- Caterpillar Products: All
Introduction
Important Safety Information
Illustration 1 | g02139237 |
Think Safety |
European Union Compliant, CE marked
Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly.
Improper operation, lubrication, maintenance, or repair of this product can be dangerous and could result in injury or death.
Do not operate or perform any lubrication, maintenance, or repair on this product until you have read and understood the Tool Operating Manual.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the "Safety Alert Symbol" and followed by a "Signal Word" such as "DANGER", "WARNING", or "CAUTION". The Safety Alert "WARNING" label is shown below.
A non-exhaustive list of operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure, work method, or operating technique that is not recommended by Caterpillar is used, the operator must be sure that the procedures are safe. The operator must also be sure that the product will not be damaged or made unsafe by any unspecified procedures.
The information, specifications, and illustrations in this publication are based on information that was available at the time that the publication was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job.
When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength, and material.
Literature Information
This manual contains safety information, operation instructions and maintenance information and should be stored with the tool group
Some photographs or illustrations in this publication may show details that can be different from your service tool. Guards and covers might have been removed for illustrative purposes.
Continuing improvement and advancement of product design might have caused changes to your service tool, which are not included in this publication.
Whenever a question arises regarding your service tool or this publication, consult Dealer Service Tools (DST) for the latest available information.
Safety Section
The Safety section lists basic safety precautions.
Read and understand the basic precautions listed in the Safety section before operating or performing maintenance and repair on this service tool.
General Information Section
The General Information section describes tooling functions and features. The section provides useful information on individual parts, additional tooling, and resources.
Operation Section
The Operation section is a reference for the new operator and a refresher for the experienced operator.
Photographs and illustrations guide the operator through correct procedures for using the tool group.
Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the service tool and the tools capabilities.
Maintenance Section
The Maintenance section is a guide to tool inspection, cleaning, storage, and tool disposal
Service Parts Section
The Service Parts section is a reference for parts identification and available part numbers.
Safety Icon Nomenclature
Personal Protection/Important Information
Illustration 2 | g02166423 |
Personal Protection/Important Information |
Prohibited Action
No smoking |
Hazard Avoidance
Crushing hazard (foot) |
Crushing hazard (hand) |
Pinch point |
Fire hazard |
Electrical Shock - Hazard |
Fire hazard |
Safety Section
At operating temperature, the hydraulic tank is hot and under pressure. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. Remove the filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand. Remove the filler cap slowly in order to relieve pressure. |
Personal injury or death can result from escaping fluid under pressure. Escaping fluid under pressure, even a very small pin-hole size leak, can penetrate body tissue and cause serious injury and possible death. If fluid is injected into your skin, it must be treated immediately by a doctor familiar with this type of injury. Always use a board or cardboard when checking for a leak. |
NOTICE |
---|
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
NOTICE |
---|
To prevent dirt and contaminants from entering the hydraulic system, always plug or cap the lines, fittings, or hoses as they are disconnected. This action also lessens the chance of oil spills. |
General Information
Introduction
This manual provides the setup and adjustment procedures for Testing and Adjusting Fuel Injection Pumps on 3046 and 3066 Engines. The fuel injection pumps are tested using the Fuel Injection Equipment Test Stand. See Special Instruction, SEHS8200, "Using the Fuel Injection Equipment Test Stand", for operating instructions.
Pumps can also be tested on earlier fuel injection test benches using the same tooling and procedures. See Special Instruction, SEHS7466.
Illustration 3 | g02807500 |
Typical Fuel Injection Pump used on 3046 and 3066 Engines |
Additional Contact Information
For additional product support questions concerning this tool, contact the Caterpillar Dealer Service Tools Hotline at:
USA: 1-800-542-8665, Option 1International: 1-309-578-7372Tooling
The tooling listed below is required to test the pump and governor assembly. Tools are not available in a group and must be purchased separately.
