Use Of 6V4068 Tool Group For Installation Of 9N5822 Thrust Washer{1253} Caterpillar

The 6V4068 Tool Group can be used to machine a counterbore and a clearance face so a 9N5822 Thrust Washer can be installed. This will give a new thrust face for the fuel pump camshaft, and make it possible to again use a fuel pump housing that has thrust face scuffing (wear).

Components of the 6V4068 Tool Group are as follows: 1-6V4067 Drill Bit; 2-6V4066 Bushing; 3-2H2525 Spring Pin; 4-6V4065 Bushing; 5-4B5276 Washer; 6-1B8710 Key; 7-3B1142 Retainer (two); 8-1B4331 Nut; 9-6V4064 Cutter; 10-6V4063 Arbor; 11-1D4566 Bolt; 12-9M5350 Spring; 13-2M849 Washer.

NOTE: If it is necessary to sharpen (make sharp) the 6V4064 Cutter, this can be done at a local tool and die shop, or other tool grinding facility. Get a copy of print FT1556, which gives all the specifications needed to sharpen the 6V4064 Cutter, from your Division Service Manager.

1 Disassemble the fuel injection pump housing, except for the front and rear bearings for the camshaft. Measure both bearings and check their dimensions with the dimensions that are given in the Service Manual. If it is necessary to install replacement bearings, install the new bearings before the pump housing is machined for installation of the thrust washer.

2 Install 6V4066 Bushing (2) in housing (14) as shown. Turn bushing (2) so drill bushing (15) is in alignment, as shown, with outside mounting pad (16).

3 Use drill bushing (15) in 6V4066 Bushing (2) as a guide, and 6V4067 Drill Bit (1) with an electric drill, to drill a 7.5 ± 1.5 (.295" ± .06") deep hole in fuel pump housing (14). In the illustration above, the 9 mm (.35") dimension compensates (makes up) for the 1.5 mm (.06") length of the tip of drill bit (1).

NOTE: It will be easier to drill the hole to the correct depth if some method is used to mark the drill bit for the correct depth. One way to do this is to put bottom face (A) of bushing (2) on a flat surface similar to block (17). Put drill bit (1) through drill bushing (15) as far as it will go, and hold it in this position. Make a mark on the drill bit, or use tape (B) as shown, that is 9 mm (.35") up from the top face of drill bushing (15). Drill the hole only until the tape, or the mark, is even with the top edge of bushing (15).

4 Put fuel pump housing (14) in a vise a shown. Install 6V4065 Bushing (4) in housing (14) so spring pin (3) is between bosses (C). Be sure face (D) of 6V4065 Bushing (4) is either even with, or just below the edge of camshaft rear bearing (18).

5 Install 1B8710 Key, 6V4064 Cutter (9), 4B5276 Washer (5) and 1B4331 Nut (8) on 6V4063 Arbor (10). Put lubricant on both bearing surfaces (E) and (F). Install arbor (10) with cutter (9) into the fuel pump housing bearings as shown.

6 Make sure that front face (G) of the fuel pump housing is clean, flat and free of burrs. Use 1D4566 Bolt (11) with 2M849 Washer (13) to assemble two 3B1142 Retainers (7) and 9M5350 Spring (12) to the end of arbor (10). Tighten bolt (11) until dimension (H), between the coils of spring (12), is approximately 1.5 mm (.06").

7 Use a ratchet wrench as shown to turn the arbor and cutter. Turn it until the end of the arbor is even with the front face of the fuel pump housing.

NOTE: When the end of the arbor is even with the front face of the fuel pump housing: the inner retainer (7) will be in contact with both the front face of the pump housing and the end of the arbor, and no force will be put on cutter (9); there will be a large reduction in the amount of force needed to turn the ratchet and arbor, and along with this there will be a reduction in the amount of compression for spring (12). This will let spring (12) turn with each turn of the arbor.

8 Remove all of the counterbore tools from the fuel pump housing. Face (J) of the counterbore must clean up 100% and it must also be completely free of any tool chatter marks. Clearance face (K) around the counterbore must clean up, at least on 75% of its circumference.

9 Install a 9N5822 Thrust Washer (19) in the new counterbore and make the checks that follow.

A - There must be a small amount of good radial movement, backward and forward, for the thrust washer. This will make sure that lock tab (20) on thrust washer (19) has some clearance in the tab hole.

B - Check the position of thrust washer (19) in the new counterbore. The thrust washer must be "flat in the bore" within .13 mm (.005").

C - Top face (L) of thrust washer (19) must be approximately .5 mm (.020") above clearance face (K) for the complete circumference of the thrust washer.

D - Axial movement of thrust washer (19) in the new counterbore must be .10 mm - .38 mm (.004"- .015").

10 Assemble the fuel pump housing. To make sure that the 9N5822 Thrust Washer will be kept in its correct installation location, the recommendation is to put the fuel pump housing in a vertical position until after installation of the fuel transfer pump and camshaft sleeve.