Tier 4A (interim)
Crawler Dozer
PIN NCDC11500 and above; PIN NDDC11000 and above;
PIN NEDC11000 and above; PIN NFDC11000 and above; PIN NFC105000 and above
SERVICE MANUAL
Part number 51418567
2nd edition English November 2017
Replaces part number 47907865
1150M
SERVICEMANUAL LowGroundPressure(LGP)-Tier4A(interim)andStageIIIB[NFC105000-] 5141856713/11/2017
Product MarketProduct Engine
F4HFE613F*A002
4A(interim)andStageIIIB NorthAmerica
1150MWideTrack(WT)/Low
4A(interim)andStageIIIB NorthAmerica F4HFE613F*A002
1150MLongTrack(LT)
NorthAmerica F4HFE613F*A002
1150MLongTrack(LT) NorthAmerica F4HFE613F*A002
1150MLongTrack(LT)
NorthAmerica
F4HFE613F*A002
1150MLongTrack(LT) NorthAmerica F4HFE613F*A002
1150MWideTrack(WT)/ LowGroundPressure(LGP) NorthAmerica F4HFE613F*A002
1150MWideTrack(WT)/ LowGroundPressure(LGP)
NorthAmerica F4HFE613F*A002
1150MWideTrack(WT)/ LowGroundPressure(LGP)
NorthAmerica
1150MWideTrack(WT)/ LowGroundPressure(LGP) NorthAmerica
F4HFE613F*A002
F4HFE613F*A002
LinkProduct/Engine
[NCDC11500-]
[NEDC11000-]
[NDDC11000-]
[NEDC11000-]
5141856713/11/2017
Contents INTRODUCTION Engine.......................................................................................10 [10.001]Engineandcrankcase.............................................................10.1 [10.202]Aircleanersandlines..............................................................10.2 [10.206]Fuelfilters..........................................................................10.3 [10.216]Fueltanks..........................................................................10.4 [10.310]Aftercooler..........................................................................10.6 Hydrostaticdrive.........................................................................29 [29.218]Pumpandmotorcomponents......................................................29.1 Brakesandcontrols....................................................................33 Hydraulicsystems.......................................................................35 [35.000]Hydraulicsystems..................................................................35.1 [35.104]Fixeddisplacementpump..........................................................35.3 [35.105]Chargepump.......................................................................35.4 [35.359]Maincontrolvalve..................................................................35.5 [35.741]Dozerbladecylinders..............................................................35.6 Tracksandtracksuspension........................................................48 5141856713/11/2017
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Cabclimatecontrol.....................................................................50 Electricalsystems.......................................................................55 [55.000]Electricalsystem...................................................................55.1 [55.011]Fueltanksystem...................................................................55.2 [55.014]Engineintakeandexhaustsystem.................................................55.3 [55.015]Enginecontrolsystem..............................................................55.4 [55.050]Heating,Ventilation,andAir-Conditioning(HVAC)controlsystem.................55.6 [55.302]Battery............................................................................55.11 [55.408]Warningindicators,alarms,andinstruments....................................55.12 [55.518]Wiperandwashersystem........................................................55.14 Dozerbladeandarm...................................................................86 [86.110]Dozerblade........................................................................86.1 [86.124]Dozerpushbeamsandstruts......................................................86.2 5141856713/11/2017
[90.124]Pneumatically-adjustedoperatorseat..............................................90.4 [90.100]Enginehoodandpanels...........................................................90.5
[90.150]Cab.................................................................................90.1 [90.160]Cabinteriortrimandpanels........................................................90.2 [90.120]Mechanically-adjustedoperatorseat...............................................90.3
5141856713/11/2017
5141856713/11/2017
INTRODUCTION
5141856713/11/2017 1
INTRODUCTION
Contents
Safetyrules.....................................................................................4 Maintenancechart............................................................................44 Basicinstructions-Movingadisabledmachine..............................................46 Productidentification-Machineorientation..................................................72 5141856713/11/2017 2
Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein
Themanufacturerreservestherighttomakeimprovementsindesignandchangesinspecificationsatanytimewithout illustrativematerialhereinareasaccurateasknownattimeofpublicationbutaresubjecttochangewithoutnotice.
