Using 8S2305, 9S228 And 9S240 Rack Position Tool Groups{650, 1250} Caterpillar


Using 8S2305, 9S228 And 9S240 Rack Position Tool Groups{650, 1250}

Usage:

Paralleling two or more like engines. Install the rack position tools on each engine. One set of tools is required for each engine. Operate the engines under load and observe the rack positions on the dial indicators. At any particular speed the power output of all engines can be equalized by adjusting the speed control levers to equalize the position of the racks. At rated speed the power output of all engines can be equalized by adjusting the high idle setting until all racks are positioned equally. Due to slight differences in governor characteristics, the rack positions will vary slightly between engines at all speeds except the speed at which the adjustment is made.

NOTE: For those engines that have a speed limiter, a method to retract (disengage) the speed limiter is given in this instruction. Due to engine installation or type of attachments, retracting the speed limiter may be difficult. When this condition exists, the recommendation is to remove the speed limiter to get free movement of the fuel rack. After the rack setting procedure is finished, install the speed limiter in the governor housing.

Reading The Dial Indicator

NOTE: Of all the dial indicators that are used, the type of dial indicator shown below is the most difficult to read. For this reason, an explanation follows for use of this type of dial indicator.

The dial indicator has two scales. On the range scale (1) each mark is equal to .001" of rack travel; it reads in hundredths and thousandths of an inch (.001" to .099"). Each graduation on revolution counter (2) is equal to one revolution of the hand on range scale (1), or .100" of rack travel. At each major graduation of the range scale are two numbers, one red and one black. Similarly, the revolution counter has a black range and a red range. The black figures are positive (+) and the red figures negative (-) rack position. To insure accurate readings, the zero point must be accurately set, as in the above illustration.

To zero the dial indicator, set revolution counter (2) exactly on the line between the red and black zeros. If the hand does not point to zero on the range scale (1), loosen screw (3) and rotate the dial face until the zero is aligned with the hand; then tighten screw (3). In the above illustration the dial face must be rotated thirteen marks counterclockwise to zero the indicator. Failure to properly set the zero point may result in an incorrect reading of the revolution counter, and result in an error of .100" in the rack setting.

To read the dial indicator in this example, first note the color and number on revolution counter (2); the counter is just beyond the line between the black 2 and 3, giving a revolution counter reading of .300". Since the revolution counter is in the black range, also read the black figures on range scale (1). The hand is seven marks (.007") beyond the black ten (.010").

Revolution Counter Reading = .300"

Range Scale Major Reading = .010"

Range Scale Minor Reading = .007"

Total = .317"

Since these readings are given on the black scale, indicating positive (+) rack position, the correct reading is +.317".

When the revolution counter hand is near the dividing line between two graduations, examine the range hand to determine which number to use for the first figure after the decimal point. If the range hand indicates a number smaller than 50, use the larger of the two revolution counter graduations. If the range hand indicates a figure larger than 50, the smaller of the two revolution counter graduations should be used.

In case of any doubt as to the figure indicated by the revolution counter, return the indicator to the zero point and slowly advance the rack while counting the revolutions of the range hand.

8S2305 Rack Position Tool Group

(1) Components of the tool group are 8S2283 Indicator (1), 9F6580 Bolts (2), 8S2306 Bracket Assembly (3), 8S2314 Adapter (4), 8S2311 Rod Assembly (5).

(2) Disconnect the governor control linkage and remove plug (6).

(3) Thread adapter (4) into rack plug hole. Thread rod assembly (5) into rack. Caution: Overtightening adapter plug or rod assembly will strip threads in the aluminum governor housing.

(4) Depress governor control linkage (7) to full-on position, allowing rack to overcome low idle spring. Push rod (5) forward and set dial indicator (1) at .220" (.270" for Model 1160). Pull rod (5) while depressing lever (7). This moves rack in shut-off direction to point where internal governor control linkage moves against high idle spring collar. Do not overcome high idle spring. Read rack setting on dial (1).

(5) To change fuel rack adjustment, remove cover (8). Be sure tool group is correctly positioned, and indicator (1) is adjusted to proper value. Move linkage (7) to full-on position; secure with wire. Loosen locknut on rack adjusting screw (9). While pulling rod (5) and rack toward shut-off position, turn screw (9) to obtain correct rack setting value on dial (1). Tighten locknut and recheck setting. Remove tag wire from lever (7) and check for smooth linkage movement. Remove 8S2305 Tool Group and install cover (8).

9S228 Rack Position Tool Group

1140 (36B539-up, 36B488, 36B489); 1145 (97B568-up, 97B470, 97B471, 97B472); 1150 (96B493-up, 96B360, 96B369, 96B392); 1160 (95B531-up, 95B522, 95B523); 3145 (96M1-up, 65P1-up); 3150 (97M1-up, 66P1-up); 3160 (98M1-up, 67P1-up); 613 (71M1-up)

The tool group consists of the 8S2283 Indicator (1), 9S8883 Point (2), and 9S225 Bracket Assembly (3). The 8S2291 Centering Pin (4) and 8S4627 Circuit Tester (5) are used but are not part of the group.

(1) For static rack setting, remove seal (6) and cover (7) from the governor. Remove cover (8) from the centering pin hole. Disconnect spring from governor control linkage.

(2) With the throttle lever in the low idle position, use a suitable tool to slide the rack toward the rear of engine, until the rack slot is beyond the centering pin hole.

(3) Insert centering pin (4) and move the throttle toward the full-ON position, thus moving the rack against the pin.

(4) Bolt bracket (3) to the governor and insert indicator (1). Slowly move the throttle lever toward the ON position, compressing the low idle spring until an additional resistance is felt (engine equipped with large governor spring), or until the stop collar (9) first stops moving (equipped with small governor spring). The low idle spring is fully compressed at this point. If the lever is pushed to full ON position, an erroneous reading of .020 to .030 can be obtained. Move the indicator until the revolution counter lies between the red and black zeros. Tighten the bracket setscrew.

(5) Rotate the dial face until the large needle is over the zero; remove the centering pin. Clip tester (5) to the contact for torque spring or rack stop bar and insert the tester pin into one of the governor cover bolt holes.

(6) Move stop collar (9) forward until stop collar adjustment screw (10) just touches torque spring or rack stop bar (11). The tester (5) light should just barely light (a dim light). Take the reading directly from dial indicator (1).

(7) To adjust the setting, loosen the locknut and turn screw (10) with a 4B9820 Wrench (12); then repeat the checking procedure. Tighten the locknut to a torque of 9 ± 3 lb.ft. (12 ± 4 N·m).

(8) For dynamic check of the rack setting, cut off the upper half of a spare governor cover to provide a "drip pan." Align boss (13) with the slot in stop collar (9) and install the modified cover.

------ WARNING! ------

Before starting the engine, remove the oil filler cap from the valve cover. This prevents crankcase pressure from forcing excessive oil out through the governor. Install the tool group and measure the rack setting as previously outlined. Do not install the tool group or adjust the rack while the engine is running.

-------WARNING!-------

(9) When cover (7) is removed, and by looking in the back of the governor, it can easily be determined if the governor is equipped with a small or large governor spring.

NOTE: Some engines have a negative or zero rack setting. To obtain the "zero" rack position mentioned in Steps 4 and 5, it will be necessary on these engines to rotate stop collar (9) 90° to prevent adjustment screw (10) from contacting the torque spring or rack stop bar. If the stop collar is not rotated, an incorrect zero position will be obtained.

