long
single eye and a slipper on the rear. A pin at- service life. Several types of tandem suspen-
taches the eye to a bracket on the frame. and sions are discussed below.
maintains axle alignment.
ift* :57-7-17r17-idarivace.
:
- 0,2
4 - 41.-t
4 (6-231)
Courtesy of Mac% Truck Limited
FROM .
AUXILIARY SPRING AUXILIARY SPRING
FRONT BRACKET REAR BRACKET
AUXILIARY SPRING
REAR SPRING
REAR SPRING REAR BRACK:T
FRONT BRACKET
464
WHEEL MACHINES 6:171
ryv
CROSS SUPPORT
TUBE
.4--EQUA'.IZING BEAMS
..41411%.
(6-233) Courfee., of Hendrickson Manufacturing Ltd
TORQUE
ROO
roRolIE
ROO
(6-234) f(
e-
465
6:172 WHEEL MACHINES
Note the following points in installation of the Four-Spring Tandem Suspension (Reyco)
equalizer beam. leaf spring suspension:
The Reyco suspension in Figure 6-236 is a
The end of the cross support tube goes four-spring tandem suspension mainly used
inside the saddle clamp. for on-highway work. As in any conventional
tandem suspension, the leaf spring assem-
The equalizer beams are mounted blies carry the axles. The springs are mounted
below the axles. lowering the center of at three different locations on each side of the
gravity and giving good stability. chassis and thus distribute the load over a
Torque arms are used for suspension large area of the frame rail.
alignment and stability.
Reyco suspension differs from other types of
Ail mountings have rubber bushings four-spring suspension such as Dayton in that
and therefore only the spring eye pin at it uses torque leaves (5. in Figure 6-236) rather
the front of each spring requires than torque rods to maintain suspension
lubrication. alignment and stability. Torque leaves provide
Stability by minimizing axle wind-up caused
Equalizing beam suspension uses the by .;.:.01ine torque. and by load transfer
lever principtes to reduce bumps by 50 during braking. Reyco suspension is aligned
percent ror example. if the wheel rises by adjusting eccentric bushings (6) located at
six Niches going over a bump the load the torque leaf mounting eyes.
will only raise three inches (Figure 6-
235).
(6-235)
Courtesy 0 Hendrickson Manufacturing Ltd.
9 9 14 9
10 11 12 3 13 12 11
5 V.1 7 $ 3
FRONT
463
WHEEL MACHINES 6:173
TRUNNION SHAFT
FRAME MOUNTING
BRACKETS
mad,
7,?-;;'-e
SPRING STRIKER
PLATES
TORQUE RODS (6)
SPRING SADDLE
(6-237)
N
Rockwell Leaf Spring Tandem Suspension Courtesy of Rockwell international Automotive Operations
On the Rockwell suspension in Figure 6-237, Oscillation of the springs and saddles on the
the load is equalized between the axles by trunnion (Figure 6-238) permit indeperdent
two full-floating leaf springs. The springs rest movement of he wheels and housings similar
at their outer ends on wear pads on the tops to the equalizing beam suspension. Trans-
of the axle housings and are mounted on verse (sideways) movement of the axles is
spring saddles by U-bolts at their centers. The prevented by the spring striker plates welded
springs and saddles are attached to, but free on the axle housings.
to oscillate on. a center member called a trun-
nion shaft The trunnion shaft is essenhally a Driving and braking forces are transmitted
dead axle attached to the frame mounting from the suspension to the chassis by a
brackets When a load is applied to the parallel torque rod system which also main-
venicle. force is applied in sequence to the tains the correct vertical position of the
frame brackets. the trunnion shaft, the spring driving axles and prevents weight transfer be-
saddles. the springs. ane finally to the axle tween tie axles. On the model shown in
housings and wheels, Figure 6-237 there are four torque rods on the
bottom, two each side. These rods hold the
housings in line with each other and square
with the frame. Two more torque rods on the
top maintain drive flange alignment.
The only lubrication needed in this Rockwell
suspension is at the spring saddles and trun-
nion. A grease fitting or oil plug is supplied.
Rockwell suspension systems are available in
various load Lirrying capac'lles and are
found on many on-highway and off-highway
tandem drive, trucks.
(6-238)
Courtesy of Rockwell International Automoire Operitti ms
467"
6:174 WHEEL MACHINES
---morrIkka., ....:.Liriiiii11
....* ,
REAR SPRING
BRACKET CAP
AND INSULATOR
tv;41:0, A
RETAINER
188-1
(6-240) SPRING ENO CONFIGURATION
Courtesy of Mack Truck Ltd
(6-239)
couriesy of Mack TIUCR Ltd
TORQUE ARMS
REAR
FRONT
SPRiNO
TRUNNION
SPRING...I..
CLIP
NUTS
LONA RIMER
SHOCK INSULATOR UPPER RUBBER
SHOCR INSULATOR CAP SHOO( INSULATOR
Ni.$4
(6-241) TYPICAL CAMELBACK SPRING ASSEMBLY
Courtesy or Mack Truck Ltd
468
WHEEL MACHINES 6:175
LOCATION OF LUKE
FITTING OR OIL FILL HOLE
CURRENT LOBE
ON NON-CURRENT BOGIE.
FITTING LOCATION
II IS AT REAR OF TAPPED HOLE WAS RETAINED
AND CLOSED WITH A PIPE
L H TRUNNION AND
AT FRONT OF R PLUG ON SOME CAPS AFTER
TRUNNION
LUBE POINT WAS MOVED TO
TRUNNION.
140.60
Zip
-:--174
469
-.- 101/1.
6:176 WHEEL MACHINES
01
;
SADDLE VERTICAL DRIVE BUSHING It
470
WHEEL MACHINES 6:177
A front suspension unit is shown in Figure 6- Figure 6-247 shows a rear suspension unit.
246. Note that this cylinder, as well as sup- The lower, inner housing slides within the up-
porting the vehicle, also has a steering arm per, outer housing and the rubber pads
that attaches to the front wheel. provide the cushioning between the two. The
upper housing and the rubber pads provide
the cushioning between the two. The upper
housing is attached to the frame through a
spherical bushing, while the lower housing is
attached to the axle box by a clevis and pin
arrangement. Mountings for these rubber
suspension units are discussed along with
hydro-air suspension mountings.
RUBBER CUSHIONED
STEERING ARM
SUSPENSION UNIT
(6.246)
Courtesy 0 Unit Rig Equipment Co
44
-e
r--
471
6:178 WHEEL MACHINES
1. Bottom section
2. Suspension housing
3. Nitrogen Gas
4. Oil (Main Chamber)
5. Annular (damping)
chamber
e. 9NI check valve
REAR HYORAIR
(6-248)
FRONT HYORAIR
Couriesy of Wabco Construction and
Mining Equipment
472
WHEEL MACHINES 6:179
mii.AA""b
(6-250)
Courtesy of Caterpillar Tractor Co.
The two rear suspension cylinders are at-
tached at the bottom to the axle and at the top
to the ends of the frame (Figure 6-250). The
axle housing is supported at the front by a Y-
shaped member called an anchor structure.
The anchor (Figures 6.261 and 6-252) is at-
(6-249) tached to the front of the housing in two
Courtesy of Caterpillar Tractor Co places and to the frame at one point. This
Wabco frame attachment has a ball bushing
arrangement which allows the housing to
oscillate from side to side, as well as ver-
tically. yet still hold the housing in line. Cater-
pillar uses a similar anchor structure on their
SUSPENSION rear hydro-air suspension. One difference.
CYLINDER
though. is that Cat uses an anchor ball rather
than a ball bushing at the frame attachment.
J
LJ
- r-r
r
**,
ANCHOR STRUCTURE
__.1
(6 -251)
Courtesy of Wabco Construction a: :
0 (4) 6
673
6:180 WHEEL MACHINES
MI NITROGEN
NI OIL
XI
(6-253) (6-255)
Courtesy of Cater') mar 'rid GiOl Co FRONT SUSPENSION CYLINDER OPERATION
For additional rear axle stability. a sway bar 1Cylinder. 2Nitrogen chamber 3Piston
(Figure 6-254) is attached to the top of the 4Onfices (two). 5Ball check. 6Cavity
axle housing and is anchored to the frame 7Cavity 8 Oil chamber.
Courtesy o! Caterpinar Tractor Co
rail. The sway bar absorbs lateral thrusts. Rear Suspension
fi
The cylinder and piston in rear suspension
Air (Figure 6-256) work opposite to the cylinder
,v and piston in front suspension. The piston is
attached to the frame and the cylinder is at-
tached to the rear axle. When the rear wheels
hit a bump. the axle raises and the cylinder
moves up over the piston. In rear suspension.
the nitrogen chamber (2) is in the core of the
piston and the cylinder is filled with oil. As the
SWAY BAR I cylir der moves up. it is cushioned by the
pressurized nitrogen pushing against the oil.
(6-254) VIEW FROM REAR OF MACHINE As in front susoension. a damping action is
Courtesy of Caterpillar Tractor Co created by oil transfer into and out of cavities
Hydra -Air Cylinder Operation (4) and (7).
Front Suspension
The front suspension cylinders consist of a
cylinder and a piston or rod. The cylinder is
attached to the truck frame and the piston or
rod to the front wheel spindles. When the
wheel hits a bump. the piston moves up into
the cylinder A chamber (2, in Figure 6-255)
between the head of the piston and the top of
the cylinder is charged with pressurized
nitrogen gas and cushions the piston as it
comes up into the cylinder. The piston (3) has
a hollow core :8) that is filled with oil.
As the piston is pushed into the nitrogen, (6-256)
pressure on the oil transfers some of the oil REAR SUSPENSION CYLINDER OPERATION
1Rod. 2Nitrogen chamber. 3Housing
4Cavity, 5-011 chamber. 6Ball check
7Cavity. 8Orifice.
Courtesy ol Catena' la; Tractor Co
474
WHEEL MACHINES 6:181
4..C.
Hendrickson
-4--FRAME HANGER
The Hendrickson air spring in Figure 6-257 BRACKET
uses the same basic design as the Hen-
drickson leaf and rubbor suspension RIGID TRAILING
previously discussed. Air suspension is ac- ARM
complished through the use of air springs
mounted on alum:num spring saddles which AIR SPRING INTERMEDIATE
also serve as air reservoirs. Vertical drive pins SADDLE SPACER
LOCATING PAD
mounte ' in rubber bushings and relieve
AXLE ADAPTER
the air spring of any function except
cushioning the load. Leveling valves are ex- (6-258)
Courtesy 01 International Harvester
ternally mounted. They automatically regulate
the amount of air pressure required for the Trailing Arms The front end of the trailing
load, as well as keep the vehicle frame at a arm is connected to the frame hanger bracket.
constant height. The rear of the arm has a support plate for the
air spring.
475
6:182 WHEEL MACHINES
bumper can either be located at the top or (6-259) AIR SPRING ASSEMBLY "14"40.
bottom of the air spring. The air bags work in
Courtesy of International Harvester
unison from front to rear (not side to side).
There is no transfer of air fro- bag to bag be- Leveling Valves The control (leveling)
cause this would cause axle roll. valve operates automatically. Valves control
the flow of compressed air into or out of the
air springs.
FRONT
'41-441a
t.1
a BELLOWS
SHOCK. 6 SHOCK
ABSORBER o ABSORBER
it
/9N, Yr; :1 ---irr_VY
0
PIVOT BOLTS
CONTROL CONTROL
BELLOWS ARM ARM
SUPPORT A.0769
BRACKET 17
473
WHEEL MACHINES 6:183
Air Bellows An air bellows (Figure 6-261) is Height Control Valve The height control
mounted between each control arm and frame valve is mounted to the frame and attached to
support bracket The bellows serves as a the forward rear axle by a non-adjustable link.
flexible connection between the frame and The valve operates when the vehicle's load in-
rear axles Flexing of the air bellows results in creases or decreases, automatically in-
an alternate increase and decrease of air creasing or decreasing pressure in the
volume This action absorbs road shocks in a bellows. As the frame settles under an
manner similar to an inflated rubber tire. increased load. the height control arm linked
to the forward rear axle is moved upward. The
BEAD PLATE WITH arm actuates the valve, and a sufficient
AIR ENTRANCE
volume of air is admitted to all four bellows to
maintain the frame at normal ride height.
During unloading, the valve exhausts air from
the bellows.
Axle Control Arms Control arms hold the
rear axle in position. transmit driving and
braking forces to the frame, and provide roll
stability. A good view of control arms is given
in Figure 6-262.
477
6:184 WHEEL MACHINES
7. List the four common types of spring 17. What are the two-purposes of the front
suspension. rubber suspension units used on large
mining trucks?
8. The stiffness of a leaf spring is referred
to as its: 18. Hydro-air suspension cylinders are
precharged with:
(a) hardness
(a) nitrogen
(b) resilience
(b) oxygen
(c) rate
(c) hydrogen
(d) size
(d) carbon-dioxide
9. Briefly explain the difference between a
constant rate spring and a progressive 19. What is the advantage of air suspension?
rate spring. Where is it likely to be used?
10. What is the advantage of a progressive 20. What is the function of leveling or height
rate over a constant rate spring? control valves on air suspension?
11. A tandem axle suspension permits the 21. The front of the axle housing on a
truck to carry heavier loads because the machine using hydro-air suspension
load is distributed over: cylinders is supported by an
(a) the cab of the truck.
(b) one axle when unloaded and two
when loaded.
(c) a greater number of springs.
(d) a greater number of axles. springs
and tires
478
WHEEL MACHINES 6:185
479
..a. ..,.........1111.041.10
6:186
CE.95970
(6.266)
Counesy of Caterpillar Tractor Co
481
6:188 WHEEL MACHINES
f I
IlEasi."W litr
iisti..,161 4,
)1 ---7_-_--(
I....._ F.....
2 .Aar .1
1
,,,....,
#
i, II
, ----a.
t A 1
. f
....oil!
A09964X I
....4.
(6-268) (6-269) 1 Retainer. 2 Soils.
Courtesy ol Caterpillar Tractor Co
C'unesy of Caterpillar Tractor Co.
482
WHEEL MACHINES 6:189
OSCILLATION
HOUSING
483
.. .
6:190 WHEEL MACHINES
484
WHEEL MACH! NES 6:191
SERVICE OF TRUCK FRAMES AND 3. Visually check the irP.me for loose bolts
REAR SUSPENSION and rivets and for cracks. Also check for
DAILY, ROUTINE MAINTENANCE ON loose components.
TRUCK REAR SUSPENSION
4. Visually check for loose torque arm
A thorough daisy, routine maintenance check bushings and sr:aching bolts. Check the
of a highway truck rear suspension would in- condition of torque arms, spring saddles.
clude: walking beam bushings.
Caution: Before doing a daily, routine
check, park the truck on level 5. Check the condition of the shock ab-
ground. turn the engine off and set sorbers. Look for any leakage.
the parking brake. 6. Check the springs for cracked or broken
1. Check the condition and pressure of the [eaves. and for worn shackle pins.
tires. (See Tire section. Daily. Walk-
Around Checks). Remember, inspecting 7. Check for loose U-bolts.
truck tires is the single most important
check for highway safely. Loose U-bolts are often the cause of leaf-
spring breakage. axle misalignment. hard
2. Visually check for loose wheel nuts. As steering. and abnormal tire wear. TIM. ten
mentioned earlier rusty marks around nuts Ubolts (Figure 6.272) after the first 500
Illicate looseness (Figure 6-271). miles (800 km) on a new vehicle as the
springs settle and cause U-boll tension to
slacken. Check the U-bolt tension of on-
highway vehicles ever/ 25.000 miles
(40,000 km). Check off-highway vehicles
weekly. The vehicle should be loader, to
its normal gross weight when tightening
the U-bolts. The use of a torque wrench is
highly recommended. if U-bolts or nuts
need replacing, do not risk an accident by
using common U-bolts or standard nuts.
Use only U-bolts and nuts of SAE Grade 8
specifications.
On off-highway trucks that have hydro-air
suspension, cheek the suspension cylin-
der piston extension (Figure 6-273). The
cheek should be made when the vehicle is
level, empty and has come to a gradual
stop. Allowable tolerances are given in
service manuals. Report if the piston ex-
tension is not within the acceptable range.
Also check the cylinders for leakage.
a
(6-271)
RUST STREAKS FROM STUD HOLES i
CAUSED BY LOOSE CAP NUTS
Courtesy of Oudd
(6-272)
Courtesy of Kenworth Truck Company
485
6:192 WHEEL MACHINES
Mar 1-
yi
4
T: J.
