Zetor 3545 repairs and servicing.

[stuzetor]

I have this week of work so i have started to clean and strip down my 1972 Zetor 3545 for general repairs and servicing.First thing to look at was the fuel injection pump and governor assembly as i knew there were problems there ???.I found the governor "central pin" seized inside the "clutch hub assembly" .Also inside the governor housing the throttle lever "adjusting screw" was seized in the "sliding block".......this was why my excess fuel button would not stay in !!.I am going to try and fit 2 new bearings and oil seals in the bottom of the fuel injection pump as they feel a bit rough.......providing i can get the camshaft out first of course !!.I presume i will have to compress all 3 fuel pumping element springs so the camshaft lobes clear the rollers ??.
The water pump will need either new bearings or complete replacement.
The 3 cylinder heads have got to come of as well as i dont think they have ever been touched.I am hoping the pistons and liners are all in good condition and do not need replacing (i fitted new ones in my brothers 4 cylinder 6911 last year).I will let you know what i find

 

[stuzetor]

I took the fuel injection pump into a diesel specialist to have the camshaft bearings replaced and a general strip down and clean / check over.I got it back today and started to reassemble the governor.Removed all 3 cylinder heads and the bores are smooth and clean but the pistons do naturally have some wear in them (i can see the rings through the gap !!) so i will be fitting new 95mm cylinder liner and piston kits to freshen the top end up .

 

[stuzetor]

I had to make a special tool to remove the slotted nut inside the governor.The governor fits on the end of the FI pump camshaft and is on a taper.After removal i carried out some small repairs to the governor assembly including making 2 new pivot pins and some shim washers and bronze welding a small crack in the body (where that strange 3 piece spring is located).Also made a gasket for the governor end cover and whilst i was at it made one for the water pump too (which i have stripped and cleaned for a rebuild including 2 new bearings and seals and a new mechanical water seal and thrust ring).
Yesterday i removed the sump and oil pick up strainer and then all 3 con-rods and pistons.The big end bearing shells and journals all look in very good condition.And so today the time had come to remove the cylinder liners......the first one (nearest the fuel tank) was VERY tight and broke the bottom of my liner puller .Some welding repairs and modifications to the puller and some heat from my oxy/acetylene gas torch finally had the stubborn liner removed .The other 2 liners came out much easier .
I have cleaned the cylinder heads and recut the valve seats.The valves and guides and injector sleeves and a couple of core plugs will all be replaced.I will also fit 3 new injector nozzles and set the "crack of" pressures to my Zetor owners manual specification (2172 psi).Thats all for now