Use Of 6V4095 Or 6V4096 Pump And Governor Tool Groups{650, 1250} Caterpillar

Use Of 6V4095 Or 6V4096 Pump And Governor Tool Groups{650, 1250}

Usage:

3300 Series Engines with Scroll Type Fuel System

The 6V4095 Tool Group and the 6V4096 Tool Group are both now available for test, adjustment and/or repair work on the scroll type fuel pump and the governor group on the above engines. The 6V4095 Tool Group has the tools needed for test, adjustment and reconditioning of the above fuel systems, including all tools that are in 6V4096 Tool Group.

The 6V4096 Tool Group has only those tools that are needed to make the governor adjustments for the above fuel systems.

The pages that follow show the parts in the 6V4095 Tool Group and the 6V4096 Tool Group. Tool installation and fuel setting check and adjustment procedures are also given. For disassembly and assembly of this type fuel pump and governor, see the Service Manual for the procedure.

NOTE: The 217956 Bolt and 5B5689 Gasket are a part of both the 6V4095 Tool Group and the 6V4096 Tool Group. These two parts are for use in the check of dynamic (running) rack setting dimension only. Do not use these two parts during static rack setting.

NOTE: The 8S4627 Circuit Tester is also needed but is not shown.

6V4095 Tool Group

(1) 6V2054 Driver

(2) 6V2014 Bracket Assem. ^* 5P4814 Collet

(3) 6V2016 Plate Assem. S1594 Bolt (2)

(4) 6V4818 Driver

(5) 6V2017 Governor Adjustment Tool

(6) S1614 Bolt (2)

(7) 217956 Bolt (1) 5B5689 Gasket (1)

(8) 6V2106 Rack Adjustment Tool Group

(9) 2P8264 Socket (5/32") 2P8265 Socket (3/16")

(10) 2P8306 Box 6V4090 Tool Holder Block 6V4093 Top Liner

(11) 8H3128 Bolt (3)

(12) 6V3075 Dial Indicator 9S229 Contact Point-9.5 mm (.375")

(13) 6V2128 Overfueling Spring Compressor

(14) 6V4186 Timing Pin

(15) 6V2163 Spring Compressor Clamp

^*5P4814 Collet is not a part of 6V2014 Bracket Assembly, even though it is shown installed.

6V4096 Tool Group

(1) 6V3073 Case 6V4091 Holder Block 6V4094 Liner

(2) 6V2017 Governor Adjustment Tool

(3) 6V2014 Bracket Assem. ^* 5P4814 Collet

(4) 6V2128 Overfueling Spring Compressor

(5) 6V2106 Rack Adjustment Tool Grp.

(6) S1614 Bolt (2)

(7) 2P8264 Socket (5/32") 2P8265 Socket (3/16")

(8) 6V3075 Dial Indicator 9S229 Contact Point - 9.5 mm (.375")

(9) 8H3128 Bolt (3)

(10) 217956 Bolt (1) 5B5689 Gasket (1)

(11) 6V4186 Timing Pin

^*5P4814 Collet is not a part of 6V2014 Bracket Assembly, even though it is shown installed.

Installation Of 6V2014 Bracket Assembly And 6V3075 Dial Indicator

1. Remove cover (1) and install 6V4186 Timing Pin (2) in the rack centering pin hole of the pump housing. Install 6V2014 Bracket (3) on the pump housing as shown. End (A) of the inner arm must be in the slot in the fuel rack. After bracket assembly (3) is installed, be sure that shaft (B) has axial (in and out) movement. If there is no axial movement of shaft (B), check to be sure arm (A) is in the slot in the fuel rack, and that bracket assembly (3) is installed correctly. Also make sure that arm (A) is straight. It must be perpendicular (at right angles) to the base.

2. Install 5P4814 Collet (4) in bracket (3). Put 9S229 Contact point (5) on 6V3075 Dial Indicator (6), then install the indicator through collet (4) as shown.

3. Move the governor control lever in the clockwise (CW) direction to the SHUT OFF position. Carefully push the timing pin all the way in, until it comes in contact with the fuel rack. DO NOT PUSH TOO HARD ON THE TIMING PIN BECAUSE IT CAN STOP MOVEMENT OF THE FUEL RACK.

4. Move the governor control lever counterclockwise (CCW) to the HIGH IDLE position. Adjust the revolution counters of the dial indicator to zero and tighten collet (4) to fasten the dial indicator in position. Turn the dial face of the indicator to get alignment of the pointer and zero. Remove the timing pin.

NOTE: With the governor control lever at the HIGH IDLE position, again check to make sure that shaft (B) has axial movement.

5. Remove plug (7) from the rear of the governor housing. Remove the bolt from 6V2128 Overfueling Spring Compressor (8). Install compressor (8) in the hole for plug (7), as shown.

