Field Installation of the Engine Speed Control{1915} Caterpillar

Integrated Toolcarrier:

IT14G (S/N: 1WN1462-UP)

Wheel Loader:

914G (S/N: 9WM1990-UP)

Introduction

The 178-0060 Engine Speed Control Conversion Ar system allows the operator to maintain the engine rpm at a desired setting. The Engine Speed Control is used with attachments that require a constant rpm setting for a prolonged period of time.

The Engine Speed Control should be installed in conjunction with the 107-4842 Speed Control Ar . The operator can independently set the engine rpm at a desired setting and the operator can maintain a constant ground speed simultaneously.

Do not perform any of the procedures until you have read the information in this publication.

Reference: Operation and Maintenance Manual, SEBU6868, "914G Wheel Loader"

Reference: Operation and Maintenance Manual, SEBU6869, "IT14G Integrated Toolcarrier"

Reference: Parts Manual, SEBP3242, "914G Wheel Loader"

Reference: Parts Manual, SEBP2344, "IT14G Integrated Toolcarrier"

Reference: Testing and Adjusting, RENR2810, "IT14G Integrated Toolcarrier and 914G Wheel Loader Braking System"

Required Parts

The following Table will list the parts that are required in order to install the 178-0060 Engine Speed Control Conversion Ar . Individual parts may not be serviceable parts.

Preparing the Machine for Servicing

1. Park the machine on a level surface.

2. Engage the parking brake. Refer to the machine's Service Manual for all safety and operation instructions.

3. Turn the engine start switch to the OFF position. Remove the key.

Standard Removals

The removal of some standard parts is necessary in order to install the 178-0060 Engine Speed Control Conversion Ar . Remove the 148-8383 Elbow that is part of the 148-2571 Service Brake Lines Gp .

Subassembly of the Actuator Group

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Illustration 1	g00984656

1. Attach three 193-4318 Brackets (13) onto the 138-3366 Actuator Mounting Bracket (25) with the following items: six 170-5632 Bolts (31), six 3B-4501 Lockwashers (34) and six 5C-8312 Nuts (40). Refer to Illustration 1 in order to correctly position brackets (13). Tighten the bolts (31) to a torque of 1.7 ± .25 N·m (15 ± 2 lb in).

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Illustration 2	g00984659

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Illustration 3	g00984661

2. Attach the 178-0055 Governor Actuator Gp (33) onto bracket (25) with the following items: 165-9104 Spacer (30), 8T-4971 Bolt (49), 8T-4138 Bolt (46) and two 8T-4205 Hard Washers (47). Tighten bolt (49) and bolt (46) to a torque of 12 ± 3 N·m (106 ± 26 lb in).

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Illustration 4	g00984670

3. Install one 142-6000 Hex Nut (26) onto the spindle for actuator group (33). Install one 7H-3937 Lockwasher (3) onto the spindle.

4. Install the 193-4319 Lever (14) onto the spindle. Refer to Illustration 4 for the correct position of lever (14). Secure lever (14) with one 142-6000 Hex Nut (26) .

   Note: Use a backup wrench in order to torque nut (26) that is securing lever (14). Failure to use a backup wrench may cause internal damage to actuator group (33) .

5. Install one 8T-3016 Washer (45) onto the 193-4320 Ball Stud (15). Attach ball stud (15) onto lever (14) with one 5W-1453 Lockwasher (42) and one 5C-2874 Nut (38). Tighten nut (38) to a torque of 1.7 ± .25 N·m (15 ± 2 lb in).

   Note: Ball stud (15) must be centered on lever (14) .

Installing the Actuator Group

The actuator group is installed onto the existing 107-4747 Cover As for the hydrostatic pump group. The top portion of the cover has three 5.5 mm (0.22 inch) predrilled holes. These holes will be redrilled in order to accept the M6 mounting hardware.

