C18 Generator set and C18 Marine Engines Caterpillar

Auxiliary Water Pump - Assemble - Type 2

Usage:

C18 C1J

Assembly Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	132-5451	Holding Fixture	1
C	1P-0510	Driver Gp	1
D	6V-5019	Jam Nut	2
E	417-6001	Seal Installer	1
F	449-1904 or FT-3171	Seal Installer	1
G	452-6006	Grease	1
G	458-0188	Grease⁽¹⁾	1
H	8T-5096	Dial Indicator Gp	1
J	-	Loctite 243	-
K	417-6000	Installer Tool⁽²⁾	1
K	533-1142	Installer Tool⁽³⁾	1
L	FT-3227	Bearing Driver	1
M	-	Loctite 542	-

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⁽¹⁾	Australia use
⁽²⁾	For drive-end body with bore depth 10.12 mm (0.398 inch)
⁽³⁾	For drive-end body with bore depth 13.12 mm (0.517 inch)

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Illustration 1	g03124637

Use a suitable press to install impeller (42) onto shaft assembly (38).
Note: Ensure that impeller is oriented as shown in Illustration 1.
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Illustration 2 g03410208
Place non-drive end of housing (39) on a flat surface.
Use Tooling (F) and a suitable press to install seal assembly (41) into non-drive end housing (39).
Remove Tooling (F).
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Illustration 3 g03410207
Place Tooling (E) on a flat surface and allow for clearance of the shaft assembly to be inserted through the center hole of Tooling (E).
Place non-drive end housing (39) on top of Tooling (E).
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Illustration 4 g03411859
Install port plate (40) into non-drive end housing (39).
Note: Align lug on port plate (40) with slot in non-drive end housing (39).
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Illustration 5 g03409746
Use a suitable hand press to install shaft assembly (38) into non-drive end housing (39). Press until the seal assembly contacts Tooling (E).
Note: Ensure that rotating face is fully seated on the shaft step. View through the water port.
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Illustration 6 g03521217
Install distance ring (28) and O-ring seal (27) onto non-drive end housing (39).
Remove from Tooling (E).
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Illustration 7 g03408289
Apply Tooling (G) onto the lip of lip seal (37).
Use Tooling (C) to install lip seal (37) into bearing housing (30) with the lip facing up.
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Illustration 8 g03521636
Install bearing housing (30), bolts (31), and washers (32) onto the non-drive end housing. Do not tighten bolts (31) at this time.
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Illustration 9 g03522098
Place Tooling (L) on a suitable press. Place bearing (36) onto Tooling (L). Place the non-drive end housing and shaft assembly on top of bearing (36). Press bearing (36) into the bearing housing and onto the shaft.
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Illustration 10 g03522157
Install retaining ring (33) and retaining ring (34). Ensure that the retaining rings are fully seated in grooves.
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Illustration 11 g03523378
Loosen bolts (31) and install 0.305 mm (0.0120 inch) 100-3063 Shims (35).
Tighten bolts (31) to a torque of 5 to 7 N·m (44 to 62 lb in).
Verify that the shaft turns freely.
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Illustration 12 g03409750

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Illustration 13 g03523585

Use straight edge and feeler gage or Tooling (H) to check the height of impeller (42). The height of the impeller should be 0.11 mm to 0.16 mm (0.004 inch to 0.006 inch) below the edge of distance ring (28).

Note: To adjust the height of the impeller, loosen bearing housing (30) and remove shims (35). See Table 2 for available shims. Use only a matched set of shims (35).

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Table 2
Shim Options
Part Number	Part Description	Qty Required
100-3061	Shim 0.127 mm (0.0050 inch)	3
100-3062	Shim 0.254 mm (0.0100 inch)	3
100-3063	Shim 0.305 mm (0.0120 inch)	3
100-3064	Shim 0.381 mm (0.0150 inch)	3

Note: Each bolt should be shimmed by equal amounts.

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Illustration 14	g03524017

Tighten bolts (31) to a torque of 5 to 7 N·m (44 to 62 lb in).
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Illustration 15 g03122996
Install port plate (26) into intermediate body (15).
Note: Align lug on port plate (26) with slot in intermediate body (15).
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Illustration 16 g03122936
Install intermediate body (15) onto the non-drive end body.
Install bolts (25) and washers (24). Tighten bolts (25) to a torque of 5 to 7 N·m (44 to 62 lb in).
Apply Tooling (M) onto the threads of plug (23). Install plug (23). Tighten plug (23) to a torque of 8 to 10 N·m (70 to 88 lb in).
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Illustration 17 g03411861
Apply Tooling (J) onto impeller threads of shaft assembly (22).
Install impeller (20) onto the shaft.
While holding shaft (22) by hand, use a soft blow hammer to tighten impeller (20).
Install O-ring seal (21) onto intermediate body (15).
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Illustration 18 g03410267
Use Tooling (F) and a suitable press to install seal assembly (19).
Remove Tooling (F).
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Illustration 19 g03410265

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Illustration 20 g03527856
Set the non-drive end body and the intermediate body on a tool that interfaces with the exposed shaft on the non-drive end.
Use a suitable press to install drive-end body (14) onto the intermediate body while holding and pressing Tooling (K) using a C-clamp.
Install bolts (12) and washers (13). Tighten bolts (12) to a torque of 5 to 7 N·m (44 to 62 lb in).
Remove Tooling (K).
Check for proper alignment of discharge manifold (5) before tightening bolts (12). Tighten bolts (12) to a torque of 6 ± 1 N·m (53 ± 9 lb in).
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Illustration 21 g03411874
With the shaft on the non-drive end of the pump still being supported perform Steps 37 through 39.
Apply Tooling (G) onto the lip of lip seal (17).
Install lip seal (17) with the lip facing out.
Use Tooling (L) to install bearing (16).
Install cup plug (18) into drive end body (14).
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Illustration 22 g03123306
Install cap (29) into bearing housing (30).
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Illustration 23 g03147116
Apply Tooling (J) onto the threads of the shaft assembly.
Install drive gear (11), washer (10), and nut (9).
Use Tooling (A) to hold drive gear (11) and tighten nut (9) to a torque of 40 ± 5 N·m (30 ± 4 lb ft).
Check the rolling torque of the auxiliary water pump. The force required should be approximately 1 N·m (9 lb in).
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Illustration 24 g03120536
Install O-ring seals (8), discharge manifold (5), washers (7), and bolts (6).
Tighten bolts (6) to a torque of 24 N·m (212 lb in).
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Illustration 25 g03147157
Install O-ring seals (4), ball valve (3), O-ring seal (2), and plug (1).
Tighten plug (1) to a torque of 50 N·m (37 lb ft).