CATERPILLAR 953 TRACK LOADER SERVICE REPAIR MANUAL 78Y00001-UP.pdf

CATERPILLAR 953 TRACK LOADER SERVICE REPAIR MANUAL 78Y00001-UP,Part Identification and Installation: Detailed step-by-step installation procedures for various components of the alternator, including diodes, bearings, housings, and fasteners.
Specific instructions emphasize avoiding impacts on sensitive components, ensuring cleanliness throughout the process, and proper lubrication where needed. There are also safety and operational warnings included for working with the refrigerant system and other vehicle parts.

1. 953 TRACK LOADER


78Y
00001
-
UP






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2. Disassembly and Assembly 2
General Service Information 1023
Schematic 1122
Specifications 1155
Systems Operation 1485
Testing and Adjusting 1828
Torque Specifications 2264
Troubleshooting 2315

3. RENR1252-01 26SI Series Alternator 2
SENR3334-02 Air Conditioning and Heating R-12 All Caterpillar
Machines 23
SENR4214-00 3204 VEHICULAR ENGINE FOR 943 & 953
TRACK-TYPE LOADERS 44
SENR4215-00 943 & 953 TRACK-TYPE LOADER POWER
TRAIN 361
SENR4216-00 943-953 TRACK-TYPE LOADERS VEHICLE
SYSTEMS 723
UENR3262-00 Seal Installation 952

4. Alternator - Assemble 2
Alternator - Disassemble 12

5. Shutdown SIS
Previous Screen
Product: TRACK LOADER
Model: 953 TRACK LOADER 78Y
Configuration: 953 TRACK TYPE LOADER 78Y00001-UP (MACHINE) POWERED BY 3204 ENGINE
Disassembly and Assembly
26SI Series Alternator
Media Number -RENR1252-01 Publication Date -01/10/1999 Date Updated -09/10/2001
i01167078
Alternator - Assemble
SMCS - 1405-016
Assembly Procedure
Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts.
Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are
worn or damaged, use new parts for replacement.
Note: Do not strike the diodes. The shock of such an impact can damage the diodes. Use
proper tools in order to press the diodes in the mountings.
Illustration 1 g00628072
1.Install 3 diodes (11) in heat sink (12) .

6. Illustration 2 g00628068
Note: Do not strike the bushing. Shocks from striking the housing can cause damage.
2.Press bushing (43) in housing (14) .
3.Install 3 diodes (13) in housing (14) .
Illustration 3 g00628067
4.Press collar (42) on rotor (39) .
5.Slide retainer (41) on rotor (39) .
6.Press bearing (40) on rotor (39) .

7. Illustration 4 g00628063
7.Press housing (31) on rotor (39) and bearing (40) .
8.Install 4 screws (38) in housing (31) .
Illustration 5 g00628057
Note: Do not strike the bearing. Shocks from striking the housing can cause damage.
9.Install the inner race. Press bearing (37) into the housing.

8. Illustration 6 g00628043
10.Press cap (36) in housing (14) .
Illustration 7 g00628041
11.Install the coil and support (34) in housing (14). Guide the field leads and the grommet
through the hole as the coil is installed in housing (14). Install 3 screws (33) .
Illustration 8 g00628037
12.Press the stator (32) and housing (14) together. Guide the stator leads and the grommet
through the hole as the stator is installed in housing (14) .

9. Illustration 9 g00628035
Note: Do not damage exposed stator windings or field windings. Bumping the windings or
scraping the windings may break the insulation. Broken insulation may create a short circuit
or a ground.
13.Join housing (31) and housing (14). Install 4 bolts (30) .
Illustration 10 g00627853
Note: Many of the alternator's internal components are covered with dielectric grease. If the
grease is removed, reapply the grease.

10. Illustration 11 g00627855
14.Install Insulator (29). Install the heat sink and diode assembly (12) in housing (14) .
Illustration 12 g00627840
15.Install separator (28) .
16.Install alternator output terminal (27). Install insulator (26). Install the nut and washer (25) .
17.Install diode trio (24) and install screw (23) .

