Usage:
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Remove Governor
START BY:
a. remove fuel ratio control (if so equipped)
1. Remove bolts (1), cover (2) and the cover gasket from the governor housing.
2. Remove the bolt from stop collar (3). Remove collar (3). Remove the collar and spring (4) from below collar (3).
3. Install tool (A) in the fuel pump housing. Make sure the correct end of tool (A) is used. Move governor bolt (5) until tool (A) is in place and the racks are in center (zero) position.
4. Remove bolts (7). Remove governor housing (6) and gasket.
5. Disconnect fuel lines (8).
6. Remove the four bolts from location (9) that hold the governor plate to the fuel injection pump housing. Remove plate (10).
NOTE: If necessary, hold the racks in the center (zero) position against tool (A) with a screwdriver while the governor plate is removed.
NOTE: It is possible to remove the governor and governor plate as a unit. The above steps must be followed before the governor can be installed again on the injection pump housing.
Install Governor
NOTICE |
---|
Drive assembly (13) must be removed from governor plate (12) before the governor plate is installed on the injection pump housing. The drive assembly can be damaged if it is installed with the governor plate and is not in alignment with the drive pinion assembly. |
1. Install a new gasket on the injection pump housing.
2. Put governor plate (12) in position on the fuel pump housing. Make sure dowels (14) in governor plate (12) are in alignment with the holes in the injection pump housing.
3. Install stop (6) in gear (10). Make sure the wide space in stop (6) is in alignment with the wide space on pinion assembly (1).
4. Install drive assembly (13). Align the holes in gear (10), stop (6) and drive assembly (13). Install pin (8). Install ring (11).
5. Install a new gasket on the governor plate. Install spring (9), spring washer, flat washer, and spring washer (not shown) and seat (7). Install governor housing (2).
6. Install spring (5) and collar (4). Install stop collar (3).
7. Install the bolts that hold the governor housing and plate to the injection pump housing.
8. Check the governor adjustment. See Governor Adjustments in Testing And Adjusting.
9. Install gasket (16) and cover (15). Make sure the dowel in cover (15) is in alignment with the notch in collar (3).
10. Connect fuel lines (17) to the governor plate.
END BY:
a. install fuel ratio control (if so equipped)
Disassemble Governor
START BY:
a. remove govenor
1. Remove plug (4) and the gasket. Remove the spring, plunger and washer from the speed limiter.
2. Bend the locks down on torque spring assembly (1). Remove the torque spring assembly.
3. Remove high idle screw (2) and low idle screw (3).
4. Bend lock (7) down, and remove the bolt from control lever (8). Remove shaft (5) and control lever (8).
5. Remove the lip-type seals and shaft bearings from housing (6).
6. Remove seat (9), the spring washer, flat washer and spring washer (10). Remove spring washer (11). Remove spring (12).
7. Remove ring (16) from seat (14). Remove dowel (15). Remove seat (14) and governor bolt (13) as a unit. Remove bolt (13) from seat (14).
8. Remove top washer (17), spring (18) and the bottom washer from the top of the servo piston assembly.
9. Remove sleeve (19). Remove the race, bearing and race from the bottom of sleeve (19).
10. Remove lock (20) from flyweight assembly (21). Remove assembly (21).
11. Bend the locks from bolts (22), and remove the bolts. Remove bracket (25) and pin (24) as a unit. Remove the pin from the bracket.
12. Remove shaft (26) from the bracket assembly with a hammer and punch.
13. Remove levers (28) and spring (27) from the bracket assembly.
14. Remove servo piston assembly (23) through the bottom of the governor plate.
15. Remove piston (31) from cylinder (29). Remove sleeve (32) from the cylinder. Remove the O-ring seals from cylinder (29) and seal (30) from sleeve (32).
16. Remove dowel (36). Remove drive assembly (33) and stop (35). Remove the snap ring from the bottom of gear (34). Remove gear (34).
