Usage:
Start By:
a. remove fuel injection lines
b. remove raw water aftercooler and air inlet manifold
FLUID SPILLAGE CONTAINMENT
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.
1. Remove the plug from cover (1) and install Tool (A). Turn the crankshaft (clockwise) until the timing pin drops into the groove (slot) in the fuel injection pump camshaft.
2. Remove two nuts (4) and tachometer drive cover (3) from front cover (2).
3. Remove tachometer drive shaft (5).
Old 5P-2371 Puller Plate shown for location purposes only.
4. Install Tooling (B) into the camshaft drive gear for the fuel injection pump. Turn the center bolt of Tooling (B) until the drive gear is free of the shaft. Remove Tooling (B).
5. Remove the plug from the timing hole in the front cover and install a 5/16 -18 NC bolt (6) 63.5 mm (2.50 in) Long. The cover bolt from hole (7) can be used. Turn the crankshaft (clockwise) until bolt (6) can be installed into the timing gear and is in the center of the timing hole. The camshaft for the fuel injection pump is now in correct time to the engine.
6. Remove lines (8) and bolts (9).
7. Remove the fuel injection pump housing and governor as a unit.
NOTE: The following steps are for installation of the fuel injection pump housing and governor.
8. Put the fuel injection pump housing and governor in position on the engine.
9. Install bolts (9) and lines (8).
Tachometer Drive Shaft
NOTE: Tachometer drive shaft must be tightened it to a torque of
149 ± 14 N·m (110 ± 10 lb ft).
10. Install tachometer drive shaft (5) and tighten it to a torque of 149 ± 14 N·m (110 ± 10 lb ft).
11. To check the timing, remove the timing pin [Tool (A)] and bolt (6). Turn the crankshaft (clockwise) two revolutions and install the timing pin [Tool (A)] and bolt (6) back in place. If the timing pin or bolt can not be installed, the fuel injection pump camshaft must be put in time again before doing Step 13.
12. Remove bolt (6) from the timing gear. Install the plug into the timing hole.
13. Remove Tool (A) from the timing groove (slot) in the fuel injection pump camshaft and install the plug.
15. Install tachometer drive housing (3) and nuts (4).
End By:
a. install raw water aftercooler and air inlet manifold
b. install fuel injection lines
Separate Fuel Injection Pump Housing & Governor
Start By:
a. remove fuel injection pump housing and governor
FLUID SPILLAGE CONTAINMENT
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.
1. Install the fuel injection pump housing on Tool (A).
2. Remove bolts (1) and governor housing (2).
3. Remove two springs (4) and seat (3).
4. Remove spring (6), seat and piston assembly (9), and spring (8) from shaft (7).
5. Remove cover (5).
6. Remove shaft (10) and lever (11).
7. Remove thrust collar (13).
8. Remove cover (12).
9. Remove two bolts (14) and torque spring assembly (15).
10. Remove pin (16).
11. Remove screw (18) and nut (19).
12. Remove the ring that holds the lever and remove lever (20) from dowel (17).
NOTE: Dowel does not need to be removed unless camshaft is to be removed.
13. Remove dowel (17).
| NOTICE |
|---|
Pull on the shield only a small amount in each location, so it will not have distortion or damage. The metal of earlier shields is moved (staked) around the camshaft and can be damaged when removed. If the shield has damage, use a new part for replacement. |
14. Remove shield (21) with Tool (B).
15. Install timing pin (C) to hold the camshaft.
16. Remove bolts (22) and flyweight assembly (23).
Connect Fuel Injection Pump Housing & Governor
1. Put the fuel injection pump housing on bracket assembly (A).
2. Install timing pin (C) to hold the camshaft.
NOTE: Be sure the pin that holds shaft (24) is in position on the back of the flyweight assembly.
3. Put flyweight assembly (23) in position on the camshaft.
4. Install the bolts that hold the flyweight assembly to the camshaft and tighten to a torque of 13.6 ± 2.8 N·m (120.00 ± 24.00 lb in)for earlier governors and 10.2 ± 1.1 N·m (90.00 ± 10.00 lb in)for later governors with thin bolt heads.
5. Remove timing pin (C).
6. Put shield (21) in position over the flyweights.
7. Use driver (D) to install the shield the remainder of the way on to the camshaft. Move the metal (stake) at two places on the shield 180 ± 5 degreesapart to hold the shield on the camshaft.
8. Put a new O-ring seal on dowel (17) and install the dowel in the pump housing. Make the dowel even with the machined surface of the counterbore on the outside of the housing.
9. Put lever (20) on dowel (17) and install the ring that holds it on the dowel.
10. Install screw (18) and nut (19).
11. Install pin (16).
12. Put torque spring assembly (15) in position on the housing and tighten two bolts (14).
13. Install cover (12).
14. Put thrust collar (13) in position between the flyweights. Lift the flyweights up with a piece of wire and push thrust collar (13) forward.
15. Put lever (11) in position in the housing and in the groove of thrust collar (13). Put a new O-ring seal on the shaft and install shaft (10) down through the housing and into the holes in lever (11).
16. Install cover (5).
17. Install spring (8).
18. Install seat and piston assembly (9).
19. Turn spring (6) on the piston and seat until it just contacts the shoulders on the piston and seat. The piston and seat must be in alignment after spring (6) is installed. If not, remove the spring and install again.
| NOTICE |
|---|
Both springs must make full contact on seat (3) before they are installed in the governor housing assembly. If the springs do not make full contact on the seat, high idle speed will not be correct and low idle governor surge can be the result. Low idle setting without stability can also be the result. |
20. Install seat (3) and two springs (4).
21. Install governor housing (2) and bolts (1).
End By:
a. make an adjustment of the fuel system setting (See Fuel System in the Systems Operation, Testing & Adjusting Manual)
b. install fuel injection pump housing and governor