1673 DIESEL TRUCK ENGINE Caterpillar


General Instructions

Usage:

These instructions will be helpful in following the instructions in the Service Manual. In analyzing a system malfunction, use this systematic procedure to locate and correct the problem.

1. Determine problem.

2. List possible causes.

3. Devise checks.

4. Conduct checks in logical order to determine cause.

5. Consider remaining service life against cost of parts and labor.

6. Make necessary repair.

7. Recheck.

Safety

The safety symbol,

in the manual indicates an item or procedure where the use of caution and safety is necessary. Always heed this symbol.

Your safety and that of others is always the number one consideration when working around machines. Safety is a matter of thoroughly understanding the job to be done and application of good common sense. It is not just a matter of "do's" and "don'ts".

Cleanliness

The most important single item in preserving the long life of the machine is to keep dirt out of vital working parts. Precautions have been taken to safeguard against this. Enclosed compartments, seals and filters have been provided to keep the supply of air, fuel and lubricants clean. It is important that these safeguards be maintained.

Whenever hydraulic, fuel, lubricating oil or air lines are disconnected, clean the point of disconnection as well as the adjacent area. As soon as the disconnection is made, cap, plug or tape the line or opening to prevent entry of foreign material. The same recommendations for cleaning and covering apply when access covers or inspection plates are removed.

Clean and inspect all parts. Be sure all passages and holes are open. Cover all parts to keep them clean. Be sure parts are clean when they are installed. Leave new parts in their containers until ready for assembly.

Removal And Installation

Unless otherwise specified, all removals should be accomplished using an adjustable lifting beam. All supporting members (chains and cables) should be parallel to each other and as near perpendicular as possible to the top of the object being lifted.


Correct and incorrect method of lifting a component.

When it is necessary to remove a component on an angle, remember that the capacity of an eyebolt diminishes as the angle between the supporting members and the object becomes less than 90°. Eyebolts and brackets should never be bent and should only have stress in tension. A length of pipe and a washer can be used, as shown, to help relieve these stresses on eyebolts.


Forged eyebolt support.

Some removals require the use of lifting fixtures to obtain proper balance and to provide safe handling.

Use a hoist to remove heavy parts. The weights of some components are given in the section DISASSEMBLY AND ASSEMBLY.

If a part resists removal, check to be certain all nuts and bolts have been removed and that an adjacent part is not interfering.

Disassembly And Assembly

When assembling a machine, complete each step in turn. Do not partially assemble one part and start assembling some other part. Make all adjustments as recommended. Always check the job after it is completed to see nothing has been overlooked.

Recheck the various adjustments by operating the machine before returning it to the job.

Service Tools

Service tools are available so the serviceman can correctly perform service operations with less effort and in a minimum of time.

There are three basic pulling problems:

1 Pulling gears, bearings, pulleys, etc. off a shaft.

2 Pulling a bearing race or cup, sleeve-type bearing, etc. out of a hole.

3 Pulling a shaft, stub shaft, idler gear shaft, etc.

The following illustrations show typical examples of four basic general usage Service Tools in use and will be referred to in the copy.

When the use of Service Tools is difficult to set up or is not obvious, or safe, as shown in these typical examples, these operations will be illustrated in the Disassembly and Assembly copy.

Puller Assembly (2 or 3 Arm)

Two or three arm puller assemblies can be used to remove gears, bearing cages, hubs, bearings, shafts, etc.


1-Puller.


1-Puller. 2-Step Plate.


1-Puller. 2-Step Plate.

Bearing Pulling Attachment

Bearing Pulling Attachments can be used with forcing bolts, to remove shafts, bearings, gears, etc. They can be used with Push Pullers to provide a variety of pulling combinations.


1-Bearing Pulling Attachment. 2-Forcing Bolts.

Bearing Cup Pulling Attachment

Bearing cup pulling attachments are used to remove bearing races or cups, sleeve-type bearings, bearings, seats, etc. and can be used with Push Pullers.


1-Screw. 2-Bearing Cup Pulling Attachment. 3-Step Plate.

Push Pullers

Push Pullers can be used to remove pulleys, gears, shafts, etc., and can be used with other Service Tools to provide a variety of pulling combinations.


*1-Adapters. 2-Ratchet Box Wrench. 3-Push Puller. 4-Step Plate. 5-Legs.


*Use the adapters as required.


1-Push Puller. 2-Adapter. 3-Step Plate.


1-Ratchet Box Wrench. 2-Push Puller. 3-Reducing Adapter.


1-Push Puller. 2-Ratchet Box Wrench. 3-Step Plate. 4-Bearing Pulling Attachment.


1-Push Puller. 2-Bearing Cup Pulling Attachment. 3-Reducing Adapter.


1-Bearing Pulling Attachment. 2-Push Puller. 3-Reducing Adapter.

A Formula For Tool Safety

------ WARNING! ------

Four general rules have been devised to cover the field of tool safety:

RULE 1-Always use safe tools.

RULE 2-Keep tools in safe condition.

RULE 3-Use the right tool for the job.

RULE 4-Safety sense with tools pays off.

--------WARNING!------

Pressing Parts

When one part is pressed into another, use white lead or a suitable prepared compound to lubricate the mating surfaces.

Assemble tapered parts dry. Before assembling parts with tapered splines, be sure the splines are clean, dry and free from burrs. Position the parts together by hand to mesh the splines before applying pressure.

Parts which are fitted together with tapered splines are always very tight. If they are not tight, inspect the tapered splines and discard the part if the splines are worn.