17. Remove the bearing for gear (34) from the governor plate.
Assemble Governor
1. If replacement of the dowels in the governor plate is necessary, see the illustration for correct installation dimensions. Later governor plates have shorter middle dowel and must extend 5.58 mm (.219 in.) from the bottom of the plate.
2. Install the bearing for drive gear (1) in the governor plate with tooling (A) until it is 0.51 mm (.020 in.) from the top surface of the governor plate.
3. Install drive gear (1). Install ring (2) with tool (B).
4. Put valve (4) in piston (5). Install piston (5) in sleeve (3).
5. Install the O-ring seals on cylinder (6).
6. Install the servo piston assembly valve (4), piston (5), sleeve (3) and cylinder (6) through the bottom of the governor plate. The valve, piston, sleeve and cylinder are parts of the servo piston assembly. Put the notch in cylinder (6) in alignment with the bolt hole in the governor plate.
7. Put spring (8) in position on inner and outer levers (9). Put levers (9) and the spring in position in bracket (10). Put the holes in the bracket in alignment with the holes in levers (9). Install shaft (7).
8. Install pin (11) in bracket assembly (10) with the grooves in pin (11) engaged with outer lever (9).
9. Put the bracket assembly into position on the governor plate with pin (11) engaged with the servo piston assembly as shown. Install the bolts and locks that hold bracket assembly (10) to the governor plate.
10. Install the flyweight and gear assembly on the servo piston assembly. Install lock (22).
11. Install race (17), bearing (20) and race (24) on sleeve (21). Install the ring under race (24) on the sleeve.
12. Put sleeve (21) on valve (23). Put the hole in sleeve (21) in alignment with the hole in valve (23).
13. Put top washer (14), the spring and bottom washer in position on the top of valve (23) as shown.
14. Install governor bolt (12) in seat (18). Put the seat and bolt in position on sleeve (21) with the hole in seat (18) in alignment with the hole in sleeve (21). Install dowel (19) and the ring.
15. Install spring washer (13) over governor bolt (12) as shown (with the concave side up). Install spring (16), the spring washer, flat washer and spring washer (not shown). Install seat (15).
16. Install bearing (28) until dimension 'Z' is 43.38 ± 0.10 mm (1.708 ± .004 in.) with tooling (D).
17. Install bearing (27) until dimension 'X' is 25.35 ± 0.13 mm (.998 ± .005 in.) with tooling (E).
18. Check dimension 'Y'. Dimension 'Y' must be 60.58 ± 0.13 mm (2.385 ± .005 in.).
19. Install the lip-type seals in the governor housing with tooling (C). Install each seal with the lip toward the inside.
20. Install washer (29), plunger (30), spring (31), seal (25) and plug (26). Tighten the plug to a torque of 100 ± 14 N·m (75 ± 10 lb.ft.).
21. Put lever (32) into position in the governor housing. Install shaft (33). Install the lock, band assembly and bolt that hold lever (32) to shaft (33).
22. Install spacers (40), bar (41), retainer (39), contact (38), insulation (37), retainer (34), lock (36) and bolts (35) on the governor housing.