The 6V2128 Overfueling Spring Compressor is needed to put the overfueling spring in compression. The overfueling spring must be put in compression during the procedure, to get a correct reading of the fuel setting measurement of the fuel rack. As compressor (8) is installed in the plug hole, it will come in contact with, and move, collar (9) inside the governor housing.

NOTE: Before the overfueling spring compressor is installed, check the operation and/or movement of its plunger. If the plunger does not have a smooth, steady movement within the adapter, see the inspection and maintenance information at the back of this instruction.

NOTE: According to engine application, some of these fuel systems will have a torque spring and some will not. This difference in fuel systems makes it necessary to have a separate procedure for the fuel setting check and/or adjustment. Be sure to use the correct procedure (one of the two that follow) to check and/or adjust the fuel setting for your fuel system.

Check and Adjustment of Fuel Setting - Fuel System Without a Torque Spring

6. Connect the wire clip end of 8S4627 Circuit Tester (10) to the rack contact, and put the other end to a good electrical ground as shown.

7. Move the governor control lever to the full FUEL ON position and hold or fasten the lever in this position. Install bolt (C) in compressor (8). Turn the bolt IN (CW) all the way. Now turn the bolt OUT (CCW) until the light just barely comes on (a dim light). The reading shown on the dial indicator is the static rack setting. See the FUEL SETTING INFORMATION for the correct setting.

NOTE: Remove cover (11) only if it is necessary to make an adjustment to the fuel setting.

8. To make an adjustment of the fuel setting, use the 6V2106 Rack Adjustment Tool Group to loosen the locknut for fuel setting adjustment screw (12), and turn the screw IN until it begins to tighten. (DO NOT TIGHTEN THE SCREW ANY FARTHER. Any additional tightening of the screw will cause damage inside the governor.) Now back the screw OUT to the correct static fuel setting, plus .1 to .25 mm (.004" to .010"). See the FUEL SETTING INFORMATION for the correct dimension.

Check and Adjustment of Fuel Setting - Fuel System With a Torque Spring

6. Connect the wire clip end of 8S4627 Circuit Tester (10) to the rack contact, and put the other end to a good electrical ground as shown.

8. Remove cover (11). Remove the bolt from the compressor. With the governor control lever still in the full FUEL ON position, push rack stop collar (13) IN, until the pointer on the dial indicator stops. This is the torque differential dimension. See the FUEL SETTING INFORMATION for the correct dimension.

9. To make an adjustment, use 6V2106 Rack Adjustment Tool Group (15) to loosen the locknut for torque differential adjusting screw (14). With the governor control lever in the full FUEL ON position, turn the torque differential adjustment screw IN (CW) until it begins to tighten. (DO NOT TIGHTEN THE SCREW ANY FARTHER. Any additional tightening will cause damage inside the governor.) Loosen the locknut for fuel setting screw (12), and turn the screw out several turns.

NOTE: The type of screw (12) that was used in some earlier governors has a flange on it, and this flange will let the screw be loosened only so far. When this type of screw is loosened, it can be loosened only until the flange starts to come in contact with the stop collar. At this point, it will again start to tighten. DO NOT TURN THE SCREW ANY FARTHER. (Any additional tightening of the screw will cause damage inside the governor.)

The screw (12) used in later governors does not have this flange, and it will come out if turned OUT too far.

10. Now turn torque differential adjusting screw (14) OUT (CCW) until the correct fuel setting dimension, plus .1 to .25 mm (.004" to .010") is shown on the dial indicator. Tighten the locknut. Make reference to the FUEL SETTING INFORMATION for the correct fuel setting dimension.

11. Connect the wire clip end of 8S4627 Circuit Tester (10) to the terminal on the governor, and put the other end to a good electrical ground as shown. Use 6V2106 Rack Adjustment Tool Group (15) to turn fuel setting screw (12) clockwise until the light in the circuit tester comes on. DO NOT PUSH IN ON THE WRENCH. Tighten the locknut. This is the balance point fuel setting.

12. Again loosen the locknut for torque differential adjustment screw (14). Turn the screw clockwise (CW) until the pointer on the dial indicator moves one-half revolution. Push on the wrench with enough force to bend the torque spring [22-90N (5-20 lbs.)] and at the same time, turn adjustment screw (14) counterclockwise (CCW) until the correct torque differential dimension is shown on the dial indicator. Tighten the locknut. See the FUEL SETTING INFORMATION for the correct torque differential setting dimension.

Linkage Adjustment Procedure for Air-Fuel Ratio Control (Engines so Equipped)

The 7N8622 Air-Fuel Ratio Control is used with the scroll-type fuel system on some 3300 Series Direct Injection Engines. All 7N8622 Air-Fuel Ratio Controls are adjusted on the 6V2029 Fixture Group, and they are all adjusted to the same dimension for all engine applications. The air-fuel ratio control connects to internal linkage (D) of the governor. Linkage (D) of the governor is adjusted to a specific dimension, for specific engine applications. Use the procedure that follows to check and/or adjust linkage (D) to a specific dimension. See the FUEL SETTING INFORMATION for the correct dimension.

