Installation of the 264-8897 Auxiliary Sea Water Pump Gp {1371} Caterpillar

Engine:

3618 (S/N: 2MW1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you read this information and you understand this information.

This Special Instruction provides the procedure for the installation of the 264-8897 Auxiliary Sea Water Pump Gp . The new pump group is intended for use on 3618 Engines only.

Many of the original pump parts are reused for this installation. A new coupling assembly will dampen torsional accelerations of the pump shaft. A new pump adapter is required in order to provide clearance for the new coupling assembly. The spacer for the pump shaft is made from a material that will provide better corrosion resistance in stagnant sea water.

Required Parts and Tools

Table 1 lists the parts that are required for installation of the new pump group.

Removal Procedure

Refer to Disassembly and Assembly, RENR1333-02, "Auxiliary Water Pump - Remove".

Inspect the Gear Train

Before the new sea water pump is installed, a visual inspection of the gear train must be completed. All gears in the front gear train must be inspected in order to ensure that any damage to gear teeth is repaired.

Closely inspect the gear that is attached to the removed pump for uneven gear wear.

Disassembly

Refer to Disassembly and Assembly, RENR1333-02, "Auxiliary Water Pump - Disassemble".

Assembly

Illustration 1	g01192020
Water pump assembly (1) 130-0480 Water Pump Housing (2) 257-5138 Spacer (3) 129-9189 Pump Impeller (4) Spring (5) 9Y-5632 Face Seal Group (6) 7E-4363 Water Pump Housing (7) 8F-8882 O-Ring Seal (8) 188-0451 Housing As (9) 7E-4356 Lip Seal (10) 9S-8007 Plug (11) 5P-7813 O-Ring Seal (12) 278-6219 Shaft (13) 188-0450 Sleeve Bearings (14) 0S-1588 Bolt (15) 3V-3308 Hard Washer (16) 1W-2828 Thrust Washer (17) 188-0449 Sleeve Bearings (18) 6V-3833 O-Ring Seal (19) 134-5958 O-Ring Seal (20) 8T-1812 Bolt

1. Inspect bearings (13) and (17). Replace the bearings if the bearings are worn or damaged. Use Tooling (C) to install bearings (17). Use Tooling (D) to install bearings (13) .
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   Illustration 2	g01191881

   1. Install bearings (13) with the bearing joints at a 15 degree angle from the vertical centerline of housing (8). Refer to Illustration 2.
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   Illustration 3	g01191883

   2. Install bearings (17) with the bearing joint at a 5 degree angle from the horizontal centerline of housing (8). Refer to Illustration 3.
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   Illustration 4	g01191898

   3. Refer to Illustration 4 in order to position the bearings correctly.

      (A) 20 ± 1 mm (0.7874 ± 0.0394 inch)

      (B) 92.5 ± 1 mm (3.6417 ± 0.0394 inch)

      (C) 112.5 ± 1 mm (4.4291 ± 0.0394 inch)

2. Position pump shaft (12) into housing assembly (8) .

3. Install thrust washer (16) onto housing assembly (8) by using bolts (14) and hard washers (15) .

4. Lubricate the bore of seal (9) with glycerin or an equivalent. Place seal (9) into housing (8) .

5. Install O-ring seal (18) .

6. Connect housing (8) and housing (6). Align the marks and the bolt holes of the housings.

7. Lubricate O-ring seal (7) and the face seal with clean water. Place the seal into pump housing (6). Ensure that the identification mark is oriented away from the seal group that is mounted on the shaft.

8. Lubricate seal group (5) with water. Install seal group (5) on shaft (12). Use hand pressure and Tool (B) in order to push the seal group on the shaft until the seal face makes light contact.

9. Install spring (4) on seal group (5) .

10. Place impeller (3) onto pump shaft (12) .

    Note: If the impeller has been balanced in the field, the impeller cannot be used. The fit between the tapered end of the pump shaft and the impeller must be checked. Refer to ""Taper Check Procedure" ". Lapping work may be performed in order to improve the fit between the tapered end of the shaft and the impeller.

11. Install spacer (2) and bolt (20). Lubricate only the threads of the bolt with 5P-3931 Anti-Seize Compound . Do not apply anti-seize compound on the following items: bolt head, face of the spacer and the face of the impeller. Tighten bolt (20) to 370 N·m (270 lb ft).

