Caterpillar cat d550 b articulated dump truck (prefix 5nd) service repair manual (5nd00001 and up)

Service Repair Manual
Models
D550B ARTICULATED
DUMP TRUCK

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Product: ARTICULATED TRUCK
Model: D550B ARTICULATED TRUCK 5ND
Configuration: D550B ARTICULATED DUMP TRUCK 5ND00001-UP (MACHINE) POWERED BY 3408 ENGINE
Disassembly and Assembly
3408 & 3408B INDUSTRIAL AND MARINE ENGINES
Media Number -SENR7382-02 Publication Date -01/12/1985 Date Updated -05/01/2016
SENR73820035
Camshaft
SMCS - 1210-011; 1210-012
Remove Camshaft
START BY:
a. remove timing gear cover
b. remove valve lifters
1/5D550B ARTICULATED DUMP TRUCK 5ND00001-UP (MACHINE) POWERED B...
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1. Remove turbocharger drain tube (1) from the flywheel housing. Remove two studs (2) with tool
(C).
2. Turn the engine with tool (B) until the bolts in camshaft rear gear (3) are visible. Remove the
four bolts.
NOTICE
Tooling (A) must be used to prevent the loss of timing of the rear
balance weight gear and to keep the rear camshaft gear in place when
the camshaft is removed.
3. Turn the engine until the "V" marks on the front timing gears are in alignment. Install tooling
(A) through the flywheel housing and into gear (3).
4. Tighten tooling (A) evenly to free the rear camshaft gear from the camshaft.
5. Remove two bolts (4) and plate (5).

NOTICE
Be careful not to cause damage to the camshaft bearings as the
camshaft is removed.
6. Remove the camshaft and gear from the cylinder block.
7. If necessary, remove the camshaft gear with tool (D). Remove the dowel on the taper end of the
camshaft with tooling (E).
Install Camshaft
NOTE: Make sure the key for gear (1) is in position on camshaft (2) before gear (1) in installed.
1. Heat gear (1) to a maximum temperature of 600°F (315°C). Install gear (1) on camshaft (2).
2. Install pin (3) until it is extended 8.76 ± 0.25 mm (.345 ± .010 in.) from the end of the camshaft.

3. Put clean engine oil on the lobes and journals of camshaft (2) and on the camshaft bearings in
the cylinder block. Install the camshaft with the "V" mark on gear (1) in alignment with the "V"
mark on gear (5).
4. Install plate (4) and the bolts.
5. Loosen bolts (6) of tooling (A) to align pin (3) and gear (7). Install one bolt in the gear to hold it
in position. Remove tooling (A).
6. Turn the engine with tool (B) until all of bolts (9) are installed. Tighten bolts (9) evenly to a
torque of 25 ± 4 N·m (20 ± 3 lb.ft.). Tighten the bolts again to a torque of 25 ± 4 N·m (18 ± 3
lb.ft.).
7. Check the camshaft end play with tool (D). End play must be 0.10 to 0.25 mm (.004 to .010 in.).
8. Install two studs (8) with tool (C) until they are extended 25.4 ± 1.5 mm (1.00 ± .06 in.) from
the surface of the flywheel housing.
9. Install the oil drain tube for the turbocharger.
END BY:
a. install valve lifters
b. install timing gear cover

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SENR73820036
Camshaft Bearings
SMCS - 1211-011; 1211-012
Remove Camshaft Bearings
START BY:
a. remove camshaft
b. remove flywheel housing
c. remove pistons and connecting rods
1. Remove the rear camshaft bearing with tooling (A).

2. Remove the remainder of the camshaft bearings with tooling (A). Start at the rear of the
cylinder block, and work toward the front.
Install Camshaft Bearings
1. Install the rear camshaft bearing and the three inside camshaft bearings with tooling (A). Install
the bearings from the rear of the block bore. Install the bearings until the front edge of the bearing
is even with the front surface (1) of the block bore.
NOTICE
Make sure the bearing is in alignment with the cylinder block bore
before the bearings are installed. Install the bearing with the oil holes
on the horizontal centerline. Make sure the bearing joint position is
above the oil holes.

2. Install the front camshaft bearing with tooling (A) until it is 33.8 ± 0.10 mm (1.331 ± .004 in.)
from the machined surface on the front of the cylinder block as shown.
END BY:
a. install pistons and connecting rods
b. install camshaft
c. install flywheel housing
Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
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Wed Feb 5 18:17:12 UTC+0800 2020

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SENR73820037
Timing Gears
SMCS - 1206-011; 1206-012
Remove Timing Gears
START BY:
a. remove timing gear cover
b. remove camshaft
1. Remove four bolts (1) and plate (2). Remove front balance gear (3).
2. Remove the bearing from gear (3) with tooling (B) and a press.

NOTE: On later engines, with the crankshaft counterbalance weights located inside the cylinder
block, there is no clearance between gear (4) and the block for tooling (A). The crankshaft must be
removed before gear (4) can be removed.
3. On earlier engines only, remove crankshaft gear (4) with tooling (A).
Install Timing Gears
NOTE: The joint in the bearing must be on a centerline ± 20° with the weight side of the balance
gear.
1. Install the bearing in front balance gear (1) with tooling (A) as shown.
2. Heat crankshaft gear (2) to a maximum temperature of 204°C (400°F). Install gear (2) with
notch (4) in alignment with the pin on the crankshaft.