1. Remove cover (1).

2. Install 7N1048 Timing Pin (2) in the rack centering pin hole, and install 6V2014 Bracket Assembly (3). The inner arm on bracket assembly (3) must go into slot (E) in the fuel rack. After the installation of bracket (3), check to make sure that shaft (B) has axial movement. If shaft (B) does not have axial movement, make sure that the inner arm of the bracket is in slot (E) of the fuel rack, and that the bracket assembly is installed correctly.

NOTE: If necessary, remove bracket (3) and check inner arm (6). Inner arm (6) must be straight, and perpendicular to the base, as shown.

3. Install 5P4814 Collet (4) on bracket (3). Put 9S229 Contact Point on the stem of 6V3075 Dial Indicator (5), then install the indicator into collet (4) on the bracket assembly.

4. Move the governor control lever in the clockwise (CW) direction to the SHUT OFF position. Carefully push 6V4186 Timing Pin (2) all the way in, until it comes in contact with the fuel rack. DO NOT PUSH TOO HARD ON THE TIMING PIN BECAUSE IT CAN STOP MOVEMENT OF THE FUEL RACK.

5. Move the governor control lever counterclockwise (CCW) to the HIGH IDLE position, and hold it in this position. (The fuel rack will move against the timing pin and stop. This is the fuel rack zero position.)

6. Adjust the dial indicator so the revolution counters are on "0" (zero), then tighten collet (4) to hold the indicator in this position. Move the dial face of the indicator to get alignment of the pointer with zero. Remove the timing pin.

NOTE: With the governor control lever at the HIGH IDLE position, again check to make sure that shaft (B) has axial movement.

7. Move the governor control lever to the FUEL OFF position and remove the air-fuel ratio control from the governor housing.

8. Use S1614 Bolts (7) to install 6V2017 Governor Adjusting Tool (8).

NOTE: Be sure edge (F) of adjusting tool (8) is behind governor linkage (D).

9. Move governor control lever (9) to HIGH IDLE, and hold it in this position. The dimension shown on the dial indicator is the air-fuel ratio control setting.

10. If an adjustment is necessary for the air-fuel ratio setting dimension, use the 6V2106 Adjusting Tool Group to turn adjustment screw (10).

NOTE: To make the air-fuel ratio setting more positive, turn adjustment screw (10) counterclockwise (CCW). Turn adjustment screw (10) clockwise (CW) to make the setting more negative.

Inspection And Maintenance Of 6V2014 Rack Position Indicator Bracket Assembly And The 6V2128 Overfueling Spring Compressor

If during the rack setting procedure, it is not possible to get a repeatable (the same, again and again) rack position dimension on the dial indicator, check the operation of the indicator bracket in the rack position indicator group. Check also the operation of the 6V2128 Overfueling Spring Compressor Group. See the information that follows for a method to check the operation of these tools.

6V2014 Rack Position Indicator Bracket

1. Check the 6V2015 Arm (1) to be sure it is straight. Arm (1) must be perpendicular to face (G) of 6V2014 Bracket Assembly (2), according to the angle shown. It is possible that if an indicator bracket (2) has a bent arm (1), and it is used in the fuel setting procedure, there will be a binding (restriction) in the movement of the fuel rack.

2. With the bracket assembly (2) installed on a pump housing, check the axial movement of shaft (3). There must be good axial movement, in both directions as shown.

6V2128 Overfueling Spring Compressor Group

Install the overfueling spring compressor and the rack position indicator group on a fuel pump and governor. When bolt (1) is turned in either direction, plunger (2) must move smoothly and easily through adapter (3). If plunger (2) does not move smoothly and easily, it can have an effect on movement of the fuel rack, which then can cause a problem during the fuel setting procedure.

NOTE: During a change in the direction in which bolt (1) is turned (CW to CCW, or, CCW to CW) there will be a small delay in the movement, and change of direction, of the rack. This type of delay is normal, and not a problem.

NOTE: Early type 6V2128 Overfueling Spring Compressor Groups are normally the compressor groups that will have the problem given above. For an easy method of identification for these early type compressor groups, the color of plunger (2) is black. Later type plungers are uncoated or natural color steel.

1. If there is a problem with the overfueling spring compressor, disassemble it. Be sure that the spring pin that fastens collar (4) to plunger (2) does not extend out of either end of the collar. If it does, use a file to make smooth any rough areas.

2. Put a small amount of 8S2259 Lapping Compound on plunger (2), and lap the plunger to adapter (3) to remove any burrs. Lap the plunger, from collar (4) forward [area (H)] far enough so that when plunger (2) is installed in adapter (3), approximately 20 mm (0.8), of the plunger, [area (J) which is beyond end (K)] of the adapter will have been lapped.

3. After the lapping procedure is complete, use soap and water to remove the lapping compound from the piece parts, then dry them.

4. Put lubricating oil on the piece parts as necessary and assemble the overfueling spring compressor group.