Usage:
FLUID SPILLAGE CONTAINMENT
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.
| NOTICE |
|---|
Before any service work is done on the fuel system, the outer surface of the injection pump housing must be clean. |
NOTE: The fuel injection pump housing and governor has been removed from the engine for illustration purposes.
1. Remove flange (1) and the flange assembly.
2. Remove cover (2).
3. Remove bypass valve (3) and the spring.
4. Install Tooling (A) on the fuel injection pump and loosen the bushing from the pump housing.
Do not loosen screws (4) that hold the levers to the shaft when the pumps are removed or installed. If the levers are moved, fuel pump calibration will be changed.
5. Remove fuel injection pump (5) from the pump housing. Sleeve (6) on the plunger will slide off the lever as the pump is removed.
6. Do Steps 4 and 5 for the remainder of the pumps.
NOTE: The following steps are for installation of the fuel injection pumps.
7. Turn the camshaft until the lifter for the pump to be installed is at its lowest position.
8. Install fuel injection pump (5) in the bore of the pump housing.
9. Sleeve (6) will be engaged with the lever when the pump is installed correctly.
| NOTICE |
|---|
If the levers have been moved on the shaft, fuel pump calibration must be made. (Refer to the Systems Operation, Testing & Adjusting Manual). |
10. Tighten the bushing with Tooling (A) to a torque of 95 ± 7 N·m (70 ± 5 lb ft).
11. Do Steps 7 through 10 for the remainder of the pumps.
12. Install bypass valve (3) and the spring.
13. Install cover (2) and the gasket on the pump housing. Be sure the spring is in the bore in the cover.
14. Install flange (1), the flange assembly, and the gaskets on the cover.
Disassemble & Assemble Fuel Injection Pumps
Start By:
a. remove fuel injection pumps
1. Remove bushing (1) and the seal from bonnet (2).
2. Remove ring (3) from the bonnet and barrel (7). Remove check valve (6) and spring (4) from the bonnet.
3. Remove spring (8) and washer (5).
NOTE: Keep the plunger and sleeve with their respective barrel for installation.
Do not use plungers, sleeves, and barrels with other plungers, sleeves, and barrels.
4. Remove plunger (9) and sleeve (10).
NOTE: The following steps are for assembly of the fuel injection pumps.
NOTE: Be sure the sleeve and plunger are installed in their original barrel and the large hole in the plunger is up. The sleeve must be installed with the thin flange up.
5. Install sleeve (10) and plunger (9) on barrel (7).
6. Install spring (8) and washer (5) on the barrel.
7. Install check valve (6) and spring (4) in bonnet (2).
8. Connect barrel (7) and bonnet (2) and install ring (3).
9. Install the seal and bushing (1) on bonnet (2).
End By:
a. install fuel injection pumps