COUNTERWEIGHT AS 4595021 - Caterpillar

Firing order (injection sequence) ... 1,5,3,6,2,4Injection timing before TC (top center):Direct Injection Engines with turbocharger ... 23 1°Direct Injection Engines without turbocharger ... 29 1°Torque for bolts that hold governor weight carrier to camshaft ... 10 2 lb. ft.(14 3 N m)Make a mark (stake) the governor weight cover in four places 90° apart directly over the groove in the camshaft.(1) Diameter of rear bearing surface (journal) of the camshaft (new) ... 2.3720 .0005 in.(60.249 0.013 mm) Bore in the rear bearing for the camshaft (new) ... 2.3750 .0005 in.(60.325 0.013 mm)Maximum permissible clearance between the bearing and the camshaft bearing surface (journal)(worn) ... .006 in.(0.15 mm)(2) Diameter of sleeve control shaft (new) ... .3530 .0003 in.(8.966 0.008 mm) Bore in the housing for the fuel control shaft (new) ... .3543 .0005 in.(8.999 0.013 mm)Maximum permissible clearance between the bore in the housing and the sleeve control shaft (worn) ... .003 in.(0.08 mm)(3) End play for camshaft with sleeve installed (new) ... .023 .018 in.(0.58 0.46 mm) When installing sleeve on end of camshaft, support the camshaft to prevent damage to parts inside of injection pump and governor housing.(4) Governor spring: Make reference to the chart "GOVERNOR SPRINGS."(5) Bypass valve: 4N605 Bypass Valve Spring:Length under test force ... .880 in.(22.35 mm)Test force ... 3.53 .18 lb.(15.7 0.8 N)Free length after test ... 1.73 in.(43.9 mm)Outside diameter ... .527 in.(13.39 mm)Pressure of fuel in housing for fuel injection pumps, (Full Load) ... 30 5 psi(205 35 kPa)(6) Diameter of front bearing surface (journal) of the camshaft (new) ... .9990 .0005 in.(25.375 0.013 mm) Bore in the front bearing for the camshaft (new) ... 1.0005 .0005 in.(25.413 0.013 mm)Maximum permissible clearance between the bearing and the camshaft bearing surface (journal) (worn) ... .002 in.(0.05 mm)
INSTALL SPRING AS SHOWN Install guide pin (A) to depth (B) [.642 .003 in. (16.31 0.08 mm)]. Slot in guide pin (A) must be in area shown from center of lifter. (7) Torque for bushing ... 70 5 lb. ft.(95 7 N m)(8) 9N5862 Spring for injection pump: Length under test force ... 1.38 in.(35.1 mm)Test force ... 12.5 1.4 lb.(56.7 6.6 N)Free length after test ... 1.61 in.(40.9 mm)Outside diameter ... .728 in.(18.49 mm)(9) Torque for bolts that hold sleeves on control shaft ... 24 2 lb. in.(2.8 0.2 N m) (10) Torque for the nuts that hold the fuel lines (use 5P144 Fuel Line Socket) ... 30 5 lb. ft.(40 7 N m) (11) Spring for the terminal shaft. Install the spring (11) for the terminal shaft so that the end of the spring is in the 30° range as shown.