Case W26 User manual

W26

Loader

Service Manual

9-78236

IReprinted I

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SECTION

I

ENGINE

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STALL

CHECKS

AND

ENGINE

REMOVAL

AND

REPLACEMENT

Burl.

Form

9-78238

KFCAO

Printed

in

U.S.A.

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TABLE

OF

CONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Specifications,

Serial

Number,

RH

and

LH

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

STALL

CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Combined

Converter

-

Equipment

Hydraulic

Stall

Test

• • • • • . . • . • • • • • • . • . . . 4

Converter Stall

Test

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Equipment

Hydraulics

Stall

Test

. . . . • . • • . . . . . • • . • • • . • . • • . • . • . . • • • • . 5

REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

ADJUSTING

IDLE

SPEEDS

AND

THROTTLE

CONTROLS • • • . • . • • . • • • • • • • • . • . • 7

2

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INTRODUCTION

NOTE:

This

manual

does

not

cover

the

Detroit

Diesel

engine,

excepting

routine

main-

tenance

items,

removal

and

installation,

and

adjustmentofthe

throttle

linkage

and

idle

speeds.

Service

problems

relating

to

the

engine

should

be

referred

to

a

Detroit

Diesel

service

center.

Specifications

Make

and

model

. • . . . . • . • . • • . • • • • • . • • • • • • . • . • . • . • • . • •

Detroit

Diesel

6V53

Recommended

fuel

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diesel

No. 2

Type

. . • . . . . • . . . . . . . • . • . . . • . . • . . • • • . 6

cylinder,

2

stroke

cycle,

valve-in-head

Piston

displacement

. . . . . . . . • . . . . . • . • . • . . . . . . . • . • • • . . . • . •

318.6

cu.

inches

Air

cleaner

..................••...............•.

Dry

type,

oil

bath

optional

Idle

speeds

No

load

governed

speed

(high idle) . • . • . . • . . . . . . . . . . . . . . . . . . 2660 + 25

RPM

Low

idle

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 750 + 25 RPM

Governor

. . . . . . . . . . . . . . . . . • . . . • • . . • . . • • . . • . .

Variable

speed,

mechanical

Engine

lubrication

Filter

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Full

flow type

Oil

pressure

..•.•.••..•.•.....•••••.•.•..•.•.•••

40-50

PSI

at

high

idle

Cooling

system

Pressurized

to

.............................................

7 PSI

Thermostat

(2

used)

...•...•.•••.•••.•.

Starts

to

open

at

175°, fully

open

at

190°

Fluid

capacities

..........•.•••••.•.•.•••••......

Refer

to

Section

IX,

Page

5.

Serial

Number

The

serial

number

plate

is

located

on

the

right

hand

side

at

the

front

of

the

engine.

See

Figure

1,

Section

IX.

3

Righi

Hand

and

Left

Hand

The

terms

"right

hand"

(RH)

and

"left

hand"

(LH),

used

throughout

this

manual,

are

determ_ined

by

standing

at

the

rear

of

the

unit

and

facing

the

direction

of

forward

travel.

This

places

the

engine

at

the

REAR

of

the

unit.

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ST~LL

CHECKS

TO

TEST

CONDITION

OF

ENGINE,

TORQUE

CONVERTER

AND

EQUIPMENT

HYDRAULIC

SYSTEMS

During

these

tests,

engine

speed

will

be

recorded

at

full

throttle

(2660 RPM) when

the

converter

and/or

equipment

hydraulic

sy-

stems

are

stalled.

The

results

of

these

tests

can

help

determine

whether

wear

or

other

faults

exist

in the

engine,

converter,

or

equip-

ment

hydraulic

system.

Test

1 -

Combined

Converter

-

Equipment

Hydraulic

Stall

Test

1.

Apply

parking

brake.

With engine

at

low

idle,

shift

into

forward.

2.

Increase

engine

speed

to

full

throttle.

Tilt

bucket

back

and hold

lever

back

to open

the

main

relief

valve.

Record

the

engine RPM.

Test

Summary

Engine

speed

shouldbe 1700 to 1800 RPM.

If

engine

speed

is

below 1700

RPM

or

if

the

engine

quits,

it

may

be

due to:

a.

Engine

worn

or

out

of

tune.

b.

Excessive

hydraulic

pressures

or

mechanical

faults

in the

converter

and/or

equipment

hydraulic

system.

If

engine

speed

is

above 1800

RPM,

it

indicates

inefficiency in

the

converter

and/or

equipment

hydraulic

system.

Possi-

ble

sources

of

the

trouble

are:

a.

