Usage:
start by:
a) remove electric starting motor
b) remove fuel injection lines
1. Remove two bolts (1) and start switch (2) from the governor housing. Let start switch hang on engine.
2. Put identification on two wires (7) and remove from switch. Disconnect tube assembly (6) from adapter (4). Remove two bolts (3) and adapter (4) from cylinder block.
3. Remove two hoses (5).
4. Disconnect tube assembly (8) from the fuel ratio control.
NOTE: No. 1 piston at top center (TC) on the compression stroke is the starting point for all timing procedures.
NOTE: The engine is seen from the flywheel end when direction of crankshaft rotation is given.
5. Install tooling (A) on flywheel housing as shown.
6. To find top center compression stroke for No. 1 piston, first turn the flywheel clockwise (opposite the direction of engine rotation) approximately 30 degrees. This procedure is to remove all play from the timing gears.
7. Turn the flywheel counterclockwise until a 3/8"-16 NC bolt (1) can be installed in the flywheel through the hole in the flywheel housing. The No. 1 piston is at top center.
| NOTICE |
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If you go past the bolt hole you must start over with Step No. 6. |
NOTE: To see if the No. 1 piston is on the compression stroke, you can remove the valve cover and look at the valves of the No. 1 cylinder. The valves will be closed if No. 1 cylinder is on the compression stroke. You must be able to move the rocker arms up and down with your hand.
8. If No. 1 piston is not on the compression stroke, remove the 3/8"-16 NC bolt and turn the flywheel 360° counterclockwise. Install the 3/8" bolt as before. The No. 1 piston is now at top center on the compression stroke (TC1).
9. To install tool (B) in the fuel injection housing assembly, remove the 3/8"-16 NC bolt from the flywheel and turn the flywheel approximately 30° clockwise.
10. Remove bolt and install tool (B) in the governor housing. Turn the flywheel slowly in a counterclockwise direction until pin (B) goes into the notch in the camshaft.
11. Put the 3/8"-16 NC bolt in the timing hole in the flywheel housing. If the bolt can be installed in the hole in the flywheel, the timing on the fuel injection pump is correct.
12. Remove nuts (9) and cover (10) from the front of the timing gear cover.
13. Remove bolt (12) and washer (11) that holds the drive gear to the fuel injection pump.
14. Install tooling (C) to loosen drive gear from the drive sleeve.
15. Remove three nuts (13) from studs. Remove the fuel injection pump housing and governor from engine.
Install Fuel Injection Pump Housing And Governor
1. Inspect the transfer pump housing O-ring seal for damage. Make a replacement if necessary.
2. Put the fuel injection pump housing and governor (1) in position on the engine and against the timing gear plate.
3. Install the three nuts (2) that hold the fuel injection pump housing to the timing gear plate. Do not tighten nuts until adapter (4) is installed.
4. Inspect the two O-ring seals on adapter and make replacements if necessary.
5. Put adapter (4) and two hoses (5) in position and install two bolts (3) to hold the adapter to block. Tighten three nuts (2).
6. Install two wires (7) on switch. Install tube assembly (6) on adapter.
7. Put the drive gear (8) in position on the fuel injection pump and install washer and bolt finger tight. Be sure that tooling (B) is in the notch in the fuel injection camshaft.
8. Install a 3/8"-24 NF, 1/2 in. long bolt in one of the holes (9) in the drive gear (8).
9. Put a torque wrench on the 3/8" bolt with the wrench in line with the center of the drive gear, and give it a torque of 45 to 50 lb.ft. (60 to 70 N·m). While this torque is held, tighten the drive gear bolt to a torque of 110 ± 5 lb.ft. (149 ± 7 N·m). Remove pin (B) from the fuel pump and the 3/8"-16 NC bolt from the flywheel.
10. Turn the engine flywheel two complete revolutions with tooling (A). If the 3/8"-16 NC bolt goes in the hole in the flywheel when the timing pin is installed in the notch in the camshaft, the timing is correct.
11. Put gasket and cover (10) in position on the timing gear cover. Install nuts. Tighten nuts to a torque of 17 ± 3 lb.ft. (23 ± 4 N·m).
12. Install fuel line (11) to the fuel ratio control.
13. Put the start switch (12) in position on the governor housing and install two bolts to hold it in place.
14. Remove tooling (A) and the 3/8"-16 NC bolt (16) from the flywheel housing.
Separation Of Governor From Fuel Injection Pump Housing
start by:
a) remove fuel injection pump housing and governor
b) remove adapter housing
c) remove service meter group
1. Put the fuel injection pump housing and governor in position on tool (A).
2. Remove seal wire (1) from cover bolts.
3. Remove four bolts (3) and bracket (4). Remove governor housing (2) from the fuel injection pump housing.
4. Remove two bolts (5) from cover (6). Remove cover (6) from over the torque spring.
5. If damaged, remove gasket (7) from the governor housing.
6. Remove spring (8), three washers (9) and seat from housing.
7. Remove bolt (11) and nut (10) from the torque spring (12). Remove the torque spring.
8. Remove pin (13) from the hole in the fuel injection pump housing.
9. Remove seat assembly (17) and spring (16) from shaft.
10. Pull shaft (14) up and remove lever (15).
11. Remove riser (follower) (19) from the shaft.
12. Remove ring and lever (18) from the dowel.
13. Remove cover (20) with tool (B).
NOTE: Tool (B) can cause damage to cover. Always inspect the cover for damage and install a new cover if needed.
14. Remove three bolts (21) that hold the flyweight assembly in position.
15. Remove flyweight assembly (22).
Connection Of Governor To Fuel Injection Pump Housing
1. Put the fuel injection pump housing on tool (A).
2. Install timing pin (B) to hold the camshaft so it will not turn.
3. Put flyweight assembly (1) in position on the camshaft.
| NOTICE |
|---|
Make sure the pin that holds the shaft in the flyweight assembly is in position before the flyweight assembly is installed. |
4. Install three new bolts that hold the flyweight assembly to the camshaft.
NOTE: The bolts that hold the flyweight assembly to the camshaft have a locking material on the threads. The bolts must not be used more than one time.
5. Install cover (3) over the flyweight assembly with tool (C).
6. Use a screwdriver (2) to make a mark (stake) on the flyweight cover in four places.
| NOTICE |
|---|
Never install a used flyweight cover that is bent. |
7. Put lever (5) on the dowel. Install ring (6).
8. Install pin (4) in the fuel injection pump housing with the round edge down.
9. Put the riser (follower) (7) in position between the flyweights. Lift the flyweights up with a piece of wire and push the (follower) forward.
10. Put lever (9) in position in the groove of the riser (follower) (7). Install shaft (8) that holds the lever in position.
| NOTICE |
|---|
If lever (9) is not installed correctly, the governor can not operate and cause the engine to overspeed. |
11. Install the torque spring (10). Install the bolt and nut that hold the torque spring in position.
12. Install the overfueling spring (12) and seat assembly (11) on the shaft.
13. Install seat (17), washer (14), wave washer (16), washer (13) and spring (15) in position in the governor housing.
14. Install cover (19) over the torque spring. Install the two bolts that hold the cover in position.
15. Put a new gasket (20) on the governor housing.
16. Put the governor housing (18) on the fuel injection pump housing. Install the bolts that hold the governor housing in position.
17. Install bracket (21) on the governor housing.
end by:
a) install service meter group
b) install adapter housing
c) install fuel injection pump housing and governor