11. Illustration 13 g00627832
18.Install the 3 screws and insulators (18). Connect wire (19) .
19.If the "R" terminal is used, install the following components: nut (20), lead (21), the washer
and terminal (21) .
Illustration 14 g00627820
20.Install the screw and insulator (16). Connect capacitor lead (17) .
Illustration 15 g00627810
Note: The 3 output diodes (11) are located in heat sink (12). These diodes are identical in
polarity. Diode (11) has red insulation on the wire. The 3 ground diodes (13) are located in
housing (14). These diodes are identical in polarity. Diode (13) has black insulation on the
wire.
21.Connect 6 diode leads. Connect 3 phase leads. Connect 3 stator phase leads. Install 3 nuts
(15).
Table 1

12. Alternator
Ground
Current Flow of the Output
Diodes
Current Flow of the Ground
Diodes
Negative
Lead to the Heat Sink Housing to the Lead
Red Wire Black Wire
Illustration 16 g00627808
22.Install mounting plate (10).
Illustration 17 g00627804
23.Install regulator (9) .
24.Install grounded mounting screw (8) .

13. Illustration 18 g00627796
25.Install 2 insulated screws (6). Connect the 3 leads.
Note: The regulator and the mounting plate are coated with dielectric grease. If the grease is
removed, reapply the grease.
26.Install nut (7) and connect the wire.
Illustration 19 g00627794
27.Install gasket (5) .

14. Illustration 20 g00627792
28.Position cover (4). Install 7 screws (3) .
Illustration 21 g00627790
29.Position plate (2). Install 4 screws (1) .
30.Install the fan, the pulley, the washer, and the pulley nut.
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Thu Sep 9 10:16:53 UTC+0530 2021

15. Shutdown SIS
Previous Screen
Product: TRACK LOADER
Model: 953 TRACK LOADER 78Y
Configuration: 953 TRACK TYPE LOADER 78Y00001-UP (MACHINE) POWERED BY 3204 ENGINE
Disassembly and Assembly
26SI Series Alternator
Media Number -RENR1252-01 Publication Date -01/10/1999 Date Updated -09/10/2001
i01167081
Alternator - Disassemble
SMCS - 1405-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 6V-7070 Digital Multimeter 1
B Variable Power Supply 1
Start By:
A.Remove the alternator. Refer to Disassembly and Assembly, "Alternator - Remove" for the
machine that is being serviced.
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This will help to prevent dirt from entering the internal
mechanism.
1.Remove the pulley nut, the washer, the pulley, and the fan.

16. Illustration 1 g00627790
2.Remove 4 screws (1). Remove plate (2) .
Illustration 2 g00627792
3.Remove 7 screws (3). Remove cover (4) .
Illustration 3 g00627794
4.Remove gasket (5) .

17. Illustration 4 g00627796
5.Remove 2 insulated screws (6). Remove the 3 leads.
Note: The regulator and the mounting plate are coated with dielectric grease. If the grease is
removed, reapply the grease.
6.Remove nut (7) .
Illustration 5 g00627804
7.Remove grounded mounting screw (8) .
8.Remove regulator (9) .

18. Illustration 6 g00627808
9.Remove mounting plate (10). The mounting plate may be stuck to the regulator.
Illustration 7 g00627810
Note: The 3 output diodes (11) are located in heat sink (12). These diodes are identical in
polarity. Diode (11) has red insulation on the wire. The 3 ground diodes (13) are located in
housing (14). These diodes are identical in polarity. Diode (13) has black insulation on the
wire.
10.Remove 3 nuts (15). Disconnect 3 stator phase leads. Disconnect 3 phase leads. Disconnect
6 diode leads.
Table 2
Alternator
Ground
Current Flow of the Output
Diodes
Current Flow of the Ground
Diodes
Negative
Lead to the Heat Sink Housing to the Lead
Red Wire Black Wire

19. Illustration 8 g00627820
11.Remove the screw and insulator (16). Disconnect capacitor lead (17) .
Illustration 9 g00627832
12.Remove the 3 screws and insulators (18). Disconnect wire (19) .
13.If the "R" terminal is used, remove the following components: nut (20), lead (21), the
washer and terminal (21) .