910 (80U); 931 (8N, 10N, 78U, 81U); D3 (6N, 79U, 82U, 83U)

(1) Use the 9S228 Tool Group (1) and 8S4627 Circuit Tester (2), 9S8518 Plug (3), 9S8521 Rod (4) and 5P130 "0" Set Gauge (5) for these machines.

(2) Remove cover (6), plug (7), fuel filter (8), and cover (9). Disconnect the linkage from lever (10). Put "0" Set Gauge (5) in position as shown, and install bolts (11). Use a 10-32 NF Screw (12) to hold the gauge in place.

(3) On engines with negative rack settings, rotate stop collar (13) 90°. Install tool group (1). Install plug (3) loosely. Push rod (4) into plug (3) to move the speed limiter out of the way. Tighten plug (3) to hold rod (4).

(4) Move lever (10) slowly toward the fuel-on position until collar (13) first stops moving without additional pressure on lever (10). Zero the dial indicator and release lever (10). For negative rack setting, turn collar (13) 90° back into position.

(5) Fasten the clip end of tester (2) to the contact for torque spring (14) or the contact for the rack stop bar. Put the pin end of tester (2) into one of the bolt holes for cover (9). Move stop collar (13) forward until adjustment screw (15) just touches the rack stop bar or torque spring (14). The tester light should just barely be lit (a dim light). Look at the dial indicator reading for the static rack setting. To adjust the rack setting, loosen locknut (16) and turn screw (15) to get the desired setting. When adjustment is complete, tighten locknut (16) to 9 ± 3 lb.ft. (12 ± 4 N·m).

9S240 Rack Position Tool Group


1 - 9S6332 Box Assembly

8S6690 Block

9S8105 Block

2 - 5S8088 Rod Assembly

5S8086 Point (part of 5S8088)

3 - 5S8090 Rod Assembly

5S8086 Point (part of 5S8090)

4 - 9S7344 Clamp Assembly

S1616 Bolt (part of 9S7344)

5 - 5S8157 Extension

6 - 9S239 Adapter

S1616 Bolt (part of 9S239)

7 - 9S227 Bracket Group

8 - 9S7343 Bracket Assembly

2A762 Bolt (part of 9S7343)

9 - 8S4627 Circuit Tester

10 - 9S7350 Bracket Group

11 - 9S2017 Spring

12 - 9S238 Bracket Group

13 - 3P1565 Collet

14 - 5P4814 Collet

15 - 9S215 Dial Indicator

9S8903 Contact Point

16 - 9S225 Bracket Assembly

2H191 Bolt

17 - 9S8521 Rod

18 - 8S2283 Dial Indicator

19 - 3S3269 Point 1" (25.4)

20 - 9S8883 Point .50" (12.7)

21 - 3S3268 Point .25" (6.4)

22 - 9S8519 Plug

23 - 9S8518 Plug

D336 - (55B, 60B); 621, J621 - (23 H); 980 - (42 H); 1676 - (54B); 623-(52U);

(1)

1 -3S3268 (.25")

2 -9S215

3 -9S239

4 -5S8088

5 -5S8157

6 -8S4627

7 -9S8521

8 -9S8519

9 -5S8090

10 -5S8086

The above components of 9S240 Tool Group are required for this group of engines.

(2) Assemble tools as shown for the desired model. Caution: Contact point (10) must be installed as shown to prevent the possibility of the point falling off inside the fuel pump housing.

(3) Remove clamps (11), plug (12), fuel ratio control (14) or cover plate, and plug (16); disconnect the linkage from the governor lever and tube (15). Loosen the bolt for cover (13) and turn the cover to the side.

(4) Loosely install plug (8); push rod (7) into the plug hole to force the speed limiter plunger out of the way. Tighten plug (8) to hold the rod. For dynamic check of the rack, remove rod (7) and plug (8) and install plug (16).

(5) Install assembled adapter (3) and rod into the cover where plug (12) was removed. Seat the shoulder of the adapter firmly against the cover.

(6) With the governor in shut-off position, depress the rack centering pin under cover (13); put cover (13) halfway over the centering pin and tighten the cover bolt finger tight. Center the fuel rack by rotating the governor control shaft toward fuel-on until the rack is solid against the centering pin. Secure the governor lever in this position.

(7) Install and zero the dial indicator. Tighten the bolt in adapter (3) to hold dial indicator (2) in the zero position. Release the governor control lever. Loosen the bolt for cover (13) and move the cover to the side to release the rack centering pin. Connect the wire clip end of tester (6) to the brass screw terminal on the side of the governor housing and put the other end to a good ground. Turn the governor control lever in the fuel-on direction until the tester light comes on bright. Hold the governor lever in this position and, using finger pressure only, push down slowly on the dial indicator stem until the tester light flickers (dim light). In this position the stop collar adjusting screw is just touching the torque spring or stop bar. Read the rack setting directly from dial indicator (2). If adjustment is needed, loosen locknut (18); turn adjusting screw (17) to obtain the correct rack setting, then tighten locknut (18) to 9 ± 3 lb.ft. (12 ± 4 N·m).

D353 - (46B, 47B, 77B) (Mechanical Governor); D9 - (18A, 19A, 34A, 49A, 50A, 66A, 90J, 91J, 29N, 30N) 594 - (62H);

(1)

1 -9S7343

2 -9S7344

3 -8S2283

4 -3S3268-(.25")

The above components of 9S240 Tool Group are required for this group of engines.

(2) Remove the governor seal and cover (5); remove cover (6) and the gasket. Disconnect the linkage from governor control lever (7).

(3) Bolt bracket (1) to the fuel injection pump housing. Locate clamp (2) on the rack as shown and tighten the locking bolt.

(4) With the rack held in shut-off position, install indicator (3) and set it at minus (-) .523" against clamp (2). To do this, move the indicator until the revolution counter reads minus (-) .500"; rotate the dial face until the large hand is on zero, then move the indicator an additional .023" (red) for the minus (-) .523" reading. Tighten the bracket (1) bolt.

(5) Move governor control lever (7) in the fuel-on direction until adjusting screw (8) contacts the stop bar; then read the setting from the dial indicator. To adjust the rack, loosen locknut (9) turn screw (8) to obtain the desired setting, then tighten locknut (9).

D353 With Hydra-Mechanical Governor (Industrial, Marine)

(1)

1 - 9S7343

2 - 9S7344

3 - 8S2283

4 - 3S3268 (.25")

Additional tools needed but not shown are: 9S8518 Plug, 9S8521 Rod and 8S4627 Circuit Tester.

(2) Remove plug (5), covers (6) and (7) and the cover gaskets.

(3) Install the 9S8518 Plug in the hole for plug (5). Put the 9S8521 Rod in the hole in 9S8518 Plug. Push in on the rod to retract the speed limiter, then tighten the plug to hold the rod in position. Fasten the clip end of the 8S4627 Circuit Tester to the brass screw terminal on the governor housing. Put the other end to a good electrical ground. Move the governor control lever to the full FUEL ON position and proceed as follows:

(4) Bolt bracket (1) to the fuel injection pump housing. Position clamp (2) on the fuel rack to the dimension shown and tighten the locking bolt.

