2000/06/01 Caterpillar

Engines:

G3606 (S/N: 3XF)

G3608 (S/N: 4WF)

G3612 (S/N: 1YG)

G3616 (S/N: 4CG)

Description of Change: The Hydrax system that is used on these engines includes a new hydraulic pump group. This hydraulic pump group provides the appropriate pressure and flow characteristics for proper operation of the choke actuator, thewastegate actuator, and the fuel actuator. This new pump group includes improved internal seals.

Adaptable To: The new 184-6957 Gear Pump Group is a direct replacement for the former 116-6964 Gear Pump Group. The former gear pump group is cancelled. The new 184-6958 Pump Kit is available to convert a former 116-6964 Gear Pump Group into the new 184-6957 Gear Pump Group. See "Instructions To Convert A 116-6964 Gear Pump Group Into A 184-6957 Gear Pump Group ". The new 184-6959 Seal Kit is available to service the 184-6957 Gear Pump Group .

Instructions To Convert A 116-6964 Gear Pump Group Into A 184-6957 Gear Pump Group

Removing The 116-6964 Gear Pump Group From The Engine Front Housing

1. Disconnect all the lines and the fittings from the gear pump group.

2. Remove the bolts that fasten the gear pump group to the engine front housing. Save the bolts. Remove the gear pump group from the engine front housing.

3. Remove pump drive gear from the shaft of the gear pump group. Save the pump drive gear.

Disassembly Of The 116-6964 Gear Pump Group

Illustration 1	g00682431
This illustration identifies the components of the 116-6964 Gear Pump Group .

1. Use a marking pen or use a scribe to put a mark across the gear pump group. The mark should be from the mounting flange (1) to the pump head (7). This mark will be used to help correctly reassemble the gear pump group.

2. Remove the four capscrews that fasten the gear pump group components together. After the four capscrews are removed, the pump components can be separated.

   Note: Be very careful not to damage the internal shaft bushings (4) when you disassemble the gear pump group.

3. Remove the front mounting flange (1) from the pump group. Carefully remove the shaft lip seal (8) and O-ring seal (2). Discard the shaft lip seal (8) and O-ring seal (2) .

4. Remove the separation plate (3) and O-ring seal (5). Discard the separation plate (3) and O-ring seal (5) .

5. Remove the driver shaft (9) and gear set assembly (6). Remove the gear set (6) from the driver shaft (9). Discard the driver shaft (9) .

6. Remove the driven shaft and gear set assembly (10). Save the driven shaft and gear set assembly (10) .

7. Remove the casing (11). Save the casing (11). Remove the O-ring seal (12). Discard the O-ring seal (12) .

8. Remove the separation plate (13). Discard the separation plate (13) .

9. Remove the O-ring seal (14) from the pump head (7). Discard the O-ring seal (14) .

Installation Of The 184-6958 Pump Kit

Note: Be sure that all of the components for the gear pump group are clean. Use hydraulic fluid in order to lubricate all of the gear pump group components.

Note: Reference marks were made before the gear pump group was disassembled. When you assemble the gear pump group, be sure to line up the reference marks.

Note: Be very careful not to damage the internal shaft bushings when you are reassembling the gear pump group.

Illustration 2	g00683298

1. Place the pump head (8) on a flat surface. The side of the pump head with the O-ring groove should be facing upward. Lubricate the O-ring seal (15) and install the O-ring seal.

2. If the dowel pins (7) were removed, install the dowel pins in the pump head (8). Use a soft hammer to tap the dowel pins into position in the pump head.

3. Install the separation plate (6). The separation plate is held in the correct position by the dowel pins (7). Lubricate the O-ring seal (14) and install the O-ring seal.

4. Install the casing (5). The casing is held in the correct position by the dowel pins (7). Lubricate the O-ring seal (13) and install the O-ring seal.

5. Use the new key and the new retaining rings from the pump kit in order to assemble the driver shaft and gear set assembly (10) .

6. Lubricate the driver shaft assembly (10) and the driven shaft assembly (11). Install the driver shaft assembly and the driven shaft assembly into the internal shaft bushings and the casing (5) .

7. Carefully slide the separation plate (3) onto the dowel pins (7), the driver shaft assembly (10), and the driven shaft assembly (11) .

   Note: A second set of dowel pins (7) can be installed if more dowel pins are needed. After the dowel pins are installed, the top of the dowel pins should be approximately 10.4 mm (0.41 inch) above the surface of the separation plate (3) .

8. Install the seal retaining ring (4) into the groove in the driver shaft assembly (10) .

9. Install the lip seal (9) in the mounting flange (1). The sealing lip of the lip seal should be toward the inside of the pump. Install the mechanical seal (2) in the mounting flange.

10. Lubricate the O-ring seal (12) and install the O-ring seal (12) in the groove in the face of the mounting flange (1) .

11. Carefully slide the mounting flange (1) onto the driver shaft assembly (10) and dowel pins (7) .

12. Install the four bolts that fasten the gear pump group together. Tighten the four bolts to a torque of 71 ± 3 N·m (52 ± 2 lb ft).

Installing The 184-6957 Gear Pump Group On The Engine Front Housing

1. Install the pump drive gear on the driver shaft assembly (10) .

2. Install a new 5D-5957 O-Ring Seal in the groove on the mounting flange (1). Put the 184-6957 Gear Pump Group into position on the engine front housing. Install the bolts that fasten the gear pump group to the engine front housing.

3. Install the fittings and connect the lines on the gear pump group.

4. Start the engine and check for leaks.