Injection Pump Cat 3406 PDF

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Modelo:3406 GEN SET ENGINE 75Z
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Service Information System Page 1 of 5
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3406 ENGINE FOR GENERATOR SET
Nmero de medio -SENR2540-00 Fecha de publicacin -01/03/1983 Fecha de actualizacin -11/10/2001
Automatic Timing Advance

SMCS - 1272-11 ; 1272-12 ; 1272-15 ; 1272-16
Remove Automatic Timing Advance

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1. Remove nuts (1), cover (2) and the gasket from the timing gear cover.
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2. Remove bolts (3), washer (4) and automatic timing advance (5) from the engine.
Install Automatic Timing Advance

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1. Remove plug (1) from the fuel injection pump housing.
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2. Time the fuel injection pump by turning the camshaft until the notch in the camshaft is in alignment
with the hole in the fuel injection pump housing. Install tool (A) through the housing and into the notch
of the camshaft.
3. Use tool (B) and put the engine at top center compression. See TESTING AND ADJUSTING.
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4. Put automatic timing advance (2) in position on the drive shaft for the fuel injection pump.
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5. Install washer (5) and bolts (4) that hold the automatic timing advance in place. Tighten bolts (4) in
the following sequence.
a) Tighten bolts (4) evenly to a torque of 35 Nm (25 lb.ft.).
b) Tighten bolts (4) evenly to a torque of 70 Nm (50 lb.ft.).
c) Tighten bolts (4) evenly to a final torque of 135 7 Nm (100 5 lb.ft.).
6. Install gasket (6) and cover (3) on the front cover.
7. To check for correct engine timing see INSTALL FUEL INJECTION PUMP HOUSING AND
GOVERNOR.
Disassemble Automatic Timing Advance

START BY:
a) remove automatic timing advance
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1. Remove retainer ring (2). Remove gear (1) from flange.
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2. Remove springs (3) and counterweights (4) from the flange.
3. Remove slides from dowels on the flange.
Assemble Automatic Timing Advance

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1. Install slides (2) on the dowels of flange (3).
2. Put clean SAE 30 oil on the slides and counterweights. Install the counterweights (1) on the flange.
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3. Install springs (4).
4. Install the gear on the flange assembly. Install retainer ring (5) that holds the gear to the flange
assembly.
END BY:
a) install automatic timing advance
Copyright 1993 - 2012 Caterpillar Inc. Sat Jan 7 21:43:02 EST 2012
Todos los derechos reservados.
Red privada para licenciados del SIS.
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Fuel Transfer Pump

SMCS - 1256-11 ; 1256-12 ; 1256-15 ; 1256-16
Remove Oil Transfer Pump

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NOTE: Put plugs or caps in all fuel line openings.
1. Disconnect fuel supply line (2) and fuel pressure line (1) from fuel transfer pump (3).
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2. Remove two bolts (4) that fasten the fuel transfer pump to the governor drive housing. Remove the
fuel transfer pump.
3. Remove the O-ring seal from the transfer pump and remove the gasket from between the governor
drive housing and transfer pump.
Install Fuel Transfer Pump

1. Clean the contact surfaces of the transfer pump and the governor drive housing.
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2. Install new gasket (1) between fuel transfer pump (2) and governor drive housing. Install an O-ring
seal on the transfer pump and put the pump in position on the housing. Install the two bolts that fasten
the pump to the housing.
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3. Connect fuel pressure line (3) and fuel supply line (4) to the transfer pump.
Disassemble Fuel Transfer Pump

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START BY:
a) remove fuel transfer pump
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1. Remove bolts (1). Remove cover (2) from the fuel transfer pump.
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2. Remove bolt (3). Remove gasket, spring and plunger from under bolt.
3. Remove gear (4).
4. Remove shaft assembly (5).
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5. Remove O-ring seal (7) from body assembly.
6. Install a 5/16"-18 NC forged eyebolt (6) in the plug. Remove plug (8) and O-ring seal. Remove the O-
ring seal from the plug.
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7. Remove valve assembly (9).
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8. Remove two lip seals (10) from the body assembly.
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9. Remove two bearings (11) from the body assembly with tooling (A).
Assemble Fuel Transfer Pump

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1. Install bearings in body (1) with tooling (A). Install bearing on gear end of body to a depth of 0.76
0.51 mm (.03 .02 in.) below the surface of the body. Install the bearing on the opposite end of the body
even with the outside surface of the counterbore.
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2. Put 8H5137 Permatex #2 Form-A-Gasket on the outside diameter of the two seals. Use tooling (A)
and install the first seal with the lip of the seal toward the bearings and 10.31 0.25 mm (.406 .10 in.)
below the outside surface of the body assembly. Use tooling (A) and install the second seal with the lip
of the seal away from the bearings and even with the outside surface of the body assembly. Put a small
amount of clean fuel on the lip of the seals.
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3. Install the valve assembly in the body assembly with tooling (A) to a depth of 14.5 0.5 mm (.57
.02 in.).
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4. Install O-ring seal (3) on the plug. Install a 5/16"-18 NC forged eyebolt (2) in the plug. Put a small
amount of clean diesel fuel on the O-ring seal and install plug (4) in the body assembly. Make sure plug
is even with the surface of the body.
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5. Install O-ring seal on the body assembly.
6. Put a small amount of clean diesel fuel on the lip seals. Put tool (B) in position on shaft assembly.
Install shaft assembly (5) in the body assembly.
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7. Install gear (7).
NOTICE
Do not allow the sealant to enter into the pump.
8. Put 8H5137 Permatex #2 Form-A-Gasket on the body assembly surface that makes contact with the
cover. Install cover (6).
9. Shaft assembly must turn by hand after cover is installed.
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10. Install plunger (8), spring (9), gasket (11) and plug (10) in body assembly. Tighten plug to a torque
of 37 4 Nm (27 3 lb.ft.).
END BY:
a) install fuel transfer pump
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Fuel Injection Lines

SMCS - 1252-11 ; 1252-12
Remove Fuel Injection Lines

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1. Remove nuts (1) and the bolts that hold fuel lines (2) in place on the engine.
2. Use tool (A) and remove fuel injection lines (2) from the fuel injection pump and cylinder head.
3. Put plugs or caps on all fuel line opening.
Install Fuel Injection Lines

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1. Put fuel injection lines (2) in position on the cylinder head and fuel injection pump. Use tool (A) and
tighten the fuel line nuts to a torque of 40 7 Nm (30 5 lb.ft.).
2. Install the bolts and nuts (1) that hold fuel injection lines (2) in place on the engine.
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Fuel Injection Lines

SMCS - 1252-11 ; 1252-12
Remove Fuel Injection Lines

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1. Remove nuts (1) and the bolts that hold fuel lines (2) in place on the engine.
2. Use tool (A) and remove fuel injection lines (2) from the fuel injection pump and cylinder head.
3. Put plugs or caps on all fuel line opening.
Install Fuel Injection Lines