12. Install O-ring seal (19) .

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Illustration 5	g01177802

13. Position housings (8) and (6) on housing (1). Align all three housings. Use the marks that were made during disassembly in order to orient the housings.

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Illustration 6	g01192026
(21) 0S-1591 Bolt

14. Install five bolts (21) .

15. Ensure that the pump shaft rotates freely when the shaft is turned by hand.

    Before the pump group can be installed on the engine, the 259-2629 Coupling As must be assembled. Refer to ""Assembly of the Coupling" ".

Taper Check Procedure

Initial Check

1. Place the base of the pump shaft on a level surface with the tapered end in the upward position. Place the impeller on the shaft with light pressure of approximately 10 pounds of force.

2. Grasp the assembly by the impeller and lift.

   The pump shaft and the impeller must remain together.

Check with Prussian Blue

1. Lightly coat the taper of the impeller with prussian blue. Allow the prussian blue to dry. Place the impeller on the tapered end of the pump shaft.

2. Remove the impeller without twisting, and examine the pump shaft for the transfer of the prussian blue.

   Prussian blue should be transfered to at least 75 percent of the taper of the pump shaft. The prussian blue should be transfered for the full length of the taper of the pump shaft at some point on the taper.

Assembly of the Coupling

Illustration 7	g01192033
Coupling Assembly (1) Coupler shaft (2) 2H-3738 Bolt (3) 9M-1974 Hard Washer (4) Coupler spring pack (5) 3F-7147 Bolt (6) Drive gear assembly (7) Coupler bearing cap (8) 1A-2343 Bolt (9) 0S-0509 Bolt

1. Remove bolt (8) from the coupler shaft. Remove coupler bearing cap (7) .

2. Remove the drive gear assembly (6) from the coupler spring pack (4) by removing 8 bolts (2) and 8 hard washers (3) .

3. Align 6 holes in coupler spring pack (4) with the 6 holes in coupler shaft (1). Install the coupler spring pack and the coupler shaft to the pump shaft by using 6 bolts (5). Tighten the bolts to 130 ± 20 N·m (96 ± 15 lb ft).

4. Install drive gear assembly (6) to coupler spring pack (4) with 8 bolts (2) and 8 hard washers (3). Tighten the bolts to 30 ± 3 N·m (22 ± 2 lb ft).

5. Install coupler bearing cap (7). Install bolt (8) to coupler shaft (1). Tighten to 30 ± 3 N·m (22 ± 2 lb ft).

Auxiliary Water Pump - Install

Illustration 8	g01177575
(1) Pump housing (A) Guide studs

1. Install guide studs (A) .

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Illustration 9	g01192043
(2) 1B-2886 Bolt (3) 5P-8245 Hard Washer (4) 6V-7702 O-Ring Seal (5) 259-2629 Coupling As (6) 259-1982 Adapter (7) 1W-0104 Hollow Dowel (8) 6V-3955 O-Ring Seal

2. Install one of the new O-ring seals (4) for the joint between front housing (1) and adapter (6) .

3. Install adapter (6) on the guide studs (A) .

4. Install the other new O-ring seal (4) for the joint between the adapter and the water pump assembly.

5. Install dowels (7) and seals (8) .

6. The auxiliary water pump weighs approximately 82.5 kg (182 lb). Attach Tooling (E) and a suitable lifting device to the auxiliary water pump.

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Illustration 10	g01177576

7. Place the auxiliary water pump into position on the guide studs. Use dowels (7) in order to align the water pump assembly with the adapter.

8. Ensure that the coupling assembly (5) is properly meshed with the idler gear.

9. Install bolts (2) and hard washers (3) that attach the water pump assembly to the front housing. Remove the guide studs. Install the remaining bolts. It may not be possible to install the top bolt due to interference of the jacket water pump that is directly above the sea water pump. This will not affect the performance of the sea water pump.

Note: Ensure that the auxiliary water pump is primed prior to start-up.

Modification of the Customer Connection

With the addition of the coupling assembly and the adapter, the sea water pump's location moves away from the front housing by 62 mm (2.4409 inch). The customer's piping will need to be modified before the pump can be reconnected to the sea water supply.

Illustration 11	g01178189