Service Manual

C at e r p i l l a r
Service Manual
920 & 930 Wheel Loader
S/N 41J, 41K, 62K,
71H, 73U, 75J, 79J
Volume 1 of 2

THIS IS A MANUAL PRODUCED BY JENSALES INC. WITHOUT THE AUTHORIZATION OF

CATERPILLAR OR IT’S SUCCESSORS. CATERPILLAR AND IT’S SUCCESSORS
ARE NOT RESPONSIBLE FOR THE QUALITY OR ACCURACY OF THIS MANUAL.

TRADE MARKS AND TRADE NAMES CONTAINED AND USED HEREIN ARE THOSE OF OTHERS,
AND ARE USED HERE IN A DESCRIPTIVE SENSE TO REFER TO THE PRODUCTS OF OTHERS.

CT-S-920W/L+
 VOLUME10F2

CATERPILLAR

SERVICE MANUAL

920.930
HEEL LOADER
SIN 41J. 41K. 12K.
71H. 73H. 75J. 79J
 3304 VEHICULAR ENGINES SPECIFICATIONS

INDEX
Air Inlet and Exhaust System Engine Design. . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . 2
Air Cleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . .. 43 Engine Mounting Bolts. . .......... ...... . . . .... . .... .. .. 76
Camshaft.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 37 Fuel System
Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 42 Fuel System Timing .................... " .. ... .... .... 6
Glow Plug Positioning................................ 41 Fuel System Usage Chart ............................. 6
Exhaust Manifold ..................................... 43 Service Meter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . .. . . . . 7
Exhaust Pipe and Muffler.. .. ... ... .... .... ... ......... 43 Tachometer Drive. . . . . . . . . . . •. . . . . . . . . . . . . . . . . . . . . . . . . 7
Turbocharger.. . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . .. 46-51 Fuel System - Scroll (01) . . . .. . . ..... ..... . ..... .... .. .. 31
Turbocharger Impeller Installation ................. , 44, 45 Fuel Injection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 32
Valves (01) ........................................... 40 Fuel Injection Pump Housing. . . . . . . . . . . . . . . . . . . . . . . . .. 31
Valves (PC) ........................................ 38,39 Fuel Transfer Pump. . . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . .. 35
Valve Cover .......................................... 42 Governor ........................................... " 34
Valve Rocker Ar'ms and Lifters ............ , .. .. . .. ..... 37 Governor Housing ..................... , ... " . . .. .. ... 33
Injection Nozzle ...................................... 33
Basic Engine Components Fuel System - Scroll (PC) .................... , ...... '" .. 27
Bearing Surface (Journal) Fuel Bypass Valve .................................... 30
Connecting Rods. . . .. ................ .. .... . .. ..... 69 Fuel Injection Equipment. . ...... . . .. ... . ..... .... ..... 27
Main Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 68
Fuel Transfer Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 30.
Connecting Rod ... " .. .... .. .. .... . . . . .. .. .. .. .. . .... 66 Governor (Earlier) .......................... ............ 28
Crankshaft ........................................... 67 Governor (Later) . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 29
Crankshaft HUb. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 70 Fuel System - Scroll (PC & 01) ......... ........ .... ..... 36
Cylinder Block Timing Gears .............. , . . . ... . . .. .. . . . . . . . . . . .... 36
Counterbored Block .......................... 60 Fuel System - Sleeve Metering (01) ............... :..... 18
Spacer Plate Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 61 Fuel Injection Equipment ........................... ",18-2(>:;
Cylinder Liner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 62 Fuel Ratio Control .................................... ·.4.T:
Cylinder Liner Projection Fuel Transfer Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. Zl~'
Counterbored Block ................................ 62
Governor Control (04E) . . ... .. . . .... .......• '1=.
Spacer Plate Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 63
Governor Control (120G & 130G) . . . . . .. \ "
Fan Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 71 Governor Control (225) .........' .... '. . I '.
Flexible Drive Coupling ................ :........... 76, 77 Governor Control (518) ... -" ..... ' """
Checking and Adjusting Alignment of the Injection Nozzle ................... ,~-:-: . . . .. .~'
Flexible Drive Coupling ........................... 78 Fuel System"':' Sleeve Metering (PC);"....... .. •... ."
Flywheel ............................................. 73
Fuel Injection Equipment .... c.>.~::j,.:.'.: c·:':.·.·· . :;J~:t
Flywheel Housing ...................... , ..... ... . . . . .. 74 Fuel Ratio Control ................ :.... . ""::;~
Flywheel Housing Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 75 Fuel Transfer Pump ....... '.' ........... .
Flywheel Housing Tightening.. .. ........ .. .. . . ... . . ... 72 Governor Control (920 & 930) .......... .
Flywheel Ring Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 72 Governor Control (950) ........ '.' .... ".'
Main Bearing and Connecting Rod Bearings ........... 70 Governor Control (951) .............. iF: .. : .... .
Pistons and Rings
Keystone .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 64
Governor Control (955L) ........... ~:r .. ,.. ...•.
Fuel System - Sleeve Metering (PC &.01) .....•
Straight Side ....................................... 65 Timing Gears...................... : ......... .
Water Separator ............•.........•...
Cooling System
Coolant Flow Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 59 Gauges
Fan Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 71 Converter Oil Temperature Indicator... . . . . .. 97
Radiator... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 58 Fuel Pressure Indicator ......................... ;...... 96
V-Belt Tension Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 57 Oil Pressure Indicator ........................... ~ .... . 97
Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 57 Water Temperature Indicator ......................... . 96
Water Temperature Regulator ......................... 59 General Tightening 'T0rques ................... .' .... :.: •. " 4
Electrical System Lubrication Systerr.
Alternators ........................................ 79-82 Engine Oil Pressure. . . . . . . . .. . . .... .... . . .... . . .. .. . .. 55
Alternator Regulator .................................. 83 Oil Breather Cap ........................ " ' : , 56
Generator Regulators. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 85-87 Oil Filter ....................................... :.'A. 55, 56
Generators ........................................ 84, 85 Oil Pump ........ " . . . . . . ... ... . . . . . . . . .. .. . ... . ... 52-54
Starter Magnetic Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 92 Oil Pressure Switch ................... : . . . . . . . . . . . . . .. 97
Starter Motors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 88-92
Starter Solenoids .................................. 93-95 Torque for Flared and O-Ring Fittings. . . . . .. . . . . . . .. .. . . 5