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1. Put fuel injection lines (2) in position on the cylinder head and fuel injection pump. Use tool (A) and
tighten the fuel line nuts to a torque of 40 7 Nm (30 5 lb.ft.).
2. Install the bolts and nuts (1) that hold fuel injection lines (2) in place on the engine.
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Fuel Injection Pumps

SMCS - 1251-11 ; 1251-12 ; 1251-15 ; 1251-16
Remove Fuel Injection Pumps

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START BY:
a) remove fuel lines
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1. Remove the bolts, clamps and service meter (1) from the accessory drive housing.
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2. Remove the bolts, stop (3), spacer (2) and the gasket from the accessory drive housing.
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3. Install stop (3) without the spacer and the gasket and install two 5/16"-18 NC bolts.
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4. Remove bolt (5) and disconnect linkage (4) from the lever on the governor housing.
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5. Remove felt washer (6) from the fuel injection pump.
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6. Use tooling (A) and remove the bushing from the fuel injection pump.
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7. Remove seal (7) from the fuel injection pump.
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8. Move lever (9) forward to move the rack to the center position and use tool (B) and remove fuel
injection pump (8) from the fuel injection pump housing.
Install Fuel Injection Pumps

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NOTICE
The fuel rack must be in the center position before the correct
installation of an injection pump is possible.
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1. Put the groove of barrel (2) in alignment with the slot of the gear segment (the slot is on the opposite
side of the gear segment teeth).
2. Move lever (3) forward to move the rack to the center position.
3. Look inside the bore of the injection pump housing to find the dowel. Put groove of the barrel in
alignment with the dowel and put the injection pump straight down into the bore.
4. Use tool (A) and install fuel injection pump (1) in the fuel injection pump housing.
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5. Inspect for wear or damage and make a replacement if necessary of seal (4).
6. Put seal (4) in position on the fuel injection pump.
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7. Install bushing (5) that holds the fuel injection pump in the fuel injection housing. If the fuel injection
pump is in the correct position, bushing (5) will turn into the fuel injection housing by hand until the top
of the bushing is even with the fuel pump housing.
8. Use tool (B) and tighten bushing (5) to a torque of 200 13 Nm (150 10 lb.ft.).
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9. Put felt washer (6) in position on the fuel injection pump.
10. After each pump has been installed, check total rack travel to make sure each pump has been
installed correctly. See TESTING AND ADJUSTING.
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11. Connect linkage (7) to the lever on the governor housing.
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12. Remove stop (8) from the accessory drive housing.
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13. Install spacer (9), the gasket and stop (8) on the accessory drive housing.
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14. Install service meter (10), the clamps and the bolts on the accessory drive housing.
END BY:
a) install fuel lines
Disassemble Fuel Injection Pumps

START BY:
a) remove fuel injection pumps
NOTICE
Be careful when the injection pumps are disassembled. Do not damage
the surfaces of the plungers, barrels and bonnets. Any scratches will
cause leakage inside the fuel injection pump. The plunger and barrel
for each pump are made as a set. Do not put the plunger of one pump
in the barrel of another pump. If one part has wear, install a complete
new pump assembly. Be careful when the plunger is put into the bore
of the barrel.
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1. Pull plunger (7), washer (6) and spring (5) out of barrel (4).
2. Remove washer (6) from plunger (7).
NOTICE
Do not remove the gear from the plunger. The gear and plunger are
assembled and adjusted at the factory.
3. Remove ring (3) and make a separation of barrel (4) from bonnet (1).
4. Remove check valve (9), seat (8) and spring (2) from bonnet (1). If the check valve assembly is
disassembled, do not mix the parts with parts from another check assembly.
Assemble Fuel Injection Pumps

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NOTICE
Put clean fuel oil on all parts during assembly.
1. Put spring (7), seat (9) and check valve (5) into position in bonnet (8).
2. Install bonnet (8) on barrel (4) and install ring (6) to hold them together. Do not slide bonnet (8)
across barrel (4) because the check valve assembly in the bonnet can cause damage to the face of barrel
(4).
3. Install spring (3) on barrel (4).
4. Install washer (2) on plunger (1) with the flat side toward the gear on the plunger.
5. Install plunger (1) in barrel (4) until washer (2) is engaged in the spring.
END BY:
a) install fuel injection pumps
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Fuel Injection Pump Housing And Governor

SMCS - 1286-11 ; 1286-12
Remove Fuel Injection Pump Housing And Governor

START BY:
a) remove fuel lines
NOTE: The photographs were taken with a Woodward Governor.
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1. Remove fuel lines (1) from the engine.
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2. Disconnect tube assembly (3) and wires (2) from the governor.
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3. Remove the bolts, the clamps and service meter (4) from the accessory drive housing.
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4. Remove bolts (5) that hold the fuel injection pump housing to the accessory drive housing.
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5. Fasten strap (7) and a hoist to fuel injection pump housing and governor (6).
6. Remove bolts (8) and fuel injection pump housing and governor (6) from the engine. The weight of
the fuel injection pump housing and governor is 39 kg (87 lb.).
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7. If necessary remove seals (9) from the fuel injection pump housing.
Install Fuel Injection Pump Housing And Governor

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1. Use tool (A) and put engine at top center compression stroke. See TESTING AND ADJUSTING.
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2. Remove nuts (1) and cover (2) from the automatic timing advance.
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3. Loosen four bolts (2) that hold the automatic timing advance to the drive shaft for the fuel injection
pump.
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4. Remove plug (3) from the fuel injection pump housing.
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5. Time the fuel injection pump by turning the camshaft until the notch in the camshaft is in alignment
with the hole in the fuel injection pump housing. Install tool (B) through the housing and into the notch
of the camshaft.
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6. Inspect for wear or damage and make a replacement if necessary of seals (4).
7. Put seals (4) in position on the fuel pump housing.
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8. Fasten strap (6) and a hoist to fuel injection pump housing and governor (5).
9. Install gasket (7) and fuel injection pump housing and governor (5) on the accessory drive housing
and engine block with the bolts that hold it.
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10. Tighten bolts (8) of automatic timing advance (9) in the following sequence.
a) Tighten bolts (8) evenly to a torque of 35 Nm (25 lb.ft.).
b) Tighten bolts (8) evenly to a torque of 70 Nm (50 lb.ft.).
c) Tighten bolts (8) evenly to a final torque of 135 7 Nm (100 5 lb.ft.).
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11. To check for correct engine timing follow the steps below.
a) Remove tool (B) from the fuel pump housing and the bolt from the flywheel.
b) Turn the flywheel counterclockwise (as seen from the front of the engine) two complete revolutions.
c) If the engine is in correct timing, tool (B) can be installed in the notch of the camshaft in the fuel
injection pump housing and the bolt can be installed in the flywheel.
d) If tool (B) and the bolt can not be correctly installed, the timing is not correct and Step 11 must be
repeated.
NOTE: The flywheel can be out of alignment 1 and still be in correct timing.
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12. Remove tool (B) and install plug (10) in the fuel injection pump housing.
13. Install service meter (11) on the accessory drive housing with the clamps and bolts.
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14. Install gasket (13) and cover (12) to the front cover.
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15. Connect tube assembly (14) and wires (15) to the governor.
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16. Install fuel lines (16) to the block and fuel injection pump housing.
END BY:
a) install fuel lines
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Fuel Injection Pump And Governor Drive

