ree Pb 10000 11000 11000 MK Il 685T ENGINES service manual Form 70645121 English 4 WARNING STUDY THE OPERATION AND MAINTENANCE INSTRUCTION MANUAL THROUGH BEFORE STARTING, OPERATING, MAINTAINING, FUELING OR SERVICING THIS MACHINE. "The Operation snd Maintenance Instruction Manual provides the instructions and. procedures for starting, operating, maintaining, fueling, shutdown and. servicing that ate necessary” for properly ‘conducting the procedures fer overhaul of the related components ‘outlined in this Service Manual, "This symbol is your safety alert sign. It MEANS ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED. Read and heed all safety instructions carrying the signal words WARNING end DANGER. Machine mounted safety signs have been color coded yellow with black borders and lettering for warning and red with white borders and lettering for danger point,OoSAFETY RULES ‘Sy de Operation nd Mina ogction Manta lee sg, oe ng, fling or sng At ed ei tty ne Maghnemonniad sayin. ave, ben cor coda ed ith white border aol lettering for dabger potas. Do ng lw snauhorize poonal osc of man ‘that isnot suthoied. Follow the Mialeace a Service cei, Study the Opnton and Mantenene lst ‘Sona Bete, owing, ag lng Always wou sty sos with side sels [Re top sch torscoling even tbo ‘upped kes cat ean etch gh movi pats, Weat Boe pont, md foe econ safely awe o fgaon resto vert ep tom Comul sour enplver for sete set epoca Do not wt control or has a ands he linking ‘0 o off mschy Hess conto are ovale ed Jo ‘oc prone tol upport Cotrlsmay azo be mare ‘nay moved causing utter mochne or supe ooo a mci Kar wo nda oe al oa bande al ie os {or set uns theyre qualified to aperte the marie ‘doe sting ese ep gatas commit, pig int, ab ‘mow accusation to minimise the ange of slipping or ‘umbing Clean mado raw fom shows blows sea Ineo mount or operate he machine Never atamot to operate the machine oF ts tol rom Sythe’ postion than astm the operator St Keep operators compartment let of loo object: tyra em i equied forszce or umtenane, Jo ot rahe or fone llchments pm ey postion see {hn ‘tented the pert seat Before sarng tonhibe'ov owing ncachment ‘orton mal sie tot Bei ted horn ed el xo ea ch Always boc wit extol suppor any Heat pst on Imachine tie eae wok anor Sheed hag, re racine per OSHA recuemnts Neer alow tavone te le unde of beat nblocked raed eaupmen ‘Raid eeting or wakg under razed Boeke amen Us You re euro Yours. ‘an exposed portion beiween useontvled oe ungoaded ssinorpoins of machine without fist providing sue nt New tis wel fi machi hth ‘iene natn a ‘Boot ew ine ‘Nien ering oc alntenne ue a a ha nor tt meets OSHA reuiremons ofeach thes {es Sek hd orm ne nora ‘Tserice ormaltenaee caret oF Sono ft atoms né down 0 mul. (Giedacording toned onal gamete crac trie and TAG consl scoring fo Der OSHA rogiemeats ‘Saree ld ner lghed mols tates or open tame {Beto the penne flammable ad Brakes ae inoperatig when manly lated for si tng Prowion rust be se to muna cota ote Iii by bledeg a olker mean Awe le the fuel noel aint the sd of he ier ‘pinay 'btoye ating and dating fl flow. To duce ihe chan of ate scr spar, kop conte ut Maetad ow haba ff ‘ee Sein making attachment Be sue poe ao loss ued cy foe alg, Stuy Ga ba, Tampspiiesinee ean ga isms ean fon tndmeintenance selon tania records: ier rss cera sara ele wl iota cn rE tcdeg areas CEOS Sains va he, ols with nes oF Bad. Use he proper Remove sharp elas and burs from reworked pare {a ny aon sy power sore oat Stars or electrical shoe Luft and handle all hemy pats with» iting devieo of oper enact. enue parte ppored by proper Hae elton Mie er pd. Wah oat ‘evar elite o¢ sen o other amma tai vo SE Ear sted echt Rosa, When using compres al or cleaning prs ws saeeySafety Rules CCENERAL Continued) duet with side sie or goggle. Limit he preware to So} atoning toe oF nttanal requirement, Dp not smoke or permit any open fame oF spa ner ‘then efcing, ot ang highly tammale materia Do, not ute an opon fame ht sure t look for [Rao for iapecsonanywbet otha hing Be sue all mechanic's tale ae Nit tie tok wth muatoomed ‘Sty se wid side ood condition, DO ‘Aways west More eauly whe unde, nor nea machine ot ipl tens, Wournused proscelve equ, suce a ard Batty lass sft shower roertan ‘When making equipment checks thst rege raening of theta hee aot the parser at a ‘ital an et the brakes und lock Reep bands and ts {it gray frm mori pa, Sati sagie and dense the Power ute vr bear stehplig duster ot ‘Never ue the busta man it Te ston pont btwn tes il not leo Eines posed wien miveng Esto fap eat [istin and acre bre moving mace fe eng Bee Gpertian ad Mintnaneeinsticton anal oy ald iy, mre mache Lo ee on if ponle [eto hock machine and it atacanent cy Aone enchine tere ground seers pase Gund est kinking chins or ete, Do no it pall ihe or An mu hay oe eg ho hal oan Sa Lene ee eames Hine peel Sabo Keay maintnac aa CLEAN and DRY, Remove water BO NOT pile iy, any rags ~ they area fre hazard Blsein Hed atc Befom string machine or moving machen chic spd ‘lust abd lock operator's seat Be sure ll pononnal the Ste lr eon stig Grove ac a ay gt nits ap oul and ama, Prepae pes Eee Rene goey BNO Secured gin uated personne Do ro sry oo bts n pockets hat mihi a un Keep catches and bras om muchine wn sischments 12 Feta Ut wh ed er le ‘Nom Manas of te manutecture tall ines, DO NOM ad Jt machine wth ening running oxeot ot spied Wear oper protective saulpmet chases gums feo” ‘ger wih de ly bard at sty oc, Er doves won mal oro uric newt oF Wer weldr'sprotetivecqupment such ax dak fey {eee cig, ese ty DONOT Cook "At" ARG Wintolt PaopeR Bye PROTECTION, Know your acing auiment ndit cept. se the ficktg pola wef‘ the maine Spree forthe ‘poled Be sr the spp forte ck the ni he ‘SPproprate locog avo afety measure before proeeting Ru’ ot mastenme work score fool ot ‘Wine rope develo stal alos, Un ahora protective EiugRSN sek a Beene ey as sho Haale al pst with exc, Keg based gers ftom boten ars, Wow stored preter eat Sich step dra, my doves let howe Inagct your sat belt east twive a yea san ff gr wean, oor wonton tat coud lon fal er cary te lint ae in opr yt lc al pan ced eo "To mininiae danas of Se and explson, i com Tedd tha fore ay melding done on «Ee tan toe IS ctl a of on el ny cen ‘Sram honed All aces of fue ms be toed bere ‘rein i wate Pod thy tale with catbon doit {602} tor st daring wetting Cope must be ema a eats and ater opens it open daring wong Dy learn ix) xual nd wk ‘Hin eves, of flor pats ot the body to avd personal en wok aid under or btnen component formpotent i pace ‘according to lal national Dp, not rn the engoe ofthis micne youd eae ‘ito pope entiation formar daa hoes ne Do not place head, Body, in, ot, gr, had ese toting se oe er [STARTING FLUID 18 FLAMMABLE. Follow the recom Tendallons a ouned in he Option and Vantgance cn Maia St one oni So ‘SBlkoreed pesentel ‘DO NOT PONCTORE DE BUN CONTAINERS. Foti te recommendation of te man facta orstorge and SponSafety Rules PNCINE ‘Tum ator cap oly to ov peste befor ror Ine Add colnt on wits ene lopped or ing no Si ‘Open and) Mainternce lassi Banta 1 agt ran eogine when reusing and us cage tenn i et due to he incewsed posit of ie i ol i soil Neve tet to check oat an lt when engine 1 ot at ongins fst pump when the machin i in Neve viet a micine withthe easing. Agi rumaing enn with open unprotected ale oes. nog unaordbl or mee eon place tecive steam over. ile opening bere erg uncrnicaL, Be sre to connect the bos cables to the proper tr- Pina (219 yan ( 10). bathed, Ave shorting ‘lamp allow the Orton ao Maimtenaneslntrcton antl procedure ‘Always tun the muster sith (ky switch if 0 oipped) {oat palton whee mantaing or svicng machine BATTERY GAS 15 HIGHLY FLAMMABLE, Lewe bt {eee ow ine ton whe hag at ‘he poms: Koop sparks or open fame sway from bedere DD fot smote pear baler) ad pin th psy ‘tan accent exploson Cock for fuel o atery chet eas before tating ‘tye oF minonance wort Elmina lake before pro Do not care bates in a cloned ae Provide proper ‘enition par gin an acedanilexloson foe evaceumulaich of elon gan hen ot he che ine poco Diconnet atiies bore woking 09 lcs yer ftvepat wot of any id lid esapng under rose om very ell oe can "mst be iis aa baveauisea foc fo po ‘te thea, Us «pe of endbat gt Wood ta each {Sr aupecied presse leaks DO NOT USE HANDS. Ind by espn fi ape dtr at once Seu be {eion ‘or reactin su reap proper mel ea ‘ment sot sine medial ‘tut of ange and be seal prema oatan ha oon {hv holon emopig panel housings cove ond Ce. ES"Gpetion and Dananee Ineo nwa ‘When making peure checks we de cot gs fr ox: Fecia prs See Operation and Mnotanaee Inve Fin Manoa or Semon Mana! for Guidance, ATTACHMENTS wa, ody nbs, fa, ands ad gsc ey trom Sem Steet per when i aed postin. Use m hood bloking ag 3 sty meses fore proceeding ‘th orc or maiennce per OSHA roguesen 1E movement of ah atashoent by man of he machine's Evdaule mem squid forsee or mamasece do fat no fower machete om a pouton ther ‘he ese he Sn, oe ig ‘les soune hor and eal for sms clr Rabe altace 1 not wee machine to cary love ableisby mens other ‘BeanaiSchmens for cueing such obs ‘Neer wan apy a lhe than dey ntiopen toca ae. Bustos: ‘Se "Operation snd" bina Tnstucson nue agp che dbl on sahie rd tackene [SST powermt ey wince nd te ‘Sit Meera ta Operon and Mnnean Intre SO NEASSa settee BONOT 5st machine with eave running eepe pce. "TIRES (APPLICABLE MACHINES) Beare tis are prety to the manatee ‘pelted pring or damage pera. Sund to onside when chang ition of ties Check ie nly when the mshine empty sn Ue ae ‘col to vod Orton Do ot oe reward Wheel te igre eis oie whom ‘pare dre onl enough to ep rim prs place uly Eid se mics fy wpe when ro sal os ‘eon yo must sept (bal) «ly Lata ‘Whey evking te lk the machine I oat and be (ts wei Aer llg up, pace ering wer mach {el prtiet trom fling ber OSHA rojaenens Dette tee before emoring oblets tlm the tra Nove inate tes, with Oaminable ge, Explosion ad Peorona ir could reatO@ Oo ceo¢ SUPPLEMENT NO. 5 SERVICE MANUAL FORM 70645121 10000, 11000, 11000 MK 11 ENGINES FIATALLIS ATTENTION: Insert this sheet in the front of publication as record of receipt. Replace or add pages in the publication according to instructions below. Additional copies ofthis supplement are available. Please direct your request to: Fiat-llis Construction Machinery, In, Publications Services Depr., 3000 South 6th Street, Springfield, Minois 62710 U.S. A Write in the following changes: Section 4, Pe. 7 Notice. . FUEL INJECTION NOZZLE-HOLDER SERVICE THESE CHANGES ARE INCLUDED IN THIS CoPY| ‘The feel injoetion noszle-bolder assemblies shoule te" removed after approximately every 2000 hours of operation tested ant acjustea If necessary. The Fequire an opening pressure of (rela te FUEL. 1 woreie ncsempetes fa. 206627 97 )- ‘hen scjsting “popping” presaure of @ new nozato~ Section 4, Ps. 8 1. Using » nonale tester simitar tothe on shown {in Fig. 10, operate tester handle 9 few gulch Strotao and observe "popping pressure of fuel Injection norse-holder a ine ntty pressure tauge of the nozne tster. Par spect fied Pressure, nefer to FUEL (Wd. MOEELE ( Aecemeies im, 7068279. NOTE Reason: Fuel injetio#nozale pressure changes, Any wa change in i eon pa of he coming tort of Pa toma ke etc epi tee ned ( act tating wel cmp hp shy brn sar st por aces Spa‘SUPPLEMENT NO. 4 SERVICE MANUAL FORM 70645121 FIATALLIS, 110000, 11000, 11000 KI ENGINES ATTENTION: Insort this sheet in the front of publication as record of receipt. Replac inthe publication according to instructions below. ‘lat-Allis Construetion Mochinery, Ine, Publications Servic ‘8000 South Beh Street, Springfield, Miois 62710 U.S. Reason: This supplement updates manual to eover the 11000 MKII es ‘Replace or add the following lke pages: 11 (No change) 3 (Revised) (Added) T6E (Added) 1-2 (Revised) 52 (Revised) (Added) 22K (Added) 54A (Added) (Reveed) 18:1 (Reve) (eveed) 182 (Nochags) 2.28 (Revised) 81 cre BK Lian (aded) 153 (Reve) 224 (Revised) i168 (Added) 164 (Nochans) 225 (Revised) 11460 (Added) Section 18: Entire 228 (Revised) 1180 (Added) ection revised 227 (Revised) 201 (Revised) 228 (Revised) 202 (Revied) ‘Wit inthe folowing changes (eyes are underlined): Page 2.2 ‘Toric Add vow sentence befor ft paragraph Refer 1o FIG, 1A, 412 raph H.2 Add new fist sentence to paragraph: Coat nozzle- holder thread 412 Paragraph HL. 2 "to “Postion tivo new rubber dust shields.” (continued)83 85 86 39 104 104A, 13 5 aua0 124 133 Legend for FIG. 1 Paragraph A. 6NOTE Paragraph B. 2 Paragraph B.5 Legend for FIG. 10 Paragraph C. 8 Paragraphi. Legend for FIG. 2 (cont) FIG. 5, Tie Paragraph B.6 Paragraph 9 Paragraph 6.1 ‘Ada to item 8: (One pices gasket effective with gine serial number 11 ‘Add to item 16 .. of rotator ‘Add to item 32: (Used prior to engine svil ‘number 11-25688), (Change “eams" to “arms.” Change“... 