Part number 48048568 1st edition English April 2017 SERVICE MANUAL 1650M Tier 2 Crawler Dozer PIN NGC107000 and above
SERVICEMANUAL [NGC107000-] [NGC107000-] 4804856826/04/2017
Contents INTRODUCTION Engine.......................................................................................10 [10.001]Engineandcrankcase.............................................................10.1 [10.202]Aircleanersandlines..............................................................10.2 [10.206]Fuelfilters..........................................................................10.3 [10.304]Enginelubricationsystem..........................................................10.4 [10.310]Aftercooler..........................................................................10.5 [10.400]Enginecoolingsystem.............................................................10.6 [10.414]Fananddrive......................................................................10.7 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 [48.138]Trackrollers........................................................................48.4 4804856826/04/2017
[48.AAA]Tracksandtracksuspensiongenericsub-group..................................48.6 [50.100]Heating.............................................................................50.1 [50.104]Ventilation..........................................................................50.2 [50.200]Airconditioning.....................................................................50.3 Electricalsystems.......................................................................55 [55.050]Heating,Ventilation,andAir-Conditioning(HVAC)controlsystem.................55.6 Dozerbladeandarm...................................................................86 [86.110]Dozerblade........................................................................86.1 [86.124]Dozerpushbeamsandstruts......................................................86.2 Tools.........................................................................................89 Platform,cab,bodywork,anddecals.............................................90 4804856826/04/2017
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[90.124]Pneumatically-adjustedoperatorseat..............................................90.2 4804856826/04/2017
4804856826/04/2017 1
INTRODUCTION
Contents INTRODUCTION Foreword-Importantnoticeregardingequipmentservicing(*)................................3 Safetyrules(*)..................................................................................4 Safetyrules-Personalsafety(*)...............................................................5 Safetyrules-Ecologyandtheenvironment(*).................................................7 Safetyrules-Donotoperatetag(*)............................................................8 Torque-Minimumtighteningtorquesfornormalassembly(*).................................9 Torque-Standardtorquedataforhydraulics(*)..............................................14 Torque-Standardtorquedataforhydraulicconnections(*).................................30 Torque-Specialtorques(*)...................................................................37 Basicinstructions-Shopandassembly(*)...................................................39 