SMCS - 1288-11 ; 1288-12 ; 1288-15 ; 1288-16
Remove Fuel Injection Pump And Governor Drive

START BY:
a) remove automatic timing advance
b) remove fuel injection pump housing and governor
c) remove fuel transfer pump
d) remove service meter
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1. Remove four bolts (1) and the retainer that hold the fuel injection pump and governor drive to the
timing gear plate.
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2. Remove injection pump and governor drive (2) and the gasket from the front cover.
Install Fuel Injection Pump And Governor Drive

1. Clean the contact surfaces of the fuel injection pump and governor drive and the front cover.
2. Install a new gasket between the fuel injection pump and governor drive and the front cover.
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3. Put the injection pump and governor drive (1) in position in the timing gear.
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4. Install retainer (2) and the four bolts that hold injection pump and governor drive to timing gear plate.
END BY:
a) install fuel injection pump housing and governor
b) install automatic timing advance
c) install service meter
d) install fuel transfer pump
Disassemble Fuel Injection Pump And Governor Drive

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START BY:
a) remove fuel injection pump and governor drive
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1. Remove the shaft (2) from housing (1).
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2. Remove O-ring seal (3) and retainer ring (4) from shaft (2).
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3. Use a press and tool (A) to remove bearing (5) from the shaft.
Assemble Fuel Injection Pump And Governor Drive
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1. Heat bearing (2) to 135C (275F) and install on it shaft (1). Install the bearing until it makes contact
with the shoulder on the shaft.
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2. Install retainer ring (3) that holds the bearing on the shaft. Install the O-ring seal on the shaft.
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3. Install the shaft assembly in housing (4) as shown.
END BY:
a) install fuel injection pump and governor drive
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Governor (Woodward)
SMCS - 1264-11 ; 1264-12 ; 1264-15 ; 1264-16
Remove Governor (Woodward)

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1. Remove the bolt and nut and disconnect linkage (1) from the governor.
2. Disconnect tube assembly (3) and wires (2) from the governor.
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3. Remove nuts (5), governor (4) and the gasket from the governor drive housing.
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4. Remove coupling (6) from the governor drive.
Install Governor (Woodward)

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1. Install coupling (1) on the gear in the governor drive.
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2. Make sure bushing (3) is in correct alignment with the coupling in the governor drive and install the
gasket and governor (2) on the governor drive.
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3. Connect linkage (5), wires (4) and tube assembly (6) to the governor.
Disassemble Governor (Woodward)

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START BY:
a) remove governor
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1. Remove screws (2) and motor (1) from the governor.
2. Remove clutch assembly (4) and screw (3) from the governor.
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Spring force is present behind cover assembly (5). To prevent possible

personal injury, carefully loosen all bolts slowly and evenly to decrease
spring force.
3. Remove bolts (6), cover assembly (5) and the gasket from the case assembly.
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4. Remove spring (7) from the seat.
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5. Remove pin (9) and lever (8) from the spring assembly and the link assembly.
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6. Remove two bolts (13), shafts (11) and (12) and lever (10) from the case assembly.
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7. Remove nut (16), seat (14) and strut (15) from lever (10).
8. Remove pin (17) from lever (10).
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9. Remove two blocks (19), the pin and washers (18) from the link assembly.
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10. Loosen bolt (21) and remove lever (20) from the shaft.
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11. Remove adjusting sleeves (24) and (25), the two washers, spring (22), lever (26) and link assembly
(23) from the case assembly.
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12. Remove cotter pin (27) and shaft (28) from lever (26).
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13. Remove nut (32), spacer (29), bolt (30) and shaft assembly (31) from link assembly (23).
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14. Remove nut (33), the washers and the piston stop from the case assembly.
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15. Remove power piston (34) from the case assembly.
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16. Use tool (A) and remove snap ring (35). Remove spring seat (36), springs (37) and piston (39) from
power piston (38).
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17. Remove spring assembly (40) from the ballhead assembly.
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18. Remove nut (41) from the valve plunger.
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19. Use a screwdriver to hold valve plunger (43) and remove spring seat (42).
NOTE: Count the number of turns for assembly purposes.
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20. Remove race (44), the bearing and the race from the valve plunger.
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21. Use tool (A) and remove the snap ring and ballhead (45) at the same time.
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22. Carefully remove cover (46) from the ballhead.
NOTE: If the cover is damaged in any way it must be replaced.
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23. Remove pins (48) and flyweights (47) from the ballhead.
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24. Remove drive cup (49) from ballhead (45).
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25. Remove bearing (50) from ballhead (45).
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26. If necessary, remove spring (51) from ballhead (45).
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27. Remove bolts (54) that hold base (52) to case assembly (53).
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28. Hold case assembly (53) and base (52) together and turn them so the case assembly is on the top as
shown.
29. Remove case assembly (53) from base (52).
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30. Remove valve assembly (56) from the case assembly.
31. If necessary, remove plug (55) from the case assembly. Mark its location for assembly purposes.
Plugs are used for governor rotation and must be installed back into their original position.
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32. Remove pilot valve bushing (57), idler gear (60) and seal (59) from the base.
33. If necessary, remove plug (58) from the base. Mark the location of plug (58) for assembly purposes.
It must be installed back in its original location.
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34. Use tool (A) and remove snap ring (63) from pilot valve bushing (57).
35. Remove bushing (62) and pilot valve plunger (61) from pilot valve bushing (57).
Assemble Governor (Woodward)

