3608 Engine Caterpillar

Fuel Transfer Pump - Assemble

Usage:

3608 1ZD

Assembly Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
B	1U-5429	Snap Ring Pliers	1
C	1P-0510	Driver Group	1
D	8T-5096	Dial Indicator Gp	1

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NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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Illustration 1	g01290484

If replacement of relief valve plug (21) is necessary, adjust screw (26) in order to obtain Dimension (X). Dimension (X) is 4.30 mm (0.169 inch). Tighten locknut (27) and then recheck Dimension (X) .

Install plug (28) .

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Illustration 2	g00618793

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Improper assembly of parts that are spring loaded can cause bodily injury.

To prevent possible injury, follow the established assembly procedure and wear protective equipment.

Install new O-ring seals on relief valve plug (21) and plug (20) .

Install plug (20) into rear housing (22) .

Note: Be sure to install the relief valve in the original location.

Install valve (23) into rear housing (22) .

Install spring (24), guide (25), and relief valve plug (21) into rear housing (22) .

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Illustration 3	g00618790

Apply a light coat of clean engine oil to shaft assembly (18) and shaft assembly (19). Install the shaft assemblies into the rear housing.

Note: In the steps that follow, ensure that the components are kept in alignment. This should be done by using the mark that was made before disassembly.

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Illustration 4	g00618789

Install new O-ring seals on gear cases (16). Apply clean engine oil to the O-ring seals in order to hold the O-ring seals in position.

Install gear cases (16) on the rear housing.

Install dowels (17) .

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Illustration 5	g01290494

Install check valves (14) in middle housing (12) .

Install a new O-ring seal (13) in middle housing (12). Apply clean engine oil to the O-ring seal in order to hold the O-ring seal in place.

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Illustration 6	g00622500

Place middle housing (12) on the dowels and install middle housing (12) until middle housing (12) sits against the gear case.

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

Install dowels (10) .

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Illustration 7	g01290508

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Improper assembly of parts that are spring loaded can cause bodily injury.

To prevent possible injury, follow the established assembly procedure and wear protective equipment.

Note: Do not touch the sealing surfaces of the carbon face seal. This may cause contamination by abrasive particles.

Install spring holder (31) and spring (30) on the shaft assembly.

Note: Install carbon seal (29) immediately after applying oil to the rubber bellows. Oil causes the rubber bellows to expand.

Apply a light coat of clean engine oil to the rubber bellows of carbon seal (29) .

Hold the outside of carbon seal (29) and place carbon seal (29) on the shaft assembly against spring (30). Seal seat (6) will be installed later in the front housing.

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Illustration 8	g01290514

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Illustration 9	g01290894

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Illustration 10	g00622447

Use Tooling (C) in order to install lip seal (8) in front housing (4). Install the lip seal with the spring-loaded lip toward the bearing. Install O-ring seal (7) in the front housing.

Note: There are two lip seals that are available for lip seal (8). One lip seal is for distillate fuel and the other lip seal is for residual fuel. Check for the engine application before installation.

Note: Install seal seat (6) soon after applying oil to the O-ring seal. Oil causes the O-ring seal to expand.

Apply a light coat of clean engine oil to the O-ring seal that is on seal seat (6). Place the seal seat in the bore of front housing (4). Ensure that the finished surface is facing upward. Do not press directly against the finished surface.

Place the cardboard disc that is contained in the seal's package over the seal seat in order to protect the seal seat while the seal seat is being installed.

Use Tooling (C) in order to press the seal seat to the bottom of the bore.

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Illustration 11	g01290831

Apply clean engine oil to the face of the carbon seal.

Place front housing (4) over the dowels in middle housing (12). Hold the front housing against the middle housing.

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Illustration 12	g00618775

Install bolts (3) in order to hold the fuel transfer pump together.

Tighten the bolts to a torque of 67 ± 13 N·m (50 ± 10 lb ft).

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Illustration 13	g01290880

Install gear (1) and install bolt (2) and the washer on the drive shaft. Tap the bolt with a hammer, and tighten the bolt again.

Use Tooling (D) in order to check the end play of the shaft assembly. The end play must be 0.11 to 0.15 mm (0.004 to 0.006 inch).

Turn gear (1). The fuel transfer pump must rotate freely when the fuel transfer pump is turned by hand. If the fuel transfer pump does not rotate freely, disassemble the fuel transfer pump in order to find the cause of the problem.