938H Wheel Loader LKM00001-UP (MACHINE) POWERED BY C6.6 Engine(SEBP46...

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Welcome: m620oby

Product: WHEEL LOADER

Model: 938H WHEEL LOADER LKM00345
Configuration: 938H Wheel Loader LKM00001-UP (MACHINE) POWERED BY C6.6 Engine

Disassembly and Assembly

C6.6 Engines for Caterpillar Built Machines
Media Number -KENR6081-15 Publication Date -01/03/2014 Date Updated -04/03/2014

i04994249

Fuel Injection Pump - Install

SMCS - 1251-012

Installation Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A (1) 9U-6198 Crankshaft Turning Tool 1

9U-7336 Housing As 1
A (2)
5P-7305 Engine Turning Tool 1
B 230-6284 Timing Pin (Camshaft) 1
136-4632 Timing Pin (Crankshaft) 1
C
268-1966 Adapter 1
Timing Tool
E 338-1054 1
(Fuel Injection Pump)
F 1U-6396 O-Ring Assembly Compound -
(1)
Install Tooling to the front pulley.

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(2)
Install Tooling into the aperture for the electric starting motor.

Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.

NOTICE

Ensure that all adjustments and repairs that are carried out to the fuel
system are performed by authorized personnel that have the correct
training.

Before beginning ANY work on the fuel system, refer to Operation and
Maintenance Manual, "General Hazard Information and High
Pressure Fuel Lines" for safety information.

Refer to System Operation, Testing and Adjusting, "Cleanliness of

Fuel System Components" for detailed information on the standards of
cleanliness that must be observed during ALL work on the fuel system.

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Illustration 1 g01572496

Typical example

Note: A new fuel injection pump is supplied, locked in the correct position. Do not unlock
the fuel injection pump before installation.

1. If the fuel injection pump timing has been lost, it is possible to reset the fuel injection pump
timing. Follow Step 1.a through Step 1.e in order to reset the fuel injection pump timing.

a. Loosen locking screw (22) and slide spacer (21) to Position (AA) . Tighten locking
screw (22) to a torque of 9 N·m (80 lb in). Placing the spacer into Position (AA) will
prevent the locking screw from tightening against the shaft of the fuel injection pump.

The fuel injection pump is now unlocked.

b. Position Tooling (E) onto the shaft of fuel injection pump (1) . Align the lever of
Tooling (E) with Keyway (Y) and engage the lever into the keyway.

Note: The lever of Tooling (E) should be a close fit in the keyway. If the lever is a loose
fit in the keyway, It is not possible to reset the fuel injection pump timing.

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c. Rotate the shaft of the fuel injection pump and engage the pin of Tooling (E) into Hole
(Z) .

The fuel injection pump timing is now set in the correct position.

d. Loosen locking screw (22) and slide spacer (21) to Position (BB) . Tighten locking
screw (22) to a torque of 9 N·m (80 lb in). The locking screw is now tightened against
the shaft of the fuel injection pump.

The fuel injection pump is now locked.

e. Remove Tooling (E) .

Illustration 2 g03172736

2. Inspect Bore (X) in front housing (20) for damage. If the bore is damaged, replace the front
housing. Refer to Disassembly and Assembly, "Housing (Front) - Remove" and Disassembly
and Assembly, "Housing (Front) - Install".

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3. Use Tooling (F) to lubricate a new O-ring seal (17) . Install the O-ring seal onto fuel injection
pump (1) .

4. Align fuel injection pump (1) with front housing (20) . Carefully install the fuel injection pump
to the front housing.

Note: The fuel injection pump should be supported by hand until the bolts are installed.

5. Install bolts (18) and new sealing washers (19) . Tighten the bolts to a torque of 25 N·m (18 lb
ft).

Note: One sealing washers should be installed to each bolt.

6. If necessary, use Tooling (A) in order to rotate the crankshaft so that number one piston is at
top dead center on the compression stroke. Refer to System Operation, Testing and Adjusting,
"Finding Top Center Position for No.1 Piston".