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1. Check the seal on plug (1) for wear or damage and make a replacement if necessary.
2. Plug (1) is used for governor rotation and must be installed back into its original location. Install plug
(1) into base (2).
3. Check seal (3) for wear or damage and make a replacement if necessary.
4. Install seal (3) on base (2) as shown.
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5. Install pilot valve plunger (5), bushing (6) and use tool (A) to install snap ring (7) in pilot valve
bushing (4).
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6. Install pilot valve bushing (4) and idler gear (8) in base (2) as shown.
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7. Put washer (10) in position on valve (11) and install valve (11) in case assembly (9).
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8. Check the seal on plug (12) for wear or damage and make a replacement if necessary.
9. Plug (12) is used for governor rotation and must be installed back in its original location. Install plug
(12) in the case assembly.
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10. Put case assembly (9) in position on base (2).
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11. Hold the case assembly and base together and turn them around. Install three bolts (13) that hold the
base to the case assembly.
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12. Put spring (14) in position on ballhead (15) with the tang end of the spring up as shown. Make an
alignment and bend the end of the spring (not shown) in the groove (slot) of the ballhead (not shown).
Make sure the spring is even (flush) with the outside surface of the ballhead to prevent movement of the
spring end when the cover is installed.
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13. Install bearing (16) in ballhead (15). Make sure the red die side of the bearing is toward the ballhead.
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14. Put drive cup (17) in position on ballhead (15). Make sure the tang of the spring fits in the groove
(slot) of the drive cup.
15. Move the cup drive and the ballhead from stop to stop for correct movement.
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16. Put flyweights (18) in position on the ballhead and install pins (19) that hold the flyweights in place.
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17. Make sure cover (20) is not damaged. Install ballhead (15) in cover (20) until the lip of the cover is
even with the outside surface of the ballhead.
18. After the ballhead assembly is completed, make the following final checks.
a) The flyweights should pivot freely.
b) Move the ballhead slightly with your fingers and let go. If the spring tang is correctly installed in the
groove (slot) of the drive cup, the ballhead will move back into its original position.
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19. Put ballhead (15) in position on pilot valve bushing (4) and use tool (A) to install the snap ring that
holds the ballhead in place.
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20. Install race (23), bearing (22) and race (21) in the ballhead.
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21. Install spring seat (24) on pilot valve plunger (5). Use a wrench or 1P87 Adjusting Wrench to hold
the spring seat and a screwdriver to center the pilot valve plunger. For the correct centering adjustment
of the pilot valve plunger, see TESTING AND ADJUSTING.
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22. After pilot valve plunger has been centered, install locknut (25) and tighten it to a torque of 8 Nm
(70 lb.in.).
23. Install spring assembly (26) on the ballhead.
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24. Install spring (28), piston (29), spring (30), spring seat (31) and use tool (A) to install snap ring (32)
in power piston (27).
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25. Put power piston (27) in position in the case assembly as shown.
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26. Install piston stop (28) in the case assembly as shown and install the washers and the nut that hold it.
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27. Put lever assembly (30) in position on link assembly (29). Install the bolt, spacer (31) and nut (32).
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28. Install lever (35) on shaft (34). Install cotter pin (33) that hold the lever and the shaft together.
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29. Put spring (36) on shaft (34). Make sure spring end (37) is installed in the hole in lever (35).
30. Put link assembly (29) and lever (35) in position in the case assembly.
31. Install washers (38) and (40) on adjusting sleeves (39) and (41).
32. Install adjusting sleeves (39) and (41) in the case assembly that hold the lever and the link assembly.
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33. Put lever (42) in position on the shaft and tighten bolt (45).
34. Install the pin, two washers (44) and two blocks (43) on link assembly (29) as shown.
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35. Install pin (47) in lever (46) with the hole in the pin as shown.
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35. Install strut (48) in lever (46).
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36. Install seat (49) on strut (48) as shown.
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37. Install nut (50) on the strut.
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38. Lift link assembly (29) and put lever (46) in position in the case assembly. Make sure blocks (43) are
installed in the grooves (slots) of the lever.
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39. Put shafts (51) and (52) in position in the case assembly that holds lever (46) in place.
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40. Install bolts (53) that hold the shafts in place.
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41. Put lever (55) with the 45 notch up in position with the forks of lever (55) between pin (54) and the
lever between the two washers. Put the opposite end of lever (55) on the spring assembly. Install pin
(56) that holds lever (55) to the spring assembly and bend it to hold it in place.
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42. Put gasket (59) and spring (58) in position on the case assembly and install cover assembly (57).
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43. Install clutch assembly (62), screw (61) and motor (60) on the governor. For the correct governor
adjustment see TESTING AND ADJUSTING.
END BY:
a) install governor
Desarmado y Armado
Governor Drive Housing (Woodward)

SMCS - 1288-11 ; 1288-12 ; 1288-15 ; 1288-16
Remove Governor Drive Housing (Woodward)

START BY:
a) remove governor
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NOTE: The rack extension is connected to the lever on governor drive housing (2). Carefully remove
the governor drive housing.
1. Remove bolts (1), governor drive housing (2) and the gasket from the fuel injection pump housing.
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2. Remove bolts (4) and support (3) from the fuel injection pump housing.
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3. Remove gear (5) from support (3).
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4. If necessary remove dowels (7) and bearing (6) from support (3).
Install Governor Drive Housing (Woodward)

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1. Use tool group (A) and install dowels (1) in support (2) 3.81 0.508 mm (.15 .02 in.) above the
outside surface.
2. Remove plug (3) from support (2) so that bearing (4) can correctly be installed.
3. Use tool group (A) and install bearing (4) even with the outside surface of support (2) and the oil
supply hole in the bearing centered in the hole of the support.
4. Install plug (3) in support (2) and tighten the plug to a torque of 4.5 0.6 Nm (40 5 lb.in.).
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5. Put gear (5) into position in support (2) as shown.
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6. Put support (2) in position on fuel injection pump housing and install the bolts.
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7. Put gasket (8) and governor drive housing (9) in position on the fuel injection pump housing. Make
sure rack extension (6) is installed in the fork of lever (7).
END BY:
a) remove governor
Disassemble Governor Drive Housing (Woodward)
START BY:
a) remove governor drive housing
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1. Loosen nut (3) and remove lever (1) and the key from the shaft.
2. If necessary, remove linkage (4) from lever (1).
3. Remove stud (2) from the shaft.
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4. Remove bolt (8) and plate (7) from the governor drive housing.
5. Remove the wire, bolt (5) and cover (6) from the governor drive housing.
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6. Remove switch (9) from the governor drive housing.
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7. If necessary, remove lock (11) and nut (10) from switch (9).
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8. Remove pin (12) and, if necessary, dowel (13) from the governor drive housing.
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9. Bend lock (17) away from bolts (16) and remove bolts (16), shaft (14) and plate (15) from the
governor drive housing.
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10. Remove ring (18) from the shaft.
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11. Move lever (22) away from the spring so it is disconnected from sleeve (21).
12. Turn shaft (19) so bolt (20) can be seen for removal as shown. Remove bolt (20).
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13. Remove shaft (19), sleeve (21), spring (23) and lever (22) from the governor drive housing.
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14. Bend lock (26) away from bolts (25) and remove bolts (25) and plate (24) from lever (22).
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15. If necessary, remove bearings (27) and dowel (28) from the governor drive housing.
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16. If necessary remove seals (30) and bearings (29) from the governor drive housing.
Assemble Governor Drive Housing (Woodward)