Illustration 4 | g02807516 |
Mounting Tools |
Mounting Tools     | ||
Ref.     | Part No.     | Description     |
(1)     | 8S-2264     | Puller Assembly     |
(2)     | 9U-7493     | Drive Adapter     |
(3)     | 0T-0722     | Bolt     |
(4)     | 4S-9191     | Flat Washer     |
(5)     | 9U-7494     | Pump Mounting Plate     |
(6)     | 6V-9138     | Mounting Assembly (T-Bar)     |
(7)     | 0T-0924     | Bolt     |
(8)     | 3B-4506     | Lock Washer     |
(9)     | 6V-9134     | Lock Screw (used with T-Bar)     |
(10)     | 6V-9132     | Base Plate     |
(11)     | 118-1713     | Washer     |
(12)     | 118-1711     | Nut     |
(13)     | 2A-4639     | Bolt (2)     |
3B-4506 | Lock Washer (2)     | |
(14)     | 6V-6048     | Drive Adapter     |
Illustration 5 | g02807561 |
Adjustment Tools |
Adjustment Tools     | ||
Ref.     | Part No.     | Description     |
(1)     | 8T-1001     | Electronic Position Indicator     |
(2)     | 8T-1002     | Indicator Probe     |
(3)     | 6V-3075     | Indicator     |
(4)     | 5P-4163     | Indicator Tip     |
(5)     | 4C-2982     | Indicator Collet     |
(6)     | 4C-5713     | Nozzle Overflow Assembly     |
(7)     | 4C-5085     | Wrench     |
(8)     | 4C-5567     | Torque Adjusting Socket     |
(9)     | 4C-6509     | Plunger Spring Retainer     |
(10)     | 5P-1720     | Seal Pick     |
(11)     | 4C-6605     | Tweezers     |
(12)     | 9Y-6051     | Locknut     |
(13)     | 4C-5604     | Copper Washer     |
(14)     | 4C-4658     | J-Tube Fitting     |
(15)     | 4C-4766     | Plunger Adapter     |
Illustration 6 | g02807566 |
Calibration Fluid and Lube Tooling |
Calibration Fluid and Lube Line Tooling     | ||
Ref.     | Part No.     | Description     |
(1)     | 1U-5431     | Fuel Injector Test Tube Assembly     |
(2)     | 4C-4909     | Transfer Plate Cover     |
(3)     | 4C-5708     | Copper Washer (2)     |
(4)     | 4C-5707     | Copper Washer (2)     |
(5)     | 4C-5706     | Copper Washer (2)     |
(6)     | 4C-6609     | Lube Oil Supply Fitting     |
(7)     | 4C-5711     | Calibration Fluid Supply Fitting     |
(8)     | 4C-5710     | Calibration Fluid Return Fitting     |
Illustration 7 | g02807570 |
Indicator Tools |
Indicator Tools     | ||
Ref.     | Part No.     | Description     |
(1)     | 8T-1001     | Electronic Position Indicator     |
(2)     | 8T-1001     | Indicator Probe     |
(3)     | 5P-4160     | Indicator Tip (part of 6V-6042 Indicator Contact Point Group)     |
(4)     | 3P-1567     | Indicator     |
(5)     | 4C-5569     | Measurement Adapter     |
(6)     | 4C-2982     | Indicator Collet     |
(7)     | 9U-6272     | Nylon Screw     |
Illustration 8 | g02807571 |
Throttle Control Indicator Group |
4C-8145 Throttle Control Indicator Group     | |||
Ref.     | Part No.     | Description     | |
(1)     | -     | Base Assembly     | |
4C-8135 |     | Lower Plate     | |
4C-8136 |     | Upper Plate     | |
9X-8873 |     | Bolt     | |
(2)     | -     | Indicator Assembly     | |
4C-8142 |     | Adjusting Block     | |
4C-8143 |     | Pointer     | |
6V-0672 |     | Knob (thumb screw)     | |
(3)     | -     | Column Assembly     | |
8T-8889 |     | Bolt     | |
8R-0739 |     | Washer     | |
4C-8137 |     | Upright Bar     | |
6V-8183 |     | Nut     | |
4K-4726 |     | Rod End     | |
(4)     | -     | Throttle Control Linkage     | |
6V-6961 |     | Knob     | |
4C-8139 |     | Sleeve     | |
4C-8138 |     | Threaded Rod     | |
4C-8146 |     | Rod End Yoke     | |
4C-8147 |     | Pin     | |
(5)     | -     | Adjusting Block     | |
6V-8189 |     | Nut     | |
4C-8141 |     | Guide     | |
3W-6756 |     | Knob     | |
(6)     | 4C-8140     | Handle     | |
- | Bolt (use bolts from throttle control)     | ||
(7)     | -     | Dial Assembly     | |
4C-8144 |     | Degree Wheel     | |
4M-5281 |     | Bolt     | |
7S-1114 |     | Spring Washer     |
Pump
Mount Pump To Test Stand
Illustration 9 | g02807573 |
Attach base plate to rails of test stand |
- Attach 6V-9132 Base Plate (1) to test stand rails using 6V-9138 Mounting Assembly and 6V-9132 Lock Screw (2) .