Leakage.

b. Worn

charging

or

equipment

pump.

c.

Low

main

relief

valve

setting.

To

narrow

down

the

problem

area,

con-

duct

Tests

2 and

3.

If

one

system

tests

satis-

factory

and the

other

system

tests

unsatis-

factory,

it

shows

that

the

engine

is

O.K.

If

both

systems

test

unsatisfactory,

the

cause

of

the

trouble

is

very

likely

the

engine.

Stall

Speed

and

Engine

Performance

Stall

speed

will

decrease

as

engine

performance

falls

off

from

wear

or

need

of

a tune up.

Test

2 -

Converter

Stall

Test

1.

Apply

parking

brake.

With engine

at

low

idle,

shift

into

forward.

2.

Increase

engine

speed

to full

throttle.

Record

the engine RPM.

Test

Summary

Engine

speed

should be 2200 to 2400

RPM.

If

engine

speed

is

below 2200

RPM,

indications

are

that

either

the engine

is

worn

4

or

there

are

hydraulic

or

meohanical

trou-

bles

in

the

transmission.

Checkoutthetrans-

mission

as

instructed

on page 33 and 34 in

Section

III,

Transmission.

Make

repairs

or

adjustments

as

required.

Repeat

Test

2.

If

engine

speed

is

still

low,

the

engine

is

the

faulty

component.

If

engine

speed

is

above 2400

RPM,

the

converter

system

is

inefficient.

This

may

be

caused

by

leakage

of

oil,

wear

in

the

charging

pump

or

faulty

regulator

valve.

SeeSectionIII.

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Test

3 -

Equipment

Hydraulics

Stall

Test

1.

Place

bucket

on ground.

Operate

engine

at

2660

RPM

(full

throttle).

2.

Tilt

bucket

back

and hold

lever

in

power

position

to

open

the

main

relief

valve.

Record

the

engine RPM.

Test

Summary

Engine

speed

should

be

2500 to 2600

RPM.

If

engine

speed

is

below 2500 RPM,

it

indicates

engine

wear

or

excessive

pres-

5

sure

or

restriction

somewhere

is

the

system.

Check

main

relief

valve

pressure

setting.

If

faulty,

repair

or

adjust.

Repeat

Test

3.

If

engine

speed

is

still

low,

the

engine

is

likely

at

fault.

If

engine

speed

is

above 2600 RPM,

the

equipment

hydraulic

system

is

inefficient,

indicating

leakage,

pump

wear,

or

a low

main

relief

valve

setting.

Further

testing

of

the

equipment

pump

can

be

done

with

a

flowmeter

as

described

in

Section VI,

Hydraulic

System.

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REMOVING

THE

ENGINE

NOTE

1: Right

hand

(RH)

side

and

left

hand

(LH)

side

are

determined

by standing

at

the

rear

of

the

machine

and

facing

the

forward

direction

of

travel.

NOTE

2:

Repair

parts,

service,

and

informa-

tion

for

the

engine on

this

machine

are

avail-

able

at

an

authorized

Detroit

Diesel

service

center.

1.

Remove

sheet

metal

parts

to gain

access

to

the

engine and

radiator.

This

includes

the

grille,

hood, and engine

side

panels.

2.

Remove

the

air

cleaner

and

brackets,

mufflers,

and

exhaust

pipes.

Seal

the

openings

against

entry

of

dirt

with

clean

rags,

aluminum

foil,

etc.

3.

Drain

the

engine coolant.

4.

Drain

the

engine

oil.

A

drain

hose

runs

from

the

engine to the

RH

side

of

the

chassis

under

the hold down. Remove

the

plug

at

this

point and allow the

oil

to

drain.

After

draining,

disconnect

or

re-

move

this

hose.

Close

openingswith

clean

caplugs.

5.

Remove

the

radiator

and

shroud

(wrap

around):

a.

Disconnect

transmission

oil

cooler

hoses

on

RH

side

of

engine.

Dis-

connect

tubing

from

clamps

under

the

radiator.

Close openings with

clean

caplugs.

b.

Remove

the

twoupperradiatorhoses

and the

lower

hose.

c.

Attach

a

hoist

to the

radiator

and

shroud

assembly.

d.

Remove

all

the

bolts,

nuts

and

wash-

ers

attaching

the

shroud

to

the

chassis.

Remove the

radiator-to-

chassis

mounting

bolts.

e.

It

is

recommended

that

the

fan

be

re-

removed

to

prevent

possible

damage

when

the

radiator

and

shroud

assem-

bly

is

lifted

out.

f.