Enginecoolingsystem-Basicinstructions(*)................................................41 Maintenancechart............................................................................43 Basicinstructions-Movingadisabledmachine(*)...........................................45 Hydrauliccontamination(*)...................................................................54 ConsumablesLoctite®ProductChart(*).....................................................55 Conversionfactors(*).........................................................................61 Generalspecification(*)......................................................................63 Productidentification-Machineorientation..................................................73 4804856826/04/2017 2
INTRODUCTION Foreword-Importantnoticeregardingequipmentservicing 1650M Anyonewhoperformsrepairandmaintenanceoperationswithoutcomplyingwiththeproceduresprovidedherein localdealers,rejectanyresponsibilityfordamagescausedbypartsand/orcomponentsnotapprovedbythemanuofdamagescausedbypartsand/orcomponentsnotapprovedbythemanufacturer. Themanufacturerreservestherighttomakeimprovementsindesignandchangesinspecificationsatanytimewithout 4804856826/04/2017 3
Personalsafety
INTRODUCTION Safetyrules 1650M
safetymessagesthatfollowthissymboltoavoidpossibledeathorinjury. CAUTIONindicatesahazardoussituationthat,ifnotavoided,couldresultinminorormoderateinjury. FAILURETOFOLLOWDANGER,WARNING,ANDCAUTIONMESSAGESCOULDRESULT INDEATHORSERIOUSINJURY. Machinesafety NOTICE: ThroughoutthismanualyouwillfindthesignalwordNoticefollowedbyspecialinstructionstopreventmachineor Information NOTE: 4804856826/04/2017 4
INTRODUCTION Safetyrules-Personalsafety 1650M Generalmaintenancesafety equipmentwhenappropriate. Alwayswashyourhandsafterhandlingbatterycomponents. Generalbatterysafety Alwaysweareyeprotectionwhenworkingwithbatteries. Ventilatewhenchargingorusinginanenclosedarea. Disconnectnegative(-)firstandreconnectnegative(-)last. ator’smanual.Donotshortacrossterminals. Followmanufacturer’sinstructionswhenstoringandhandlingbatteries. 4804856826/04/2017 5
INTRODUCTION Air-conditioningsystem Service,repair,orrechargingmustbeperformedonlybyatrainedservicetechnician. PersonalProtectiveEquipment(PPE) DoNotOperatetag Beforeyoustartservicingthemachine,attacha‘DoNotOperate’warningtagtothemachineinanareathatwillbe 4804856826/04/2017 6
INTRODUCTION Safetyrules-Ecologyandtheenvironment 1650M disposalofproductsofachemicalandpetrochemicalnature. Helpfulhints • • thatmaybeharmfultoyourhealth. • • Avoidspillagewhenyoudrainfluidssuchasusedenginecoolantmixtures,engineoil,hydraulicfluid,brakefluid, • • Theair-conditioningsystemcontainsgasesthatshouldnotbereleasedintotheatmosphere.Consultanair-condi• • Donotincreasethepressureinapressurizedcircuitasthismayleadtoacomponentfailure. • coolant,etc. Batteryrecycling Batteriesandelectricaccumulatorscontainseveralsubstancesthatcanhaveaharmful CONSTRUCTIONstronglyrecommendsthatyoureturnallusedbatteriestoaCASE CONSTRUCTIONdealer,whowilldisposeoftheusedbatteriesorrecycletheused Mandatorybatteryrecycling NOTE: CONAMAResolution401/2008requiresyoutoreturnallusedbatteriestothebatterydealerwhenyoureplaceany Pointsofsaleareobligedto: • Acceptthereturnofyourusedbatteries • Storethereturnedbatteriesinasuitablelocation • Sendthereturnedbatteriestothebatterymanufacturerforrecycling 4804856826/04/2017 7