Bolts And Bolt Torque

Use bolts of the correct length. A bolt which is too long may "bottom" before the head is tight against the part it is to hold. The threads can be damaged when a "long" bolt is removed.

If a bolt is too short, there may not be enough threads engaged to hold the part securely.

Apply proper torque values to all bolts and nuts when assembling Caterpillar equipment. When a specific torque value is required, the value is listed in the SPECIFICATIONS or the DISASSEMBLY AND ASSEMBLY sections of the Service Manual. Tighten all other bolts and nuts for general usage, hydraulic valve bodies, or taperlock studs to the torque values given in the charts at the front of the SPECIFICATIONS.

Locks

Lockwashers, flat metal locks or cotter pins are used to lock nuts and bolts.

Flat metal locks must be installed properly to be effective. Bend one end of the lock around the edge of the part. Bend the other end against one flat surface of the nut or bolt head.

Always install new locks in compartments which house moving parts.

When installing lockwashers on housings made of aluminum, use a flat washer between the lockwasher and the housing.


Correct and incorrect methods of installing flat metal locks.


Correct and incorrect method for lock positioning and bending.

Lines And Wires

When removing or disconnecting a group of lines or wires, tag each one to assure proper assembly.

Lubrication

Where applicable, fill the compartments of the components serviced with the amount, type and grade of lubricant recommended in the Lubrication and Maintenance Information part of this Manual.

Rust Preventive Compound

Clean the rust preventive compound from all machined surfaces of new parts before installing them.

Shims

When shims are removed, tie them together and identify them as to location. Keep shims clean and flat until they are reinstalled.

Bearings

Anti-Friction Bearings

When an anti-friction bearing is removed, cover it to keep out dirt and abrasives. Wash bearings in nonflammable cleaning solution and allow them to drain dry. The bearing may be dried with compressed air but do not spin the bearing.

Discard the bearings if the races and balls or rollers are pitted, scored or burned. If the bearing is serviceable, coat it with oil and wrap it in clean paper. Do not unwrap new bearings until time of installation.

The life of an anti-friction bearing will be shortened if not properly lubricated. Dirt in an anti-friction bearing can cause the bearing to lock resulting in the shaft turning in the inner race or the outer race turning within the cage.


Effect of dirt in bearing.

Double Row, Tapered Roller

Double row, tapered roller bearings are precision fit during manufacture and the components are not interchangeable. The cups, cones and spacers are usually etched with the same serial number and letter designator. If no letter designators are found, wire the components together to assure correct installation. Reusable bearing components should be installed in their original positions.

Heating Bearings

Bearings which require expansion for installation should be heated in oil not to exceed 250° F. (121° C.). When more than one part is heated to aid in assembly, they must be allowed to cool and then pressed together again. Parts often separate as they cool and shrink.

Installation

Lubricate new or used bearings before installation. Bearings that are to be preloaded must have a film of oil over the entire assembly to obtain accurate preloading. When installing a bearing, spacer or washer against a shoulder on a shaft, be sure the chamfered side is toward the shoulder.


Correct and incorrect installation of spacer.

When pressing bearings into a retainer or bore, apply pressure to the outer race. If the bearing is pressed on the shaft, apply pressure on the inner race.

Preload

Preload is an initial load placed on the bearing at the time of assembly. Whether a taper roller bearing should have preload could depend on any of several conditions: rigidity of the housings and shaft, bearing spread, speed of operation, etc.

The only certain way to determine what a bearing requires, preload or end clearance, is to consult the DISASSEMBLY AND ASSEMBLY part of the Service Manual.

Care should be exercised in applying preload. Misapplication of preload to bearings requiring end clearance can result in bearing failure.

Sleeve Bearings

Do not install sleeve bearings with a hammer. Use a press if possible and be sure to apply the pressure directly in line with the bore. If it is necessary to drive on a bearing use a bearing driver or a bar with a smooth flat end. If a sleeve bearing has an oil hole, align it with the oil hole in the mating part.

Gaskets

Be sure the holes in the gaskets correspond with the lubricant passages in the mating parts. If it is necessary to make gaskets, select stock of the proper type and thickness. Be sure to cut holes in the right places. Blank gaskets can cause serious damage.

When removed, always install new cylinder head and manifold gaskets using recommended gasket compound on head gaskets to allow uniform sealing.

Batteries

Clean batteries by scrubbing with a solution of baking soda and water. Rinse with clean water. After cleaning, dry thoroughly and coat terminals and connections with an anti-corrosion compound or grease.

If a machine is to be stored or not used for a long period of time, the batteries should be removed. Store them in a warm, dry place, preferably on wooden sleeves. Never store on concrete. A small charge should be introduced periodically to keep the specific gravity rating at recommended level.

Seals

Lip-Type Rubber Seals

Lubricate the lips of lip-type rubber seals before installation. Use the same type lubricant in which the seal will be operating. Do not use grease on any seal except a grease seal.

The main parts of a lip-type seal are the case, sealing element, and garter spring. The picture below illustrates the construction of a simple lip-type seal. The cross section at the top shows the terms "heel" and "toe" used to identify the sides of a single element seal. With few exceptions, the toe of an oil seal with one lip is next to the lubricant that is sealed. Some seals have a second auxiliary lip, which does not carry a garter spring. Use the spring-loaded lip to orient the installation of such seals.


Lip-Type seal construction.

If, during installation, the seal lip must pass over a shaft that has splines, a keyway, rough surface or a sharp edge, the lip can be easily damaged. Shim stock or other such material can be formed around the area to provide a smooth surface over which to slide the seal.

Fractions, Decimals And Millimeters

The following table shows fractions and decimals of an inch and the millimeter equivalents.

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