Usage:
815 (91P1-up, 15R1-up);
816 (57U1-up);
966C (78G1-up, 42J1-up, 76J1-up, 30K1-up, 25U1-up);
977L (14X1-up, 64X1-up, 95X1-up)
The 1N3061 Direct Injection Engine Arrangement is the replacement for the original precombustion chamber engine used in the above machines. Before installation of the new engine, it will be necessary to exchange some parts between the old engine and the new engine, to adapt the new replacement engine to a specific machine.
This instruction gives the procedure needed, according to machine model, for installation of the replacement engine. When a part is removed from the old engine for installation and use on the new engine, make a good inspection of that part before it is installed on the new engine. If reconditioning of one of these parts is necessary, do it before the part is installed on the new engine.
NOTE: See the specific Service Manual for any specifications needed during reconditioning and parts installation procedures.
Find and write down the engine serial number, engine arrangement number of the original engine, and also find the serial number of the machine. These numbers will be needed for reference during the engine change procedure.
NOTE: A 4N4227 Governor Spring, a 4N4366 Governor Control Detent Spring, and a 6N581 Torque Control Group are in the fuel injection pump and governor group of the 1N3061 Replacement Engine Arrangement. Check the PARTS BOOK and the FUEL SETTING INFORMATION for the specific machine, to find what part number governor spring, detent spring, and torque control group are needed. If necessary, these parts can be exchanged from the old fuel system to the new fuel system. See the Service Manual for any disassembly and assembly procedures.
| NOTICE |
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The new engine as sent from the factory will not necessarily have the same BHP (brake horsepower) as your old engine. The correct low idle and high idle rpm and the fuel setting for your machine are given in the FUEL SETTING INFORMATION. Check these settings and make the necessary adjustments before the engine is put into steady operation. It must be remembered that because of the differences in the engine models, arrangements, and applications, it will be necessary to always check and/or adjust the high idle and low idle rpm and the fuel setting before the engine is put to use in normal operation. |
NOTE: For those engines that were equipped with glow plugs, either remove the wire from the heat-start switch to the glow plug lead assembly, or put tape over the end of the wire when it is disconnected. This wire will not be needed because the new engine does not have glow plugs.
977L Track Loader
(1) Remove the engine from the machine; see the Service Manual for the procedure. Put both engines, new and old, in a position that will give good access to their front, rear, top and both sides.
(2) Remove the crankshaft pulley, crankshaft damper, and the engine front support from the old engine, and install them on the new engine.
(3) Remove the flywheel from the old engine. Exchange the flywheel housings between the old engine and the new engine. Install the flywheel from the old engine on the new engine.
(4) On both engines, loosen tube assembly (1) at both ends, then completely disconnect it from oil level guide (2). Exchange oil pans [including oil level gauge (3) and guide (2)] between the new and old engines. After oil pan installation is complete, fasten each guide (2) in position, then connect tube assembly (1) to the guide.
(5) Remove oil filler pipe (4) from the old engine and exchange it with the oil filler on the new engine.
(6) Remove water temperature regulator housing (5) and temperature regulator (6) from the old engine and install these parts on the new engine.
(7) Remove the fumes disposal tube, hose and clamps from the old engine and install them on the new engine. The remainder of parts needed for a complete installation, such as starting motor, alternator, vee belts, fan drive group, etc., are to be removed from the old engine and installed on the new engine.
(8) Install the new engine in the machine. See the Service Manual for engine installation procedure and specifications.
NOTE: Before starting the engine, check and/or adjust the fuel setting dimension. See the FUEL SETTING INFORMATION for the correct fuel setting dimension according to engine application.
814 Tractor, 815 Compactor, 816 Compactor, 966C Wheel Loader
(1) Remove the crankshaft pulley, vibration damper, and engine front support from the old engine and install these parts on the new engine.
(2) Remove the flywheel housing from the rear of the new engine. Remove the oil manifold plug at the rear of the cylinder block of the new engine [location (A)]. Install a 1S1768 Sleeve with a 2M4453 O-ring Seal in the hole at location (A) where the plug was removed.
(3) Make sure that gasket (1) is in position on the rear of the new engine, then install the rear gear group, flywheel housing and the flywheel from the old engine, on the new engine.
(4) If the replacement engine is to be installed in an 815 or 816 Compactor, for both the new and old engine, loosen tube assembly (2) at both ends, then completely disconnect it from oil level guide (3). Exchange the oil pans [including oil level gauge (4) and guide (3)] between the new and old engines. After oil pan installation is complete, fasten each guide (3) in position, then connect tube assembly (2) to the guide.
(5) Remove the air compressor and the air compressor lines from the old engine and install them on the new engine.
(6) Remove the fumes disposal tube, hose and clamps from the old engine and install them on the new engine. The remainder of parts needed for a complete installation, such as starting motor, alternator, vee belts, fan drive group, etc., are to be removed from the old engine and installed on the new engine.
(7) Install the new engine in the machine. See the Service Manual for engine installation procedure and specifications.
NOTE: Before starting the engine, check and/or adjust the fuel setting dimension. See the FUEL SETTING INFORMATION for the correct fuel setting dimension according to engine application.