Governor SMCS - 1286-015; 1286-016; 1286-076; 1286-077

Separate Governor From Fuel Injection Pump Housing Start By: a. Remove fuel injection pump housing and governor

-------------------------------------------------------------------------------NOTICE Read and understand publication NEHS0622 prior to separation of the governor from the fuel injection pump housing.

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

NOTE: Before separation of the governor from the fuel injection pump housing, remove all dirt and grease from the governor and the fuel injection pump housing.

Ver imagen

Ver imagen

Ver imagen

1. Mount the fuel injection pump housing and governor on Tools (B) and (C) as shown.

Ver imagen

Ver imagen

Ver imagen

Ver imagen

Ver imagen

2. If equipped, remove tag wire seal (1) from the governor housing. 3. Remove threaded cap (2) from the full load stopper bolt.

Ver imagen

4. Remove locknut (3) from full load stopper bolt.

Ver imagen

5. Remove threaded cap (5).

Ver imagen

6. Remove idling subspring (6).

Ver imagen

Ver imagen

7. Remove four bolts (8) and washers. 8. Remove cover (7).

Ver imagen

9. Remove seal from cover (7)

Ver imagen

10. Use Tool (H) to remove torque control spring (9).

Ver imagen

Ver imagen

11. Loosen two plugs (A) at top of governor cover. Loosen one bolt (B) on fuel shutoff lever, and loosen on bolt on control lever (C). NOTE: These items are to be loosened at this time for removal later.

Ver imagen

12. Remove six screws (10). NOTE: Top two screws are longer than the rest. 13. Lightly tap governor cover (11) with a wooden or plastic hammer to separate it from governor housing (12).

Ver imagen

14. Push link's leaf spring (13) from above with a screwdriver or similar tool a move the governor cover to the left or right to separate the link from the control rack.

NOTICE Take care not to bend link. Ver imagen

15. Using long nose pliers, remove starting spring (26) from the spring eye. Governor cover (24) can now be removed. Remove the gasket between the governor cover and the governor housing.

Ver imagen

Ver imagen

16. Install Tool (D) to the drive side coupling and remove round nut (15) and spring washer (16) with Tool (G).

Ver imagen

Ver imagen

17. Use Tools (L) and (K) to remove flyweight (17) and woodruff key (18).

Ver imagen

Ver imagen

NOTE: If the pump is to be disassembled, do not remove housing (12). 18. Remove six bolts (19) and one bolt (20).

Ver imagen

19. Lightly tap governor housing (12) with a wooden or plastic hammer to separate it from the fuel injection pump housing. Check the gasket between the governor housing and the fuel injection pump housing. If the gasket is damaged, replace with a new part. Connect Governor To Fuel Injection Pump Housing NOTE: Before connecting the governor to the fuel injection pump housing, replace all gaskets, O-ring seals, and oil seals with new parts.

Ver imagen

1. Place a new gasket between the governor housing and the fuel injection pump housing. Put governor housing (12) in position and secure with six bolts (19) and one bolt (20). Tighten bolts (19) to a torque of 7 to 9 Nm (5 to 7 lb ft). Tighten bolt (20) to a torque of 15 to 18 Nm (11 to 13 lb ft).

Ver imagen

2. Install woodruff key (18) in its original position on the camshaft.

Ver imagen

3. Install flyweight (17), spring washer (16), and round nut (15). Use Tools (D) and (G) to tighten round nut (15) to a torque of 49 to 59 Nm (36 to 44 lb ft).

Ver imagen

Ver imagen

4. Install a new gasket on the governor housing and place governor cover (11) in position. 5. Use long nose pliers to connect starting spring (14) to the spring eye.

Ver imagen

6. Connect the link's leaf spring (13) to the control rack.

Ver imagen

7. Install six screws (10) to secure the governor cover to the governor housing. Tighten screws (10) to a torque of 7 to 9 Nm (5 to 7 lb ft).

Ver imagen

8. Install torque control spring (9). Hand tighten until final adjustment is accomplished on a test bench. After adjustment on test bench, use Tool (H) and tighten the torque control spring to a torque of 18 to 21 Nm (13 to 15 lb ft).