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Illustration 5	g00986744

6. Redrill the existing holes with a 8.2 mm (0.32 inch) drill bit.

7. Attach the actuator assembly onto the 107-4747 Cover As with the following items: three 8T-4138 Bolts (46), six 8T-4205 Hard Washers (47) and three 5C-2890 Nuts (39). Tighten nuts (39) to a torque of 12 ± 3 N·m (106 ± 26 lb in).

   Note: The following procedure will aid in installing the actuator group. Disconnect the batteries and remove the two bolts that are securing the battery tray. The battery tray can be removed in order to gain access to the underside of the 107-4747 Cover As .

Modifying the Cable for the Actuator

Note: The cable assembly that is part of the 109-6673 Cable Control Kit (23) must be modified before installation.

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Illustration 6	g00984886

8. Remove the inner cable that is inside of the outer cover.

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Illustration 7	g00984888

9. Measure the inner cable from the center point of the ballstud socket. Make a mark at 1015 mm (39.96 inch). Cut the inner cable.

10. Measure the outer sleeve from the back of the adjustment nut. Make a mark at 710 mm (27.95 inch). Cut the outer sleeve.

11. Insert the inner cable into the outer sleeve. Install the end sleeve onto the end of the outer sleeve that was cut. Install the dust cap.

Installing the Cable Assembly

12. Insert the 109-6673 Cable Control Kit (23) into the 138-3366 Actuator Mounting Bracket (25). The adjuster assembly will secure the cable assembly into bracket (25) .

13. Connect the ball socket that is on the cable assembly onto the 193-4320 Ball Stud (15) that is on the actuator lever.

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Illustration 8	g00985917

14. Remove the 140-9586 Plate (N) that is covering the fuel injection pump.

    Note: Be sure not to drop the 6G-2263 Spacer (M) that is installed with the plate.

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Illustration 9	g00984883

15. Temporarily install the 171-5580 Bracket (7) onto the bracket for the governor cable. Temporarily secure bracket (7) with the 8T-4189 Bolt (Q) and 5P-4116 Hard Washer (P) that were removed from the 140-9586 Plate (N) .

16. Secure the 109-6673 Cable Control Kit (23) onto bracket (7) with the following items: 197-7257 Clamp (16), two 170-5632 Bolts (31) and two 3B-4501 Lockwashers (34). Tighten to a torque of 1.7 ± .25 N·m (15 ± 2 lb in).

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Illustration 10	g00984950

17. Install the 171-5581 Lever (8) onto the fuel injection pump. Secure lever (8) with the following hardware: one 8C-8451 Bolt (44), two 8T-4205 Hard Washers (47), one 3P-9716 Spacer (36) and one 129-3178 Locknut (24). Tighten to a torque of 12 ± 3 N·m (106 ± 26 lb in).

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Illustration 11	g00984953

18. Install the 197-7263 Bushing (18) into lever (8). Secure bushing (18) with one 197-7262 Spring Washer (17) and one 160-8503 Nut (28). Tighten nut (28) to a torque of 10 ± 2 N·m (89 ± 18 lb in).

19. Attach the 197-7265 Linkage Pin (20) and the 197-7264 Shim (19) onto bushing (18). Secure linkage pin (20) with one 161-6987 Hard Washer (29) and one 179-4324 Locknut (11). Tighten locknut (11) to a torque of 2.25 ± .25 N·m (20 ± 2 lb in).

Note: Lever (14) that is installed on actuator group (33) must be rotated as far clockwise as possible.

20. Insert cable assembly (23) into linkage pin (20). Remove all slack from the cable assembly. Tighten the set screw that is located on linkage pin (20) .

21. Install the 197-7267 Clamp (22) onto the excess portion of the cable assembly. Position clamp (22) next to linkage pin (20). Secure clamp (22) with the 197-7266 Bolt (21) .

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Illustration 12	g00984973

22. Remove the 8T-4189 Bolt (Q) that was used to support bracket (7). Install plate (N) for the fuel injection pump that was removed in Step 3. Secure the plate with the existing hardware. Secure bracket (7) with the 8T-4189 Bolt (Q) that is installed into the plate. Bracket (7) must be installed on the outside of plate (N). Tighten the bolts to a torque of 28 ± 7 N·m (21 ± 5 lb ft).

