Calibrating The 133-8985 Governor And Fuel Injection Pump Group Heavy Sleeve Metering Fuel System (HSMFS){650, 1250} Caterpillar

NOTE: Do NOT perform any procedure outlined in this Special Instruction until you have read and understood the information.

Reference; Special Instruction; SMHS6988, "Use Of 3P-2200 Calibration Tool Group".

Special Instruction; SMHS7013, "Use Of The 5P-4203 Field Service Tool Group Or 5P-6577 Fuel Setting Tool Group".

Introduction

This Special Instruction explains the calibration procedure for the heavy sleeve (commonly called the thick sleeve) metering fuel system. This Special Instruction shows:

* The differences between the new 133-8985 Governor And Fuel Injection Pump Group, (HSMFS) and the 109-0324 Governor And Fuel Injection Pump Group, Sleeve Metering Fuel System (SMFS).

* Calibration procedure for setting the 124-5932 Lever Assemblies.

Recommended Tools

* 4C-9738 Torque Screwdriver set at 1.7 N·m (15 lb in).

* 4C-9738 Torque Screwdriver set at 4.0 N·m (35 lb in).

Required Tooling

* 3P-2200 Sleeve Setting Group: The HSMFS Injection Pump Group requires the use of many of the past 3208 Calibration Tools. A few new dedicated tools are required for the HSMFS.

Illustration 1. Parts included, and parts required but not included within the 3P-2200 Sleeve Setting Group. See Chart 1 and Chart 2 for item and part numbers.

The 3P-2200 Sleeve Setting Group is used to set, test and adjust SMFS Injection Pump Groups.

Reference, Special Instruction; SMHS6988, "Use Of 3P-2200 Calibration Tool Group".

Special Instruction, SMHS7013, "Use Of The 5P-4203 Field Service Tool Group Or 5P-6577 Fuel Setting Tool Group".

NOTE: All tools may be stored in a 6V-3073 Plastic Case. The lid contains a 6V-4094 Liner and 6V-4873 Packing in the bottom for protection. The 6V-4873 Packing is topped with a 2P-8289 Tool Holder Block.

Illustration 2. The 5P-4203 Tool Group. See chart 3. for item and part number.

109-0324 Governor And Fuel Injection Pump Group (SMFS).

Illustration 3. View of the 109-0324 Governor And Fuel Injection Pump Group (SMFS). (1) 9N-5820 Lever. (2) 124-5941 Shaft. (3) 9Y-7791 Sleeve.

The SMFS Injection Pump Group 9.0 mm (.35 in) 9Y-7791 Sleeve (3) has four 9N-5820 Levers (1) on each 124-5941 Shaft (2). The 9N-5820 Levers are indexed from the front. The 9Y-7791 Sleeve and 9N-5820 Lever indexes with the groove in the 9Y-7791 Sleeve.

133-8985 Governor And Fuel Injection Pump Group (HSMFS).

Illustration 4. View of the HSMFS Injection Pump Group.
(1) 124-5932 Lever Assembly. (2) 124-5941 Shaft. (3) 124-5934 Sleeve.

Illustration 5. View of the HSMFS Injection Pump Group.
(1) 124-5932 Lever Assembly. (4) 126-7232 Dowel.

The new 124-5934 Sleeve (3) is thicker than the former 9Y-7791 Sleeve (3). The new 124-5934 Sleeve can be operated at higher injection pressures needed for emissions control. As a result of its increased thickness, the 124-5934 Sleeve can not be indexed from the front. It must be indexed between two 124-5934 Sleeves.

The new 124-5932 Lever Assembly (1) has a 126-7232 Dowel (4) that is split in half. The split 126-7232 Dowel is positioned between two 133-8984 Fuel Pump Assemblies and indexes two 124-5934 Sleeves (3) at the same time.

Illustration 6. Side view of one bank of the HSMFS Injection Pump Group. (1) 124-5932 Lever Assemblies. (2) 124-5941 Shaft.