3
 3304 VEHICULAR ENGINES SPECIFICATIONS

CAMSHAFT

NOTE: Put a layer of graphite grease on lobes of camshaft when

installing.
(1) Width of groove in camshaft for thrust washer
(new) ...................... 190 ± .002 in. (4.83 ± 0.05 mm)
Thickness of thrust washer
(new) . . . . . . . . . . . . . . . . . . . .. .183 ± .001 in. (4.65 ± 0.03 mm)
End play of the camshaft
(new) ......................007 ± .003 in. (0.18 ± 0.08 mm)
Maximum permissible end play (worn). . . . . .. .025 in. (0.64 mm)
(2) Diameter of camshaft bearing surface Uournal)
(new) ............... 2.3110 ± .0005 in. (58.699 ± 0.013 mm)
(3) Bore in bearing for camshaft
(new) ............... 2.3150 ± .0024 in. (58.801 ± 0.061 mm)
Clearance between bearing and bearing surface
Uournal) (new) ............. .002 to .006 in. (0.05 to 0.15 mm)
#'

Maximum permissible clearance between bearing and bearing

surface Uournal) (worn) ....................008 in. (0.20 mm)
NOTE: Make reference to CYLINDER BLOCK for installation dimen- 5
sions.
(5) Height of camshaft lobes.
To find lobe lift, use the procedure that follows:
A. Measure camshaft lobe height (5).
B. Measure base circle (6).
C. Subtract base circle (STEP B) from lobe height (STEP A). The
difference is actual lobe lift (4).
D. Specified camshaft lobe lift (4) is . .. . .. .3300 in. (8.382 mm)
Maximum permissible difference between actual lobe lift (STEP C)
and specified lobe lift (STEP D) is ...............010 in. (0.25 mm) 74239- TXT ~----------6------~----~~'