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1. Use tool group (A) and install bearing (3) in the governor drive housing to a diameter of 72.14 mm
(2.84 in.) from the inside face of counterbore (1) to inside face of bearing (3). Make sure the bearing is
pushed on the stamped side only.
2. Use tool group (A) and install bearing (5) in the governor drive housing to a dimension of 130.56 mm
(5.14 in.) from outside surface (2) of the governor drive housing to inside face of bearing (5). Make sure
the bearing is pushed on the stamped side only.
3. Install dowel (6) in the goveror drive housing to a dimension of 28.45 mm (1.12 in.) from inside
surface (4) of the governor drive housing to the end of dowel (6).
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(.53 in.) from the inside face of counterbore (1) (see picture B65771X1) to the inside face of bearing (7).
Make sure the bearing is pushed on the stamped side only.
(.58 in.) from outside surface (2) of the governor drive housing to inside face of bearing (10). Make sure
the bearing is pushed on the stamped side only.
6. Use tool group (A) and install seal (8) with the lip toward the inside as shown to a dimension of 1.27
mm (.05 in.) from the inside face of counterbore (1) (see picture B65771X1) to inside face of seal (8).
7. Use tool group (A) and install seal (9) with the lip toward the inside as shown to a dimension of 2.032
mm (.08 in.) from outside surface (2) of governor drive housing to inside face of seal (9).
8. After seals (8) and (9) have been installed, put clean engine oil on the lips of the seals.
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9. Put plate (14) in position on lever (11) and install lock (13) and bolts (12) as shown.
10. Bend lock (13) against the flat side of the bolts as shown.
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11. Put spring (16) in position on sleeve (15) and make an alignment of the bolt holes as shown.
12. Put sleeve (15) and lever (11) in position in the governor drive housing and install shaft (17) as
shown.
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13. Make an alignment of the bolt holes in the spring, the sleeve and the shaft and install the washer and
bolt (18).
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14. Turn shaft (17) until lever (11) can be connected to sleeve (15).
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15. Install ring (19) on the shaft.
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16. Put shaft (20) and plate (21) in position in the governor drive housing. Make sure dowel (6) is in the
notch of plate (21).
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17. Install lock (23) and bolts (22) that hold the plate to the shaft.
18. Bend lock (23) against the flat side of bolts (22) as shown.
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19. Install pin (24) in the governor drive housing to a dimension of 1.575 mm (.062 in.) above the
outside surface.
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20. Install pin (25) in the governor drive housing with the chamfered end installed first and the collar
end last.
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21. Install lock (28) and nut (27) on switch (26).
22. Install switch (26) in the governor drive housing.
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23. Install cover (29) and bolt (30) in the governor drive housing.
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24. Install plate (34) and the bolt on the governor drive housing.
25. Install linkage (32) on lever (31).
26. Install the key and lever (31) on shaft (17) as shown.
27. Install stud (33) on the shaft.
28. See TESTING AND ADJUSTING for the correct governor drive adjustment.
END BY:
a) install governor drive housing
Desarmado y Armado
Governor (Hydramechanical)
SMCS - 1264-15 ; 1264-16
Disassemble Governor (Hydramechanical)

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1. Remove the bolt, cover (1) and the gasket from the housing assembly.
2. Remove the bolts, nuts, covers (3) and the gaskets from plate assembly (2).
3. Remove the bolts, plate assembly (2) and the gasket from the cover assembly.
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4. Remove idle screw (4), bolt (6), cover assembly (7) and gasket (8) from housing assembly (5).
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5. Remove strainer assembly (10) and insulator (9) from cover assembly (7).
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6. Bend locks (12) and (15) away from bolts (11) and (16).
7. Remove bolts (11) and (16) and remove levers (13) and (14) from shaft (17).
8. Remove shaft (17) from cover assembly (7).
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9. Remove seals (18) and (19) from cover assembly (7).
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10. Remove bearings (20) and (21) from cover assembly (7).
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11. Remove screw (24) and collar (23) from bolt (22).
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12. Remove bolts (25), housing assembly (5) and the gasket from the fuel injection pump housing.
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NOTICE
Make a note of the correct sequence of parts for the torque group for
assembly purposes.
13. Remove torque control group (27) and valve body (26) from housing assembly (5).
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14. Remove seal (28) and valve (30) from valve body (26).
15. Remove seal (29) from valve (30).
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16. Bend lock (33) away from bolt (34) and remove the bolt from shaft (31).
17. Remove shaft (31) and lever (32) from the housing assembly.
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18. Remove seal (35) from housing assembly (5).
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19. If necessary, remove plug (36) from housing assembly (5).
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20. Remove bearings (37) from housing assembly (5).
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NOTE: For the correct procedure to remove the spring guide see SPECIAL INSTRUCTION Form
SMHS7356.
21. Use tooling (A) and remove the spring guide from housing assembly (5).
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22. Remove seat (39) and spring (38) from seat assembly (40).
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23. Use tool (B) and remove ring (42), piston assembly (41) and seat assembly (40) from the guide.
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24. Remove spacer (43), piston assembly (41) and spring (44) from the seat assembly.
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25. Remove spring (44) from piston assembly (41).
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26. Use tool (B) and remove ring (47) from piston assembly (41).
27. Remove ring (46) and spool (45) from piston assembly (41).
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28. Remove ring (49) and bearing (48) from the seat assembly.
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29. Remove bolt (50) from piston assembly (40).
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30. Bend the tabs of lock (51) away from bolts (52).
31. Remove bolts (52) and piston assembly (53) from the fuel injection pump housing.
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32. Remove dowel (54) and guide (55) from the weight assembly.
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33. Remove lock (56) that holds weight assembly (57) to piston assembly (53).
34. Remove weight assembly (57) from piston assembly (53).
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35. Remove dowels (59) and weights (58) from the weight assembly.
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36. Remove valve (61) from the piston.
37. Remove sleeve (60) from piston assembly (53).
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38. Remove piston (62) and seal (63) from sleeve (60).
Assemble Governor (Hydramechanical)