Ver imagen

9. Install seal on cover (7).

Ver imagen

10. Install cover (7) with secure with four bolts. Tighten bolts to a torque of 7 to 9 Nm (5 to 7 lb ft).

Ver imagen

11. Install idling subspring (6).

Ver imagen

12. Install threaded cap (5).

Ver imagen

13. Install locknut (3) on full-load stopper bolt (4).

Ver imagen

14. Install threaded cap (2). 15. If necessary, install tag wire seal (1). NOTE: Governor must be adjusted on test bench. Disassemble Governor Start By: a. separate governor from fuel injection pump housing

Ver imagen

1. Remove start spring (1).

Ver imagen

2. Loosen nut (2). 3. Make sure threaded bolt (3) is not damaged.

Ver imagen

4. Loosen bolt (4). 5. Remove control lever (5). NOTE: Be careful not to lose any of the loosened components under the control lever.

Ver imagen

Ver imagen

6. Remove woodruff key (6), washer (7), collar (8), and shims (9).

Ver imagen

7. Remove threaded plugs (10) and (11).

Ver imagen

8. Remove tension lever shaft (12).

Ver imagen

9. Pull tension lever (14) to the top of the governor cover as shown and disconnect it from governor spring (13). 10. Remove tension lever (14). 11. Remove governor spring (13) from the swivel lever (15).

Ver imagen

12. Use a screwdriver or similar tool to remove retaining rings (16 and 17).

Ver imagen

13. Tap lightly with a hammer and punch to remove bushings (18 and 19). Remove swivel lever (16) from the governor.

Ver imagen

14. Check the condition of the O-ring seals (20) on bushings (18 and 19) for damage.

Ver imagen

15. Remove swivel lever (21) from the governor.

Ver imagen

16. Remove guide lever assembly (22) from the governor cover.

Ver imagen

17. Check the face of screw (23) in governor cover. Remove if damaged.

Ver imagen

18. Remove bolt (24) and lever assembly (25). Replace O-ring under lever. NOTE: Watch for shims, washers and other small parts. Assemble Governor Ver imagen

1. Install O-ring under lever assembly (25). 2. Install lever assembly (25) and bolt (24).

Ver imagen

3. Install screw (23) in governor cover.

Ver imagen

4. Install guide assembly (22) in the governor cover.

Ver imagen

5. Install swivel lever (21) in the governor cover.

Ver imagen

6. Install O-ring seals (20) on bushings (18 and 19).

Ver imagen

7. Install bushings (18 and 19).

Ver imagen

8. Install retaining rings (16 and 17).

Ver imagen

9. Install governor spring (13) on swivel lever (15). 10. Install tension lever (14). 11. Connect governor spring (13) to tension lever (14).

Ver imagen

12. Install tension lever shaft (12).

Ver imagen

13. Install threaded plugs (10) and (11).

Ver imagen

14. Install woodruff key (6), washer (7), collar (8), and shims (9).

Ver imagen

15. Install control lever (5) and tighten bolt (4).

Ver imagen

16. Tighten nut (2) on threaded bolt (3).

Ver imagen

17. Install start spring (1). End By: a. connect the governor to the fuel injection pump housing

Fuel Pump Housing SMCS - 1253-015; 1253-016

Disassemble Fuel Injection Pump Housing Start By: a. separate governor from fuel injection pump housing NOTE: Clean the outside of the fuel injection pump before disassembly and drain the pump camshaft chamber.

Ver imagen

1. Remove three nuts (1) and washers. 2. Remove fuel priming and transfer pump (2). For details on disassembly and assembly of the fuel priming and transfer pump see the topic "Disassemble and Assemble Fuel Priming and Transfer Pump" in this module.

Ver imagen

3. Check O-ring seal (3) on fuel priming and transfer pump (2). Replace if necessary.

Ver imagen

4. Remove two bolts (4) and washers. 5. Remove cover (5). Remove the gasket on the back of cover (5).

Ver imagen

6. Install Tool (D) to rotate the camshaft until the tappets are in the top center position. 7. Insert Tool (N), (tappet holders) into the small holes (6) on the tappet body to separate the tappet from the camshaft.

Ver imagen

8. Rotate the fuel injection pump housing on its side and remove six screws plugs (7).

Ver imagen

9. Remove two center bearing screws (8) with a screwdriver.

Ver imagen

10. Rotate the camshaft until the key groove is facing up, remove Tool (D), use Tools (L and K) to remove Tool (D).

Ver imagen

11. Remove four bearing cover bolts (9).

Ver imagen

12. Tap the camshaft lightly from the governor end with a soft hammer to loosen bearing cover (10). Remove bearing cover (10).