VALVE ROCKER ARMS AND LIFTERS

(1) Bore in bearing for shaft
(new) ................. 7263 ± .0005 in. (18.448 ± 0.013 mm)
Diameter of shaft
(new) ................ .7245 ± .0005 in. (18.402 ± 0.013 mm)
Maximum permissible clearance between bearing and shaft
(worn) ................................ .008 in. (0.20 mm)
(2) Torque for locknut on valve adjustment
screw. . . . . . . . . . . . . . . . . . . . . . . . .. 21 ± 5 lb. ft. (26 ± 7 N·m)
(3) Clearance for valves:
Intake valves ............................015 in. (0.38 mm)
A15656Xl
Exhaust valves .. . . . . . . . . . . . . . . . . . . . . . .. .025 in. (0.64 mm)
(4) Diameter of valve lifter
(new) ............... 1.3105 ± .0005 in. (33;287 ± O:013mm)
Bore in block for valve lifter
) (new) ............... 1.3145 ± .0010 in. (33.388 ± 0.025 mm)
Maximum permissible clearance between lifter and bore
for valve lifter (worn) . . . . . . . . . . . . . . . . . . . .. .012 in. (0.3QlDffi)

37
3304 VEHICULAR ENGINE
SYSTEMS OPERATION
Air Inlet and Exhaust System. .. .. . ... .. .. ..... .. . .. .. . .. 31
Air Inlet and Exhaust System. . . . . . . . . . . . .. . . . .. 31 and 32
Timing Gears ..................... " .,. ........ ... .... 33
Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 32
Valves and Valve Mechanism .......................... 33
Basic Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 40
Crankshaft ........................................... 40
Cylinder Block and Liners. . . . . . . . . . . . . . . .. . . . . . . . . . . .. 40
Pistons, Rings, and Connecting Rods.. .......... .. .. .. 40
Cooling System".. .. .. .. .. .. .... ..... . .......... ..... .. 38
Coolant for Air Compressor ......................... ,. 39
Electrical System ....................................... 41
Charging System Components.. .... .. . .... .. . .... . ... 41
Electrical System Schematic. . . . . . . . . . . . .... . . . . . . . . . .. 45
Other Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 44
Starting System Components. . . . . . . . . . . . . . . . . . . . . . . . .. 43
Fuel System (Scroll-Ol) ................................. 27
Fuel Injection Pump.. .. .. .. . . .. . .. .... ....... .. ... .. .. 27
Fuel System Timing .............................. " . .. 27
Governor (Hydra-Mechanical) ......................... 28
Injection Nozzles ..................................... 30
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 27
Fuel System (Scroll-PC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 24
Fuel Injection Pump.. .. .. . ...... .. .. ..... . ... ... .. .... 24
Fuel Injection Valve ........................... , . . . . . .. 26
Fuel System Timing. .. ..... .... .. .......... ... ..... ... 24
Glow Plugs ............... " .. ...... ... ... . . .. .. .. . ... 26
Governor Operation ............ '. . . . . . . . . . . . . . . . . . . . . .. 25
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 24
Fuel Systyem (Sleeve Metering) ............... ,......... 6
INDEX
Adjustments To The Sleeve Metering Fuel System...... 18
Fuel Flow After Engine Stops Running. ..... .. .. ....... 16
Fuel Flow Using The Priming Pump and Bleed Valve. . .. 15
Fuel Flow With Engine Running ....................... 7
System With Constant Bleed Valve. . . . . . . . . . . . . . .. . . . 9
System With Siphon Break. . . .... .... . . . .... ........ 7
System With Siphon Break and
Constant Bleed Valve. . . .... . .... . .. . .... .. . ... ... 13
System Without Siphon Break or
Constant Bleed Valve ............................. 11
Fuel Injection Pump Operation........................ 17
Fuel Injection Valve-PC. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 23
Fuel Injection Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fuel Priming Pump. . .. . . . ... ... . . .. . . .. . .. .... . ...... 15
Fuel Ratio Control .................. ,................. 22
Fuel System Operation .................... '" .... '" .. 18
Fuel System Timing... . . ......... . ... ... . ... .. . . ... .. . 6
Fuel Transfer Pump ............... ,-' .. '" ........... 15
Glow Plugs-PC................... ................ .23
Governor ........................ , ...... , . . . . . . . . . . . .. 20 ~
Injection Nozzle-Ol .................................. 23
Introduction ..... , . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Non-Adjustable Oashpot Governor. . . . . . . . . . . . . . . . . . . .. 21
Siphon Break.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15
Water Separator ...................................... 6
General Information. . . . . . .. .. .. . . . . .. .. .. . . ... .. . . .... . . 5
Engine Design .................... " .. . . ....... . ... .. . 5
Fuel System Usage Chart ............................. 5
Lubrication System ..................................... 34
Oil Flow In The Engine. . . . .. .... ..... . ... ... .. . . ... ... 36
Oil Flow Through The Oil Filter and Oil Cooler. . . . . . . .. 36
3
3304 VEHICULAR ENGINE
TESTING AND ADJUSTING