19-22 Ibs. to“. 1035 It (1.44.8 itm) for stud nuts and 14-45 Ib (182m orglawbota Change test sentence to read: ‘Tighten 1/2 in, nuts to 100 lb-ft (13.8 kgm), 1/2 no Serows to 115 Ibsft (ise and . nuts paeraws to 186 Ibe (25.6 ke) Adi to item 4: (Not necessary with one piece gk) (Change “45-50 Tht” to “10 Itt (9.7 kgm), Ada: It flywheel is fastened by socket head capsoowe igiten to 188 A CST hea. Omit: Legond for FIG. 2 (continued), tems 25 through 28, Add: Used prior to engine serial number ii2aigyoentnes ‘Change next to last sentence to read: “tighten nut fo 125-185 Ibt(17.3 187 kgm)” ‘Add new sentence and change fist sentence \pply sealant to camshatt bore plug. Install Sony agin cone bole Replace piston rng end gap dimensions with the following new data ‘Top Ring First Type Pistons 0.018.0.088 in (0,83-0.84 mm) Second Type Pistons 0,010,028 in (0.33.0.71 mim) 2nd and 3rd rings 0.018.0.88 in (0,33-0.84 mm) 4 xing 0,008-0.028 in (0.20 0.71 mm) (continued)134 136 us M4 155 Paragraph E. 2 ‘Toric2 Legend FIG. 1 Paragraph 6 Section 4, rght- hand column, tied para ‘eaph. Replace piston rng-togroove clearance dimensions ‘withthe following new data: ‘Top ting 0.004.0.007 in (0.00.18 mm ) 2nd and Bed ings 0.008-0.005 in (0.08-0.19 mm) 4th sing 0.0015-0.004 in (0.04-0.10 mm) [Add to paragraph 4: Oa current engines with ‘bwelvepoint capserows instead of nuts tightn See Gem a [Add to item 3: (Used prior to engine sei ‘number 11-19386), |Add: On current engines with twelre-point capserews instead of nuts, tighten eapserows 9.160 Ute (22.1 gsm) (217 Nm) Change socond sentence to read this lubricant is not available, use liquid edible vegetable ol Delete sub-paragraph a, and b,ATTENTION: insert thi Replace the following like pages Index Pg.3 (Revised) Sect. Pg. (so change) Sect: Pel? (Revised) Sect.2 Pe-t (Revised) Sectl2 Pelz (Mo change) Sect. 2 Bg. 11 (No change) Sect? Pelz (Reviseal Sect.2 Pg. 27 (Revised) Sect? Pe. 26 (Revises) Sect.5 Pet (Revised) Sectl3 gl? (Mo changed Sect.5 Pg. 3 (No change) Sects Pyld (Revised) Sect.3 Pg.te (Added) Sect. 5A Pg. (Ady Searls Pe? (a sect.5a Pg. 3 fhasea) Sect 5A Pg. 7Aadee) SUPPLEMENT NO.3 SERVICE MANUAL FORM 0645121-5 (7-66) 10000 -11000 ENGINES CONSTRUCTION MACHINERY DIVISION heat Into the {ront of publication as record of lon according £0 instructions below. Sect. Sect Seet Tem oceipt, Replace Be.7 (Added) fa Pe (aadea) 5A Be.9 taddea) 5A BE. to (addee) 5 Pg. (Xo changed 5 Ppl (Revised) 8 Pe. (Revised) 8 Pal (Revised) 10 Pg.3 Revised) 10 Ped (Revised) 10 Pg. a (Added) 13. Pg. (Revised) 13 Pelz Revised) 12 Pg.3 Revised) 13 gla (Revises) 13 Pg.5 (Revised) 13 Big 6 (Revised) 13 PT (aadea) 15 Pg. 5 (Revised) 1S Pelé tRevisea) Reglon: hie eupplement adds the Booch (Germany) injection perp data andNOTICE OF CHANGE SERVICE MANUAL 645121 (7-68) ENGINES CONSTRUCTION MACHINERY DIVISION Welte in te conowing changost Section 2, Page 16 Legend for Fig. 112 Ast 3, Spider Kit the following ke pages Section t Bg. 1 (No change) Section 4 Be. 7 (Reviced) Section 10 Pe. 3 (Revised) ‘Section | Pg. 2 Utevised) Section & Pe. & (Revised) xo elange) Soction 2 PE. 3 (No change) Section 5 Bg 7 (0 chy 10 otangs) Seetion 2 Pe. & Revised) Section 5 Pe 8 (Reyjéed) Section 14 PE 2 (Revised) Section ? P18 (Revised) Soction 8 Pe. 3 (pi cbangs) Section 14 Pg. 7 (Revised) Section 2 Pgs 14 (Revised) Seetion 8 Pe, {Atericed) Section 14 Py. 8 (No change) ( Section 2 Pe, 21 (Revised) Section 8 29/5 (Revised) Section 15 Pg. 5 (Revises) ( Section? BE, 22 (No change) Section 8/286 (No chanzo) Section 19 Pg. © (No charge) Section 2 Pg. 28 (Revised) Sectig( 8 Pe 18 (No chang Section 18 Pg. 3 (Revises) Section 2 PE, 24 (Revised) Seeyln 8 BE. 14 (Revised) Section 18 Pg. 6 (Revised) Soetion 2 Pe. 25 (Revised) foson 8 Pg, 15 (40 change) Section 18 Pg. 7 (Revisee) Seetin 2 Pe. 26 (Revised) Aoction 8 Pe 10 (Revised) Section 18 Pg. 8 (Revised) Section 3 Pe, 1 (Revised) Section 9 Pg 1 (Revised) Soetion 3 PE: 2 (No change) Section 9 Pe 2 (No change) ( \ Reason: is mating proyhes latest information on 10000 & 11000 engines inser pis SHEET INTO THE FRONT OF MANUAL 0649121 (7-68) TO INDICATE, MAILING NO. 2 Printed 9 USA, Tasved $270,‘The following replace lke pages: Sect, set sect, Sect Sect, Sect, ithe fa USA. Pe Pe Pe PE Pe Pe 1 oviso9) 2 (Revised) 1 (revised) 2 (Revises) 2 (Revises) 4 Revised) 5 (Revises) (Revises) 1 oRevsa0a) 8 (revised) 2 (Revised) 10 (Revises) 11 (rovse@) ‘ocont engine changes. apna (7-68) SERVICE MANUAL, 11000 21 Revises) 21 (Revisea) 28 aes) 24 (aes) 25 (ase) 28 (ae) 21 (Ades) 2 (Ae) Sect Sect sec. sect, sect, Beet, 1 (reviaes) 2 (ho change) 5 (No enange) 8 Revised) 1 (Revise) 8 Revises) 9 (revise) 10 (eevee) 1 (Added) 1 (adaes) 1 (No enange) 2 (revised) 1 {No change) 2 (Revised) fs SHEET INTO THE FRONT OF MANUAL 645124 (7-68) TO INDICATE RECEIPT OF THIS ‘Additional copies of this malling are available. Please direct your order to Parts Orderesl "the nt be which he engin ea "may be fousd te the Operation and Mtia- ‘This manusl hasbeen prepared to providemainesance personae with information and instrue- tions for repairing and overhauling those engines. In ores to betore familiar with the vations parts of the engines, 1 ia Urged thatthe mintenance personnel study the Instructions tad lustrstions inthe maiuslanduseitas reference when performing Tepsr oF ovectatl operations Al information, sustrstons, and specications inthis manual are ase on information aval- tle at the time of publication. FIAT-ALLIS reserves the right tomeke changes, aa) The terms "ont, rene, "eft", and righ" assed inthis mantal are defined as ftlows: ees POI Sa nom SRR he Many omners of FIAT-ALLIS equipment employ the Dealers Service Dapartment forall ‘work other than routine care an aastment, Tata practice ie enoousaged se our Dealers ere kept voll informed by tha ietory regarding advanced methods vf servicing FIAT ALLS ‘roduets and are equipped to render satisfactory sevice, ‘To asgure the best results and maintain the orignal quality but into the engines i important har FIAT-ALLIS porte be seed when new parts sre requitede mpornaar Abways furnish wait and engine serial tibers when ordering parte ‘This manial may not be reprinled or reproduced, either i whole or in prt, without written permseion of FIAT “ALLIS.sussect DESCRIPTION AND SPECIFICATIONS... COOLING SYSTEM. eee ee reese SUBJECT INDEX ELECTRICAL SYBTEM 6... seeri0n FUEL SYSTEM (With American Bosch Fool Injection Pump)... 6. ++ FUEL SYSTEM (Wit Roose actor Fucl Injection Pump) « FUEL SYSTEM (With Bosch (Germany) Fuel Injection Pump) A CLEANER AND INTAKE MANIFOLD... [BXHAUST MANIFOLD AND TURBOCHARGER ‘VALVES, VALVE OPERATING MECHANISM, ANDCYLINDER BEADS « [FLYWHEEL AND RING GEAR; FLYWHEEL HOUSING AND CRANKSHAPT REAR OIL SEAL LUBRICATING SYSTEM CAMSHAFT AND CAMSHAFT BEARINGS... PISTONS, PISTON RINGS, CONNECTING RODS, AND CONNECTING ROD HEARINGS «ss = (CRANKSHAPT AND CRANKSHAFT GEAR, MAIN BEARINGS AND MAIN BEARING CAPS ENGINE REMOVAL AND INSTALLATION . FITS AND TOLERANCES AND TORQUE SPECIFICATIONS . [TROUBLE SHOOTING SERVICE TOOLS... SERVICE MANUAL 10 2 Gotaber 1071SECTION 1 - DESCRIPTION AND SPECIFICATIONS 1, DESCRIPTION A. General BL Principles of Operation +. St 2, SPECIFICATIONS ‘A. Englte Data and Characteristics « « ‘Buel Injection (Ameriean Bosch (P88) ici Ihjection Bune) Poel Injection (Roos Master Fue! Injection Pump without ‘tomate Tsing Advance) uel Injection (Roose Master Pel section Puy with" ‘Automate Ting Advance Valve Bing Labeeation ng Spee TOPIC 1 - DESCRIPTION AL GENERAL fied be 11000, Sora ibe Trbs- ‘Pool is supped to te eylindors by = fel injection [fin The pump dove secuataly motored wane {lice of fuely under high pressure, Seough fval i= jection noose, into the cyibders atx definite ting {n elation tothe engin riageyete, Thotvel is ignited ty heat genurated by compression of to air tn the pliner ‘A comustion chamber is located in the head of each Piston and the fuel iajecton nomsles are mound in fhe eplinder bead. ‘The orifices inthe tp of the nozzle Svedelledat a sight ange so thatthe felis sprayed Aireety into the combuntionshamber whch i sight fy offs toward the camshaft sie of the engine. The Shape of the combustion chambor, angle of fuel In jecloa, andthe shrouded tate valves, causes extreme Etbatence of the a within the epinders and osu Inthe foe and aie being Doroughly mixed for com= pte combustion. ‘The engines are fllpressore ubricatedby a goar tpt ol pump driven by the crankshaftgear- Engine cool {s accomplished by coolant, freed throuth te eagine ‘Cooling and radiator system by a cootrifugn type water [npe The water pump Sobel dive 1B. PRINCIPLES OF OPERATION 1m afour cycle iesel engine, a power stroke 1s mae by eh piston for every two complete revolutions of the crankshaft. The sequence of the strokes isa follows: Intake, compression, power, and exhausts INTAKE STROKE, ‘As the piston mores downward on the {ist oF intake iro, air slers the oylinder thro the al tae Ihanltld, andthe lake valve whieh starts to open 8 {ey degrees belore te piston reaches top deadcenter ‘The intake change consists of alr nly, Wi fuel 2. COMPRESSION STROKE ‘ory aftr the piston tarts to move apward onthe Second, or compression stroke the intake vlve closes. {The ti is comproseed inthe cylinder and compres Sion of the sir suines the temperacoe in the linger fo aoproximately 1000°P. At the propor moment tring the compression stroke, « metered quay of fet ie injected into the combustion chamber under fxizemely high pressure. The tneky atomized fuel Sn ionted uy beat of the comprossed ir and starts {0 bom immediately. 2. POWER STROKE ‘Bxpansion of the baroing gnses forces the piston down sand on ie thtd, or power tzwho. Neo the boom Gt the power stoke, the exaust vaive starts to open. 4, ExHAUsT STROKE, ‘As te piston moves upward onthe fourth or exhaust ‘rok, the exaust valve $s open andbarnedgasos are Toreed‘out of the ey liner bythe spar travel ofthe Histon. "A few dagrensbolore the piston eaches top "ead Cees, the intake valve starts to opento admit & fresh ehargo of sir to he cflinder. ‘Aw degrees Liter top dead center, the exaust valve comletely ‘loses and to cyele Is repeated. SERVICE MANUaL, S60” 47ETY PUES ot 0 HOLOA e pwFeeand uO pis 1967 aTOPIC 2 - SPECIFICATIONS A. ENGINE DATA AND CHARACTERISTICS Number of Cinder 6 Bor. “448% in 1271 mm) Strake 515625 in (14129 mm) ‘Total paceman ‘sdin? (8a) Gants Rotation (Viewed ton Fan Bad) Clockwite ‘Number o€ Ms Bering 7 Comprsion Ratio (Nomina) 624 ‘Compson Pest ins) Se evel 600 rpm hot 15 ps (313 talon) Fling One 1s3524 Minium Stsitiaed Wier Temps “i70'9P" 64%) Maximum ai otk Restwtson: 80 in (962 mr #0 Main Parmimbl Exhaust Restrtion ‘Notary Aspirated Bin He (102 4) Tantockaood Tinie (34 ia) B. FUEL INJECTION PUMP (AMERICAN noscu tsb) Nossa Opening Pouce: 98009860 pei (26722707 ‘slen’) el nein Tins ‘Track'ype Tractors without "Torque Converter td Motor Grades 300 ‘TackeType Factors with Toreve Commer me "Tactor Loader aed Testor Does ‘Tho 22 a0, 30 ae ue nton ing Spd iis i rani)" 1 (6. PUELINJECTION PUMP (ROOSA MASTER WITHOUT AUTOMATIC-TIMING ADVANCE) Noxelo Opening Pressure Fel neti Ting 2825 psi 0986 xem 7) ‘Netrly Aspiested Engine (10000) 300 ‘Tubornuied Eases (11000), B50 Fuel Teton Pump Speed (Ratio fo Crankait) "12 . FUEL INJECTION PUMP (kOOSA MASTER ‘WITH AUTOMATICIANNG ADVANCE) Nozele Opening Prosure (Fiat type). 28002860 pa ‘Go 004 bets) Nogale Opening Pesaze (Second Type) 88009850" pe'267.2.2707 kom *) ‘Pal injection Pp Ting 11000 249 BTDC (State), 98° BTDC (Running) 11000 MkH (DB, DC): 18°HTDC (Satie) 98°RTDC (ussing), 11000. MK {DAs 11° BTDC (State), 96° BDC anning Fuel Injection Pump Spec (Ratio to Cranbatt) 1:2 1. PUBL INJEGTION PUMP (BOSCHLGERMANY) Nosle Opening Presane 3800-850 p (Ginz207 keen’ Fuel Injection Timing BTDC HAT 103 Clr Tractor soo 120.) He 1000, 1800. 