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487
6:194 WHEEL MACHINES
SERVICE REPAIR OF TRUCK FRAMES There are several methods of identifying heat-
AND REAR SUSPENSION treated frame rails. The most common is a
stencil marking on the inside middle section
Frame Alignment of the rail or a stencil mark on one of the
cross members. The stencil notes that the rail
Frames can become misaligned, although is heat-treated and rail flanges must not be
usually misalignment will occur only as a drilled or welded. It is a caution against
result of an accident. When a frame is welding additional, brackets cross members,
misaligned the cross members are out of or full length reinforcement rails to the frame.
square with the rail& The cause cln be a bent Minor repairs to heat-treated frames. as
or twisted rail or one of the rails could be shown further on in this section. are ac-
pushed forward or backwards. A vehicle with ceptable.
an obviously misaligned frame would be sent
to a frame shop for repairs. or to have one or A second method of identifying heat frame
both of the rails replaced (on larger trucks). rails is to have small patches covering
"Brinell- test marks along the inside (web) of
Frame alignment can be checked by dropping the rail. These patches are found about every
a plumb bob from the frame to the floor at three or four feet. The patch can be removed
points K in Figure 6-275. If the diagonals are to expose the "Brinell" marking. A third
not the same or within allowable tolerances of method is to stamp "H" for heat-treated on the
one another. that section of the frame is upper face of the rai; flange about three in-
misaligned. The use of the plumb bob to trans- ches from the rail end.
fer frame points to the floor is necessary be-
cause all the parts and pieces attached to the REPAIR ON NON-HEAT-TREATED FRAMES
frame make it impossible to put a square
against the rail and cross member or to Cutting
measure the diagonals with a tape.
Whenever it is necessary to cut the frame. the
&de rail should be cut at an angle of 45
degrees. This method distributes the cut and
web over a greater area than a cut made at
right angles.
CROSS MEMBER
DIAGONALS
Reinforcing
Reinforcements may be made with flat. chan-
nel or angle stock. Reinforcement thickness
K should not exceed the original side rail
(6-275) thickness. Because of difficulties en-
Frame Repair countered when inserting channel rein-
forcements into the frame side rails. the use of
The following material about frames, and angle reinforcements is acceptable. When
frame repair, is used courtesy of International ever possible, the reinforcement should ex-
Harvester. tend from the front axle to slightly beyond the
rear spring front mountini bracket. If a rail is
Since frames must keep the major com- damaged beyond repair. cr if it is too costly to
ponents of a vehicle in their relative positions. repair. the complete rail may be removed and
they should be kept in good condition. Truck be replaced wilt, a new one. (New rails may
frames are manufactured with frame rails of also be installed on heat - treated and
either non-heat-treated steel, heat-treated aluminum alloy frames.)
steel or aluminum alloy. It is importaat to be
able to recognize the different frames be- Hot rivets are acceptable to attach rein-
cause they have different repair procedures, forcements, and they can be driven with hand
tools. Cold rivets should only be used when
No difficulties should be encountered in iden- you have tools of sufficient power to properly
tifying aluminum alloy frames because the set the rivets. The diameter of the rivets
side rails and cross members are made of should be 50 to 100 percent of the total
thicker material than are the components of a thickness of the plates to be riveted.
steel frame of comparative size. If there is any
doubt, use a file to check the material's hard-
ness or color.
488
WHEEL MACHINES 6:195
Welding
Electric arc-welding is recommended for all
frame welding. The reinforcements should be
welded to the frame after the reinforcements
are riveted. All unused holes should be filled
with welding material. The v eldingrod should
have a substantial amount of the same
material that is used in the frame. WELD
REINFORCEMENT
Preparation Of Frame For Repair PLATE
3/4" MINIMUM
METHOD OF REINFORCING
(6.278) CRACK IN FRAME
Courtesy of iniernatsonat Harvester
. , 489
6:196 WHEEL MACHINES
Frame Straightening
When heat-treated frame rails have been bent
or twisted, they should not be heated for
straightening. Straightening should be done
with the frame rails cold. Heating is likely to
destroy the rail temper in localized areas and
cause rail failures. (6-280)
Courtesy of Hendrickson Manufacturing Lid
Repairs On Aluminum Alloy Frames
The cutting of aluminum alloy frame rails for
repair or reinforcement is not approved be-
cause aluminum rails cannot be welded
without losing their original strength. Also
490
WHEEL MACHINES 6:197
4 The frame is then blocked. A floor jack is bushings. Pressures required to remove the
paced under the spring and saddle bushing and sleeve assemblies will generally
assembly (one at a time), the spring pin is be between 35 to 50 tons.
removed, and the spring is rolled out on
the jack (Figure 6-281). Note: Do not use a cutting torch to aid in the
removal of bushings from equalizer
beams. The beams are heat-treated
and the heat from the torch will
f weaken them. Repair of spring
suspension parts are discussed below.
Spring Hangers
Check the condition of spring hangers. Also
check the spring pin holes on the front
hangers and the cams on the rear hangers. If
the hangers are worn excessively. they should
be replaced. At major overhauls. spring
hanger pins and spring eye bushings (if the
springs are to be reused) should be replaced.
4 "."...
ei,......W. Springs
4 . ,
." ..... 4
e( --.;..0.1. . va..., .- Putting aside the fact that springs can be
i:-....:"""mw. ---,%:. -... ' ."....4....:Szist--4 -4.! 4_ broken by loose U-bolts, springs eventually
(6-281) wear out due to metal fatigue. Fatigue cracks
Courtesy of Hendrickson Manufacturong LW
start at a scratch, notch or rust spot and
progressively deepen and lengthen. Some of
Cleaning and Inspection the factors affecting fatigue (i.e.. spring life)
are: vehicle gross weight, type of load, road
Clean all dirt from the suspension parts and conditions. vehicle speed, and suspension
inspect them carefully for cracks or damage. maintenance practices.
Magnaflux or fluorescent equipment may be
used to inspect the parts. Inspect the rubber Before disassembling the spring. mark with a
bushings for damage or deterioration. chalk or grease pencil down one side of the
Petroleum products usually will not harm the spring so that you know the original position
Hendrickson equalizing beam center of the leaves on reassembly. To disassemble
bushings because they are not in an exposed the spring. place it in a vise (small springs) or
position. However, the outer edges of the an arbor press (large springs) next to the cen-
beam's end bushings are exposed and will ter holt.
deteriorate from continuous oil saturation. If The problem when inspecting springs is to
the suspension has been in service for a long determine if it is better to repair or to replace
period of time. it is advisable to replace all broken springs. Consideration should be
bushings. given to spring mileage, number of previous
Most repairs to spring suspension systems repairs and relative cost of repairs compared
consist of replacing worn or damaged parts. to the cost of new springs. If one spring is
The major item that will concern the ser- replaced. it is recommended that the other be
viceman on equalizer beam suspension is replaced as well. otherwise the deflection
removal and replacement of the rubber would differ on each side. The same can be
bushings. While bushings have long life. they said for shock absorbers. replace them in
eventually deteriorate arid need replacing. pairs. Below is a guideline to use when con-
Special service tools for replacing bushings sidering the question whether to repair or
on equalizing beams are made: they are the replace springs.
best tools for the job. but are not absolutely
necessary. If press equipment is available, When To Repair Broken Springs
standard steel tubing having diameters to 1. If the spring has been repaired not more
match the bushing sleeves (metal bands than once already.
surrounding the rubber bushings) can be used
as adapters for removing ard installing the
491
6:198 WHEEL MACHINES
Torque Rods
Torque rod ends deteriorate after long service
SPACER SHIMS
life. Many torque rod models have replaceable
ends (Figure 6-282) that are press fit into the TORQUE ARM
rods. BRACKET
492
WHEEL MACHINES 6:199
Checking Alignment
A common method (courtesy of Rockwell In-
ternational) for checking bogie alignment is
given below. This method involves squaring
and clamping a straight edge to the frame and
then measuring from the straight edge to each
side of the axle (Finure 6-284). The
measurements should be the same (or within
allowable tolerances) if the axle is aligned
with the frame. Note that the straight edge
should extend at least one foot further than
the overall tire width. The straight edge
method is used here to check the alignment of
tandem axles, but it may also be used to
check single axle alignment, front or rear.
..M. ..
I.... M.I .,
'..
.wOmb 411
I
_ ..-0
--
1111 .,1I
I
I iI
.11 AelI
011
In
....T.
Uk=m0
A
STRAIGHT EDGE
TOOL
4,
1
Courtesy ol Rockwell international
(6-284) Automotive Operations
493
6:200 WHEEL MACHINES
1. Measure distances (A) from the straight Universal Joint Companion Flanges
edge to the connecting tube centers.
Tolerance: 1/16". This measurement tells A very important adjustment related to rear
you if the suspension assembly is parallel suspensor. is the parallel alignment of the
with the frame. universal joint companion flanges (Figure 6-
285). Removal and installation of the rear
2. Measure distances (B) from the straight suspension assembly or the upper torque
edge to the back rear axle center. arms can throw out the universal flange align-
Tolerance. 1/8". This measurement tells ment if not done correctly. A one degree
you if the back rear axle is perpendicular tolerance is all that is allowed.
with the frame.
When removing shimmed torque rods.
3. Measure distances (C) from the straight carefully note the number or size of the shims
edge to the front rear axle center. and reinstail the rods with exactly the same
Tolerance: 1/8". This measurement tells size shim pack. When removing an adjustable
you if the front rear axle is perpendicular torque rod, be careful not to disturb the
or aligned with the frame. threaded adjustment; the adjustment must be
in exactly the same position as when the rod
4. Measure axle center distances (D) to see was removed.
if the axles are parallel. Tolerance: 1/4".
Note the tool that is used to measure the
Apart from improperly installed torque arms.
axle centers. universal misalignment on tandem axles can
If misalignment is found, first check to see also be caused by worn torque arms. To
that it is not caused by: correct the misalignment, torque rods have to
be adjusted to tilt the axle up or down.
bent axle housings Depending on the type of torque rod, ad-
frame damage justing the rod involves: (1) adding or taking
away shims. (2) adjusting the rod itself or (3)
wheel bearings obtaining a new rod of the correct length. An
If it is not, then refer to the service manual for apprentice should not attempt to correct
the procedures to correct the misalignment. universal misalignment unless under the
Some faulty alignments may be corrected by guidance of a journeyperson.
simply making adjustments, while others will Note that misalignment of.the universal com-
require repair or replacement to correct such panion flanges or yokes on single axle trucks
things as loose bolts, elongated holes in the is not usually a problem because spring sad-
frame support and connecting tube brackets. dles are solidly fixed to the housing and the
and worn torque rod ends. Servit,:: manuals fronts of the rear springs are attached to the
often give a list of likely causes of misalign- frame by shackle pins.
ment. Check through this list carefully, be-
cause often corrective action can be made on
the suspension without having to do a com-
plete rebuild.
FLANGES MUST BE PARALLEL
VERTICALLY AND HORIZONTALLY
(6-285)
494
WHEEL MACHINES 61201
495
$1202 WHEEL MACHINES
Charging The Cylinders With Nitrogen Charging Procedures (Refer to Figure 6.287)
Warning: Dry nitrogen is the only gas ap- Warning: For personal safety it is very im-
proved (or use in suspension cylin- portant that valves be opened or
ders. Accidental charging a cylin- closed in the correct order.
der with oxygen will cause an ex-
plosion. This danger can be 1. Close the charging chucks (1).
eliminated by only using nitrogen 2. Close shut-off valve (2).
cylinders that have the correct
connections. Never use an adapter 3. Connect the nitrogen charging equip-
to connect a nitrogen charging ap- ment.
paratus to a valve outlet that has 4. Open the charging chucks (1).
been used interchangeably on
nitrogen, oxygen, or other gas 5. Open the nitrogen tank valve (3) and ad-
cylinders. Do not rely on color just the valve until the gauge reads ap-
coding or other methods of iden- proximately 500 P.S.I. (35.15 kg/cm2).
tification to distinguish between
nitrogen and oxygen cylinders. Be 6. Open the individual cut-off valves (5) and
absolutely certain the tank con- open the shut-off valve (2). Charge the
tains dry nitrogen. cylinders until the proper extension is
reached.
1 2 3
7. To stop the charge close:
(a) the shut-off valve (2)
(b) the nitrogen tank valve (3)
(c) the charging chucks (1)
5
4 8. Note that step 7 must be followed each
: time the rod extension is checked while
charging.
9. After performing step 7. the equipment
can be disconnected.
10. Recheck the rod extensions after the
vehicle has operated a few cycles. In-
crease the nitrogen pressure. if
necessary.
Front Suspension
lAt3S412x1 e-
496
WHEEL MACHINES 6:203
:f, t. 2
4
LOWERING SUSPENSION CYLINDER
1Rope sling. 2Mounting flange.
3Suspension cylinder. 4Lifting eye.
5 Chain hoist.
PREPARING TO REMOVE WHEEL AND SPINDLE (6-289)
1 -Wheel brake hydraulic line. 2 Bolts (four). Courtesy of Wabco Construction and
Mining Equipment
3Spindle. 4Steering arm.
(6-288)
Conitosy of Caterpillar 'tractor
497
1
6:204 WHEEL MACHINES
498
WHEEL MACHINES 6:205
499
t-
500
WHEEL MACHINES 6:207
501
6:208 WHEEL MACHINES
FLAP
WHEEL LOOSE LOCKING
DISC FLANGE RING
TUBE
TIRE (6-290) TUBE TIRE
Courtesy of Fotesione Canada Inc
504
6:210 TIRES, RIMS AND WHEELS
(6-291) TUBELESS
TIRE
TREAD
.
4.tr;'.714-44:4-'` _
.41-------TREAD SHOULDER
BODY PLIES
VALVE STEN
AIR CONTAINER
BEAD
X2534
(6-292)
Courtesy of John Deere Ltd.
505
TIRES: RIMS AND WHEELS 6:211
Body Plies
Plies are layers of rubber-cushioned cord or
fabric that make up the body of the tire. The
strength built into the plies retains the air
pressure that supports the load and cushions
the shocks. Each cord in each ply is
completely surrounded by a resilient rubber SMALLER LARGER
compound. and each ply is insulated from the CORDS CORDS
next by a layer of the same compound.
The cord material may be made of cotton,
rayon, nylon, polyester, or other materials.
Rayon and nybn have been the most popular,
but recently more and more tire cords are
being made with polyester.
Tires have different numbers of plies. Tires for
4-PLY TIRE 2PLY TIRE
automobiles, station wagons and light pick-up X*535 (6_293) FOUR PLY RATED
trucks have two. four or six plies. Tires for
large highway trucks have from six to 14 plies Courtesy of John Deere Ltd.
and tires for large off-highway equipment can Types Of Ply Construction
have up to 20, or more, plies.
Bias Ply
Ply-Rating
Standard tires have a bias ply construction.
Ply-rating indicates the strength of a tire, but Bias means that the ply cords run from one
does not necessarily tell the number of cord tire bead to the other at an angle. Alternate
plies the tire has. For example, a tire with a plies run at diagonals to one another (Figure
four ply rating may only have two plies. The 6-294). Bias play construction gives rigidity to
four ply rating means that the two plies have both the sidewall and the tread. Two disad-
added strength and will carry the load of a tire vantages of bias ply are (1) the layers of ply
that has four standard plies (Figure 6-293). All tend to work against one another creating a
off-the-road tires are ply-rated. Automobile heat which can be a problem at high speeds.
and truck tires used to have a ply-rating but and (2) bias ply tends to cause the tread to
are now identified by what is called a load tighten or squeeze at the road surface in-
creasing tire wear.
Belts
506
6:212 TIRES, RIMS AND WHEELS
Belted-Bias Ply Both bias ply and radial ply tires are used on
heavy duty equipment. but the trend is
Belts are added to a bias ply construction to towards radial ply. Note that the type of ply
make a belted-bias ply tire. The belts are com- construction of a tire is often marked on the
posed of very low angle cords; they surround tire: B for bias - belted; R foi radial; and D for
the tire body underneath the tread. This bias (diagonal).
construction gives rigidity to both the
sidewalls and the tread. The belts reduce Wire Reinforced Ply
tread motion during contact with the road and
thus improve tread life. Some big tires for earthmoving and other
equipment. have a layer of wire between the
Belted-Radial Ply tread and the body of the tire (Figure 6-295).
This protective layer of wire keeps most cuts
On a belted-radial ply tire the ply cords run from penetrating the tire body. It also keeps
across the body from bead to bead at almost a tread cuts from enlarging and holds them
right angle. Fairly rigid belts composed of closed so that sand and dirt will not enter and
steel or fabric cords surround the tire body cause separation.
underneath the tread. As with belted-bias
tires. the belts recipe tread motion during SHREDDED
contact with the road, and thus improve tread 7NyHRE UNDERTREADI
life. Radial ply construction gives better sup-
port to the tread than the other two types of
ply. Three advantages are c r red for radial
tires:
'1. They generate less heat when properly in-
flated.
AN
YLON BODY
2. A broader base of rubber contacts the '1/4
road making the tire less likely to skid,
especially at corners.
3. They wear better because they don't
cause the tread to squeeze.
