Reuse and Salvage for Mechanical Governor Groups in 3114, 3116, and 3126 Engines Equipped with Mechanical Unit Injectors (MUI) {0374, 1000, 1050, 1250, 1300} Caterpillar

Caterpillar Products

All 3100 Engines

Introduction

© 2018 Caterpillar® All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law.

Information contained in this document is considered Caterpillar: Confidential Yellow.

This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) interface.

Canceled Part Numbers and Replaced Part Numbers

This document may not include canceled part numbers and replaced part numbers. Use NPR on SIS for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Important Safety Information

Illustration 1	g02139237

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, or operating technique is not recommended by Caterpillar, ensure that it is safe for you and for other people. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

Show/hide table

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the safety alert symbol which is followed by a signal word such as danger, warning, or caution. The "WARNING" safety alert symbol is shown below.

Illustration 2	g00008666

This safety alert symbol means:

Pay attention!

Become alert!

Your safety is involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, you must determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.

Summary

The information in this guideline is intended for use when performing a complete rebuild or overhaul of a governor with high operating hours or miles. Also, refer to the Governor Service Manual, SENR6454, and the appropriate Parts Manual for the particular machine.

Installing new parts during a governor rebuild is often unnecessary and this guideline provides visual examples to help determine if the part is reusable.

This Guideline is intended for Types III, IV, V, VI, and VII Governors. Illustrations and part numbers listed are for these later type of governors.

Early Type I and Type II Governors had limited production and were phased out in late 1990 and early 1991, depending on application. Identification of Type I and Type II Governors is described in the Governor Service Manual. Type I and Type II Governors are no longer serviced, and complete replacement governors are only for Type III through Type VII. The early governors may be inspected and reconditioned. However, parts from Type I and Type II Governors are generallynot interchangeable with the later types of governors. This is because of major internal changes to the design, and to the housings and drive parts.

Some internal parts for Type I and Type II Governors are no longer serviced at all, or may be serviced only by larger assemblies. Therefore, when reconditioning a Type I or Type II Governor, complete governor replacement may be needed, depending on the condition of the particular governor.

Governor parts used in the same application and meeting the "Use Again" specifications in this guideline, can be expected to give normal performance until the next overhaul.

Never install a governor part that this Guideline shows cannot be used again. During reconditioning, correct any conditions that might have caused the original failure

Service Letters and Technical Information Bulletins

References

Tooling and Equipment

Standardized Parts Marking Procedure

Reference: SEBF8187Reuse and Salvage Guidelines, "Standardized Parts Marking Procedures".

The code is a Cat standard and is used to record the history of a component. The code will identify the number of rebuilds and hours at the time of each rebuild. This information is important and should be considered for any decision to reuse a component.

Ensure that the mark is not covered by a mating part. Use a metal marking pen to mark the code onto the component.

Illustration 3	g06124077
DO NOT use numbering stamp punches to mark internal components.

The procedure for marking components is a Cat standard. This code is helpful when the machine is sold into a different territory after the first rebuild. During an overhaul, the previous code of a part should never be removed.

Example 1

Illustration 4	g03856853
Typical Example

Illustration 4 shows code (1-15). The first number (1) indicates that the gear had been rebuilt once. The second number (15) indicates that there were 15,000 hours on the gear at the time of rebuild.

Example 2

Illustration 5	g03856857
Typical Example

Illustration 5 shows code (1-12) and code (2-10). Code (2-10) represents the information from the second rebuild. The first number (2) indicates that the gear had been rebuilt twice. The second number (10) indicates that 10,000 hours accumulated on the gear between the first and second rebuild.

Note: Add the first and second rebuild hours to obtain the total number of hours for the gear in Illustration 5. In this example, the gear has a total of 22,000 hours.

Replacement Parts

Consult the applicable Parts Identification manual for your engine.

Show/hide table

When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specifications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death.

The parts listed in Table 4 should always be replaced during each rebuild procedure, to provide maximum component life after the rebuild. Reusing the parts in Table 4 could affect the performance or the service life of the governor. However, automatic replacement of these parts is not recommended if the governor is in the shop only for bench testing or minor repair. All other parts should be replaced, if necessary, as determined by inspection.

Nomenclature

Illustration 6	g06346338
Cross-section of fuel transfer pump. (1) 7E-0155 Fuel Inlet Screen Assembly (if equipped). (2) Inlet check valve. (3) Spring (4) Piston assembly (5) Outlet check valve (6) Piston check valve (7) Tappet assembly (8) Cam (9) Passage. (10) Plug (11) Fuel inlet fitting

Visual Inspection

Housing and Inlet Screen

Illustration 7	g06346352
Remove the fuel inlet fitting (11) and inspect for damage on the inlet check valve surface seating.