200 lotr Grae: ze 46, TUG, 7488, TASH hel Losier | 340 Fol ijeton Pup Speed (ao to Ceanshat) F. VALVE TIMING 12 NOTE aly model engines sed cama pat no, 4596774 and ater mol ene eum ‘att part mo, ¢387125, ‘Th pat no, Sree a a 1024 in (Ot. 0.018i8 (046m) Iniake VatveOpensBTDC 21 g0P Intake VatreClows ABDC 55°00 Duration 2022000 Biase Vabe Opens BoDC “85°08 Bhat Vale Clee ATDC 33° 400 Darton weap Oreran eae Ranning Cleence for Valve 0.018 in (0.48 mm) HOT “Tapets (intake and Exhaust}0.020 ip (0.51 man) COLD 6, Lupricarion Type oo Ful Presane ect Oi ioe Tul Flow Uabeeting Oil Speciation: |, 0b, MiicLesa9en Mii 20040 (it Pump. Speed Ratio to Cranlahat ‘21 NH, ENGINE SPEEDS For specifi hgh and low ile engine speeds which vary depending upon he uni Heh tbe ening pnd ot forthe OPERATION AND MAINTENANCE INSTRUC TON SHANUAL frm withthe wait, Study SAFETY RULES, pages I thu Il thoroughly forthe protection of personal and machine safety (avid 6-78) 7‘onto. SECTION 2 - COOLING SYSTEM nme Com RADIATOR (EXCEPT 126 CRAWLER LOADER) Ae General = Socrates oe 1B Rasintor Removal nd tasaliatuin: SL 222 DL ane ©. Radiator epection sve vss ove e ese ae RADIATOR (126 CRAWLER LOADER) jomenlecit ete B. Radistor Reinoval ind tasalatca ) 2222222 ©: Radiator mepection www vs svc ces sssese FAN, PAN BELTS, FAN HUB, FAN BELT TIGHTENER, AND FAN DRIVE (EXCEPT 126 CRAWLER LOADER) Abeerioeeaeti eee ee Pan Bett adjustment» 022 2 7 ee G. Fan Removay tnpection” and bistatiation © 22111 I III Dy Pan Belt Removal, Inpection,andlastalaion | 222221 Pan Bb Removal, Disassembly and nepeeton 222222221) EF Fan Hub Assembly and installation. « ae G. Pan Belt Tightener Removal, Dleasconbi, ad nepoction. <<< 1B Pan Belt Tiphtoner Assembly and Installation == > = ae 1 Pan Drive Romoval, Disassembly, and Inspection (Traek-Type ‘Tractor Engines w/Ammerican Bosch Fuel jection Dump) ens « + + Pan Drive Assembly and Installation (Teack-Type Tractor Eogines ‘w/Amesican Bosch Fuel Inject Pump). « » « , Pan Drive Removal Disasgembly, an ingpelion (Crawler Tvactsr Engines ‘¥/Reoea Master or Bocch (Germacy) Fusl Injection Pump). ws ss = 1 Eas Drie Aste a tition (Crier Tractor Engine w/oa ‘Master or Boas (Germany) Fue Injection Pum) vss = = +» FAN, FAN BELTS, AND FAN DRIVE (12G CRAWLER LOADER) Ae Deseripton =n B. an Bolt Aajusront« C. Fun Removal, Inpociion, and Instatation ae D, an Beit Removal, opection, and inatallaion v0 2 2222 Ban Hb Removal, Bsassemhiy, Inspection, ASoembly, and Installation see nt tes et sevens , Tun Drive Removal, Disassembly, Inapection, Asseinly, cod eae ee ee ee eee ‘rHERMOsTAm AeGeneral eee ee B. Thermostat Removal, Testing, and Installation? 2222222205 'B. Oll Cooler Removal | S21 ee D. Ou Cooter Testing 22D T II IIIT 2, OU Cooler Intainuon ©2222 TTT EITIIITY WATER PUMP. BL Water Pomp nenoral <2 TII LEED DILL (©. Water Pump Disastertiy, inspection, ‘and As D. Water Punp Insalltion = sree es eee eee (COOLANT FILTER Ai Goneral eens eee ee : Bi Coolant Fatcr Sewae <7 ee Once Coolant Filter Removat apd tnraadiog IL SERVICE MANUAL sama ) oe ss Saal Loe Dek eeeee g ‘october 1071 eeTOPIC 1 - GENERAL AIL units, using engines covered inthis mani, with ‘ho excoption of early model motor graders, Rave 3 rized cooling system. A double acting prea” Sure reliet yalve is provided in the raditor ler ap. The waive is set to opan at appromantely pi Barly model motor gradors have an open type vented cooling system, “Tho water pump draws water trom the Bottom ofthe Fadiator and forces Wt though the oll cooler ad th fored water passages inthe engine. The coolant ts Aiseharged trom the cylinder head into the water futct manifold, through the thermostst sd upper allator hore and ito the wer past of the radar ‘The coolant digtpates Ite heat abit passes from the top to the bottom of the radiator through the conling ores. The fan Belge ateipate she heat ae i forces ir through the sadist. The thermostats, loetted ia the termortat housing at the frout ent of the water futlet manifold, operate automatically to malnsia Tnimum ecolant temperature of 170"P: TOPIC 2 - RADIATOR (EXCEPT 12G CRAWLER LOADER) A. GENERAL ‘The radiator used on motor graders, tractor loaders, 4nd tractor dozers is 4 one plece welled assembly, 2 top and otiom tank, core, and se members bolted together and serviced separately. (On trackstype tractors, the radiator Is mounted on 8 mainframes (o> motor graders, the radiator is bolied to the ‘radiator gril, Pig 2, which fs bolted tothe grader mainframe, (On tractor loaders, and tractor dozens the radiator 4s bolted to the radiator support, Pig. 8, whichis bolted othe loader mn frame 8, RADIATOR REMOVAL AND INSTALLATION 1. TRACK=TYPE TRACTORS (Fig. 1 Drain cooling system, b, Remove or tit radiator par forward, . Discomect radiator inlet and oxtlet hore. Disconnect any vrives which may be atached to radiator. The radiator (1) and radistor suppor (2) may sow be removed a an ansombly by temoving fan guard s0 equipped), support mounting capserowe (8), and eapacrews (0) oF the rae Sor may be removed trom the support by ‘omoving capecrems (13) and loekwasters {nal by ainet reversalof remove procedure, ‘ith capscrews (13) and lockewashers Pig. 1~Typical Radetor Mousting (Hratictype Tractors) r-t6a15) 4. Radiator Assembly a Nat 2 Radiator Sopport Capscrew 5 Nat 10, Plain Waster Dock Nat 1k Lockwasher 5 Brace 12 Nat & Gapserew 13 Capscrews 1 Lookwasher ‘Sluty SAFETY RULES, pages Iu horough fore protector of personal and machine sly‘r80172 FIG, 1A COOLANT FLOW SCHEMATIC 1, Drain cock 8. Water pump 2. Thermostat 9. Coolant filter 5. Bypass pipe 10. Engine ol cooler 44 Thermostat housing cover AL. Torque converter fluid cooler 5. Pressure cap (7 psi) (0.49 kg/cm?) 1B Immersion beter temo) opi 6. Vent cocks 418, Immersion heater ia T. Radiator M4, Water outlet manifold ‘Study SAFETY RULES, pages J thru I, thoroughly for the protection of personat and machine safety 220 (Added 5-78)oO eS ©ig. 2-Typical Radiator Mouating (Gtotor Grasers) (r-71403) 1. Radiator net Hoos 5 Raaiatr cra 4 Gapscrows ‘Radiator Outlet Hose & Gioserew Miata Brame 8. Complete so Ing system, 2, MOTOR GRADERS (Pig. 2) 1. Drain cooling system, by, Remove engine hood. Discomect radiator inlet) and outlet (5) 4. Romove capserows (8) attaching radiator grill (3) grader main frame (i) sed remove ‘udalor and radiator grill as an assembly ‘8. Remove capserews (i) and plain washers at= {aching raaator (2) to radiator grill) and remove radiator 1 Install radiator in radiator gril and Snstall Yadintor gril and radiator on grader, 49 48 seombly, by direct reveral of removal pro- Ful coting system. Pig, S—typieal Radiator Mounting (rvactor Loasers and "Tractor Dozers) res) 1, Radiator Inet Hose 2% Radiator Support Fan Gaara 4 Capscrewe 5 Radiator Outlet Hose |. TRACTOR LOADERS AND TRACTOR DOZERS we) 4. Drats cooling system. 'b, Remove the engine hood and side plates, Discomect raator inlet (2) and owt (6) 4, Remove fan mara Remove espserews (4), outs plain washers and fubber washers stacking radiator fo aioe apport. Say SAFETY RULES pe ag het a pn and mine sy ‘SERVICE MANUAL April 1867 eabrat (60) Tet, PetIota radiator by a eet reverse semorat ‘aching capscrewe, place one rubber washer between the radiator and radiator support, Pace the olher rliber washer under the lta washer na then instal he st . RADIATOR INSPECTION 1. Thoroughly cleanextarior of radiator, removing AI foreign material trom betwesn cooling strnghten ay fia srebects 2, Test raditoe for make. Cover inlet and outlet pening and immerse in water. Test ving m0 ‘ove tan 10 pa internal ni preseure Do aot paint radiator core as this decreases ‘cooling eftcieney. TOPIC 3 - RADIATOR (12G CRAWLER LOADER) A, GENERAL tre one piece welded assemblies, Hach radiator le ported by two rubber suubbers atthe bottom and ‘fFubber encloged mount atthe top. The cooling syste {Sled through a mutual expansion ak mont bor he radiatore B. RADIATOR REMOVAL AND INSTALLATION 1, Remove radiator grill and top corer 2, Drain cooling spstom. S. Remove capserews holding radiators into rubber 4, untott lower radiator elbows sromrastore, 5. Disconnect upper radiator hoses. 5. Remove (wo capserews altzching each spper radiator mounting brackst to radiator suport 1 Install by airect reversal of removal prosodsre ‘Make certain correetengtheapserews re useato event interference between radiator aod gear, € RADIATOR INSPECTION 1. Thoroughly lesa exterior of radiator, removing A foreign material from between coding eares Sind fine, Be caret not to bend fina, straighten fy that are eat. peng mere inate. ‘est wing ipoRTaNT Bo not pant radator core as this decreases ooling etctney TOPIC 4 - FAN, FAN BELTS, FAN HUB, FAN BELT TIGHTENER, AND FAN DRIVE (EXCEPT 12G CRAWLER LOADER) A, DESCRIPTION ‘The engine may be equipped with citer 2 pusher f7pe for suction type fan depending upon the engine 2p- cation, (A reversible fan is available aa special equip~ ‘ont for most models) ‘The fan pushes or pull ar trough the radiator and fs mounted on a bracket bolted t9 the font ord of fhe ‘engine. Tho fan hub on track type tractors 1s Given from the fan devo pully by Y-bells. The fan hub on motor graders, trator Toners, and trtce toe davers i driven from the crtnkatal pulley By Velts FAN BELT ADJUSTMENT 1, TRACK-TYPE TRACTORS (Fi. 4) ‘The fan vets (6) are property adjusted when they can be! pressed imvard by hand approximately 4/6" 1/2" at a pont ball way boteoon the fan hub (2) and fan deve pulley 8). "To adjust belts, loosen Jam act. SERVICE MANUALFig, 4-Fan Belt Adjustment Location (reuck-Type Tractors) r-2asee) 4, Water Pump and Generator rive Belt 2 Ban tab Sam Bot 4 Pan Drive Putiey 8 Pan Belt Adjustment Screw Ban Drive Bete (9) an turn saustnet screw (6) i or out as neces tty to obtain proper tension onthe belts, Cen Ugbten fam aut). 2, MOTOR GRADERS (Fig. 5) ‘The fan belts (@) are properly adjusted when the Straiphe side of the bells san be pressed ward by fun spproximately 3/4" ata point hallway between the fam hub (1) aod the crankshat pelley. To adjat belt, loosen Locking camp capecrew () and jam nut (Gy. "Toon adjostment sevow (2) in ov oul as neces Sty tor obtain proper. tension op the belts, thes {Seen jam mut (9) ane eapscrew (8. 3, TRACTOR LOADERS AND TRACTOR DOZERS e0) ‘rhe fan belts are property adjusted when they can be pressed inward by. hand approximately 1/2" 0 S/a? area point taltway botween the fan ub and the rankshalt pulley. To najot belts, loosen fan spindle focknat (2. Ture adjustment sorew (1) in or out a inocoesary 9 obtain proper tension oa the bolt, hen tienen locket (- SERVICE MANUAL, Bastar 86) sy SAFETY RULES pe hr om he ti on and machine Fig, 5-Fan Belt Adjustment Location Iatctor Graders) (38914) Z Fan Batt Adustment serow 4. Pan Belt Tighter 3. Loculng clamp Capscrew Fig, 6-Pan Belt Adjustment Location (Tractor Leasors and Tractor Doze) (t=28059) 1, Fan Belt Adjustment Serew Test 2, Pe¢. FAM REMOVAL, INSPECTION, AND INSTALLATION Remove fan guard if 90 esuipped Remove capscrews attaching fan to fan bub find remove Tan.” Remove fan spacer K 20 ‘uipped. 8, Inspect fan for cracks, lose rivets, oF bent Dlades. Repair or veplzce it necessary, 4. Install fan by sect reversal of removal procedure, FAN BELT REMOVAL, INSPECTION, AND ISTALLATION 2, Roliove tension on fan bets unt nets can be ‘lpg olf of pulleys. Remove fan belt, 4. Inspec fan belts for excessive sickness, oil soak, wear, (ears, racks and overstreteking ‘The tan bets are'a matched pane ony one eit feplacement is required both bltemust be replaced fo atoare satisfactory belt per= Insta tan belts by slipping belt into proper frooves in pulley and adjusting belts to proper 5 natal fa 5. FAN HUB REMOVAL, DISASSEMBLY, AND INSPECTION 1. FAN HUB REMOVAL (TRACK-TYPE TRACTORS) Pig? 4. Remove fan (1), 3 amore fan belt and generator drivel rom «6. Discomect and remove Iubriating hose (24) Remove ut and lockwashor attaching fan bet phtener assembly. to fan" movnting bracket (Gh and remove fan belt tghtener & Remove. capscres attaching fan_ mounting bracket (9) te cylinder block and’ remove Pract and fan hi sagemnbly @)aa's ont Remove roll pin (6), slotted mat (7), and washer (). Remove pipe nipple Pull fan tub assembly (0) from mounting racket () ‘Apes 1960 Shee 2 Pa ‘SAFETY RULES. page np fh pete teen a mac at 2, FAW HUB REMOVAL (MOTOR GRADERS, ‘TRACTOR LOADERS, AND TRACTOR DOZERS) Hig 4, Remove fan (1) and fan spacer (2) if enipped. , Remove fan belts and generator drive belt from fan + Remove roll pin (), slated ast (7), andwashor cs xore. {place of the slotted nat (0) andthe fol pin (@) isnot used. 4 Remove adjustment sorew () sod pl fan hab Assembly (@) from bracket @), Remove washer (29) from spindle (23). 