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1. Put 1P808 General Purpose Lubricant in the seal groove of sleeve (2) and on seal (3).
2. Install seal (3) on sleeve (2).
3. Install piston (1) in sleeve (2) as shown.
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4. Install sleeve (2) and the piston in piston assembly (4).
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5. Install valve (5) in piston (1).
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6. Put weights (6) in position on weight assembly (8) and install pins (7).
7. Use a punch and move the metal (stake) around each dowel (7) to hold them in place.
8. Check to make sure weights (6) move (pivot) freely and have an end play of 0.025 to 0.178 mm (.001
to .007 in.) on dowels after assembly.
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9. Put weight assembly (8) in position on piston assembly (4) and install lock (9) that holds them
together.
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10. Put guide (10) in position on valve (5) and install the dowel that holds them together.
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11. Put piston assembly (4) and lock (11) in position on the fuel injection pump housing and install bolts
(12). Bend the tabs of lock (11) against the flat side of bolts (12).
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12. Install bolt (13) in seat assembly (14).
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13. Install bearing (15) and ring (16) in seat assembly (14).
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14. Install spool (17), ring (20) and use tool (A) to install ring (18) on piston assembly (19).
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15. Install spring (22) on piston assembly (19).
16. Install spring (22) on seat assembly (14).
17. Install spacer (21) in seat assembly (14).
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18. Put seat assembly (14) in position on weight assembly (8) and use tool (A) to install the ring that
holds the two together.
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19. Install spring (23) and seat (24) on seat assembly (14).
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NOTE: For the correct procedure to install the spring guide, see SPECIAL INSTRUCTION Form No.
SMHS7356.
20. Use tooling (B) and a press to install the spring guide in housing (25).
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NOTE: For the correct procedure to swage (change shape of) the end of the stem in the chamfer of the
bore in the housing see SPECIAL INSTRUCTION Form No. SMHS7356.
21. Use tooling (C) and a press to swage (change shape of) the end of the stem in housing (25).
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22. Use tool group (D) and install bearing (26) in housing (25) to dimension (Y) or 43.38 0.15 mm
(1.708 .006 in.). After assembly the inside diameter of the bearing must be 15.761 0.038 mm (.620
.001 in.).
23. Use tool group (D) and install bearing (27) in the housing to dimension (X) or 60.58 0.13 mm
(2.385 .005 in.). After assembly the inside diameter of the bearing is 15.761 0.038 mm (.620 .001
in.).
24. Use tool group (D) and install plug (28) in housing (25) as shown.
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25. Use tool group (D) and install seal (29) with the lip of the seal toward the inside as shown and even
with the outside surface of the housing. Put clean engine oil on the lip of the seal.
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26. Put lever (31) in position in the housing and install shaft (30). Install lock (32) and bolt (33) that
hold the shaft and the lever in place. Bend the tab of the lock against the flat side of the bolt as shown.
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27. Inspect seals (34) and (36) for wear or damage and make a replacement if necessary.
28. Install seal (34) on body (35) and seal (36) on valve (37).
29. Install valve (37) in body (35).
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30. Put clean engine oil in the valve body bore of the housing and install body (35) and the valve in the
housing.
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31. Install torque control group (38) on housing (25). Make sure the tabs of the lock are bent against the
flat side of the bolts.
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32. Install the gasket and housing (25) on the fuel injection pump housing.
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33. Install spring (40) and collar (39) on bolt (13).
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34. Install seal (48) in the housing with the lip of the seal toward lever (47).
35. Use tool group (D) and install bearing (49) in the housing to dimension (O) or 92.862 mm (3.656 in.)
from the center of bore to the outside edge of the bearing as shown.
36. Use tool group (D) and install bearing (43) in the housing to dimension (P) or 98.68 mm (3.885 in.)
from the outside edge of bearing (49) to the inside edge of bearing (43).
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40. Install strainer (50) in cover assembly (51) as shown.
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41. Install gasket (52) and cover assembly (51) on housing (25).
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42. Inspect seal (53) for wear or damage and make a replacement if necessary.
43. Put seal (53) in position on idle adjustment screw (54) and install it in cover assembly (51).
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44. Install the gaskets, plate assembly (56), cover (55) and cover (57) as shown.
45. Make adjustments to the governor. See GOVERNOR ADJUSTMENTS in TESTING AND
ADJUSTING.
Desarmado y Armado
Fuel Injection Pump Housing

SMCS - 1253-15 ; 1253-16
Disassemble Fuel Injection Pump Housing

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START BY:
a) remove fuel injection pump housing and governor
b) remove governor drive housing (Woodward Governor only)
c) remove governor (hydramechanical only)
1. Remove the protection caps and the felt washers from the pumps.
2. Use tool (A) to remove the bushing that holds the pumps in the fuel injection pump housing.
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3. Remove seal (1) from the fuel injection pump housing.
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4. Install tool (C) on the end of the fuel injection pump housing as shown.
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Woodward Governor Shown
5. Move the adapter and rack (Woodward Governor) or rack (hydraulic governor) against tool (C) to
center the rack and use tool (B) to remove fuel injection pump (2) from the fuel injection pump housing.
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6. Remove spacer (3) from the fuel injection pump housing.
7. Repeat Steps 1-6 for removal of the remaining fuel pumps.
NOTE: Put identification on the injection pumps and spacers as to their location in the pump housing.
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8. Remove adapter (7) and the rack from the fuel injection pump housing (Woodward Governor only).
Remove the rack from the fuel injection pump housing (hydramechanical governor only).
9. Bend tabs of lock (5) away from bolts (4). Remove bolts (4) and guide (6) from the fuel injection
pump housing (Woodward governor only).
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10. Remove adapter (7) and spring (8) from rack (9) (Woodward Governor only).
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11. Remove lifters (10) from the fuel injection pump housing.
NOTE: Keep lifters together with identification as to their location in the pump housing.
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12. Bend lock (12) away from bolts (11). Remove bolts (11), locks (12), the sleeves and gear (13) from
the camshaft.
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13. Remove pin (16) and spring (14) from gear (13).
14. Remove pin (17) and yoke (15) from spring (14).
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15. Remove plate assembly (18) and the gasket from the fuel injection pump housing.
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16. If necessary, remove bushing (19) from the plate assembly.
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17. Remove bolts (21) plate (23) and spacer (22) that hold camshaft (20) in the fuel injection pump
housing.
18. Remove camshaft (20) from the fuel injection pump housing.
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19. If necessary use tool group (D) and remove the camshaft bearing from the automatic timing advance
end of the fuel injection pump housing.
20. If necessary, remove rack bearing (24) from the automatic timing advance end of the fuel injection
pump housing.
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21. If necessary remove rack bearing (25) and dowels (26) from the governor drive housing end of the
fuel injection pump housing.
22. If necessary, use tool group (D) and remove camshaft bearing (27) from the governor drive housing
end of the fuel injection pump housing and the center bearing in the fuel injection pump housing.
Assemble Fuel Injection Pump Housing