There are two 124-5932 Lever Assemblies (1) on the 124-5941 Shaft (2) of the HSMFS Injection Pump Group, instead of four 9N-5820 levers (1) on each 124-5941 Shaft (2) on the SMFS Injection Pump Group. Each 124-5932 Lever Assembly is positioned in between two and indexes two 133-8984 Fuel Pump Assemblies and two 124-5934 Sleeves.

Illustration 7. View of the HSMFS Injection Pump Group.
(5) 2N-2658 Bolt. (6) 124-5949 Shutoff Lever.

The 124-5940 Shutoff Lever (6) is attached by two 2N-2658 Bolts (5) on each 124-5932 Lever Assembly (1). The 124-5932 Lever Assembly tightens on the 124-5941 Shaft when the 124-5940 Shutoff Lever is tightened.

Calibration Procedure

Illustration 8. (1) 3P-1546 Calibration Pin. (2) Hole where 3P-1546 Calibration Pin is inserted.

Illustration 9. (3) 3P-1565 Collet. (4) Hole where 8S-7271 Setscrew (not pictured) is inserted. (5) 145-1853 Calibration Fixture. (6) Bolts.

1. Install the 3P-1546 Calibration Pin (1) in hole (2). Install the 145-1853 Calibration Fixture (5). Install two bolts (6) and the 8S-7271 Setscrew (not shown) in the hole (4) in top of the 145-1853 Calibration Fixture. Tighten the 8S-7271 Setscrew using the 2P-8264 Socket (not shown) to a torque of 2-3 N·m (18-27 lb in).

Illustration 10. (7) 4N-2708 Setscrew. (8) 9.0 ± 1.0 mm (.35 ± .04 in) dimension. (9) Nut. (10) 4N-2577 Low Idle Lever.

2. Set the 4N-2577 Low Idle Lever (10) to dimension 8. Tighten the nut (9) to hold the 4N-2708 Setscrew (7).

3. Use the 8S-2243 Injection Valve Wrench to remove the 133-8984 Fuel Pump Assemblies.

Illustration 11. View of the 5P-4209 Lever Set Gauge.
(11) Hole for dowel. (12) Machined flats.

4. The 5P-4209 Lever Set Gauge has a hole (11) to fit the dowel (15), and machined flats (12) that tie in the calibration dimensions between the 3P-1546 Calibration Pin and the 124-5941 Shafts and 124-5932 Lever Assemblies.

Illustration 12. (13) 5P-4209 Lever Set Gauge.
(14) 2N-2658 Bolts. (15) 4N-3921 Dowel.

Illustration 13. (15) 4N-3921 Dowel.

* Make sure the 2N-2658 Bolts (14) are loose.

* Insert the 4N-3921 Dowel (15) into the 5P-4209 Lever Set Gauge hole (11).

* With a snapping motion pull up and down a couple of times and then snap down on the 5P-4209 Lever Set Gauge (13). Snug up the 2N-2658 bolts (14).

* Remove the 5P-4209 Lever Set Gauge (13).

Using the 6V-0190 Clamps.

Illustration 14. View of the HSMFS Injection Pump Group.
(1) 6V-0190 Clamps.

1. Install the 6V-0190 Clamps (1).

Show/hide table

Wear safety glasses while installing the clamps. The clamps can fly out and cause injury to the eyes.

NOTE: The purpose of the 6V-0190 Clamps (1) is to hold down the 124-5941 Shaft on the bottom of the clearance. The 124-5941 Shaft must be held tight while being calibrated to the correct setting.

Using the 141-6727 Calibration Pump Assembly.

Illustration 15. View of the 141-6727 Calibration Pump Assembly. (1) 8T-0116 O-Ring. (2) 5P-6557 Spring. (3) 3P-1542 Barrel. (4) 141-6730 Plunger.

* The 141-6727 Calibration Pump Assembly is the tool used to calibrate the 124-5932 Lever Assemblies and 124-5934 Sleeves within the HSMFS Injection Pump Group.

Illustration 16. (3) 3P-1542 Barrel. (4) 141-6730 Plunger.

The HSMFS Injection Pump Group is in calibration when the top of the 141-6730 Plunger (4) is flush with the top of the 3P-1542 Barrel (3) in all barrel bores.