Ver imagen

13. If necessary, use Tool (F) to remove bearing race (11) and oil seal (11) from bearing cover (10).

Ver imagen

14. Remove camshaft (14) together with center bearing (13) from the drive side of the fuel injection pump housing (12). NOTE: Check the camshaft surfaces for damage or wear. Also, check the camshaft threads and the key groove for damage. Check the areas that contact the oil seal for damage or wear.

Ver imagen

15. Remove center bearing (13) from camshaft (14). NOTE: Check the area of the center bearing that contacts the camshaft for wear or damage. Replace the bearing if necessary.

Ver imagen

16. If necessary, remove bearings (15 and 16) from camshaft (14) with a suitable press as shown.

Ver imagen

17. Remove bearing seat (17) and washers (18) from between camshaft (14) and bearings (15 and 16). NOTE: Now the governor housing can be removed, bearing race inspected, and gasket removed.

Ver imagen

18. Position the pump on its side. Insert Tool (M) into the bottom plug hole. Push the tappet with Tool (M) and remove the tappet holder, Tool (N).

Ver imagen

19. Insert Tool (Q) through the bearing cover hole, secure tappet (19) and remove it from the fuel injection pump housing. NOTE: Replace the tappets if they are damaged or worn.

Ver imagen

NOTE: Before plungers are removed make sure the control rack is in the center. See Note after Step 29 on Page 47. 20. Use Tool (P) to remove plunger (21) together with lower spring seat (20).

NOTICE The plungers must not contact other parts during removal. Put the plungers in clean fuel oil in their order of removal. Replace the plungers if they are damaged or worn. Ver imagen

21. Remove plunger spring (24), upper spring seat (23) and control sleeve (22).

Ver imagen

22. Components previously removed. Check each part carefully. Replace them if they are damaged or worn. 23. Stand the fuel injection pump housing upright.

Ver imagen

24. Remove bolt (25) and washer. 25. Remove delivery valve holder lock plate (26).

Ver imagen

26. Carefully remove delivery valve holder (27) and the O-ring. NOTE: There is a slight spring pressure under the delivery valve holder. Be careful not to lose any of the components when the delivery valve holder is removed.

Ver imagen

27. Remove stopper (31), delivery valve spring (30), delivery valve assembly (29), copper seal (35), and plunger barrel (28) from under delivery valve holder (27). NOTE: Use Tool (R) to remove components. Put the delivery valves in clean fuel oil in their order of removal with their corresponding plungers.

NOTICE Keep each plunger with its corresponding plunger barrel. If the plungers and barrels are not matched, the clearances between them may not be as specified.

NOTE: Check each part carefully. Replace them if they are damaged worn.

Ver imagen

28. Remove control rack guide screw (33). 29. Remove control rack cap (32) from the fuel injection pump housing.

Ver imagen

Assemble Fuel Injection Pump Housing

NOTICE Once removed, gaskets, O-rings, and oil seals must not be reused. New ones must be used when assembling the fuel injection pump housing.

Ver imagen

1. Install plunger barrel (1) so that the locating pins in the fuel injection pump housing are correctly positioned in the grooves in the plunger barrels. NOTE: Ensure that the plunger barrel cannot be rotated manually.

Ver imagen

2. Install delivery valve assembly (2). Always install a new copper seal (2A).

Ver imagen

3. Install delivery valve spring (4) and stopper (3).

Ver imagen

4. Put a new O-ring seal on delivery valve holder (5) and install the delivery valve holder. NOTE: The following procedure is for the tightening of the delivery valve holder. a. Tighten the delivery valve holder to a torque of 39 5 Nm (29 4 lb ft). b. Loosen the delivery valve holder. c. Retighten the delivery valve holder to a torque of 39 5 Nm (29 4 lb ft). d. Loosen the delivery valve holder. e. Finally tighten the delivery valve holder to a torque of 39 5 Nm (29 4 lb ft).

Ver imagen

5. Insert control rack (6) into the fuel injection pump housing. 6. Screw the guide screw into the back of the fuel injection pump housing and ensure the control rack moves freely. NOTE: The line on the control rack marked X must be flush with the threaded plug on the end of the fuel injection pump housing to correctly position the control rack.