9. FAN HUB DISASSEMBLY AND INSPECTION (ig. Tor 8) ‘Tho internal parts of the fan hub assembles, Figs. 7 nd &y are Sentical and the following dstouembly Dprocedare applies to both 1 Remove soap ring (8) and hub exp (10) , Remove lockeire (22) and turn retainer (21) fut of fan nub (1D. Remove sealing washer (20), retaining wather (0), and anche (0) from fan ha. fe, Place fan nob assembly in a press, fan end Up. recs on fan end of splndie (23) and rex Tove spindle and bearings (10) 00) from ‘ab ( 4 Remove coter pin (18) and mut (12) and press Spindle (25) from bearings (14) (1), ‘6, Wash all parts thoroughly clean solvent or {et abd inspect parte for wear oF damage. Rotate tell bearings by and and check for Tooemnese, roughness, and binding. tpoct sine. and make. certain st is not bent oF ‘worn and" that the threads are not daaged, tbat pulley grooves are smooth and tat pulley {oot chipped or cracked. Discard sealing ‘usher (20) and retaining washer gasket (18). Inopect generator drive bet andfan dewebets Replace if they are wore or Cred. F, FAN HUB ASSEMBLY AND INSTALLATION 1, PAN HUB ASSEMBLY (Fi. Tor 8) ‘The lntornal parts of the fan ub assembles, Figs. 7 SERVICE MANUALCoie snd G, ane identical and the following assexbly procedare applies fo both 1. Pross rear ball bearing (27) onto spade (23) ring spacer (10) and washer (05) and press front ball bearing 2 onto reen brerngs all al ero eaag ira ‘Proms pine ito potion a 11 Rese Bal Bearing 4. install & now gasket (18) and washer (19) on ntl hole in retainer is aliened ‘ith bole 0 {an ha, the install ocwire (22). fe. Install hub cap (20) a 1732" below fan bab aot 2. FAN HUB INSTALLATION (TRACK-TYPE TRACTORS) Figs? ce, tab) sseby 8) poston in cle) “Ima ppe note tn opedPig, 8-Fan lub Details (hotor Grader s» @ ‘tractor Loaders, and Tractor Doses) r-14061) 1. Pan 8 Snap Ring 17, Roar Bat Bearing 2, Pan Spacor (For Use With 10, nub cap 1, Retaining Washer Gasket Siction Fan Only) 11, Fan Im 1, Bearing Rtainer Washer , Install pla washer (8) and nut (1 on spine (aa). Tighten nat eacorely and Seta rol ini). fy Install fan moanting Braet (9) sm position on {inn os and sere wt coer and 44 Install fan bolt tghtoner assembly on fan mounting bracket. belt { Tnetall nd connect iibrieating hose (2). ‘Install fan (1). ‘h, Labrteae fan tb and (an elt leone at ube sutngs. ‘4 Pan taunting tacket TE Spindle tat 20, Spnate Seating Washer (Cort) 4 Aajostment Screw 18 cater Pin 21, sealing Waaber Retainer Plan Waster 14, Front Ball Bearing 22 Pan ti Lockwire & Roll Pin 1S, Spacing Washer 28. Spindle 4 loted at 16, Bearing Spacer 24, Bron! Spindle Washer & Fan i Assembly 3, FAN HUB INSTALLATION (MOTOR GRADERS, TRACTOR LOADERS, AND TRACTOR DOZENS) Fig. 4, Place washer (24) on spindle (28) and install fan bub assembly () in postion sa racket (3). stall adjustment serow (4), washer (8), and Slotted ‘nt (7) but do ot tighten wt a hls Install and adjust fan belts and generator drive bly hen tighten lated nat (1) securely and {oak with vot pin). (On inter model engines a flanged mat is used tn place of the sloted mit (7) and te rll pin (@)Senoe wee 4, Install fan (1) nd fan spacer (2) £30 eine. i 1967 SERVICE MANUAL, cee ee(©. FAN BELT TIGHTENER REMOVAL, DISASSEMBLY, AND INSPECTION 1, FAN BELT TIGHTENER REMOVAL, DISASSEM- BLY, AND INSPECTION (TRACK-I¥PE TRAC ‘Ton Fis. ‘Loosen tension on fan belts, b, Remove out (18) and tockvaster (14) from ‘lide clamping bolt (10) and remove fan belt {sktenor from fan mounting bracket + Remove pulley cover (8) and gasket 8). 4, Remove front snap rng €, Placetightener assombip ina press, pty side py and presa fan belt Uphtener leo (18) from pulley Remove oil sea 0) and rear anap ring (and frive oF prese ball bearing (from pally (8) f+ Wash all parts thorough an clean solvent oF {et abd Inspect parts for wear oF damage, Rotate ball bearing by hand and check for Iooreners, regimes, and binding. Replace i necosears. Tho besring must fit smugly ia Dalley and on lide shat, Inspect te fas belt Sl hens a mane eran ie od Make cortan that grooves um ple are smoot fd tal pulley 16 not chipped or cracked Replace fan drive belts if they are morn oF Irayea. 2, PAN BELT TIGHTENER REMOVAL, DISASSEM- BLY, AND INSPECTION (MOTOR GRADERS) Fig. 10 b, Remove tocking clamp capscrew (17), look ‘washer (08), and locking clam (1), Pull fan belt tgutener assembly from fan rosnting bracka 13). Pan Belt Tightener Detaile (trasictype Tractors) r-t0aai) 5 Polley Cover Gases 8 Panes Front Snap Ring 4 Bal Bearing 1 eae Sap Ring 8 on seal 10, tide lamp Bat 12, Pan Bolt Adjustment Screw 1, Lieatg ig 15, Nat 1, Pan Belt Tighter side sence masya, 200 2MENV RES a eet "ig, 10~ Fa Bl Tar Detain “een Gasket ray Front Ball Bearing Snap ing Bearing Sacer eae Bul Deating On Seat Lever Assembly Fan houtng Bracket Fan Bot hajostnont Sone Jam ait Locker 1%, Locking Clamp Canserew4 Romove pulley cover (1) and gasket (2) . Place tghtoner assembly in a press, pulley ‘end up. Press on (rot end of lever assembly i) ana press lover out of pulley (3), £ Drive or prose front ball bearing (6) {rom palley )." Remove snap ring (1) ahd beating Spacer (8. fe Drive or press rear ball Bearing (8) and oil Seal (10) trom pally 3). fh, Wash all parts thoroughly clean solvent oF {et and fnopect parts for wear or damage. Totate ball bearings by hand and check for looseness, roughness, and binding. Replace A necessixy. The bearings must Ht sragly in pulley and on lever aasemtiy.lnpect the lever sasembiy and make crtain tien 500d Condition and thatthe erence passage i clean Dake certain that grooves in pulley are moots A that pulley 1s not chipped or eracked. Roe place fan drive belts i they are worm frayed H. FAN BELT TIGHTENER ASSEMBLY AND INSTALLATION 1, FAN BELT TIGHTENER ASSEMBLY AND 1 STALLATION (TRACK-TYPE TRACTORS) Fig. fy ross bail bearing (7 ato pay (6) so tat st |S Ugh against eountarbore in pulley. b. tactatt sear snap sing (8) and of sat (0) wi Staling Hp of eal cirected toward rear af rales. ©. Drive oF prese tghtener slide shaft into position in pulley. Install font snap ring 4 Install gasket (4) and patley cover (3) fe, Install fan belt tahtener on fan mounting Bracket, Tstall and adjust fan belts. { Labeicate fan etteghtner, through sbricsting ‘iting (1), aoing clean ball and roller bearing "abricant 2, FAN BELT TIGHTENER ASSEMBLY AND TN STALLATION (MOTOR GRADERS) Fig. 10 2 Insta nap ving (2) i pulley (8) >, Pross roar ball nearing (2) ita alley (9) lat rear face of bearing te below counterbore ‘Press oll seal (10) ito polly (9) with seating lip of sea) diracted tad rear of yuley 4. Place pulley (9) na prose, front end vp. Center ‘bearing spacer ‘@) oh inner race of ear ball vearing (0) and press ‘root ball bearing () into position in pales. Turn pulley assembly over and place a suite ale sleeve beteeen saner race of front ball bearing (6) and bed pte of the press, then press lever sesembly (it) into poston in pulley assembiy. Insal slotted nat (6) and ipten securely then Install enter pin (8, & Install cover gate (2) and palley cover (). Fl ightener with clean ball andlor bearing Inbricant trough lubricating tang. hy Install fan belt ughterer on fan mounting bracket, inal fan bub and’ adjust Tan and fenerator drive belts - FAN DRIVE REMOVAL, DISASSEMBLY AND INSPECTION (TRACK-TYPE TRACTOR ENGINES W/AMERICAN BOSCH FUEL INJECTION PUMP) FAN DRIVE REMOVAL (Fig. 1) naporrant Before attempting to remove the fan dive, Femove the timing window over trom the ot Snjactinn pr tent gins and Uetthe masked tots on the lange erive ear ts aligned with the ting mane Loosen tension on fan belts ant remove them from fan drive puliey Fig (3). . Remove capscrewe, Fig. I (17) and lock- vsshers (16) ana ‘remove pulley (@) trom ‘mounting ange Remote capscrens (15) and lockuashers (14) tnd remove fan drive anoroly from ing rar hong cove FAN DRIVE. DISASSEMBLY AND INSPECTION (mig. 11) A. Remove retaining mut (1) and drive Uimingsehalt (ia) from fan drive gest (1), . Using suitable puller tools, remove pulley mounting lange (]- Remove wodrat key (10) fe Remove flange (5) from besring retainer (8. 4. Press fan deive gear (11) from bearing ree tain () 6, Delve or press roll bearing 7) frm bearing retainer ‘pei 1901 _senvice manuay itaFig. 11 ~ Pan Drive Details (Prack=-Type Tractor Engines ‘9/Aimoricat Booch Fuel Injection Pam) (-70423) 1 Plange Retaining Nat 1. Roller Bearing 13, Peel Injection Pump 2 Fan Drive Pulley 8 Bearing Retainer ‘Timing Salt A Pulley stonting Mange 2 OnRing 14. Lackwashor t ouseal 10. Woodrutt Key 15, Capeere 5. Seal Retaining Flange 11, Pan Deve Gear 18 Locewasher Gasket 12, O-Ring Tt. Capecrew 41, Remove ofl sea 4) from geal retaining fangs Go. f Wash all parts in clean solvent of fuel and Inspect for wear or damage. —Hotate bearing by band and eheck for looseness, roughness, tid binding. Inspect interior. tod ererior teeth of fan drive sear for cracks of meat, Tspect bore in bearing retainer for sigs wear. Replace any worn or eamaged parte |. FAN DRIVE ASSEMBLY AND INSTALLATION (TRACK-TY@E TRACTOR ENGINES ‘W/ AMERICAN BOSCH FUEL INJECTION Pune) PAN DRIVE ASSEMBLY (Fig. 1) 4. Press coller bearing (7) ino bearing retainer (@) ntl ie botome in counterbore, by Lubricate bearing, and press fan drive gear (Gt) Se position Sa wearing . Tastall a, new ofl seat (2) tn seat retaining flange (5, with co spring side of sea facing Dearing. 4. Using @ now gasket (6), place flange (6) in position on Dearing retainer) 6, Install woodraf key (10) and pulley mounting fHange (9). Install retaining nit (2, ghten securely, and lock tut in postion by sting 2, PAN DRIVE INSTALLATION (Pig, 11) sta a new Ocring (12) on timing shaft (13) fad rive shaft into position in fan drive goar {tn “natal est spring in ond of tang eat, Db. Instat a now O-ring (9) on bearing retainer o. Remove timing access cover from tning 4 Start fan drive gear into mesh with camshat fear enters internal teeth of fan arive Rea, Sign marked tooth in fel injection pup wath timing mare, walng wrench on eof the ‘working trough the timing secese hole, Mold {Be pump in this positon and ps fan drive {nto potion on ming gear hous cover Note Due to the bella teth ofthe fan drive gear, {Ge fan drive ll rotate slightly to the eft ith th fel eeton po t nove te Imoved one toth to the right. Taiyo ral fnd error method and must be reposted itl ‘te mared tooth sx aligned wih the fst pointer when the fan drive a sted © Secure the fan drive tothe timing gear hosing over with apuerens (15) ad loershere (1) Install patley (2) 09 fan mounting ange (8) wth eapecrews (17 andock washers (8). Install and aus fan ett1b. Check Aiming of ful injection pump (refer 0 SPUEL SYSTEM" Section) lnstal Unig ‘window cover oa fel injection pomp. Install ‘Umning access cover on timing get housing AK. FAN DRIVE REMOVAL, DISASSEMBLY AND INSPECTION (CRAWLER TRACTOR EGINES w/ROOSA MASTER OR BOSCH (GERMANY) FUEL IWUECTION PUMP) 1. PAN DRIVE REMOVAL (Fig. 114) ‘Loosen tension on fan belts and remove them ‘rom fan drive pulley Remove capserens (I) andlockwaahers attaching Dolley (2) to pulley mounting ange (8) and ren ‘ove ple. ce. Remove capscrems (#) and lockvashers attaching fan drive bearing retainer (6) to ming gear housing cover and remove bearing retainer and Goring @ 2. FAN DRIVE DISASSEMBLY AND INSPECTION (Pig 114) 2, Romove retaining not (1) 1. Using itable puller tools, remove pulley mounting flange (B). Remove woodrlt key (10). © Prete fan drive goar (0) trom rotainor ) [Bearing cont (i1)"and Spacer (1) "wll be Fe moved withthe drive gear 4 Remove ofl seal (18) and bearing cone (18) ‘rom retainer (5) ef necessary, bearing eups (12) ant (18) can be ‘etoved with suitable puller tools. The bearing {serviced only as a unt and ire now bourne {6 fo be invaied the old bearing spacer snap ing (6) mst be removed andthe new one (Gurushed with thebearing) istalledin ite pce 4 Wast all parts in clean solvent or fel and ne pect for wear or damage. Rotate Bearings bp ‘band and cheek for looseness, roughness, nd Dining. tnepect teeth of fas dive soar or ‘ras oF wear. Inspect ores nbearingretalnar {for signe of wear and tke certain ll passages re open andetean, Replace ary wornor damaged caurion ‘The bearing te serviced only se aunitand must bbe installed as such. Never inermix parte of now bearing with parts from an old one. L FAM DRIVE ASSEMBLY AND INSTALLATION (CRAWLER TRACTOR ENGINES w/ROOSA ASTER OR BOSCH (GERMANY) FUEL UECTION PUMP) 1 FAN DRIVE ASSEMBLY (Fig. 114) a. Inotll bearing apacer snap ving (6) mn groove snore of boring retainer () eet 4 ‘ig. 11--Pan Drive Detail (Crawler Tvastor Eneines =/Rooes Master of Booch (Geeta) Fvelinjeetion Puss) (7237) 1. Capserow 1. Bearing Spacer 12, Bearing Cup 2 Ran Drive Pulley & o-nine 1X Bearing Gop & Pulley Mouiting Mange 2. Pan Drive Gear 14, Bearing Cone 4 Gapserew 10, Woorat Key 18, OM seal 5. Bearing Retainer 41, Bearing Cove 18, Flange Retaining Not Bearing pacer Snap Ring ‘ay SAFETY RULES, page ay fe pan ft a tin ay, Brass besring cups (12) and (18) into retainer {@) unl tay sre Heh again soap ring). Prose Bearing cone (1) onto fan driv gear (@) ‘il is ght against shoulder on shat (4 install bearing epacer (1) on shalt next to bear fg cone (1). Install fan drive geur (0) in bearing retainer cr 1 Prose bearing cone (14) onto shaft nti tis ‘lent nexint spacer (D Lubricate bearings and snatll @ new oft seal a5) 2 stall woodratt key (10) and pulley mounting ‘ange (3) on shat. 1, nll Mange retaining mt andtghton toa torque of 200 = 220 te. Lack mutby pacing 2. FAN DRIVE INSTALLATION (Fig. 114) 1 Install O-ring (8) om bearing retatnr and place fan drive assembly im portion oa ting gear housing cover. Secure with capecrews an lock= ». Placo fen drive pulley (2 in position on mount- ing ange (0) ant secure with espacrews and Toexwashers. atl fon drive belts on pulley and aust to proper tension (refer t9 "FAN BELT ADJUST Sig in tie Section) TOPIC 5 - FAN, FAN BELTS, AND FAN DRIVE (126 CRAWLER LOADER) A. DESCRIPTION ‘Tae 196 Craver Loador is oquippe with win pusber fan mounted atthe seas ofthe tracion.