1. Clean the top surfaces of the HSMFS Injection Pump Group. Clean the seat area and the groove of the 141-6727 Calibration Pump Assembly. Put clean diesel fuel on the 141-6730 Plunger (4) for lubrication.

Illustration 17. (5) 141-6727 Calibration Pump Assembly.

2. Insert the 141-6727 Calibration Pump Assembly (5) into one of the end HSMFS Injection Pump Group barrel bores.

Illustration 18. View of the HSMFS Injection Pump Group.
(4) 141-6730 Plunger. (6) 7W-8120 Bushing. (7) HSMFS Injection Pump Assembly barrel bores. (8) 126-7232 Dowel. (9) 124-5932 Lever Assembly.
Illustration 18 shows a view of the HSMFS Injection Pump Group with the 141-6730 Plunger (4) indexed with the 126-7232 Dowel (8) in the 141-6730 Plunger groove.

Illustration 19. (1) 8T-0116 O-Ring Seal. (10) The flat on the 141-6730 Plunger. (11) The slot on the 141-6730 Plunger. (12) Bottom edge of the 141-6730 Plunger.

3. The 141-6730 Plunger has a flat (10) on the end of it. Insert the 141-6727 Calibration Pump Assembly into the barrel bore (7). The 126-7232 Dowel (8) should be flush with the flat. As the 141-6727 Calibration Pump Assembly is turned counterclockwise the 8T-0116 O-Ring Seal (1) compresses and the 126-7232 Dowel rotates into the slot (11). The bottom edge of the 141-6730 Plunger (12) is held down against the lower machined edge. When the 141-6730 Plunger is correctly inserted, the calibration length and shaft, side to side position is correct.

* The 7W-8120 Bushing (6) is used to hold the correct length dimension for the 141-6727 Calibration Pump Assembly in the barrel bores (7) during the calibration process.

4. Screw the 7W-8120 Bushing (6) into the barrel bore (7) over the 141-6727 Calibration Pump Assembly. Torque the 7W-8120 Bushing to 81.6 N·m (60 lb ft). Wiggle the 124-5932 Lever Assembly (12) by hand to make sure the 126-7232 Dowel (8) is seated into the groove of the 141-6730 Plunger (4).

Using the 3P-1567 Indicator.

Illustration 20. (1) 3P-1567 Dial Indicator. (2) 141-6737 Adjustable Microgauge.

Illustration 21. 141-6737 Adjustable Microgauge.
(3) 3H-1392 Socket Head Bolt. (4) Locations for the 4C-9508 Wicking Thread Sealant. (5) Block (no part number).

* The 141-6737 Adjustable Microgauge consists of the 3H-1392 Socket Head Bolt (3) and a block (5) (no part number). The 141-6737 Adjustable Microgauge comes with two washers used for manufacturing. Remove the washers and discard.

NOTE: The 141-6737 Adjustable Microgauge must be adjusted before it is used and checked periodically while in use.

To set the 141-6737 Adjustable Microgauge:

Illustration 22. Setting the 141-6737 Adjustable Microgauge. (1) 3P-1568 Dial Indicator. (2) 141-6737 Adjustable Microgauge. (6) 3P-2226 Collet.

* Set the 141-6737 Adjustable Microgauge (2) to minus .025 mm (.0010 in), using the 3P-1568 Dial Indicator (1). Use 4C-9508 Wicking Thread Sealant (4) to lock the 3H-1392 Socket Head Bolt (3).

Setting the 3P-1567 Dial Indicator to zero:

* Put the 3P-1567 Dial Indicator (1) on the 141-6737 Adjustable Microgauge (2) and hold them together tightly. Loosen the indicator dial lock screw and turn the face to put the pointer at "0". Tighten the dial lock screw.

* Remove the 3P-1567 Dial Indicator (1) from the 141-6737 Adjustable Microgauge (2). Look at the face of the 3P-1567 Dial Indicator while putting the indicator back on the 141-6737 Adjustable Microgauge. The pointer must move through one to one and one half revolutions before stopping at exactly "0". If the number of revolutions is not correct, loosen the 3P-2226 Collet (6) and adjust the position of the indicator until the adjustment is correct.