- Attach 9U-7494 Pump Mounting Plate (8) to base plate using four 0T-0924 Bolts and 3B-4506 Lock Washers .
- Mount pump to pump mounting plate (8) using four 0T-0722 Bolts and 4S-9191 Flat Washers (3) .
Illustration 10 | g02807574 |
(3) 0T-0722 Bolt and 4S-9191 Washer (4) 4C-6609 Lube Oil Supply Fitting (5) 4C-5706 Copper Washer (6) Nuts (7) 4C-4909 Transfer Plate Cover (8) 9U-7494 Mounting Plate |
- Remove transfer pump and install 4C-4909 Transfer Pump Cover (7) using previously removed nuts and washers (6). Tighten nuts to 5 N·m (3.7 lb ft).
Install Calibration Fluid and Lube Lines
- Install oil supply fitting into injection pump.
- Remove original oil supply fitting.
- Place 4C-6609 Fitting (4) and two 4C-5706 Copper Washers (5), one on each side of fitting, onto original fitting.
- Install assembly and tighten to 12 N·m (8.9 lb ft).
- Install calibration fluid return fitting (9) using original fitting with a 4C-5710 Calibration Fluid Return Fitting and two 4C-5708 Copper Washers .
Illustration 11 | g02807576 |
(9) Fluid Return Fitting (10) Fluid Supply Fitting |
- Install calibration fluid supply fitting (10) using original fitting with a 4C-5711 Calibration Fluid Supply Fitting and two 4C-5707 Copper Washers .
- Install lines from injection pump to test stand ports.
- Hook up supply line (11) to "Calibration Fluid Supply".
- Hook up return line (12) to "Calibration Fluid Return".
- Hook up lube oil line (13) to "Lube Oil Supply".
Illustration 12 | g02807596 |
(11) Supply Line (12) Return Line (13) Lube Oil Line |
Connect Pump Drive Adapters To Test Bench
Illustration 13 | g02807598 |
Install pump adapter |
- Install drive adapters (1) and (3) .
- Connect pump drive to test stand drive.
- Move base plate forward.
- Align key way and connect the drive adapter to the chuck. Insert shaft approximately 1 inch into chuck.
- Tighten two bolts (5) in chuck.
- Tighten lock screw on base plate.
- Install guards.
Illustration 15 | g02807601 |
Connect pump to test stand |
- Install six 1U-5431 Fuel Injector Test Tube Assemblies (6) from the top of fuel pump to manifold block and tighten.
Illustration 16 | g02807617 |
Connect fuel injector test tube assemblies |
- Remove plug from top of governor and fill housing with approximately 750 cc of test stand lube oil. This amount of oil fills the camshaft and governor chambers. Install plug and tighten to 4 N·m (3.0 lb ft)
Illustration 17 | g02807636 |
Fill case with oil |
Note: Housing cannot be over-filled. All excess oil will run out drain hole at front of the pump.
Attach Measurement and Control Tooling
- Install 4C-5569 Measurement Adapter (2) with 9U-6272 Nylon Screw (1). Install 4C-2982 Indicator Collet (4) and 9U-6272 Nylon Screw (3) to hold indicator or probe.