IV
(6-295) WIRE- REINFORCED CONSTRUCTION. OF
HEAVY -OUTY TIRE
Courtesy of John Deere Ltd.
Sidewalls
Sidewalls are the rubber coverings on both
sides of the body. They are made to flex and
bend without cracking during both ordinary
deflection and extreme sudden shock.
Tread
The tread is the part of the tire which contacts
the road. It must provide traction, give long
wear and resist cuts. Tire treads have many
patterns and depths for different types of ser-
vice. Examples of tread for off-the-road tires
are given in Figure 6-296 and for over-the-
road tires in Figure 6-297.
/160
2r, 'elUe
(6-296)
Courtesy of Caterpillar Tractor Co
5.07
TIRES, RIMS AND WHEELS 6:213
(6-296)
Courtesy of Caterpillar Tractor Co.
Rock tires are used on scrapers, wheel
loaders and trucks working in rock quarries.
The bars on these tires provide excellent
resistance to cutting and bruising by rocks.
The larger bars give increased tire-to-ground
contact and much better weight distribution.
(6-296)
Courtesy of Caterpillar Tractor Co.
Flotation tires are used primarily on free
rolling wheels or for oeneral traction. They
are a very wide tire and thus distribute the
vehicle weight over a broad surface area. The
ugs are placed close together to give a
reasonably smooth ride.
4
(6-296)
Courtesy of Caterpillar Tractor Co.
508
6:214 TIRES, RIMS AND WHEELS
I))
(6-296)
Courtesy of Caterpillar Tractor Co.
/ . _A"5"--
Apdp.-14b.
-.1
riA ,6 ..,
(6-297) OVER-THE-ROAD TIRE TREADS
Counesv of Fire Slone Canada Inc
509
TIRES, RIMS AND WHEELS 6:215
510
6:216 TIRES, RIMS AND WHEELS
FACTORS IN SELECTING
OFF-THE-ROAD TIRES
The type of tread. as stated earlier. is a factor
in selecting tires to do a job. Two other fac-
tors are load size and machine speed. which
(6 -3Q0) together give the Ton-Mole-PerHour Rating
(TM PH) that is used in choosing a tire of
suitable size and strength. The TMPH for a
large earthmover would he found in the
following way (Courtesy of Caterpillar):
Rims
Tires are mounted on rims. Rims may be part
of or separate from the wheel; those separate
from the wheel are called demountable rims.
Most automobiles and heavy duty vehicle r"as
and wheels are made of steel. In the past few
years, however. other metals such as
magnesium (automobiles) and aluminum
5.11
. TIRES, RIMS AND WHEELS 6:217
oo
9
6
(6-303) Courtesy of DaytonWalther
513
TIRES, RIMS AND WHEELS 6:219
(6-309)
Courtesy of Firestone Canada Inc
(6-307)
Courtesy of Budd Company
514
6:220 TIRES, RIMS AND WHEELS
Inner Dual
DUAL Cap Nut
(6.310)
Outer Dual
Cap Nut
AI
(6.311)
Courtesy ol 13urid Company
515
TIRES, RIMS AND WHEELS 6:221
OUTER THREAD
(6-313) OUTER CAP NUTS
Courtesy 01 Budd Company
516
6:222 TIRES, RIMS AND WHEELS
-Ifiti;c,-4(1
4.....t...-
5j7
TIRES, RIMS AND WHEELS 6:223
....1.
Dry Ballast
Dry ballast. although not as common as liquid
ballast. is also used for weighting tires. Some
dealers are equipped to install dry ballast and
a few manufacturers are installing dry ballast
at the factory. Normally. tires are filled to 87 to
95 percent of capacity with a ballast powder
made of a clay. limestone and barium sulfate
compound. Dry ballast comes in weights of 10.
518
6:224 TIRES, RIMS AND WHEELS
Chains.
Mud or snow lug tires. under certain cir-
cumstances. may not be sufficient to give a
machine the traction to keep it moving. In this
event traction devices are required. The most
common traction device is skid chains. Skid
chains are used on two and four wheel drive
vehicles operating either on or off the high-
way. Even tandem drive vehicles will oc
casionally require chains.
Truck and bus chains for traction in snow. ice.
and mud are illustrated in Figure 6.319. Figure (6-320
6.320 shows skidder chains. Courtesy of International Harvester
519
TIRES, RIMS AND WHEELS 6:225
Beadiest Tires
Caterpillar has developed another trac-
tion/protection device called a beadless tire
(Figure 6-321). made for loaders working in
rock. It is a specially designed one-piece tire
having an oval air chamber called a carcass.
The carcass is one ply, and instead of beads
has a framework of helically wound cable to
give it support. The carcass is mounted to a
unique two-piece split rim. A replaceable,
cable-reinforced rubber belt encircles the
outer circumference of the carcass. The belt
is held in place by air pressure in the carcass
and by matching grooves on the inside of the
belt and on the outside of the carcass. Steel
shoes bolt directly to anchor plates moulded
to the mounting belt. The shoes. belt and car-
cass are all replaceable.
(6.321) 1Two piece rim. 2Carcass. 3Mounting Courtesy of Caterpillar Tractor co,
belt. 4Shoes. 5Center mounting bolt,
5go
6:226 TIRES, RIMS AND WHEELS
QUESTIONS TIRES, RIMS AND WHEELS, 15. Weight can properly be added to a
BALLAST, TRACTION DEVICES machine by:
2. What are the two general types of tires (b) piling up rocks on the machine.
and what are the two types of tire con- (c) filling the tires with liquid or dry
struction? ballast.
3. What do the allowing letters and num- (d) inflating the tires.
bers refer to with respect to tire sizing:
H.R. 78-15? 16. The recommended maximum amount of
liquid ballast that can be put into tires is:
4. What is the purpose of tire beads?
(a) 50% calcium chloride. 50% air.
5. True or False? Ply-rating gives the
strength of the tire. but does not (b) 75% calcium chloride. 25% air.
necessarily give the number of cord (c) 90% calcium chloride. 10% air.
plies.
(d) 100% calcium chloride, no air.
6. What is the main advantage of belted-
bias and radial- belted tires over bias ply 17. What precaution must be observed when
tires? removing ballast weighted wheels?
7. Drive wheel tires with a V-tread pattern 18. Tire chains on a grader working in win-
must be mounted for forward rotation so tery conditions would be needed for
the V-pattern points: Tire chains on a
(a) downward as viewed from the front.
loader in a rock quarry are used for
(b) downward as viewed from the rear. 19. What does a beadless tire have ea place
(c) upward as viewed from the front. of tread?
(d) either (a) or (c).
8. True or False? Tire flaps are needed in
tubeless tires to help seal the tire at the
rim.
9. What two other factors are considered
besides tread design when selecting off-
the-road tires?
10. How does a cast spoke wheel with a
demountable rim differ from a disc
wheel?
11. Briefly explain how the method of
retaining the rim on a cast spoke wheel
differs from retaining the rim on a disc
wheel.
12. What precautions must be observed
when removing split-rim wheel?
13. How are the double nuts and studs used
to attach disc wheels marked to indicate
thread direction?
14. If a machine working in off-theroad con-
ditions has insufficient weight, excessive
of the tires.will result.
521
TIRES, RIMS AND WHEELS
522
6:228 TIRES, RIMS AND WHEELS
Effects Of Incorrect Inflation ched with a correctly inflated tire on one side
of a tandem. the under inflated tire would slip
Attention to tire pressures on the front wheels for those 22 revolutions because it must travel
is as important to the safe control of the truck at the same speed or revolutions per mile as
as is tire balance and front-end alignment the correctly inflated tire. During the first
With lower pressure. tire contact area with the
1.000 miles it will slip 13-1/2 miles. and after
road increases. More contact area means 10.000 miles it will have slipped 135 miles. Tire
more resistance against rolling and poorer
fuel mileage. If front tire pressures are treads have been known to be ground off in
unequal. the wheels will tend to steer to the less than 10,000 miles.
side of lowest pressure causing extra tread
wear. Such a steering pull may not be noticed Under inflation can affect more than the tread
when driving with power-assist steering until of a lire. Under inflated tire: flex ,xcessively
the brakes are applied. During braking ap- and this results in high internal tire tem-
plication the tire with the lowest pressure will peratures that can cause premature tire
pull the truck to its side. A sudden. hard ap- damage such as flex breaks. radial cracks
plication of the brakes on a slippery road and ply separation. Over inlfation is also bad
might start a tractor-trailer rig lack-knifing. for tires. It prevents full contact of the tire with
the ground causing excessive wear at the
Consider the change in the overall diameter center of the tread. An over inflated tire is too
01 two similar tires with different tire pressures rigid and is more vulnerable to snags, cuts.
(and constant load) (Figure 6-322) The lower and punctures. Figure 6-323 illustrates over.
the air pressure the shorter the overall
under and proper inflation. Note that a proper
diameter becomes Since the overall diameter inflation permits all of the tread to contact the
is smaller in the under inflated tire. it will ground, but doesn't allow the tire to flex ex-
travel more revolutions in a mite (i.e., faster at cessively.
constant speed). in this case about 22 extra
revolutions. If this underinflated tire was mat-
I
OVERALL
DIAMETER
40"
I
39.3/8"
1 I
80 P Si 50 P S I.
(6-322)
523
TIRES, RIMS AND WHEELS 6:229
524
6:230 TIRES, RIMS AND WHEELS
It is most important that a gauge be accurate 2. Use a rubber covered steel hammer on
Accuracy can only be determined by rims and tires; it won't damage the rim or
checking the gauge against a gauge of chip off bits of metal that may cause injury
known accuracy. For this reason. keep one (Figure 6-327).
accurate gauge for the sole purpose of
checking the accuracy of the gauge normally
used. This practice is especially important
when working with low-pressure gauges.
(6-325)
Counesy 0 Mack Truck Ltd
Inflating Tires (6-328) SAFETY PRESS
ounesy of Mack Truck Co
1. Before inflating a tire make certain the rim
lock ring is seated to the full depth of the
groove. fits tightly all around. and is
securely locked (Figure 6-326). Improperly
seated rings are a main cause of rim
failure.
525
TIRES, RIMS AND WHEELS 6:231
5. if it is not possible to use a safety device Imagine a set of tandem axles, directly
use a sell attaching air chuck and stand connected by the prop-shaft. rolling on
behind the tire tread while inflating. eight tires all of a significantly different
radius. The rear axle will try to over-, Jr)
the lorward axle and the forward axle will
try to hold back the rear axle. The tires
will squirm and scrub. This is wheel fight.
It tries to wind up the prop shaft and twist
the axle shafts. Wheel fight causes the
ring and pinion gear teeth to grind under
extreme pre-.....-es and the differential and
bearings to work beyond their normal
limit. If these conditions are allowed to
continue, internal mechanical damage will
surely result.
526
6:232 TIRES, RIMS AND WHEELS
3. Mark the size on each tire with chalk and 2. Tires for construction equipment such as
arrange them in order of size. largest to larger wheel loaders or graders
smallest.
These tires and wheels are large enough
4. Mount the two largest tires on one side of to be dangerous if they fail over and thus
one axle and mount the two smallest on require a forklift or an overhead crane and
the opposite side of the same axle. It is sling to remove and to move them (Figure
advisable to allow only a half inch dif- 6-333).
ference in diameter between duals. or one
and a half inch difference between cir- 1
5.
cumferences.
Mount the four other tires on the other
axle in the same manner. If the vehicle
I 1
has tridem axles. the same system is used:
arrange the tires in order of size. The two
largest and two smallest go on one axle,
the next two largest and smallest go on
the second axle, and the remaining four
go on the third axle. This system of mat- a
ching has two benefits:
(a) each running pair is closely matched.
(b) the total rolling circumference of the
four tires on an axle will be ap- 09i05X1 '
proximately the same for all axles. (6-333)
Courtesy of Caterpillar Tractor Co
6. Test run the vehicle to get accurate rear
axle lubricant temperature readings on 3. Tires and wheels for large off-highway
the two axle lubricant temperature haulers in the 100-200 ton range
gauges. Vary tire air pressure. within the These tires and wheels are very large and
tire manufacturers recommended range. heavy; a forklift (Figure 6-334) with a tire
so that the lubricant temperatures of both attachment is generally used to remove
axles are within 30 F. of each other and them from the machine. Slings are also
not in excess of 220 F. This will usually used.
result in uniform tire loading and good tire
life.
Tire Rotation
Generally speaking. if a tire is broken in on
the front wheels and then moved to the rear
axle(s). it will have a longer overall service
life. For this reason. some fleet owners will
rotate tires from front to rear wheel positions
on a scheduled rotation plan. The plan will
vary depending on the type of vehicle and the
size of tires. Note that any tire that has been
recapped or regrooved should not be used on
the front of a vehicle. Heavy duty tires and
wheels can be put into three size categories (6-334)
according to the way they're handled. Courtesy of Caterpillar Tractor Co
52
TIRES, RIMS AND WHEELS 6:233
Torquing Nuts
When tire and rim problems occur. incorrect
installation and tightening practices are often
the cause.
1. Wheel nuts must be torqued:
3
(a) in the correct sequence.
(b) in several stages to the correct 4
torque specifications.
Figure 6.335 shows the torquing sequen-
ces of a five point spoke wheel and a ten
6
stud disc wheel. Note the pattern of
torquing opposite nuts in sequence.
(6-335)
Courtesy of Mack Truck Company
528
6:234 TIRES, RIMS AND WHEELS
3. Tightening procedure:
(a) The first time around and in the
proper sequence lightly tighten nuts
with a wheel wrench so that the
wheel is seated on the hub disc
wheels. or the rim is seated on the
wheel for spoke wheels.
(b) On the second round. tighten the
nuts with a wheel wrench or air
wrench (Figure 6-336) so that the rim
or wheel is correctly positioned and
snug.
(c) Finally, tighten the nuts with a torque
wrench (Figure 6-336) to the torque
specified in the manual. Excessive
tightening can distort the wheel or
cause inconsistent brake action.
while under torquing can cause the
wheel to loosen. Avoid these
problems: use a torque wrench.
Note: On disc wheels having an inner
and outer nut these three
procedures would be gone
through twice. once for the inner
nut and once for the outer nut.
1/4
529
TIRES, RIMS AND WHEELS 6:235
(r)
530
6:236 TIRES, RIMS AND WHEELS
4. As stated above the most accurate way to 6. To properly check the torque of previously
tighten wheel nuts is with a torque tightened nuts, a torque wrench should be
wrench. However. if a torque wrench is used. Apply the torque wrench on a
not available. a fairly close feet-pound ap- previously tightened nut and at the point
proximation can be achieved with a stan- the nut starts to turn read the torque in-
dard wheel wrench. Since feet-pounds of dicated on the gauge.
torque is nothing more than weight ap-
plied in pounds times distance in feet. the 7. An accurate reading cannot be obtained
mechanic weighing 180 pounds steadily on the inner cap nuts without loosening
applying his full weight three feet out on the outer cap nuts. Back off the outer cap
th9 wrench handle (Figure 6-337) until the nuts a few turns. and check the torque of
cap nut will no longer tighten will have the inner cap nuts. Then retighten the
540 feet-pounds of torque. A 200 pound outer cap nuts to the specified torque.
man applying his weight 2-1/2 feet out on
the extension would get 500 feet-pounds
of torque.
.
a
180 Pt
LBS.
AN&
, 540
LELIFT.
5. If a spongy feel is obtained when the cap 8. A check should be made for tire runout (a
nuts are tightened. or if the nuts cannot be wabbfe in the wheel) after the wheel stud
pulled into a solid seat something is nuts have been torqued (Figure 6.338). AU
wrong. The assembly should be checked. wheels are susceptible to run out from im-
with wheels dismounted. for evidence of proper tightening. and spoke wheel more
worn ball seats. damaged studs or defec- so than others.
tive wheel nuts.
531
TIRES, RIMS AND WHEELS 6:237
532
6:238 TIRES, RIMS AND WHEELS
Replace
/
ti I
(6-341) STRIPPED
Counesy of Budd Company
_ Replace
(6-343) Courtesy of Budd Company
533
TIRES, RIMS AND WHEELS 6:239
installing Chains
Skid chains may be installed in one of two
ways. In a shop. jack or lift the vehicle so it
clears the ground. Then place the chain over
the top of the tire and latch the ends of the
side links together at the bottom. The chain
cross-links must then be positioned around
the lugs of the tire so that they lay as straight
(6-344) as possible across the face of the tire.
Courtesy *1 Mack Truck Company Retighten the couplers so that the chain is
snug but not too tight. A word of advice: put-
ting on chains is more difficult than it sounds.
especially on large wheels.