23. Install the high idle screw and low idle screw.
Caterpillar 3408 Service Manual Pdf
24. Check the governor adjustment. See Governor Adjustments in Testing And Adjusting.
END BY:
a. install governor
INSTANT DOWNLOAD
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MANAUL LIST:
SENR3581 – Specifications (3208 Marine Engine).pdf
SEBR0541 – Service Manual (3208 Diesel Truck Engine)
SEGV3008 – Systems Operation (Fundamentals Electrical System for All Caterpillar Products)
SENR2131 – Specifications (3208 Marine Engine)
SENR2133 – Specifications (3208 Marine Engine Attachments)
SENR2135 – Disassembly and Assembly (3208 Marine Engine)
SENR3130 – Torque Specifications
SENR3581 – Disassembly and Assembly (3208 Marine Engine)
SENR3581 – Systems Operation (3208 Marine Engine)
SENR3581 – Testing and Adjusting (3208 Marine Engine)
SENR3581 – Troubleshooting (3208 Marine Engine)
SEBU6090 – Engine Safety (3208 Marine Engine).pdf
SEBU6090 – Maintenance Intervals (3208 Marine Engine).pdf
SENR2132 – Systems Operation (3208 Marine Engine).pdf
SENR2132 – Testing & Adjusting (3208 Marine Engine).pdf
SENR2134 – Systems Operation (3208 Marine Engine Attachments).pdf
SENR2134 – Testing & Adjusting (3208 Marine Engine Attachments).pdf
RENR1377 – Systems Operation (Electric Protection System Energize-To-Run for Generator Set, Industrial & Marine Diesel Engines)
RENR1377 – Testing & Adjusting (Electric Protection System Energize-To-Run for Generator Set, Industrial & Marine Diesel Engines)
SENR3981 – Schematic – Fluid Power & Electrical Graphic Symbols
UENR3262 – Disassembly & Assembly – Seal Installation
SEBF9050 – Applied Failure Analysis – Engine Valve Failure Modes{1100, 1105}.pdf
SEBU6875 – Owner’s Manual (Caterpillar Driver Information Display).pdf
SENR2995 – Product Safety.pdf
SENR3130 – Specifications (Torque Specifications for All Caterpillar Products).pdf
Spec+Sheets Cat+3208+Propulsion.pdf
Spec+Sheets+-+Cat+3208+Propulsion.pdf
…
SENR3581 – Specifications (3208 Marine Engine).pdf
SEBR0541 – Service Manual (3208 Diesel Truck Engine)
SEGV3008 – Systems Operation (Fundamentals Electrical System for All Caterpillar Products)
SENR2131 – Specifications (3208 Marine Engine)
SENR2133 – Specifications (3208 Marine Engine Attachments)
SENR2135 – Disassembly and Assembly (3208 Marine Engine)
SENR3130 – Torque Specifications
SENR3581 – Disassembly and Assembly (3208 Marine Engine)
SENR3581 – Systems Operation (3208 Marine Engine)
SENR3581 – Testing and Adjusting (3208 Marine Engine)
SENR3581 – Troubleshooting (3208 Marine Engine)
SEBU6090 – Engine Safety (3208 Marine Engine).pdf
SEBU6090 – Maintenance Intervals (3208 Marine Engine).pdf
SENR2132 – Systems Operation (3208 Marine Engine).pdf
SENR2132 – Testing & Adjusting (3208 Marine Engine).pdf
SENR2134 – Systems Operation (3208 Marine Engine Attachments).pdf
SENR2134 – Testing & Adjusting (3208 Marine Engine Attachments).pdf
RENR1377 – Systems Operation (Electric Protection System Energize-To-Run for Generator Set, Industrial & Marine Diesel Engines)
RENR1377 – Testing & Adjusting (Electric Protection System Energize-To-Run for Generator Set, Industrial & Marine Diesel Engines)
SENR3981 – Schematic – Fluid Power & Electrical Graphic Symbols
UENR3262 – Disassembly & Assembly – Seal Installation
SEBF9050 – Applied Failure Analysis – Engine Valve Failure Modes{1100, 1105}.pdf
SEBU6875 – Owner’s Manual (Caterpillar Driver Information Display).pdf
SENR2995 – Product Safety.pdf
