Service Manual: Table of Contents

Product Overview

Welcome to the comprehensive Service Manual, a detailed guide for maintaining and servicing your machinery. This manual covers essential components and systems, providing crucial information for troubleshooting and repairs.

Contents

1. General
2. Engine
3. Fuel System
4. Electrical
5. Steering
6. Transmission
7. Brakes
8. Hydraulics
9. Chassis and Mounted Equipment

Manual Extract: Fuel Injection Pump Installation and Timing

It is essential to time the Fuel Injection Pump, especially when:

• A new pump is installed.
• A repaired pump is installed.

Note: Ensure that all new or repaired fuel injection pumps are of the same class.

To install and time the fuel injection pump, follow these steps:

• Position the No. 1 piston at Top Dead Center (TDC) on the compression stroke, ensuring both valves are closed.
• Remove the rocker cover, rocker assembly, and valve spring from the inlet valve, and allow the valve to rest on the piston.
• Attach a loaded dial gauge, OEM 1029, onto the inlet valve stem and reset to zero.
• Rotate the crankshaft counterclockwise until the piston moves 3mm.
• Turn the crankshaft clockwise until the dial gauge reads 2.92 mm, effectively removing backlash and setting the injection timing to 16u00b0 Before Top Dead Center (B.T.D.C).
• Attach the dial gauge (OEM 1029) and long probe (CAS 204 7-1) into the timing setting tool (CAS 204 7) under load and secure it with the retaining screw.
• Install the timing setting tool onto a flat surface. Press the steel ball until it is level with the bottom of the tool. Reset the dial gauge to zero.
• Mount the timing setting tool into the engine block and record the dial gauge reading. This value indicates the number of shims needed for installation.
• Remove the tool, add the necessary shims, and reattach the tool to ensure the dial gauge reads zero.
• Add extra shims corresponding to the value stamped on the injection pump (e.g., +3 = 0.3 mm) before installation.
• This will result in a measurement of 80.4 mm (A) between the bottom of the injection pump and the camshaft’s inoperative surface.
  Repeat this procedure for each pump.
• Use silicone sealant as a gasket when installing the injection pumps.

Note: Ensure all injection pumps used are of the same class.