(5) Install indicator (3). Use a pry bar, or other similar tool, through the hole for cover (7) in the pump and governor housing and push the fuel rack away from the governor to the FUEL OFF position. (This will be as far as the fuel rack can be moved toward the fuel transfer pump end of the fuel pump housing.) Hold the fuel rack in this position and adjust dial indicator (3) to minus (-) .525". To do this, move the indicator until the revolution counter reads minus (-) .500"; rotate the dial face until the large hand is on zero, then move the indicator an additional .025" (red) for the minus (-) .525" reading. Tighten the bracket (1) bolt.

(6) Slowly release the pressure on the fuel rack, and allow the fuel rack to gradually move toward the FUEL-ON position. When the tester light just barely comes on (a dim light) the adjustment screw on the rack stop collar is just touching the stop bar. Read the dimension on the dial indicator and compare this dimension with the rack setting dimension given in the book, FUEL SETTING INFORMATION.

(7) To adjust the fuel rack setting, remove the air-fuel ratio control. Loosen locknut (8) and use the 9S1742 Hex Key Wrench (9) to adjust the rack setting to the correct dimension. When the rack setting dimension is correct, tighten locknut (8) to a torque of 9 ± 3 lb.ft. (12 ± 4 N·m).

D353 With Hydra-Mechanical Governor (D9 And 594 Only)

(1)

1 -5S8090

2 -9S239

3 -8S2283

4 -3S3268

5 -8S4627

The above components of 9S240 Tool Group are required for this group of engines.

(2) Remove plug (6) and cover (7).

(3) Install rod (1) in adapter (2) so the threaded contact point is on the dial indicator end of adapter (2). Install adapter (2) in the hole for plug (6). Fasten the clip end of tester (5) to the brass screw terminal on the governor housing. Put the other end to a good ground. Move the governor control lever in the fuel-on direction so the internal linkage is against the speed limiter, and proceed as follows:

a - Use a pry bar (8), or other similar tool, through the hole for cover (7) in the pump and governor drive housing, and push the fuel rack away from the governor to the fuel-off position. (This will be as far as the fuel rack can be moved toward the fuel transfer pump end of the fuel pump housing.) Hold the fuel rack in this position and adjust the dial indicator to minus .525". To do this, move the indicator until the revolution counter reads minus (-) .500"; rotate the dial face until the large hand is on zero; then move the indicator an additional .025" (red) for the -.525" reading. Tighten the clamp bolt.

b - Slowly release the pressure on the fuel rack, and allow the fuel rack to gradually move toward the fuel-on position. When the tester light just barely comes on (a dim light) the adjustment screw on the rack stop collar is just touching the stop bar. Read the dimension on the dial indicator and compare this dimension with the rack setting dimension given in the book, FUEL SETTING INFORMATION.

(4) To adjust the fuel rack setting, remove the air-fuel ratio control. Loosen locknut (9) and use the 9S1742 Hex Key Wrench (10) to adjust the rack setting to the correct dimension. When the rack setting dimension is correct, tighten locknut (9) to a torque of 9 ± 3 lb.ft. (12 ± 4 N·m).

641 - (64F, 41M); 657 - (31G, 46M); 650 - (63F, 77F); 660 - (77F, 90F); 651 - (33G, 44M); 666 - (77F, 32G, 64H)

(1)

1 -9S225

2 -8S2283

3 -9S2017

4 -3S3268-(.25")

The above components of 9S240 Tool Group are required for this group of engines.

(2) Remove the governor seal and cover (5). Remove fuel air ratio control (6) and tube (7). Disconnect linkage from governor control lever (8).

(3) Bolt bracket (1) to the governor housing and position indicator (2) in the bracket. To check the rack dynamically, also install spring (3). With the rack held in shut-off position, set indicator (2) at minus (-) .317". To do this, move the indicator until the revolution counter reads minus (-) .300"; rotate the dial face until the large hand is on zero, then move the indicator an additional .017" (red) for the minus (-) .317" reading. Tighten the bracket (1) bolt.

(4) To read the rack setting, move lever (8) toward fuel-on until the stop collar on the rack just touches the torque spring. If it is difficult to see when contact is made use a .003" thickness gauge (9) between the stop and spring; take the measurement when a slight drag is felt on the gauge. Read the setting from indicator (2), allowing for the thickness of gauge (9), if used. To adjust the rack, remove shims (10) to increase rack travel, or add shims (10) to decrease rack travel.

D379 (68B1616, 69B824) (HYDRA-MECHANICAL); D398 (66B2049, 67B920); D399 (35B, 91B)

(1)

1 -9S227

2 -8S2283

3 -8S4627

4 -8S3675 (.125")

5 -9S8521

6 -9S8519

The above components of 9S240 Tool Group are required for this group of engines.

(2) Remove eyebolt (7), cover (8), the plug and O-ring. Remove fuel air ratio control (9), tube (10) or the cover, if so equipped. Remove plug (11) and disconnect the linkage from the governor control lever.

(3) Loosely install plug (6); push rod (5) into the plug hole to force the speed limiter out of the way. Tighten plug (6) to hold the rod. For dynamic check of the rack, remove rod (5) and plug (6) and install plug (11).

(4) Bolt bracket (1) to the fuel pump housing.

(5) With the governor in fuel-ON position, place spacer (12) of the bracket group between the shoulder on the rod in bracket (1), and the bracket. Apply pressure toward the fuel pump housing to hold the spacer snug. Install and zero indicator (2), then tighten the bracket screw. Remove spacer (12) and dust cap (13) from the dial indicator. Attach one end of tester (3) to the brass screw terminal on the governor housing, and ground the other end. Rotate the governor control shaft in the fuel-ON direction. Rotate only far enough to obtain a bright light condition and secure in place. Push the fuel rack in the fuel-ON position by applying force on the backside of the dial indicator stem at the point where dust cap (13) was removed. Keeping a slight amount of pressure on the backside of the dial indicator stem and using a 1.25" open end wrench, slowly rotate the rack manual shut-off lever (14) in the fuel shut-off direction until the light very nearly goes out (a dim light). Observe the dial indicator reading at this point; the reading obtained is the static rack setting. To adjust the rack, loosen locknut (15), turn adjusting screw (16) to obtain the desired setting, then tighten locknut (15) to 9 ± 3 lb.ft. (12 ± 4 N·m).

NOTE: The Hydraulic Servo-Valve that operates the rack when the engine is running, does not provide a positive link between the rack and governor when moving the rack in the fuel-ON direction under static conditions. The rack can overshoot its set position by about .100". Because of this condition, the rack setting must be checked while applying a force against the rack in the fuel-OFF direction to eliminate the slack in the linkage between the rack and the stop collar.

D339 - (34B); 571 - (64A); D7 - (17A, 47A, 48A); 572 - (21A, 65A)

(1)

1 -9S7343

2 -9S7344

3 -8S2283

4 -3S3269 (1.0")

The above components of 9S240 Tool Group are required for this group of engines.

(2) Remove cover plate (5) and gasket, the governor seal and cover (6). Disconnect the linkage from the governor control shaft lever.

(3) Bolt bracket (1) to the fuel pump housing. Install clamp (2) to the rack so the edge of the clamp is aligned with the second line from the governor end of the pump.

(4) With the rack in shut-off position, set indicator (3) at minus (-) .453". To do this, move the indicator until the revolution counter reads minus (-) .400"; rotate the dial face until the large hand is on zero, then move the indicator an additional .053", (red) for the minus .453" reading. Tighten the bracket (1) bolt.

(5) For static check only on engines with a speed limiter, move the speed limiter out of the way by removing plug (7) and applying air pressure to the oil passage or remove cover (8) and push the limiter out of the way.