Electrical Installation

Illustration 13	g00984974

Illustration 14	g00984975

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Illustration 15	g00985124

23. Attach the 4P-7581 Clip (37) onto the cover for the hydrostatic pump with the existing hardware. Tighten bolt (L) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).

24. Connect the AC-C2 harness connection that is on the 178-5049 Harness (10) onto the connector for the actuator group (33). Secure the connection onto clip (37) with one 7K-1181 Cable Strap (43) .

25. Route the other end of harness (10) through the slot that is in the cover for the hydrostatic pump.

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Illustration 16	g00985130

26. Route harness (10) through the engine firewall. Route harness (10) around the outside of the hydraulic tank. The harness should be adjacent to the ROPS post on the right hand side of the machine. Secure harness (10) onto the existing chassis harness with one 7K-1181 Cable Strap (43) .

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Illustration 17	g00985135

27. Continue routing harness (10) with the chassis harness. Harness (10) should exit next to the hoses for the pilot control. Secure harness (10) onto the chassis harness with two 7K-1181 Cable Straps (43) .

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Illustration 18	g00985136

28. Attach the 155-2651 Electronic Distributor Group (27) onto the 171-5579 Plate (6) with two 8T-9043 Bolts (50) and two 8T-4224 Hard Washers (48). Tighten bolts (50) to torque of 25 ± 6 N·m (221 ± 53 lb in).

29. Attach plate (6) onto the weld bosses that are on the cab platform. Secure plate (6) with two 5C-9553 Bolts (41) and two 8T-4205 Hard Washers (47). Tighten bolts (41) to a torque of 12 ± 3 N·m (106 ± 26 lb in).

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Illustration 19	g00985178

30. Locate the 8-pin connector for the Engine Speed Control that is on the cab harness. Remove the 184-5224 Plug As that is installed from the factory. Refer to Table 5 for the configuration of the 8-pin connector.
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    Table 5

    Configuration for the 8-pin Connector
    Wire	Pin Location
    103-YELLOW	1
    202-BLACK	2
    450-YELLOW	3
    F796-GREY	4
    604-ORANGE	5
    614-PURPLE	6
    128-PINK	7
    BLANK	8

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Illustration 20	g00985191

31. Route harness 219-4208 Harness (1). Refer to Illustration 16 for a complete view of routing harness (1). Connect the CA-C1 harness connection onto the 8-pin connector that was located in Step 30.

32. Connect the CA-C7 harness connection onto the 155-2651 Electronic Distributor Group (27) .

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Illustration 21	g00985207

33. Connect the 3E-5239 Relay As (2) onto the CA-C2 harness connection.

34. Connect the 106-8704 Arc Suppressor (4) onto the CA-C10 harness connection.

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Illustration 22	g00985219

35. Remove bolt (T) that is securing the ECM module. Attach relay assembly (2) onto bolt (T) and install bolt (T). Tighten bolt (T) to a torque of 12 ± 3 N·m (106 ± 26 lb in).

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Illustration 23	g00985225

36. Secure arc suppressor (4) and harness (1) onto the cab harness with two 7K-1181 Cable Straps (43) .

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Illustration 24	g00985226

37. Route the following harness connections through the 148-5689 Split Grommet that is below the fuse block: CA-C4, CA-C3 and CA-C5.

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Illustration 25	g00985229

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Illustration 26	g00985237

38. Remove the plug and gasket assembly that is adjacent to the control switch for the coupler. Route the CA-C4 harness connection through the switch panel. Connect the 178-0057 Switch (9) onto harness connection CA-C4. Install switch (9) into the switch panel.

39. Remove the three 9X-2042 Screws that are securing the 125-7043 Box on the right hand side of the operator compartment. Remove the box assembly.