(& neverai~ ‘ie tan is svalinble as special eqipmoat. Bach fan hae ite own faa ub and mounting brackot The fans fre, driven by sltgle fan drive using 4 singe set oft Vevey, ‘The fan drive ip driven bp drive Shalt aseemiy whic ie aziven by & special power {ahe-otineorporstd in the torque convent. B. FAN BELT ADJUSTMENT lt are properly adjusted when they can bo do- pressed 2" to. 1" alfway betrecn te fan ceive ocombly and left side fan pulley. Acjst fan dive Dele 2 follower 1. Remove seat assembly, 2, Remove coter pin from dso aagombly pivot ‘apaerevs; loosen sloted nut 4. Loren strap attaching capserew and adjustment 4. Bey of puch fan drive assembly down to obtain 8, Hold fan drive aagombiy in this position and tighten sajstmentoapecrey, stra attaching cay ‘screw, an slotted not on pivot eapacrey. Secure C. FAN REMOVAL, INSPECTION, AND INSTALLATION 1. Remove radiators (refer to "RADIATOR RE MOVAL AND INSTALLATION in this Section}. 2 Remove eapserews attaching to fn hub and 3. tnapect fan for eraeka, loose rivets, oF bent blades, Repair or replace irneceasery 4. install fan by ctroot rovorsal of removal pro- . FAN BELT REMOVAL, INSPECTION, AND INSTALLATION 1, Remove left radiator (refer to "RADIATOR REMOVAL AND INSTALLATION in tha Go ton 2. Remove cotter pin from dive assembly pivot 8 oasen strap stachingcapserew and adjstmneht ‘apecrer 4 Retieve tenston on fan belts unit Belts ean be Dipped off of drive pulley. Remove fan belts. 5, nepect fan belle for exoessive atckness oll- oats ment, fears, cracks, and overateatcing ‘The tan belts are’ » matebed sot Irony ove OF panos antmacnve 8%. Barch 1979i vw } a ny]two belts need replacing, all three must bee placed to assure salisactory beltpertormance 5 tnatall fan vette by slipping belts over the fans and ino their proper pulley grooves. 1, Ads fan bells to proper tension, 4, mstall radiator (refer to"RADIATOR REMOVAL, AND INSTALLATION” in this Sesto . FAN HUB REMOVAL, DISASSEMBLY, INSPECTION, ASSEMBLY, AND INSTALLATION 1. Remove radiators (refer to" RADIATOR REMOV- ALAND INSTALLATION" inthis Seton. 2, Remove capserews attaching fan to fan nub and romove faa, Fig. 1B 4, Relieve tension on fan belts util belts ean be 4, Remove self-locking mi (4) andwaser (5) 5. Pull fan hub (8) from mounting bracket (4) 6, Remove wonerutf key and mounting spacer (1) 7. Remove snap ring (6) and pulley exp (. Presson threaded end of shai) and remove {an end bearing (@) bearing spacer (10) andshat. “Torey ands enanng baring 10, Remove bearing and bearing spacer Seam shat. 11, Wash alt parts thoroughty in cloansolventor fl SH and inapect parts for wets or camage. Rotate al beariage by hand and check for Looaebess, Fovghoess and binding. Inspect shaft and make (ortn ite not tent oF morn, Inapect fan ply {or wear and make certain that plley grooves re smth and that pulley ts mt chipped or 12, Press ball bearing (9) sno pulley enéotan hab 13, Prone bearing (0) onto shat 14, Pu cavity inside fant 1/3 ful wth bal bearing Ibicant. Preas shalt, sith apacer (10) tnplace, 15, Insta ol seal (12) and spacer (1 16, Install exp (7) 0 that cap ash to 1/32 below fan tub surface, then install snap ein (8) 17, Place fan nub assembly into place in fan racket (08) with woodrtt key An kepway. Install pain Wasner (9) abd nut (8). Torque mut to 280" 280, 18, Install fan belts and ad to proper tension 18, Attach fan to fan hb assembly. 20, install racators (rer to "RADIATOR REMOV- AL AND INSTALLATION in tho Seton, F. FAN DRIVE REMOVAL, DISASSEMBLY, INSPECTION, ASSEMBLY, AND INSTALLATION (F16. 11¢) 1, Remove lott radtor (refer to "RADIATOR RE MOVAL AND INSTALLATION" tn ths Section 2, Remove lot fan from fan tub. 45. Loosen eapzerew (19) and remove capscrew (1) 4. Remove cotter key (17) mt (18) andeapecrew (2) 5. tare fan detve assembly (1) off racket and fan 6. To remove fan drive shaft assembly (19), remove estrieting angle (3) and let fron flor plate 1 Unbott sront end yoke (20) from eoupting ange (2. Removesmaft assembly (1) rearwarsteom factor ', Removo ant (12) washer (2) and ply (1) rom Sat (3). Remove woodrll key andpuiley spacer ito. 8 Place assembly, with threaded end of shat up, fn sitahle press, Prese out te shat (3), seal (dh and spacer 10. Remove bearing (8) 20m shat (8) 1, Remove bearing (9) an sea (2) rombousing 12, Wash all parts in clean solvent or fuel oi and Inspect for wear or samago. Rotate beurings by and and check for Jowenees, roughness, and Dining. 15, To reassemble fan ceive assembly press bearing (5) onto shat (9) unt stottome aglnst shoul Install shaft snd bearing fate Nous (7 slp bearing spacer onto shaft and press bearing (@) foto housing and onto shat 14, Instat gate (4) (0) ato nousing oo toy are tush ‘th ends of oun 15, natal spacer (10), Key pulley, washer and aut ‘Torque mutt 250-360 Ie. 16, Tne fan drive and fn deve shaft assembiy by 1 dlpeet reversal of temoval proceasre Ape 1067 Sate PETTOPIC 6 - THERMOSTATS A. GENERAL “The two thermostats Jooated atthe front ofthe water tot manifold through the water bypase tube and tok tothe ilo side of he water mp. Before the thermostats open, the coolant cireuates thvcugh ‘te eagine circulating system oly. When the thermostats open, the e2olat treater (rows fhe raalntor and Whe engine Circulating system. 2 aster Conecting Tube 5 Water Outtet Rront Manifold ‘The thermortats are of the by-pass type. Both ‘ermastats ave an opening temperature. rate of 10°F. 1 does not make any dference tn thet op- ration ‘whieh, dhermonta i placed in the oat oF ‘Gormostats aro designed te start opening at 180°F. Sd to be fully opened at 109°F. Replacement of the termostats is necessary whenTHERMOSTAT REMOVAL, TESTING, AND INSTALLATION. 1. THERMOSTAT REMOVAL (Fig. 12) 2 Drain cooling system, {how to thermostat nodsing aba remove gasket . Remove capscrers (6) and lockrashers (0 Remove housing (10) and gasket (11). Remove ‘mermostate (0) 4. Clean and inspect housing (10) ant examine gasket (It) and scaly (@); replace garket or ‘To remove seas (8), py them fromthe seats fn thermostat housing. Install new seals inthe Inserts using a eutabie driver. Tae open side of the seal must be positioned towar! top of ertostat nosing 2. THERMOSTAT TESTING 2 Suspend thermostat a a pan of clean water bo that the thermontate aP0 completely ie , Gradually heat the water and use an accurate thermometer to check the temperature of the TOPIC 7- OIL Generar AL engines covered in thix manual are equlpped with fn éogine oil cooler excantthe engine ueed inthe ‘T1200 Tractor Loaser, Im ation to the engine ot cooter mostot the engines fre oqulpped with an engine claten 0 ooolee, oegue Converter oil cooler, andor a transtlestonciicooler ‘pending ‘spon the engine appliestion, Each oil cooler consists ofa eaoling core and a tar The eolant lows Ghrough the tabes of the core aha the lt circulates tough the tank B. Ol COOLER REMOVAL 1. BNGINE OIL COOLER REMOVAL, (TRACK-TYPE TRACTORS) ig. 19 2, Drain cooling systom, b. Remove ol iter body and filter element ce Remove capserews ($) and lockrashers (4) nore Stir water during tie proceaure sothathests evenly distributed inthe volume of water ©, Observe the thermostats as temperature ofthe Water reaches 160°F. Hf thermostats are hie tioning property, thermostats shoul begin fo open at 180°F. and be fully open at 195°F Dus or mine's" or ether tate ‘The termostata are not adjustable and they do not open or close wihin the sbove iis, THERMOSTAT INSTALLATION (Pig. 12) Place gasket (1) in postion and snstltthermo= sate ', Position housing (10) in position on mane (6) and secure with capacrems (6) and lockwashers m Place raditor snot elbow and asketin position Gn termontat hoveng aa secure wi cape ‘erews and loeloashers 4 Pa cots ayatem, COOLERS Allaching engine oll cooler (8) to bead as sembly 44 Romove capscrows (18) and lockwashers (1) aching” adapter (13) to. torque. converter Snw/or transmission oll cooler. Remove cape Screws (10) and lockvasbers (@) atacing ot cole () to eflinder block. ©. Remove engine oil cooler (3) and gnsets (2) (6) ane (12) om engine. Remove capserows (7) and lockwashers (8) and omove adapter (3) “and gaseet (II) trom ‘ngine ol ester (3) . ENGINE OIL COOLER REMOVAL (MOTOR GRADERS) Fig >, Discomect engine lubricating oil islet and ‘cate nes fran the oi cooler 8) ce Remove capscrens (18) and lockwashers (1) ‘april 1961 S82" SAFETY ALLE, pe 4 ah Ne en lee mie MY. SERYTCE MANUALFig, 13-Bogine Oil Cooler Detals (Track Type Tractors) (ratoas) 1, OU Filter Head 4 Lockoaaner aserbly 8 Kockwashor 2, Gasket 10. Capscrow 4 ingine Ot Cooler 11, Gat. 4 Loekwasher 12 Gasket 5 Capscrew AS Adapter & Gasket 1A, Lockovasher 1 Capserox 18, Capscrew attaching oll cooler (4) to wator inet con- nection (8 4 Remove capserows (17) (18) and lockwashor (48) (a) and remove engine ofl eoter (8) and Water outlet convection (i) fram he engine 25 En assembly. Remove guskats (2) and 3). 6, Remove capscrews (14) and loclwashers (15) And remove outlet connection (1) an! gasket {s) om oft eater SERVICE MANUAL 5. GN ott cooLER REMOVAL (rmacron Reler to "TORQUE CONVERTER OtL, COOLER RB- MOVAL (TRACTOR LOADERS)" sss Toc 4, TRANSNESSION, TORQUE CONVERTER, AND/OR ENGINE. CLUTCH OlL, COOLER REMOVAL (TRACK-TYPB TRACTORS) Fig. 18, ‘The front and rear covers (10) (1) are te sume on AI engines usea in track-tpe tractors, however, the {ype of oll cooler used doponts upon the engine ap= plcatin. ‘The rariou of coolersusedareiilustrated fn Fig, 19 and the followingemoval procedure apples toll ‘4 rain cooling aystemn, Disconnect hose (18). fe Disconneet all external hoses from the trans- ‘mission, torque converter and/or engin elteh 44, Romove capsorews and lockrashers attaching front cover (10) fool eooterte). {aching front ‘cover (10) to cylinder block and omove front cover spacing washer (14), abd faskets (13) and (2) oF (1 fil coolers) to rear cover (i and remove ol cooler. 5. TORQUE CONVERTER O11. COOLER REMOVAL (TRACTOR LOADERS) Fig. 18 », Disconnect ll external hoses from the oil cooler e+ Remove capscrows and lockwashers attaching water outlet connection (I) to ail cooer() and section and gasket (2), 4. Remove capserews and lockashers attaching fh coolers) to water inlet connection (2) ad remove ol cooler). 6. TRANSMISSION, TORQUE CONVERTER, AND ENGINE O1L. COOLER (2G CRAWLER LDADER [AND 145 WHEEL LOADER) Fig. 184 1 Drain cooling syste, ». Disconnect all external hoses and fbes fom oi ‘coolers al 1987 PETFig. 14-Engine Ol Cooler Details (Motor Graders) r=13160), 1, Water Ostet Connection nose 14, capserew 3. Water Pump 15, Lokwasher Lnckewasber 16 Lockwaster Cepscrew Tt, Gopserew Leleasher 18, Capecrew Water ftet Comection (Capscrew 18, Lackewaeber Loosen ogo clamps on hose (7. 4. Remove eapacrews attaching ol coolers (2) and (@) to rear cover 1) Remove eapacrew and nuts Attaching stort cover () t cyl ‘emove cover snd coolers 38 an lock ana sembly . Remove cayserems attaching oil coolerato cover @. ©. on cooter cteamine "To function sffilently the oil cooler tank and core ‘ust be Rept as clean as possible. Scale and odes (epost reduce the cooling eapacty ofthe ol cooler, ‘Whenever an oil cooler is removed from te eagine rif the efficiency of the cooler istmpatred doe to 3 Sccumplaton of sludge or scale the oil colar sel be cleaned 1m many repair shops and. service departments, iuatie compounds, are used to clean grensey diet, ‘aint eaakot Temuants, ster off parts. These come April 1967 pounds are voryelfective and very usefa when a Doperg bt cin eae seaiderae damage fo Materials sich as sluminus, rubber, fiber, sintered Dronse and bonding agents are particelariy tonnes tov all highly concentrated caustic cleaners, "There fre many of these cleaning compounds on the market, Under various trade names, but the majority of them be based on We sume active agent ~ sod hyo ile. Steam "Jenny" compounds also genorally con Some current ofl coolers and radiators are being manufactured with ahutainum fina, A few cleaning Solutions ave heen found to reac with aluelna fhe extent of alstolvng the metal. We recommend that Trichlorethylene solvet_or qutvalent be used for both intersal and extemal Clothing of ol coolers and radiators used ia Pinte Alli units since there ja no reaction bebveon seRvicE manuaL SeeFIG. 