(6) To read the rack setting, move the governor control lever toward fuel-on position until the stop collar on the rack just touches the torque spring. If it is difficult to see when contact is made, use a .003" thickness gauge between the stop and spring; take the measurement when a slight drag is felt on the gauge. Read the setting from indicator (3) allowing for the thickness of the gauge, if used. To adjust the rack, remove shims (9) to increase rack travel or add shims (9) to decrease rack travel.

D342 - (31B, 32B, 49B); D8 - (14A, 15A, 22A, 35A, 36A, 46A, 52A, 68A) (With Forged Body Fuel Pumps); 583 - (16A, 38A, 61A) (With Forged Body Fuel Pumps)

(1)

1 -9S7343

2 -9S7344

3 -8S2283

4 -3S3269 (1.00")

The above components of 9S240 Tool Group are required for this group of engines.

(2) Remove cover plate (5) and gasket, the governor seal, cover (6) and gasket. Disconnect the linkage from the governor control shaft lever.

(3) Bolt bracket (1) to the fuel pump housing and lock clamp (2) on the rack, .19" from the third line, counting from the governor end of the pump.

(4) With the rack held in shut-off position, set indicator (3) at minus (-) .461". To do this, move the indicator until the revolution counter reads minus (-) .400"; rotate the dial face until the large hand is on zero, then move the indicator an additional .061" (red) for the minus (-) .461" reading. Tighten the bracket (1) bolt.

(5) For static check only on engines with a speed limiter, move the speed limiter out of the way by removing plug (7) and applying air pressure to the oil passage or remove cover (8) and push the limiter out of the way.

(6) Move the governor control lever toward fuel-on position until the stop collar on the rack is against the stop bar. Read the setting directly from indicator (3). To adjust the rack, remove shims (9) to increase rack travel or add shims (9) to decrease rack travel.

D311H - (51B); D320 - (63B); D330 - (56B, 57B, 81B, 82B, 85B, 86B, 98B, 99B, 29F, 37F); D333 - (58B, 59B, 79B, 80B, 87B, 88B, 34F); 814 - (90P, 14R); 815 - (91P); 816 - (57U); 920 - (41J, 75J, 62K); 922 - (59A, 94A, 97A, 74J, 88J); 930 - (79J, 41K); 933 - (25A, 42A); 941 - (70H, 71H, 75H, 80H, 16U); 944 - (43A, 70A, 77J, 87J); 950 - (90A, 99A, 15J, 43J, 73J, 81J, 31K); 951 - (89A, 92A, 15F, 32F, 69H, 79H, 72J, 78J, 86J, 63K); 955 - (26A, 45A, 51A, 60A, 72A, 77A, 93A, 48H, 53H, 61H, 31J, 57J, 64J, 71J, 85J); 966 - (33A, 75A, 57H, 42J, 76J, 30K); 977 - (53A, 46H, 76H, 48J, 70J, 11K); 980 - (89P); D7F - (91E, 92E, 93N, 94N); 1670 - (6A, 61B); 1673 - (70B, 74B, 78B, 1L); D4 - (24A, 29A, 30A, 39A, 40A, 54A, 55A, 67A, 69A, 78A, 85A, 86A, 88A, 91A, 22C, 97F, 44H, 47H, 18J, 20J, 49J, 58J, 59J, 60J, 61J, 65J, 66J, 82J, 83J, 84J, 69K. 7R); D5 - (98A, 51H, 52H, 81H, 82H, 83H, 84H, 21J, 37J, 50J, 52J, 54J, 62J, 63J, 67J, 68J, 93J, 94J, 95J, 96J, 97J, 98J, 6R, 12R); D6 - (31A, 32A, 37A, 41A, 44A, 56A, 57A, 71A, 73A, 74A, 76A, 82A, 83A, 96A, 37H, 38H, 46J, 47J, 55J, 56J, 69J, 99J, 10K, 26K, 17R); 561 - (62A, 85H, 92J); 571 - (95N); 572 - (96N); NO. 112 - (46D, 68E, 82F, 91G, 72H, 74H, 80J, 89J); NO. 120 - (89G, 60H, 14K, 35K, 10R); NO. 140 - (55F, 11R, 24R); NO. 12 - (94C, 38E, 99E, 12F, 21F, 73G, 59H, 89H, 94H, 13K, 17K, 33K); NO. 14 - (64C, 78E, 35F, 96F, 72G, 99G, 12K); 627 - (50K, 54K, 68M, 69M); 637 - (64M, 91N, 92N); 518 - (50S)

(1)

1 -9S8519

2 -9S8521

3 -9S8903 (bevel)

4 -9S215

5 -9S238 (except D7F, 571, and 572 which use 9S7350)

The above components of 9S240 Tool Group are required for the above engines.

(2) Remove cover (6), cover (7), plug (8), bolt (9) and tube (10). Disconnect the linkage from the governor control shaft lever.

(3) Bolt bracket (5) to the fuel pump housing and position indicator (4) in the bracket. Do not force the bracket against the housing; a gap between them is normal.

(4) Loosely install plug (1); push rod (2) into the plug hole to force the speed limiter out of the way. Tighten plug (1) to hold the rod. For dynamic check of rack, remove rod (2) and install plug (8).

(5) With the governor in shut-off position place spacer (10) of the bracket group between the shoulder on the rod in bracket (5), and the bracket. Apply pressure toward the fuel pump housing to hold the spacer snug. Zero indicator (4), then tighten the bracket bolt. Remove the spacer. To read the rack setting, move the governor control lever in the fuel-on direction until the stop collar on the rack just touches the stop bar or torque spring. If it is difficult to see when contact is made, use a.003" thickness gauge between the stop and spring; take the measurement when a slight drag is felt on the gauge. Read the setting from indicator (4), allowing for the thickness of the gauge, if used.

(6) To adjust the rack, loosen locknut (11) and turn adjusting screw (12) to obtain the desired setting, then re-tighten locknut (11) to 9 ± 3 lb.ft. (12 ± 4 N·m).

D330C (2B, 4B, 5B); D333C (23C, 66D, 67D); 1673 (69D); 3304 (2B4364, 4B6032, 5B1197, 78P); 3306 (23C740, 66D8891, 67D1103, 3N)

(1)

1 -8S4627

2 -9S8518

3 -9S8521

4 -9S8903 (Bevel)

5 -9S215

6 -9S7350

The above components of 9S240 Tool Group are required for this group of engines.

(2) Remove cover (7), fuel air ratio control (8) and plug (9). Disconnect the linkage from the governor control shaft lever.

(3) Bolt bracket (6) to the fuel pump housing; do not over-tighten - a gap between the bracket and housing is normal. Install indicator (5).

(4) Loosely install plug (2); push rod (3) into the plug hole to retract the speed limiter plunger, then tighten plug (2) to hold the rod. For dynamic check of rack, remove rod (3) and install plug (9).

(5) With the rack held in shut-off position, place spacer (10) of the bracket group between the shoulder on the rod in bracket (6) and the bracket. Apply force toward the fuel pump housing to hold the spacer snug. Zero dial indicator (5), then tighten the bracket bolt and remove the spacer.