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1. Use tooling (A) to install the camshaft bearings in fuel injection pump housing (1). Install the
camshaft bearings so that the bearing joints are 15 from the vertical centerline of the bores. Install the
front and rear camshaft bearings even with the outside surfaces of fuel injection pump housing (1).
Install the center camshaft bearing to a distance of 122.2 0.5 mm (4.81 .02 in.) from rear face (X).
After assembly the inside diameter of the camshaft bearings must be 53.988 0.038 mm (2.125 .01
in.).
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2. Use tooling (B) and install the rack bearing even with the outside surface of fuel injection pump
housing (1). Make sure the tab in the rack bearing is installed toward the inside and within .05 mm (.003
in.) of the vertical center line of the bearing bore. After assembly the inside diameter of the rack bearing
must be 12.758 0.046 mm (.502 .002 in.).
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3. Use tool group (C) to install the rear rack bearing. Install the rack bearing to a depth of 7.16 0.13
mm (.282 .005 in.) below the outside surface. The small holes in the rear rack bearing must be
installed parallel to the vertical centerline of the bearing bore. After assembly the inside diameter of the
bearing must be 12.746 .046 mm (0.502 0.002 in.).
4. Install dowels (2) in the fuel injection pump housing 15.7 0.5 mm (0.618 0.02 in.) above the
outside surface.
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5. Put clean engine oil on camshaft (3) and carefully install it in the fuel injection pump housing.
6. Install spacer (4), plate (5) and the bolts that hold camshaft (3) in place.
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7. Make sure all gasket surfaces are clean and free of dirt.
8. Put gasket (6) in position on the fuel injection pump housing.
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9. Use tool group (C) and install bushing (8) in plate assembly (7) even with outside surface (X).
10. Put plate assembly (7) in position on the fuel injection pump housing as shown.
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11. Install yoke (10) on spring (9) and install the pin that holds them together.
12. Install spring (9) on gear (11) and install the pin that holds them together.
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Woodward Governor Shown
NOTE: Steps 13, 18, 20, 22, 23, 28, and 29 have the guide shown for Woodward Governor only.
13. Install gear (11), lock (14) and the bolts on the end of the camshaft. Bend lock (14) against the bolts.
14. Install guide (12), lock (13) and the bolts on the plate assembly. Bend the tabs of lock (13) against
the bolts (Woodward Governor only).
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15. Install spacers (15) with their respective lifters (16) in the pump housing. If new lifters and/or pumps
are to be installed, make adjustment of the fuel pump timing dimension. See SETTING THE
INJECTION PUMP TIMING DIMENSION: OFF ENGINE TESTING AND ADJUSTING.
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16. Install spring (17) and adapter (18) on rack (19) (Woodward Governor only).
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17. Put adapter (18) and the rack in position in the fuel injection pump housing (Woodward Governor
only).
18. Put the rack in position in the fuel injection pump housing (hydramechanical governor only).
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19. Install tool (D) on the fuel injection pump housing.
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NOTICE
The plunger from one pump can not be installed in another pump. Do
not install the pumps until the rack is in center position (centered).
20. Move adapter (18) and the rack against tool (D) to center the rack (Woodward Governor only).
21. Move the rack against tool (D) to center the rack (hydramechanical governor only).
22. Use tool (E) and install fuel pump (21) in its respective bore in the fuel injection pump housing.
23. Make sure groove (slot) (24) in the gear and groove (23) in the barrel are in alignment with pin (20)
in the lifter and dowel (22) in the fuel injection pump housing.
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24. Inspect seal (25) for wear or damage and make a replacement if necessary.
25. Install seal (25) in the fuel injection pump housing.
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26. Put pressure by hand on tool (E). Tighten bushing (26) by hand (finger tight only) until the bushing
is even with the top of the fuel injection pump housing. If the bushing can not be installed by hand,
remove the bushing and the fuel pump and repeat Steps 20-25.
NOTICE
Do not put force on bushings with a wrench to make them even with
pump housing. Pump is not installed correctly if a force has to be used
to install bushing.
27. If the rack movement (travel) is correct (see Step 28). Use tool (F) to tighten bushing (26) to a torque
of 200 13 Nm (150 10 lb.ft.).
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28. Use tooling (G) to check the rack movement (travel) after each fuel pump is installed. Total rack
movement (travel) must be 20.32 mm (.800 in.). See INSTALLATION OF FUEL INJECTION PUMPS
in TESTINA AND ADJUSTING.
29. Install felt washer (27) and protective cap (28) on the fuel pumps.
30. To install remaining fuel pumps repeat Steps 20-29.
END BY:
a) install fuel injection pump housing
b) install governor drive housing (Woodward Governor)
c) assemble governor (hydramechanical governor)
Desarmado y Armado
Fuel Injection Valves

SMCS - 1254-11 ; 1254-12
Remove Fuel Injection Valves

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START BY:
a) remove valve cover bases
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1. Use tool (A) to disconnect the fuel line assemblies from the cylinder head.
2. Disconnect fuel line assemblies (1) from the fuel injection valves and remove them from the engine.
Install covers on all fuel line connections to keep dirt or foreign material out of the fuel system.
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3. Remove nut (2) that holds the fuel injection valve to the adapter assembly.
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4. Use tool (B) to remove the fuel injection valves.
5. If the fuel injection valves can not be removed with tool (B), use tooling (C).
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6. Remove nozzles assembly (3) from body (4).
7. Remove seal (5) from the body.
Install Fuel Injection Valves

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1. Use tool (A) to install seal (2) on valve body (1).
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2. Install nozzle assembly (3) on the valve body. Tighten nozzle finger tight only.
3. Put a small amount of clean diesel fuel on the seal and install the fuel injection valves in the adapter
assemblies.
4. Install the nut that holds the fuel injection valves and tighten to a torque of 75 7 Nm (55 5 lb.ft.).
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5. Remove the covers from the fuel line connections. Put fuel line assemblies (4) in position on the
engine. Use tool (B) to tighten the fuel line nuts on the cylinder head adapter assembly.
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6. Use tool (C) to tighten fuel line nuts to a torque of 40 7 Nm (30 5 lb.ft.).
END BY:
a) install valve covers and bases
Page 1 of 1
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Grfio y contenido
GRAFICO #1
c236476
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3406 GENERATOR SET ENGINE

Nmero de medio - SEBP1369-00|Fechadepublicacin-
01/03/1983|Fechadeactualizacin- 06/10/2001

7N1219 FUEL INJECTION PUMP GROUP
PART OF 7N1256 FUEL INJECTION PUMP GROUP SHOWN ON PAGE 178
GRUPO ENTERO
Ref. Cant. NPR Nota No. de pieza Nombre de la pieza
Grp NPR 7N-1219 PUMP GP-FUEL INJECTION
PIEZAS INDIVIDUALES
Cant.
req.
1 NPR 9L-6892 1 COLLAR-CHECK VALVE
2 NPR 6N-0024 1 SPRING
3 NPR 9L-6893 1 BONNET-VALVE
4 NPR 9N-0593 1 CHECK AS-PUMP
5 NPR CL 7W-1927 1 RING-RETAINER

RING-RET-CLA
CL NPR 387-2935 1

6 NPR 7N-1220 1 PLUNGER AS-PUMP
7 NPR 7N-1208 1 SPRING-LIFTER
8 NPR C 7N-1066 1 WASHER-RETAINER
Abreviaturas:
CL - Pieza Classic disponible