Use Again - if there is no apparent damage to the fitting.

Illustration 8	g06346357
Inspect the fuel inlet fitting for damage to check valve seating area.

Use Again - if no damage is present.

Note: Some governors are not equipped with a 7E-0155 Fuel Inlet Screen Assembly, if the fuel system is known to have some type of primary fuel filter between the fuel tank and the governor. A 7E-0155 Fuel Inlet Screen Assembly may be added to the governor, if desired. The fuel inlet screen keeps large particles from entering the fuel transfer pump.

Illustration 9	g06346363
Inspect the front housing assembly for damage. Inspect drive gear (1) for cracked, broken, or missing teeth. Inspect outlet check valve (5) seating face in housing.

Use Again - if no damage is present.

Note: The housing is serviced as an assembly. If any of the parts are damaged, replace the entire front housing assembly.

Check the fit between the front gear and drive shaft. Hold the gear and drive shaft, turning them back and forth in opposite directions to check for looseness between the two parts. If there is a clicking sound during this check, the O-rings have deteriorated and the housing assembly must be replaced.

Governor Drive Shaft

Illustration 10	g06346369
Normal wear on governor drive shaft.

Use Again - if cam surface is not damaged. Polishing is acceptable.

Do Not Use Again - if surface is concave due to tappet wear.

Throttle Shaft

Illustration 11	g06346374
Polishing and light frosting on the throttle shaft.

Use Again - if wear step cannot be felt with a seal pick.

Illustration 12	g06346376
Wear steps on throttle shaft can be felt with a seal pick.

Do Not Use Again

Control Lever

Illustration 13	g06346378
Light wear on contact surface of control lever.

Use Again - if wear step cannot be felt with a seal pick.

Illustration 14	g06346379
Indentation on contact surface of control lever.

Do Not Use Again

Pivot Shaft

Illustration 15	g06346382
Pivot shaft assembly for the older style torque cam assembly.

Do Not Use Again - if wear step can be felt with seal pick.

Torque Cam Assembly

Illustration 16	g06346385
Torque cam assembly.

Use Again - if wear on shaft or cam face cannot be felt with a seal pick.

Torsion Spring

Illustration 17	g06346386
Wear on coil of torsion spring for torque cam assembly.

Use Again

Lever Assemblies

Illustration 18	g06346390
Light wear on ball of lever assembly.

Use Again

Note: Wear on swivel pins and mating surfaces result in excessive clearances between the parts. This can cause instability in governor operation resulting in:

• bench setting difficulty,

• engine surge/instability, or

• engine cutout at idle.

Illustration 19	g06346393
Wear on ball of lever assembly.

Do Not Use Again

Illustration 20	g06346395
Line contact wear on balls of pivot shaft lever assembly.

Use Again

Note: Wear on swivel pins and mating surfaces result in excessive clearances between the parts. This can cause instability in governor operation resulting in:

• bench setting difficulty,

• engine surge/instability, or

• engine cutout at idle.

Illustration 21	g06346399
Wear on balls of pivot shaft lever assembly.

Do Not Use Again

Illustration 22	g06346402
Limit lever assembly.

Use Again -

• if there is no wear (flat spot) on the torque cam follower.

• light marks from adjusting screws are acceptable.

• no flats are allowed on the sleeve follower.

Illustration 23	g06346408
Limit lever assembly with flat (1) on torque cam follower. Wear impressions (2) from the stop screws are acceptable.

Do Not Use Again

Illustration 24	g06346414
Lever (FARC follower - Type III and IV).

Use Again - if lever tangs have a polished appearance.

Do Not Use Again - if lever exhibits wear steps and/or has flat areas.

Illustration 25	g06346446
Lever assembly (FARC follower - Type V, VI, and VII).

Use Again - if there are no flat spots worn on swivel pins (1).

Shutoff Shaft

There are shutoff shaft assemblies with two different types of blades. Either type is acceptable for reuse.

Illustration 26	g06346451
Shutoff shaft assembly with rectangular blade. Check for loose bolts.

Use Again

Note: If bolts are loose, replace.

Illustration 27	g06346455
Shutoff shaft assembly Check for loose bolts.

Use Again

Note: If bolts are loose, replace.

Illustration 28	g06346459
Indentation on blade of shutoff shaft assembly. This is acceptable wear, however, the blade may be turned over, if desired.

Use Again

Bracket Assembly

Illustration 29	g06346500
Bracket assembly.

Use Again - if the spring is not broken, and there is no flat worn on surface (1).

Servo Assembly

There have been several changes made to the servo mechanism during the evolution of the governor.

Illustration 30	g06346505
Servo parts for Types V, VI, and VII Governors (later version).

Illustration 31	g06346510
Servo parts for Types III and IV Governors (later version).

