Testing and Adjusting Fuel Injection Pump and Governor on 3064 and 3066 Engines{0374, 0599, 0706} Caterpillar


Testing and Adjusting Fuel Injection Pump and Governor on 3064 and 3066 Engines{0374, 0599, 0706}

Usage:

769C 01X
Caterpillar Products: All

Introduction

Important Safety Information




Illustration 1g02139237

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 2g02166423

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

------ WARNING! ------

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.

----------------------

------ WARNING! ------

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 3g02807500

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: 1-309-578-7372

Tooling

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 4g02807516

Mounting Tools

Table 1
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 5g02807561

Adjustment Tools

Table 2
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 6g02807566

Calibration Fluid and Lube Tooling

Table 3
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 7g02807570

Indicator Tools

Table 4
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 8g02807571

Throttle Control Indicator Group

Table 5
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 9g02807573

Attach base plate to rails of test stand

  1. Attach 6V-9132 Base Plate (1) to test stand rails using 6V-9138 Mounting Assembly and 6V-9132 Lock Screw (2) .

  1. Attach 9U-7494 Pump Mounting Plate (8) to base plate using four 0T-0924 Bolts and 3B-4506 Lock Washers .



    Illustration 10g02807574

    (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

  1. Mount pump to pump mounting plate (8) using four 0T-0722 Bolts and 4S-9191 Flat Washers (3) .

  1. 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

  1. Install oil supply fitting into injection pump.

    1. Remove original oil supply fitting.

    1. Place 4C-6609 Fitting (4) and two 4C-5706 Copper Washers (5), one on each side of fitting, onto original fitting.

    1. Install assembly and tighten to 12 N·m (8.9 lb ft).



    Illustration 11g02807576

    (9) Fluid Return Fitting (10) Fluid Supply Fitting

  1. Install calibration fluid return fitting (9) using original fitting with a 4C-5710 Calibration Fluid Return Fitting and two 4C-5708 Copper Washers .

  1. Install calibration fluid supply fitting (10) using original fitting with a 4C-5711 Calibration Fluid Supply Fitting and two 4C-5707 Copper Washers .



    Illustration 12g02807596

    (11) Supply Line (12) Return Line (13) Lube Oil Line

  1. Install lines from injection pump to test stand ports.

    1. Hook up supply line (11) to "Calibration Fluid Supply".

    1. Hook up return line (12) to "Calibration Fluid Return".

    1. Hook up lube oil line (13) to "Lube Oil Supply".

Connect Pump Drive Adapters To Test Bench




Illustration 13g02807598

Install pump adapter

  1. Install drive adapters (1) and (3) .

    1. Install 9U-7493 Drive Adapter (1) with 118-1713 Flat Washer and 118-1711 Nut (2) .



      Illustration 14g02807600

      Install drive adapter.

    1. Install 6V-6048 Drive Adapter (3) with two 2A-4639 Bolts and 3B-4506 Lock Washers (4) .



    Illustration 15g02807601

    Connect pump to test stand

  1. Connect pump drive to test stand drive.

    1. Move base plate forward.

    1. Align key way and connect the drive adapter to the chuck. Insert shaft approximately 1 inch into chuck.

    1. Tighten two bolts (5) in chuck.

    1. Tighten lock screw on base plate.

    1. Install guards.



    Illustration 16g02807617

    Connect fuel injector test tube assemblies

  1. Install six 1U-5431 Fuel Injector Test Tube Assemblies (6) from the top of fuel pump to manifold block and tighten.



    Illustration 17g02807636

    Fill case with oil

  1. 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)

Note: Housing cannot be over-filled. All excess oil will run out drain hole at front of the pump.

Attach Measurement and Control Tooling




    Illustration 18g02807637

    Install measurement adapter and indicator

  1. 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.

  1. 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 .



    Illustration 19g02807638

    Install governor control linkage

  1. 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.

    1. Attach column assembly (8) to base assembly (7) and fasten the base to the rails of test stand.

    1. Attach indicator assembly (9) .

    1. Assemble and install control linkage assembly (10). The control linkage provides fine adjustment for setting rack position.