20. Illustration 10 g00627840
14.Remove screw (23) and remove diode trio (24) .
15.Remove the nut and washer (25). Remove insulator (26). Remove alternator output terminal
(27) .
16.Remove separator (28) .
Illustration 11 g00627853
Note: Many of the alternator's internal components are covered with dielectric grease. If the
grease is removed, reapply the grease.
Illustration 12 g00627855
17.Remove the heat sink and diode assembly (12) from housing (14). Insulator (29) may be
stuck to heat sink (12) .

21. Illustration 13 g00628035
Note: Do not damage exposed stator windings or field windings. Bumping the windings or
scraping the windings may break the insulation. Broken insulation may create a short circuit
or a ground.
18.Remove 4 bolts (30). Carefully separate housing (31) from housing (14) .
Illustration 14 g00628037
19.Pull apart stator (32) and housing (14). Guide the stator leads and the grommet through the
hole as the stator is removed from housing (14) .

22. Illustration 15 g00628041
20.Remove 3 screws (33). Remove the coil and support (34) from housing (14). Guide the field
leads and the grommet through the hole as the coil is removed from housing (14) .
Illustration 16 g00628043
21.Position a small screwdriver in slot (35). Pry cap (36) from housing (14) .
Illustration 17 g00628057

23. Note: Do not strike the bearing. Shocks from striking the housing can cause damage.
22.Wipe the excess grease from the bearing well. Press bearing (37) into the housing. Remove
the inner race.
Illustration 18 g00628063
23.Remove 4 screws (38) from housing (31) .
24.Lift rotor (39) and bearing (40) from housing (31) .
Illustration 19 g00628067
25.Pull bearing (40) from rotor (39) .
26.Pull retainer (41) from rotor (39) .
27.Pull collar (42) from rotor (39) .

24. Illustration 20 g00628068
Note: Do not strike the bushing. Shocks from striking the housing can cause damage.
28.Press bushing (43) from housing (14) .
Note: Do not strike the diodes. The shock of such an impact can damage the diodes. Use
proper tools in order to press or pull the diodes from the mountings. As much as 890 N (200
lb) of force may be needed to remove a diode.
29.Remove 3 diodes (13) from housing (14) .
Illustration 21 g00628072
30.Remove diode (11) from heat sink (12) .
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Thu Sep 9 10:16:41 UTC+0530 2021

25. Refrigerant Orifice Tube - Remove and Install 2
In-Line Refrigerant Dryer - Remove and Install 6
Receiver-Dryer - Remove and Install 9
Refrigerant Expansion Valve - Remove and Install 12
Refrigerant Accumulator - Remove and Install 14
Refrigerant Compressor - Remove and Install 15
General Information 17
Machine Preparation for Disassembly and Assembly 19

26. Shutdown SIS
Previous Screen
Product: TRACK LOADER
Model: 953 TRACK LOADER 78Y
Configuration: 953 TRACK TYPE LOADER 78Y00001-UP (MACHINE) POWERED BY 3204 ENGINE
Disassembly and Assembly
Air Conditioning and Heating R-12 All Caterpillar Machines
Media Number -SENR3334-02 Publication Date -01/08/2002 Date Updated -23/08/2002
i01790846
Refrigerant Orifice Tube - Remove and Install
SMCS - 7320-010
The orifice tube may be located in the refrigerant line near the evaporator inlet, or in the in-line
dryer.
If the orifice tube is located in the refrigerant line near the evaporator inlet use the procedure that
follows. If the orifice tube is located in the in-line dryer, refer to Dryer Replacement.
Removing the Orifice Tube
Refer to Safety Requirements before service work is performed on the air conditioning system.
The refrigerant must be recovered before removing the accumulator. Refer to the Service Manual,
SENR3334, "Refrigerant Recovery" section in testing and adjusting.
NOTICE
Do not attempt to remove the orifice tube with pliers. Do not twist or
rotate the orifice tube in the tube assembly.