INTRODUCTION Foreword-Importantnoticeregardingequipmentservicing
5141856713/11/2017 3
Personalsafety
Machinesafety
Information
NOTE:
INTRODUCTION Safetyrules
ThroughoutthismanualyouwillfindthesignalwordsDANGER,WARNING,andCAUTIONfollowedbyspecialinFAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT INDEATHORSERIOUSINJURY.
NOTICE: Noticeindicatesasituationthat,ifnotavoided,couldresultinmachineorpropertydamage. ThroughoutthismanualyouwillfindthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor propertydamage.ThewordNoticeisusedtoaddresspracticesnotrelatedtopersonalsafety.
5141856713/11/2017 4
Generalmaintenancesafety
Generalbatterysafety
INTRODUCTION Safetyrules-Personalsafety
Installguardsandshieldsafterservicingthemachine. Donotattempttoclean,lubricate,clearobstructionsormakeadjustmentstothemachinewhileitisinmotionorwhile Alwaysmakesureworkingareaisclearoftools,parts,otherpersonsandpetsbeforeyoustartoperatingthemachine. equipmentinaraisedpositionwhileparkedorduringservice,unlesssecurelysupported. Stoptheengine,removekeyandrelievepressurebeforedisconnectingorconnectingfluidlines. acapturnitslowlytoallowpressuretoescapebeforecompletelyremovingthecap. Engine,transmission,exhaustcomponents,andhydrauliclinesmaybecomehotduringoperation.Takecarewhen
ator’smanual.Donotshortacrossterminals. Followmanufacturer’sinstructionswhenstoringandhandlingbatteries. 5141856713/11/2017 5
INTRODUCTION Air-conditioningsystem Service,repair,orrechargingmustbeperformedonlybyatrainedservicetechnician. PersonalProtectiveEquipment(PPE) DoNotOperatetag Beforeyoustartservicingthemachine,attacha‘DoNotOperate’warningtagtothemachineinanareathatwillbe 5141856713/11/2017 6
INTRODUCTION Safetyrules-Ecologyandtheenvironment Soil,air,andwaterqualityisimportantforallindustriesandlifeingeneral.Whenlegislationdoesnotyetrulethe legislation.Wherenolegislationexists,obtaininformationfromsuppliersofoils,filters,batteries,fuels,anti-freeze, cleaningagents,etc.,withregardtotheeffectofthesesubstancesonmanandnatureandhowtosafelystore,use, Helpfulhints • • • • etc.Donotmixdrainedbrakefluidsorfuelswithlubricants.Storealldrainedfluidssafelyuntilyoucandisposeof • Donotallowcoolantmixturestogetintothesoil.Collectanddisposeofcoolantmixturesproperly. • • • • Batteryrecycling Batteriesandelectricaccumulatorscontainseveralsubstancesthatcanhaveaharmful CONSTRUCTIONstronglyrecommendsthatyoureturnallusedbatteriestoaCASE batteriesproperly.Insomecountries,thisisalegalrequirement. Mandatorybatteryrecycling NOTE: Batteriesaremadeofleadplatesandasulfuricacidsolution.Becausebatteriescontainheavymetalssuchaslead, CONAMAResolution401/2008requiresyoutoreturnallusedbatteriestothebatterydealerwhenyoureplaceany Pointsofsaleareobligedto: • Acceptthereturnofyourusedbatteries • Storethereturnedbatteriesinasuitablelocation • Sendthereturnedbatteriestothebatterymanufacturerforrecycling 5141856713/11/2017 7
