Usage:
NOTE: The plate is a piece of 1/4" flat steel with six holes drilled through. Two holes 9.5 mm (.375 in) are drilled to attach the plate to 9S6363 Fixture Assembly. Three holes 9.5 mm (.375 in) are drilled to attach the fuel injection pump to the plate. One hole 69.85 mm (2.750 in) is drilled through the plate for clearance for the fuel injection pump shaft.
START BY:
a. remove fuel injection pump
NOTE: Maintain cleanliness at all times during this disassembly and assembly procedure. Keep the work area clean, the tools clean, and the mechanics hands clean at all times during this procedure.
NOTE: All seals and gaskets should be replaced during the assembly procedure.
1. Mount pump in fixture as shown.
2. Remove O-ring seal (1).
3. Remove three bolts (2) and washers, and governor control cover (3).
NOTE: As you remove the governor control cover, note how the solenoid assembly (4) is hooked in the governor control.
4. Remove two nuts (5), two electrical plugs (6), two washers, two nuts, and two seals. Remove the gasket and the solenoid assembly (4).
5. Remove throttle shaft assembly key (7) and slide out the throttle shaft lever assembly (8).
NOTE: For later assembly, not the position of the throttle shaft lever key in relationship to the groove of the throttle shaft assembly.
6. Loosen guide stud (9). While holding the governor spring and components (10) together, remove guide stud (9), and the governor spring and components (10).
7. While depressing the metering valve assembly (11), raise the governor linkage hook assembly (12) from the metering valve arm pin. Disengage the linkage hook assembly (12) from governor arm and lay the linkage hook assembly (12) over the side of the housing.
8. Remove the metering valve assembly (11).
9. Remove vent wire screw assembly (13).
10. Remove cap locking screw (14), plate (15), and seal (16).
11. Remove end cap assembly (17) using 4C6989 Socket (D).
12. Remove regulating assembly (18) from the end cap.
13. Remove inlet filter screen (19).
14. Remove plug (20), spring (21), and piston (22) from regulating assembly (18).
NOTE: Some 3054 Fuel Injection Pumps have a bushing pressed into the regulator instead of a seal. The bushing should not be removed and the seal is not required if the bushing is present.
15. Remove four blades (23), two springs (24), and liner (25).
16. Remove O-ring seal (26).
17. Loosen two locking head screws (27). Remove one of them.
18. Invert the pump and holding fixture in the vise. Loosen and remove head locating screw (28).
19. Remove two O-ring seals from head locating screw (28).
20. Remove advance plug (29) and seal.
NOTE: Tap lightly with hammer to loosen plug.
21. Using 4C8129 Wrench (E) remove spring side advance piston hole plug (30). Remove two seals from plug.
22. Remove slide washer (32), piston (33), springs (34), and spring guide (35).
23. Remove power side advance piston hole plug (36).
24. Remove slide washer (32), piston (37), piston ring (38), and two seals (31).
NOTE: When removing power side advance piston hole plug (36), note the "C" or "CC" marking. This mark designates pump rotation. The power side piston is always located on the side of the housing that has this mark.
NOTE: Removing screw without the special tool could break the screw.
26. Remove head locking screw (previously left loose).
27. Carefully remove hydraulic head assembly (40) with a slight rotary motion.
28. Remove thrust sleeve (41) and thrust washer (42) behind the sleeve.
29. Remove six weights (43).
30. Remove one pivot shaft retainer nut and seal (44).
31. Remove the pivot shaft (45) and governor arm (46).
32. Remove the snap ring (47) located on the back side of the drive shaft. Slide out drive shaft (48), spring washer (49), and thrust washer (50).
33. Remove liner locating ring (51) and two rotor retainers (52).
34. Turn the head and rotor assembly over. Mark location of weight retainer assembly (55) to rotor (53).
NOTE: Weight retainer assembly (55) may have a notch that aligns with mark on rotor (53).
35. Remove retaining ring (54) and weight retainer assembly (55).
36. Remove cam ring (56).
NOTE: Note orientation of the cam ring for later assembly.
| NOTICE |
|---|
Do not handle the ground surface of the rotor. |
37. Remove rotor assembly (57) from head assembly (58).
38. Remove screw (59), leaf spring (60), shims (if any), two rollers (61), and two shoes (62).
39. Using a brass tool, push out two pumping plungers (63).
40. Remove plug from motor.
41. Using 4C6827 screwdriver, remove delivery valve stop screw (64). The delivery valve stop (65) and spring (66) may now be removed. Discard the delivery valve stop. If the delivery valve does not slide freely from its bore use 4C8128 Extractor (J) to remove it.
NOTE: Delivery valve (66) is specific to each fuel injection pump. If replacing this valve, contact Caterpillar Service Technology Group (CSTG) for the correct specification and part number. Refer to the TMI.
42. Remove timing window cover (68).
43. (Inspect and clean all parts. Discard all O-rings and seals.
44. Check bearing (not shown). If bearing is worn, replace it by installing the special tool K and hitting it with a hammer to break the drive shaft bearing seal. Use a bench press to remove the drive shaft bearing.
45. Clean the pump housing.