(6) Attach one end of tester (1) to the brass screw terminal on the governor housing and ground the other end. Rotate the governor control shaft in the fuel-on direction until the tester light comes on bright; slowly rotate the control shaft toward the fuel-off position until the light goes out. Then again, very slowly, turn the shaft toward the fuel-on position until the light just barely comes on (a dim light). This is the point at which the stop collar screw is just touching the torque spring...when the light is bright, the torque spring is actually slightly depressed. Read the rack setting directly from the dial indicator. To adjust the rack, loosen locknut (11), turn adjusting screw (12) to obtain the desired setting, then tighten locknut (11) to 9 ± 3 lb.ft. (12 ± 4 N·m).

D334 - (92B, 93B); 1674 - (94B); D8, (583) (With Compact Fuel System)

(1)

1 -8S4627

2 -9S8519

3 -9S8521

4 -9S8903 (Bevel)

5 -9S215

6 -9S238

The above components of 9S240 Tool Group are required for this group of engines.

(2) Remove covers (7) and (8), fuel air ratio control (9) and plug (10). Disconnect the linkage from the governor control shaft lever.

(3) Bolt bracket group (6) to the fuel pump housing; do not overtighten-a gap between the bracket and housing is normal. Install indicator (5).

(4) Loosely install plug (2); push rod (3) into the plug hole to retract the speed limiter plunger, then tighten plug (2) to lock the rod. For dynamic check of rack, remove rod (3) and plug (2), and install plug (10).

(5) Move the governor control lever to shut-off position. Depress rack centering pin (11) and move the governor control lever in the fuel-on direction until the rack is solid against pin (11). Secure the governor lever in this position. Zero dial indicator (5), then tighten bracket (6) bolts. Release the governor control lever and rack centering pin (11). Attach the wire clip end of tester (1) to the brass screw terminal on the governor housing and ground the other end. Move the governor control lever in the fuel-on direction until the test light comes on bright; slowly rotate the control lever toward the fuel-off direction until the light goes out. Now, slowly, turn the governor lever in the fuel-on direction until the test light just barely comes on (a dim light). This is the point when the stop collar, or stop collar adjusting screw is just touching the torque spring or stop bar.

(6) To adjust the setting for engines without a stop collar adjusting screw, add shims (12) to decrease rack travel, or remove shims (12) to increase rack travel.

(7) To adjust the rack setting on engines that have a stop collar adjusting screw (13), loosen locknut (14), turn adjusting screw (13) to obtain the desired rack setting, then tighten locknut (14) to 9 ± 3 lb.ft. (12 ± 4 N·m).

D346 - (39J, 40J, 98N); D348 - (36J, 38J, 57K); D349 - (61P, 62P, 32R); 641B - (65K); 651B - (67K); 650B, 660B (58K); 657B - (68K); 666B - (66K); 992 - (25K); 772 - (80S); 773 - (63G); 777 - (84A) *

(1)

1 -5S8157

2 -9S239

3 -5S8088

4 -5S8086

5 -9S215

6 -8S3675" (.12")

7 -8S4627

8 -9S8519

9 -9S8521

10 -5S8090

The above components of 9S240 Tool Group are required for this group of engines.

(2) Remove plugs (11) and (12), fuel air ratio control (13) and tube (14). Disconnect the linkage from the governor control shaft lever.

(3) Loosely install plug (8); push rod (9) into the plug hole to retract the speed limiter plunger, then tighten plug (8) to lock the rod. For dynamic check of rack, remove plug (8) and install plug (11).

(4) Assemble the tools as shown for the desired model. Caution: contact point (4) must be installed as shown to prevent the possibility of the point falling off inside the fuel pump housing.

(5) For static check only, remove the standard dust cover (15) from indicator (5).

(6) Install the assembled adapter (2) into the hole where plug (12) was removed. Install dial indicator (5) to the adapter.

(7) Remove the locating pin from its storage location under bracket (16).

(8) Install a bolt (17) and nut on pin bracket (16) to prevent the pin from dropping into the fuel pump camshaft timing slot.

(9) With the governor in shut-off position, install the locating pin in the threaded hole to the right of its storage location. Hold the rack against the pin and zero dial indicator (5). Tighten the bolt on clamp (2).

(10) Attach one end of tester (7) to the brass screw terminal of the governor housing, and ground the other end. Rotate the governor control shaft in the fuel-ON direction until the tester light comes on bright; while holding the governor control lever in the fuel-ON direction, slowly depress dial indicator stem (18) (slight pressure) until the tester light just barely comes on (a dim light). This is the point at which the stop collar screw is just touching the torque spring. Read the rack setting directly from the dial indicator. To adjust the rack, loosen locknut (19) and turn screw (20) to the desired setting, then tighten locknut (19) to 11 ± 1 lb. ft. (1.52 ± 0.14).


*Rack setting procedure for the 777 Truck Engine is on the pages that follow, beginning on page 28.

Rack Setting Procedure for 777 Truck Engine

Three separate methods of rack setting are given for this machine; they are as follows: Fuel Rack Setting with the Engine Installed in the Truck; Fuel Rack Setting with the Fuel Pump Housing and Governor Installed on a Caterpillar Fuel Injection Test Bench; Fuel Rack Setting with the Engine Installed on a Dynamometer. Use the procedure that best fits your purpose.

NOTE: These rack setting and high idle setting dimensions are for an altitude of 0-7500 feet (0-2300 m).


NOTICE

Be careful to not cause damage to the torque spring at disassembly or assembly of the governor, or when removing and installing the air-fuel ratio control. The torque spring is very thin, and can be damaged or bent quite easily. DO NOT USE A DAMAGED OR BENT TORQUE SPRING.


Fuel Rack Setting With The Engine Installed In The Truck

(1) Start the engine and adjust the high idle speed to 2230 ± 30 RPM. Operate the engine long enough to let the engine and the machine hydraulic system become warm (normal operating temperature). Again check the high idle speed and make an adjustment if necessary.

(2) Stop the engine. Install the rack position tools according to the procedure given in steps 1-9 on pages 26-27.

(3) Rotate the governor control shaft to the wide open position "FULL COUNTERCLOCKWISE ROTATION" and hold it in this position. Loosen locknut (19) and adjust screw (20) to get a reading on dial indicator (5) that is the same as the dimension given for "Static Rock Position" in the fuel setting information. (Torque spring and stop collar position shown above.) Tighten locknut (19) and release the governor control shaft.

(4) Connect the 8S4627 Circuit Tester to the brass screw terminal on the governor housing. Again move the covernor control shaft to the wide open position and hold it in this position. Turn the manual shut-off lever in the shut-off direction until the circuit tester light goes off.

(5) Slowly release the pressure on the shut-off lever until the circuit tester light begins to glow (a dim light), and read the rack setting dimension on the dial indicator. The dimension on the dial indicator must be the same as the "Static Balance Point" given in the fuel setting information. Torque spring and stop collar position shown above.).

NOTE: If the reading on the dial indicator is not the same as the dimension given in step 5, check the torque spring for damage. Check also, torque spring thickness [must be .009" (0.23)] and spacer thickness [must be .126" (3.20)]. Now do steps 1-5 again.

NOTE: Final torque for locknut (19) is 9 ± 3 lb.ft. (12 ± 4 N·m).

(6) After the rack setting procedure is complete (fuel setting information dimensions have been obtained), write this rack setting dimension in the machine history folder and make a notation that it is an "In Vehicle Rack Setting".

Fuel Rack Setting Using A Caterpillar Fuel Injection Test Bench

(1) Install the fuel injection pump and governor on the test bench. Install the rack position tools according to the procedure given in steps 1-9 on pages 26-27.

