Disassembly and Assembly SUPPLEMENTAL STEERING SYSTEM
Diverter Valve
SMCS - 1065-15; 1065-16
Removal, Disassembly and Inspection
DIVERTER VALVE REMOVAL
1. Outlet in valve for return of supplemental oil to tank. 2. Inlet in valve for supply of oil from the primary pump. 3. Inlet for supplemental oil supply from the hydraulic tank. 4. Outlet in valve for oil supply to inlet of valve for steering control.
5. Diverter valve. 6. Oil tubes between pump for the supplemental system and the diverter valve. 7. Location of reversing spool. 8. Pump for supplemental system.
Disconnect oil tubes at inlet and outlet openings (1), (2), (3), (4) and (6).
Remove the three bolts that hold the diverter valve to its bracket.
Lift the diverter valve from the machine.
DIVERTER VALVE
1. Outlet in valve for return of supplemental oil to tank. 2. Inlet in valve for supply of oil from primary pump. 3. Inlet for supplemental oil supply from the hydraulic tank. 5. Diverter valve.
Oil from the primary pump goes to inlet (2). The orifice pushed in the bore at inlet (2) is the control for oil pressure to the diverter spool. Each model of the diverter valve (used on the several machines) must have an orifice of the correct size. With an orifice that is the wrong size, the performance of the supplemental steering system will not be good enough.
CHECK VALVE REMOVED
2. Inlet in valve for supply of oil from the primary pump. 3. Inlet for supplemental oil supply from the hydraulic tank. 4.
Outlet in valve for oil supply to inlet of valve for steering control. 5. Diverter valve. 6. Inlets and outlets for oil tubes between pump for the supplemental system and the diverter valve. 7. Location of reversing spool. 9. Check valve.
Remove plug, spring and check valve (9). Check valve (9) must open for oil flow of the primary circuit from inlet (2) to outlet (4). When there is no oil flow from the primary pump, valve (9) must close to stop any oil flow from the supplemental circuit to inlet (2). When check valve (9) does not close, part of the oil of the supplemental circuit can go out inlet (2) and go to the tank through the primary pump. For good performance when there is no oil flow from the primary pump, all oil flow of the supplemental system must go out outlet (4).
Make an inspection for scratches or other damage to the check valve and its seat in the valve bore.
Oil to supply the supplemental circuit goes in inlet (3) to fill the manifold along the top of the valve. Two passages inside the valve make connections between the manifold and the bore for the reversing spool.
REVERSING AND DIVERTER VALVE SPOOLS
4. Outlet in valve for oil supply to inlet of valve for steering control. 5. Diverter valve. 10. Reversing spool. 11. Check valve. 12. Diverter spool.
Remove plugs, cap, reversing spool (10), check valve (11) and its spring, and diverter valve (12) and its spring.
The shim adjustment between the diverter valve and its spring makes the selection of the time when the diverter spool shifts to send supplemental circuit oil to either the steering circuit or to the tank. Do not throw away any shims that are between the diverter valve and its spring. The shims were installed during factory adjustment. Adding shims causes a delay in the shift of the diverter spool (12). The rate of primary oil flow must then be faster to give a larger difference in pressure between before and after the orifice. The engine rpm must be greater before the diverter spool shifts. Removing shims causes the diverter valve to shift when the flow of primary oil is at a lower rate.
Make an inspection of spool (12) for free movement in its bore.
When check valve (11) is closed, flow of supplemental oil is stopped from going to the passage that makes a connection with the valve bore for check valve (9) and the passage to outlet (4). If valve (11) does not close, some flow of the primary circuit oil must become part of the flow of supplemental oil and go back to the tank. Under this condition, the steering characteristics must become slower than normal.
When engine is under 900 to 1000 rpm, the diverter valve (12) shifts to stop flow of supplemental oil to the tank. When the flow of supplemental oil is stopped, the pressure increase opens check valve (11). Oil flow of the supplemental circuit then goes through a passage to the valve bore for check valve (9) and becomes part of the oil flow to the steering cylinders.
Oil flow of the supplemental circuit comes in inlet (2) and goes around reversing spool (10). Each change of direction of the machine causes the direction of pump rotation to change and the reversing spool to shift. The shift of the reversing spool makes a selection of one of the inlet-outlet (6) for sending oil to the supplemental pump. Supplemental oil comes back through the other inlet-outlet. Oil flow from the pump, going in either inlet-outlet (6) goes through a passage to the diverter spool (12).
Make an inspection of reversing spool (10) for scratches or other damage and for free movement in the bore of the valve. Copyright 1993 - 2021 Caterpillar Inc.
Rights Reserved.
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1. Put the pump in a vise with the shaft end of the pump on top. Put blocks of wood between pump and vise for protection of the pump.
2. Remove the eight hollow-head bolts (12). Lift flange (8) from body (2) of pump.
2. Body of pump. 8. Flange. 11. Drive shaft and gear assembly. 12. Hollow head bolts (eight).
PUMP
BACK-UP RINGS AND SEALS
6. Seals. 7. Back-up rings.
3. Lift seals (6) and rings (7) from around shafts.
BUSHINGS
BUSHINGS AND SEALS
2. Body of pump. 4. Bushing (two). 11. Drive shaft and gear assembly.
4. Bushing (two). 5. Spring pin (two). 6. Seal (two). 7. Back-up ring (two). 13. Dowel (two). 14. Ball (two).
REMOVING BUSHINGS
2. Body of pump. 15. Bore for drive shaft and gear assembly (11). 16. Bushings. 17. Bore for idler gear.
4. Lift drive shaft and gear assembly (11) part of the way out of the body of the pump. If the shaft assembly is not free, turn the shaft assembly and use small radial movements until it is free. Lift bushings (4) from around the shafts. Remove spring pin (5) and ball (14) from each bushing.
5. Lift the drive shaft and gear assembly (11) and the idler gear and shaft assembly (3) out of the body of the pump.
6. Remove body of pump (2) from vise. Turn the open end down. Let the body fall against a block of wood until bushings (16) fall from the body. Be careful so there is no damage to the face of the body that fits against the flange (8). Bushings (16) are the same as bushings (4).
7. Check the bores (15) and (17) in body for wear. Do not use a new body (2) unless a gear has worn more than .015 in. (0,38 mm) of metal from the bore in any area of (17).
8. Remove snap ring (10) from flange (8).
REMOVING SNAP RING
8. Flange. 10. Snap ring.
SEAL REMOVED
8. Flange. 9. Lip-type seal. 18. O-ring seal.
9. Put flange (8) on bench with the face that has the seat for seal (18) on top. Drive the lip-type seal (9) from the flange.
2. Use a handle (19) and a drive plate (20) to install lip-type seal (9) in flange (8).
INSTALLING BALL 14. Ball.
INSTALLING SPRING PIN
5. Spring pin.
3. Install a ball (14) and a spring pin (5) in bushings (16). Put a little clean grease in the holes for the spring pins to keep the pins from falling out.
4. Put a little clean grease on the two O-ring seals (6) and install in bushings (16).
5. Put a little clean grease on two back-up rings (7) and install them on bushings (16).
INSTALLING O-RING SEAL
6. O-ring seal.
INSTALLING BACK-UP RING
7. Back-up ring.
INSTALLING DOWEL
13. Dowel.
6. Put dowel (13) in one of the bushings. Put the flat side of the other bushing in a position so that its dowel hole will fit over the dowel. The ends of the bushings that have the seals must be side-by-side.
INSTALLING BUSHINGS
7. Put a little clean oil in the bores (15) and (17). Install bushings (16) in the body of the pump. The ends with the seals must be against the bottom of the pump chamber.
8. Install gear and shaft assemblies (3) and (11).
9. Do Step 6 again using bushings (4). Install the two bushing assemblies on the shaft assemblies in the body of the pump. The ends of the bushings with the seals must be against flange (8).
10. Put pump in vise as during disassembly. Put flange (8) in position so that dowel holes in flange fit dowels in pump body. Install bolts (12) and tighten.
11. Turn shaft (11). Shaft must turn freely and have no tight places.
12. Install the remainder of the bolts (12). Tighten the eight bolts to 30 to 35 lb. ft. (4,1 to 4,8 mkg).
Disassembly and Assembly 3304 VEHICULAR ENGINE FOR 920 & 930 WHEEL LOADERS
Accessory Drive Shaft (Compact Fuel System)
SMCS - 1207-12; 1207-11
Remove Accessory Drive Shaft
start by:
a) remove timing gear cover
b) remove fuel injection pump housing and governor
c) remove fuel transfer pump
NOTE: The engine is removed for photo illustration only.
1. Turn the fuel valve to the "OFF" position. The location of the fuel valve is under the fuel tank.
2. Remove the nut and washer that hold the drive gear to the accessory drive shaft.
3. Use tooling (A) to remove the drive gear from the accessory drive shaft. Remove the sleeve from the drive shaft.
4. Disconnect the fuel line from the fuel filter base and put caps and plugs on the openings to keep dirt and foreign material out of the fuel system.
5. Remove bolts (1), locks (2) and retainer (3) to remove the accessory drive housing (4) and fuel filter base from the engine as a unit.
6. Remove the drive shaft and bearing from housing (4).
7. Use tool (B) to remove the bearing from the drive shaft.
Install Accessory Drive Shaft
1. Heat the bearing to a maximum temperature of 275° F (135°C) and install it on the accessory drive shaft (1).
2. Install the sleeve for the drive gear on the end of drive shaft (1) next to the bearing.
3. Install drive shaft (1) in the accessory drive housing.
4. Put the fuel filter base, accessory drive housing (2) and the gasket in position. Install the retainer, locks and bolts to hold housing (2).
5. Turn the accessory drive shaft until tool (A) can be installed with the dowel holes in tool (A) in alignment with the dowels in housing (2).
6. Put the drive gear in position on the drive shaft and install the washer (with the outside diameter in contact with the gear) and nut (3). Tighten nut (3) to a torque of 100 ± 10 lb.ft. (135 ± 14 N·m).
7. Remove all plugs and caps from the fuel openings and connect the fuel line to the fuel filter base.
8. Turn the fuel valve to the "ON" position. end by:
a) install fuel transfer pump
b) install fuel injection pump housing and governor
Do not disconnect the air lines until the air pressure in the system is at zero.
1. Drain the coolant from the cooling system. The capacity of the system is 8 U. S. gal. (30 litre).
2. Open the drain valve on the air tank.
3. Remove water lines (1) and (3), and air inlet line (2) from the engine. Disconnect air lines (4) and (5) from the air compressor.
4. Disconnect oil line (8) from the air compressor.
5. Remove all of bolts (7) and (9) to remove air compressor (6) from the timing gear cover.
NOTE: For more information and to disassemble and assemble the air compressor, see SINGLE CYLINDER AIR COMPRESSOR, FORM NO. REGO1343 or AIR COMPRESSORS, FORM NO. REG00914 in the Disassembly and Assembly section.
Install Air Compressor
1. Put the air compressor (1) and gasket in position on the timing gear cover and install the bolts and washers to hold them.
2. Connect oil line (2) to air compressor (1).
3. Install air inlet line (5) and water lines (3) and (6) on the engine.
4. Connect air lines (4) and (7) to the air compressor.
5. Install the panel assembly to the right side of the rear frame.
6. Fill the cooling system with coolant to the correct level.
7. Close the drain valve on the air tank.
Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees.
Disassembly and Assembly 3304 VEHICULAR ENGINE FOR 920 & 930 WHEEL LOADERS
Alternator
SMCS - 1405-11
Remove Alternator
1. Remove panel assembly (1) from the left side of the machine.
2. Disconnect electric wires (2) and (3) from the alternator.
3. Loosen bolts (5) and (6) to remove vee belts (4) from the alternator pulley.
4. Remove bolts (5) and (6) and remove the alternator.
Install Alternator
1. If a new pulley has been installed on alternator (1), tighten the nut that holds it to a torque of 75 to 90 lb.ft. (100 to 120 N·m).
2. Put alternator (1) in position on the engine and install the bolts to hold it hand tight.
3. Put vee belts in position on the alternator pulley.
4. Use a belt tension gauge such as Borroughs Tool Company Part No. BT-33-72-4-15 or an equivalent and make an adjustment of vee belts (3). Measure the belt nearest the radiator. Tighten new belts until the gauge indication is 120 ± 5. Operate the engine at high idle for a minimum of 30 minutes after Step 5. Make another adjustment of the belt tension. The correct gauge indication for used belts is 90 ± 10. Tighten the bolts that hold the alternator in position.
5. Connect electric wires (2) and (4) to the alternator. Tighten the ground terminal nuts to a torque of 25 to 30 lb.in. (2.8 to 3.4 N·m). Tighten the positive terminal nuts to a torque of 225 to 250 lb.in. (25.4 to 28.3 N·m).
6. Install the panel assembly on the left side of the machine.
This is the sample of the manual click on the download link for complete manual
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