Usage:
1. Coat the outside bearing walls with 5P3321 Epoxy.
2. Using a bench press, press bearing into pump housing.
3. Allow the epoxy to set overnight.
4. Make sure all pump components are wet with test oil throughout the entire assembly.
5. Using lubricant and 4C6829 Installer (L), slide two cup seals (1) onto drive shaft (2). Put one seal in one direction and the other seal in the other direction.
6. Install shaft assembly from front of pump. Make sure the cup seals do not flip over.
7. Insert thrust washer (4) in the proper orientation to the shaft (2).
8. Insert spring washer (3) and snap ring (5). Make sure the mark on the end of the shaft is orientated towards the top of the pump.
9. Insert rotor assembly (6) in the head assembly (7) to prevent touching the ground surface.
10. Install delivery valve (8), spring (9), and a new delivery valve stop (10) and screw (11). Tighten screw (11) to a torque of 9.5 to 10 N·m (80 to 90 lb in).
| NOTICE |
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Overtightening of the screw could result in the seizure of the hydraulic head and rotor assembly. Undertightening could result in leaking and hard starting. |
11. Install plungers (12), two shoes (13), two rollers (14), shims (if necessary), leaf spring (15), and screw (16).
12. Remove rotor assembly (6) and install in 4C6845 Fixture (H). Using the air pressure specified in the TMI, check the roller-to-roller dimension and check the centrality. Set the roller-to-roller dimension to the TMI specification.
NOTE: Using the Tool and the specification furnished by Caterpillar Service Technology Group, the roller-to-roller dimension can be obtained. To set the roller-to-roller dimension to the specification, turn the leaf adjusting screw clockwise (inward) to increase and counterclockwise (outward) to decrease the roller-to-roller dimension.
13. Rinse the hydraulic assembly in clean calibrating oil. Remove the rotor assembly from the fixture, taking care that the shoes and rollers do not leave their respective slots, and rinse in oil. Carefully, insert the rotor assembly into the hydraulic head.
14. Install cam ring (17).
NOTE: Position cam ring into original position as noted when disassembled.
| NOTICE |
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Directional arrow indicates the rotation of the pump. (Pump rotation is as viewed from the drive end). If installed incorrectly, the pump will not be in time with the engine. |
15. Install weight retainer assembly (18) and retaining ring (19) to rotor.
NOTE: Make sure the marks line up as marked during disassembly step.
16. Turn head assembly over. Install two rotor retainers (20) with the cutout positions meeting over the roll pin hole in the head.
17. Install liner locating ring (21).
| NOTICE |
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Position the split in the ring 90° from the split in the retainers. |
18. Install a new transfer pump end cap seal (22) into the head.
NOTE: The seal has an oval cross section and can be readily identified by rolling it between your fingers. Maker sure the seal is placed all the way into its locating groove.
19. Insert transfer pump liner (23) so that the slot is in line with the hole which the regulator assembly roll pin enters.
20. Install four blades (24) and two springs (25) (not shown).
| NOTICE |
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During installation, the blade springs must be compressed. Be careful not to cock the blades, since the sharp edged liner can score the blade ends. |
NOTE: Oversize blade should be fitted into the proper slot. It is permissible to use both oversize and standard size blades in the same rotor. Be careful not to lose the alignment of the hole.
21. Install seal (29) into regulator (30). Install piston (26), spring (27), plug (28).
| NOTICE |
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Make sure the plug is flush with the end of the regulator so no damage will occur when the fuel injection pump is operated. |
22. Install regulating assembly (30).
23. Install inlet filter screen (31).
24. Install cap (32). Rotate the cap counterclockwise until a slight "click" is heard; then turn the cap clockwise by hand until tight.
NOTE: Before assembly, apply 5P0960 Molybdenum Grease to the outside of the pressure plate and to the threads of the end cap.
25. Turn head-assembly over and install six weights (33).
26. Instal washer (34) (not shown) and thrust sleeve (35) in the center of the weights on the groove.
NOTE: The two deep grooves of the thrust sleeve should face upward as assembled.
NOTE: When assembled, sight across the tops of the assembled weights. They all should be level and resting against the thrust sleeve.
27. The hydraulic head and rotor assembly including the transfer pump assembly, cam ring, and governor assembly, are now ready to put into the housing. Install a new seal (36) on the hydraulic head after first greasing it slightly. Apply a light film of clean grease around the inside edge of the housing and tilt the housing slightly downward at the rear to aid in assembly. Rotate the cam ring so that the unthreaded hole is in line with the metering valve bore. This will insure proper position of the cam ring. Grab the hydraulic head firmly in both hands and insert it into the housing bore with a slight rotary motion. Do not force. If the assembly should jam during insertion, withdraw, and start over.
NOTE: Exercise care not to insert the head assembly too far into the housing. Pushing the head in too far will damage the seal on the hydraulic head and result in leakage. Turn drive shaft if needed to align tang with slot in head.
28. Rotate head assembly until the head locking screw holes line up with there corresponding holes in the housing. Install two head locking screws (37) finger tight.