Illustration 18 | g02807637 |
Install measurement adapter and indicator |
- Install indicator probe from 8T-1001 Electronic Position Indicator or 3P-1567 Indicator (5) with 5P-4160 Tip (6). The 5P-4160 Tip is part of the 6V-6042 Indicator Contact Point Group .
- Install 4C-8145 Throttle Control Indicator Group . See the "Throttle Control Indicator Group", Table 5 in the ""Tooling"
" Section for a complete listing of parts.
- Attach column assembly (8) to base assembly (7) and fasten the base to the rails of test stand.
- Attach indicator assembly (9) .
- Assemble and install control linkage assembly (10). The control linkage provides fine adjustment for setting rack position.
- Install lever (11) with two bolts, not shown.
- Attach degree wheel (13) with bolt and spring washer (14) .
- Connect rod end yoke to handle with pin (12) .
- Position indicator assembly (9) to point at degree wheel (13). Tighten holder in place with thumb screw.
Illustration 19 | g02807638 |
Install governor control linkage |
Test Procedure
Before starting any test or adjustment procedure refer to TMI, Technical Marketing Information, LEBQ0724 and Tool Operating Manual, NEHS0594, "Using the TMI System to Retrieve Off Engine Injection Pump Test Specifications for the Fuel Injection Equipment Test Stand". These manuals provide information on using TMI to obtain test and adjustment specifications.
Zero the Rack
Illustration 20 | g02807639 |
Remove cover (1) |
- Remove two bolts (2) and cover (1) .
- Pull fuel shut off lever (3) to fully closed position (shut-off position).
Illustration 21 | g02807641 |
Move rack to full open position |
- Push gear segment (4) on rack fully forward towards front of pump.
- Zero the indicator or probe. Repeat Steps 3 and 4 twice to make sure indicator reading stays at zero.
- Start the test stand. See Special Instruction, SEHS8200, "Using the Fuel Injection Equipment Test Stand", for starting procedure.
- Turn lube oil ON and adjust pressure to 70 kPa (10.2 psi).
- Turn calibration fluid ON and adjust pressure to 150 kPa (21.8 psi).
- Check TMI for direction of rotation. Select the correct rotation and turn main drive to "ON".
- Increase speed of rotation to 450 rpm.
- Pull fuel shut-off lever (3) to the fully closed position. The indicator should read zero. If the indicator does not read zero, repeat Steps 3 and 4 .
Check Fuel Flow
This procedure is used only when the pump has not been disassembled, taken directly from engine.
- Obtain fuel flow specifications from TMI.
- Check flow reading on test stand.
If the flow rate acceptable, check governor and pump timing.
Check Injector Timing
Set-Up
- Lock the governor control lever in full open position, toward front of pump.
- Remove tube assembly (1) .
Illustration 22 | g02807656 |
(1) Tube assembly (2) Delivery valve lock holder (3) Delivery valve holder |
- Remove delivery valve lock holder (2) plate.
- Remove delivery valve holder (3) .
Note: When installing delivery valve holder, tighten to 39 N·m (28.8 lb ft).
Illustration 23 | g02807657 |
(3) Delivery valve holder (4) Stopper (5) Delivery valve spring (6) Gasket (7) Delivery valve assembly |
- Remove delivery valve stopper (4) and spring (5) .
Illustration 24 | g02807658 |
Remove stopper and spring |
- Using 4C-6605 Tweezers , remove gasket and delivery valve assembly, two pieces.
Illustration 25 | g02807660 |
Remove gasket and delivery valve |
- Install fuel flow drain and indicator holder assembly. Assemble the following parts to make up this unit:
- 4C-4766 Plunger Adapter (12)
- 4C-4658 J-tube Fitting (10)
- two 4C-5604 Copper Washers (11)
- 4C-2982 Indicator Collet and 9U-6272 Nylon Screw (9)
- 6V-3075 Indicator (8)
- and 5P-4163 Indicator Tip .
Note: The copper washers should be installed on each side of the J-tube fitting.