17 HEAT EXCHANGER "7.80457 FIRST TYPE: Used prior to engine serial number 11-21925, SECOND TYPE: Etfetive with engine serial number 11:21026, 1. Cover 6. Cover 2. Gasket 7 Stud 3. Exchanger 8. Gasket 4. Bxchanger 9. Hose 5. Gasket 10, Cover A won 4 12, 43, 4 45, ‘Trichlorethylene solvent is toxie and very volatile. Use only in a well ventilated room or area, Do not inkl the fume Do not allow i to come in contact with the skin. Gasket 16, Elbow 24. Gasket Gasket Yi ORing 22) Bracket Plange 18. Bow 23. Clamp Oring 19. Tube 24, Connector ‘Tube 20. Elbow In all clesning operations care must be taken inthe seloetion of cleaning materials, When any doubt exists as (0 whothor or not caustic compounds ‘would damage the materials to be cleaned, the se ‘of such compounds must be avoided. Study SAFETY RULES, pages | thru Il, thoroughy forthe protection of personal and machina safety. 2.23 (Revised 5-78)», OIL COOLER TESTING 1. Unga inprovsd sal, such w a metal pate and ‘ber gases iter the. ai Inet oF outlet ‘eorbote tote other openings 2.Submergee ll cole in water bested to appro ‘mately 180°. (82 °C) and alow sulfate fort coote to warm up, then est for Teak wing SF undo preate of 100 pa (1.0 ke! om?) or ‘ear tht prosur spoasle Ai bubbles observed at siher open end of the oi Cooler idate tata sling ore tube may hate 3 panetue or be defective in mother vey. IC coalng Sepa of ll Goler tani ir neem, he Papal st Imad bya reputable adatorrepa sho. O11. COOLER INSTALLATION 1. Refer to Fig’ 13 ehrw 17 and ital oleae 6) Syd several of renioral predate Use a keer uke are requ, (On late model enas, oly one (1) Ovni sed on ‘ich ad of ofl tbe, Fig, 175,18) O-ing ms Belcan end groove of each abe. Fil coling sytem, Operte engine and eheck for olor waa eae oi Soler comsetons. "Core ay lane found Check feolant evel i the radiator und addsoolnt Kt nec Sey. Check theo level of any felted components sch athe. cankew, engine clutch Gf ate), torque conver, andlor tansnision, Fl to the proper oe sth he soit TOPIC 8 - WATER PUMP |. DESCRIPTION ‘A cents type watoe pump is provided for cxclating oalant through the nie ad radiator. ‘The water pump i tange mounted on the font of the ene Uninet ousog and belt dient 1.26 times canshat spe ‘The pump sat i supported in he pump body by to ball Sher The impelerureaned om ie pup alt by tad cotter pin (st type) ot by fs i (cond Troe} A sp loaded al nem ands wate ingot Ie proved at the fon of the mele to pete colant ftom enesing the testing compartent side ofthe pump Body. "tne pomp safe and bariagt ewan fe pn boly bya wealngwaser rae these nto Oe Frnt of te pump bythe eter socked a pouion Into pump boy by Tock ‘The comstreton ofthe mater pump is conducve to Tong Le oti minim alten peonidag sal clan tet added tthe cooling stam. Water containing ex ‘nivel oF 6d i oepeciy amt to the com 1. WATER PUMP REMOVAL (Fg. 18) 1. Drain cooing system. Remove vd. 2.Diseonoct the water pump Wrcating hos if 50 cruel 3. Loosen sepraror alustiog am eapsren, move ‘seneretor ov, and slip belt off weer pup ple. Remove capers ad lokwsens secusing wer pup pally (1) to pulley flange and rerove the pully Remove capcrons and loskwasbers securing waler on sucebly (0) co ining pas bowing (22 Ree ove the water pump aera WATER PUMP DISASSEMBLY INSPECTION, AND ASSEMBLY WATER PUMP DISASSEMBLY (Fg. 18) 1.0 fist pe remore coir pin an impeller anne ut trom pup abt (5) Phe tapped ble ee pros Sided ine impale (2) for use of pallet eve Impate tom sh Uaing sutable bar expe pull, pull impeller from eat ‘The seal asembly (3 oF 19) is now accessible. Te ‘sal ssambiy replacement ony to be made, it wi ot be ecamry to emore Sat (8) fram pup. ‘Study SAFETY ULES, pages | thu Il thoroughly for the protection of personal and machine safety (Reet 578) 204T8041 FIG, 18 WATER PUMP FIRST TYPB: Used prior to engine serial number 11-27856, SECUND TYPE: ‘tletive with engme seal humber 11-21996, 1. Pumpassy, 6. Body 11, Seal washer 15, Pulley 19. Coramie sal 2 Impeller assy. 7. Bearing 12, Retainer 36. Gasket 20: Cover 3. Seal as. 8. Spacer 18. Lockwire YT. Gasket 24. Housing 4. Flinger 9. Bearing 1A, Flange 18, Volute 5. Shaftassy. 10: Ring washer Remove locking nut and retaining aut from pump shaft (8). Remove body (8) 4. Remove retainer lockwire (18) and turn seal: ing washer retainer (12) from pump body (6). Remove sealing washer (11) and ring ‘washer (10) from pump body. ‘© Place pump body (6) in postion in a press, ‘with Impeller end of shaft up. Pross on im peller end of shaft and remove shaft (3) Dearing spacer (8), and hearings (7) and (9) ‘rom the pump body. Pros shaft (5) from bearings. Study SAFETY RULES, pages | thru Il, thoroughly forthe protection of personal and machine 2.05 (Revised 5.78) 2, WATER PUMP INSPECTION (Fig. 18) Repair of wator pump will consist of replacement ‘of any worn or damaged parts. - If ceramic insert, bonded to impeller (2), i scored or rough, a new impeller must bein Stall. If sealing face of seal assembly (3) is scored or rough, drive seal asombly from bump body, , Clean and inspect bearings (7) and (9) tor looseness, roughness, and binding; replace it necessiy. ©. Thoroughly clean pump body (6) and check condition of beating bore in pump body. Replace pump body it necessary :Lrg, 19 ware romr-stcrionat view —! (uRst TYP) 1. pele Retsinng Nat 2 Cole Fin 3. Impaler 4. Soa Ano 8. Pun Sua T oodat Key & aterPump Body 9. Rear Ball Beung 10. Bearing Spacer 12) Retaining Washer 13, Selig Washor 18, Selig Waser Retainer 13, Retainer Locke TT, Flange Retaining Nut 18, Locking Nut 18. Gored Opening (Sa Dain Passage) 2D. Goramie nr Done tlie ‘503128 a (794 me) “BY OBS = 049 ty (0461.26 mm) Pst Type 18. Gra in (0.81.39 mn) Second Type ‘toms not usd on cond type 4 Inspect condition of pump shat (8) and water Hingse (ereplce i nocast, S. WATER PUMP ASSEMBLY (Pi. 18 nd 19) 4 Install water ings (4) om pump, sat (5) so hat ‘ged eas Toeted 03125 9 (1 94 mm) tom front fa of hte sone er iene A 3) Pros sear ball seng (1) ont ett (8) making feet thal sbllded side of Daring towards i fuller an sate Place bearing sucer (8) potion fn Sat Pes bering (7) ont Sal making een that ihisded ie of Baring towns pulley sd of eat ‘ace pump body (6) in poston ona prs, with im Daler dof body down Start shaft with Bering) {nto postion to pump body Presing om ier ane of ‘ont bal Burne pes shat (wth earn) nto postion in pump” bods. Whe presing sat into Damp. body, band pack ste betwens beatings al Fal with deca ballad oles boning aban. natal etal washer (20) In pump Bods. Inset ow seding waar (21) In sling washer stn fx (12) and tn retane nto pump body ene Ble inthe etainer ane ih bole a body fr he Ittner ostre. Intl! retaner Tock (03) Install asmbly (8) in psion on impale end {t pump shaft and lao postion inthe pum bed ‘tng eat to proven damgs fsa semi Make Sette eter weter mutase wiped die wih ‘Sr aleoent paper om lnttnce oth I thorough ‘nln eannot be accomplished is ay, as «nom taxi, oon‘lammable cleaning clution and thn ‘mpe’ clean DO "NOT APPLY Olly FOR GREASE ‘TO ine| CARBON WASiIER SURFACE Place ipller (2) in positon on pump shatt and Sar impale eiing rut. Tighten etait ut torn wrque 9°30 Ib (L190 bg Tae at pes impllor ont shaft 50 that a eentance of O18 (f9 In (046-124 mm} i provided. etme ‘of body (vler to dimension Sicond type Pcs sapport andor threaded end of sat sed prem fon impeler. Pace of impler mist be from O10 in {G05 mm) sbove to tah with end of sat TAS Sold" malatin the specified nance of 018 (072 ly (0384.88 mm) between imple and tae fice of body (ter to dimension "Bs Mg. 19 Tea fw impale ud, abd has protective wax Tie coming covering cerais sing ng, the coating ‘Bus be more Gere saseling pele t al (On sist type imal Woodeutt key ip postion in imp shaft and sae paloy Mange (18) onto bat Ital age rataing nut and etn nce hes oak staining na by intl locking aut Study SAFETY RULES, pages thrall, thoroughly for the prtecton of personal and machine eatty. (Revised 6.78). WATE PUMP INSTALLATION (ig 18) 1. hae water pump sembly (1) in positon in Sing ar, housing, making corn that gue (16) in food andi and that siled psn for ab ‘ting hose isa the top. Secure war Pump tO ling par housing with eapsrews ab loclwaer, 2 Insall water pump pully (15) apes on pulley ‘lange and seca with eapsrews and locewasber, 8. Intl brining hoo (iso equpped) fit king evan ha han en god eonon 4. Inntall and adios the water pump and generator tive be 5. Install che rit and fl colig pete, TOPIC 9 — COOLANT FILTER A. GENERAL, Met lat model engines coveted in this manual re equip pd wth coolant iter, Mig 20 ot Fz. 208. Mos: lee Ee mounted ons bree! acho to te enw. Woes {he ters sot "mount dnc on the eno, I ‘Mounded 10 che nae wih ground wie "The lake and outlet raves inst both be open. tore coolant ca erent through the fer, Colne eas the ‘ott ofthe titer and cielates upwerd throws the onowion resior plat, iter eement. and sper sate {Gotan aaer te tof the fier sad earn ta the ‘ooigsyse. perform the following funetons 1, linger sludge and abrasive dist su pended in th coolant 2. Prevents the formation of sele on metal suraces ‘tie the eoolng yom by emovng, through {Er loneashange resin contin in the coo, “Thr water” depot fom he colt, 8. Reduces rust fomation and conelon, ettecting (he mont dale ae aleve 4. Protdes »potetve tim on cooing system ses through combination of rast into cont Jn the er lmen 5, Prevents plting of metal tubes and walls within tho ool sistem by controling coetaiteStion {hough the cectochemies! sorarion estor pt ‘T8081 1G. 20 COOLANT FILTER DETAILS ——J (Ute rir to engine tel suber 1122075) 1. Filter body 4 Filter cleat 2 Spun 5. Upper pice 3. Coration 6. Gua reson pa 4 Cover ‘Study SAFETY RULES, pages! hv Il, thoroughly fr the protection of personal and machin sey. Rested 5.78)B, COOLANT FILTER SERVICE, ‘The coolant filter element must be changed after each 500 hours of operation, or more often de pending upon amount of coolant added to cool. Ing system duving this operating period, For detsled instructions on filter element replace- ment, refer {0 the OPERATION AND MAINTE. NANCE MANUAL furnished with the unit, - st 16 USAGE: Eitective with ongine s'n 11-22075 Valve Bushing Teo Drain cock ‘Tube Spacer FIG, 20A COOLANT FILTER AND LINES. ©. COOLANT FILTER REMOVAL AND INSTALLATION If for any reason the coolant filter must be re moved from engine, close inlet and outlet stut- oft valves, Disconnect inlet and outlet linee and either te move filter fom its mounting. bracket, or re ‘move filter and mounting bracket as an assm- bly. Install the filter by revesing the removal procedure 1. Bracket 8. Filter 9, Tube 10, Base assy. LL. Elbow (First type) Valve (Second typo) Study SAFETY RULES, pages | thru I, thoroughly or the protection of personal and machine sefety (Revised 6-78) 228SECTION 3 - ELECTRICAL SYSTEM 1 GENERAL AL Charging Cirexit 'B Cranking Cireut C Aeceatory Cireut WARRANTY AND ADJUSTMENT . ENERATOR BB Gonerstor Maintenance (GENERATOR REGULATOR A. Deseription BL Gonerator Regulator Removal and acai’ STARTER, 5: Sereer Series . Starter Removal and tasiitation A. Doseripton oe eee ALTERNATOR REGULATOR ‘A. Description = Operation ¢ TOPIC! - GENERAL ‘The stectleal eystem, whieh Snciudes the startory generator (or alternator) generator regulator (oF SIternator regelator), battles, amd ammeter i 824 ott ayetoun tnougnout, Currant 1s suppliee by wet {ell storage batterie, ‘Three ciruite wore together to mupply the neadoa electrical enerey~ A. CHARGING cIRCUIT ‘The basic units of the charging circuit are the bate feriesy generac, and generator regulator. The bat= fories! are. the storage plant for electrical enerzy Sud mist be lp fly charged while using a mis Shout of water. Retort the "Operator's tania”, ‘rished withthe unt forbatery testing information: Hlectrical energy, drained trom the battries, is replaced by the generator. Too much generator Gute Dt sll ustally burn out the generator ov damage the Eateries so they Will nt hold charge, To prevent this, 2 generator zegulator 1s comected into the uy APE RULES ape ie uy pena mai SERVICE MANUAL Tat (88) RANKING ciRcuIT ‘The basic units of the cranking cist are the bat= levies starter, solenoid suite, abd a Temte control fiten- The ‘remote control teh completes the "leat between the bsteies and solenoid teh. AS furrent flows through the solened, th drive pnionat the starter ta shifted ino mesh withthe yw) ring tran; the main conto in ie soleold close, cosnects {ng the batteries direety to the starter which turns the engine. When the engine starts and the remote fontrol vite (starter button oF ition key te Te= Ienee, the solenots contacts open and te drive nion {automatically dsongagod, ‘To prevent overheaing Sod damage, sever operate the starter for more than 530 roconds at's me. c. AccessoRY ciRcUIT ‘The accessory cireutiscomposedontirely of current= Consuming devices suoh a8 Ugh, horn, heaters, se In thin elreat, good conmections at junction pint, fises, switched, tod cireutt breakers, are importa fo prevent vollage losses which will reauce the sttitoney of Operation, october 1971 Beet PeTOPIC 2 - WARRANTY AND ADJUSTMENT Manufacturers of the batteries, starter, generator, fd generator regulator, doed on the anit are respon ible tor this esuipment during the warranty period, ‘ny claim for replacement or repr of an af coe lite must be presented to the manufacturer, aat TOPIC 3 - WI Henry cables comecttntries and starr, Al Chie Soe color code for etitextion proses ingen euny ott ny hae cos SSG cate protcting bots tre In gpd contin sod ‘roentgen cometons wp any Fayed iu tet tape to prevert t sicts"Chck al ae’ ip a me ern TOPIC 4 - A. DESCRIPTION The gonorator 16 @ direct current (DC) unit. The (Generaior pole pisces and the fld winding are SSationary and te fel lends sre Inealted fro the ouning High outpatrarrantfeetbe srmatare singe Shas (Cul) is pleked up by the Brasher when te B. GENERATOR MAINTENANCE Inspection of generator brishes, commutator, dive belt, sod terminal ‘connections “should be’ made periodiealy. 