INTRODUCTION Safetyrules-Donotoperatetag 1650M WARNING Maintenancehazard! visiblearea. W0004A AttachaDONOTOPERATE(TAG)tothemachineinanareathatisclearlyvisiblewheneverthemachineisnot Completethetaginformationforthe"REASON"thetagisattachedbydescribingthemalfunctionorservicerequired. (A) (D) (E) (B) (F) (C) 87358697 1 TagComponents C.CNHPartNumber-(RequestthispartnumberfromyouServicePartsDealertoobtainthisDONOTOPERATE D.DONOTOPERATE-(Warning!) F.Signedby-(Signaturearea-tobesignedbythepersonvalidatingthereasonforinstallationofthetag.) 4804856826/04/2017 8
INTRODUCTION Torque-Minimumtighteningtorquesfornormalassembly 1650M METRICNON-FLANGEDHARDWARE NOM. SIZE CLASS8.8BOLTand CLASS8NUT CLASS10.9BOLTand CLASS10NUT LOCKNUT W/CL8.8 BOLT LOCKNUT W/CL10.9 BOLT UNPLATED PLATED W/ZnCr UNPLATED PLATED W/ZnCr 2.2N·m (
(
specificationsareshowninpound-feet. 4804856826/04/2017 9
19lb ) 2.9N·m ( 26lb ) 3.2N·m ( 28lb ) 4.2N·m ( 37lb ) 2N·m ( 18lbin ) 2.9N·m ( 26lb )
40lb ) ( 52lb ) ( 57lb ) ( 75lb ) 4N·m ( 36lbin ) ( 51lb ) ( 66lb ) 10N·m ( 89lb ) 11N·m ( 96lb ) 15N·m ( 128lb ) ( 60lb ) 10N·m ( 89lb ) ( 163lb ) ( 217lb ) ( 234lb ) ( 311lb ) ( 151lb ) ( 212lb ) M10 37N·m ( 27lbft ) ( 36lb ) 52N·m ( 38lbft ) ( 51lb ) ( 25lb ) ( 35lb ) M12 64N·m ( 47lbft ) ( 63lb ) 91N·m ( 67lbft ) ( 90lb ) ( 43lb ) ( 61lb ) M16 158N·m ( 116lb ) 210N·m ( 155lbft ) 225N·m ( 166lb ) 301N·m ( 222lb ) 143N·m ( 106lb ) 205N·m ( 151lb ) M20 319N·m ( 235lb ) 425N·m ( 313lbft ) 440N·m ( 325lb ) 587N·m ( 433lb ) 290N·m ( 214lb ) 400N·m ( 295lb ) M24 551N·m ( 410lb ) 735N·m ( 500lbft ) 762N·m ( 560lb ) 1016N·m ( 750lbft ) 501N·m ( 370lb ) 693N·m ( 510lb ) NOTE:
( 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 )
INTRODUCTION METRICFLANGEDHARDWARE NOM. SIZE CLASS8.8BOLTand CLASS8NUT CLASS10.9BOLTand CLASS10NUT LOCKNUT CL.8 W/CL8.8
LOCKNUT CL.10 W/CL10.9 BOLT
UNPLATED
BOLT
UNPLATED PLATED W/ZnCr
PLATED W/ZnCr
IDENTIFICATION MetricHexheadandcarriagebolts,classes5.6andup 20083680 1 1.Manufacturer'sIdentification MetricHexnutsandlocknuts,classes05andup 20083681 2 4804856826/04/2017
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 ( 48lbft ) 68N·m ( 50lb ) 91N·m ( 67lb ) 50N·m ( 37lbft ) 71N·m ( 53lbft ) 1/2 74N·m ( 54lb ) 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
NOTE: 1/4in and 5/16in hardwaretorquespecificationsareshowninpound-inches. 3/8in through 1in 4804856826/04/2017 11
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 )
INTRODUCTION INCHFLANGEDHARDWARE NOMINAL SIZE SAEGRADE5BOLTand NUT SAEGRADE8BOLTand NUT LOCKNUT GrFW/Gr5 BOLT LOCKNUT GrGW/Gr8
orPLATED SILVER PLATED W/ZnCr
UNPLATED orPLATED
PLATED
BOLT UNPLATED
GOLD
SILVER
W/ZnCr GOLD
IDENTIFICATION InchBoltsandfree-spinningnuts 20083682 3 GradeMarkingExamples SAEGradeIdentification 1 4 2 5 120° Apart 3 6 60° Apart 4804856826/04/2017
INTRODUCTION InchLockNuts,AllMetal(Threeoptionalmethods) 20090268 4 GradeIdentification GradeCornerMarkingMethod(1)FlatsMarkingMethod(2)ClockMarkingMethod(3) GradeA NoNotches NoMark NoMarks GradeBOneCircumferentialNotch LetterB ThreeMarks GradeCTwoCircumferentialNotchesLetterC SixMarks 4804856826/04/2017
) 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 ( 254.5lbft ) 207N·m ( 152.7lbft ) 220N·m ( 162.3lbft ) 132N·m ( 97.4lbft ) 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 )