Air Inlet and Exhaust System...........................
Checking Inlet Manifold Pressure At Torque
Converter Stall Speed. .............................
Compression.. ..... ... ..............................
Crankcase (Crankshaft Compartment) Pressure.......
Cylinder Head. ... ..... ..............................
Glow Plug and Precombustion Chamber Removal
and Installation ....................................
Measurement of Exhaust Temperatures...............
Measurement of Pressure in Inlet Manifold............
Procedure for Measuring Camshaft Lobes. . . . . .. . . .. ..
Restriction of Air Inlet and Exhaust.......... .........
Turbocharger. ..... ..................................
Valve Clearance .....................................
Basic Block.. .... ................................... ... 122
Connecting Rod and Main Bearings................... 122
Connecting Rods and Pistons........................ 122
Cylinder Block. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 124
Cylinder Liner Projection ......................... 122,123
Counterbored Block ............................... 122
Spacer Plate Block...... ....... .................... 123
Flywheel and Flywheel Housing.................. 124-127
Oil Pump Installation. ... ... .... ........ .............. 127
Piston Ring Groove Gauge. .. .......... .............. 122
Cooling System ........................................
Checking Coolant Temperature .......................
Checking Fan Speed .................................
Checking Radiator Air Flow ..........................
Filler Cap and Pressure Relief Valve ..................
Gauge for Water Temperature.................... ....
Pressure Cap ........................................
Testing Radiator and Cooling System for Leaks .......
Testing the Cooling System ..........................
V-Belt Tension Chart. . . . . . . . . . .. . .. . . . . . . . . .. . . . . . . ..
Visual Inspection of the Cooling System..............
Water Temperature Regulators .......................
Electrical System ......................................
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Charging System ....................................
Starting System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
Flexible Drive Coupling.. ...... ................ ........ 128
Checking Flexible'Drive Coupling Alignment.......... 128
Fuel System .......................................... " 60
Adjustment and Cleaning of 7N449 Fuel Injection
Nozzles............................................ 70
Checking Engine Cylinders Separately... .. ............ 60
Checking Engine Timing With 6V3100 Diesel
Engine Timing Indicator Group... ............ .. . .... 74
Engine Speed Measurement............ . . . . . . . .. . . . . .. 73
Finding Top Center Compression Position for
No.1 Piston ........................................ 75
NOTE: This book has been completely changed from the former issue.
SPECIFICATIONS
·NOTE: For Specifications with illustrations, make reference to SPECIFICA-
TIONS for 3304 VEHICULAR ENGINE, Form No. SENR7590. If the
Specifications in Form SENR7590 are not the same as in the Systems
Openltion and the Testing and Adjusting, look at the printing date on the
back 'cover of each book. Use the Specifications given in the book with the
latest date.
4
INDEX
107 Flow Checking Fuel Injection Pump Timing
(PC Engines Only) . . .. . . . . . . . . . . . .. . . .. ... . . . .. .. . .. 73
/
108 Fuel Injection Lines. . . . . . . . . . . . . . . . .. . . . . . . . . . . .. .. . .. 72
109 Fuel System Inspection ............................... 60
109 Start-Up Procedure. . . . . . .. . . . . . . . . .. . . .. ... . . . . . . . ... 73
109 Test Sequence - Precombustion Chamber (PC)
Fuel Nozzle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 62
110 Testing 7N449 Fuel Injection Nozzles. . . . . . . . . . . . . . . . .. 63
109 Testing Capsule-Type Fuel Injection Nozzles. . . . . .. . . .. 60
107 Troubleshooting of 7N449 Fuel Injection Nozzles. . . . . .. 69
112 Fuel System (Scroll-DI) ................................. 99
107 Checking the Fuel Injection Valves ..................... 99
108 Checking the Plunger and Lifter Washer of an
111 Injection Pump ..................................... 99
Fuel Injection Pump Timing Dimension Setting:
Off Engine. .. ..... ................................. 103
Fuel Injection Timing Check (Timing Pin Method) ..... 102
Fuel Rack Setting. .... . .............................. 104
Fuel System Adjustments.. . . . . . . . . . .. . . .. . . . . . . . . .. .. 101
Injection Pump (Install) .............................. 100
Injection Pump (Remove) ............................. 99
Fuel System (Scroll-PC) . . . . . . . . . . . . . . . . .. . . .. . . . .. . . . . .. 91
Checking the Fuel Injection Valves. . .. . . . . . . .. . . . . . .. .. 91
Checking the Plunger and Lifter Washer of an
Injection Pump...... ............................... 91
Fuel Injection Service. . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . .. 91