Illustration 32	g06346512
Servo parts for Types III and IV Governors (early version).

Early Types III and IV servos contain parts which should not be reused. They are clevis (2), servo valve (6), servo piston (5), servo sleeve (3), control sleeve (7), and limit sleeve (8). These parts should be replaced with the parts listed in Table 5.

Table 5 shows the replacement part numbers for servos used in Types III and IV Governors.

Illustration 33	g06346528
Servo piston with light polishing on the sliding contact surfaces.

Use Again

Illustration 34	g06346532
Servo piston with more wear.

Use Again - if wear step or scratches cannot be felt with a seal pick.

Illustration 35	g06346540
Servo piston sleeve with crosshatching (1) due to honing. The anti-friction coating (2) is worn away.

Do Not Use Again - if crosshatched, or if anti-friction coating is worn away.

Illustration 36	g06346544
Servo piston sleeve with gouge and anti-friction material worn away (shiny area).

Do Not Use Again - if scratches can be felt with a seal pick, or if anti-friction coating is worn away.

Illustration 37	g06346548
Clevis. Unless the ears remain parallel, the pin is difficult to remove or install.

Use Again - if ears are parallel.

Note: The clevis pin should be installed in the clevis when the governor is not installed on an engine. This reduces the possibility of damaging the clevis.

Illustration 38	g06346549
Clevis with ears bent inward.

Do Not Use Again

Illustration 39	g06346552
Clevis with ears bent outward.

Do Not Use Again

Note: The two clevises shown in Illustration 38 and 39 should not be reused, even if they are in good condition. They should be replaced with a 108-1612 Clevis (refer to Illustration 37).

Illustration 40	g06346554
Servo valve with narrow groove (1) for thin retainer.

Do Not Use Again - replace with servo valve having wider groove for thicker retainer.

Illustration 41	g06346560
Servo valve with wide groove (2) for thicker retainer.

Use Again - if wear step cannot be felt with a seal pick.

Illustration 42	g06346564
Servo valve with two wide grooves (3) for thicker retainer. Minor wear (4) on diameter of shaft.

Use Again - if wear step cannot be felt with a seal pick.

Illustration 43	g06346566
Sleeve.

Use Again - if wear on contact surfaces cannot be felt with a seal pick.

Illustration 44	g06346571
Sleeve.

Use Again - if wear on contact surfaces cannot be felt with a seal pick.

Illustration 45	g06346574
Rack control and limiting sleeve.

Use Again - if wear on contact surfaces cannot be felt with a seal pick.

Illustration 46	g06346577
Rack control and limiting sleeve.

Use Again - if wear on contact surfaces cannot be felt with a seal pick.

Riser Shaft and Pin

Illustration 47	g06346580
Riser shaft.

Use Again - if there is no wear step on the shaft, which can be felt with a seal pick. If a step is present, it will generally occur near the center of the shaft.

Illustration 48	g06346583
Normal wear on pin at end of riser shaft.

Use Again

Illustration 49	g06346588
Pin with material eroded away near the center relief.

Do Not Use Again

Flyweight and Dowel

Illustration 50	g06346593
Flyweight toe with gouges near dowel hole.

Do Not Use Again - if wear marks can be felt with a seal pick.

Illustration 51	g06346599
Flyweight toe wear.

Do Not Use Again

Illustration 52	g06346602
Flyweight toe wear.

Do Not Use Again - if there are any signs of "flat spots". Worn flyweight toes may be highly polished so that flat spots are difficult to feel. Hold the flyweight toe surface in bright light and watch for changes in reflection in worn areas. Use a new flyweight toe for comparison.

Illustration 53	g06346609
Acceptable wear on flyweight dowel.

Use Again - if wear cannot be felt with a seal pick.

Illustration 54	g06346611
Heavy wear on flyweight dowel.

Do Not Use Again

Note: Examine the dowel seating area on the flyweight carrier. If there is any apparent wear, reinstall dowels in the unused positions, 90 degrees from original position.

Bearing Assembly

Illustration 55	g06346614
The bearing (white collar) shown in position on the FARC diaphragm retainer (Type V, VI, and VII Governors) shows wear.

Do Not Use Again

Governor Spring Seat

Illustration 56	g06346615
Governor spring seat with typical wear.

Use Again - if there are no gouges to surfaces (1) on the spring seating area.

Spring Pack

Illustration 57	g06346618
End view of governor spring pack.

Use Again - after realignment.

Note the off-center position of the internal springs with respect to the outside spring. This can cause governor instability, which results in surging. Rotate the springs on their seat so that the inner springs are aligned (centered) with respect to the outer spring. Remove sharp edges (A) from the inside diameter of the flat surface on the springs to ensure springs seat properly.