Illustration 23. (2) 141-6737 Adjustable Microgauge.
(7) Top of the 3P-1542 Barrel. (8) 141-6727 Calibration Pump Assembly.

1. Place the 141-6737 Adjustable Microgauge on top of the 3P-1542 Barrel of the 141-6727 Calibration Pump Assembly.

2. When starting to torque 124-5932 Lever Assemblies, the difference between the face of the 141-6730 Plunger and the 2N-2658 Bolt is about 0.03 mm (.001 in). By setting the 141-6737 Adjustable Microgauge (2) on top of the 141-6727 Calibration Pump Assembly (8), the 141-6737 Plunger can be positioned 25.40 mm (.001 in) above the face of the 3P-1542 Barrel (7).

Illustration 24. (9) 2N-2658 Bolt. (10) 124-5940 Shutoff Lever.

3. As the 2N-2658 Bolt (9) is torqued, the 141-6730 Plunger will move down flush with the 3P-1542 Barrel (7) or will be very close to being flush. The calibration can begin from this point.

NOTE: The 2N-2658 Bolts must freely turn in and out of the 124-5940 Shutoff Levers (10) because the calibration depends on where the head of the 2N-2658 Bolt (9) first begins to clamp the 124-5940 Shutoff Lever for the starting point of the calibration.

End Play Adjustment

1. In order to save time, use two torque wrenches (color-coding is convenient for distinguishing between the two wrenches). Set one torque wrench to 1.7 N·m (15 lb in) and the second torque wrench to N·m (35 lb in).

Illustration 25. (1) 124-5941 Shaft. (2) 4N-1826 Dowel on one end of the HSMFS Injection Pump Group. (3) 126-7232 Dowels.

2. Adjust the end play in the 124-5941 Shaft. The SMFS 109-0324 Governor And Fuel Injection Pump Group had the dowel in the middle of the sleeve and a large amount of end play in the shaft was acceptable. Now that the 126-7232 Dowels (3) are between two 124-5934 Sleeves, the amount of end play is important. It is necessary that an adjustment be performed to minimize the amount of end play in the 124-5941 Shaft (1).

3. The 126-7232 Dowels (3) are located between two 124-5934 Sleeves. Set the 126-7232 Dowels between 0.25 to 0.40 mm (.010 to .016 in) by tapping in the 4N-1826 Dowels (2) until the desired end play is achieved.

* With the 1.7 N·m (15 lb in) torque wrench, torque the 2N-2658 Bolts to 1.7 N·m (15 lb in).

* Then use the 4 N·m (35 lb in) torque wrench to torque the 2N-2658 Bolts to 3.4 N·m (30 lb in) in order to calibrate within specifications.

Calibrating the 124-5932 Lever Assemblies.

Illustration 26. Calibrating the 124-5932 Lever Assemblies.
(1) 2N-2658 Bolts. (2) 124-5940 Shutoff Lever.

1. Begin with the first 2N-2658 Bolt (1) and turn it until it just begins to clamp (feels snug) on the 124-5940 Shutoff Lever (2).

2. Move to the other side and turn the second 2N-2658 Bolt (1) until just begins to clamp (feels snug).

* Alternate between sides and tighten each 2N-2658 Bolt about 15 degrees each time.

Illustration 27. View of the HSMFS Injection Pump Group.
(3) Top of the 141-6730 Plunger shown flush with the 3P-1542 Barrel (4).

3. Continue until the torque reaches 1.7 N·m (15 lb in). The top of the 141-6730 Plunger (3) should be almost flush with the top of the 3P-1542 Barrel (4) at a torque of 1.7 N·m (15 lb in).

Illustration 28. View of the HSMFS Injection Pump Group.
(5) 3P-1567 Dial Indicator.

4. Zero the 3P-1567 Dial Indicator (5) to [.000 ± .010 mm (.000 ± .0004 in)]. The more the first 2N-2658 Bolt (1) is torqued, the more the 3P-1567 Indicator reads a negative value. When the 124-5932 Lever Assembly is clamped and the first 2N-2658 Bolt is loosened, then torqued, the second 2N-2658 Bolt (1) will also loosen. This results in a nonzero value.