115 Accessory Drive Shaft Timing ....................... 95
115 Checking With 8S4620 Gauge ....................... 93
117 Checking With 8S7167 or 5P4158 Gauge ............. 94
117 Fuel Injection Pump Timing Dimension Setting:
119 Off Engine. . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . .. 94
119 Fuel Rack Setting. . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . .. 96
118 Injection Pump ..................................... 91
118 Injection Pump Installation... .............. . ..... ... 91
115 Injection Valve (Capsule-Type Nozzle) ............... 91
121 Governor Adjustments ................................ 97
115 Fuel Ratio Control Setting. . . . . . . . . . . . . . . . . . . . . . . . . .. 98
120 Fuel System (Sleeve Metering). . . . . . . . . . . . . . . . . . . . . . . . . .. 79
Fuel Injection Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 79
129
Fuel Pump Calibration ................................ 86
129
Fuel Ratio Control Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . .. 85
129
Fuel System Adj ustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 80
132
Fuel System Setting. . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. 83
Governor Adjustments........ ......... ... ............ 82
Lubrication System .................................... 113
Oil Pressure is High .................................. 114
Oil Pressure is Low .................................. 113
Too Much Bearing Wear... ............... .. . ........ 114
Too Much Oil Consumption. ...... ... . ....... ...... .. 113
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 46-59
SCROLL FUEL SYSTEM-PC
FUEL INJECTION PUMP
1. Fuel manifold. 2. Inlet port. 3. Check valve. 4. Gear seg-
ment. 5. Pump plunger. 6. Spring. 7. Fuel rack. 8.
Lifter. 9. Camshaft.
GOVERNOR OPERATION
The accelerator pedal is connected to the control
lever on the engine governor. The governor controls
the amount of fuel needed to keep the desired engine
rpm.
The governor has governor weights (11) driven by
the engine through drive gear (7). When the engine is
running, the rotation of weights (11) makes a force.
The difference in the force of weights (11) and spring
( 4) controls the movement of valve ( 12). Valve (12)
sends engine oil to either side of piston (13). Piston
( 13) will move the rack to increase or decrease fuel to
the engine.
When engine load increases, engine rpm de-
creases. The speed of rotation of weights (11) be-
comes less. Weights (11) move toward each other
and make less force. Governor spring (4) can move
valve (12) forward. As valve (12) moves forward, oil
passage (6) around valve ( 12) opens to pressure oil.
Oil is sent through passage (6) and fills the chamber
behind piston (13). The pressure oil pushes piston
( 13) and the rack forward. This increases the amount
of fuel to the engine. Engine rpm increases until the
force from the rotation of weights (11) makes a
balance with the force of governor spring (4).
When engine load decreases, engine rpm in-
creases. The speed of rotation of weights (11) in-
creases. Weights (11) move apart and make more
SYSTEMS OPERATION
HYDRAULIC GOVERNOR
(Later Governor Shown)
1. Collar. 2. Lever assembly. 3. Seat. 4. Governor spring.
5. Thrust bearing. 6. Oil passage. 7. Drive gear (weight
assembly). 8. Cylinder. 9. Bolt. 10. Spring seat. 11.
Weight. 12. Valve. 13. Piston. 14. Sleeve. 15. Oil
passage. The governor valve is shown in the position when the
force of the weights and the force of the spring are balanced.
force against governor spring (4). Valve (12) moves
backwards and sends the oil behind piston (13)
through a drain passage, opened at the rear of piston
(13). The pressure oil in the chamber between sleeve
( 14) and piston ( 13) pushes piston (13) and the rack
backwards. This decreases the amount of fuel to the
engine. Engine rpm decreases until the force from
the rotation of weights (11) makes a balance with the
force of governor spring (4).
On earlier engines, when the engine is started, the
speed limiter plunger restricts the movement of the
governor control linkage. When operating oil pres-
sure is reached, the plunger in the speed limiter
retracts and the governor control can be moved to the
HIGH IDLE position.
When engine rpm is at LOW IDLE, a spring-
loaded plunger in lever assembly (2) comes in con-
tact with a shoulder on the adjustment screw for low
idle. To stop the engine, pull back on the governor
control. This will let the spring-loaded plunger move
over the shoulder on the low idle adjusting screw and
move the fuel rack to the fuel OFF position. With no
fuel to the engine cylinders, the engine will stop.
Oil from the engine lubrication system gives lubri-
cation to the governor weight bearing. The other
parts of the governor get lubrication from "splash-
lubrication" (oil thrown by other parts). Oil from the
governor runs down into the housing for the fuel
injection pumps.
25
ENGINE DISASSEMBLY AND ASSEMBLY