(2) Run the test bench long enough to let the governor get warm.

(3) Stop the test bench. Rotate the governor control shaft to the wide open position "FULL COUNTERCLOCKWISE ROTATION", loosen locknut (19) and adjust screw (20) to get a dimension on dial indicator (5) that is the same as the dimension given for "Static Rack Position" in the fuel setting information. (Torque spring and stop collar position shown above.) Tighten locknut (19).

NOTE: This rack setting dimension is a starting point and may need to be changed in later steps.

(4) Start the test bench and adjust the test bench speed to 1050 ± 5 RPM. Adjust the governor high idle screw to obtain the governor balance point.

(5) Connect the 8S4627 Circuit Tester to the brass screw terminal on the governor. With the test bench operating at the speed given in step 4, move the governor control several times to be sure that the balance point is correct. The reading on dial indicator (5) must be the same as the "Dynamic Balance Point Setting" given in the fuel setting information, at the governor balance point (torque spring and stop collar position shown above). At governor balance point, the light in the circuit tester will just begin to glow (a dim light).

NOTE: If the reading on the dial indicator is not within the specifications given in step 5, check the torque spring for damage. Check the thickness of torque spring (21) and spacer (22). Torque spring thickness must be .009" (0.23); spacer thickness must be .126" (3.20). If the torque spring and spacer are within specifications, inspect and test the governor spring and also check the flyweight toes and the thrust bearing for wear.

(6) Increase and decrease the test bench speed several times, to ensure that the governor balance point is correct. Adjust the high idle if necessary.

(7) Adjust the test bench for a full load speed of 950 RPM. At this speed, the reading on dial indicator (5) must be the same as the "Full Load Rack Setting" given in the fuel setting information. (Torque spring and stop collar position shown above.)

NOTE: Minor adjustments of rack setting and high idle speed are permitted to obtain the "Full Load Rack Setting" dimension, however, if any adjustments are made, steps 5-7 must be done again.

NOTE: Final torque for locknut (19) is 9 ± 3 lb.ft. (12 ± 4 N·m).

(8) Check again for the correct static rack setting, as given in step 3. Write this rack setting dimension in the machine history folder and make a notation that it is a "Fuel Injection Test Bench Setting".

Fuel Rack Setting With The Engine On A Dynamometer

(1) Start the engine and adjust the high idle to 2260 ± 30 RPM. Operate the engine long enough to let all systems become warm, then again check the high idle setting. Make an adjustment if necessary.

(2) Stop the engine. Install the rack position tools according to the procedure given in steps 1-9 on pages 26-27.

(3) With the engine stopped, rotate the governor control shaft to the wide open position "FULL COUNTERCLOCKWISE ROTATION", loosen locknut (19) and adjust screw (20) to get a reading on dial indicator (5) that is the same as the one given as "Static Rack Position" in the fuel setting information. (Torque spring and stop collar position shown above.) Tighten locknut (19).

NOTE: This rack setting dimension is a starting point and may need to be changed in later steps.

(4) Connect the 8S4627 Circuit Tester to the brass screw terminal on the governor housing. Start the engine and apply the dynamometer load to check governor balance point. At an engine speed of 2100 ± 10 RPM, the rack setting dimension on the dial indicator must be the same as the "Dynamic Balance Point Setting" dimension given in the fuel setting information.

NOTE: If the engine speed or rack setting dimension is not within the specifications given in step 4, check the torque spring for damage. Check the thickness of the torque spring and the spacer. Torque spring thickness must be .009" (0.23); spacer thickness must be .126" (3.20). If the torque spring and stop bar thickness are both within specifications, inspect and test the governor spring, and also check the flyweight toes and the thrust bearing for wear.

(5) Increase the dynamometer load to run the engine at a full load speed of 1900 ± 10 RPM. The rack setting dimension on dial indicator (5) must be the same as the "Full Load Rack Setting" given in the fuel setting information. (Torque spring and rack stop collar position shown above.)

NOTE: Minor adjustments of rack setting and high idle speed are permitted to obtain the rated speed and rack setting as given; however, if any adjustments are made, steps 4 and 5 must be done again.

NOTE: Final torque for locknut (19) is 9 ± 3 lb.ft. (12 ± 4 N·m).

(6) Stop the engine and again check the "Static Rack Position" according to the procedure in step 3. Write this rack setting dimension in the machine history folder and make a notation that it is a "Dynamometer Rack Setting".

D343 - (33B3028- UP, 62B6728- UP); NO. 16 - (49G799 - UP) (EXCEPT 49G803); 631 - (13G4610- UP); 633 - (44J446- UP); 637 - (65M, 79P); 657 - (53K631 - UP, 47M91- UP); 666 - (20G205- UP); 768-(79S); 769 - (99F1792- UP); 824 - (36H811- UP, 43N); 834 - (43E511- UP, 44N); 825 - (43N); 835 - (44N); 826-(58U); 983 - (38K); 988 - (87A3093- UP); 1693 - (65B782- UP)

(1)

1 -8S4627

2 -9S8521

3 -9S215

4 -5P4814

5 -9S8883 (.50")

6 -9S8518

The above components of 9S240 Tool Group are required for this group of engines.

(2) Remove plug (7), cover (8), fuel ratio control (9) and tube (10). Disconnect the linkage from the governor control shaft lever.

(3) Remove plug (11) and loosely install the plug (6); push rod (2) into the plug hole to retract the speed limiter. Tighten plug (6) to hold rod (2). For dynamic check of the rack, remove plug (6) and install plug (11).

(4) Install collet (4) in the hole for plug (7).

(5) Move the governor control lever to the shut-off position; depress the rack centering pin and hold it down by putting cover (8) over the pin and tightening (finger tight) the hold-down bolt. Center the rack by moving the governor control lever in the fuel-on direction until the rack is solid against the pin. Hold or fasten the governor control lever in this position.

(6) Install and zero dial indicator (3), then tighten the nut on collet (4) just enough to hold dial indicator (3) in position. Remove the centering pin and release the governor control lever.

(7) Fasten the clip end of tester (1) to the brass screw terminal on the governor housing and put the other end to a good ground. Rotate the governor control lever in the fuel-on direction until the tester light comes on bright; slowly rotate the governor control lever toward the fuel-off position until the light goes out. Now again, very slowly, turn the governor control lever toward the fuel-on direction until the tester light just barely comes on (a dim light). This is the point at which the rack stop collar is just touching the torque spring or stop bar. Read the rack setting dimension directly from the dial indicator and compare this dimension with the dimension given in the FUEL SETTING INFORMATION. To adjust the rack setting dimension, loosen locknut (12) and turn adjustment screw (13) to obtain the desired rack setting, then tighten locknut (12) to a torque of 9 ± 3 lb.ft. (12 ± 4 N·m).

NO. 16 - (49G1-49G798, 49G803); D326 - (25B, 26B, 39B, 40B); D337 - (22B, 37B, 38B); D343 - (33B1-33B3027, 62B1-62B6727); DW15 - (45C, 59C, 70C, 75D, 76D); DW20 - (21C, 57C, 67C, 87E, 88E, 6W); DW21 - (58C, 69C, 85E, 86E, 8W); 619, J619 - (89E, 90E, 61F, 62F); 630 - (52F, 14G); 631 - (51F, 13G1-13G4609); 632 - (14G); 633 - (44J1-44J445); 657 - (19G, 53K1-53K630, 47M1-47M90); 666 - (20G1-20G204); 769 - (99F1-99F1791); 824 - (29G, 36H1-36H810); 834 - (43E1-43E510); 988 - (87A1-87A3092); 1693 - (65B1-65B781)

(1)

1 -9M9268

2 -9M9335

3 -9M9345

4 -1A9136

5 -9M9342

The above parts, components of 9M9267 Tool Group, are required for this group of engines.