To put on chains on the road. lay the chain out
flat in front or rear of the tire and run the tire
onto the chain a foot or two from the end. The
other end of the chain is then dragged over
the top of the tire so the two ends can be
coupled together. Chains are heavy and often
there are obstructions like fenders that make
it difficult to work the cross-links around so
they lay straight enabling the side links to be
534
6:240 TIRES, RIMS AND WHEELS
snugged up. A bar will often help in working Protection chains. due to their weight, are
the chain into position. Once the chain is more difficult to install than traction chains.
coupled. moving the vehicle back and forth Figure 6.346 shows how the chains can be in-
will aid in positioning the chain and will take stalled by hooking one t,nd to a small chain
out the slack. To help tighten chains. chain tied part way around the tire. The machine is
tighteners can be made from strips of old in then backed up to drape the chain around the
ner labs. with hooks on each end. On each tire. Final hooking is done with the aid of the
cha.n two tighteners are attached to the side loader's hydraulics. in a shop, these protec-
links in a diagonal (Figure 6-345). tion chains can be installed by jacking up the
machine and lifting the chains onto the tire
with a hoist. The method above. though, is
probably the easiest.
RUBBER TIGI-ITENERS
(6-345)
Courtesy Dominion Chain Co
(6-346)
maw
Air 411111. I. :. -.4-
_Irs.te-froifisissian
ve
"11
=
ree
;: .
535
TIRES, RIMS AND WHEELS 6:241
QUESTION"' TIRES, RIMS, WHEELS 11. Wheel and tire runout can be caused by:
MAINTENANCE AND REPAIR
(a) improperly adjusted wheel bearings.
1. Low tire pressure causes:
(b) a bent wheel.
(a) increased tire contact with the road.
(c) an improperly tightened wheel.
(0 increased rolling resistance.
(d) a faulty tire.
(c) increased tire heat due to flexing.
(e) all of the above can cause runout.
(d) only (a) and (c) are correct.
12. What is the general rule of repair for
(e) (a). (b) and (c) are all correct. worn or damaged rims, studs. nuts and
hubs?
2. When is the best time to take tire
pressure? 13. If one stud breaks on a ten stud disc
wheel. the accepted practice is to:
3. What is rapid heat build-up in ileavy
equipment off-the-road tires caused by? (a) replace all the studs.
4 When inflating a tire. what precautions (b) replace the broken stud and the two
must be taken? studs on either side of it.
5 When matching tires on a tandem truck. (c) replace the broken stud and the
the allowable difference in tire cir- stud 180° opposite it.
cumferences is:
(d) change at least five studs.
1/4"
14. True or False? When installing wheel
3/4" nuts, they should be clean and dry, and
not lubricated.
2-1 /2"
1-1/2"
15. How do you check the torque of a
previously tightened nut?
6 True or False/ A recapped or 16. Why should broken cross-links on chains
regrooved tire should not be used on the be fixed immediately?
front of a vehicle.
7. What is the minimum depth of tread
allowed by safety standards for front
tires?
8. When installing wheels, the nuts should
be tightened in a:
(a) circular pattern clockwise.
(b) circular pattern anti-clockwise.
(c) crisscross pattern. tightening op-
posite nuts on sequence.
(d) Any of the above.
9. A wrench is recommended
for final tightening wheel nuts.
10. When removing rims and tires from dual
cast spoke wheels what .: a good prac-
tice to follow before removing the lug
nuts?
536
6:242 TIRES, RIMS AND WHEELS
537
TIRES, RIMS AND WHEELS 6:243
538
6:244 TIRES, RIMS AND WHEELS
SERVICE REPAIR
1. Inspect the rims on a wheeled vehicle for
cracks. bends. or other damage. Check
the condition of the locking ring. Check
for worn or damaged studs. bolts, moun-
ting holes, retaining lugs. Make any
necessary repairs or replacements or
report damage that makes the vehicle un-
safe to operate.
539
WHEEL MACHINE FINAL DRIVES 6:245
FROM
PURPOSE OF WHEEL FINAL DRIVES DIFFERENTIAL PINION
GEAR
The purpose of final drives on wheel
machines is similar to those on track
machines: to decrease speed to the drive
wheels while simultaneously increasing wheel
torque or turning power. There are three main AXLE
types of wheel final drives:
TO
single reduction spur gear AXLE WHEEL
o
Ar
SHAFT
sprocket and chain
planetary (inboard and outboard)
/ -10
SINGLE REDUCTION SPUR GEAR
FINAL DRIVE
Single reduction spur gear final drives are FINAL DRIVE
(6-347) SPUR GEAR
mainly used on farm tractor& although they
SINGLE REDUCTION SPUR GEAR
are also used on some graders and on some FINAL DRIVE
large off-highway rear dump trucks. Spur gear X 2 287
Courtesy of John Deere Ltd
final drives operate on the basic gear prin-
ciple that when a small gear drives a large Final drive housings serve as the oil reservoir
gear. the RPM's of the large gear decreases for the assembly maintaining oil at a level that
while its torque or turning power increases. supports a splash lubrication system for the
Power is supplied by the axle shaft to the gears and bearings. The housing may be
drive pinion gear which meshes with the large separate from. or part of. the main trans-
final drive gear. Both gears are supported by mission and differential case. An example of a
bearings: a short axle shaft that may be part housing assembly is shown in Figure 6-348. It
of. or spfined to. the final drive gear transmits has single reduction final drives located in
power to the wheel (Figure 6.347). housings on either side of the bevel gear com-
partment.
BEVEL
DRIVE PINION
FINAL DRIVE GEAR
PINION DRIVE PINION BEARING
SUPPORT BEARING
AXLE SHAFT
FINAL DRIVE GEAR
CIRCULAR FLANGE (6-348)
Courtesy 0 Champion Road Machinery Limited
541
6:246 WHEEL MACHINE FINAL DRIVES
FINAL DRIVE
SPROCKETS (2)
WHEEL
SPINDLE WHEEL
SPINDLE
SPROCKET
DRIVE CHAIN
(6-349)
Courtesy of Champion Road Machinery Limded
542
WHEEL MACHINE FINAL DRIVES 6:247
INBOARD
PLANETARY
Courtesy of Jain Deere Lid
r
A Li _0". 47®,
(6 -351) CoaftesY of Caterpillar Tractor Co
Outboard planetaries are the most common
type of wheel final drive used today. a main
reason being that they are conveniently
located for servicing. Most of the necessary
service on these planetaries can be performed
without jacking up the unit or removing the
OUTBOARD PLANETARY
fires. The outboard position also gives the
torque increase at the wheel and so the axle
Inboard planetaries are used mainly for farm shaft doesn't have to carry the increased
tractors. although Caterpillar uses one on torque. The housings for outboard planetaries
their grader. Some large electric drive mine are incorporated within the wheel-hub assem-
trucks also use inboard planetaries. bly and are mounted on the outer ends of the
rigid axle housing (which includes the dif-
ferential and axle housings) (Figure 6-352).
4
DIFFERENTIAL
(6-352)
FINAL DRIVE HOUSING
Courtesy of Rockwell Internahonal
Automotive Opera lions As you recall from the introduction to
planetaries in Block 5, Power Trains, there are
various possible combinations of the three
SUN OR planetary gears (the ring. sun, and planet
CENTER GEAR carrier) each of which will give a different
torque/speed ratio and direction of power
flow. The combination used for wheel
planetaries is (Figure 6-353):
AXLE
SHAFT
PLANET
CARRIER
GEARS (6-353) RING OR
INTERNAL GEAR
543
6:248 WHEEL MACHINE FINAL DRIVES
n 110111111
544
WHEEL MACHINE FINAL DRIVES 6:249
12
Io
14 14 15
tt
1---L ;571-7-1F-6"(11
el ---
19
. 28 21
1..))
L.
545
6:250 WHEEL MACHINE FINAL DRIVES
DAILY, ROUTINE MAINTENANCE Indications that final drives need repair are:
CHECKS 1. Accumulation of metal chips found in the
A visual inspection of th final drives should final drive oil when changing it.
be included as part of tie daily walk around 2. A leaking final drive that requires frequent
check. The inspection involves checking for topping up.
oil leaks and periodically (approximately
every 250 hours) checking the oil level. Note 3. UnusP.al noises in the wheel assembly.
that outboard planetaries and grader chain Not heec.ing these warning signs could lead
and sprocket tandem wheel assemblies have to complete failure of the unit.
their own oil supplies, whereas inboard
planetaries and spur gear final drives usually Procedures required to gain access to the dif-
share a common oil reservoir with the dif- ferent types of final drives single reduction
ferential. Always maintain final drives at the spur gear. sprocket and chain, and planetary
correct oil level; if the oil is down, overheating vary, but there are some similarities such
will occur and the gear will be damaged. as cleaning the assembly. draining its oil and
removing wheels. Outboard planetaries are
the most common type of wheel final drive,
and so points about its removal and repair are
given below:
546
WHEEL MACHINE FINAL DRIVES 6:251
22.011MMINr.-
(6 -358)-
USING THREADED BOLTS IN THE PULL HOLES
PROVIDED, EVENLY REMOVE PLANET CARRIER
ASSEMBLY. USE CAUTION AS NOT TO RUN
CARRIER OFF STUDS BEFORE A CHAIN SUP-
PORT IS USED
ceunesy of Clarke Equipment Company
6. Once disassembled, all final drive parts
such as gear teeth, shafts, thrust washers.
splines should be cleaned and inspected
for wear and damage. (Refer to the sec-
(6-358) REMOVE PLANET COVER tion on types of gear wear in Crawler Final
CounesY of Clarke Equipment Company Drives.) Replace all badly worn or
damaged parts saving the old parts for
comparison with the new before installing
the new ones.
1'4?
Good Installation Practices For Final Drives
1. Pre-lub all gear shafts and thrust washers.
2. Replace all gaskets and 0-rings.
547
6:252 WHEEL MACHINE FINAL DRIVES
(6-360)
1Brake drum. 2Wheel. 3Special tool.
4Ring gear. 5Torque wrench. 6Locknut
Courtesy of Terex. General Motors Corporation
548
WHEEL MACHINE FINAL DRIVES 6:253
Adjusting Axle End play 5. Attach an over head crane or similar type
of lifting equipment to the housing.
Some types of drive assemblies call for a Remove the housing attaching bolts and
slight amount of end play. This means that the lift the housing clear of the machine. Note
shaft, when properly adjusted. must be free to that the center drive sprocket may have to
move endways within the limits specified. The
be removed before the housing can be
end movement in most cases is between 0.001
and 0.010 inches. To obtain the proper end
r red and the brake lines discon-
nected.
play. shims or an adjusting nut are provided.
Measure the end play with a dial indicator. As 6. Disassemble the spindles. Clean and in-
shown in Figure 6-361: this is a single spect the sprockets. drive chains. splines.
reduction final drive assembly for a small bearings and seals for damage and wear.
wheel tractor. Make a list of the parts required.
7. Reassemble the tandem in the reverse or-
der, following recommended torques and
adjustments given in the service manual.
8. Refill the housing with the correct type
and amount of oil. Check for leaks.
549
6:254 WHEEL MACHINE FINAL DRIVES
QUESTIONS WHEEL FINAL DRIVES 12. To check the preload on wheel bearings
using the spring scale method:
1. Wheel final drives:
(a) multiply the pounds pull on the
(a) decrease speed and increase scale times the circumference of the
torque. hub.
(b) increase speed and decrease (b) multiply the pounds pull times the
torque. diameter of the hub.
(c) decrease speed an decrease (c) multiply the pounds pull times the
torque. radius of the hub.
(d) increase speed and increase torque. (d) multiply the pounds pull times the
2. List the three major types of final drives number of wraps of cord around the
used on wheel equipment. hub.
3. What is the advantage of having the final 13. True or False? Some graders have two
drive out at the wheel assembly rather final drive reductions: one before the
than next to the differential? tandem housing and one within the tan-
dem housing.
4. How can the sprockets and chains in a 14. Does the drive sprocket in a tandem
grader tandem housing give a reduction? housing have to be taken off before the
5. What is the most common type of final housing can be removed?
drive used on wheel machines? Give at
least two examples of machines using
these final drives.
550
WHEEL MACHINE FINAL DRIVES 6:255
55i
6:256 WHEEL MACHINE FINAL DRIVES
SERVICE REPAIR
1. Using the correct jacking and blocking
procedures (on articulated machines in-
stall the steering safety rod), raise a wheel Cr,
machine with final drives and block it
securely at a height that allows the wheel
and final drive assembly to be safely
removed.
2. Using the correct tools, lifting equipment
and procedures outlined in the service
manual:
'a) drain the final drive housing.
(b) remove the wheel and steam clean
the final drive assembly.
(c) disassemble, inspect the gears.
bearings. seals (sprockets and
chains if grader). Write a parts list.
Make the necessary repairs and
replacements.
(d) pre lubricate the final drive parts,
reassemble and adjust the bearings.
(e) install the wheel. tightening the nuts
in the correct sequence.
(f) fill the drive line housing with the
correct type and amount of oil, and
ensure there are no leaks.
552
BLOCK
653
WHEEL MACHINE STEERING AND FRONT SUSPENSION G:257
554
6:258 WHEEL MACHINE STEERING AND FRONT SUSPENSION
555
WHEEL MACHINE STEERING AND FRONT SUSPENSION 6:259
WORM HOUSING
COVER
FILLER PLUG
WORM COVER
SHIM PACK TUBE
WORM
ROLLER SHAFT
ROLLER, '
ADJUSTING SCREW
ADJUSTING SCREW
=KNOT
DRAIN PLUG
(6-369) Courtesy of Mack Truck Limited
WORM AND ROLLER GEAR
556
6:260 WHEEL MACHINE STEERING AND FRONT SUSPE%SION
Recirculating Ball Steering Gear Provision is made to externally adjust the
A recirculating ball steering gear: worm shaft bearings and the sector shaft. The
worm shaft (1) is mounted between two
1. Uses a straight worm as opposed to the tapered roller bearings (10. 16). Preload on
hourglass-shaped worm of the worm and these bearings is adjusted by means of a
roller steering gear. thrust bearing adjuster (2) which is threaded
2. Has a bail nut that is supported on the into the steering gear housing (4). The sector
worm by a number of steel balls that act shaft (28) is mounted in bushings in the gear
as bearings, minimizing friction between housing and the side cover (20). Lash between
the ball nut and worm. During movement the sector gear and ball nut is controlled by a
of the ball nut on the worm the steel balls lash adjuster (21), located in the side cover.
continuously recirculate from one end of End play of the sector shaft is controlled by a
the nut to the other through a ball return shim (23) under the head of the lash adjuster.
guide (9, in Figure 6-370).
3 Uses a sector gear and shaft in place of
the roller and shaft in the worm and roller 26
gear. The sector is meshed with teeth cut 25
into the side of tne ball nut. 24 22
15 \ 13
16
21,4111W111
X:.
IMEAre'
4/5/ / "W
1
36-48
557
WHEEL MACHINE STEERING AND FRONT SUSPENSION 6:261
Cam and Lever Steering Gear When the steering wheel is turned, the cam
The cam and lever steering gear (Figure 6.
turns. The lever shaft studs, which are
engaged in the cam groove, follow the groove
371) has a tapered stud (single lever design),
or two tapered studs (twin lever design), and cause the lever shaft to rotate. The
rotating lever shaft sets the Pitman arm and
which engage helical grooves in a cylindrical steering linkage in motion to steer the vehicle.
cam. (The cam is similar to the worm used in
the recirculating ball steering gear). The The cam is mounted on ball bearings and the
studs are attached to an t.-shaped lever arm tapered studs are mounted on roller bearings.
that replaces the sector gear and shaft or Cam bearing preload is adjusted by a shim
roller gear and shaft used in the two pack between the upper cover and the
previously described steering gears. housing. End play of the lever shaft is con-
trolled by an adjusting screw mounted in the
side cover.
The cam and lever steering gear made by
Ross is very common in the heavy duty field. A
single lever model is made for smaller
UPPER COVER PLATE
AND SCREWS vehicles and a twin lever for larger ones. A
cam and lever gear is often used with power-
SHIM PACK
assist linkage steering. in which cap the
ROLLER
FILLER PLUG power-assist control valve will usually be in
BEARING the same location as the upper cover plate.
siva
NUTS UPPER BEARING Rotary movement of the cam and subsequent
CAM end thrust created by the lever shaft moves
the control valve to provide the power-assist.
LEVER SHAFT
FRONT SUSPENSION AND FRONT AXLES
Front suspension and front axles are an in-
tegral part of steering. Figure 6-372 shows an
assembled and a disassembled view of a
typical front suspension system. Suspension
OIL SEAL
components are discussed below:
HOUSING
SIDE COVER
ADJUSTING
NUT OWER BEARING
FRI
FRONT MOUNTING
SPACER
BRACKET SPRING
AXLE
moss
U-BOLT
(6-372) Couiesy of General Motors Corporation
558
6:262 WHEEL MACHINE STEERING AND FRONT SUSPENSION
REAR HANGER
U-BOLTS
SHACKLE SHACKLE
LINK
FRONT HANGER
o
BUMPER --110 U-BOLT
SPACER
SHOCK
SHACKLE
SPRING ASSEMBLY O 0 PIN
LINERS
0
SPACER A-0479
BUSHING
relation to the hanger. Since there is no metal A number of different types of shock ab-
across metal movement, no lubrication is sorbers have been made in the past, but the
needed Another function of The rubber center hydraulic shock (Figure 6-373) is the only one
of this bustling is to help dampen suspension in common use today. It is referred to as a
noise. directacting, telescoping shock absorber.