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Illustration 27	g00985289

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Illustration 28	g00985293

40. Route the CA-C5 harness connection through the opening that is below the fuse box. Route the harness connection into the space that is below the 125-7043 Box mounting location.

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Illustration 29	g00985296

41. Cut the 121-0191 Loop Fastener (52) into two equal lengths of 120 mm (4.7 inch). Cut the 121-0192 Hook Fastener (51) into two equal lengths of 120 mm (4.7 inch).

42. Clean the surface of the 178-0054 Engine Speed Control Gp (32) thoroughly. Attach the two pieces of loop fastener (52) onto control group (32) .

43. Attach the two pieces of hook fastener (51) onto the two pieces of loop fastener (52) .

44. Connect the CA-C5 harness connection onto the 178-0054 Engine Speed Control Gp (32) .

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Illustration 30	g00985300

45. Remove the protective adhesive paper from the two pieces of hook fastener (51). Clean the surface on the rear of the fuse box thoroughly. Position control group (32) against the rear of the fuse box. Press control group (32) firmly against the fuse box.

46. Install the 125-7043 Box . Secure the box with the 9X-2042 Screws that were removed in Step 39. Tighten the screws to a torque of 12 ± 3 N·m (106 ± 26 lb in).

    Note: The CA-C3 harness connection is used for diagnostic purposes. The CA-C3 harness connection should be placed into the area that is below the fuse box.

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Illustration 31	g00985305

47. Connect the CA-C6 harness connection onto the AC-C1 harness connection for harness (10). Secure the connection onto the chain link for the cab platform with one 7K-1181 Cable Strap (43) .

48. Connect the CA-M1 and CA-T2 ring terminal connections onto the ground stud for the cab platform.

Installing the Brake Pressure Switch

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Illustration 32	g00985313

1. Disconnect the brake hose that is connected to the outlet port of the service brake control valve. Remove the 148-8383 Elbow .

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Illustration 33	g00985314

2. Install the 170-0966 Tee (5) into the outlet port on the service brake control valve. Tee (5) will be torqued in Step 3.

3. Connect the existing brake hose onto tee (5). Tighten the hose to a torque of 42 ± 2 N·m (31 ± 1 lb ft). Tighten tee (5) to a torque of 86 ± 4 N·m (63 ± 3 lb ft).

4. Install one 3J-1907 O-Ring Seal (35) onto the 183-5035 Pressure Switch (12) .

5. Install pressure switch (12) into tee (5). Tighten pressure switch (12) to a torque of 35 ± 3 N·m (26 ± 2 lb ft).

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Illustration 34	g00985317

6. Connect the CA-C9 harness connection onto pressure switch (12). Secure the harness connection and secure the harness to the cab harness with two 7K-1181 Cable Straps (43) .

Operation of the Engine Speed Control

Illustration 35	g00985325

The Engine Speed Control is controlled by the 178-0057 Switch (9) that was installed into the switch panel. Push switch (9) to the ON position in order to activate the engine speed control. The amber light that is in switch (9) will illuminate.

Setting the Engine Speed with the Governor Pedal

Note: The 178-0057 Switch has the following three positions: OFF, ON and SET. The SET position is a momentary position that is used to make precise settings. The OFF position is toward the rear of the cab. The ON position is in the middle of the switch.

1. Push the governor pedal in order to achieve the desired rpm.

2. Push switch (9) to the SET position. Remove your foot from the governor pedal. The Engine Speed Control will set the rpm at the requested setting.

The rpm can be increased to a higher rpm by depressing switch (9) to the SET position.

Setting the Engine Speed with the 178-0057 Switch

1. Push switch (9) and continue depressing switch (9) to the SET position. The rpm will increase steadily. Release switch (9) when the desired rpm has been reached.

The rpm can be increased to a higher rpm by depressing switch (9) to the SET position.

Disengaging the Engine Speed Control

1. The engine speed control can be disengaged by depressing the brake pedal. Also, the engine speed control can be disengaged by pushing switch (9) into the OFF position.