Carefully

lift

the

radiator

and

shroud

from

the

machine

as

an

assembly.

6

Use

care

not

to

damage

the

oil

cooler

tubes

during

removal

process.

6. Open the

drain

cock

on

the

bottom

of

the

main

air

reservoir

and

depressurize

the

air

system.

Then

remove

the

air

lines

from

the

governor

and

compressor

to

the

main

air

reservoir.

7.

Disconnect

the

engine

from

the

electrical

system:

a.

Tag

and/or

mark

wires

and

cables

and

their

terminals

which

will

have

to be

disconnected

for

correct

rein-

stallation.

b.

Disconnect

the

battery

cables.

Dis-

connect

the

ground

cable

first.

c.

Disconnect

wires

from

the

alterna-

tor,

regulator,

starter,

switches,

sending

units,

etc.

as

required

to

free

the

engine

from

the

electrical

system.

d. Remove

clamps

as

required.

8.

Disconnect

the

fuel

lines

from

the

RH

side

of

the

engine.

Close

openings

with

clean

caplugs.

9.

Disconnect

the engine fuel and

air

shut-

off

controls

from

the

top

of

the

engine.

10.

Remove

or

disconnect

the

driveshaft

to

the

transmission.

11.

Two

lift

lugs

are

provided

on

the

engine.

Attach

a

hoist

and

take

out

the

slack.

Hoist

capacity

should

be

at

least

oneton.

12.

Remove

the

front

mounting

bolt,

nut, and

lockwashers.

13.

Remove

two

bolts,

nuts,

andlockwashers

from

the

mounting

bracket

on

each

side

at

the

rear

of

the

engine.

14.

Thoroughly

inspect

the engine

to

see

that

wll

necessary

items

have

been

removed

or

disconnected.

When

all

is

clear,

carefully

lift

out

the

engine.

NOTE:

Engine

overhaul

and

repairs

other

than

routine

maintenance

(

oil

changes,

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filter

service,

etc.)

should

be

done

at

an

authorized

Detroit

Diesel

service

center.

INSTALLING

THE

ENGINE

1.

The

engine

should

be

installed

in

the

reverse

order

of

the

instructions

under

"Removing

the

Engine" above,

2, In

addition,

the

following

illustrations

will

be

helpful

during

the

installation:

Electrical

wiring

-

Figure

1, SectionII

Air

system

diagram

-

Figure

1,

Section

V

Transmission

cooler

hydraulics

-

Figure

2,

Section

III.

3,

Install

oil,

fuel,

and

engine

coolant

as

follows:

a.

Replace

engine

oil

filter.

Add 19

U.S.

quarts

of

SAE 30

(MIL-L-

2104B),

Series

1,

heavy

duty

lubri-

cating

oil.

NOTE:

The

above

oil

is

recommend-

ed

for

year

round

use

except

where

extreme

cold

prevents

starting.

b.

Fill

fuel

tank

with

No, 2

diesel

fuel.

Capacity

is

85 U.S.

gallons.

c.

Fill

thecoolingsystemwith33

quarts

of

coolant-1/2

water,

1/2

permanent

anti-freeze.

4,

Pressurize

the

air

system

as

described

under

"Pressurizing/Depressurizing

the

Air

System",

Section

V.

5,

Adjust

the

engine

idle

speeds

and

throttle

controls

as

described

in

this

section

starting

below.

ADJUSTING

IDLE

SPEEDS

AND

THROTTLE

CONTROLS

Specifications

Low

idle

speed

. . . • . . . . . 750 + 25

RPM

High

idle

speed

. ,

.•.••..

2660 + 25 RPM

Adiustment

Procedures

1.

Warm

engine

to

approximately

140°

F.

2.

Remove

throttle

and

fuel

shut

off

cables

from

speed

control

and

stop

lever,

Figure

1.

SPEED

CONTROL

LEVER

\

~

,/

~

BOOSTER

\ \"

SPRING \

RETAINING,

NUT

&

BOLT

Figure

1

OP

LEVER

------

~

UFFER

CREW

691597

7

High Idle

Speed

Adjustment

3.

Back

off

buffer

screw

four

(4)

turns,

Figure

1.

4.

Turn

on

the

engine

and

check

by

hand

the

maximum

no

load

speed.

It

should

be

2660 + 25

RPM.

Move

speed

control

lever

clockwise.

SPRING

HOUSIN

SHIMS

SPRING

RETAINER

SOLID

STOP

VARIABLE

SPEED

SPRING

Figure

2

O

691596

FER

SCREW

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