(2) Remove cover (6) and the rack limiter, if so equipped.

(3) Move the rack forward and slide gauge (5) between the collar on the rack and the pump housing. In this position the rack is set on the centerline of the fifth tooth of the pump gear sector. Pull the rack rearward to hold the gauge in place.

(4) Attach indicator (1) to adapter (2) and bolt the adapter to the governor housing. Be sure the adapter arm is positioned in front of the rack collar and moves with the rack. Zero dial indicator (1). Remove gauge (5) and move the rack back and forth several times, checking to insure that only the flat surface of the dial indicator tip contacts the adapter dowel throughout rack travel. Install gauge (5) and check zero point setting of indicator (1). Remove gauge (5).

(5) Install plate (3) with the upper edge tightly against bracket (2), to minimize oil leakage. To check the rack, adjust the governor control lever so the rack stop is within .001" of the torque spring. Read the rack setting on dial indicator (1). To adjust the rack, loosen locknut (6); turn adjusting screw (7) to obtain the desired setting, then tighten the locknut.

D364 - (19B, 20B, 21B); D375 - (16B, 17B, 18B, 43B, 44B); D386 - (13B, 14B, 15B); D397 - (10B, 11B, 12B, 41B, 42B)

(1)

1 -9M9268

2 -9M9354

3 -9M9357

4 -9M9359

5 -1A9136

6 -9M9331

The above parts, components of 9M9267 Tool Group, are required for this group of engines. The 9S7344 Clamp, which is part of 9S240 Tool Group, can be used in place of clamp (3).

(2) Remove the side covers from the fuel pump housing. Attach indicator (1) to adapter (2) and bolt the adapter to the fuel pump housing. Remove the rack limiter, if so equipped.

(3) Install clamp (3) on the rack, using screw (6) to lock it in place.

(4) Center the rack by using gauge (4) to position the rack on the centerline of the fifth tooth of the pump gears.

(5) With centering gauge (4) installed, loosen screw (6) and slide clamp (3) along the rack bar until a zero reading is obtained on indicator (1); remove gauge (4) and move the rack back and forth several times. Install gauge (4) and recheck the zero reading. Repeat until a consistent zero is obtained. Remove gauge (4). To check the rack, adjust the governor control lever so the rack stop is within .001" of the torque spring. Read the rack setting on dial indicator (1). If the rack setting is not correct, adjust the rack stop or torque spring accordingly.

D311 - (7S5001, 9S); D315 - (48B, 52B, 9S5001, 5V); D318 - (45B, 53B, 5V5001, 6V); D2 - (4U, 5U); D4 - (6U, 7U); D6 - (8U, 9U); NO. 6 - (10A); DW10 - (1V); 933 - (11A); 955 - (12A); 977 - (20A); NO. 12 - (80C, 70D, 71D, 8T); NO. 112 - (81C, 3U); NO. 212 - (79C, 95C, 9T)

(1)

1 -9M9268

2 -9M9361

3 -9M9357

4 -9M9359

5 -1a9136

6 -9M9331

The above parts, components of 9M9267 Tool Group are required for this group of engines. Remove the covers from the side of the fuel pump housing and remove the rack limiter, if so equipped.

(2) Fasten indicator (1) to one end of bar (2) and bolt bar (2) to the fuel pump housing; indicator (1) must be parallel to and more than 1.5" lower than the rack. Install clamp (3) on the rack and lock it with screw (6).

(3) Position the rack on the centerline of the fifth tooth by engaging the inner set of notches on centering gauge (4) behind the last tooth on each side of one of the fuel pump sector gears. Draw the shoulder of the gauge up over the rack.

(4) With gauge (4) in place, loosen screw (6) and slide clamp (3) along the rack until indicator (1) reads zero. Remove gauge (4) and slide the rack back and forth several times. Install the gauge and recheck the zero reading. Repeat this procedure until a consistent zero reading is obtained. To check the rack, adjust the governor control lever so the rack stop is within .001" of the torque spring. Read the rack setting on dial indicator (1). If the rack setting is not correct, adjust the rack stop or torque spring accordingly.

D3400 - (9J4001, 1N7001, 3R6001, 3S7001, 9S4001, 1T7001); D4400 - (4H1, 4H9001, 1N4001, 3R2001, 1S1, 6S1); D4600 - (4H8001, 1N1, 3R4001, 1S5001, 5S1); D6600 - (5E9501); D7700 - (4C6501, 4H6001, 9J3001, 9J6501); D8800 - (5E5001, 4H3269, 9J2001, 9J6001, 1N8001, 2S1, 6S5001); D11000 - (4C8001, 4H7001, 9J1001, 9J8001); D13000 - (28B, 29B, 30B, 5E2001, 9J1, 9J7501, 1N1001, 1N9001, 3R7001, 3S2001, 4S1, 4S1001, 7S1, 1T1, 2V5001); D17000 - (5E9001, 9J5001, 9J8501, 3S1, 8S5001, 2V1, 8V1); D2 - (3J, 5J); D4 - (4G, 7J, 2T, 5T); D6 - (4R, 5R); D7 - (9G2876, 7M, 3T, 4T, 6T); D8 - (13A, 1H2409, 8R, 2U); NO. 10 - (1K, 2K,); DW10 - (1N2001, 6V5001); NO. 11 - (5K, 6K); NO. 48 - (5F); NO. 112 - (2M, 4M); NO. 212 - (1M, 1R, 1U)

(1)

1 -9M9268

2 -9M9361

3 -9M9362

4 -9M9359

5 -9M9360

6 -1D4538

7 -9M9331

8 -1A9136

The above tools, part of 9M9267 Tool Group, are required for this group of engines.

(2) Remove the cover from the side of the fuel pump. Remove the rack limiter, if so equipped. Fasten indicator (1) to one end of bar (2) with bolt (8). Bolt bar (2) to the fuel pump housing using spacer (5) and bolt (6). Install clamp (3) on the rack and lock it with screw (7).

(3) Position the rack on the centerline of the fifth tooth by engaging the inner set of notches on gauge (4) behind the last tooth on each side of one of the fuel pump sector gears. Draw the shoulder of the gauge up over the rack. With gauge (4) in place, loosen screw (7) and slide clamp (3) along the rack until indicator (1) reads zero. Remove gauge (4) and slide the rack back and forth several times. Reinstall the gauge and check the zero reading. Repeat this procedure until a consistent zero reading is obtained. To check the rack, adjust the governor control lever so the rack stop is within .001" of the torque spring. Read the rack setting on indicator (1). If the rack setting is not correct, adjust the rack stop or torque spring according.

3406 - 90U, 91U, 92U, 70V

(1)

1 -9S7350

2 -8S4627

3 -9S215

4 -9S8903

5 -9S8519

6 -9S8521

The above components of 9S240 Tool Group are required for this group of engines.

(2) Remove stop (7), spacer (8) and gaskets (9). Disconnect the governor control linkage at the governor lever.