Shock absorbers are made in various sizes
Springs and strengths.
Heavy duty front suspension springs are
generally semi-elliptical. having multiple
leaves of graduated lengths. The width,
thickress and number of leaves, and the
overall length of the spring, are determined by
the type of vehicle the springs are used on.
The leaves are drilled at their centers and are
held together by a center bolt. The head of the
center bolt is round and fits into a correspon-
ding hole in the axle. The bolt thus acts as a
dowel holding the axle square with the frame.
Clips are placed at intervals along the spring PISTON ROD SEAL
PISTON ROD
leaves to keep the leaves in line. Often the
second leaf will have its end rolled around the
eyes of the main leaf to provide additional
support.
560
6:264 WHEEL MACHINE STEERING AND FRONT SUSPENSION
PITMAN
STEERING LEVER STOP SCREW
SPRING PADS
KING PIN '`-.....%.
(KNUCKLE PIN)
AXLE CENTER
_.-=a111.
TIE ROD
TIE ROD
.. TIE ROD - CLAMP 141.70
END
Courtesy of Mack Truck Lrintied
(6-374)
WHEEL MACHINE STEERING AND FRONT SUSPENSION 6:265
Cap Screw
There are two main types of axles: reversed 2 Cap (Upper)
Elliot and Elliot. The difference in the two lies 3 Kingpin
in whether the connecting yoke is on the axle 4 Bushing (Upper)
5 Sleeting Knuckle or
end or on the steering knuckle. On a reversed Spindle Assembly
Elliot axle (Figure 6-375). the yoke is on the 6 flushing (Lower)
steering knuckle whereas on an. Elliot axle 7 Cap (Lower)
8 Upper Grease Seal
(Figure 6-376). the yoke is on the axle end. (Rounded Edge Up)
The reversed Elliot is the most common axle. 9 Shims
10 Axle Center
11 Draw Key (Short)
12 Thrust Bearing
Assembly
13 Lower Grease Seal
(Rounded Edge Down)
14 Draw Key (Long)
.8
7 13--7-7*(;)
A441,
(6-375)
REVERSED ELLIOT AXLE
KNUCKLE HAS THE YOKE
AXLE Courtesy of General Motors Corporation
YOKE
DUST CAP
doKING PIN
BUSHINGS
0* (6-376) sssss
562
6:266 MINEEL MACHINE STEERING AND FRONT SUSPENSION
Steering Knuckle Pins (King Pins) A steering knuckle for a reversed Elliot Axle is
shown in Figure 6-377. This knuckle will have
Non-driving front axles can have straight bushings in the upper and lower pin bosses
knuckle pins or tapered knuckle Dins.(The two and the knuckle will turn around the pin on
axles in Figure 6-375 and 64 both have these bushings. (If the knuckle was for an
straight pins.) Straight knuckle pins are held Elliot axle the bushings would be in the axle
by tapered dowel keys (11) and (14) in Figure pin bosses.) Bushings may be bronze, steel
6-375). Tapered knuckle pins are drawn into backed bronze or plastic. Whatever their
position and held by a nut at the upper end of material, all bushings have grooves to allow
the pin. The pins are constructed of a high grease to flow uniformly to the high-pressure
grade steel and have a case hardened outer areas. Grease fittings are installed in both up-
surface for strength and resistance to wear. per and lower pin bosses. Note that instead of
bushings. some machines will use needle
Steering Knuckle and Bushings bearings as a bearing surface.
WHEEL SPINDLE
THRUST BEARING
SPINDLE ARM
TAPERED BOLT
563
... ......---..-
STEERING LINKAGE
LOCK WASHER
584
6:268 WHEEL MACHINE STEERING AND FRONT SUSPENSION
o,
STEERING CYLINDERS TIE ROD
4140,
poh
TILT CYLINDER
KING PIN
WHEEL TILT
MOT BOLT
565
WHEEL MACHINE STEERING AND FRONT SUSPENSION 6:269
FRONT AXLE
566
6:._70 WHEEL MACHINE STEERING AND FRONT SUSPENSION
Booster cylinders contain a piston attached to The description given here is an example of
a rod that protrudes through the end of the one type of power-assist steering. Other
cylinder. The cylinder is usually mounted with manufacturers will have different
its fixed end anchored to the front axle and arrangements of me parts. Whatever the
the piston rod clamped to the tie rod. design, though. all power linkage systems
However, some powerassist linkage steering have the common purpose of providing an
systems have the cylinder and control valve assist for turning.
mounted as an assembly within the drag link.
Each end of the double-acting booster cylin- FULL POWER STEERING
der has a port so that steering fluid can be
directed into it. Fluid sent to one side causes In power-assist steering a control valve and
the booster piston to exert a force on the tie power cylinder are added to manual linkage
rod in a left direction, fluid to the other side to reduce the effort needed to turn the vehicle.
causes the piston to exert a force on the tie The power-assist. in effect, is tacked onto a
rod in a right direction. As steering fluid is ad- manual steering system. In full-power
mitted to one end of the cylinder during a turn. steering. on the other hand. the power assem-
fluid in the opposite end is discharged to the bly is an integral part of the system because
steering valve and from there goes back to the booster cylinder and control valve are in-
the reservoir. corporated within the steering gear box. The
gear box on full-power steering acts as a
Some booster cylinders relieve pressure hydraulic cylinder. Note in Figure 6-383 that
automatically as the piston nears either end of oil is fed directly into the steering box. A full-
its stroke. Relief is accomplished by a taper at power system is dm) called integral power
each end of the cylinder bore (the end of the steering.
bore is larger than the center) so arranged
that as the piston approaches the end of its
stroke. the taper allows the fluid to bypass the
piston. thereby reducing the pressure and
limiting the force the piston can exert. This RESERVOIR
(INTEGRAL
feature automatically eliminates damage to wITH PUMP)
the cylinder and steering linkage. and
prevent:: overheating of the steering fluid and PUMP OUTLET
pump.
As a safety precaution. booster cylinders be-
come neutralized if the pump fails. Without
pump pressure oil would flow from one end of
the cylinder to the other, and the booster
would have no effect on steering. The vehicle
can be steered manually. albeit with con- POWER
" ___
STEERING GEAR -
OUTLET 0
STEERING GEAR
LEVER STEERING
LEVER
(6-383)
Courtesy of Mack Truck !Amsted
567
WHEEL MACHINE STEERING AND FRONT SUSPENSION 6:271
The Sheppard steering gear box described When the wheels are straightened after a turn,
here is one of a number of types available; it the activating valve centers, and the hydraulic
consists of four basic parts: the actuating power no longer acts on the steering. Thus
shaft. the actuating valve, the actuating piston the driver has a good feel of the road when
and the output shaft (rigure 6-384). the vehicle is moving straight ahead.
ACTUATING Another important part of the Sheppard in-
SHAFT AND ACTUATING tegral power steering discussed here is the
SEARING VALVE titett messing - set of relief valves. These two valves are
RELIEF RELIEF
PLUNGER VALVE . VALVE
PLUNGER located in the piston and are activated by
--"- i.-L plungers at each end of the cylinder housing
(Figure 6-384). Either one or both of the
plungers is adjustable. Correct setting of the
plungers will be dealt with in future training.
In operation, the valves serve to relieve
hydraulic pressure as the piston approaches
the end of the housing. A valve bail it; un-
STEERING COLUMN seated by the portion of the plunger which ex-
tends into the cylinder. When the ball is off its
ACTUATING seat, pressure cannot be built up. This feature
PISTON OUTPUT SHAFT
AND GEAR prevents overloading of the hydraulic system
and controls the degree of turn. The relief
NEUTRAL POSITION X414.
valves also allow the vehicle to be steered
(6-384) manually if the pump fails.
Courtesy of Mack Truck Limited
Full-power steering systems are made that
have dual steering boxes (Figure 6-385). The
The actuating shaft is connected to the box connected to the steering wheel is the
steering column and thus to the steering control, while the second one is a slave cylin-
wheel. The shaft rotates whenever the der. The two steering boxes work together to
steering wheel is turned. The actuating shaft give an increased steering force.
has a multiple start thread which is engaged
with a similar thread in the actuating valve.
The piston has a gear surface called a rack
gear cut on one side of it that is meshed with
a gear splined to the output shaft. The output
shaft has the Pitman arm attached to it. When
the actuating shaft is rotated by the steering
wheel, resistance created by the vehicle's
wheels to the turn causes the actuating valve
to move slightly (maximum 1/321 within the
piston.
The valve is fitted to a very fine tolerance in a
bore in the piston. As the valve moves in
response to steering wheel movement. landS
and grooves on its outer diameter alternately
cover or uncover ports in the piston. As these
ports are covered or uncovered, fluid.
pressurized by the pump. is directed to the
correct end of the piston while at the same
time fluid at the opposite end of the piston is
returned to the reservoir. As the piston moves
back and forth the output shaft is forced to
rotate, moving the Pitman arm and thus
providing the linear motion to turn the front
wheels. A small effort on the steering wheel of
this full-power system has resulted in a large
effort being applied to the wheels.
568
6:272 WHEEL MACHINE STEERING AND FRONT SUSPENSION
Cr RETURN
SLAVE
a,. RESERVOIR
"N
J IFOR PUMP
LINE NO. 2 UNE No. 1-0'
STEERING GEAR
PIMP
INLET LINE i
1=1 .....1
i
RETURN LINE TO L STEERING COLUMN
SECONDARY
(SLAVE) GEAR
....
', mounted on top of the axle bolster. A shaft ex-
tends down through the bolster to connect
with the steering arms. The oil flow in the
steering system is as follows: the oil is drawn
from the reservoir (1) through the screen (2) to
the steering pume (3); from the pump the oil
flows through the steering relief MVO (4) and
into the steering box (5). Return c.l from the
steering box flows back to the reservoir. If II
(6-386)
1Hydraulic systems reservoir. 2Hydraulic
screen. 3 Steering pump. 4Steering
relief valve. 5Steering box.
SHAFT CONNEGING
WITH STEERING ARMS
Courtesy of Champion Road Machinery Limited
569
WHEEL MACHINE STEERING AND FRONT SUSPENSION 6:273
steering box is overloaded, the relief valve The oil flow in this Char-Lynn hydrostatic
opens and the oil bypasses the box and steering system. with the steering wheel in
returns to the reservoir. Operation of the neutral, is as follows: The steering pump (3)
steering box is similar to that described for draws oil from the hydraulic systems reservoir
the Sheppard integral system. (4). From the puma the oil flows through the
pressure relief valve (2) to the steering unit
Both full-power (integral) steering and power- (1). From the steering unit the oil returns to
assist (linkage) steering are generally used the reservoir via the double filter assembly
on-highway trucks of all sizes and on off - (10) and a one-way valve not shown. The one-
highway vehicles such as logging and gravel way valve prevents the oil from escaping out
trucks Many types of industrial equipment of the reservoir when the filter elements are
also use full-power and power-assist steering changed. The steering unit is simply a direc-
tional valve that directs oil to the steering
HYDROSTATIC STEERING cylinders (7 and 8) as the steering wheel is
rotated. For example, if the wheel was turned
Hydrostatic is a third type of power steering. It to the left, oil would be directed to the piston
is used mainly on slow moving venicles such rod end of the L.H. cylinder (8) and the anchor
as graders, loaders. scrapers, fork lifts and end of the R.H. cylinder (7), resulting in the
large off-highway haulage trucks. Often wheels being turned to the left. Return oil
hydrostatic steering is also used on ar- flows from the anchor end of the L.H. cylinder
ticulated maines. and the piston rod end of the R.H. cylinder
In hydrostatic steering, as opposed to full- back to the steering unit.
power or power-assist steering. the steering The steering cushion valve (6) cushions shock
wheel is not mechanically connected to the loads that the front wheels are subjected to
wheels. Turning the steering wheel moves a and thus protects the steering cylinders.
control valve that directs oil to either a right
or lel turn hydraulic cylinder These cylinders The filter assembly (10) consists of two filter
supply the force needed to turn the machine. elements, one 10 microns and the other 40,
A hydrostatic steering system for a grader is which should be changed when the indicator
shown in Figure 6-387. It uses an orbital on the filter head is in the red.
steering control valve made by Char-Lynn.
570
6 ......ee 4...
(6-388)
t R.H. Steering Booster
2 Oil Pump
3 Flow Regulator & Relief Valve
011 Tank
., Steering Wheel
6 Rotary Shut-off Valve
7 Orbitrol Steering Valve
8 L.H. Steering Booster
9 Double Relief Valve
Courtesy of Terex. General Motors Corporation
571
WHEEL MACHINE STEERING AND FRONT SUSPENSION 6:275
Some articulated loaders and scrapers have 2. Moves the control valve to counteract
hydrostatic steering. The hydraulic steering road shock.
control used on these machines consists of
(1) a mechanical steering assembly coupled When making a turn on one of these ar-
by linkage to a hydraulic valve mechanism. ticulated machines. movement of the steering
and (2) a mechanical link connected between wheel. left or right. causes the worm. con-
the steering gear assembly and the rear main nected to the steering shaft. to turn inside the
frame section. referred to as the follow-up restraining nut gear The resistance created
linkage (Figure 6-389). This follow-up linkage causes an endwise movement of the steering
should not be confused with the steering shaft and hence a movement of the hydraulic
linkage described earlier that transmitted ac- control valve. The valve directs oil under
tual steering force. the only parts that trans- pressure to the head end and rod end of op-
mits turning force on these machines are the posite cylinders. causing the machine to ar-
hydraulic cylinders. ticulate and steer in one direction. The
moment the operator releases the effort on the
Follow-up linkage is connected to the sector steering wheel. the follow-up linkage. by way
shaft at one end. and to the frame via an arm of the sector gear. nut gear and steering shaft.
at the other end. This linkage: returns the control valve to neutral. holding
1 Aids in returning the control valve to a the machine at the desired angle of turn.
neutral position after a turn.
STEERING HYDRAULIC SYSTEM
11.11 sott %IP OH 1= KV" Olt
WC( P.4011 Mr Oil
45114
'04414A1011
%TO
vevt4t,T..
LP .1
_ I
Am%
re6gROt
..11141 *AMP
572
6:276 WHEEL MACHINE STEERING AND FRONT SUSPENSION
Steering
Control Valve
Hydraulic
0../ Pump
N
Flow Divider Emergency
Steering
Piping
Hoist
Relief Emergency
Valve Steering
Pump
Steering ji 11)
Relief Oil Filter
Valve
Hydraulic Tank
(6.390)
Courtesy of Wabco Construction and Mining Equipment
573
..-e..10,..... -....
SPINDLE SUPPORT
FRONT OF CAR
LEAD POINT
WHEEL CONTACT POINT
(6-391)
574
6:278 WHEEL MACHINE STEERING AND FRONT SUSPENSION
(6.393)
POINT OF LOAD
0
-8 IRON?
0
0
SHIM
AXLE
Aros3
5 75
.....0..
Since camber is built into a rigid axle, it will The purpose of toe-in is to offset the small
not change unless the axle takes on a per- deftections in the front suspension and
manent set from overloading or severe steering linkage when the vehicle is moving
usage, or becomes bent or twisted by hitting forward. It ensures parallel rolling of the front
an obstruction or colliding with another wheels and tires and minimizes tire wear from
vehicle. scuffing. A toe-in error of 1/8 of an inch is
equivalent to dragging the tire crossways 11
Camber may be checked with a wheel feet for each mile the vehicle is driven. To ob-
aligning gauge or by measuring the angle tain maximum tire mileage, the running toe-in
formed between the outer edges of the wheel should be zero. The stationary toe-in of a
and a square resting on the floor. vehicle should be just enough to offset the
The harmful effects of incorrect camber are looseness, and spreading action in the
excessive wear to: linkage, caused by camber, when the vehicle
is being driven forward.
ball joints or king pins
Trucks using bias ply tires generally call for
wheel bearings 1/16 inch toe-in, while those using radial ply
excessive wear on one side of the tire tires call for a zero toe-in. Toe-in amounts for
tread; inside tread wear is caused by automobiles are somewhat higher due to their
negative camber. outsid: wear by more flexible front suspension.
positive camber. Note that although, as
was said abce, only positive camber is
used. Over a period of time of wear and
tear negative camber will start to ap-
pear.
Toe-in
Toein is the distance that the front of the
front wheels are closer together than the rear
of the front wheels (the distance B minus A in
Figure 6-394). Conversely. toe-out is the
distance the front of the front wheels are far-
ther apart than the rear of the front wheels.