INTRODUCTION Safetyrules-Donotoperatetag WARNING Maintenancehazard! Beforeyoustartservicingthemachine,attachaDONOTOPERATEwarningtagtothemachineina visiblearea. W0004A AttachaDONOTOPERATE(TAG)tothemachineinanareathatisclearlyvisiblewheneverthemachineisnot Completethetaginformationforthe"REASON"thetagisattachedbydescribingthemalfunctionorservicerequired. havebeencompleted. (A) (D) (E) (B) (F) (C) 87358697 1 TagComponents C.CNHPartNumber-(RequestthispartnumberfromyouServicePartsDealertoobtainthisDONOTOPERATE D.DONOTOPERATE-(Warning!) F.Signedby-(Signaturearea-tobesignedbythepersonvalidatingthereasonforinstallationofthetag.) 5141856713/11/2017 8
89lb )
37lb
75lb )
96lb ) 15N·m
36lbin
128lb ) 6.8N·m
60lb ) 10N·m
51lb
89lb )
163lb ) 25N·m ( 217lb ) 26N·m ( 234lb ) 35N·m ( 311lb ) 17N·m ( 151lb ) 24N·m ( 212lb )
M10 ( 27lbft ) 49N·m ( 36lb ) ( 38lbft ) 70N·m ( 51lb ) 33N·m ( 25lb ) 48N·m ( 35lb )
M12 ( 47lbft ) 85N·m ( 63lb ) ( 67lbft ) 121N·m ( 90lb ) 58N·m ( 43lb ) 83N·m ( 61lb )
M16 ( 116lb ) ( 155lbft ) ( 166lb ) ( 222lb ) ( 106lb ) ( 151lb )
M20 ( 235lb ) ( 313lbft ) ( 325lb ) ( 433lb ) ( 214lb ) ( 295lb )
M24 ( 410lb ) 735N·m ( 500lbft ) ( 560lb ) 1016N·m ( 750lbft ) ( 370lb ) ( 510lb )
NOTE:
INTRODUCTION Torque-Minimumtighteningtorquesfornormalassembly METRICNON-FLANGEDHARDWARE NOM. SIZE CLASS8.8BOLTand CLASS8NUT CLASS10.9BOLTand CLASS10NUT LOCKNUT CL.8 W/CL8.8 BOLT LOCKNUT CL.10 W/CL10.9 BOLT UNPLATED PLATED W/ZnCr UNPLATED PLATED W/ZnCr 2.2N·m ( 19lb ) 2.9N·m ( 26lb ) 3.2N·m ( 28lb ) 4.2N·m (
) 2N·m ( 18lbin ) 2.9N·m ( 26lb ) 4.5N·m ( 40lb ) 5.9N·m ( 52lb ) 6.4N·m ( 57lb ) 8.5N·m (
4N·m (
) 5.8N·m (
) 7.5N·m ( 66lb ) 10N·m (
11N·m (
(
(
(
18N·m (
5141856713/11/2017 9
INTRODUCTION METRICFLANGEDHARDWARE NOM. SIZE CLASS8.8BOLTand CLASS8NUT CLASS10.9BOLTand CLASS10NUT LOCKNUT CL.8 W/CL8.8 BOLT LOCKNUT CL.10 W/CL10.9 BOLT UNPLATED PLATED W/ZnCr UNPLATED PLATED W/ZnCr ( 21lb ) ( 28lb ) ( 31lb ) ( 41lb ) ( 19lb ) ( 27lb ) ( 43lb ) ( 58lb ) ( 62lb ) ( 83lb ) ( 39lb ) ( 57lb ) 8.3N·m ( 73lb ) ( 96lb ) ( 105lb ) ( 141lb ) 7.5N·m ( 66lb ) ( 96lb ) ( 179lb ) ( 240lb ) ( 257lb ) ( 343lb ) ( 163lb ) ( 240lb ) M10 40N·m ( 30lbft ) 54N·m ( 40lb ) 57N·m ( 42lbft ) 77N·m ( 56lb ) 37N·m ( 27lbft ) 53N·m ( 39lbft ) M12 70N·m ( 52lbft ) 93N·m ( 69lb ) 100N·m ( 74lb ) 134N·m ( 98lb ) 63N·m ( 47lbft ) 91N·m ( 67lbft ) M16 174N·m ( 