3. Install gear (1). Make sure the "V" mark on gear (1) is in alignment with the "V" mark on gear
(2).
4. Install plate (3) with the groove toward gear (1). Install the four bolts that hold plate (3).
END BY:
a. install camshaft
b. install timing gear cover
Wed Feb 5 18:18:08 UTC+0800 2020

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SENR73820038
Flywheel
SMCS - 1156-011; 1156-012
Remove Flywheel
1. Fasten tooling (A) and a hoist to flywheel (2).
2. Remove bolts (1). Remove the flywheel. Weight of the flywheel is 50 kg (110 lb.).
Install Flywheel

1. Put the flywheel in position on the crankshaft with tooling (A). Make sure dowel (1) is in
alignment with hole (2) in the flywheel.
NOTE: Two 5/8"-18 NF guide bolts, 6 in. (152 mm) long, can be used to put the flywheel in
alignment with the crankshaft.
2. Install the bolts that hold the flywheel to the crankshaft. Tighten bolts to a torque of 270 ± 27
N·m (200 ± 20 lb.ft.).
3. Check the run out (eccentricity) of the flywheel. See Flywheel And Flywheel Housing in
Specifications.
Wed Feb 5 18:19:04 UTC+0800 2020

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SENR73820039
Flywheel Housing
SMCS - 1157-011; 1157-012
Remove Flywheel Housing
START BY:
a. remove oil pan
b. remove flywheel
c. remove rear seal
1. Remove bolts (2). Move bracket (1) for the fuel filter to one side.

2. Remove turbocharger drain line (6).
3. Remove four bolts (7), two bolts (4) (found on the rear of the flywheel housing) and four nuts
(5). Remove bracket (3).
4. Fasten tooling (A) and a hoist to the flywheel housing.
5. Remove bolts (10) and bolts (11).
6. Remove bolts (9). Remove plate (8). Remove one bolt found behind plate (8).
7. Remove the flywheel housing. Weight of the housing is 36.3 kg (80 lb.).
Install Flywheel Housing
1. Install a new gasket on the cylinder block.

2. Put the flywheel housing in position on the rear of the engine with tooling (A).
NOTE: Put 9S3263 Thread Lock on the bolts that hold the flywheel housing to the cylinder block.
3. Install the bolt in location (1). Install the remainder of the bolts that hold the flywheel housing
to the cylinder block. Cut the flywheel housing gasket even with the bottom of the cylinder block.
4. Install plate (5). Put bracket (3) in position on the flywheel housing. Install four bolts (4) and
two bolts (2).
5. Put 5P3931 Anti-Seize Compound on studs (6). Install the nuts on studs (6), and tighten them to
a torque of 25 ± 4 N·m (20 ± 3 lb.ft.).
6. Install turbocharger drain line (8).
NOTE: Put 5P3931 Anti-Seize Compound on bolts (7) which hold line (8) to the turbocharger.
7. Install the bracket for the fuel filter on the side of the flywheel housing.
END BY:
a. install rear seal
b. install flywheel
c. install oil pan
Wed Feb 5 18:19:59 UTC+0800 2020

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SENR73820040
Crankshaft Rear Seal And Wear Sleeve
SMCS - 1161-011; 1161-012
Remove Crankshaft Rear Seal And Wear Sleeve
START BY:
a. remove flywheel
1. Put holes (2) evenly around seal (1) with a sharp punch as shown. Remove seal (1) with tool (A).
NOTE: When a replacement of the earlier type rear seal is made, a replacement of the wear sleeve
is to be made also. Later type seals and wear sleeves come as a set and must be replaced as a set.

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2. Install tool (C) in the rear seal bore.
3. Install tool (B) between tool (C) and the wear sleeve. Turn tool (B) until the edge of the tool
makes a flat place (crease) in the wear sleeve. Do this in two or more places until the wear sleeve is
loose.
4. Remove tool (C) and the wear sleeve by hand.
Install Crankshaft Rear Seal And Wear Sleeve

1. Install earlier crankshaft rear seals and wear sleeves with tooling (A) or later crankshaft rear seals
and wear sleeves with tooling (B) as follows:
a. Install locator (2) and the bolts on the rear of the crankshaft.

b. Clean and prepare the wear sleeve inside diameter and crankshaft outside diameter with 6V1541
Quick Cure Primer. Apply 9S3265 Retaining Compound to the crankshaft outside diameter and
wear sleeve inside diameter before the wear sleeve is installed on the crankshaft.
c. For earlier type seals, put clean engine oil on the seal lip of the seal and on the outside diameter of
the wear sleeve. Install the seal on wear sleeve. Make sure the lip of the seal is toward the inside of
the engine and the outside diameter bevel of the wear sleeve is toward the outside of the engine.
NOTE: Later type seals and wear sleeves cannot be used again after the seals and wear sleeves are
separated.
d. Put the wear sleeve and seal in position on locator (2) as a unit.
NOTICE
On later type seals, make sure the seal is installed with the part
number and the arrows showing crankshaft rotation toward the
outside.
NOTICE
On later type seals, the front and rear seals and wear sleeves have
different spiral grooves in the seal. Because of this type of design, the
front seal group for an engine is different from the rear seal group. If a
seal group is installed on the wrong end of the engine, oil can actually
be taken out of the engine instead of moving the oil back into the
engine.
e. Put the correct installer (4) in position on locator (2).
f. Put clean engine oil on the face of nut (3) and its contact area on installer (4). Install nut (3) on
locator (2).
g. Tighten nut (3) until the inside surface of installer (4) comes in contact with locator (2).
NOTICE
On some early engines with lip-type seals, if the seal goes against the
bottom of the bore, a resistance (increase in torque) will be felt on nut
(3). Do not tighten nut (3) too tight or the case (body) of the seal will be
damaged.
h. Remove tooling (A) or (B).

Caterpillar cat d550 b articulated dump truck (prefix 5nd) service repair manual (5nd00001 and up)

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Caterpillar cat d550 b articulated dump truck (prefix 5nd) service repair manual (5nd00001 and up)