Toe-in is considered the most serious tire
wearing angle. Incorrect toe-in (or toe-out)
appears as a feather-edged scuff across the
face of both tires. Because of its harmful ef-
fect on tires, it is extremely important that toe-
in be checked carefully.
(6.394)
576
.1.
6:280 WHEEL MACHINE STEERING AND FRONT SUSPENSION
1
bent steering arms or bent. worn. or damaged
linkage. Improper toe-out on turns will result
in tire wear similar to that caused by improper
toe-in adjustment POINT OF CONTACT
11
(6-396) KING PIN OR BALL JOINT INCLINATION
Courtesy of Ford Motor Company
577
,%
WHEEL MACHINE STEERING AND FRONT SUSPENSION 6:291
Caster, as discussed earlier. is the tilt of the WHEEL BALANCE AND UNBALANCE
. king pin toward the back of the vehicle.
Caster. therefore, has an effect on K.P.I. The Proper tire and wheel balance is essential for
effect, though, is not significant, since caster good steering and handling. Unbalanced
angle is generally small. wheels and tires can result in shimmy and
erratic steering conditions. There are three
types of wheel unbalance: static. kinetic, and
dynamic.
Static
A static unbalance condition exists in a wheel
when (1) the wheel has a heavy spot. and (2)
the wheel is not rotating. A wheel is said to be
in static balance when it has the weight
AXLE POSITION ON TURN equally distributed around the circumference
(i.e. it has no heavy spots) in such a manner
that there is no tendency for the wheel to
rotate by itself when it hangs free (Figure 6-
398). Conversely, if a wheel has static un-
balance, it has a heavy spot(s) that would
cause the wheel to rotate so that the heavy
I spot rests at the bottom.
AXLE POSITION STRAIGHT-AHEAD
(6-397)
Courtesy of Ford Motor Company
578
6:282 WHEEL MACHINE STEERING AND FRONT SUSPENSION
CENTERLINE Li-CENTERLINE
OF WHEEL OF WHEEL
S a;
!II
I SIDE TO SIDE
i
AND
UP AND DOWN \\\ =,,...=..dr_._.--) UP AND DOWN
VIBRATION VIBRATION
579
WHEEL MACHINE STEERING AND FRONT SUSPENSION 6:283
QUESTIONS WHEEL VEHICLE STEERING 10. Unlike those on automobile& most heavy
duty spring shackle pins and bushings
1. Through the actions of the steering gear have
in a manual steering system, rotary
motion of the steering wheel is converted 11. A leaf spring is properly located on the
to: axle mounting pad by means of the:
(a) vertical motion of the linkage (a) spring hanger
(b) sideways motion of the linkage (b) center bolt
(c) linear motion of the linkage (c) spring shackle
(d) one-way motion of the linkage (d) rebound clips
2. Synchronized movement of the two 12. The purpose of shock absorbers is to:
wheels is accomplished by connecting
them together with a: (a) help the spring support the load
(b) act as an overload device
(a) drag link
(c) control spring oscillations
(b) steering arm
(0) sway bar 13. True or False? A shock absorber works
on the principle of a drag being created
(d) tie rod when fluid moves through restricting
3. The drag link connects the: orifices.
(a) steering knuckles together 14. On a vehicle with e- reverse Elliot front
axle. the thrust Searing is positioned be-
(b) steering gear to the cross shaft tween the steering knuckle and:
(c) Pitman arm to the tie rod
(a) the top of the a, le eye
(d) Pitman arm to the steering control
(b) the bottom of the axle eye
arm
(c) either (a) or (b). depending on the
4. What are the three basic types of wheel machine
vehicle steering systems?
15. What is the brake foundation assembly
5. What are the three common types of attached to?
manual steering gears used in heavy
duty equipment. 16. Are there any grease fittings at the axle
knuckle connection?
6. True or False? Recirculating ball
steering gears are more common on 17. Compared to other wheel vehicle
heavy duty vehicles than worm and roller steering systems, what additional func-
steering gears. tion must grader steering perform?
7. The worm on a worm and roller steering 18. A is used to
gear is shaped, whereas tilt the front wheels on a current grader.
the worm on a recirculating bail gear is
19. Besides giving ease of operation, power
steering is necessary on large off-
8. A cam and lever steering gear uses: highway equipment because of difficult
steering caused by:
(a) a sector gear
(b) a roller gear (a; the weight of these machines
(b) their large tire-ground contact area
(c) a lever and stud srrangement in-
stead of a gear (c) the soft uneven ground they work in
(d) any of the three can be used (d) all of the above are correct
9. Why is a swinging shackle needed on a 20. What are the three basic types of power
leaf spring? steering?
21. What are the two locations where the
booster on power-assist (linkage)
steering is located?
680
6:284 WHEEL MACHINE STEERING AND FRONT SUSPENSION
22. In a linkage power steering system, the 32. True or False? Positive caster helps
spool valve is located in the: keep the wheels moving straight- ahead.
(a) steering gear 33. Positive camber is created by:
(b) steering box (a) tilting the axle or spindle assembly
(c) power piston backward
(d) steering linkage (drag link) (b) an angle in the axle that tilts the top
of the wheels outward.
23. Another name for full-power steering is (c) using a larger inner wheel bearing.
34. True or False? Camber is a tire wearing
24. On integral power steering, the control angle.
valve is located in the:
(a) tie rod 35. Excessive wear to the outside of a tire
tread indicates too much:
(b) steering box
(c) drag link (a) positive caster
(d) steering shaft (b) positive camber
(c) negative caster
25. How does a hydrostatic steering system
differ from linkage or full-power (d) negative camber
steering? 36. An Incorrect camber setting on a rigid
26. What happens in the steering unit (i.e., front axle:
the orbital control valve) of a hydrostatic (a) cannot be adjusted without bendi ig
steering system when the steering wheel the axle
is turned?
(b) can be adjusted by shimming the
27. True or False? The follow-up linkage axle
used in steering on some articulated (c) can be corrected by changing the
machines trans-nits all the steering force size of the inner wheel bearing
between the two frame halves.
(d) can 'be corrected by installing a
28. What is the function of the emergency spindle of a different angle
steering system on hydrostatic steering?
What are the three common types of 37. Toe-in on a solid axle truck suspension
emergency systems? can be adjusted by:
29. Br;efly explain the term steering (a) shimming the spring pad and spring
geometry. pack
(b) bending the axle
30. Caster may be defined as:
(c) adjusting the length of the drag link
(a) the inward or outward tilt of the
wheel (d) adjusting the length of the tie rod
(b) sideways inclination of the king pin 38. True or False? Toe-out on turns is
achieved by having the steering arms
(c) forward or backward tilt of the k'ng
pin
bent slightly inward toward the center of
the vehicle.
(d) none of the above
39. The purpose of king pin inclination is to:
31. When a caster shim is placed so that the
thick end of the shim faces the rear of (a) offset negative caster
the vehicle. the vehicle has: (b) provide a means of adjusting caster
(a) positive caster (c) make turning easier
(b) negative caster (d) bring the steering pivot axis nearer
the center of tire-road area contact
(c) increased K.P.I.
581
WHEEL MACHINE STEERING AND FRONT SUSPENSION 8:285
582
6:286 WHEEL MACHINE STEERING AND FRONT SUSPENSION
583
WHEEL MACHINE STEERING AND FRONT SUSPENSION 6:287
LUBRICATION CHART
K-100 SERIES
-I F
wealcara INTERVAt INTERVAL LURRICANT
CAD TILT
-1
TILT PIVOTS et 6 ...,
CL
STRING TINS
lOss twosome% vial
STEERING U JOINTS
%Om ONIoduthes$1 CI. a ------- 10 CAS LIS I CYLINDER ANCHOR TINS
R STEERING RESERVOIR
Odes Mud Soul
CI Mud sod Isar
Voduu A 61$1000 NTS
Rau Irolausl$ AU
Durward Iloupull 10
, LueArcafts kr(
ell - DOI Rums Gm* EI
lIG - NU* Gros ISM 001 ow)
Ct. - Como lobe
SO - &Nos Od
INTERVAL kilt GO - Gm 0.I
6 6000 Wu OD 000 $N1 NY - INOSOIN C0000I/ 04
I!
at It 000 IOUs 1200001ml NTS - SuuvANN Turoomoso SN.d
N.S wrechht Trsooutoon F1040 Tvp0 C 2
2S 25 000 OM Da 000 Soil
SI. - Wens Isamu,
A 0000100 tt - Loa Lotsieso I
AR As Reasos4 SG - PaNsuuou Gm* Sack
(6.400)
Courtesy ol Kenworth Truck Company
584
6:288 WHEEL MACHINE STEERING AND FRONT SUSPENSION
Front Wheel Bearing Packing and Adjusting REMOVING FRONT WHEEL BEARINGS
Periodic inspection of wheel bearings, as well Before wheel bearings can be inspected or
as regular lubricant changes. are necessary packed, they must be removed. Two views of
for maximum wheel bearing life. The wheel bearings are shown in Figures 6-401
frequency of lubricant changes depends upon and 6-402. Bearing removal involves jacking
individual vehicle operating conditions, the vehicle up so that the wheel clears the
speeds and loads. Under normal conditions, floor, and then removing the wheel and hub as
the following lubrication intervals for wheel an assembly. After the hub cap (dust cap) and
bearings are recommended for on-highway bearing adjusting nut are removed, the wheel
trucks: and hub assembly are slid from the spindle
with care taken not to drag the hub or inner
Grease Lubricated For bearings that bearing cone over the spindle threads.
are lubricated with grease, changes are
recommended whenever the seals are The outer bearing race will fall out as the hub
replaced or brakes are relined or at 25,000 and wheel are removed. The inner race can be
to 30.000 mile intervals. For vehicles easily removed by driving it out with a drift
operating less than 30,000 miles annually, from the outside toward the inside. The
the lubricant should be changed twice a grease seal will be pushed out at the same
year. Wheel bearing grease should meet time. usually without damaging it.
manufacturer's specifications.
Oil Lubricated For bearings lubricated WEAR SLEEVE
with oil, changes are recommended
whenever the seals are replaced or at HUB SEAL
brake reline time, or at least once a year.
Wheel bearing oil should meet manufac-
turer's specifications.
(6-401)
Courtesy of Ford Motor Company
VENT
SEAL
JOURNAL
LOCK NUT
LOCK WASHER
BEARING
(6-40 2) Courtesy of Ford Motor Company
ADJUSTING NUT
585
WHEEL MACHINE STEERING AND FRONT SUSPENSION 6:289
586
6:290 WHEEL MACHINE STEERING AND FRONT SUSPENSION
In most cases wheel bearing adjustment in- Tighten inner nut with 12 inch wrench.
volves: while rotating the wheel, until there is a
slight bind so that all bearing surfaces are
1 Tightening the bearing nut while rotating in contact. Then back off inner nut one-
the wheel alternately in both directions. quarter to or.c-third turn to allow the
until a slight bind is felt. Four types of wheel to rotate freely. Install lock washer.
bearing nut arrangements are shown in Tighten jam or outer nut. Final bearing ad-
Figure 6-404. justment should be wtihin .001 inch to .010
inch end play. Lock nut at this position.
2. Backing off the nut a fraction of a turn to
align with the nearest locking hole. Note the following two factors that can in-
terfere with getting a correct bearing ad-
3. Locking the nut. justment:
Below are two examples of adjusting make certain that brake shoes aren't in
procedures for grease or oil lubricated
contact with the drum because you will
bearings taken from Timken service in- get a (else adjustment.
formation.
do not confuse bearing tightness wi.h a
ORE ASE RE TAINER
;140
possible drag of the seal.
BEARINE G
BEARING CUP RAC BEARING
1202 COTTER 1201 RACE
PIN 1216
INNER BEARING BEARING CUP
1211 1217 WASHER
1195
CUTER BEARING
1216 INNER BEARING ADJUSTING NOT
1201
LOCK NUT
3295
GREASE
wASHER RETAINER
1105
IHO
BEARING WASHER
ADA/STNIG NUT 1216 1A043
3113811S
F100-350 SERIES
(DISC) LOCK NUT 12000 Le, AXLE
113041.5 (CENTER POlt1T1
BEARING
RACE
1201 OUTER DINER
BE 12ARING SEARING
16 1201
wog 0 BEARING
1201
RING
GREASE AO2USTING
RETAINER 1101
WO
GREASE
RETAINER
BEARING
RACE
1216 ACOUSTING NUT
351163.5
'COTTER PIN
5000 - 5500 - 6000 - 7000 LS AXLES (6.404)
16000. 18000. 20000 LB. AXLES
Courtesy ot Ford Motor Company
WHEEL MACHINE STEERING AND FRONT SUSPENSION 6:291
Checking Wheel Bearings 2. Block and jack the vehicle high enough
so that the wheels clear the ground. A
The discussion on bearing adjustment above good place to block is on the frame lust
assumed that the bearings had been removed behind the rear of the front springs. The
and were adjusted when reinstalled. vehicle can also be raised with a chain
Following is a quick method of checking hoist and suitable rigging or with an
bearings without removing an ?thing: jack up overhead crane.
the front axle until the wheels clear the floor.
Check the bearing play by grasping the tire at Caution: Whatever lifting method is
the top and pulling back and forth, or by using used, make sure that the
a pry bar under the tire. If the bearings are device has adequate lilting
properly adjusted. movement of the brake capacity. Also. use good sound
drum in relation to the backing plate will be blocking like that shown in
barely noticeable and the wheel will turn Figure 6-405.
freely. If the movement is excessive. adjust as
above.
$88
1
6:292 WHEEL MACHINE STEERING AND FRONT SUSPENSION
6. Support the front axle and springs with steering-front suspension overhaul, the
suitable blocking or, even better, with two general practice is to send the springs to
floor jacks. Remove the spring shackle a spring shop for rebuilding. Rebuilding a
pins and lower the spring axle assembly to spring involves replacing all cracked or
the floor. Note: Make a punch mark on broken leaves and rearcing the ser-
the front of the spring pad before viceable leaves. New spring eye bushings
removing the axle. If the axle center is not and a new center bolt are put in. A rebuilt
marked, it could be installed backward spring is virtually as good as a new one.
and the camber could be wrong. Figure 6-407 shows a dismantled assem-
bly.
Repair 01 Front Suspension and Steering
Note the following when installing
1. Once the axle and springs have been springs:
removed and taken out from under the
vehicle, a careful inspection should be (a) Springs must be installed in the
made of the spring hangers and their correct direction: i.e., the center bolt
frame mounts. Tighten any loose bolts and is often off center making the
replace any loose rivets. If the hanger distance from the bolt to the spring
brackets are damaged in any way, they eye longer one-way than the other.
should be replaced. The frame and cross
(b) If a spacer is used between the
members should also be carefully spring and the axle. be sure to insert
checked and any cracks must be repaired
the center bolt head through the hole
by a welder or competent journeyperson.
in the spacer and into its slot in the
2. Remove the springs from the axles at the axle. Similarly. if alignment shims (for
U-bolts. Note the position of shims. spacer caster) are used. Install them in the
blocks, shock brackets and dowel pins so correct direction and in their original
that they can be correctly reinstalled. position. Again, be sure that the cen-
Springs become fatigued and flattened af- ter bolt fits through the hold in the
ter long service. When doing a complete shims and into its axle slot.
REAR HANGER
U-BOLTS
SHACKLE
LINK
FRONT HANGER
BUMPER-10 U-BOLT
SPACER
CENTER 19®
BOLT
SHOCK
EYE BOLT
SPRING ASSEMBLY
LINERS
O
es
SPACER A4479.
589
11111111MINIMINIIME
WHEEL MACHINE STEERING AND FRONT SUSPENSION 6:293
(c) Tighten U-bolts with a torque wrench procedures.) Figure 6-408 shows a king
to the specified torque listed in the pin being removed with a hammer and
service manuals. drift. In some cases, however, a press may
be required to remove the pin. Check the
3 Repairs to the steering axle consists of king pins by raising the wheel and moving
removing the steering knuckles from the it in and out at the top and bottom. If
axle center and replacing the king pins wheel play is excessive, it is an indication
and bushings. (See the service manual for that the king pins are loose.
-%*
1.,7r
Ott:
itkiA
,-
590
6:294 WHEEL MACHINE STEERING AND FRONT SUSPENSION
4. Small cracks may exist in steering parts. indicator. Use of a dial indicator is
Since these parts are so vital to the safety described below:
of the vehicle, it is a good practice to have
knuckles, spindles, steering arms and axle (a) Set up the dial indicator as shown in
ends X-rayed or magnafluxed for defects. Figure 6-410. This dial indicator has a
Some shops have the policy of magnetic base to attach it to the
automatically magnafluxing or raying spindle. Other dial indicators can be
vital steering parts. Spindles are the most affixed by a clamp.
vulnerable parts for cracking, especially (b) Place the dial indicator plugger on
at the point where they join the knuckle the exposed end of tha knuckle pin
right near the seal surface (Figure 6-409). so its line of action is apprnxima'ely
parallel to the knuckle ;. n , vertu's.