5. Back the first 2N-2658 Bolt (1) out to about .5 N·m (4 lb in) and torque it again to 1.7 N·m (15 lb in). The reading will probably not return to zero. Check the zero reading by flipping the 124-5940 Lever Assembly against the 126-7232 Dowel. Tap down on the 124-5941 Shaft to ensure it is down against the bottom of the clearance. The 124-5940 Lever Assembly should be in calibration.

Checking the Calibration of the Next HSMFS Injection Pump Group Barrel Bore.

1. Loosen and remove the 7W-8120 Bushing.

2. Push down and turn the 141-6727 Calibration Pump Assembly in a counterclockwise motion to line the 126-7232 Dowel up with the flat of the 141-6730 Plunger. Remove the 141-6727 Calibration Pump Assembly.

3. Move to the adjacent HSMFS Injection Pump Group barrel bore.

NOTE: Move to barrel bore number 8 if barrel bore number 1 was used for the first calibration. Otherwise move to any adjacent barrel bore.

NOTE: See the above illustrations to complete the following steps:

4. The 141-6730 Plunger has a flat on the end of it. Insert the 141-6727 Calibration Pump Assembly into the barrel bore. The 126-7232 Dowel should be flush with the flat. As the 141-6727 Calibration Pump Assembly is turned counterclockwise the 8T-0116 O-Ring Seal compresses and the 126-7232 Dowel rotates into the slot. The bottom edge of the 141-6730 Plunger is held down against the lower machined edge, calibrating length and side to side.

* The 7W-8120 Bushing is used to hold the correct length dimension for the 141-6727 Calibration Pump Assembly in the barrel during the calibration process.

5. Screw the 7W-8120 Bushing into the adjacent barrel bore over the 141-6727 Calibration Pump Assembly. Torque the 7W-8120 Bushing to 81.6 N·m (60 lb ft). Wiggle the 124-5932 Lever Assembly by hand to make sure the 126-7232 Dowel is seated into the groove of the 141-6730 Plunger.

Using the 3P-1567 Indicator.

* The 141-6737 Adjustable Microgauge consists of the 3H-1392 Socket Head Bolt and a block (no part number).

1. Put the 141-6737 Adjustable Microgauge on the stem of the 3P-1567 Dial Indicator. Zero the indicator.

2. The HSMFS Injection Pump Group is in calibration when the top of the 141-6730 Plunger is flush with the top of the 3P-1542 Barrel in all barrel bores.

3. Use the 3P-1567 Dial Indicator to check the calibration of the adjacent barrel bore. If the reading is not zero:

* Zero the 3P-1567 Dial Indicator to [.000 ± .010 mm (.0000 ± .0004 in)]. The more the first 2N-2658 Bolt is torqued, the more the 3P-1567 Indicator reads a negative value. When the 124-5932 Lever Assembly is clamped and the first 2N-2658 Bolt is loosened, then torqued, the second 2N-2658 Bolt will also loosen. This results in a nonzero value.

* Loosen the first 2N-2658 Bolt to about .5 N·m (4 lb in) and torque it again to 1.7 N·m (15 lb in). The reading will probably not return to zero. Check the zero reading by flipping the 124-5940 Lever Assembly against the 126-7232 Dowel. Tap down on the 124-5941 Shaft to ensure it is down against the bottom of the clearance. The 124-5940 Lever Assembly should be in calibration.

Rechecking the Calibration of the First HSMFS Injection Pump Group Barrel Bore.

1. After completing the calibration of the adjacent barrel bore, go back to the first barrel bore calibrated.

2. Repeat the above steps to insert the 141-6727 Calibration Pump Assembly and check the calibration with the 3P-1567 Dial Indicator. If the setting is not correct, repeat the steps to calibrate the 124-5932 Lever Assemblies. After this final process, the calibration is done on that set of barrel bores. Move to the next set.

Repeat the above steps until all barrel bores nave been checked and calibrated.