Usage:
Start By:
a. remove fuel injection pump housing and governor
b. remove fuel transfer pump
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.
NOTE: If it is desired to only remove the governor so the fuel injection pump housing can be disassembled, do only Steps 1, 2, 3, 4, 5, 6, 18, 24, 27, 28, 29, 30, 34, 36, and 39.
1. Put the fuel injection pump housing and governor in position on Tool (A).
2. Remove bolt (3) to disconnect the lever and link.
3. Remove bolts (2) and remove control linkage (1) from the governor shaft.
4. Remove bolts (4) and plate (5).
5. Remove cover assembly (6), plate (9), and shutoff solenoid (7) from rear governor housing (8).
6. Remove the bolts, rear governor housing (8) and gasket from the front governor housing.
7. Remove the governor spring (10) and seat from the guide in the rear governor housing.
8. Remove bolt (11) that holds lever assembly (12) to the shaft.
NOTE: There is a key in the (slot) groove of the shaft assembly that must be removed before the shaft assembly is removed from the rear governor housing.
9. Remove shaft (13), lever (12), lever (14) and the spacer from the rear governor housing.
10. Remove plug (16) and lip seal (15) from the housing.
NOTE: Spacers (17) and (19) are different sizes. Make sure they are assembled in the correct position.
11. Use needle nose pliers, and remove the shaft. Remove spacer (17), lever (18) and spacer (19) from the governor housing.
12. Remove two setscrews and locknuts (20) if necessary.
13. Release spring (21) from the notch in the housing. Remove snap ring (22), and remove shaft (23) from the housing. Remove lever (24) and spring (21).
14. Remove lip seal (25) from the housing.
15. If necessary, remove the screws, cover (26) and the gasket from the governor housing.
16. Remove high idle cover (27) and three O-ring seals (28).
17. Remove lip seal (30), dashpot valve (31), fitting (29), insulator and high idle adjustment (32) from the rear housing.
18. Remove two bolts (33), housing (34) and the gasket from the fuel pump housing.
19. Remove bolts (35), and remove torque control group (36) from the block.
| NOTICE |
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Depending on the different engine applications, torque control groups will vary. Inspect all parts for wear and damage, and make a note of the correct sequence of the parts for assembly purposes. |
NOTE: For additional information, see the Specifications Manual.
20. Remove the bolts and block (37) for the full load stop from the housing.
21. Remove the bolt that holds collar (39) to bolt (40).
22. Remove collar (39) and spring (38) from bolt (40). Remove bolt (40) from the block.
23. If necessary, remove the stop screw and the power setting screw from collar (39).
NOTE: It may be necessary to turn the piston to remove the servo from the rack.
24. Remove the three bolts and governor servo (41) from the fuel injection pump housing.
25. Remove lockring (47), seat (46), spring (45) and sleeve (44) from valve (43). Remove lockring (42) from the groove in the center of valve (43).
26. Remove sleeve (48), valve (49) and piston (50) from the governor servo. Remove O-ring seal (54) from sleeve (48). Remove pin (51) and lever (52) from cylinder (53).
27. Use Tool (C) to hold spring (55) under compression so the ring on the governor shaft can be removed.
28. Remove the ring, and carefully remove Tool (C).
29. Remove bearing (56) the sleeve and spring (55) from the governor shaft.
30. Remove ring (57) and dashpot assembly (58) from the governor shaft.
31. Use Tool (B), and remove ring (64) from seat (61).
32. Remove ring (63) and spool (62) from seat (61).
33. Remove seat (61) and spring (60) from shield (59).
34. Remove over fueling spring (66), if equipped, and riser (65) from the governor shaft.
NOTE: Later models do not use over fueling spring (66).
35. Remove ring (67), races (68) and bearing (69) from the riser.
36. Remove the bolts and carrier assembly (70) from the fuel injection pump housing.
37. Remove dowels (72) and flyweights (73) from the carrier assembly.
38. Remove dowel (71) from the governor shaft, and remove the governor shaft from the carrier assembly.
39. Remove races (74) and (76) and bearing (75) from the camshaft in the fuel injection pump housing.
Assemble Governor
1. Put the fuel injection pump housing in position on Tool (A). Install race (76) bearing (75) and race (74) on the end of the camshaft in the fuel injection pump housing.
2. Put flyweights (73) in position on carrier assembly (70), and install dowels (72) to hold the flyweights in place. The flyweights must move freely on the dowels and have 0.010 to 0.230 mm (.0004 to .0090 in) end play.
3. Install governor shaft (77) on carrier assembly (70).
4. Install dowel (71) in governor shaft (77) and slide carrier assembly (70) down on the governor shaft until dowel (71) fits into the slot in the carrier assembly.