- 4C-4766 Plunger Adapter (12)
NOTICE |
---|
Use extreme caution when removing, handling, and storing delivery valve assembly. |
Illustration 26 | g02807661 |
(8) 6V-3075 Indicator and 5P-4163 Indicator Tip (9) 4C-2982 Indicator Collet (10) 4C-4658 J-tube Fitting (11) 4C-5604 Copper Washer (two) (12) 4C-4766 Plunger Adapter |
- Remove calibration fluid return line and install 8S-4950 Cap (13). Tighten to 20 to 25 N·m (14.8 to18.4 lb ft).
Illustration 27 | g02807665 |
Install 8S-4950 Cap |
Measure Pre-Stroke
Illustration 28 | g02807666 |
Measuring pre-stroke |
This procedure measures the lift or pre-stroke of number one injector plunger.
- Rotate camshaft to bottom of stroke (BDC).
- Zero the indicator.
- Turn the test stand ON.
- Adjust the test oil to 20 kPa (2.9 psi). Oil should be flowing from J-tube.
- Rotate camshaft, by hand, in direction of rotation until test oil stops flowing from J-tube. Injection is now beginning. Record indicator readings. See TMI for lift measurement specifications and direction of rotation.
- If indicator reading does not fall within TMI specifications, adjust the lift with shims. See Section ""Adjust Pre-stroke" ".
Adjust Pre-stroke
If the indicator reading is not as specified in TMI, the lift of the plunger must be adjusted by adding or removing shims.
Illustration 29 | g02807671 |
Put 4C-6509 Plunger Spring Retainer under spring |
- Rotate camshaft to top dead center (TDC).
- Install 4C-6509 Plunger Spring Retainer (1), u-shaped bracket, under spring.
- Rotate camshaft until plunger drops away from spring.
- Remove shim (2) and install appropriate shim to achieve the desired free stroke.
- With new shim in place measure the pre-stroke again.
Set Timing of #1 Lobe
- Rotate camshaft by hand, in direction of rotation, until test oil stops flowing from J-tube. Injection is now beginning.
- Turn the test stand OFF.
- move pointer or degree wheel to any number and lock the wheel in place. Record the number.
Note: Do not rotate camshaft or all settings will have to be reset.
Illustration 30 | g02807673 |
Set pointer on degree wheel and record setting. |
- Remove indicator and 4C-4766 Plunger Adapter .
Illustration 31 | g02807674 |
Remove Indicator and 4C-4766 Plunger Adapter |
- Install delivery valve assembly (two pieces), gasket, spring and stopper, and delivery valve adapter. Tighten adapter to 64 N·m (47.2 lb ft) torque.
- Install delivery valve holder lock plate and install number one fuel line.
- Install flow diverter valve in manifold. Position the diverter on the next injector in the firing sequence. For example, the next firing order sequence on a six cylinder injection pump is #5 or #3 on a four cylinder engine.
- Remove fuel injection tube.
- Install diverter.
- Install fuel injection tube into flow diverter.
- Open valve, two or three turns, counterclockwise and position to drain on the table.
- Turn the test stand ON.
- Increase pressure to 150 kPa (21.8 psi).
- Rotate camshaft until the fuel stops flowing from the nozzle overflow assembly.
Illustration 32 | g02807678 |
4C-5713 Nozzle Overflow Assembly |
- Read the angle on the degree wheel.
- Compare the actual reading to the specifications in TMI. If the angle is incorrect, adjust the shim pack using the 4C-6509 Plunger Spring Retainer .
- Turn the test stand OFF.
- Reposition the overflow valve to the next injector in the firing sequence and repeat Steps 10 through 13. Check the angle of all plungers and barrels.
- When all plungers and barrels have been adjusted, rotate the camshaft two or three complete revolutions to check for smooth operation and/or binding.
- Remove overflow valve assembly from manifold and connect fluid injector test tube assembly.
- Remove cap from return line and install return line.
Check and Adjust Fuel Delivery
Preparation
- Recheck zero rack position. See Section ""Zero the Rack" ".
- Install cover (1) and tighten bolts (2) hand tight.
Illustration 33 | g02807680 |
Install cover |
- Start the test stand using the start button of "Test Oil System".