INTRODUCTION Torque-Standardtorquedataforhydraulics 1650M NOTICE: NOTICE: NOTE: Handinstallandhandtightenallconnectionsbeforeusingtoolstosetthetorque.Thiswillreducethepossibilityofthreaddamage. TorquesforMetricO-RingBoss(ORB)studendsandportconnections S-Series(HeavyDuty) L-Series(LightDuty) Metric Thread Ferrous Non-Ferrous Ferrous Non-Ferrous M8x1 ( 7.7lbft ) ( 4.6lbft ) ( 6.3lbft ) 5N·m ( 3.7lbft ) M10x1 21N·m ( 15.5lbft ) ( 9.2lbft ) ( 11.4lbft ) ( 6.9lbft ) 37N·m ( ) 22N·m ( ) 27N·m ( ) 16N·m ( ) M14x1.5 ( 34.7lbft ) ( 20.7lbft ) ( 27.3lbft ) ( 16.2lbft ) 58N·m ( 42.8lbft ) 35N·m ( 25.8lbft ) 42N·m ( 31.0lbft ) 25N·m ( 18.4lbft ) 74N·m ( ) 44N·m ( ) 47N·m ( ) 28N·m ( ) 105N·m ( ) 63N·m (
NOTE: 10% TorquesforMetricO-RingBoss(ORB)portplugs Ferrous Metric Thread InternalHex ExternalHex Non-Ferrous
(
( 34.7lbft ) ( 20.7lbft ) 58N·m ( 42.8lbft ) 35N·m ( 25.8lbft ) 74N·m ( ) 44N·m ( ) 105N·m ( ) 63N·m ( ) M27x2 ( 131.3lbft ) ( 78.9lbft ) M30x2 225N·m ( 166.0lbft ) 135N·m ( 99.6lbft ) M33x2 325N·m ( ) 195N·m ( ) M42x2 345N·m ( ) 207N·m ( ) M48x2 ( 324.5lbft ) ( 194.7lbft ) M60x2 525N·m ( 387.2lbft ) 315N·m ( 232.3lbft ) NOTE: 10% 4804856826/04/2017
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 ( )
INTRODUCTION TorquesforBritishStandardPipeParallel(BSPP)straight-pipe-threadportconnections MetricTubeOD Ferrous Non-Ferrous BSPP Thread S-Series (HeavyDuty) L-Series (LightDuty) S-Series (HeavyDuty) L-Series (LightDuty) S-Series (HeavyDuty) L-Series (LightDuty) G1/8A 6mm ( ) 12.5N·m ( ) 6mm 8mm G1/4A 8mm10mm 63N·m ( 46.5lbft ) 53N·m ( 39.1lbft ) 38N·m ( 28.0lbft ) 32N·m ( 23.6lbft ) 10mm G3/8A 12mm 12mm 95N·m ( 70.1lbft ) 84N·m ( 62.0lbft ) 57N·m ( 42.0lbft ) 50N·m ( 36.9lbft ) 15mm G1/2A 16mm 18mm 136N·m ( 100.3lbft ) 105N·m ( 77.4lbft ) 82N·m ( 60.5lbft ) 63N·m ( 46.5lbft ) G3/4A 20mm22mm 210N·m ( 154.9lbft ) 210N·m ( 154.9lbft ) 126N·m ( 92.9lbft ) 126N·m ( 92.9lbft ) G1A 25mm28mm ( ) ( ) ( ) ( ) 30mm35mm ( 387.2lbft ) ( 387.2lbft ) ( 232.3lbft ) ( 232.3lbft ) 38mm42mm 660N·m ( 486.8lbft ) 660N·m ( 486.8lbft ) 396N·m ( 292.1lbft ) 396N·m ( 292.1lbft ) NOTE: 10% 4804856826/04/2017
INTRODUCTION TorquesforMetricO-RingFaceSeal(ORFS)portsandstudendconnections
Ferrous Non-Ferrous BSP
S-Series (HeavyDuty) L-Series (LightDuty) S-Series (HeavyDuty) L-Series (LightDuty) S-Series (HeavyDuty) L-Series (LightDuty)
MetricTubeOD
Thread
18mm
(
(
20mm23mm
(
(
25mm30mm 525N·m (
525N·m (
32mm36mm 630N·m (
630N·m (
10% 4804856826/04/2017
M10x1 4mm ( ) 12.5N·m ( ) M12x1.5 4mm 6mm 47N·m ( 34.7lbft ) 32N·m ( 23.6lbft ) 28N·m ( 20.7lbft ) 19N·m ( 14.0lbft ) 5mm 7mm 63N·m ( 46.5lbft ) 53N·m ( 39.1lbft ) 38N·m ( 28.0lbft ) 32N·m ( 23.6lbft ) 7mm 9mm 84N·m ( 62.0lbft ) 63N·m ( 46.5lbft ) 50N·m ( 36.9lbft ) 38N·m ( 28.0lbft ) 8mm 11mm ( ) ( ) ( ) ( ) M20x1.5 10mm 147N·m ( 108.4lbft ) 88N·m ( 64.9lbft ) 12mm14mm 158N·m ( 116.5lbft ) 147N·m ( 108.4lbft ) 95N·m ( 70.1lbft ) 88N·m ( 64.9lbft )
210N·m
154.9lbft ) 126N·m ( 92.9lbft ) 16mm
) ( ) M33x2
400N·m
295.0lbft ) 400N·m
295.0lbft ) 240N·m ( 177.0lbft ) 240N·m ( 177.0lbft ) M42x2
387.2lbft )
387.2lbft ) 315N·m ( 232.3lbft ) 315N·m ( 232.3lbft ) M48x2
464.7lbft )
464.7lbft ) 396N·m ( 292.1lbft ) 396N·m ( 292.1lbft ) NOTE: