910 Cargador Frontal 40Y Motor 3204 Todos Los Sistemas

5/5/2016 910WHEELLOADER40Y00001UP(MACHINE)POWEREDBY3204ENGINE(SEBP125403)Documentation
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Welcome:r080am5
Product:COMPACTWHEELLOADER
Model:910COMPACTWHEELLOADER40Y
Configuration:910WHEELLOADER40Y00001UP(MACHINE)POWEREDBY
3204ENGINE
SystemsOperation
3204VEHICULARENGINE
MediaNumberREG0122205 PublicationDate01/03/1984 DateUpdated10/10/2001

SystemsOperation
Introduction
NOTE:ForSpecificationswithillustrations,makereferencetoSPECIFICATIONSfor3204VEHICULAR
ENGINE,FormNo.REG01254.IftheSpecificationsinFormREG01254arenotthesameasinthe
SystemsOperationandtheTestingandAdjusting,lookattheprintingdateonthebackcoverofeachbook.
UsetheSpecificationsgiveninthebookwiththelatestdate.
EngineDesign
DIENGINE
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PCENGINECYLINDERANDVALVELOCATION
Bore...4.50in.(114.3mm)
Stroke...5.00in.(127.0mm)
NumberandArrangementofCylinders...4,inline
FiringOrder(InjectionSequence)...1,3,4,2
RotationofCrankshaft(whenseenfromflywheelend)...counterclockwise
RotationofFuelPumpCamshaft(whenseenfrompumpdriveend)...counterclockwise
NOTE:Frontendofengineisoppositetoflywheelend.Leftsideandrightsideofengineareasseenfrom
flywheelend.No.1cylinderisthefrontcylinderontheengine.
FuelSystem
FuelFlow
FUELSYSTEMSCHEMATIC
1.Fueltank.2.Fuelreturnline.3.Fuelinjectionnozzle.4.Fuelinjectionline.5.Fuelinjectionpump.6.Primaryfuelfilter.7.
Fueltransferpump.8.Secondaryfuelfilter.9.Constantbleedvalve.10.Fuelinjectionpumphousing.
Fuelispulledfromfueltank(1)throughprimaryfuelfilter(6)byfueltransferpump(7).Fromthefuel
transferpumpthefuelispushedthroughsecondaryfuelfilter(8)andtothefuelmanifoldinfuelinjection
pumphousing(10).Abypassvalveinthefueltransferpumpkeepsthefuelpressureinthesystemat20to
40psi(140to280kPa).Constantbleedvalve(9)letsaconstantflowoffuelgothroughfuelreturnline(2)
backtofueltank(1).Theconstantbleedvalvereturnsapproximately9gal.(34liters)perhouroffueland
airtothefueltank.Thishelpskeepthefuelcoolandfreeofair.
Fuelinjectionpump(5)getsfuelfromthefuelmanifoldandpushesfuelatveryhighpressurethroughfuel
line(4)tofuelinjectionnozzle(3).Thefuelinjectionnozzlehasverysmallholesinthetipthatchangethe
flowoffueltoaveryfinespraythatgivesgoodfuelcombustioninthecylinder.
FuelInjectionPump
Thefuelinjectionpumpincreasesthepressureofthefuelandsendsanexactamountoffueltothefuel
injectionnozzle.Thereisonefuelinjectionpumpforeachcylinderintheengine.
Thefuelinjectionpumpismovedbycam(14)ofthefuelpumpcamshaft.Whenthecamshaftturns,the
camraiseslifter(11)andpumpplunger(6)tothetopofthestroke.Thepumpplungeralwaysmakesafull
stroke.Asthecamshaftturnsfarther,spring(8)returnsthepumpplungerandliftertothebottomofthe
stroke.
Whenthepumpplungerisatthebottomofthestroke,fuelattransferpumppressuregoesintoinletpassage
(2),aroundpumpbarrel(4)andtobypassclosedport(5).Fuelfillstheareaabovethepumpplunger.
Afterthepumpplungerbeginstheupstroke,fuelwillbepushedoutthebypassclosedportuntilthetopof
thepumpplungerclosestheport.Asthepumpplungertravelsfartherup,thepressureoffuelincreases.At
approximately100psi(690kPa),checkvalve(1)opensandletsfuelflowintothefuelinjectionlinetothe
fuelinjectionnozzle.Whenthepumpplungertravelsfartherup,scroll(9)uncoversspillport(10).Thefuel
abovethepumpplungergoesthroughslot(7),alongtheedgeofscroll(9)andoutspillport(10)backto
fuelmanifold(3).Thisistheendoftheinjectionstroke.Thepumpplungercanhavemoretravelup,butno
morefuelwillbesenttothefuelinjectionnozzle.
FUELINJECTIONPUMP
1.Checkvalve.2.Inletpassage.3.Fuelmanifold.4.Pumpbarrel.5.Bypassclosedport.6.Pumpplunger.7.Slot.8.Spring.9.
Scroll.10.Spillport.11.Lifter.12.Fuelrack.13.Gear.14.Cam.
Whenthepumpplungertravelsdownanduncoversbypassclosedport(5),fuelbeginstofilltheareaabove
thepumpplungeragain,andthepumpisreadytobeginanotherstroke.
Theamountoffueltheinjectionpumpsendstotheinjectionnozzleischangedbytherotationofthepump
plunger.Gear(13)isattachedtothepumpplungerandisinmeshwithfuelrack(12).Thegovernormoves
thefuelrackaccordingtothefuelneedsoftheengine.Whenthegovernormovesthefuelrack,andthefuel
rackturnsthepumpplunger,scroll(9)changesthedistancethepumpplungerpushesfuelbetweenbypass
closedport(5)andspillport(10)opening.Thelongerthedistancefromthetopofthepumpplungertothe
pointwherescroll(9)uncoversspillport(10),themorefuelwillbeinjected.
Tostoptheengine,thepumpplungerisrotatedsothatslot(7)onthepumpplungerisinlinewithspillport
(10).Thefuelwillnowgooutthespillportandnottotheinjectionnozzle.
FuelInjectionNozzle
Thefuelinjectionnozzlegoesthroughthecylinderheadintothecombustionchamber.Thefuelinjection
pumpsendsfuelwithhighpressuretothefuelinjectionnozzlewherethefuelismadeintoafinesprayfor
goodcombustion.
FUELINJECTIONNOZZLE
1.Carbondam.2.Seal.3.Spring.4.Passage.5.Inletpassage.6.Orifice.7.Valve.8.Diameter.
Seal(2)goesagainstthecylinderheadandpreventsleakageofcompressionfromthecylinder.Carbondam
(1)keepscarbonoutoftheboreinthecylinderheadforthenozzle.
Fuelwithhighpressurefromthefuelinjectionpumpgoesintoinletpassage(5).Fuelthengoesinto
passage(4)totheareabelowdiameter(8)ofvalve(7).Whenthepressureofthefuelthatpushesagainst
diameter(8)becomesgreaterthantheforceofspring(3),valve(7)liftsup.Whenvalve(7)lifts,thetipof
thevalvecomesoffofthenozzleseatandthefuelwillgothroughthefour.012in.(0.31mm)orifices(6)
intothecombustionchamber.
Theinjectionoffuelcontinuesuntilthepressureoffuelagainstdiameter(8)becomeslessthantheforceof
spring(3).Withlesspressureagainstdiameter(8),spring(3)pushesvalve(7)againstthenozzleseatand
stopstheflowoffueltothecombustionchamber.
FuelTransferPump
Thefueltransferpumpisasinglepistonpumpthatismovedbyacamlobeonthecamshaftforthefuel
injectionpump.
Whenthecamshaftturns,thecamlobemovestappet(1)intothepumpbody.Thetappetpushespiston(3)
againsttheforceofpumpingspring(6).Outletcheckvalve(2)closesandinletcheckvalve(4)inthepiston
opens.Fuelinfuelinletchamber(5)flowsthroughtheinletcheckvalvetotheoutletsideofthepiston.
Asthecamshaftcontinuestoturn,thecamlobeletsthetappetmoveoutofthepumpbody.Pumpingspring
(6)pushespiston(3)towardsthetappet.Inletcheckvalve(4)inthepistonclosesandoutletcheckvalve(2)
opens.Theforceofthepumpingspringpushesfuelthroughtheoutletcheckvalveandintothefuelsystem.
Theforceofpumpingspring(6)limitsthepressureofthefuelinthesystemsothatabypassvalveisnot
needed.
FUELTRANSFERPUMP
1.Tappet.2.Outletcheckvalve.3.Piston.4.Inletcheckvalve.5.Fuelinletchamber.6.Pumpingspring.
Governor
Thegovernorcontrolstheamountoffuelneededbytheenginetomaintainadesiredrpm.
Thegovernorflyweights(8)aredrivendirectlybythefuelpumpcamshaft.Riser(10)ismovedby
flyweights(8)andgovernorspring(1).Lever(7)connectstheriserwithsleeve(2)whichisfastenedto
valve(3).Valve(3)isapartofgovernorservo(5)andmovespiston(4)andfuelrack(6).Thefuelrack
movestowardthefrontofthefuelpumphousing(totherightintheillustration)whenmovedintheFUEL
OFFdirection.
GOVERNOR
1.Governorspring.2.Sleeve.3.Valve.4.Piston.5.Governorservo.6.Fuelrack.7.Lever.8.Flyweights.9.Overfuelingspring.
10.Riser.11.Springseat.12.Stopbolt.13.Torquespring.14.Powersettingscrew.15.Torquerisesettingscrew.16.Stopcollar.
17.Stopbar.
Theforceofgovernorspring(1)alwayspushestogivemorefueltotheengine.Thecentrifugal(rotating)
forceofflyweights(8)alwayspushtogetareductionoffueltotheengine.Whenthesetwoforcesarein
balance(equal),theenginerunsataconstantrpm.
Whentheengineisstartedandthegovernorisatthelowidleposition,overfuelingspring(9)movesthe
riserforwardandgivesanextraamountoffueltotheengine.Whentheenginehasstartedandbeginsto
run,theflyweightforcebecomesgreaterthantheforceoftheoverfuelingspring.Therisermovestothe
rearandreducestheamountoffueltothelowidlerequirementoftheengine.
Whenthegovernorcontrolleverismovedtothehighidleposition,governorspring(1)isputin
compressionandpushesriser(10)towardtheflyweights.Whentherisermovesforward,lever(7)moves
sleeve(2)andvalve(3)towardtherear.Valve(3)stopsoilflowthroughgovernorservo(5)andtheoil
pressuremovespiston(4)andthefuelracktotherear.Thisincreasestheamountoffueltotheengine.As
enginespeedincreases,theflyweightforceincreasesandmovestherisertowardthegovernorspring.When
therisermovestotherear,lever(7)movessleeve(2)andvalve(3)forward.Valve(3)nowdirectsoil
pressuretotherearofpiston(4)andmovesthepistonandfuelrackforward.Thisdecreasestheamountof
fueltotheengine.
Whentheflyweightforceandthegovernorspringforcebecomeequal,theenginespeedisconstantandthe
enginerunsathighidlerpm.Highidlerpmisadjustedbythehighidleadjustmentscrew.Theadjustment
screwlimitstheamountofcompressionofthegovernorspring.
Withtheengineathighidle,whentheloadisincreased,enginespeedwilldecrease.Flyweights(8)movein
andgovernorspring(1)pushesriser(10)forwardandincreasestheamountoffueltotheengine.Asthe
loadisincreasedmore,governorspring(1)pushesriser(10)fartherforward.Springseat(11)pullsonstop
bolt(12).Stopcollar(16)ontheoppositeendhaspowersettingscrew(14)andtorquerisesettingscrew
(15)thatcontrolthemaximumamountoffuelracktravel.Thepowersettingscrewmovesforwardand
makescontactwithtorquespring(13).Thisisthesetpoint(balancepoint).Ifmoreloadisaddedtothe
engine,enginespeedwilldecreaseandpushriser(10)forwardmore.Thiswillcausepowersettingscrew
(14)tobend(deflect)torquespring(13)untiltorquerisesettingscrew(15)makescontactwithstopbar
(17).Thisisthepointofmaximumfueltotheengine.
GovernorServo
Thegovernorservogiveshydraulicassistancetothemechanicalgovernorforcetomovethefuelrack.The
governorservohascylinder(3),cylindersleeve(4),piston(2)andvalve(1).
GOVERNORSERVO(Fuelonposition)
1.Valve.2.Piston.3.Cylinder.4.Cylindersleeve.5.Fuelrack.A.Oilinlet.B.Oiloutlet.C.Oilpassage.D.Oilpassage.
WhenthegovernormovesintheFUELONdirection,valve(1)movestotheleft.Thevalveopensoiloutlet
(B)andclosesoilpassage(D).Pressureoilfromoilinlet(A)pushespiston(2)andfuelrack(5)totheleft.
Oilbehindthepistongoesthroughoilpassage(C),alongvalve(1)andoutoiloutlet(B).
GOVERNORSERVO(Balancedposition)

Whenthegovernorspringandflyweightforcesarebalancedandtheenginespeedisconstant,valve(1)
stopsmoving.Pressureoilfromoilinlet(A)pushespiston(2)untiloilpassages(CandD)areopened.Oil
nowflowsthroughoilpassage(D)alongvalve(1)andoutthroughoiloutlet(B).Withnooilpressureon
thepiston,thepistonandfuelrack(5)stopmoving.
GOVERNORSERVO(FuelOffPosition)
WhenthegovernormovesintheFUELOFFdirection,valve(1)movestotheright.Thevalveclosesoil
outlet(B)andopensoilpassage(D).Pressureoilfromoilinlet(A)isnowonbothsidesofpiston(2).The
areaofthepistonisgreaterontheleftsidethanontherightsideofthepiston.Theforceoftheoilisalso
greaterontheleftsideofthepistonandmovesthepistonandfuelrack(5)totheright.
Dashpot
Thedashpothelpsgivethegovernorbetterspeedcontrolwhentherearesuddenspeedandloadchanges.
Thedashpothascylinder(1),piston(2),dashpotspring(3),needlevalve(5)andcheckvalve(6).Piston(2)
andspringseat(4)arefastenedtodashpotspring(3).
DASHPOT(GovernorMovingtoFuelOn)
1.Cylinder.2.Piston.3.Dashpotspring.4.Springseat.5.Needlevalve.6.Checkvalve.7.Oilreservoir.
WhenthegovernormovestowardFUELON,springseat(4)andpiston(2)movetotheright.This
movementpullsoilfromoilreservoir(7)throughcheckvalve(6)andintocylinder(1).
DASHPOT(GovernorMovingtoFuelOff)
1.Cylinder.2.Piston.3.Dashpotspring.4.Springseat.5.Needlevalve.6.Checkvalve.7.Oilreservoir.
WhenthegovernormovestowardFUELOFF,springseat(4)andpiston(2)movetotheleft.This
movementpushesoiloutofcylinder(1),throughneedlevalve(5)andintooilreservoir(7).
Ifthegovernormovementisslow,theoilgivesnorestrictiontothemovementofthepistonandspringseat.
IfthegovernormovementisfastintheFUELOFFdirection,theneedlevalvegivesarestrictiontotheoil
andthepistonandspringseatwillmoveslowly.
OilFlowForFuelPumpAndGovernor
Oilfromthesideofthecylinderblockgoestosupport(9)andintothebottomoffrontgovernorhousing
(4).Theflowofoilnowgoesinthreedifferentdirections.
Apartoftheoilgoestotherearcamshaftbearinginfuelpumphousing(5).Thebearinghasagroove
aroundtheinsidediameter.Oilgoesthroughthegrooveandintotheoilpassageinthebearingsurface
(journal)ofcamshaft(7).Adrilledpassagethroughthecenterofthecamshaftgivesoiltothefront
camshaftbearingandtothethrustfaceofthecamshaftdrivegear.Drainhole(6)inthefrontoffuelpump
housing(5)keepstheleveloftheoilinthehousingevenwiththecenterofthecamshaft.Theoilreturnsto
theoilpanthroughthetiminggearhousing.
Oilalsogoesfromthebottomofthefrontgovernorhousingthroughapassagetothefuelpumphousing
andtogovernorservo(2).Thegovernorservogiveshydraulicassistancetomovethefuelrack.
Theremainderoftheoilgoesthroughpassagestotherearofreargovernorhousing(3),throughcover(1)
andbackintoanotherpassageinthereargovernorhousing.Nowtheoilgoesintothecompartmentforthe
governorcontrols.Drainhole(8)keepstheoilatthecorrectlevel.Theoilinthiscompartmentisusedfor
lubricationofthegovernorcontrolcomponentsandtheoilisthesupplyforthedashpot.
Theinternalpartsofthegovernorarelubricatedbyoilleakagefromtheservoandtheoilisthrownbyparts
inrotation.Theflyweightcarrierthrustbearinggetsoilfromthepassageattherearofthecamshaft.
Oilfromthegovernorreturnstotheoilpanthroughaholeinthebottomofthefrontgovernorhousingand
throughpassagesinthesupportandcylinderblock.
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FUELPUMPANDGOVERNOR
1.Cover.2.Servo.3.Reargovernorhousing.4.Frontgovernorhousing.5.Fuelpumphousing.6.Drainhole.7.Camshaft.8.
Drainhole.9.Support.
FuelSystem
SchematicOfTheFuelSystem
1.Fuelinjectionline(undervalvecover).2.Fuelinjectionline.3.Housingforfuelinjectionpumps.4.Glowplug.5.Fuel
injectionvalve(PC)ornozzle(DI).6.Governor.7.Precombustionchamber.8.Fuelfilter.9.Fuelprimingpump.10.Fueltransfer
pump.11.Fueltank.
Thisenginehasapressuretypefuelsystem.Thereisoneinjectionpumpandoneinjectionvalveforeach
cylinder.Theinjectionpumpsareininjectionpumphousing(3)onthetopoftheengine.Theinjection
valvesforthePCengineareintheprecombustionchambers(7).FortheDIengine,theinjectionvalvesgo
throughthecylinderheaddirectlyintothecylinder.Bothtypesarefoundunderthevalvecovers.
Fuelispulledfromfueltank(11)throughafilterscreenintheinletvalveoffueltransferpump(10).The
fueltransferpumpsendsfuelthroughfuelfilter(8)tofuelmanifoldininjectionpumphousing.Fuelinthe
manifoldoftheinjectionpumphousingisthesupplyfortheinjectionpumps.
Theinjectionpumpsareintimewiththeengineandsendfueltotheinjectionvalvesunderhighpressure.
Whenthefuelpressureattheinjectionvalvesishighenoughthevalveopensandsendsfuelintothe
precombustionchamberordirectlyintothecylinder.
Fueltransferpump(10)hasapressurereliefspringthatcontrolsthemaximumfuelpressureoutputofthe
pump.Asthefuelpressureincreases,thepumppistonwillnotreturntoitsformerpositionsincetheforce
ofthespringononesideandthefuelpressureontheothersideareequal.Inthispositionthecamofthe
pumpcontinuestomovebutcannotreachthepiston.Withoutpistonmovement,nomorefuelcanbe
pumped.Whenthepressuredecreases,thespringrateagainpushesthepistonbacktowardthecamandthe
pistonstartstopumpfuelagain.
Whenthereisairontheinletsideofthefuelsystem,fuelprimingpump(9)isused.Operationofthe
primingpumpfillsthesystemwithfuel.Thisforcestheairbackintothetank,ortothepointwhereafuel
linehasbeenloosened.
FuelInjectionPump
Injectionpumpplungers(4)andlifters(8)areliftedbycamsoncamshaft(9)andalwaysmakeafullstroke.
Theforceofsprings(5)holdthelifters(8)againstthecamsofthecamshaft.
Whenthepumpplungerisdown,fuelfromfuelmanifold(1)goesthroughinletpassage(2)andfillsthe
chamberabovepumpplunger(4).Astheplungermovesup,itclosestheinletpassage.
Thepressureofthefuelinthechamberabovetheplungerincreasesuntilitishighenoughtocausecheck
valve(3)toopen.Fuelunderhighpressureflowsoutofthecheckvalvethroughthefuellinetothe
injectionvalveuntiltheinletpassageopensintopressurereliefpassageinplunger(4).Thepressureinthe
chamberthendecreasesandcheckvalve(3)closes.
CROSSSECTIONOFTHEHOUSINGFORTHEFUELINJECTIONPUMPS
1.Fuelmanifold.2.Inletpassageinpumpbarrel.3.Checkvalve.4.Pumpplunger.5.Spring.6.Gear.7.Fuelrack.8.Lifter.9.
Camshaft.
Thelongerperiodthattheinletpassageisclosed,thelargertheamountoffuelwhichwillbeforcedthrough
checkvalve(3).Theperiodforwhichtheinletpassageisclosediscontrolledbythepressurereliefpassage.
Thedesignofthepassagemakesitpossibletochangetheinletpassageclosedtimebyrotationofthe
plunger.Whenthegovernormovesfuelrack(7),itmovesgears(6)thatarefastenedtoplungers(4).This
causesarotationoftheplungers.
FuelInjectionValves
DirectInjectionNozzle
Fuelinlet(6)andnozzletip(13)arepartsofnozzlebody(11).Valve(8)isheldinpositionbyspringforce.
Theforceofthespringiscontrolledbypressureadjustmentscrew(3).Locknut(4)holdspressure
adjustmentscrew(3)inposition.Theliftofvalve(8)iscontrolledbyliftadjustmentscrew(2).Locknut
(10)holdsliftadjustmentscrew(2)inposition.Compressionseal(7)goesonnozzlebody(11).
Thecompressionsealgoesagainstfuelinlet(6)andpreventstheleakageofcompressionfromthecylinder.
Carbondam(12),atthelowerendofnozzlebody(11)preventsthedepositofcarbonintheboreinthe
cylinderhead.
FUELINJECTIONNOZZLE
1.Cap.2.Liftadjustmentscrew.3.Pressureadjustmentscrew.4.Locknutforpressureadjustmentscrew.5.Oringseal.6.Fuel
inlet.7.Compressionseal.8.Valve.9.Orifices(four).10.Locknutforliftadjustmentscrew.11.Nozzlebody.12.Carbondam.
13.Nozzletip.
Fuel,underhighpressurefromthefuelinjectionpumpgoesthroughtheholeinfuelinlet(6).Thefuelthen
goesaroundvalve(8),fillstheinsideofnozzlebody(11)andpushesagainstthevalveguide.Whenthe
forcemadebythepressureofthefuelismorethantheforceofthespring,valve(8)willlift.Whenvalve
(8)lifts,fuelunderhighpressurewillgothroughthefour.0128in.(0.325mm)orifices(9)intothe
cylinder.Whenthefuelissenttothecylinder,theforcemadebythepressureofthefuelinthenozzlebody
willbecomeless.Theforceofthespringwillthenbemorethantheforceofthepressureofthefuelinthe
nozzlebody.Valve(8)willmovetotheclosedposition.
Valve(8)isaclosefitwiththeinsideofnozzletip(13),andthismakesapositivesealforthevalve.
Whenthefuelissenttothecylinder,averysmallquantityoffuelwillleakbythevalveguide.Thisfuel
giveslubricationtothemovingpartsofthefuelinjectionnozzle.
PCTypeNozzle
Fuel,underhighpressurefromtheinjectionpumps,issentthroughtheinjectionvalvesintothe
precombustionchambers.Oneprecombustionchamberislocatedaboveeachcylinder.
Theinjectionvalveshavealargesingleorifice.Theactionofthefuelflowingthroughthisorificecauses
thefueltoatomize(changetoverysmalldrops).Thismakesitpossibleforthefueltoburnwithahigh
levelofefficiency.
HydraMechanicalGovernor
Theacceleratorpedal,orgovernorcontrol,isconnectedtothecontrolleverontheenginegovernor.The
governorcontrolstheamountoffuelneededtokeepthedesiredenginerpm.
Thegovernorhasgovernorweights(12),drivenbytheengine,governorspring(5),valve(14)andpiston
(15).Thevalveandpistonareconnectedtofuelrack(18).Thepressureoilforthegovernorcomesfromthe
engineoilpump.Pressureoilgoesthroughoilpassage(17)andaroundsleeve(16).Theacceleratorpedal,
orgovernorcontrol,controlsonlythecompressionofgovernorspring(5).Compressionofthespring
pushestogivemorefueltotheengine.Thecentrifugalforce(rotation)ofgovernorweights(12)pullstoget
areductionoffueltotheengine.Whenthesetwoforcesareinbalance,theenginerunsatthedesiredrpm
(governedrpm).
HYDRAMECHANICALGOVERNOR(TypicalExample)
1.Collar.2.Speedlimiterplunger.3.Leverassembly.4.Seat.5.Governorspring.6.Thrustbearing.7.Oilpassage.8.Drivegear
(weightassembly).9.Cylinder.10.Bolt.11.Springseat.12.Governorweights.13.Spring.14.Valve.15.Piston.16.Sleeve.17.
Oilpassage.18.Fuelrack.
Valve(14)isshowninthepositionwhentheforceofthegovernorweightsandtheforceofthegovernor
springareinbalance.
Whenthereisanincreaseinengineload,therewillbeadecreaseinenginerpmandtherotationof
governorweights(12)willgetslower.(Thegovernorweightswillmovetowardeachother.)Governor
spring(5)movesvalve(14)forward(towardtherightinpictureshown).Whenvalve(14)movesforward,
anoilpassagearoundvalve(14)openstopressureoil.Oilnowflowsthroughoilpassage(7)andfillsthe
chamberbehindpiston(15)(therearendofthevalvestopsoilflowthroughtherearofthecylinder,around
thevalve).Thispressureoilpushesthepistonandrackforwardtogivemorefueltotheengine.Enginerpm
goesupuntiltherotationofthegovernorweightsisfastenoughtobeinbalancewiththeforceofgovernor
spring(5).
Whenthereisareductioninengineload,therewillbeanincreaseinenginerpmandtherotationof
governorweights(12)willgetfaster.Thiswillmovevalve(14)backwards(towardtheleftinpicture
shown).Thismovementstopsoilflowfromtheforwardpassagethroughpiston(15)andallowstheoil
behindthepistontogooutthroughapassageattherearofthepiston,aroundvalve(14).Now,thepressure
oilbetweensleeve(16)andpiston(15)pushesthepistonandfuelrackbackwards.Thereisnowareduction
intheamountoffueltotheengine.Enginerpmgoesdownuntilthecentrifugalforce(rotation)ofthe
governorweightsisinbalancewiththeforceofthegovernorspring.Whenthesetwoforcesareinbalance,
theenginewillrunatthedesiredrpm(governedrpm).
WhenenginerpmisatLOWIDLE,aspringloadedplungerinleverassembly(3)comesincontactwitha
shoulderontheadjustmentscrewforlowidle.Tostoptheengine,pullbackonthegovernorcontrol.This
willletthespringloadedplungermoveovertheshoulderonthelowidleadjustmentscrewandmovethe
fuelracktothefuelclosedposition.Withnofueltotheenginecylinders,theenginewillstop.
Aftertheenginehasstopped,spring(13)movesvalve(14)andpiston(15)tothefullloadposition.This
movestheracktofulltravelpositionandgivesfullfuelflowthroughthefuelinjectionpumptostartthe
engine.
Oilfromtheenginegiveslubricationtothegovernorweightbearing.Theotherpartsofthegovernorget
lubricationfrom"splashlubrication"(oilthrownbyotherparts).Oilfromthegovernorrunsbackintothe
housingforthefuelinjectionpumps.
Inearlierengines,whenthegovernorcontrolismovedtofuelonpositiontostarttheengine,plunger(2)of
thespeedlimiterputsarestrictiononthemovementofleverassembly(3).Afteroilpressureoftheengine
getstoasafelevel,plunger(2)ofthespeedlimitermovesback(outoftheway)andthegovernorcontrol
canbemovedtoincreaseenginerpm.Laterenginesdonothaveaspeedlimiter.
Asmallforcefromspring(13)movesfuelrack(18)togivealittlemorefuelforenginestart.Withthe
enginerunning,therotationofgovernorweights(12)willputspring(13)incompressionandcausefuel
rack(18)tomoveback.(Spring(13)isextendedonlywhentheengineisstoppedoratstart.)Whenthe
engineisrunning,spring(13)isincompression.
AirInletAndExhaustSystem
AIRFLOWSCHEMATICOFTHEAIRINLETANDEXHAUSTSYSTEM(PCTYPESHOWN)
1.Inletmanifold.2.Cylinderhead.3.Airinletpassage.4.Exhaustvalvelocation.5.Intakevalvelocation.6.Exhaustmanifold.
Theairinletandexhaustsystemcomponentsare:airprecleaner,aircleaner,intakemanifold,cylinderhead,
valvemechanism,exhaustmanifoldandmuffler.
Theprecleanerandaircleanerfiltertheairbeforeitgetsintotheinletmanifoldandthepassageinthe
cylinderhead.Thiscleanairpassesthroughtheinletmanifoldandfillstheinletportsinthecylinderheads.
Airflowfromtheinletportintothecylinderiscontrolledbytheintakevalves.
Thereisoneintakeandoneexhaustvalveforeachcylinder.MakereferencetoValvesAndValveSystem
Components.Intakevalve(5)willopenwhenthepistonmovesdownontheinletstroke.Whentheintake
valveopens,airfromtheinletportispulledintothecylinder.Theintakevalveclosesandthepistonbegins
tomoveuponthecompressionstroke.Theairinthecylinderiscompressed.Whenthepistonisnearthe
topofthecompressionstroke,fuelisinjectedintotheprecombustionchamberabovethecylinderonthePC
engine,anddirectlyintothecylinderontheDIengine.Thefuelmixeswiththeairandcombustionstarts.
Theforceofcombustionpushesthepistondownonthepowerstroke.Whenthepistonmovesupagain,itis
ontheexhauststroke.Exhaustvalve(4)opens,andtheexhaustgasesarepushedthroughtheexhaustport
intoexhaustmanifold(5).Exhaustgasesthenpassthroughtheexhaustoutletpipe,themufflerandthe
exhauststack.Afterthepistonmakestheexhauststroke,theexhaustvalveclosesandthecycle(inlet,
compression,power,exhaust)startsagain.
ValvesAndValveSystemComponents
Thevalvesystemcomponentscontroltheflowofinletairintoandexhaustgasesoutofthecylindersduring
engineoperation.
Thecrankshaftgeardrivesthecamshaftgear.Thecamshaftgearmustbetimedtothecrankshaftgeartoget
thecorrectrelationbetweenpistonandvalvemovement.
Thecamshafthastwocamsforeachcylinder.Onecamcontrolstheexhaustvalvetheothercontrolsthe
intakevalve.
Asthecamshaftturns,thelobesofcamshaft(6)causelifters(5)togoupanddown.Thismovementmakes
pushrods(3)moverockerarms(2).Movementoftherockerarmsopenandclosevalves(4)(intakeor
exhaust)accordingtothefiringorder(injectionsequence)oftheengine.Thereisoneintakeandone
exhaustvalveforeachcylinder,andonerockerarmforeachvalve.
Valvesprings(1)causethevalvestoclosewhentheliftersmovedown.
VALVESYSTEMCOMPONENTS
1.Valvespring.2.Rockerarm.3.Pushrod.4.Valve.5.Lifter.6.Camshaft.
LubricationSystem
LubricationSystem(EnginesWithNewScrollFuelSystem)
SCHEMATICOFTHELUBRICATIONSYSTEM
1.Verticaloilpassageatrearofcylinderblock.2.Oilpassageincylinderhead.3.Rockerarms.4.Shaftfortherockerarms.5.
Oilsupplypassageforcamshaftbearings.6.Oilsupplypassageforbearingsofthecrankshaftandconnectingrods.7.Shaftfor
theidlergear.8.Pistoncoolingjets.9.Mainoilpassage.10.Bypassvalveforoilfilter.11.Oilpassagefromoilcoolertooil
filter.12.Oilpassagefromoilpumptooilcooler.13.Oilpassageinshaftforidlergear.14.Bypassvalveforoilpump.15.Oil
filter.16.Oilcooler.17.Bypassvalveforoilcooler.18.Suctionpipeforoilpump.19.Oilpump.
Thelubricationsystemofthisenginehasthepartsthatfollow:oilpan,oilpump,oilcooler,oilfilter,
bypassvalveforoilcoolerandoilfilterandoilpassagesinthecylinderblock.
Oilfromtheoilpanissentbyoilpump(19)toanoilpassage(12)attherightfrontofthecylinderblock.
Oilfromthispassagegoesthroughoilcooler(16)fromfronttorear.Fromtheoilcooler,theoilgoes
throughoilfilter(15)andthenintomainoilpassage(9).Themainoilpassageislocatedintherightsideof
thecylinderblock,justabovetheoilpassagefortheoilcooler.
Frommainoilpassage(9),oilgoesthroughoilpassages(5and6)tocamshaftbearingsandcrankshaft
bearingsandthroughoilpassage(13)toidlergearshaft(7).Oilinpassages(6)alsogoestopistoncooling
jets(8)innumbers2and4mainbearingsupports.Pistoncoolingjets(8)arepressedintodrilledholesin
thesupportsforthemainbearings.
Oilfortherockerarms(3)comesfrompassage(1)attheleftrearofthecylinderblock.Itthengoesintothe
cylinderheadthroughahollowdowelinthetop,leftsideofthecylinderblock.Passage(2)inthecylinder
headsendsoilintoanoilholeinthebottomoftherearbracketthatholdsshaft(4)fortherockerarms.The
oilthengoesintothecenteroftheshaftfortherockerarms,whereitispushedoutthroughsmallholesfor
lubricationofeachrockerarm.Someoftheoilisalsosentforlubricationofthevalves,pushrodsandvalve
lifters(camshaftfollowers).
Thereisanoillineconnectedfrommainoilpassage(9)toanelbowonthebottomofthefuelinjection
pump.Oilissentfromthiselbowforoperationandlubricationofthegovernor,andalsoforlubricationof
thepartsinthefuelinjectionpumphousing.Someoftheoilalsogiveslubricationtothebearingonthe
shaftofthefuelpumpdrivegear.Aftertheoilhasdoneitswork,itwillreturntotheengineoilpan.
Thereisabypassvalve(14)inthecoveroftheoilpump(19).Thisbypassvalvecontrolsthepressureof
theoilfromtheoilpump(19).Theoilpumpoutputcapacityisnormallylargerthanthesystemwillneed.
Whenthereismoreoilavailablethanneeded,theoilpressurewillincreaseandbypassvalve(14)will
open.Theoilthatgoesthroughthebypassvalveisnotneeded,andthisextraoilisreturnedtotheinletoil
passageofoilpump(19).
Withtheenginecold(startingconditions),bypassvalves(10and17)willopenandgiveimmediate
lubricationtoallcomponentswhencoldoilwithhighviscositycausesarestrictiontotheoilflowthrough
oilcooler(16)andoilfilter(15).Oilpump(19)sendsthecoldoilthroughthebypassvalvesaroundtheoil
coolerandoilfiltertooilmanifold(9)inthecylinderblock.
Whentheoilgetswarm,thepressuredifferenceinthebypassvalvesdecreasesandthebypassvalvesclose.
Nowthereisanormalflowofoilthroughtheoilcoolerandoilfilter.
Thebypassvalveswillalsoopenwhenthereisarestrictionintheoilcooleroroilfilter.Thisactiondoes
notletanoilcooleroroilfilterwitharestrictionpreventlubricationoftheengine.
EngineswithSerialNumbers45V1through45V32893
theidlergear.8.Mainoilpassage.9.Oilpassageinshaftforidlergear.10.Oilpassagefromoilcoolertooilfilter.11.Oil
passagefromoilpumptooilcooler.12.Bypassvalvefortheoilpump.13.Oilfilter.14.Oilcooler.15.Suctionpipefortheoil
pump.16.Oilpump.
Thelubricationsystemofthisenginehasthepartsthatfollow:oilpan,oilpump,oilcooler,oilfilterandoil
passagesinthecylinderblock.
Oilfromthispassagegoesthroughoilcooler(14),fromfronttorear.Fromtheoilcooler,theoilgoes
Fromthemainoilpassage,oilissentthroughpassages(5),(6)and(9)tothemainbearings,connecting
rods,camshaftbearingsandtheidlergearoftheaccessorydrive.
Oilforrockerarms(3)comesfrompassage(1)attheleftrearofthecylinderblock.Itthengoesintothe
cylinderheadthroughahollowdowelpininthetop,leftsideofthecylinderblock.Passage(2)inthe
cylinderheadsendsoilintoanoilholeinthebottomoftherearbracketthatholdsshaft(4)fortherocker
arms.Theoilthengoesintothecenteroftheshaftfortherockerarms,whereitispushedoutthroughsmall
holesforlubricationofeachrockerarm.Someoftheoilisalsosentforlubricationofthevalves,pushrods,
andvalvelifters(camshaftfollowers).
shaftoftheaccessorydrivegear.Aftertheoilhasdoneitswork,itwillreturntotheengineoilpan.
Thereisabypassvalveinthecoveroftheoilpump.Thisbypassvalvecontrolsthepressureoftheoilfrom
theoilpump.Theoilpumpoutputcapacityisnormallylargerthanthesystemwillneed.Whenthereis
moreoilavailablethanneeded,theoilpressurewillincreaseandthebypassvalvewillopen.Theoilthat
goesthroughthebypassvalveisnotneeded,andthisextraoilisreturnedtotheinletoilpassageoftheoil
pump.
Thissystempermitsaconstantcontrolledoilpressureforengineoperation.
EngineswithSerialNumbers45V32894Up
theidlergear.8.Mainoilpassage.9.Oilpassageinshaftforidlergear.10.Bypassvalveforoilfilter.11.Oilpassagefromoil
coolertooilfilter.12.Oilpassagefromoilpumptooilcooler.13.Bypassvalvefortheoilpump.14.Oilfilter.15.Oilcooler.
16.Suctionpipefortheoilpump.17.Oilpump.
Thelubricationsystemofthisenginehasthepartsthatfollow:oilpan,oilpump,oilcooler,oilfilterandoil
passagesinthecylinderblock.
Oilfromthispassagegoesthroughoilcooler(15),fromfronttorear.Fromtheoilcooler,theoilgoes
Fromthemainoilpassage,oilissentthroughpassages(5),(6)and(9)tothemainbearings,connecting
rods,camshaftbearingsandtheidlergearoftheaccessorydrive.
Oilforrockerarms(3)comesfrompassage(1)attheleftrearofthecylinderblock.Itthengoesintothe
cylinderheadthroughahollowdowelpininthetop,leftsideofthecylinderblock.Passage(2)inthe
cylinderheadsendsoilintoanoilholeinthebottomoftherearbracketthatholdsshaft(4)fortherocker
arms.Theoilthengoesintothecenteroftheshaftfortherockerarms,whereitispushedoutthroughsmall
holesforlubricationofeachrockerarm.Someoftheoilissentforlubricationofthevalves,pushrods,and
valvelifters(camshaftfollowers).
shaftoftheaccessorydrivegear.Aftertheoilhasdoneitswork,itwillreturntotheengineoilpan.
Thereisabypassvalve(13)inthecoveroftheoilpump(17).Thisbypassvalvecontrolsthepressureof
theoilfromtheoilpump(17).Theoilpumpoutputcapacityisnormallylargerthanthesystemwillneed.
Whenthereismoreoilavailablethanneeded,theoilpressurewillincreaseandbypassvalve(13)will
open.Theoilthatgoesthroughthebypassvalveisnotneeded,andthisextraoilisreturnedtotheinletoil
passageofoilpump(17).
Withtheenginecold(startingconditions),bypassvalve(10)willopenandgiveimmediatelubricationtoall
componentswhencoldoilwithhighviscositycausesarestrictiontotheoilflowthroughoilfilter(14).Oil
pump(17)sendsthecoldoilthroughthebypassvalvearoundtheoilfiltertomainoilpassage(8)inthe
cylinderblock.
Whentheoilgetswarm,thepressuredifferenceinthebypassvalvedecreasesandthebypassvalvecloses.
Nowthereisanormalflowofoilthroughtheoilfilter.
Thebypassvalvewillalsoopenwhenthereisarestrictionintheoilfilter.Thisactiondoesnotletanoil
filterwitharestrictionpreventlubricationoftheengine.
OilFilterBase
FLOWOFOIL(BypassValve(10)Closed)
FLOWOFOIL(BypassValve(10)Open)
CoolingSystem
SCHEMATICOFTHECOOLINGSYSTEM
1.Cylinderhead.2.Elbow.3.Radiatorcap.4.Coolantline.5.Cylinderblock.6.Waterpump.7.Coolantline.8.Engineoil
cooler.9.Coolantline.10.Radiator.
Waterpump(6)isdrivenfromthecrankshaftpulleybyaVtypebelt.Thewaterpumpgetscoolantfrom
thebottomofradiator(10)andsendsitintowaterpassagesofcylinderblock(5).Thesepassagessend
coolantaroundthecylinderstotakeawaytheheatofcombustion.
Someofthecoolantinthecylinderblockissentthroughcoolantline(7)intooilcooler(8)tocooltheoil
forlubricationoftheengine.Thecoolantthengoesthroughline(9)totheinletsideofthewaterpump.The
remainderofthecoolantincylinderblock(5)goesupintocylinderhead(1).
Coolantmovesthroughthecylinderheadtoathermostatunderelbow(2)atthefrontoftheengine.Ifthe
coolantiscold(cool),thethermostatwillbeclosed.Thecoolantwillgothroughapassageinthefront
covertothewaterpump.Ifthecoolantiswarm,thethermostatwillbeopenandcoolantwillgothrough
line(4)andintothetoptankofradiator(10).Coolantthengoesthroughthecoreoftheradiatortothe
bottomtank,whereitisagainsentthroughthecoolingsystem.
Radiatorcap(3)isusedtokeepthecorrectpressureinthecoolingsystem.Thispressurekeepsaconstant
supplyofcoolanttothewaterpump.Ifthispressuregoestoohigh,avalveintheradiatorcapmoves
(opens)togetareductionofpressure.Whenthecorrectpressureisinthecoolingsystem,thevalveinthe
radiatorcapmovesdown(closed).
NOTE:Thethermostatisanimportantpartofthecoolingsystem.Ifthethermostatisnotinstalledinthe
systemmostofthecoolantfromthecylinderheadwillgototheradiator.Thiswillresultinhighflow
throughtheradiator,reducingtheamountofheatrejectionfromthecoolant,causingboilingtotakeplaceat
thewaterpumpinlet.Thisresultsinwaterpumpcavitationwhichreducestheflowofcoolanttotheengine.
Bothconditionsresultsinoverheating.Incoldweatherthecoolantthatflowstotheradiatorwillalsobetoo
much.Theenginewillnotgettonormaltemperatureforoperation.
BasicBlock
Crankshaft
Thecrankshaftrotationchangesthecombustionforcesinthecylinderintousabletorquethatpowersthe
machine.Thereisagearatthefrontofthecrankshafttodrivetheaccessorydrivegear,camshaftgearand
theoilpumpgear.
Thecrankshaftissupportedbyfivemainbearings.Pressureoilissuppliedtoallconnectingrodbearing
surfacesthroughdrilledholesinthecrankshaft.
Lipsealsareusedatbothendsandawearsleeveisusedattherearofthecrankshaftforeasyreplacement
andareductionofmaintenancecost.
Camshaft
Thisengineusesasingle,forgedcamshaftthatisdrivenatthefrontendandissupportedbyfourbearings.
Eachlobeonthecamshaftmovesavalvelifter,whichinturnmovesapushrod,rockerarm,andavalve
(eitherexhaustorintake).Therearetwolobesforeachcylinder.
PistonsAndRings
Thecastaluminumpistonhastworingsonecompressionringandoneoilring.Theringsarelocatedabove
thepistonpinbore.Thecompressionringisastandard(conventional)type.
Theoilringisastandard(conventional)typeandisspringloaded.Holesintheoilringgrooveprovidefor
thereturnofoiltothecrankcase.
Thedirectinjectionpistonhasaspecialshape(cardioiddesign)ofthetopsurfacetohelpcombustion
efficiency.Thispistonalsohasataperedpinbearingdesign.Thisprovidesalargersurfaceareaatthetopof
thepinbearingtotaketheloadofthepowerstrokemoreevenly.
Theprechamberpistonhasasteelheatplugassembledinthepocket(crater)ontopofthepiston.Thisplug
protectsthetopofthepistonfromerosion(distortionbyheat).
Thepistonpinisretainedbytwosnapringswhichfitingroovesinthepinbore.
ConnectingRods
TheDIconnectingrodeyeendhasthetapereddesignwiththelargerbearingsurfaceatthebottomofthe
eye.Thisprovidesmoresurfaceareafortheincreasedloadofthepowerstroke.
ThePCconnectingrodeyehasthestandard(conventional)typebearing.
ElectricalSystem
Theelectricalsystemhasthreeseparatecircuits:thechargingcircuit,thestartingcircuitandthelighting
circuit.Someoftheelectricalsystemcomponentsareusedinmorethanonecircuit.Thebattery(batteries),
disconnectswitch,circuitbreaker,ammeter,cablesandwiresfromthebatteryareallcommonineachof
thecircuits.
NOTICE
Thedisconnectswitch,ifsoequipped,mustbeintheONpositiontolet
theelectricalsystemfunction.Therewillbedamagetosomeofthe
chargingcircuitcomponentsiftheengineisrunningwiththe
disconnectswitchintheOFFposition.
Thechargingcircuitisinoperationwhentheengineisrunning.Analternatormakeselectricityforthe
chargingcircuit.Avoltageregulatorinthecircuitcontrolstheelectricaloutputtokeepthebatteryatfull
charge.
Ifthemachinehasadisconnectswitch,thestartingcircuitcanoperateonlyafterthedisconnectswitchis
putintheONposition.
Thestartingcircuitisinoperationonlywhenthestartswitchisactivated.
Thestartingcircuitofa"PC"enginecanhaveaglowplugforeachcylinder.Glowplugsaresmallheating
unitsintheprecombustionchambers.Glowplugsmakeignitionofthefueleasierwhentheengineisstarted
incoldtemperature.
Thelowamperagecircuitandthechargingcircuitarebothconnectedthroughtheammeter.Thestarting
circuitisnotconnectedthroughtheammeter.
ChargingSystemComponents
Alternator
ThealternatorisdrivenbyaVtypebeltfromthecrankshaftpulley.Itisa12volt,40ampereunitwitha
regulatorwhichhasnomovingparts(solidstate).Theonlypartinthealternatorwhichhasmovementis
rotorassembly(9).Rotorassembly(9)isheldinpositionbyaballbearingateachendofrotorshaft(8).
Thealternatorismadeupofaframe(3)onthedriveend,rotorassembly(9),statorassembly(5),rectifier
assembly(11),brushes(7)andholderassembly,sliprings(13),rearendframe(12)andregulator(6).Drive
pulley(1)hasafan(2)forheatremovalbythemovementofairthruthealternator.
ALTERNATORSCHEMATIC(WITHREGULATORATTACHED)
1.Pulley.2.Fan.3.Driveendframe.4.Statorcoils.5.Statorassembly.6.Regulator.7.Brushes.8.Rotorshaft.9.Rotor
assembly.10.Fieldwindings.11.Rectifierassembly.12.Rearendframe.13.Sliprings.
Rotorassembly(9)hasfieldwindings(10)(wiresaroundanironcore)whichmakemagneticlinesofforce
whendirectcurrent(DC)flowsthroughthem.Astherotorturns,themagneticlinesofforcearebrokenby
statorassembly(5).Thismakesanalternatingcurrent(AC)inthestator.Rectifierassembly(11)hasdiodes
whichchangethealternatingcurrent(AC)fromthestatortodirectcurrent(DC).Mostofthedirectcurrent
(DC)goestochargethebatteryandmakeasupplyofdirectcurrent(DC)forthelowamperagecircuit.The
remainderofthedirectcurrent(DC)issenttofieldwindings(10)throughbrushes(7).
AlternatorRegulator
Theregulatorisfastenedtothealternatorbytwodifferentmethods.Onemethodfastenstheregulatortothe
top,rearofalternator.Withtheothermethodtheregulatorisfastenedseparatelybyuseofawireanda
connectorthatgoesintothealternator.
Thevoltageregulatorisasolidstate(transistor,nomovingparts)electronicswitch.Itfeelsthevoltagein
thesystemandgivesthenecessaryfieldcurrent(currenttothefieldwindingsofthealternator)forthe
alternatortomaketheneededvoltage.Thevoltageregulatorcontrolsthefieldcurrenttothealternatorby
switchingonandoffmanytimesasecond.Thereisnovoltageadjustmentforthisregulator.
StartingCircuitComponents
Solenoid
Asolenoidisamagneticswitchthatdoestwobasicoperations:
a.Closesthehighcurrentstartermotorcircuitwithalowcurrentstartswitchcircuit.
b.Engagesthestartermotorpinionwiththeringgear.
SOLENOIDSCHEMATIC
Thesolenoidswitchismadeofanelectromagnet(twosetsofwindings)aroundahollowcylinder.Thereis
aplunger(core)withaspringloadinsidethecylinderthatcanmoveforwardandbackward.When
electricityissentthruthewindings,amagneticfieldismadethatpullstheplungerforwardinthecylinder.
Thismovestheshiftlever(connectedtotherearoftheplunger)toengagethepiniondrivegearwiththe
ringgear.Thefrontendoftheplungerthenmakescontactacrossthebatteryandmotorterminalsofthe
solenoid,andthestartermotorbeginstoturntheflywheeloftheengine.
Thetwowindingsinthesolenoidaretheholdinwindingandthepullinwinding.Bothhavethesame
numberofturnsaroundthecylinder,butthepullinwindingusesalargerdiameterwiretoproducea
greatermagneticfield.Whenthestartswitchisclosed,partofthecurrentflowsfromthebatterythruthe
holdinwinding,andtherestflowsthruthepullinwindingstomotorterminal,thenthruthemotorto
ground.Whenthesolenoidisfullyactivated(connectionacrossbatteryandmotorterminaliscomplete),
currentisshutoffthruthepullinwindings.Nowonlythesmallerholdinwindingsareinoperationforthe
extendedperiodoftimeittakestostarttheengine.Thesolenoidwillnowtakelesscurrentfromthebattery,
andheatmadebythesolenoidwillbekeptatanacceptablelevel.
Whenthestartswitchisopened,currentnolongerflowsthruholdinwindings.Thespringnowpushesthe
plungerbacktotheoriginalposition,and,atthesametime,movesthepiniongearawayfromtheflywheel.
OtherComponents
CircuitBreaker
Thecircuitbreakerisaswitchthatopensthebatterycircuitifthecurrentintheelectricalsystemgoes
higherthantheratingofthecircuitbreaker.
CIRCUITBREAKERSCHEMATIC
1.Resetbutton.2.Discinopenposition.3.Contacts.4.Disc.5.Batterycircuitterminals.
Aheatactivatedmetaldiscwithacontactpointcompletestheelectriccircuitthroughthecircuitbreaker.If
thecurrentintheelectricalsystemgetstoohigh,itcausesthemetaldisctogethot.Thisheatcausesa
distortionofthemetaldiscwhichopensthecontactsandbreaksthecircuit.Acircuitbreakerthatisopen
canberesetafteritcools.Pushtheresetbuttontoclosethecontactsandresetthecircuitbreaker.
WiringDiagrams
WIRINGDIAGRAMFORD3TRACTORSAND931TRACKTYPELOADERSWITHDIENGINE
WIRINGDIAGRAMFOR910WHEELLOADERSWITHDIENGINE
WIRINGDIAGRAMFORD3TRACTORSAND931TRACKTYPELOADERSWITHPCENGINES
WIRINGDIAGRAMFOR910WHEELLOADERSWITHPCENGINE(FROM80U998UPTHEREISNODISCONNECT
SWITCH)
Copyright19932016CaterpillarInc. ThuMay05201615:17:27GMT0500(Horaest.Pacfico,Sudamrica)
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