(3) Remove the plug in the bottom of the governor housing. Install plug (5) and rod (6). Push in on rod (6) to retract the speed limiter and tighten plug (5) to hold the rod. Install bracket group (1), with the dial indicator, in place of stop (7), spacer (8) and gaskets (9). With the governor control lever in the shut-off position, put spacer (10) of the bracket group [the spacer is on the rod connected to the chain] over the rod that makes contact with the fuel rack. [Put force on the end of the rod that contacts the fuel rack, to hold the spacer in position.] Zero the dial indicator and tighten the clamp bolt to hold the indicator in position. [The dial indicator is now adjusted to the same position as when the fuel rack is centered.]

(4) Connect the clip end of tester (2) to the brass screw terminal on the governor housing and put the other end to a good ground. Turn the governor control lever in the fuel-on direction until the tester light comes on bright; slowly rotate the governor control lever to the shut-off position until the test light goes out. Now, very slowly, turn the governor control lever in the fuel-on direction until the test light just barely comes on (a dim light). This is the point at which the stop collar is just touching the torque spring or rack stop bar. Read the rack setting dimension directly from the dial indicator and compare it with the dimension given in the FUEL SETTING INFORMATION.

(5) To adjust the rack setting dimension, loosen locknut (11) and turn adjustment screw (12) to obtain the desired rack setting, then tighten locknut (11) to a torque of 9 ± 3 lb.ft. (12 ± 4 N·m).

3408 - (67U, 99U527, 28V, 48W); 3412 - (60M, 38S, 73W)

(1)

1 -8S4627

2 -9S215

3 -9S229 (.38)

4 -3P1565

Also needed but not shown: 5P9697 Timing Pin.

The above components (except for the 9S229 Contact Point) are all part of the 9S240 Tool Group, and are required for this group of engines.

(2) Remove plug (5) and plug (6) from the fuel injection pump housing.

NOTE: The 9S229 Contact Point is part of the 5P7264 Indicator Contact Point Group.

NOTE: The illustrations in this procedure show only a 3408 Engine. The tools and procedure for a 3412 Engine are exactly the same as those used for the 3408 Engine.

(3) Disconnect the governor linkage at the governor lever to allow full rack travel. Move the governor control lever to the shut-off position. Put the end of timing pin (7) in the hole for plug (5). Install the collect clamp (4) in the hole for plug (6). Put the dial indicator (2), with contact point (3) in collet clamp (4). Move the governor control lever toward the fuel-on position until the fuel rack stops against timing pin (7). Hold the governor lever in this position, adjust indicator (2) to zero and tighten the nut on collect clamp (4) to hold the indicator at the zero position. Move the governor lever to the shutoff position and remove timing pin (7).

NOTE: If the fuel system is equipped with a shutoff solenoid, it may be necessary to remove the solenoid to install and read the indicator.

(4) Connect the clip end of tester (1) to the brass screw terminal on the governor housing and put the other end to a good ground.

(5) Rotate the governor control lever in the fuel-on direction until the tester light comes on bright; slowly rotate the governor control lever toward the shut-off position until the light goes out. Now, again, slowly turn the governor control lever toward the fuel-on position until the tester light just barely comes on (a dim light). This is the point at which the rack stop collar is just touching the torque spring or stop bar. Read the rack setting dimension directly from the dial indicator. The correct rack setting dimension can be found in the FUEL SETTING INFORMATION or on the ENGINE INFORMATION PLATE installed on the engine.

(6) To adjust the rack setting, remove the cover on the top of the governor housing. Loosen locknut (8) and turn adjustment screw (9) to obtain the desired rack setting. After the adjustment procedure is complete, tighten locknut (8) to a torque of 9 ± 3 lb.ft. (12 ± 4 N·m).

Caterpillar Information System:

Reconditioning Dimensions for Track Links, Idlers, Rollers and Scraper Elevator Rollers{4154, 4159, 4171, 4180, 6248, 6260} Reconditioning Dimensions for Track Links, Idlers, Rollers and Scraper Elevator Rollers{4154, 4159, 4171, 4180, 6248, 6260}
Troubleshooting And Repair Of The 5P2160 Engine Horsepower Meter Arrangement<FONT SIZE=-1>*</FONT>{0781, 0782} Troubleshooting And Repair Of The 5P2160 Engine Horsepower Meter Arrangement<FONT SIZE=-1>*</FONT>{0781, 0782}
Installation Of Flywheel Adapter Groups(Allison Transmissions){1157} Installation Of Flywheel Adapter Groups(Allison Transmissions){1157}
Use Of The 9S1990 And 1P7400 Battery Charger Testers{0785} Use Of The 9S1990 And 1P7400 Battery Charger Testers{0785}
Use of 7S1100 Hydraulic Press Arrangement{0738} Use of 7S1100 Hydraulic Press Arrangement{0738}
Using 5P170 Or 5P4180 Hydraulic Hose Press Arrangement{0624} Using 5P170 Or 5P4180 Hydraulic Hose Press Arrangement{0624}
Parts Cleanliness Testing for Caterpillar Dealers - Visually Identifying Particulate Parts Cleanliness Testing for Caterpillar Dealers - Visually Identifying Particulate
Parts Cleanliness Testing for Caterpillar Dealers - Cleanliness Testing Process Parts Cleanliness Testing for Caterpillar Dealers - Cleanliness Testing Process
Parts and Components Cleaning Guide Parts and Components Cleaning Guide
Alignment of Two-Bearing Generators Alignment of Two-Bearing Generators
MTA Assembly and Service Manual MTA Assembly and Service Manual
MTA Nomenclature MTA Nomenclature
Use Of The 5P300 Electrical Tester{0651} Use Of The 5P300 Electrical Tester{0651}
Using The 5P2160 Engine Horsepower Meter Arrangement<FONT SIZE=-1>*</FONT>{0781, 0782} Using The 5P2160 Engine Horsepower Meter Arrangement<FONT SIZE=-1>*</FONT>{0781, 0782}
Alignment of Two Bearing Generators{4450} Alignment of Two Bearing Generators{4450}
Troubleshooting And Repair Of The 1P3500 And 2P8280 Injection Timing Groups{0782} Troubleshooting And Repair Of The 1P3500 And 2P8280 Injection Timing Groups{0782}
Service Information And Instructions For Use Of 5P3600 Hydraulic Flow Meter{0650, 5050} Service Information And Instructions For Use Of 5P3600 Hydraulic Flow Meter{0650, 5050}
Installation Of 7N4295 Rebuild Kit For Refrigerant Compressor - Clutch And Drive{1802} Installation Of 7N4295 Rebuild Kit For Refrigerant Compressor - Clutch And Drive{1802}
5P6590 Tester Schematic{0785, 0709, 1406, 1408} 5P6590 Tester Schematic{0785, 0709, 1406, 1408}
Installation Of Coolant Conditioner Group{1350} Installation Of Coolant Conditioner Group{1350}
INSTALLATION, OPERATION AND MAINTENANCE OF 9N3771 INJECTION GROUP (CETANE){1250} INSTALLATION, OPERATION AND MAINTENANCE OF 9N3771 INJECTION GROUP (CETANE){1250}
5P8579 Air Conditioning Charging And Testing Tool Group{1802, 0768, 0774} 5P8579 Air Conditioning Charging And Testing Tool Group{1802, 0768, 0774}
Welding Procedure For Sprocket Rim Replacement{4156} Welding Procedure For Sprocket Rim Replacement{4156}
Using The 5P-4150 Nozzle Testing Group{0782} Using The 5P-4150 Nozzle Testing Group{0782}
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