(c) Zero the dial indicator
(d) Using a suitable lever or bloc!: and
lever. lift the knuckle and take the
dial reading.
(e) Repeat the above procedures with
the knuckle in full right and full left
turn positions.
(f) If the clearance is not right, correct it
VULNERABLE
AREA by adding or taking out shims be-
tween the axle and the knuckle.
(6-409)
Courtesy of Rockwell Internalionat
Automotive Operations
591
WHEEL MACHINE STEERING AND FRONT SUSPENSION 6:295
STEERING LINKAGE REPAIRS changed by bending the axle. and few shops
are equipped to do this: K.P.I. is built into the
When a complete overhaul is done on axle design; and toe-out on turns is part of
steering, linkage parts (tie rod, tie rod ends. steering arm design. Problems in these three
drag link) should be carefully checked. If areas will require more extensive repair or
worn or faulty. they should be replaced, not replacement of parts.
repaired. Some large tie rods and drag links
have replaceable ends that are rekitted
(Figure 6-411), but the majority are replaced
as an assembly.
Alignment Checks
Easy. accurate steering depends on precise
alignment of the front wheels. Alignment on
heavy duty vehicles generally consists of get- ADimension varies with different size tires. Set stop
screws to provide iS" clearance between fires
ting the correct turning angle. caster and toe- and chassis at extreme turn positions. moue
in. The other alignment factors, camuer. king
pin inclination, and toe-out on turns. are con-
sidered non-adjustable. Camber can only be (6-412) STOP SCREW ADJUSTMENT
Courtesy of General Motors Corporation
592
6:296 WHEEL MACHINE STEERING AND FRONT SUSPENSION
The angles should be set with these factors in (see Figure 6-412). When servicing the springs
mind: and front axle of a vehicle equipped with
caster plates. mark the position of the thick
1. On extreme right or left turn there must be end before removing it to insure correct
a clearance (recommendations vary from reassembly.
1/2 inch to 1 inch) between the tires and
the chassis or drag link. To check caster. the alignment equipment
below is required (instruction will be supplied
2. There must be a minimum of 1/2 inch with the equipment):
clearance between moving steering
linkage and the chassis. Two turntables marked out in degrees
to place underneath the tires.
3. On vehicles with power steering, an ad-
ditionai step must be taken. The internal A portable caster/camber gauge with a
relief valves of integral power steering magnetic head for attaching to the end
gears and the steering gear lever stops of of the spindle. When a caster setting
linkage power-assist systems must be ad- that varies greatly from the specified
justed to cut off the power before the axle figure is found. check for problems in
stops are contacted. Clearance between the front springs or axle. Weak or
the knuckle and stop should be 1/16 to 1/8 broken springs, in particular. can throw
inch when power is cut Adjust for both out caster. Replace defective front end
right and left turns. See service manual for parts before proceeding with the caster
adjusting procedures. check. Do not attempt to corre..:,
severely misaligned caster by using an
4. For good steering performance. the extreme angle caster plate. If it is
steering gear should be centered when necessary to change the caster setting,
the wheels are in a straight-ahead stay within the specifications recom-
position. 11 the gear is centered. it will not mended by the manufacturer.
bottom when the front wheels are at
maximum angle. the steering wheel Toe-In
should have one-third tuft remaining
when the front w heels are at the axle Toe-in misalignment occurs when the wheels
stops. in the straight-ahead position are pointed in-
wards beyond an acceptable amount. (Many
To check steering gear centering, place steering systems are set up to have a slight
the front wheels in a straight-ahead toe-in.) An obvious sign of excessive toe-in is
position. and then disconnect the drag a saw-toothed pattern across the face of the
link at one end. Turn the steering gear to tire which can be felt 1,, running your hand
its center position and try to reconnect the across the tire. (Toe-ou. will gave an opposite
drag link. 11 the drag link can be rein- saw-tooth pattern to toe-in.)
stalled without disturbing the front wheels
or steering gear. the system is satisfac- Measuring Toe-In
torily centered. If the drag link ball stud
does not line up with its mating hole, the The method below is the most common and
system is not centered and corrections the most accurate way of measuring toe-in:
must be made. See the service manual for 1. Raise the front wheels until they clear the
cente ring procedures.
floor.
Caster
2. Using the instrument shown in Figure 6-
413, inscribe a fine line around the ap-
As stated earlier, most trucks have a positive proximate center of each tire.
caster, i.e.. the knuckle pin is tilted to the rear.
3. Lower the vehicle to the floor and turn the
The angle of tilt should not vary more than wheels straight-ahead (Note: Do not take
half a degree between the right and left side.
a toe-in measurement with the front axle
Caster is adjusted by wedge shaped shims
called caster plates located between the jacked up.)
spring and the axle. Caster plates are factory 4. Before taking a toe-in measurement, nor-
installed. For positive caster the thick end of malize the suspension parts by rolling the
the shim faces the rear of the vehicle; for vehicle 12 to 15 feet ahead. This is
negative caster the thick end faces forward necessary because when the vehicle is
593
WHEEL MACHINE STEERING AND FRONT SUSPENSION 6:29T
first lowered, the tires grip the floor. done on large mine haulage trucks. Below is
preventing the wheels from returning to the method one manufacture recommends to
their normal operating position. measure toe-in. Refer to Figure 6-414.
5. Measure the distance between these two 1. Position the truck on a hard even surface
scribed lines at the front of the tires and at with the front wheels straight-ahead. Ad-
the rear. The two measurements should be just the front suspension cylinder to the
within allowable tolerances. recommended pressure and piston ex-
posure.
A quicker but less accurate method of
measuring toe-in is to measure the distance 2. Using a plumb-bob and a block (the block
between the tire tread centers or the insides is used to provide an extension of the
of the tires. both at the front and back of the wheel hub surface), establish a point on
tires. the ground from both the front and rear of
the wheel hub. Do this at each front wheel.
Correcting Toe-In
3. Using a chalk line, snap the line on the
Before snaking a toe-in adjustment. the ground between these points. Extend the
wheels must be normalized (see point 4, line out beyond the front and rear of the
above). tire.
Minor toe-in corrections, on vehicles with 4. Drop a plumb-bob from the approximate
straight cross steering tubes, are made by front center of the tire and mark a point.
loosening the clamp bolts and turning the
cross steering tube. The tube and ball sockets 5. Drop a plumb-bob from the approximate
have either right and left hand threads or rear center of tire and mark a point. Do
threads of different pitch. If the cross steering this at both front wheels.
tube has a drop-center design. it generally is 6. Measure the distance between the two
necessary to disconnect the tube and rotate lines at the front of the tires and at the
the ball socket(s). If a major correction is rear. On this particular machine the
required, first check for bent steering levers distance at the front of the tires should be
or a bent cross steering tube. between half to one inch less than the
distance at the rear of the tires. In other
Toe-In On Large Mine Haulage Trucks words. a toe-in of half to one inch is
Toe-in is the only alignment procedure that is
desired; anything over that should be
corrected.
_ , , .._ -, . .
594
WHEEL MACHINE STEERING AND FRONT SUSPENSION
PLUMB-SOB
CHALK LINE
T TO MEASURE TO
(6-414)
Courtesy of Wabco Construction
and Mining Company
595
WHEEL MACHINE STEERING AND FRONT SUSPENSION 6:299
Wheel Balancing
the rim, for example ten ounces, place five
More attention is paid today than in the past ounces, inside the rim and five ounces
to wheel balancing on heavy duty highway outside the rim. This method will even out
trucks. The reason is that trucks travel faster the weight on the rim.
due to improved roads and tires. At the
present time, very few heavy duty shops have Note: Once the wheel has been balan-
wheel balancing equipment. When a balan- ced. don't forget to readjust the
cing problem occurs. it is handled by a tire wheel bearing and brake.
shop. This situation is changing. though. and
PO doubt in the future wheel balancing equip- Troubleshooting Steering
ment will become as common in heavy duty
shops as it is in automotive ones. In the discussion above. steering was E.:ig: 6. _,
as part of front end overhalii p7ocg!ii01(1
When faced with an assumed wheel balan- More commonly. a vehicle wit: corn,- :1:n a
cing problem, you first should check some shop with what is vaguely ref !feel to as a
other likely possibilities that could be causing steering problem. When inVeSligat -:g a
the problem. Check for: steering problem that has no evident causem.
an out of round tire. it is good diagnostic procedure to begin with
excessive wheel or tire runout that the simplest possible cause. Then progress
could be caused by an improperly through to the more complex causes until the
tightened or mounted wheel problem has been found. Check first for
unequal tire pressures. loose wheel stud nuts.
mud build-up on the inside of the wheel worn steering linkage. worn or dry king pins,
As was mentioned earlier. dynamic wheel loose or worn wheel bearings or a misaligned
balancers are used to determine a wheel's front end assembly. If these are in satisfactory
state of balance. Two types are available, one condition, then isolate the steering gear for
for on-vehicle and one for off-vehicle balan- diagnosis by disconnecting both the drag link
cing Balancers indicate the location of heavy from the Pitman arm end and the steering
spots and in some cases give the amount of column universal joint from the worm shaft.
weight required to balance the wheel. If the General steering gear problems and causes
balancer does not give the weight requ'sed, are listed below:
then a trial and error method is used to find Problem: Hard Steering
the ,orrect amount of balancing weight.
1. Lack of lubricant (tight king pin).
When a wheel balancer is not available. an
unbalanced condition can be detected in the 2. Binding universal joints or slip joint.
following way:
3. Worm bearing or Pitman arm shaft ad-
1. Jack the wheel up so that it clears the justed too tight.
floor.
4. Worn steering gear bearings or bushings.
2. Back off the brake adjustment so that
there is no interference from the brake 5. Worn or damaged worm gear or roller.
shoes. 6. Binding cover boot in cab.
3. Adjust the wheel bearing so that the
wheel will turn freely by itself. Problem: Wandering or Weaving
4. Spin the wheel and allow it to come to 1. Excessive Pitman arm shaft backlash.
rest. Chalk the tire at the bottom. 2. Loose steering gear mounting bolts.
5. Repeat spinning the wheel. If the chalk 3. Worn universal joints or slip joint spines.
mark continually appears at the bottom. a
heavy spot is indicated at this point. 4. Loose spring U-bolts.
6. If wheel weights are at hand, you can get 5. Worn shackle pins and bushings.
a reasonably close wheel balance setting.
Select weights by trial and error placing 6. Worn king pins.
them on the rim 160 from the heavy spot 7. Excessive toe-in or toe-out.
until the wheel has no tendency to stop at
any given spot. When attaching weights to 8. Worn tie rod ends.
6:300 WHEEL MACHINE STEERING AND FRONT SUSPENSION
UNIVERSAL
COUPLING
597
WHEEL MACHINE STEERING AND FRONT SUSPENSION 6:301
Manual Steering Box Repair and Adjustment 6. Pre-lube all parts and reassemble.
1 In keeping with good repair practices. 7. There are two adjustments to be made on
clean the exterior of the gear box with a gear box:
solvent before disassembling it. white
cleaning the housing. inspect for cracks. (a) worm shaft preload adjusted by
shims
2. Drain the oil. sector shaft backlash adjusted by
(b)
3. Disassemble as described in the service adjusting screw.
manual. Where applicable keep shim The worm shaft bearing preload is always
packs together as they will be needed for done first and the sector shaft backlash
adjustment on reassembly.
second. Again follow the procedure in the
4. Wash all internal parts and carefully in- service manual. In the 'exploded view of
spect the gears for damage and wear. the steering box in Figu 3 6-416 note the
shims (5) for worm shaft bearing preload
5 Make parts list keeping in mind that these adjustment and also the adjusting screw
boxes work under heavy loads and (21) for sector backlash adjustment.
therefore should automatically have the
bearings, seals and cover gaskets 8. Fill the box with the correct type and
replaced. amount of lubricant.
2
1
I 9. Before reinstalling the steering box,
9 4 carefully check the frame mount. If any
cracks are found they should be repaired.
Since mounting bolts are subjected to a
terrific load and are susceptible to
6 breaking after a tong service life, it is a
good idea to replace them on rein-
stallation. The replacement bolt should be
of equal grade to the originals. Where cot-
-7 8
ter pins are used, make sure they are in-
serted after tightening.
9
el 10
2928
(6-416) EXPLODED VIEW OF
STEERING GEAR BOX 20
1273, 1427
24 0 co
25
26
I WORM COVER CAPSCREW 16 CROSS SHAFT BUSHING
2 WORM SHAFT OIL SEAL 17 PITMAN ARM
3 BREATHER 18 OIL DRAIN PLUG
4 WORM COVER 19 EXPANSION PLUG
5 WORM COVER SHIMS 20 CROSS SHAFT ASSEMBLY
6 WORM BEARING CUP 21 ADJUSTING SCREW
7 WORM BEARING CONE 22 ADJUSTING SCREW THRUST WASHER
8 WORM & SHAFT ASSEMBLY 23 ADJUSTING SCREW RETAINER
9 WORM BEARING CONE 24 CROSS SHAFT BUSHING
10 WORM BEARING CUP 25 CROSS SHAFT COVER GASKET
11 HOUSING 26 CROSS SHAFT COVER
12 OIL FILL PLUG 27 ADJUSTING SCREW LOCKNUT
13 PITMAN ARM PINCH BOLT 28 CROSS SHAFT COVER CAPSCREW
14 PITMAN ARM PINCH BOLT NUT 29 CROSS SHAFT COVER 0-RING
15 CROSS SHAFT OIL SEAL Courtesy of keewortu Truck Co.
6:302 WHEEL MACHINE STEERING AND FRONT SUSPENSION
599
WHEEL MACHINE STEERING AND FRONT SUSPENSION 6:303
17. If a front wheel on a loaded truck has ex- 25. When installing a rebuilt steering box, it
cessive negative camber, the: is a recommended Practice with moun-
ting bolts to:
(a) outer wheel bearing has the
greatest load (a) carefully check the bolts for cracks
(b) inner wheel bearing has the and replace the faulty ones
greatest load (b) reuse the bolts as they almost never
(c) both wheel bearings are loaded the get damaged
same (c) replace all the bolts with new ones
of equal grade to the originals
18. If toe-out on turns is incorrect, the fault
is:
600
6:304 WHEEL MACHINE STEERING AND FRONT SUSPENSION
9. To allow the spring to lengthen and shor- 30. (c) forward or backward tilt of the king
ten as it flexes. pin
12. (c) control spring oscillations 33. (b) an angle in the axle that tilts the top
of the wheels outward.
13. True.
34. True.
14. (b) The bottom of the axle eye
35. (b) positive camber
15. The flange on the wheel spindle.
36. (a) cannot be adjusted without bending
16. Yes, two fittings. One each at the upper the axle
and lower pin bosses.
37. (d) adjusting the length of the tie rod
17. Grader wheels must tilt as well as turn.
38. True.
18. ... hydraulic tilt cylinder ... bring the steering pivot axis nearer
39. (d)
19. (d) all of the above are correct. the center of the tire-road contact area
20. - power-assist 40. ... unbalanced ....
- full power 41. .... heavy spots. ... vibrates....
- hydrostatic
42. Kinetic unbalance that causes an up and
21. The booster can be either: down wheel motion or wheel tramp.
(a) mounted to the front axle with the 43. (c) 180 from the heavy spot.
piston rod clamped to the tie rod
(b) mounted within the drag link along
with the control valve
22. (d) steering linkage (drag link)
23. .... integral power steering ...
WHEEL MACHINE STEERING AND FRONT SUSPENSION 6:305
604
BLOCK
Working Attachments
605
WORKING ATTACHMENTS 6:309
DEFINITION
Working attachments are the implements that
do a machine's work. Several types of im.
plements can be used on the same machine.
74..r example, the bucket on a wheel loader
can be removed and replaced with log forks.
This section discusses the working at-
tachments available for common heavy duty
mac hines.
CRAWLER DOZERS
A number of blades are available for dozers,
each suited to a different type of job. Four
common ones are shown in Figure 6.417.
Universal and cushion blades are generally ANGLE BLADE FOR PIONEERING, BACK-
only used on large machines. Specialty at- FILLING. WINDROWING. THIS MULTI-PURPOSE
tachments are also available for dozers such TOOL ANGLES 25° TO EITHER SIDE, GREATER
as the wood chip bucket in Figure 6.418 and MOLDBOARD CURVATURE GIVES MORE
the land clearing rake in Figure 6-419. ROLLING ACTION.
(6-417)
4
1.
STRAIGHT BLADE FOR GENERAL DOZING CUSHION BLADE FOR PUSH SCRAPERS.
WHERE MATERIAL DRIFTED OVER A SHORT TO SHOCK ABSORBING FEATURE PERMITS EASY,
MEDIUM PASS. (6-417) ON.THE-GO CONTACT. BLADE CAN ALSO BE
USED FOR CLEAN-UP AND GENERAL WORK,
(6-417)
Courtesy of Caterpillar Tractor Co.
