CATERPILLAR AP-800C BARBER-GREENE BG-230 Asphalt Pavers 1PM00001-...

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Product:  ASPHALT PAVER

Model:  AP-800C ASPHALT PAVER 1PM
Configuration: CATERPILLAR AP-800C BARBER-GREENE BG-230 Asphalt
Pavers 1PM00001-UP (MACHINE) POWERED BY 3054 Engine

Disassembly and Assembly

3054 Engine for Caterpillar Built Machines
Media Number -SENR6241-13 Publication Date -01/08/2008 Date Updated -04/08/2008

  
i02046409

Fuel Injection Pump - Install - Type 2 Engines and 7BJ Engines

SMCS - 1251-012

Installation Procedure
Table 1

Required Tools    
Tool     Part Number     Part Description     Qty    
150-3992     Timing Pin (1)     1  
A  
150-3993 Timing Pin (2)     1  
171-1085
B   or Tamper Resistant Tool Gp     1    
173-9774    
( 1 ) Tooling (A) is required in order to install Bosch fuel injection pumps.
( 2 ) Tooling (A) is required in order to install Dephi (Lucas) and Stanadyne fuel injection pumps.

NOTICE
Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

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Illustration 1 g01059878
Typical example

1. Check the condition of O-ring seal (13) on fuel injection pump (12). If the seal is worn or damaged,
replace the seal.

2. Lightly lubricate O-ring seal (13) with clean engine oil. Install O-ring seal (13) on fuel injection pump
(12) .

NOTICE
The No. 1 cylinder must be at the top center position on the
compression stroke before the fuel injection pump is installed. If the
crankshaft needs to be rotated, the fuel injection pump must be
mounted temporarily or the loose gear could cause damage to the front
housing.

Illustration 2 g00808376
Typical example

3. Put fuel injection pump (12) in position on the engine. Ensure that the timing gear is aligned with the
hub of fuel injection pump (12). Install three flange nuts (11) and tighten the flange nuts to a torque of
28 N·m (21 lb ft).

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Illustration 3 g00808370
Typical example

4. Position gear (9) on the shaft of the fuel injection pump.

Note: Some fuel injection pumps are installed with tamper proof bolts. Tooling (B) may be necessary
in order to install the tamper proof bolts.

5. Put the timing gear plate in position and install four bolts (3). Tighten the four bolts finger tight.

Note: The fuel injection pump gear will only fit in one position. Install the gear with the letters "C"
and "M" facing away from the engine.

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Illustration 4 g00808245
Typical example

6. Loosen locking screw (2) (if equipped) until locking spacer (1) moves freely. Move locking spacer (1)
into position (A). Tighten locking screw (2) to a torque of 10 N·m (7 lb ft).

Note: The location of Tooling (A) for Bosch fuel injection pumps will be located toward the top of the
fuel injection pump. The location of Tooling (A) for Dephi (Lucas) and Stanadyne fuel injection
pumps will be located toward the bottom of the fuel injection pump.

7. Install Tooling (A) through hole (6) in the timing gear and hole (7) in the hub. Push Tooling (A) into
position in hole (8) in the fuel injection pump body. If Tooling (A) can be fully seated, the fuel
injection pump timing is correct. No resistance should be felt when the timing pin is inserted into hole
(8) of the fuel injection pump body.

NOTICE
The fuel injection pump may be supplied with the fuel injection pump
shaft in the locked position. The drive shaft of the fuel injection pump
must not be rotated without the spacer in position under the locking
screw. Damage to the drive shaft of the fuel injection pump will result.

8. When the timing plate is installed, rotate gear (9) by hand in a counterclockwise direction in order to
remove the backlash between gear (9) and the idler gear. Do not rotate the crankshaft or the fuel
injection pump shaft. Tighten bolts (3) to a torque of 28 N·m (21 lb ft).

9. Remove Tooling (A) from the fuel injection pump gear.

End By:

a. Install the fuel injection lines. Refer to Disassembly and Assembly, "Fuel Injection Lines - Remove
and Install".
b. Install the water pump. Refer to Disassembly and Assembly, "Water Pump - Install".

Copyright 1993 - 2013 Caterpillar Inc.

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