SENR3130 – Specifications (Torque Specifications for All Caterpillar Products).pdf
Spec+Sheets Cat+3208+Propulsion.pdf
Spec+Sheets+-+Cat+3208+Propulsion.pdf
…
ENGINE – GENERATOR SET
Model Prefix
3208 GEN SET ENGINE 29A
3208 GEN SET ENGINE 2HG
3208 GEN SET ENGINE 30A
3208 GEN SET ENGINE 5YF
Model Prefix
3208 GEN SET ENGINE 29A
3208 GEN SET ENGINE 2HG
3208 GEN SET ENGINE 30A
3208 GEN SET ENGINE 5YF
ENGINE – INDUSTRIAL
Model Prefix
3208 INDUSTRIAL ENGINE 03Z
3208 INDUSTRIAL ENGINE 90N
3208 REMAN ENGINE 9WC
Model Prefix
3208 INDUSTRIAL ENGINE 03Z
3208 INDUSTRIAL ENGINE 90N
3208 REMAN ENGINE 9WC
ENGINE – MACHINE
Model Prefix
3208 ENGINE – MACHINE 03Z
3208 ENGINE – MACHINE 79V
3208 ENGINE – MACHINE 90N
3208 ENGINE – MACHINE 93Z
Model Prefix
3208 ENGINE – MACHINE 03Z
3208 ENGINE – MACHINE 79V
3208 ENGINE – MACHINE 90N
3208 ENGINE – MACHINE 93Z
ENGINE – TRUCK
Model Prefix
3208 REMAN ENGINE 5CD
3208 REMAN ENGINE 62W
3208 TRUCK ENGINE 02Z
3208 TRUCK ENGINE 32Y
3208 TRUCK ENGINE 40S
3208 TRUCK ENGINE 51Z
Model Prefix
3208 REMAN ENGINE 5CD
3208 REMAN ENGINE 62W
3208 TRUCK ENGINE 02Z
3208 TRUCK ENGINE 32Y
3208 TRUCK ENGINE 40S
3208 TRUCK ENGINE 51Z
MARINE PRODUCTS
Model Prefix
3208 MARINE ENGINE 01Z
3208 MARINE ENGINE 75V
Model Prefix
3208 MARINE ENGINE 01Z
3208 MARINE ENGINE 75V
EXCERPT:
Fuel Injection Pump Housing And Governor
SMCS – 1286-11; 1286-12
SMCS – 1286-11; 1286-12
Remove Fuel Injection Pump Housing And Governor
View Image
start by:
a) remove air cleaner
b) remove fuel injection lines
c) Remove air inlet manifold
View Image
1. Remove plug from cover in fuel injection pump housing and install tool (A). Turn the crankshaft (clockwise) until the timing pin drops into the groove (slot) in the fuel injection pump camshaft.
View Image
2. Remove two nuts (2) and the tachometer drive housing (1).
3. Remove tachometer drive shaft (3).
View Image
4. Install tooling (B) into the camshaft drive gear for the fuel injection pump. Turn bolts (4) evenly until the drive gear is free of the shaft. Remove tooling (B).
View Image
5. Remove the plug from the timing hole in the front cover and install a 5/16″-18 NC bolt (5) 2 1/2 in. long. The cover bolt from hole (6) can be used. Turn the crankshaft (clockwise) until bolt can be installed into the timing gear and is in the center of the timing hole. The camshaft for the fuel injection pump is now in correct time to the engine.
View Image
6. Remove line (7). Remove bolts (8) from base of the fuel injection pump housing.
View Image
7. Remove the fuel injection pump housing and governor as a unit.
Install Fuel Injection Pump Housing And Governor
1. Put the fuel injection pump housing and governor in position on the engine. Install the bolts and lines.
Caterpillar 3408 Diesel Engine
2. Install the tachometer drive shaft and tighten it to a torque of 110 ± 10 lb. ft. (149 ± 14 N·m).
3. To check the timing, remove the timing pin and the bolt. Turn the crankshaft (clockwise) two revolutions and install the timing pin and bolt back in place. If the timing pin or bolt can not be installed, the fuel injection pump camshaft must be put into time again before Step 4 is done.
4. Remove the bolt from the timing gear. Install the plug into the timing hole.
5. Remove the timing pin from the timing groove (slot) in the fuel injection pump camshaft.
6. Install the tachometer drive housing.
end by:
a) install air inlet manifold
b) install fuel injection lines
c) install air cleaner
…
…
Category: Manual