When selecting a blade. tractor size and the
type of material that the dozer will cut and
move must be considered. The weight and
horsepower output of a tractor determine the
,
blades ability to bulldoze materials. An in-
i...t.i
k'i."::.,,..- .,...._.6,
dication of a blade's ability to penetrate and
obtain a blade load is horsepower per foot of
, ....;22./.....±.1., cutting edge (1-1P/It). The higher the HP /ft.. the
0 ,0: 4, 0_ 4,) more aggressive the blade. Similarly, an in-
dication of a blades potential to push material
is horsepower per loose cubic yard (HP/LCY).
The higher the HP/LOP. the better and faster
the Wade can push material.
UNIVERSAL BLADE MOVES LARGE VOLUME
LOADS OVER LONG DISTANCES BLADE DESIGN Below are characteristics of materials that in-
DIRECTS MATERIAL FORWARD AND TOWARD fluences the ease or difficulty with which they
THE CENTER IN A CUPPING ACTION. can be dozed,
(6-417)
606
6:310 WORKING ATTACHMENTS
4ou
(6-419)
Wood Chip Blades handle
volume loads. Bowl-type and Courtesy of Caterpillar Tractor Co.
U-type are available.
:44
607
WORKING ATTACHMENTS 6:311
::>..)
GREASE FITTING
41.4 12
12 14 21
TRUNNION
CARRIAGE BALL
t
'NO 12
13
IS
.1 f sob
6:312 WORKING ATTACHMENTS
Crawler Altachmersto
.4 variety of rear-mounted attachments are
also available for crawler dozers. Winches are
often mounted on the rear of dozers for win-
ching or towing (Figure 6-421). (Winches are
dealt with in detail in Block 9.) Scarifiers or
rippers can also be mounted on the rear of a
dozer. their purpose to loosen the ground for
easier dozing (Figure 6-422).
MIMIMINN
a
4,- L
-
A' V
1
,
......... .
..
i.
609
WORKING ATTACHMENTS 6:313
ATTACHMENT
PIN HOLES
SHANK
CENTER LINE
SHANK
EAR RECESSESS
.4r____..---- RIPPER NOSE
..............-- NOSE FLATS
POINT BUSHING
POINT
POINT PIN
RAMP
610
6:314 WORKING ATTACHMENTS
kali,'
..
SOO..'- .":
6 ./
Trees can be felled with butt
ends aligned to aid skidding.
..) ! r
et
. 611
WORKING ATTACHMENTS 6:315
CRAWLER LOADERS
Crawler loaders are similar to crawler dozers
except that they use a bucket instead of a
blade. The loader bucket. lift arms and cylin-
ders are attached on each side of the machine
to a loader tower (Figure 6-427). The lower is
made of plates which are attached to or are
part of the main frame. Various buckets are
available to meet different working
requirements.
LOADER TOWER
LIFT ARMS
CYLINDER
PLATES
;-- -,a4.,...e5a4.4k
,... 404
612
6:316 WORKING ATTACHMENTS
WHEEL LOADERS
Various types of buckets are available for
wheel loaders. General purpose buckets and
rock buckets (Figure 6-429) are the most com-
mon. Some specialty buckets are a side dump
bucket (Figure 6-430), a multi-purpose bucket
(Figure 6-430), and a bucket that could be
used for such materials as chips or snow
(Figure 6-431).
"NA
Y. t.e.
MULTI-PURPOSE BUCKET
17'
Can load and strip top
soil. The bucket clamps
hydraulically to grip logs.
pipes and other hard to
grasp material.
(6.430)
Courtesy of Caterpillar Tractor Co
SIDE DUMP BUCKET
Dumps forward or to the
left. For close quarter work.
(6-430)
4 613
WORKING ATTACHMENTS 6:317
BUCKET WITH CUTTING EDGE AND WEAR STRIP BUCKET WITH REPLACEABLE TEETH. ALSO
BOLTED TO THE LOWER EDGE. ALSO CORNER HAVE REPLACEABLE WEAR PLATES UN-
BITS ARE ATTACHED TO THE LOWER OUTSIDE DERNEATH FRONT EDGE.
CORNERS. Courtesy of Caterpillar Tractor Co (G-432) Courtesy of Caterpillar Tractor Co.
PROT CTOR
WEAR PLATE
SIDE PIN
4 ADAPTER COVER
CUTTING EDGE j
SEGMENT ABRASION TIP
(6.434)
Courtesy of Caterpillar Tractor Co
614
6:318 WORKING ATTACHMENTS
(6-435)
BUNCHING SHEARS FALLS AND BUNCHES
SMALL TO MEDIUM SIZE TREES
(6-435)
QUICK COUPLERS PERMIT QUICK SWITCHES
OF WORKING ATTACHMENTS
(6-435)
LOW PROFILE FORKS-HANDLE TREE LENGTH
PULPWOOD
(6.435)
DIRECTIONAL FELLING' SHEARS CUTS TREES
UP TO 30 INCHES THICK
L
(6-435) LOG FORKS
,"114V,E
1.4
_.../111111S
615
WORKING ATTACHMENTS 6:319
HYDRAULIC EXCAVATOR
Hydraulic excavators are built primarily for
digging; a typical one rigged for digging is
shown in Figure 6-437. Many shapes and sizes
of buckets or dippers are available for ex-
cavators. Note in Figure 6-437 the different
hydraulic cylinders that are used to operate
the dipper. Figure 6-438 shows a more DIG WRIST
detailed view of the type of hydraulic cylinder CYLINDER CYLINDER
that is found on excavators.
(6-437)
DIPPER
4.'.____
! CYLINIER HOUSING
.7. 111
ROD WIPER
PISTON USING
(6-438)
616
6:320 WORKING ATTACHMENTS
LUGS
TOP BEAM
CLOSED
LIFTWG
RING
RUNNER
FRONT BEAM
LEFT
HAND
SIDE OF
BUCKET
R1GHTHAND
BLADE TYPE
S1DECUTTER
BODY (Geo. Purpose)
SIDE
REINFORCING
PLATE TOOTH
SPOOL & WEDGE
SIDECUTT ER
PLOW BOLT.
LOC KWASHER POINT
& HEX NUT PIN & LOCK
LIP
LEFrHAND
TOOTHTYPE
SIDECIITTER ADAPTER
617
WORKING ATTACHMENTS 6:321
TOOTH TYPE
COMBINATION
(6-440) SIDECUTTERS
Courtesy of Caterpillar 'tractor Co.
Although hydraulic excavators are used
mainly for digging, optional working at-
tachments are available for them. Some are
shown in Figure 6-441.
Quick Coupling Devices Bunching Shears Ditch Forming Bucket Ditch Cleaning Bucket
For quickly changing For falling and
working attachments bunching trees
(6-441)
618
6:322 WORKING ATTACHMENTS
HOIST
CABLES
EQUALIZER
ASSEMBLY
TYPICAL
SNUBBER REPLACEABLE
DIPPER ASSEMBLY DIPPER TEETH
STICK
TYPICAL
DIPPER
DIPPER
TRIP
LEVER
PITCH
BRACE
CABLE
TO DIPPER
TRIP MOTOR DIPPER
(6-442)
LATCH
LATCH BAR
Courtesy of Harnischfeger Corporation P&H
619
WORKING ATTACHMENTS 6:323
COLLAR
\
,
ADJUSTING
NUT
i_.._.._1 Point
SNUBBER ARM
THRUST 1111
COLLAR .,
CONICAL POINT (6-444)
WELD-ON ADAPTER
bi.
'
GREASE FITTINGS
-.......
SNUBBER
PIN
Courtesy of Esco Corporation
HYDRAULIC CRANES
Many hydraulic cranes use hydraulic
telescopic booms such as the one shown in
Figure 6-445. The boom is constructed of
N........"..
several sections (two, three or four). each sec-
2247
tion having a hydraulic cylinder. Hydraulic
(6-443) TYPICAL DIPPER DOOR SNUBBER lines are all internal. The boom can be ex-
Courtesy of Harnischfeger Corporation P&H panded or retracted as desired, and in its
retracted positions all the sections fit inside of
one another like a telescope. The cable from
the winch passes over the top of the boom.
ROOM POINT SECTION
PAO RETAINER
FIRST INTERMEDIATE
TELESCOPING CYLINDER
SECOND INTERMEDIATE
TELESCOPING CYLINDER
TRUNNION MOUNT
FOR TELESCOPING CYLINDER
620
6:324 WORKING ATTACHMENTS
SKIDDERS
Some of the attachments used on a skidder
are: a blade for roughing out skid roads, a
winch, an arch and fairlead, and a grapple
(Figure 6-446 and 6-447). If a skidder has a
grapple the arch is generally hydraulically
raised and lowered to allow the tongs to pick
up the load and lift it for skidding.
(6-446) BLADE
Courtesy 0 International Harvester
(6-446) WINCH
Courtesy of International Harvester
(6-446) GRAPPLE
Courtesy of International Harvester
FAIRLEAD
CB
(6-447) SKIDDER
Courtesy of Intonation! Harvester
621
WORKING ATTACHMENTS 6:325
GRADERS
A grader blade (Figure 6-448) is longer and
narrower than a dozer blade. The main sec-
tion of the blade is the curved moldboard. Stif-
feners are welded to the back of the mold-
board to give it support. Various mounting
brackets also add support. For protection, a
cutting edge is bolted to the bottom of the
blade and end bits are bolted to the outer
ends.
CIRCLE i
-- 4:-SeA
4x-P-i
MOLDBOARD
TILT CYLINDER
-
SIDE SHIFT CYLINDER
p ,..zu
1, ,;:,,,,,
622
6:326 WORKING ATTACHMENTS
A grader blade has a unique mounting (Figure Two common working attachments found on
6.449). Located between the front and rear graders are rippers and scarifiers. Rippers
wheels under the arch of the main frame. the (Figure 6-450) are mounted at the rear of the
blade is mounted on a mechanism which per- machine. Hydraulic controls raise. lower and
mits the blade to move in the following ways. tilt the rippers. Scarifiers are also
hydraulically operated. Located just ahead of
swing in an arc en a horizontal plane the blade. scarifiers (Figure 6-451) are mount-
from a full left to a full right position. ed to thebolster end of the main frame with a
tilt so that the blade will grade side pivot pin. They have much shorter teeth than a
hills on the left or the right side. ripper and are intended mainly to loosen
extend outward from either side of the material before it reaches the blade. Teeth for
machine. scarifiers and rippers are replaceable.
(6.449)
Courtesy of Champion Road Machinery Limited
(6-450) RIPPER
Courtesy of Catespillar Tractor Co
(6-451) V-SCARIFIER
Counesy of Wabco Construction and
Mining Equipment
623
WORKING ATTACHMENTS 6:32T
WING-PLOW
624
6:328 WORKING ATTACHMENTS
FRONT END
COUNTERWEIGHT (6-454)
Courtesy of American Hoist and Derrick Co
..?11411
.
*.
Counterweights may be added or removed .
when, for example, a longer or shorter boom E.
is put on the machine or the machine's weight -
625
WORKING ATTACHMENTS 6:329
CANOPIES
Canopies, or ROPS (Roll Over Protection
Structure), are required by law on most heavy
duty machines. A typical ROPS mounting for a
crawler dozer is shown in Figure 6-456.
Sweep Assembly
Lin
1
2 Nuts LIFTING
3 Flat Washers BRACKET
4 Bolts
5 Canopy Assembly
6 Bolts
7 NuIS & Lockwashers
626
6:330 WORKING ATTACHMENTS
MAINTENANCE AND SERVICE REPAIR 3. Teeth check for worn or missing teeth.
OF WORKING ATTACHMENTS Also check for loose adapters.
dippers. blades. rippers. scarifiers. make the 6. Hydraulic cylinders check for cylinder
relevant checks from Cie list below. Report or hose leaks. Also check that the mounts.
repairs that need attention. pins fittings and hoses are tight.
1. Weld joints check for cracks or wear. Examples of service manual preventive main-
2. Bucket or dipper check for: tenance checks for working implements for a
Caterpillar wheel loader and grader are
(a) corners worn thin shown below.
(b) bent or broken reinforcing gussets.
(c) bending or bell-mouthing of the
bucket.
(d) bottom runners that are worn thin.
(e) worn or cracked mounting brackets
or lugs.
WHEEL LOADER
When Required
GRADER
When Required
Cutting Edge and End Bits Change when worn close to moldboard.
Ripper Tips Change when worn close to shank.
627
WORKING ATTACHMENTS 6:331
As mentioned earlier. some companies, especially large ones. have their own P.M. check sheets.
Below are two examples of checks on shovel working attachments taken from company P.M. sheets.
I. Adapters. Wedges.
C-C lamps
HHH
?. Teeth
Turned
Replaced or AAA
Note: Longest Teeth to
Operator Side FA
F IF
A ti
IF 1
Trip Cable
I.
UMW
5. Latch Lever Pins and
Locks VOA
5. Latch Bar Dutchman AAA
Shims
Arkr
AFTON MINES
SHIFT PREVENTIVE MAINTENANCE
P & H SHOVEL
DATE: MECH
1900 AL SHOVEL Hr. Reading: 301 302__ 303 301 302 303
2. Sidecutters. Keepers
628
6:332 WORKING ATTACHMENTS
.41111111111.11Mmar---irm--
629
WORKING ATTACHMENTS 6:333
f
C
1. ;71:11SIV f
GRADER END BITS SIDECUTTERS AND MOUNTING BOLTS
(6-459) (6-459)
Courtesy of Caterpillar Tractor Co. Courtesy of Caterpillar Tractor Co.
630
6:334 WORKING ATTACHMENTS
t Cutting Edges
2 R.H. Corner Sit
3 Blade
4 Grease Fitting
5 Bolt & Nut
6 Pin
7 L H. Corner Bit
8 Bolt. Washer & Nut
9 Boll & Nut 10...-1
10 Bolt & Nut
11 Cutting Edge
631
WORKING ATTACHMENTS 6:335
tY
1-
..
.4k$41,. Aor..
0:4%.":".Nt..
BUCKET
Courtesy of Caterpillar Tractor Co.
'..z
04
.
(6 -462) EMOVING SCARIFIER TIP
11 I
,
TEMPLATE FO
SCRIBING
LIP-WING CONTO
QUESTIONS WORKING ATTACHMENTS 14. Give two reasons for adding coun-
terweights to a machine.
1. When selecting a dozer blade, what are
the two main factors to consider? 15. Counterweights can be actual weights or
they can be in the form of
2. True or False? Hardened steel cutting
edges are welded to the bottom edge of 16. What methods do shovels and cranes of-
a dozer blade to extend blade lite. ten have for raising and lowering coun-
terweights?
3. What function does a ripper perform?
17. What safety procedure must be taken if
4. How does a loader bucket mounting dif-
the front end of a counterweighted
fer from a dozer blade mounting? machine is removed?
5. What are the three common types of 18. Part of preventive maintenance programs
protection available for loader buckets? is to make regular checks on working at-
6. What job would a grapple be used for on tachments:
a wheel loader? daily
(a)
7. What is the function of a quick coupling (b) weekly
device for a hydraulic excavator?
(c) monthly
8. The devices used to protect the front cor- (d) twice yearly
ners of an excavator dipper and to aid in
digging are called: 19. Referring to the service mantra: in-
formation given in this section for a
(a) side lips Caterpillar grader, when is it recom-
(b) wear plates mended that scarifier tips be replaced?
(c) tooth points 20. What two maintenance adjustments are
(d) sidecutters required on large shovel dippers?
9. How do shovel dippers differ from ex- (a) dipper door hinge pins and trip lever
cavator dippers? (b) dipper door latch bar and trip lever
10. What device is used to prevent door tc) dipper door latch bar and snubber
slamming on a shovel dipper? (d) dipper door hinge pins and tooth
(a) snuffer points
(b) snubber 21. When working on or inspecting working
door stopper
attachments, what safety precaution
(c)
must be taken?
(d) tension bolt
22. True or False? New parts such as cut-
11. A tooth point used on a shovel dipper is ting edges and corner bits should have
held by a: the paint scraped off their contact sur-
faces to prevent the parts from working
(a) weld loose in service.
(b) bolt
23. Now do you remove bolts on working at-
(c) friction bit tachments that are hard to get oft with a
(d) drift pin wrench?
12. True or False? Adapters for shovel dip- 24. Many bucket teeth are two-sided, having
per teeth are virtually indestructable. a side and a
side.
13. A scarifier on a grader is mounted:
(a) at the rear of the machine
(b) just behind the grader blade
(c) just ahead of the grade blade
(d) ahead of the front wheels
I 634
6:338 WORKING ATTACHMENTS
635
WORKING ATTACHMENTS 6:339
SERVICE REPAIR
4
636