7. Use Tooling (B) in order to lock the camshaft in the correct position. Use Tooling (C) in order
to lock the crankshaft in the correct position. Refer to Disassembly and Assembly, "Gear
Group (Front) - Remove" for the correct procedure.

8. Install the fuel injection pump gear to the fuel injection pump. Refer to Disassembly and
Assembly, "Fuel Injection Pump Gear - Install" and refer to Disassembly and Assembly, "Gear
Group (Front) - Install".

Note: Ensure that the fuel injection pump is unlocked after the installation of fuel injection
pump gear is completed.

9. Install the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and
Install".

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Illustration 3 g01563333

Typical example

10. Position support bracket (14) onto the fuel injection pump. Install bolts (15) finger tight. Install
bolts (16) finger tight.

11. Tighten bolts (15) to a torque of 22 N·m (16 lb ft). Tighten bolts (16) to a torque of 22 N·m (16
lb ft).

If the support bracket is secured by an M10 bolt, tighten the bolt to a torque of 44 N·m (32.5 lb
ft).

Note: Ensure that the fuel injection pump is not stressed as the bolts are tightened.

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Illustration 4 g01563276

Typical example

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Illustration 5 g01563275

Typical example

12. Install the banjo bolt and new sealing washers to tube assembly (8) . Install tube assembly (8)
for the oil feed to the fuel injection pump. Tighten the banjo bolt and the nut to a torque of 15
N·m (11 lb ft).

13. Install a new fuel injection line (5) . Refer to Disassembly and Assembly, "Fuel Injection Lines
- Install".

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14. Install new sealing washers (12) and banjo bolt (13) to tube assembly (11) . Install tube
assembly (11) . Tighten the banjo bolt to a torque of 21 N·m (15 lb ft).

15. Connect tube assembly (4) to fuel injection pump (1) .

16. Connect plastic tube assembly (9) to fuel injection pump (1) .

17. Connect plastic tube assembly (10) from fuel injection pump (1) .

18. Connect harness assembly (6) to solenoid (3) . Connect harness assembly (6) to position sensor
(7) . Slide the locking tab into the locked position.

19. Connect plastic tube assembly (2) to fuel injection pump (1) .

20. If necessary, install the fuel priming pump. Refer to Disassembly and Assembly, "Fuel
Priming Pump - Remove and Install".

21. If necessary, install the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter Base
- Remove and Install".

22. Turn the battery disconnect switch to the ON position.

23. Turn the fuel supply to the ON position.

24. Remove the air from the fuel system. Refer to Operation and Maintenance Manual, "Fuel
System - Prime" for more information.

Copyright 1993 - 2015 Caterpillar Inc. Mon Jan 12 13:52:34 UTC+0200 2015
All Rights Reserved. m620oby
Private Network For SIS Licensees.

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Previous Screen

Welcome: m620oby

Product: WHEEL LOADER

Model: 938H WHEEL LOADER LKM00345
Configuration: 938H Wheel Loader LKM00001-UP (MACHINE) POWERED BY C6.6 Engine

Disassembly and Assembly

C6.6 Engines for Caterpillar Built Machines
Media Number -KENR6081-15 Publication Date -01/03/2014 Date Updated -04/03/2014

i03083621

Fuel Injection Pump - Remove

SMCS - 1251-011

Removal Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A (1) 9U-6198 Crankshaft Turning Tool 1

9U-7336 Housing 1
A (2)
5P-7305 Engine Turning Tool 1
B 230-6284 Timing Pin (Camshaft) 1
136-4632 Timing Pin (Crankshaft) 1
C
268-1966 Adapter 1
D 278-4138 Cap Kit 1
(1)
Install Tooling to the front pulley.
(2)
Install Tooling into the aperture for the electric starting motor.

Start By:

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A. Remove the front cover. Refer to Disassembly and Assembly, "Front Cover - Remove and
Install".

Note: Either Tooling (A) can be used. Use the Tooling that is most suitable.

Contact with high pressure fuel may cause fluid penetration and burn
hazards. High pressure fuel spray may cause a fire hazard. Failure to
follow these inspection, maintenance and service instructions may cause
personal injury or death.