27. Illustration 1 g00379603
Orifice tube
(1) O-Ring seals
(2) Lugs
(3) Body
(4) Drive screw
(5) Finger lock
1.Disconnect the high side line at the enlarged section of the evaporator inlet port. This will
expose the orifice tube for removal.
2.The short prongs on the 208-1375 Orifice Tool Gp must be aligned with the ribs on the
orifice tube. Insert the tool onto the tube until the tool bottoms out.
3.Turn drive screw (4) clockwise. Turn far enough to engage the lugs (2) on the orifice tube in
the finger lock (5). The finger lock (5) is part of the removal tool.
4.Hold the drive screw (4) stationary. Thread the body (3) forward until the body makes
contact with the inlet port.
5.Continue holding the drive screw stationary, and thread the body forward until the orifice
tube becomes free.

28. Illustration 2 g00381412
Removing the broken orifice tube
(3) Body
(4) Drive screw
(6) Extractor tip
6.In order to remove the orifice tube assembly, use the extractor tip (6) on 208-1375 Orifice
Tool Gp. Insert the tool into the evaporator inlet tube and thread the tool into the brass
center of the orifice tube.
7.Repeat steps 3 and 4.
8.If only the brass center of the orifice tube is removed, thread the tool into the plastic body
and repeat step 3 and 4.
Orifice Tube Installation
1.Lubricate the O-Ring on the orifice tube with the proper clean refrigerant oil.
2.Place the orifice tube into the 208-1375 Orifice Tool Gp. Insert the orifice tube straight into
the evaporator inlet tube without twisting until the tube is seated.
3.Disengage the removal tool from the orifice tube.
4.Use a new O-Ring that is lubricated with clean refrigerant oil. Reconnect the high side line
at the enlarged section of the evaporator inlet port.
5.Do a leak test. Evacuate the system and recharge the system. Refer to the Service Manual,
SENR3334, "Refrigerant Systems-Evacuate" section in testing and adjusting. Also, refer to
the Service Manual, SENR3334, "Refrigerant Systems-Charge" section in testing and
adjusting.

29. Shutdown SIS
Previous Screen
Product: TRACK LOADER
Model: 953 TRACK LOADER 78Y
Configuration: 953 TRACK TYPE LOADER 78Y00001-UP (MACHINE) POWERED BY 3204 ENGINE
Disassembly and Assembly
Air Conditioning and Heating R-12 All Caterpillar Machines
Media Number -SENR3334-02 Publication Date -01/08/2002 Date Updated -23/08/2002
i01790844
In-Line Refrigerant Dryer - Remove and Install
SMCS - 7322-010

30. Illustration 1 g00654556
Typical In-Line Dryer
(1) Inlet hose with air conditioner quick disconnects
(2) Outlet hose with air conditioner quick disconnects
In order to replace the in-line dryer and the orifice tube that is in the in-line dryer, use the
procedure that follows.
Before any service work is performed on the air conditioning system, refer to the Service Manual,
SENR3334, "Machine Preparation for Troubleshooting" section in Testing and Adjusting.
1.Stop the engine for five minutes in order to equalize the pressure in the air conditioning
system.
2.Disconnect the inlet hose (1) from the old in-line dryer.

31. 3.Connect the inlet hose that was disconnected in Step 2 to the inlet on the new in-line dryer.
4.Start the engine and operate the air conditioning system.
5.With the air conditioning system in operation, disconnect the outlet hose (2) from the old in-
line dryer.
6.Stop the engine for five minutes in order to equalize the pressure in the air conditioning
system.
7.Connect the outlet hose (2) that was disconnected in Step 5 to the outlet on the new in-line
dryer.
Note: Do not add oil to the in-line dryer.
Copyright 1993 - 2021 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Thu Sep 9 10:15:53 UTC+0530 2021

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