C - CHANGE FROM PREVIOUS TYPE
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Grfico slo
GRAFICO #1
c222742
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Grfico slo
GRAFICO #1
c413079
Page 1 of 2
3406 GENERATOR SET ENGINE

Nmero de medio - SEBP1369-00|Fechadepublicacin-
01/03/1983|Fechadeactualizacin- 06/10/2001

7N1256 FUEL INJECTION PUMP GROUP
PART OF 7N1258 & 7N1259 GOVERNOR & FUEL INJECTION PUMP GROUPS
SHOWN ON
PAGES 171 & 172. 7N1219 PUMP PARTS ARE SHOWN ON PAGE 182
GRUPO ENTERO
Grp NPR 7N-1256 PUMP GP-FUEL INJECTION
PIEZAS INDIVIDUALES
Cant.
req.
1 NPR 1M-1077 6 SEAL-O-RING
2 NPR 2M-4314 6 BUSHING
3 NPR 8H-9204 6 WASHER-FELT

SPACER
4 NPR B 4N-9844 6
5.67MM(.223IN)THK
5 NPR 4N-7354 1 SPACER
6 NPR 9S-4181 1 PLUG-O-RING
7 NPR 7M-8485 1 SEAL-O-RING
8 NPR 2P-8617 1 RACK-REGULATOR
9 NPR Y 7N-1219 6 PUMP GP-FUEL INJECTION
10 NPR 4N-7353 1 PLATE-THRUST
11 NPR C 4W-0736 6 LIFTER AS
12 NPR 0S-1618 4 BOLT
13 NPR 7F-8036 1 LOCK
14 NPR 9M-1974 2 WASHER
NPR 6N-1172 2 SLEEVE
15 NPR 4N-0631 1 GEAR AS-FLEXIBLE DRIVE

GEAR-GOVERNOR DRIVE
NPR 4N-0629 1
(72 TEETH)
SPRING-LEAF
16 NPR 4N-2483 1

YOKE
17 NPR 4N-4051 1

PIN-SPRING
18 NPR 6D-9953 2

PIN
19 NPR 4N-0627 1

20 NPR 6N-1483 1 CAMSHAFT AS-PUMP
PIN-SPRING
21 NPR 9F-7882 1

22 NPR 6N-4448 1 HOUSING AS-FUEL PUMP
23 NPR 4B-9782 1 BALL
Page 2 of 2

PIN-LIFTER GUIDE
24 NPR 4M-1474 3

BEARING-SLEEVE
25 NPR 9S-4160 1

BEARING-RACK
26 NPR 1S-1953 1

BALL
27 NPR 1P-0232 6

DOWEL
NPR 1P-0234 6

BEARING-SLEEVE
28 NPR 1S-7101 2

PLUG
29 NPR C 9F-2247 1

DOWEL
30 NPR 9S-9702 2

BEARING-SLEEVE
31 NPR 1S-7103 1

PLUG-PIPE
32 NPR 5M-6214 3
(PIPE)
- OR -
PLUG
NPR C 1N-5999 3
(STR THREAD)
NPR C 7J-0204 3 SEAL-O-RING
SPACER
33 NPR B 4N-9837 6
4.96MM(.195IN)THK
SPACER
NPR B 4N-9838 6
5.06MM(.199IN)THK
SPACER
NPR B 4N-9839 6
5.16MM(.203IN)THK
SPACER
NPR B 4N-9840 6
5.26MM(.207IN)THK
SPACER
NPR B 4N-9841 6
5.36MM(.211IN)THK
SPACER
NPR B 4N-9842 6
5.47MM(.215IN)THK
SPACER
NPR B 4N-9843 6
5.57MM(.219IN)THK
Abreviaturas:
B - USE AS REQUIRED
C - CHANGE FROM PREVIOUS TYPE
Y - SEPARATE ILLUSTRATION
Copyright 1993 - 2012 Caterpillar Inc. Sun Jan 8 17:38:37 EST 2012
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Injection Pump Cat 3406 PDF

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Injection Pump Cat 3406 PDF

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Page 1 of 1

Cambiar configuracin del producto o de la pieza

Automatic Timing Advance

Remove Automatic Timing Advance

Install Automatic Timing Advance

1. Remove plug (1) from the fuel injection pump housing.

a) Tighten bolts (4) evenly to a torque of 35 Nm (25 lb.ft.).

b) Tighten bolts (4) evenly to a torque of 70 Nm (50 lb.ft.).

c) Tighten bolts (4) evenly to a final torque of 135 7 Nm (100 5 lb.ft.).

6. Install gasket (6) and cover (3) on the front cover.

Disassemble Automatic Timing Advance

a) remove automatic timing advance

1. Remove retainer ring (2). Remove gear (1) from flange.

2. Remove springs (3) and counterweights (4) from the flange.

3. Remove slides from dowels on the flange.

Assemble Automatic Timing Advance

1. Install slides (2) on the dowels of flange (3).

3. Install springs (4).

a) install automatic timing advance

Fuel Transfer Pump

Remove Oil Transfer Pump

NOTE: Put plugs or caps in all fuel line openings.

Install Fuel Transfer Pump

Disassemble Fuel Transfer Pump

a) remove fuel transfer pump

3. Remove gear (4).

4. Remove shaft assembly (5).

5. Remove O-ring seal (7) from body assembly.

7. Remove valve assembly (9).

8. Remove two lip seals (10) from the body assembly.

Assemble Fuel Transfer Pump

5. Install O-ring seal on the body assembly.

7. Install gear (7).

9. Shaft assembly must turn by hand after cover is installed.

a) install fuel transfer pump

Fuel Injection Lines

Remove Fuel Injection Lines

3. Put plugs or caps on all fuel line opening.

Install Fuel Injection Lines

Fuel Injection Lines

Remove Fuel Injection Lines

3. Put plugs or caps on all fuel line opening.

Install Fuel Injection Lines

Fuel Injection Pumps

Remove Fuel Injection Pumps

a) remove fuel lines

5. Remove felt washer (6) from the fuel injection pump.

7. Remove seal (7) from the fuel injection pump.

Install Fuel Injection Pumps

6. Put seal (4) in position on the fuel injection pump.

9. Put felt washer (6) in position on the fuel injection pump.

11. Connect linkage (7) to the lever on the governor housing.

12. Remove stop (8) from the accessory drive housing.

a) install fuel lines

Disassemble Fuel Injection Pumps

a) remove fuel injection pumps

2. Remove washer (6) from plunger (7).

Assemble Fuel Injection Pumps

3. Install spring (3) on barrel (4).

a) install fuel injection pumps

Fuel Injection Pump Housing And Governor

Remove Fuel Injection Pump Housing And Governor

a) remove fuel lines