NOTICE

Ensure that all adjustments and repairs that are carried out to the fuel
system are performed by authorised personnel that have the correct
training.

Before begining ANY work on the fuel system, refer to Operation and
Maintenance Manual, "General Hazard Information and High
Pressure Fuel Lines" for safety information.

Refer to Systems Operation, Testing and Adjusting Manual,

"Cleanliness of Fuel System Components" for detailed information on
the standards of cleanliness that must be observed during ALL work
on the fuel system.

NOTICE

Care must be taken to ensure that fluids are contained during

performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.

Dispose of all fluids according to local regulations and mandates.

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Note: Put identification marks on all hoses, on all hose assemblies, on wires and on all tube
assemblies for installation purposes. Plug all hose assemblies and tube assemblies. This helps to
prevent fluid loss and this helps to keep contaminants from entering the system.

1. Turn the fuel supply to the OFF position.

2. Turn the battery disconnect switch to the OFF position.

3. If necessary, remove the fuel filter base. Refer to Disassembly and Assembly, "Fuel Filter
Base - Remove and Install".

4. If necessary, remove the fuel priming pump. Refer to Disassembly and Assembly, "Fuel
Priming Pump - Remove".

5. Use Tooling (A) in order to rotate the crankshaft so that number one piston is at top dead
center on the compression stroke. Refer to System Operation, Testing and Adjusting, "Finding
Top Centre Position for No.1 Piston".

6. Use Tooling (B) in order to lock the camshaft in the correct position. Use Tooling (C) in order
to lock the crankshaft in the correct position. Refer to Disassembly and Assembly, "Gear
Group (Front) - Remove" for the correct procedure.

7. Remove the backlash from the fuel pump gear. Lock the fuel injection pump in the correct
position and remove the fuel pump gear. Refer to Disassembly and Assembly, "Fuel Pump
Gear - Remove and Install" for the correct procedure.

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Illustration 1 g01563275

Typical example

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Illustration 2 g01563276

Typical example

8. Disconnect plastic tube assembly (2) from fuel injection pump (1) .

9. Disconnect harness assembly (6) from solenoid (3) . Slide the locking tab into the unlocked
position and disconnect harness assembly (6) from position sensor (7) .

Note: The harness assembly should be positioned in order to avoid an obstruction to the fuel
injection pump.

10. Disconnect plastic tube assembly (10) from fuel injection pump (1) .

11. Disconnect plastic tube assembly (9) from fuel injection pump (1) .

12. Disconnect tube assembly (4) from fuel injection pump (1) .

13. Remove banjo bolt (13) and remove sealing washers (12) . Remove tube assembly (11) .

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Note: In order to drain the fuel from the cylinder head, first disconnect tube assembly (11) at
the fuel injection pump.

14. Plug or cap all open ports and tube assemblies immediately with new plugs or caps.

Note: Ensure that quick fit connections are clean before the tube assemblies are plugged.

15. Remove fuel injection line (5) . Refer to Disassembly and Assembly, "Fuel Injection Lines -
Remove". Use Tooling (D) in order to plug the open ports in the fuel injection pump and in the
fuel manifold. Discard the fuel injection line.

16. Remove tube assembly (8) for the engine oil supply to the fuel injection pump. Remove the
banjo bolt and the sealing washers from the tube assembly.

Illustration 3 g01563333

Typical example

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17. Remove bolts (15) and remove bolts (16) . Remove support bracket (14) .

Illustration 4 g01563853

Typical example

18. Remove bolts (18) and remove sealing washers (19) .

Note: The fuel injection pump should be supported by hand as the bolts are removed.

19. Carefully remove fuel injection pump (1) from front housing (20) . Ensure that bore (X) in the
front housing is not damaged as the fuel injection pump is removed.

20. Remove O-ring seal (17) from fuel injection pump (1) .

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Copyright 1993 - 2015 Caterpillar Inc. Mon Jan 12 13:55:00 UTC+0200 2015
All Rights Reserved. m620oby
Private Network For SIS Licensees.

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