- Adjust the test oil pressure to 150 kPa (21.8 psi) and lube oil pressure to 70 kPa (10.2 psi).
- Set direction of rotation according to the TMI specifications and start "Main Drive".
- Increase the speed to 700 rpm.
- Allow the test stand to run until the test oil temperatures reach 40° C (104.0° F).
Illustration 34 | g02807681 |
Lock lever (3) in full open position. |
- Use governor control lever and nylon screw to lock the rack in position according to TMI specifications.
Check and Adjust
- Compare the actual delivery specifications to TMI. If the delivery is incorrect, the pump must be adjusted.
- Shut the test stand OFF.
- Remove bolts (2) and cover (1) .
Illustration 35 | g02807682 |
Remove cover |
- Change the delivery by adjusting each control sleeve as follows:
- Loosen pinion clamp screw (3) .
- Rotate control sleeve (4) and adjust the delivery. Rotate the control sleeve clockwise, toward governor, to increase fuel flow.
Illustration 36 | g02807756 |
Adjust each injector to the correct delivery rate |
- Adjust all control sleeves until the delivery is correct. See TMI for specifications.
Governor
If the governor is only checked, no disassembly, place the pump and governor on the test stand. Check the governor specifications using TMI and Figures 37 and 38 in the Section ""Governor Performance Specifications" ". Follow the steps in the Section ""Preparation for Adjustment" " to set up the pump and governor.
If the governor is disassembled, adjustments will be required. This section provides the preparation instructions and test procedures to adjust and check the governor specifications.
Note: Always check and make sure that the pump is adjusted and operating correctly before adjusting or testing the governor.
This section provides steps to check and adjust the following function of the governor.
- Full-load adjustment (temporary)
- Torque control spring adjustment (when installed)
- Idling adjustment
- Maximum-speed adjustment
- Speed Droop adjustment
- Full-load adjustment
- Control lever angle measurement
- Idle control spring adjustment (when installed)
- Boost compensator adjustment (when installed)
Governor Performance Specifications
Illustration 37 | g02807776 |
The solid line shows control rack position until contact with the maximum-speed stopper. The bold broken line shows control rack-position during idling. |
A-B - Control rack position for engine starting.
B-C - Control rack position while the start spring is extended due to centrifugal force of the flyweights.
C-D - Control rack position during injection of excessive fuel sufficient for the torque control stroke.
D-E - Control rack position at low and medium speed when the centrifugal force of the flyweights exceeds the torque control spring force. The torque control spring being compressed.
E-F - Control rack position when the shifter contacts the tension lever at normal-full load operation.
F - Governor spring is actuated.
G - Control lever set point. The rated output of the engine can be obtained. For construction equipment, which experiences extreme load changes, operation is normal.
H - No-load maximum speed is the maximum speed of the engine.
H-I - Range where the governor spring and the idling subspring actuate together.
Illustration 38 | g02807816 |
Governor performance chart showing TMI reference points |
The bold broken line shows control rack position during idling. The control lever is in the idling position and speed is increased from zero. Point L is the specified idling position. If idling speed decreases below this point, the idling subspring will move the control rack in the fuel-increase direction.
Set up for Checking Specifications
- Mount the fuel injection pump on the test stand. See Section ""Mount Pump To Test Stand" " in this manual.
- Add 200 cc of oil into the governor chamber and 90 cc into the injection pump cam chamber.
- Install 4C-5569 Measurement Adapter (2) with 9U-6272 Nylon Screw (1). Install 4C-2982 Indicator Collet (5) and 9U-6272 Nylon Screw (3) to hold indicator or probe. Install indicator probe from 8T-1001 Electronic Position Indicator or 3P-1567 Indicator (4) with 5P-4160 Tip . The 5P-4160 Tip is part of the 6V-6042 Indicator Contact Point Group .
Illustration 39 | g02807817 |
Attach indicator |
- Start the test stand. See Special Instruction, SEHS8200, "Using the Fuel Injection Equipment Test Stand", for startup procedures.
- Set the control rack "zero" position.
- Maintain pump speed at 750 rpm.
