PLUNGER AS 4P9830 - Caterpillar

Illustration 1 g01394088
(1) O-ring seal ... Lubricate the bore lightly with the lubricant that is being sealed. (2) Minimum assembled backlash for pinion assembly ... 0.02 mm (0.001 inch) (3) Press the pump drive gear so that the gear is flush with the shoulder of the pinion assembly. (4) Minimum assembled backlash for bevel gear ... 0.02 mm (0.001 inch)
Illustration 2 g01394146
View B-B (5) Fuel injection pump (6) 8N-1415 Spring Length under test force ... 8.69 mm (0.342 inch) Test force ... 111.21 6.45 N (25 1.5 lb) Free length after test ... 12.12 mm (0.477 inch) Outside diameter ... 9.78 mm (0.385 inch) (7) 7N-1208 Spring Length under test force ... 29.26 mm (1.152 inch) Test force ... 325 16.5 N (73.00 3.65 lb) Free length after test ... 48.03 mm (1.891 inch) Outside diameter ... 25.27 mm (0.995 inch) (C) Thickness of spacers 9N-6496 Spacer ... 4.115 0.013 mm (0.1620 0.0005 inch) 9N-6495 Spacer ... 4.216 0.013 mm (0.1660 0.0005 inch) 5M-2697 Spacer ... 4.318 0.013 mm (0.1700 0.0005 inch) 2M-4208 Spacer ... 4.420 0.013 mm (0.1740 0.0005 inch) 2M-4209 Spacer ... 4.521 0.013 mm (0.1780 0.0005 inch) 2M-4210 Spacer ... 4.623 0.013 mm (0.1820 0.0005 inch) 2M-4211 Spacer ... 4.724 0.013 mm (0.1860 0.0005 inch) 2M-4212 Spacer ... 4.826 0.013 mm (0.1900 0.0005 inch) 5M-2691 Spacer ... 4.928 0.013 mm (0.1940 0.0005 inch) 5S-7189 Spacer ... 5.029 0.013 mm (0.1980 0.0005 inch) (D) Dimensions for the fuel injection pump plunger Length of a new fuel injection pump plunger ... 69.118 0.013 mm (2.7212 0.0005 inch) Minimum length of a fuel injection pump plunger that may be reused ... 69.079 mm (2.7196 inch) (E) Dimensions for the fuel rack Diameter of a new fuel rack ... 12.662 0.005 mm (0.4985 0.0002 inch) Bearing bore in the front of the pump housing after installation of the bearing ... 12.758 0.038 mm (0.5023 0.0015 inch) Bore in the rear of a new pump housing ... 12.758 0.046 mm (0.5023 0.0018 inch) Maximum clearance between a fuel rack and bearings that are worn ... 0.18 mm (0.007 inch) (F) Camshaft bearing journals Bore in the camshaft bearing after installation into the fuel pump housing ... 53.988 0.038 mm (2.1255 0.0015 inch) Diameter of the camshaft bearing journals ... 53.899 0.013 mm (2.1220 0.0005 inch) Maximum clearance between a camshaft and bearings that are worn ... 0.25 mm (0.010 inch)
Illustration 3 g01394217
Note: Install the correct spacer thickness (G) in order to obtain the necessary timing dimension (H) . (8) Use the 5P-4158 Gauge (Fuel Injection Timing) to measure the timing dimension. Timing dimension with the pump on the engine ... 106.487 0.051 mm (4.1924 0.0020 inch) Timing dimension for bench test ... 110.335 0.013 mm (4.3439 0.0005 inch)