1, BRUSHES AND COMMUTATOR Brush spring tension must not be less, orexcoed, that specified by the manufactures, Excessive tension sell cause rapid wear of brishes and commutator: Tow tonsion will eauso arolngand reduced generator court 1 the brushes are worn down to less than Mal their rormal tee, ty should be replaced. New brushes Should be eater with a brush seating sone. Bo ot tse emery clot, Blow oat dest, If he committe {out of tound Gr rough, it thst be trued in late fr replaced. Aftor Uulng commutator, the mica Uetwoen the segments faust be undeeat 1/22". 2, GENERATOR DRIVE BELT ADJUSTMENT Keep drive belt properly adjusted. When the gen= erator drive belt can be pressed Inward, by band, S78 to 1/2" at point half-way between galley snd of uch equipment are represented by dicteibtars oF Gleaiers in nearly all cites; they are suihoried fo ‘make reasonable agjustments or replacements for thet respective companies. Always give the serial ‘umber of the unit and te date the uit aa delivered ‘then presenting latin af this mater IRING SYSTEM ‘To prevent possibilty of boty injury, always (iq elactreal system master siek handle to the “OFP" position o deeonnectatery round eable before cleaning, repeiring, ds Soret comesting any oe hy GENERATOR fan hu, the bolt ts property aajusted. To adjust dive Delt, loosen generator adjusting capecrewy move fencrator sp or down t0 obtain proper tension, ad flpiten the capscrews. ‘A Disconneet wiring harness from generator; ‘ety cables to sinlity Installation. Remove capscrews and locovasbersataching fseneralor to We generator mounting bracket Install gonerator by a reversal af the above roceaure ceaeearo8 Peroux Fig. 1 — Polariring Cireat Diagram (raison ‘Sludy SAFETY RULES, pages ! thru II, thoroughly forthe protection of personel and machine saely.maportant ‘onnecteg, st must be polarised. 4, POLARIZING GENERATOR 4. If generator ts eqaipred witha cover band, i= Sulte generator brushes from the armature by ‘ing’ piece of cardboard between the brushes {nl Sonmnnr, i gmerator ine aeletype Femoving the commutator end frame, Ison the tnsion on the gencrator drive bet and sip off of neratnr drive ply. by, Using a short Numper" ead, momentary touch vmpen"lead #9 "BAT" (Batley) andto "GEN" (Generator) terminals of the generator reg- Remove cardboard from under the generator Dushes snd inetall cover band oF install and Adjust genoator ve bat Do not run oF t26t tho generator on an open 1 st should necome necessary to operate the fenerator ‘without it being connectod to bat= fries, It showld he shore cireited. Ths can tbe done by disconnecting the lead comected to "GEN" termina of the regulator andconnectng the end of Testo 3 comventent ground TOPIC 5 - GENERATOR REGULATOR A. DESCRIPTION ‘The generator regulator, used to mkt the generator Gulia consste of three units, the suteout relay 0 prevent battery current drain when be generator Slows fw or stops! the voliage Fegulator‘o prevent system Voltage (rom exceeding a specified maxim, has ‘protecting the batory and ier toltage sensitive Sruipnent the current reswlator toil the current foutpat and prevent the generator from burning ott. 8. GENERATOR REGULATOR REMOVAL AND INSTALLATION Removal ofthe repulator may be accomplishoaby as lscrews, nats, and lockwashers. Be certain toidentify fhe wires so they can be reinstalled in the corvoct laeations Alter instalation ofthe roglatoratwayspolar- tne the sytem. TOPIC 6 - STARTER A. DESCRIPTION ‘The starter, mounted onthe engine fywheelhoasing is fn Sobrash, depole, 24svolt heavy duty uit. The “Armature i eupportodbybashings at drive end, centan, fa commutator end. A sprag tpeoverruningclitch {fused to mech drive pion of starter with the fy vio rng gsr B. STARTER stRvicE Field eeevice on starter wil be limited to cleaning of Starter, cleaning af commutator, replacement. of Drushes, brush springs, or starter svteh All other djustmente or repairs require wee of speci eqp~ ent. For tvs reason, twilbenecessary to remove tartar and ake Ht to a dapentable electrical rpalr Shop, whea repair oF adjustment is ncessary. With folly’ charged batteries the starter” wil engage Dromptiyané ora speine st an adequate cranking Speed. However, in cold wosther,"ezag" eased by old oi Between pistons and eylndér Wall, and the bearings of the spgine, causes engine Uo eran harder eporrant 30 seconds at anyon time without a pause to ‘Tho starter must NEVER be used tomove the vehicle. Folia to observe thoze rules may resulta failure 1, If atarter fits to operate proroly, remove ‘The commutator should be clean, aot out of fund or exrensively worn, and witoul Bsa fica. or burned bars A giaved or blsed Committee does aot indctte 4 conationre= Istactory condition on ausedunt.Allelectrial fonnestione shosld be kept clean and Wah, ‘brush spring tension shouldbe 88 cones, and ‘brushes must not be worn shorter than ball ‘Study SAFETY RULES, pages ! thr Il, thoroughly forthe protection of personal and machine safety.their original long. The brush springtension fan bo tested by atnching a small spring see to esch brush, directly under head of serew 2, A disty commutator should be cleaned with #00 andpape Never ure emery clth 1 dat and art have accumulated ia starter, it should be cloaned with compressed air as ‘such seoanlatons are likely W interfere with operation of oth starter and) searter die Siren. CContiued cranking of starter, ater starter ‘eriteh bation bas been reledsedy indieates Shorted taror sn the solendd switch windings, fr that the Soleoid switch i mounted oat Hine causing binding of the soloord plunger. Chattoring of te. solegold ‘switch indteates teri It ie recommented th the elena Switehes be takan to'a dependable electrical repair shop when ‘repair or adjstnest is G. REMOVAL AND INSTALLATION (oF STARTER 1, Torn electrical system master sviteh tthe ott Discomect strtor-to-ground strap. from Stator. Disconnect wiring, harness front * arter to tiywheel housing and remove stator find starter adapter, 4 Install starter by 2 direct reversal of removal TOPIC 7 — ALTERNATOR | DESCRIPTION ‘The altertor ie continuous output, diode rect fea, alternating current (AC) generatar, I normaly ‘il’ require very litle maintenance. ‘The bearings fre provided wth = self-coutainedqrense sippy ths etminating the noo for porte brea, 1W0 hp rings to the Weld’ cos) mounted on the Totar, Since the bruskes carry ony the smal eld eatrent fbi are stra long thy wl require litle atlention, ‘The stator windings of the generator are assembled tn the insia of elamisatedeorethatforms part of the {genorator frame, Siz rectifier dloles ae touted ia {he slip ring end fram and are comected tothe 8. OPERATION The diodes aro a unique feature of the alternator, ‘They fetion as electeieal chock valvon allowing current to. pass in ene direction only according to faeir potaity, Three negative dodes are mounted fn the nd frame. have postive diodes are mounted in 41 "oat SUNN” whe So inouated from he eo fre, By their ungue ability to permit current to pass Jn one direction ony, the diodes are able to convert ‘he pulsating alternating current from th stator winds Ings to airct current the generator cpt ternal, ‘The ability of the odes te permit current to pass frety ta 1 of opie posit of the Sods rem sires special precautions lo preclude reversing ths polarity of the’ battery or of charging oF boosting ‘ids tht may be connected tothe eine. Th follows Ing precautions must b oben 0, Be 1, Whon installing a batery, always mike sar the {round polarity ofthe taiory and the ateretor re tho same, Ifthe batory polarity loreversed, tho pattery willbe drzcty shortee trough 8 lode. Burved wiring harness and burned open Aiodes wal probably Tonle, 2, Whon connecting a booster baltery, make certain the uegatve battery termsnals are connected fo {elbur and the positive terminals are connested together, 8, When comecting @ charger to the battery, cote ‘net the. charger positive lesa tthe Utiay positive terminal ant th ebaeger negative eat {orth batory negative terminal, 4. Never operate tho altraator ca open circuit. Dako estan all connections tp the eros Ses fight and tess, Do not short acroes or ground any ofthe terme fia of the llecntar or regulator. © Do not attempt to palrize the alternator, 1 Prior to disconnecting or removing para ofthe lectceal system, turn electrical ays master ‘seen, handle to the “OF” position or aise ‘onnectbattery-to-ground eabler SERVICE MANUAL,TOPIC 8 — ALTERNATOR REGULATOR 1 DELCO-REMY: A, DESCRIPTION [A double contact regulator is used withthe alterna for, The terminate of the vegulator are of the slip ‘connection type and apecial connector boy on to loader wiring harness Se eyed to mating sot in the regulator base fo inrore proper connactions. pro ection on the consector bey sorves to atch the a8 fembly together to prevent aceLSental disconnection, ‘The vogslator assemly consists ofa double contact oltse reeslaor unit and a iolé relay uni The Yoltage regulator unit Hmite the altersator outpt lage ta. pre-aet value whoreas tho fold relay Sonnects the alleraator field winding drecty to te batony. 8. OPERATION When the starter swith is activated, the old relay Trindlng inthe reguintor is connected directly t te nti causing the contacts to close. This connects (he alternator ‘elt winding directly to the batary, Slowing els current to flow trom the battery to Us SERVICE MANUAL rogulator No. % terminal, through the field relay ‘contact and then through’ tho voltage rogulator (or Series) contacts, Current oxtinues to flow tothe ‘ogulator“"P” torminal and Wan Urough Us aterm {or field winding to ground, When the alternator bee fine to operate, AC wolages are gonerated inthe ‘Bator winlings These voles are then changed to DDC voltages the output terminal Hl MOTOROLA [A DESCRIPTION ‘Te rogutor 16 a fully tranststoried unt that has two base eizeults, te Load elreult abd the control flreui, It fe factory adjusted and coal and cannot ‘be adjusted inthe to, 8. OPERATION ‘The regulator i an electronic switeing device which Season the voltage at the subile key site an supe Bliss the necessary fold current to maintain system olage at the altraator output terminal.