- Loosen lock nut (6) and back out stopper bolt (7). Move the control lever (8) back to the full closed position.
- Push the control pinion fully forward using a screwdriver. The position where the control rack does not move forward is the control racks "zero" position.
Show/hide tableIllustration 41 g02807821
Push the control pinion fully forward using a screwdriver
- Set the dial of indicator (4) to zero.
Illustration 40 | g02807820 |
Set the control rack "zero" position |
- Move control lever (8) to the full closed position.
Note: Check the operation and stroke of the rack, by operating the control lever. The full stroke of the control rack is 21.00 mm (0.827 inch). If the control rack does not move the full stroke, or does not move smoothly, reinspect the injection pump and governor and correct the problem.
- Set the minimum speed stopper bolt (7) with a control rack position of 0.5 to 1.0 mm (0.02 to 0.04 inch). Undue force is prevented on the link mechanism when the control lever is moved in the stop position.
- The performance of the governor depends on the engine specifications. See Section ""Governor Performance Specifications" " for additional information.
Preparation for Adjustment
Illustration 42 | g02807837 |
Remove cap |
- Remove cap (1) .
- Remove locknut (2) and four bolts and lockwashers (3) from cover (4) .
Illustration 43 | g02807838 |
Remove cover |
- Remove idling spring (5) and locknut (6) with 4C-5085 Wrench (7) and 4C-5567 Torque Adjusting Socket (8).
Illustration 44 | g02807840 |
Remove idling spring |
- Remove idling sub spring (9) .
- Remove cap.
- Hold slotted adjusting screw and remove idling sup-spring (9) and washer.
Show/hide tableIllustration 46 g02807858
Remove idling sup-spring
Illustration 45 | g02807841 |
Remove torque control spring |
Full-load Adjustment - Temporary
- Hold the control lever against the maximum speed stopper bolt (1) .
Illustration 47 | g02807860 |
Set maximum speed stopper bolt (1) |
- Temporarily set the control lever so that the speed at the start of high-speed control is Nf rpm. See TMI for the Nf specification.
Note: When adjusting pump speed at the start of high-speed control, gradually increase the pump speed to Nf rpm. Set the maximum speed stopper bolt (1) so that the control rack starts moving from the Re mm position toward the fuel-increase direction.
Illustration 48 | g02807861 |
- Set full-load stopper bolt (2) so the control rack is positioned at Re while maintaining pump speed at Ne.
Illustration 49 | g02807865 |
Set full-load stopper bolt (2) |
Illustration 50 | g02807866 |
Torque Control Spring Adjustment - When Installed
- Adjust the injection pump rpm to a speed slightly less than Nb.
- Position the control lever to contact the maximum-speed stopper bolt.
- Install the torque control spring and adjust so the control rack moves from Re to Rg.
Illustration 51 | g02807867 |
Torque control spring |
- Lock the torque control springs in place with locknut.
Illustration 52 | g02807868 |
- Increase pump speed to Nc rpm and set the torque control springs so that the control rack position is Rf.
Illustration 53 | g02807877 |
Set the torque control stroke |
- Gradually increase pump speed. Confirm that the pump speed is Nd when the control rack position reaches Re.
Illustration 54 | g02807878 |
- Gradually decrease pump speed. Confirm that pump speed is Nb when the control rack position reaches Rg.
Illustration 55 | g02807879 |
Note: If the torque control stroke does not meet TMI specifications, adjust the torque control spring. If Nb and Nd do not meet TMI specifications, replace the torque control spring.
Idling Adjustment
- Stop operation of the pump.
- Position the control lever, control rack position, to Rd. Usually 10 to 11 mm.
- Start the pump with an rpm of Na. Adjust the idling sub spring with a screwdriver to a control rack position of Rc and lock this position with the locknut.
Illustration 56 | g02807916 |
Adjust the idling sub spring and lock in position with the locknut |
- Increase pump speed greater than Na to make sure that the control rack position reaches Ra.
Illustration 57 | g02807917 |
NOTICE |
---|
If the idling sub spring is over-tightened, engine speed will exceed specifications at no-load maximum speed, resulting in engine damage. |
- Replace cap and lock into position.