5. Install carrier assembly (70) on the end of the camshaft.
6. Install race (68), bearing (69), race (68) and ring (67) on riser (65).
7. Install riser (65) and over fueling spring (66), if equipped, on the governor shaft.
8. Install spool (62) and ring (63) on seat (61) and use Tool (B) to install ring (64) to hold them in position.
9. Install seat (61) on spring (60). Install spring (60) on shield (59).
10. Install dashpot assembly (58) on the governor shaft.
11. Install ring (57) in the groove on the governor shaft. Install sleeve (78), spring (55), the sleeve and bearing (56) on the governor shaft.
12. Use Tool (C) to hold spring (55) under compression, and install the ring in the groove on the governor shaft.
13. Put lever (52) in position on governor servo (53), and install pin (51) to hold the lever in place. Use a hammer and chisel to move the metal (stake) four places 90 degrees apart on the outside surface on both legs of the governor servo to hold pin (51) in place.
14. Install O-ring seal (54) on sleeve (48). Install piston (50) and sleeve (48) in the governor servo as shown.
15. Install valve (49) in the governor servo as shown.
16. Install lockring (42) in the groove near the center of valve (43). Put sleeve (44), spring (broken link spring) (45) and seat (46) in position on valve (43), and install lockring (47) to hold them in place.
17. Put governor servo (41) in position on the fuel injection pump housing with piston (50) engaged over the rack. Make sure the lever is engaged in the (slot) groove of riser (65).
18. If dowel (82) was removed, install it in block (83) 31 ± 0.5 mm (1.22 ± .02 in) above the outside surface of the block.
19. Install bolt (40) in block (83) and spring (38) on bolt (40).
20. Install stop screw (80) and the locknut on collar (39). Install power setting screw (81) and the locknut on the collar.
21. Install collar (39) on bolt (40). Make an alignment of the hole in the collar with the notch in bolt (40) and install bolt (79).
22. If the dowels that align block (37) with the front governor housing were removed, install them 4.0 ± 0.5 mm (.16 ± .02 in) above the outside surface of the front governor housing.
23. Put block (37) in position on the front governor housing with the holes in the block in alignment with dowels in the front governor housing.
24. Install dowels (84) in the front governor housing 6.0 ± 0.5 mm (.24 ± .02 in) above the outside surface of the front governor housing.
25. Assemble torque control group (36) in the correct sequence, and install it on the block.
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To avoid possible personal injury and damage to the engine when front governor housing (34) is installed on the fuel injection pump housing, make sure the flange on bolt (40) is behind the shield of the dashpot. If the flange on the bolt is installed on the wrong side of the shield, the riser in the governor will be held in the maximum fuel delivery position. |
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26. Install the gasket and front governor housing (34) on the fuel injection pump housing. Make sure the flange on bolt (40) is behind the shield of dashpot (58).
27. Check the seal on dashpot valve (31) for damage or wear, and make a replacement if necessary.
28. Install dashpot valve (31), insulator (85), fitting (29) high idle screw (32) and the locknut in rear governor housing (8). Tighten insulator (85) to a torque of 4.5 ± 0.5 N·m (40 ± 4.4 lb in).
29. Use Tool Group (D), and install seal (30) with the lip of the seal down as shown. Put clean engine oil on the lip of the seal. Install high idle screw cover (27) and O-ring seals (28).
30. Install the lip seals in housing (8) with Tool Group (D) as shown.
31. Install the gasket and cover (26) in the governor housing.
32. Put clip (86) in position on shaft (23), and install shaft (23) into the housing through spring (21) and lever (24). Put the key in the lever in alignment with the keyway in the shaft.
33. Install clip (22) on the shaft, and install screw (87) and the locknut on the lever. Put the end of the spring in position in the notch in the housing as shown.
34. Install screws (89) and locknuts (20) on lever assembly (18). Tighten locknuts (65) to a torque of 1.70 ± 0.25 N·m (15 ± 3 lb in).
35. Install shaft (90) in the housing. Install long spacer (19), lever assembly (18) and the short spacer on shaft (90).
36. Check the condition of the O-ring seal on the plug. Lubricate the O-ring seal with clean engine oil, and install the plug to hold shaft (90) in position.
37. Install lever assembly (12) on shaft assembly (13). Be sure the alignment marks on the components are in alignment with each other.
38. Install shaft (13) into the housing. Put washer (91) and lever (14) in position on the shaft. Put key (92) in the key slot on shaft (13), and install lever (12) over the key on the shaft. Align the bolt hole in lever (12) with the groove in the shaft (13), and install the bolt.
39. Install seat (93), and spring (10) on guide (94).
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To avoid possible personal injury and damage to the engine when rear governor housing (8) is installed on the fuel injection pump housing, make sure the flyweights are toward the fuel injection pump housing. If the flyweights are extended out too far, the riser in the governor will be held in the maximum fuel delivery position. |
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Typical Example
40. Install gasket (95) and rear governor housing (8) on the front governor housing.
41. Make the governor adjustments. See the topic "Governor Adjustments" in the Systems Operation, Testing & Adjusting Manual.
42. Hold shaft (13) in the fuel off position, and install shutoff solenoid (7).
End By:
a. install fuel transfer pump
b. install fuel injection pump housing and governor