    1. Install lever (11) with two bolts, not shown.

    1. Attach degree wheel (13) with bolt and spring washer (14) .

    1. Connect rod end yoke to handle with pin (12) .

    1. Position indicator assembly (9) to point at degree wheel (13). Tighten holder in place with thumb screw.

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 20g02807639

Remove cover (1)

  1. Remove two bolts (2) and cover (1) .



    Illustration 21g02807641

    Move rack to full open position

  1. Pull fuel shut off lever (3) to fully closed position (shut-off position).

  1. Push gear segment (4) on rack fully forward towards front of pump.

  1. Zero the indicator or probe. Repeat Steps 3 and 4 twice to make sure indicator reading stays at zero.

  1. Start the test stand. See Special Instruction, SEHS8200, "Using the Fuel Injection Equipment Test Stand", for starting procedure.

    1. Turn lube oil ON and adjust pressure to 70 kPa (10.2 psi).

    1. Turn calibration fluid ON and adjust pressure to 150 kPa (21.8 psi).

    1. Check TMI for direction of rotation. Select the correct rotation and turn main drive to "ON".

    1. Increase speed of rotation to 450 rpm.

  1. 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.

  1. Obtain fuel flow specifications from TMI.

  1. Check flow reading on test stand.

If the flow rate acceptable, check governor and pump timing.

Check Injector Timing

Set-Up

  1. Lock the governor control lever in full open position, toward front of pump.



    Illustration 22g02807656

    (1) Tube assembly (2) Delivery valve lock holder (3) Delivery valve holder

  1. Remove tube assembly (1) .

  1. Remove delivery valve lock holder (2) plate.



    Illustration 23g02807657

    (3) Delivery valve holder (4) Stopper (5) Delivery valve spring (6) Gasket (7) Delivery valve assembly

  1. Remove delivery valve holder (3) .

    Note: When installing delivery valve holder, tighten to 39 N·m (28.8 lb ft).




    Illustration 24g02807658

    Remove stopper and spring

  1. Remove delivery valve stopper (4) and spring (5) .



    Illustration 25g02807660

    Remove gasket and delivery valve

  1. Using 4C-6605 Tweezers , remove gasket and delivery valve assembly, two pieces.


    NOTICE

    Use extreme caution when removing, handling, and storing delivery valve assembly.





    Illustration 26g02807661

    (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

  1. Install fuel flow drain and indicator holder assembly. Assemble the following parts to make up this unit:

    Note: The copper washers should be installed on each side of the J-tube fitting.




    Illustration 27g02807665

    Install 8S-4950 Cap

  1. Remove calibration fluid return line and install 8S-4950 Cap (13). Tighten to 20 to 25 N·m (14.8 to18.4 lb ft).

Measure Pre-Stroke




Illustration 28g02807666

Measuring pre-stroke

This procedure measures the lift or pre-stroke of number one injector plunger.

  1. Rotate camshaft to bottom of stroke (BDC).

  1. Zero the indicator.

  1. Turn the test stand ON.

  1. Adjust the test oil to 20 kPa (2.9 psi). Oil should be flowing from J-tube.

  1. 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.

  1. 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 29g02807671

Put 4C-6509 Plunger Spring Retainer under spring

  1. Rotate camshaft to top dead center (TDC).

  1. Install 4C-6509 Plunger Spring Retainer (1), u-shaped bracket, under spring.

  1. Rotate camshaft until plunger drops away from spring.

  1. Remove shim (2) and install appropriate shim to achieve the desired free stroke.

  1. With new shim in place measure the pre-stroke again.

Set Timing of #1 Lobe

  1. Rotate camshaft by hand, in direction of rotation, until test oil stops flowing from J-tube. Injection is now beginning.

  1. Turn the test stand OFF.



    Illustration 30g02807673

    Set pointer on degree wheel and record setting.

  1. 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 31g02807674

    Remove Indicator and 4C-4766 Plunger Adapter

  1. Remove indicator and 4C-4766 Plunger Adapter .

  1. 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.