A58737Xl

8
ENGINE DISASSEMBLY AND ASSEMBLY

ALTERNATOR
REMOVE ALTERNATOR 1405-11

1. Remove panel assembly (1) from the left side of

the machine.
2. Disconnect electric wires (2) and (3) from the
alternator.
3. Loosen bolts (5) and (6) to remove vee belts (4)
from the alternator pulley.

4. Remove bolts (5) and (6) and remove the alter-

nator.

INSTALL ALTERNATOR 1405-11

1. If a new pulley has been installed on alternator

(1), tighten the nut that holds it to a torque of75 to
90 lb.ft. (100 to 120 N·m).
2. Put alternator (I )in position on the engine and
install the bolts to hold it hand tight.
3. Put vee belts in position on the alternator pulley.
4. Use a belt tension gauge such as Borroughs Tool
Company Part No. BT-33-72-4-15 or an
equivalent and make an adjustment of vee belts
(3). Measure the belt nearest the radiator.
Tighten new belts until the gauge indication is
120 ± 5. Operate the engine at high idle for a
minimum of 30 minutes after Step 5. Make
another adjustment of the belt tension. The
correct gauge indication for used belts is 90 ± 10.
Tighten the bolts that hold the alternator in
position.
5. Connect electric wires (2) and (4) to the
alternator. Tighten the ground terminal nuts to a
torque of 25 to 30 lb.in. (2.8 to 3.4 N·m).
Tighten the positive terminal nuts to a torque of
225 to 250 lb.in. (25.4 to 28.3 N·m).
6. Install the panel assembly on the left side of the
machine.

9
POWER TRAIN DISASSEMBLY AND ASSEMBLY

TORQUE CONVERTER CLEARANCE CHECKS

TORQUE CONVERTER CLEARANCE
CHECKS
Tools Needed A 8
589079 Nut 4
8S2328 Dial Test Indicator Group

-'W: There must be a minimum radial (running) clear-

ance between the inside diameter of the rotating
housing and turbine.

2. Check the clearance between the inside diameter

of the rotating housing and the turbine as follows:

a) Install tooling (A) in four positions in the

'-rotating housing as shown.

b) Put the rotating housing on a smooth flat

surface. Install turbine (1) in the housing.

c) Put tooling (B) in the position shown.

d)DRush turbine (1) toward tooling (B) until it

" makes contact with the inside diameter of the
rotating housing. Adjust the diaL indicator
until it is on zero. Slide the turbine 1800 away
from tooling (B) until it makes contact with
the other side of the rotating housing. Make a
record of the dimension measured.

e) Make this check at several locations around

the housing. Make a record of each of the
dimensions measured. The largest dimension
measured is used for the clearance between
the two parts. The total clearance measured
across the diameters must be .020 to .040 in.
(0.51 to 1.02 mm) with a maximum permis-
sible clearance of .045 in. 0.14 mm). The .
radial (running) clearance is half of the di-
A538S3Xt
mensions measured.

80
VEHICLE SYSTEMS DISASSEMBLY AND ASSEMBLY

LOADER MAIN FRAMES

9. Put plate (4) in position on the machine and )
install two of the bolts that hold it 1800 apart.
Tighten the bolts to a torque of 15 lb.ft. (20
N·m).

10. Measure the distance between plate (4) and the

frame (360 0 around the plate) with a feeler gauge.
Make a note of the minimum measurement.

11. Remove plate (4) and install shims (5) that have a
thickness of the minimum measurement taken in
Step 10 minus .010 in. (.25 mm). Install the plate
and tighten the seven bolts.

12. Connect oil lines (6) to the liftkickout and bucket·

positioner slave cylinders.

13. Connect air line (7) to the horn valve.

14. Connect hose assemblies (8), (9), (10) and (11)

to their correct location on the front frame. )

108