® © oC eoSECTION 4 - FUEL SYSTEM (WITH AMERICAN BOSCH FUEL INJECTION PUMP) re coxuman sasca MON. oe 2 effcrmna oF rues vereM ee oo 4 £ hogged Fuel Futers or Coltspsea Riel ithe : noe Thoporetive Fuel Pressure Relief Valve or Puc Transter Pulp” & Maltinetioning Fuel injection Noeale- Holder Assemblies Nalfunclining Fuel Infection Pump 3 FUEL FILTERS AND FUEL FILTER HEAD BL Piel Pter Head 4 UBL INJECTION NOZZLE-HOLDER ASSEMBLIES General Sel Injection Kéale-oLder Oparaion Furl Injection Noaale-Holser Service Ful Injection Norsle-Holaer Removal” 1 ‘Testing and Adjusting Pusl injection Nosate-Hotaees Novel spray" Pater Creaning and inpection of Fact Ian Node ‘Ruel injection Nowsiestslder Installation tioider UBL INTECTION NOZZLE-HOLDER SLEEVES B. Poe! Injection Nozale-Holder Sleeve Removal «- . |. ee G; Furl injection Nosrle-alder Sleeve Installation o « [FUEL INJECTION PUMP AND GOVERNOR, Description uel Injection Bip Oparation Fuel Injection Pump Service [Rue Injection Pump Removal © [Rel Injetion Pump Installation and ising ‘orermor Adjustment mppoep 1 VENTING OF FUEL SYSTEM |A. Venting of Low Pressure Feel System ‘ ant BL Venting of High Prensure Fuel System, : est a FUEL TRANSFER PUMP, BL Fuel Bransie® Pump Seivieo «| Poel Tranater Pump Removal and fsttiation TOPIC 1 - GENERAL DESCRIPTION system consists of to Gael pressure the fuel transfer pump (2). ‘The ful is ten forced ‘Tne engine ta Srstems, the low pressure, ayetom and the Mgh through the second stage filter (7) tothe fel Sn Dresrure eytam. Jetion pump (11, Once the injection pomp sump is [en the envess fact ite up preseure, pone tbe tn the tow pressure system, fuel is drawn from the fel presouro.rellf valve (10) flows tothe fer Fel tank through the frst stage ‘ker, Fig 1(8), by head (2) and returns tthe fue tab ‘Study SAFETY RULES, pages {hry Il thoroughly forthe protection of personal and machine sfey.erin ‘Bi nection Nose Holder Fuel Dressure Gauge RSL BSA Lise Ge Ba First stage Fue Puter Second Stage Fuel Filer Buel Tranter Purp ‘lel Pressure Rell Valve ‘Rul Injetion Pomp In the high pressure system the fae injection map ploks sp ‘atl from the low pressive sump, meteors find forces the fuel, nde extremely Meh preseure, Fiz 2— Location of tom Presure Fue ‘r=ti008) ‘Second Stage Fuel Futer Vent Screw Second Stage Fuel Pllter Shall Retaining Nut Filing fr Fuel Pressure Gauge Line Tirat Stayo Pel Filter Ven Serew Firat Stage vel Filter She etalon Net {the fuel injection nonales. The aozales spray ‘he fool Into the engine combustion chambers. "The fuel injection lines. are seamless’ ste] tubing te ch ine is the same length. Those lines bing of feat length aasores proper tang ai the proper ‘Shnountof foe to etch injection moze. ‘There is a certain amount of fuel seepage between the’ ‘lapped surfaces ofeach fvel injection nozzle ‘aive and its botyy whlch is necessary for ibrica- flon. “This teakage of fuel accamslatas around the te and in the sping compartment of exch foe, jection nozsle-holder and in retvtned through the feet retarn manifold tothe fel retara lies The fxover fio delivared to the fuel injection pump by ‘el transter pump flows lo the filter head sod TOPIC 2 - CHECKING OF FUEL SYSTEM ising” oF uneven running of the engine, exces ive Vibration, stalling when idling, and loss of fower are indications ef inalficient fel sappy to the engine. ‘Belore performing any of the following shocks, mako certain hore is ab ample supply of flean fuel in the fuel tank and thatthe foe ane Shutotlvalve Uo equipped) 38 open. 1B. AIR IN SYSTEM (Fig. 2) ‘Loosen the vont sevew (1) in top of second stage fue filter retaining mt (2). Crank engine with starter. {ffl containing babies fn from sro the rene forer, air being drawn into the. system on the Suction ide ofthe ful transfer pomp is inestoc. Correct this condition ty tighlening any loose ow ‘presse fel line connections first sage fue ter ‘Study SAFETY RULES, pages thru Il thoroughly forthe protectin of personal and machine safely. 4a> mca andthe fst sags ft ter set 1 ‘ins €. cLogeso rus rurEns on comLarseo ( a ( Poet Lines (Fg. 3) p— Loosen the vent stay () np asso tag tek : ‘Gia Scat (0? Sela" ot ete Ta doe ofc woskwtnon on Sten tment Yat set cognate o— itor he ors gps at age ol ter al Sig's uit ae cntos Enc samare asec es cage er Site tna eee ese ut tes 6 , iNoPERATIVE FUBL PRESSURE RELIEF \vatve on rust TRawsran PUMP ( a ‘The fue) transfer pump (2) shold deliver more fae) tothe Tue! sump of the fol injection pump tan 1s quired for engine operation. ‘The fuel pressure Folie! valve (1) connected into the fel return pase Fig. 4 — Fuel Prosgure Relief Valve Detalls fgo-of the Tool Injection pump, controls maximam re11529) fet Dresoure. within the fuel Simp of the injection pimp. ‘The valle! valve le. set to open between 8 Sha 50 pat. When fel pressure within the fel samp Soap Ring Eng Rolie Valve Stop Rule Valve Sop prin Ball elie Valve Body of te lection pump ences sel vale sting feet to retsmn tothe fol tne thrush te fac er heat and fel return ne ‘Check for an inoperative foel pressure relief valve (Gj"or an inoperative fuel transter pump (2) a5 foltows: 1, Start engine and operat at approximately one- ‘all trot, Observe te foe! presbare gangs Gauge shosid Insite a preswure of B30 pte It gauge indicates a pressurebelow peet~ ‘Hed minimum, stop engine and dceannoet te Fellefvalvectfilter hes fel return line (8). 2, Start engine and operate at approximately one low the tpecuied minimum, ets a ow ff fel is observed from datonnected retrn fine, this nteates that the. pressure rele waive (Q) sa stuck in the open position and the gwen indietes a pressure below speiied minim and ile oF no foo Is abearve rom ‘isconsected. return line, an inoperative foe "ig, 8 ~ Typleal Fuel Ietion Pump Tstalation tranafer pump (2) la Sodedted, aod the tran r=71408) fer pimp mist be removed, inpecte, and replaced ast uni if necenesry. 1. Fuel Pressure Relief Valve 7 2, Buel Tranater Pam 3. Ia pressure above 30 pal ia inteatea by the 8. Biel Injection Pump fier, the fool pressure relies valve (1) 12 AL Rolle Valvero- Filter Head Fuel Return Line Itopetative ana mast be replaced az sant. ‘Study SAFETY RULES, pages | thru Il) thoroughly forthe protection of personal and machine safely. 44 Stop engin and comect fel setae line (8). &. MALFUNCTIONING FUEL INJECTION NOZZLE-HOLDER ASSEMBLIES “stssing”oF uneven running ofthe engine and iss of goser face a mafnctotnuelijertion oi Section norslesolder assemblies ss flows Fun engine at low fle speed and “cut-out” each {oe injection noszle-Rolder In tara by loosening te {se injection line et staching the fel injection line toite corresponding fuel injection nozzlecholder. caution eep hands auay trom loosened nate while performing is tet. ‘A decrease in engine spood with injection line sat Teosened, ndleates that the Tuel injection aoaalee holder for Oat eplinder ss fasetionng properly. fogine speed does not decrease, the foe injston rozzle-holder 8 maituetioning and must be re- Moved, tested, adjusted snd cleaned fefer to "FUEL INJECTION NOZZLE-HOLDER ASSEMBLIES” ints Section. F. MALFUNCTIONING FUEL INJECTION PUMP Do not replace the fuel injection pump before making compression test (reer to "TROUBLE SHOOTING® Section. ‘The compression test wil sndiate whether oF not burned of stuck valves, worn oF scored pistons aed ‘Amproper engine operation. ginatedy andthe engine still rune vneveniy and normal engine performance Ss not obtained, the fel Injection pump Wil be considered at fault and shold be repaived or replaced. ‘The fslty feel injection Dump esth governor) shosld be taken to your nearest TOPIC 3 - FUEL FILTERS AND FUEL FILTER HEAD ‘The rat stage and second stage (uel fier each con tain npeplaceble element (6 (18). stand seckment fave collected by the frst stage fel iter (8) ant {Ei or sediment paesing throu the fret stage fuel filter and the fuel transfer pump so collected by the Second stage uel filler (3) and prevented. from fntering the fel injection pump. A arain cock (@) {provided sn the Bntiom ‘ofeach fel filer shell (@) Go) for araining any water oF setiment 1, SERVICE (Pig. 8 (Open te arin cook (8) sn the bottom of each fel ‘iter stot (@) (0) day, before te start ofthe aye (Of the day's operation in freering weather, and allow FIRST STAGE FUEL FILTER ELEMENT RE- PLACEMENT (Fi. 8) 8, Cloan all dirt from axound fitter head (17) and Shou! (@). "Loosen vent sevew (1) and drain oek (2) Sot Allow the ler stellt desi ose the 0 tank shat valve by Loosen retaining mt () ia the iter head nt Cig free from shall controle an remove ‘iner shell (from te iter head + Remove and discard fiter element (8)andsell fst (7 ‘Thoroushiy wash and ry ho 8 4, Install a new filter element and push it down Install & now shell gnskot (7) tn poston tx Up of the shell. Hot filter shel a psiion tudor ‘iter head and engage tareads of re= Sng wi se centro Fike the caution Do not overtshtes retaining mit (2). £. Close dratn cock (0). ‘Alter replacing titer elements, vont fue eys~ fem (eter to "VENTING OF FUEL SYSTEM" Initis Secon. 3. SECOND STAGE FUEL FILTER ELEMENT REPLACEMENT (Pig. 5) 2. Clean all aire from around filter head (17) Sint shell (10). Loosen vant serem (0) aid ‘aun cock (0) and allow filter shell to drain Study SAFETY RULES, pages | thru Il thoroughly forthe protection of personal and machine setey.Fig, § = Ps) Fier Beale « (T-22878) 1. Voot Screws 2, Copper Washers 5S. Seat taining Note 3 Gankete 5, Meeetead Pipe Pugs 8 Fiese Staze Fue Pitor Plement 4 Biter Sell Gaskets Pleat Stage Puc Filter Shell 5. Drain Cocks 10, Second tage Fuel Fer Shell Ti Element Sprine 12, Mota Washer 15, Element Seating Plate Gasket 14, Element Seating Plate 18, Second Stage Fuel Filter Element 18, Blement Centering Guides Tt, Biter Head nore cose te fuel tank shutatt valve '. Loosen retaining mot (3), inthe fiter hen, Cott ite ine from shell conterbolt and ree tove shel rom filter head, e+ Remove and discard Gilter element (15). Res move centering guide (16), clement soating ie (0 ating pie eae! G9) nd eat ard senting plate gasket (13), metal washer (aay, and shen gasket 4. Thorooshiy ash and dey seterior of tater ‘hel. Close and tonto drain cok (0) fe Place element spring (11), largo end down fall's now metal washer (12) over the shell Install a new seating plate gasket (18) in pos ton in element seating plate (1) then nett foment ceating” plato position on shell When installing element cating plato and (eset on. shell centrtolt, ital seating Plate so that the gasket contacts the metal + Ital centering guide (18) i position near the top of shell centerbolt and install new iter ftenent (19) in position in tho ster abel natal a new adel! gaskot (7) In position in Iip of fter shel. 1b, FU filter shell with CLEAN fool. Hold citer ‘hel in position under flter heed and instal ‘etining mat @) Sad gasket (@e“nugoon the ft securely. rove, AMter replacing fiterslemente, vent fel ays fam (refer to "VENTING OF FUEL SYSTEM Inthe Section) FUEL FILTER HEAD (Fig. 5) ‘The fuel ter head (17) 15 x manifold to collet and Gistetate fuel and also serves t= 8 holier forthe filter elements and iter skal ‘To remove fuel {iter head! from the engine, when Aismantling of sitere oF cloment replacement Is Dot ‘equired dre the following procedsre {Loosen went serews (1) Inthe tp of the filter heady and drain cocks () i tho bottom of fe Shells, "sllowing. the Alter” shells to drain ‘completely. (Close fuel tank shatott valve 2 Disconnect all hoses necessary to permit re= ‘Study SAFETY RULES, pages ! thru Il, thoroughly forthe protection of personel and machine safety.moral of the filter head, Retnove capscreva, Inekvashers, and nts ascuring te filter bead {othe moattng bracket and remove the a 4, Install fuel tor head using a reversal ofthe ‘owoval proceaure. Ven the fast system (for fer to "VENTING OF FUEL SYSTEM" in this Section). TOPIC 4 - FUEL INJECTION NOZZLE-HOLDER ASSEMBLIES ‘A. GENERAL (Fig. 6) Bach epider ofthe ongin is provided witha multi= hol, ‘aiforenial cede, nydrauliealy-ted fet ek fel injection nosslenhalder $8 10 direct the Iotered quantity of fuel, recetved from the fuel Infection pump, into the eorvespanding comustion Camber of the engine in highly atomized, pres etermined spray ptlern arin euch a coaer 8 to proaice the most efficient engine performance, ach uel injection aozsle-holder consists of two ASsenblieg the. holder assembly and nozzle S== Sembly. ‘The holder assembly 16 used to old the oezle In its correct postion ia the eflindar head tid to provide'a meant of conducting fuel, received {rom the fuel injection pump, t the potato. The holder assembly consists ot» older body (spindle (@), spindle spring (), pressure adustng screw (2), adjusting serew locks (3, protection eap (0), 20d norale etasing oat (12s ‘The nozele consists of & nonale valve (6), anda tonal valve body (L1) in whieh ia loctedtour equally ‘paced spray onices, ‘The nose is positioned on the folder body By two ‘mole, Fig. 7), 20 positioned that te four epray orifices are on 2 plate parallel to the top of to piston aad the fue) duct st the aaee ie vegistered 1. FUEL INJECTION NOZzZLE-HOLDER OPERATION ‘The metored quantity of fuel under pressure, dom Livered by the fuel injection pump, enters the fue Inlet pastage ‘of the soazle-helaer passes through the older fee. dsct into the novsie feel. ict and then into the pressure chamber above the nozalo valve seat.” At tho instant the pressure of the fact In the preanure chamber exceeds the presture ex fried. on the spindle and the ors ralve Oy te Spindle spring, the morse valve fs lifted off ts seat hd the fuel is foreed through the orifices inthe Gnd of the valve body and into the corresponding ‘combustion chamber of the engine. The nore valve ie returaod to ts seat by the pressure exerted by the spindle spring as soon 22 the fuel injection ‘pump bas ceased lo aller fuel i te nosse=tolder, ‘Thore ts a certain amount of fuel seepage inthe Pig. 6 — Fuel Injection Nogsle-Holder ~ tntaod oasis) Protection Cap Pressure Aajuting Screw ‘Adjusting Serew Lack Nut Sprung Retatning Net, Spine Sorin Holdor Body Soule st Dowel ‘ovale Retaining Nut Combstion Chamber Sole vale Nozale Valve Body roaale betreen the lapped surfaces of each noazle ‘alve and valve body, which ts necessary for bi ation, This leakage of ful accumulates sound fhe spindle and in the epring compartment of he honslecholéer, and ss seturmed ‘through the. foe ecumn tanfold ad fel Seturn lines tothe fel tak, Study SAFETY RULES, pages | thr il thoroughly for th protection of personal and machine safety.