  1. Install delivery valve holder lock plate and install number one fuel line.

  1. 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.

    1. Remove fuel injection tube.

    1. Install diverter.

    1. Install fuel injection tube into flow diverter.

    1. Open valve, two or three turns, counterclockwise and position to drain on the table.

  1. Turn the test stand ON.

  1. Increase pressure to 150 kPa (21.8 psi).



    Illustration 32g02807678

    4C-5713 Nozzle Overflow Assembly

  1. Rotate camshaft until the fuel stops flowing from the nozzle overflow assembly.

  1. Read the angle on the degree wheel.

  1. 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 .

  1. Turn the test stand OFF.

  1. 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.

  1. When all plungers and barrels have been adjusted, rotate the camshaft two or three complete revolutions to check for smooth operation and/or binding.

  1. Remove overflow valve assembly from manifold and connect fluid injector test tube assembly.

  1. Remove cap from return line and install return line.

Check and Adjust Fuel Delivery

Preparation

  1. Recheck zero rack position. See Section ""Zero the Rack" ".



    Illustration 33g02807680

    Install cover

  1. Install cover (1) and tighten bolts (2) hand tight.

  1. Start the test stand using the start button of "Test Oil System".

  1. Adjust the test oil pressure to 150 kPa (21.8 psi) and lube oil pressure to 70 kPa (10.2 psi).

  1. Set direction of rotation according to the TMI specifications and start "Main Drive".

  1. Increase the speed to 700 rpm.



    Illustration 34g02807681

    Lock lever (3) in full open position.

  1. Allow the test stand to run until the test oil temperatures reach 40° C (104.0° F).

  1. Use governor control lever and nylon screw to lock the rack in position according to TMI specifications.

Check and Adjust

  1. Compare the actual delivery specifications to TMI. If the delivery is incorrect, the pump must be adjusted.

  1. Shut the test stand OFF.



    Illustration 35g02807682

    Remove cover

  1. Remove bolts (2) and cover (1) .



    Illustration 36g02807756

    Adjust each injector to the correct delivery rate

  1. Change the delivery by adjusting each control sleeve as follows:

    1. Loosen pinion clamp screw (3) .

    1. Rotate control sleeve (4) and adjust the delivery. Rotate the control sleeve clockwise, toward governor, to increase fuel flow.

  1. 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 37g02807776

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 38g02807816

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

  1. Mount the fuel injection pump on the test stand. See Section ""Mount Pump To Test Stand" " in this manual.

  1. Add 200 cc of oil into the governor chamber and 90 cc into the injection pump cam chamber.



    Illustration 39g02807817

    Attach indicator

  1. 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 .

  1. Start the test stand. See Special Instruction, SEHS8200, "Using the Fuel Injection Equipment Test Stand", for startup procedures.



    Illustration 40g02807820

    Set the control rack "zero" position

  1. Set the control rack "zero" position.

    1. Maintain pump speed at 750 rpm.

    1. Loosen lock nut (6) and back out stopper bolt (7). Move the control lever (8) back to the full closed position.



      Illustration 41g02807821

      Push the control pinion fully forward using a screwdriver

    1. 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.

    1. Set the dial of indicator (4) to zero.

    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.

  1. Move control lever (8) to the full closed position.

  1. 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.

  1. The performance of the governor depends on the engine specifications. See Section ""Governor Performance Specifications" " for additional information.

Preparation for Adjustment




Illustration 42g02807837

Remove cap

  1. Remove cap (1) .



    Illustration 43g02807838

    Remove cover

  1. Remove locknut (2) and four bolts and lockwashers (3) from cover (4) .



    Illustration 44g02807840

    Remove idling spring

  1. Remove idling spring (5) and locknut (6) with 4C-5085 Wrench (7) and 4C-5567 Torque Adjusting Socket (8).



    Illustration 45g02807841

    Remove torque control spring

  1. Remove idling sub spring (9) .

    1. Remove cap.



      Illustration 46g02807858

      Remove idling sup-spring

    1. Hold slotted adjusting screw and remove idling sup-spring (9) and washer.

Full-load Adjustment - Temporary




    Illustration 47g02807860

    Set maximum speed stopper bolt (1)