Maximum-Speed Adjustment
Illustration 58 | g02807918 |
Set maximum-speed stopper bolt |
- Set control lever to contact maximum-speed stopper bolt.
- Gradually increase pump speed to Nf and set maximum-speed stopper bolt so the control rack starts moving from Re position toward the fuel-decrease direction.
Illustration 59 | g02807919 |
Speed Droop Adjustment
Speed droop can be calculated using the formula:
Ng-Nf     | x 100 (%)     |
Nf     |
NOTICE |
---|
Excessive speed droop increases the no-load maximum speed (Ng) over a specified value, resulting in damage to the engine. |
Too small a speed droop can result in high-speed hunting. Speed droop of the RSV type mechanical governor can be adjusted freely, corresponding to engine use. See Figure 60.
Illustration 60 | g02807938 |
Relation between engine output performance and governor performance. |
- Increase the pump speed slowly. Determine if pump speed reaches Ng when control rack position is Rb.
- If pump speed is not within TMI specifications, adjust height of screw (1) on swivel lever. Tightening the adjusting screw decreases speed droop and loosening increases speed droop.
Note: Adjusting screw (1) can be loosened a maximum of 20 notches (clicks) or approximately five turns from a tightened position. Loosening the screw further may disengage the adjusting screw from the swivel lever, resulting in damage to the governor. Always tighten adjusting screw until at least one click is heard.
Illustration 61 | g02807940 |
View of adjusting screw Governor has been removes for clarity |
- Remove plug (2) .
Illustration 62 | g02807941 |
Remove the plug |
- Adjust speed. If Ng exceeds TMI specifications, tighten the adjusting screw. If Ng is less than the specified value, loosen the adjusting screw.
Illustration 63 | g02807956 |
Set speed by turning adjusting screw |
- Adjust the maximum-speed stopper bolt until the speed at the start of high-speed control is Nf.
Illustration 64 | g02807957 |
Adjust the maximum-speed stopper bolt |
- Check that the no-load maximum speed is Ng (described in Step 1). Continue adjustment until the specified value is obtained.
- Increase pump speed to make sure that the control rack position reaches Ra.
Illustration 65 | g02807958 |
Illustration 66 | g02807959 |
Full-load Adjustment
- Install cover (3) on governor using bolts and lockwashers (2). Use caution when installing the cover to make sure that the O-ring seal is in the seal groove.
Illustration 67 | g02807997 |
Install the cover and adjust full-load stopper bolt |
- Position the control lever at maximum-speed position.
Illustration 68 | g02807999 |
- Adjust full-load stopper bolt (1) to the f"ull-load fuel injection quantity" position. See TMI for the specifications (Point A).
- Install cap.
Control Lever Angle Measurement
- Measuring the control lever angle at the "idling" and "full" positions.
Illustration 69 | g02808016 |
Measuring control lever angle at the "full-speed" and "idling" positions. |
- If the angle is not as specified by TMI, replace the shifters shim. If the control lever is positioned toward the "full" position, replace the shifters shim with a thicker one. When control lever is toward the "idling" position, replace the shim with a thinner one.
Check Starting Delivery
- Remove measurement adapter (1) .
Illustration 70 | g02808018 |
Remove measurement adapter |
- Install cap (2) .
Illustration 71 | g02808038 |
Cap must be installed to check delivery rate |
- Run pump at speed specified in TMI.
- Check delivery rate with specifications listed in TMI.
- Stop pump rotation.
- If delivery rate does not meet TMI specifications, remove cap (2), loosen lock nut, and adjust screw (3). Adjusting screw outward decreases fuel flow and inward increases fuel flow.
Illustration 72 | g02808058 |
Adjusting screw for setting fuel flow |
- Install cap (2) and recheck delivery rate. Repeat Steps 2 through 6 until delivery rate is at specified value.
Lockwiring Caps of Adjustment Screws
All adjustment stops (screws) that directly affect engine performance should be lockwired after adjustment. Do not readjust any stop without using the test stand can adversely affect the engine and engine performance.