128lb ) 231N·m ( 171lb ) 248N·m ( 183lb ) 331N·m ( 244lb ) 158N·m ( 116lb ) 226N·m ( 167lb ) M20 350N·m ( 259lb ) 467N·m ( 345lb ) 484N·m ( 357lb ) 645N·m ( 476lb ) 318N·m ( 235lb ) 440N·m ( 325lb ) M24 607N·m ( 447lb ) 809N·m ( 597lb ) 838N·m ( 618lb ) 1118N·m ( 824lbft ) 552N·m ( 407lb ) IDENTIFICATION MetricHexheadandcarriagebolts,classes5.6andup 20083680 1 1.Manufacturer'sIdentification MetricHexnutsandlocknuts,classes05andup 20083681 2 5141856713/11/2017
37lbft
1/2
53lbft
48lbft
) 98N·m ( 73lbft ) 104N·m ( 77lbft ) 139N·m ( 103lbft ) 76N·m ( 56lbft ) 108N·m ( 80lb )
9/16 107N·m ( 79lbft ) 142N·m ( 105lbft ) 150N·m ( 111lbft ) 201N·m ( 148lbft ) 111N·m ( 82lbft ) 156N·m ( 115lb )
5/8 147N·m ( 108lbft ) 196N·m ( 145lbft ) 208N·m ( 153lbft ) 277N·m ( 204lbft ) 153N·m ( 113lb ) 215N·m ( 159lb )
3/4 261N·m ( 193lbft ) 348N·m ( 257lbft ) 369N·m ( 272lbft ) 491N·m ( 362lbft ) 271N·m ( 200lb ) 383N·m ( 282lb )
7/8 ( 310lbft ) ( 413lbft ) ( 438lbft ) ( 584lbft ) 437N·m ( 323lb ) 617N·m ( 455lb )
1 ( 465lbft ) ( 620lbft ) ( 656lbft ) ( 875lbft ) ( 483lb ) ( 681lb )
INTRODUCTION 1.Manufacturer'sIdentification 3.ClockMarkingofPropertyClassandManufacturer'sIdentification(Optional),i.e.marks 60° apartindicateClass 120° INCHNON-FLANGEDHARDWARE NOMINAL SIZE SAEGRADE5BOLT andNUT SAEGRADE8BOLT andNUT LOCKNUT GrBW/Gr5 BOLT LOCKNUT GrCW/Gr8 BOLT UNPLATED PLATED SILVER PLATED W/ZnCr GOLD UNPLATED orPLATED SILVER PLATED W/ZnCr GOLD 1/4 8N·m ( 71lb ) 11N·m ( 97lb ) ( 106lbin ) ( 142lbin ) 8.5N·m ( 75lbin ) ( 109lb ) 5/16 ( 150lbin ) ( 204lbin ) ( 212lbin ) ( 283lbin ) 17.5N·m ( 155lb ) ( 220lb ) 3/8 ( 22lb ) ( 30lbft ) ( 31lb ) ( 42lb ) 31N·m ( 23lbft ) 44N·m ( 33lbft ) 7/16 48N·m ( 36lb ) 65N·m (
) 68N·m ( 50lb ) 91N·m ( 67lb ) 50N·m (
) 71N·m (
)
74N·m ( 54lb
NOTE: 1/4inand 5/16in hardwaretorquespecificationsareshowninpound-inches. 3/8in through1in 5141856713/11/2017 11
INTRODUCTION INCHFLANGEDHARDWARE NOMINAL SIZE SAEGRADE5BOLTand NUT SAEGRADE8BOLTand NUT LOCKNUT GrFW/Gr5 BOLT LOCKNUT GrGW/Gr8 BOLT UNPLATED orPLATED SILVER PLATED W/ZnCr GOLD UNPLATED orPLATED SILVER PLATED W/ZnCr GOLD 1/4 ( 80lbin ) 12N·m ( 106lb ) 13N·m ( 115lb ) 17N·m ( 150lb ) ( 71lbin ) 12N·m ( 106lb ) 5/16 19N·m ( 168lb ) 25N·m ( 221lb ) 26N·m ( 230lb ) 35N·m ( 310lb ) 17N·m ( 150lb ) 24N·m ( 212lb ) 3/8 ( 25lb ) ( 33lb ) ( 35lb ) ( 46lb ) ( 22lbft ) ( 32lbft ) 7/16 ( 39lb ) ( 52lb ) ( 55lb ) ( 74lb ) 48N·m ( 35lbft ) 68N·m ( 50lbft ) 1/2 81N·m ( 60lb ) 108N·m ( 80lb ) 115N·m ( 85lb ) 153N·m ( 113lbft ) 74N·m ( 55lbft ) 104N·m ( 77lb ) 9/16 117N·m ( 86lb ) 156N·m ( 115lbft ) 165N·m ( 122lbft ) 221N·m ( 163lbft ) 106N·m ( 78lbft ) 157N·m ( 116lb ) 5/8 162N·m ( 119lb ) 216N·m ( 159lbft ) 228N·m ( 168lbft ) 304N·m ( 225lbft ) 147N·m ( 108lb ) 207N·m ( 153lb ) 3/4 287N·m ( 212lb ) 383N·m ( 282lbft ) 405N·m ( 299lbft ) 541N·m ( 399lbft ) 261N·m ( 193lb ) 369N·m ( 272lb ) 7/8 462N·m ( 341lb ) 617N·m ( 455lbft ) 653N·m ( 482lbft ) 871N·m ( 642lbft ) 421N·m ( 311lb ) 594N·m ( 438lb ) 1 693N·m ( 512lb ) ( 682lbft ) ( 722lbft ) ( 963lbft ) 631N·m ( 465lb ) 890N·m ( 656lb ) IDENTIFICATION InchBoltsandfree-spinningnuts 20083682 3 GradeMarkingExamples SAEGradeIdentification 1 4 2 5 120° Apart 3 6 60° Apart 5141856713/11/2017
INTRODUCTION InchLockNuts,AllMetal(Threeoptionalmethods) 20090268 4 GradeIdentification GradeCornerMarkingMethod(1)FlatsMarkingMethod(2)ClockMarkingMethod(3) GradeA NoNotches NoMark NoMarks GradeBOneCircumferentialNotch LetterB ThreeMarks GradeCTwoCircumferentialNotchesLetterC SixMarks 5141856713/11/2017
INTRODUCTION Torque-Standardtorquedataforhydraulics NOTICE: NOTICE: NOTE: Handinstallandhandtightenallconnectionsbeforeusingtoolstosetthetorque.ThiswillreducethepossiTorquesforMetricO-RingBoss(ORB)studendsandportconnections S-Series(HeavyDuty) MetricL-Series(LightDuty) Thread Ferrous Non-Ferrous Ferrous Non-Ferrous M8x1 10.5N·m ( 7.7lbft ) 6.3N·m ( 4.6lbft ) 8.5N·m ( 6.3lbft ) ( 3.7lbft ) M10x1 21N·m ( 15.5lbft ) ( 9.2lbft ) ( 11.4lbft ) ( 6.9lbft ) 37N·m ( ) 22N·m ( ) 27N·m ( ) 16N·m ( ) ( 34.7lbft ) ( 20.7lbft ) ( 27.3lbft ) ( 16.2lbft ) M16x1.5 ( 42.8lbft ) ( 25.8lbft ) ( 31.0lbft ) ( 18.4lbft ) 74N·m ( 54.6lbft ) 44N·m ( 32.5lbft ) 47N·m ( 34.7lbft ) 28N·m ( 20.7lbft ) 105N·m ( ) 63N·m ( ) 63N·m ( ) 38N·m ( ) M27x2 ( 131.3lbft ) ( 78.9lbft ) ( 77.4lbft ) ( 46.5lbft ) M30x2 225N·m ( 166.0lbft ) 135N·m ( 99.6lbft ) 136N·m ( 100.3lbft ) 82N·m ( 60.5lbft ) M33x2 325N·m ( ) 195N·m ( ) 168N·m ( ) 101N·m ( ) M42x2 345N·m ( ) 207N·m ( ) 220N·m ( ) 132N·m ( ) M48x2 ( 324.5lbft ) ( 194.7lbft ) ( 201.4lbft ) ( 121.0lbft ) M60x2 525N·m ( 387.2lbft ) 315N·m ( 232.3lbft ) 330N·m ( 243.4lbft ) 198N·m ( 146.0lbft ) NOTE: 10% MetricFerrous Thread InternalHex ExternalHex M8x1 8.5N·m ( 6.3lbft ) 10.5N·m ( 7.7lbft ) 6.3N·m ( 4.6lbft ) M10x1 16N·m ( 11.8lbft ) 21N·m ( 15.5lbft ) ( 9.2lbft ) 23N·m ( ) 37N·m ( ) 22N·m ( ) ( 34.7lbft ) ( 20.7lbft ) M16x1.5 ( 42.8lbft ) ( 25.8lbft ) 74N·m ( 54.6lbft ) 44N·m ( 32.5lbft ) 105N·m ( ) 63N·m ( ) M27x2 ( 131.3lbft ) ( 78.9lbft ) M30x2 225N·m ( 166.0lbft ) 135N·m ( 99.6lbft ) M33x2 325N·m ( 239.7lbft ) 195N·m ( 143.8lbft ) M42x2 345N·m ( ) 207N·m ( ) M48x2 ( 324.5lbft ) ( 194.7lbft ) M60x2 525N·m ( 387.2lbft ) 315N·m ( 232.3lbft ) NOTE: 10% 5141856713/11/2017