  1. Hold the control lever against the maximum speed stopper bolt (1) .



    Illustration 48g02807861

  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 49g02807865

    Set full-load stopper bolt (2)

  1. Set full-load stopper bolt (2) so the control rack is positioned at Re while maintaining pump speed at Ne.



Illustration 50g02807866

Torque Control Spring Adjustment - When Installed

  1. Adjust the injection pump rpm to a speed slightly less than Nb.

  1. Position the control lever to contact the maximum-speed stopper bolt.



    Illustration 51g02807867

    Torque control spring

  1. Install the torque control spring and adjust so the control rack moves from Re to Rg.



    Illustration 52g02807868

  1. Lock the torque control springs in place with locknut.



    Illustration 53g02807877

    Set the torque control stroke

  1. Increase pump speed to Nc rpm and set the torque control springs so that the control rack position is Rf.



    Illustration 54g02807878

  1. Gradually increase pump speed. Confirm that the pump speed is Nd when the control rack position reaches Re.



    Illustration 55g02807879

  1. Gradually decrease pump speed. Confirm that pump speed is Nb when the control rack position reaches Rg.

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

  1. Stop operation of the pump.

  1. Position the control lever, control rack position, to Rd. Usually 10 to 11 mm.



    Illustration 56g02807916

    Adjust the idling sub spring and lock in position with the locknut

  1. 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 57g02807917


    NOTICE

    If the idling sub spring is over-tightened, engine speed will exceed specifications at no-load maximum speed, resulting in engine damage.


  1. Increase pump speed greater than Na to make sure that the control rack position reaches Ra.

  1. Replace cap and lock into position.

Maximum-Speed Adjustment




Illustration 58g02807918

Set maximum-speed stopper bolt

  1. Set control lever to contact maximum-speed stopper bolt.

  1. 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 59g02807919

Speed Droop Adjustment

Speed droop can be calculated using the formula:

Table 6
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 60g02807938

Relation between engine output performance and governor performance.

  1. Increase the pump speed slowly. Determine if pump speed reaches Ng when control rack position is Rb.



    Illustration 61g02807940

    View of adjusting screw

    Governor has been removes for clarity

  1. 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 62g02807941

    Remove the plug

  1. Remove plug (2) .



    Illustration 63g02807956

    Set speed by turning adjusting screw

  1. Adjust speed. If Ng exceeds TMI specifications, tighten the adjusting screw. If Ng is less than the specified value, loosen the adjusting screw.



    Illustration 64g02807957

    Adjust the maximum-speed stopper bolt

  1. Adjust the maximum-speed stopper bolt until the speed at the start of high-speed control is Nf.

  1. Check that the no-load maximum speed is Ng (described in Step 1). Continue adjustment until the specified value is obtained.



    Illustration 65g02807958

  1. Increase pump speed to make sure that the control rack position reaches Ra.



Illustration 66g02807959

Full-load Adjustment




    Illustration 67g02807997

    Install the cover and adjust full-load stopper bolt

  1. 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 68g02807999

  1. Position the control lever at maximum-speed position.

  1. Adjust full-load stopper bolt (1) to the f"ull-load fuel injection quantity" position. See TMI for the specifications (Point A).

  1. Install cap.

Control Lever Angle Measurement




    Illustration 69g02808016

    Measuring control lever angle at the "full-speed" and "idling" positions.

  1. Measuring the control lever angle at the "idling" and "full" positions.

  1. 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




    Illustration 70g02808018

    Remove measurement adapter

  1. Remove measurement adapter (1) .



    Illustration 71g02808038

    Cap must be installed to check delivery rate

  1. Install cap (2) .

  1. Run pump at speed specified in TMI.

  1. Check delivery rate with specifications listed in TMI.

  1. Stop pump rotation.



    Illustration 72g02808058

    Adjusting screw for setting fuel flow

  1. 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.

  1. 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.

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