Ver imagen

7. Install control sleeve (7) with the control pinion slit facing out as shown.

Ver imagen

8. Install upper spring seat (8) and plunger spring (9).

Ver imagen

9. Use Tool (P) to insert plunger (10) together with lower spring seat (11) into the plunger barrel. Ensure the helix marked Y is facing up as shown.

Ver imagen

10. Hold the tappet (not shown) with Tool (Q). 11. Align the tappet guide with the fuel injection pump housing guide groove and insert the tappet. 12. Use Tool (M) to push the tappet and align the plunger flange with the control sleeve groove. When the plunger is completely inserted into the barrel and sleeve, insert Tool (N) (tappet holder) into the small hole on the tappet body. 13. Use Tool (E) to install the washers, bearing seat, and the bearings in their original position on camshaft (16).

Ver imagen

14. Place a new gasket between the governor housing and the fuel injection pump housing. Put governor housing (12) in position and secure with six bolts (14) and one bolt (13). Tighten bolts (14) to a torque of 7 to 9 Nm (5 to 7 lb ft). Tighten bolt (13) to a torque of 15 to 18 Nm (11 to 13 lb ft).

Ver imagen

15. Coat the inside surface of center bearing (15) with grease and position it on camshaft (16). 16. Insert the camshaft and the center bearing into the fuel injection pump housing.

Ver imagen

17. Secure the center bearing with two screws (17).

Ver imagen

18. Install Tool (J) (seal protector) on end of the camshaft. 19. If the bearing race and oil seal were removed from bearing cover (19), replace them with new parts. NOTE: Apply a small amount of grease to the seal guide and the oil seal lip. 20. Install bearing cover (19). Make sure to use a new gasket (18).

Ver imagen

21. Install four bolts (20) to hold bearing cover (19). Tighten bolts (20) to 7 to 9 Nm (5 to 7 lb ft). 22. Remove Tool (J) (seal protector). NOTE: The drain holes in cover (19) are at the top.

Ver imagen

23. Install Tool (D) and check endplay as shown. Endplay is .02 to .07mm.

Ver imagen

24. Rotate the camshaft with Tool (D) until the tappet holders, Tool (D), can be removed.

Ver imagen

25. Install delivery valve holder lock plate (21) and secure with bolt (22). Tighten bolt (22) to a torque of 4 to 5 Nm (35 to 45 lb in).

Ver imagen

26. Install cover (24) and secure with two bolts (23) and washers.

Ver imagen

27. Install fuel priming and transfer pump (25) with three nuts (26). 28. Instal threaded plugs (27). Tighten threaded plugs (27) to a torque of 55 to 75 Nm (40 to 55 lb ft).

Ver imagen

End By: a. connect governor to the fuel injection pump housing

Fuel Priming and Transfer Pump SMCS - 1256-015; 1256-016; 1258-015; 1258-016

Disassemble Fuel Priming and Transfer Pump Ver imagen

1. Remove priming pump (1).

Ver imagen

2. Remove check valve (2), and spring (3) and O-ring seal (4).

Ver imagen

3. Remove outlet fitting (5).

Ver imagen

4. Remove check valve (6), spring (7) and O-ring seal (8).

Ver imagen

5. Remove inlet fitting (9).

Ver imagen

6. Remove inlet screen (10), gasket (11), banjo fitting (12) and gasket (13).

Ver imagen

Ver imagen

7. Remove plug (14), spring (15), piston (16) and gasket (17).

Ver imagen

8. Remove snap ring (18) and remove roller follower (19).

Ver imagen

9. Remove shaft (20).

Ver imagen

10. Remove lip-type seal (21). Assemble Fuel Priming and Transfer Pump Ver imagen

1. Install lip-type seal (21).

Ver imagen

2. Install shaft (20).

Ver imagen

3. Install roller follower (19) and snap ring (18).

Ver imagen

4. Install gasket (17), piston (16), spring (15) and plug (14).

Ver imagen

5. Install gasket (13), banjo fitting (12), gasket (11) and inlet screen (10).

Ver imagen

6. Install inlet fitting (9).

Ver imagen

7. Install O-ring seal (8), spring (7) and check valve (6).

Ver imagen

8. Install outlet fitting (5).

Ver imagen

9. Install O-ring seal (4), spring (3) and check valve (2).

Ver imagen

10. Install priming pump (1).