3608 Engine Caterpillar

Disassembly Procedure

Start By:

1. Remove the fuel transfer pump. Refer to Disassembly and Assembly, "Fuel Transfer Pump - Remove".

Note: Use 8T-0447 Dial Calipers to measure the dimensions in the following procedure.

Illustration 1	g00618774

1. Loosen bolt (2) and use Tooling (A) in order to separate gear (1) from the pump shaft.

2. Remove bolt (2), the washer, and gear (1) from the pump shaft.

3. Remove the O-ring seal from the fuel transfer pump.

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Illustration 2	g00618775

4. Put an alignment mark across the sections of the fuel transfer pump. This is done in order to maintain alignment when the pump is assembled.

5. Remove bolts (3) that hold the fuel transfer pump together, but do not separate the components at this time.

6. Position the fuel transfer pump on the end of relief valve. This is the flat end.

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Illustration 3	g00618778

7. Carefully lift front housing (4) off the dowels. Ensure that front housing (4) is oriented straight when front housing (4) is being lifted.

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Illustration 4	g00618780

8. Inspect bearing (5) in front housing (4). The inside diameter of a new bearing (5) must be 15.951 mm (0.6280 inch).

9. If bearing (5) is worn or damaged, replacement of front housing (4) is necessary.

10. Turn over the front housing.

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Illustration 5	g00618781

11. Remove O-ring seal (7) from front housing (4) .

Note: Seal seat (6) has an O-ring seal which gives resistance to movement.

12. Remove seal seat (6). Seal seat (6) has an O-ring seal around the outside. Be careful not to damage front housing (4) while seal seat (6) is being removed.

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Illustration 6	g00618783

13. Remove lip seal (8) from front housing (4). Be careful not to damage front housing (4) while the lip seal is being removed.

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Illustration 7	g00618785

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Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened.

14. Remove carbon face seal (9). The seal components are shown in the inset. Seal seat (6) was previously removed from the front housing.

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Illustration 8	g00622500

15. Use Tooling (B) in order to remove retaining ring (11) .

16. Remove dowels (10) .

17. Carefully lift middle housing (12) off the dowels. Ensure that middle housing (12) is oriented straight when middle housing (12) is being lifted.

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Illustration 9	g00618788

18. Remove O-ring seal (13) .

19. Remove check valves (14) from middle housing (12) .

20. Inspect bearings (15) in middle housing (12). The inside diameter of new bearings (15) must be 15.951 mm (0.6280 inch).

21. If bearings (15) are worn or damaged, replacement of middle housing (12) is necessary.

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Illustration 10	g00618789

22. Remove dowels (17) .

23. Remove gear cases (16) .

24. Inspect the gear cases for wear. Also ensure that the gear cases are not damaged.

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Illustration 11	g00618790

25. Remove shaft assembly (18) and shaft assembly (19) .

26. Inspect the shaft assemblies for wear. Ensure that the shaft assemblies are not damaged. The shaft diameter of a new shaft should be 15.869 ± 0.006 mm (0.6248 ± 0.0002 inch).

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Illustration 12	g00618791

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Illustration 13	g00618793

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Personal injury can result from parts and/or covers under spring pressure. Spring force will be released when covers are removed. Be prepared to hold spring loaded covers as the bolts are loosened.

Note: Mark the location of relief valve plug (21) so that the plug can be installed in the same place.

Note: Do not change the position of the adjustment screw in relief valve plug (21) .

27. Remove plug (20) from rear housing (22). Remove relief valve plug (21), guide (25), spring (24), and valve (23) from rear housing (22) .

28. Inspect valve (23) and the valve seat in rear housing (22) .

29. Inspect spring (24). The free length of spring (24) is 57.1 mm (2.25 inch).

30. Inspect the washer and inspect relief valve plug (21). If the washer is damaged, relief valve plug (21) will need to be replaced.