29. Use 4C6989 Socket (D) and torque the end cap to 41 to 50 N·m (30 to 37 lb ft).
30. Install seal, plate (38), and screw to cap (39). Tighten screw to a torque of 8 to 9 N·m (72 to 80 lb in).
31. Install vent wire screw assembly (40). Tighten screw to a torque of 3 to 3.5 N·m (27 to 31 lb in).
32. Install governor arm (41), pivot shaft (42), new O-ring seals (43), and nut (44). Tighten nut to a torque of 2 to 3 N·m (18 to 27 lb in).
33. When assembling the pivot shaft, make sure the knife edge mates with the groove in the governor arm.
34. Install metering valve assembly (45).
NOTE: Make sure that none of the components are distorted during assembly.
35. Depress metering valve assembly (45), install guide stud (46) and guide stud washer (47), and tighten.
36. Engage the linkage hook (48) on the governor arm (41) and install on the metering valve assembly arm pin (45).
37. Install spring and components (49) on guide stud (46).
NOTE: Check and make sure that there is free movement on all of the governor components.
38. Install new washers and seals on throttle shaft assembly. Install throttle shaft assembly through shaft lever. Install throttle shaft assembly.
39. Install new Mylar washers and seals to the throttle and shutoff shafts. Apply a light film of grease to each seal. Assemble the throttle shaft assembly partially through its bore in the housing. Slide the throttle shaft lever over the throttle shaft so that the projection in the throttle shaft lever bore engages the rear keyway on the shaft. Position the forked end of the throttle lever so that it straddles the guide stud. Assemble the shutoff shaft assembly with a slight rotary motion, so as not to damage the seal. If the throttle shaft lever is correctly installed, rotating the throttle shaft assembly to the rear will cause compression of the governor spring.
40. Install two seals on head locating screw (50). Apply a small amount of grease to the head locating screw (50) and install. Tighten screw (50) to a torque of 20 to 25 N·m (15 to 18 lb ft). Tighten the two head locking screws (37) from step 28 to a torque of 20 to 25 N·m (15 to 18 lb ft).
NOTE: If screw (50) is not properly seated, the seal may be sheared during tightening.
41. Install advance cam screw (51) using 4C6621 Bushing (F) and 4C6623 Bit (G). Tighten screw to a torque of 50 to 52 N·m (36.5 to 38.5 lb ft).
42. Install two O-ring seals (52), spring guide (53), springs (54), piston (55), and slide washer (56) into spring side advance piston hole plug (57) and install into housing.
43. Install two O-ring seals (58), piston ring (59), piston (60), and slide washer (56) into power side advance piston hole plug (61) and into housing.
44. Install advance plug (62). Tighten advance plug to a torque of 8 to 11 N·m (72 to 99 lb in). Tighten plugs (57 and 61) to a torque of 24 to 30 N·m (18 to 22 lb ft).
45. Invert the pump and fixture in the vise. Prior to measuring and adjusting the linkage cap.
a. The torque screw (if used) should bee backed out.
b. With the throttle lever in the wide open position, push the vertical tab of the linkage hook toward the drive end of the pump, and rotate the drive shaft in the proper direction of rotation until a slight "click" is heard and the toes of the governor arm engage slots in the thrust sleeve.
c. Loosen the adjusting screw and slide linkage to maximum open length.
d. With the throttle lever held in the wide open position, use 4C8124 Kit-Linkage (N) to set the clearance between the rear of the throttle shaft and the vertical tab on the linkage hook. (Refer to pump specifications for correct dimensions).
e. Insert the preferred size step of the gauge between the throttle shaft and the vertical tab of the linkage hook.
f. Push on the linkage hook vertical tab to close the gap down to a thickness of the gauge which should also push the governor arm forward fully seating the governor weights in their retainer.
g. While pinching the gauge between the throttle shaft and the vertical tab, tighten the adjusting screw.
h. Check the setting by pushing on the vertical tab of the linkage hook and inserting 4C8124 Kit-Linkage (N) to determine if the gap is within tolerance. If not, reset as outlined in Steps 1 through g.
NOTE: When the linkage is adjusted, the pump must be tested to specifications.
46. Hold throttle open. Push metering valve back. Check clearance. If correct, adjust screw until clearance is correct, then tighten.
47. Compress both sides of the throttle and shutoff shaft and install a new shutoff cam and/or a new throttle shaft retainer clip as needed with the straight inner edge engaging the slot. The cam or clip should snap into position when installed correctly.
48. Install solenoid assembly (63) and gasket.
49. Install two new seals (64), two washers (65), two nuts (66), two electrical plugs (67), two washers (68), and two nuts (69).
50. Install gasket (70) to cover (71). Install cover, making sure hook on solenoid assembly (63) goes under the lever on the governor control. Install three bolts and washers. Tighten three bolts to a torque of 4.0 to 5.0 N·m (35 to 45 lb in) using 4C6624 Pin.
51. Install timing cover (72) and gasket. Remove pump from holding fixture and install pump flange seal.
End By:
a. install fuel injection pump