WIRING GP-UNIT INJECTOR 2389661 - Caterpillar

Measure the distance from the top of the surface plate to the top of Tooling (G). Record this dimension as Dimension (X). Measure the distance from the top of Tooling (G) to the top of retainer plate (25). Record this dimension as Dimension (W).
Table 2
CALCULATION
Subtract Dimension (W) from Dimension (X) to obtain Dimension (Y).
Dimension (Y) is the Lift Off Height. Note: The correct Lift Off height is 100.06 +0.00-0.20 mm (3.93936 +0.00-0.0079 inch) for standard machines. Call this height Dimension (Z).
Table 3
CALCULATION
Subtract Dimension (Y) from Dimension (Z) to obtain the thickness of shim (29) providing the correct Lift Off Height.
Illustration 31 g00875186
Install shim (29). Refer to Step 23.i for the correct size. Install spring assembly (28) in the correct sequence.
Illustration 32 g00875182
Install ball joint (26) on the shim and barrel assembly (27).
Illustration 33 g00875175
Install pistons (24) and retainer plate (25).
Illustration 34 g00875902
Wrap a piece of nylon string around the pistons, as shown.
Illustration 35 g00875903
Lower rotating assembly (23) into the pump. Use the nylon string to hold the assembly together during installation. Remove the nylon string.
Illustration 36 g00875056
Illustration 37 g00875132
Improper assembly of parts that are spring loaded can cause bodily injury.To prevent possible injury, follow the established assembly procedure and wear protective equipment.
Install O-ring seal (21) to compensator valve (22).
Install piston (17) to head (7).
Install retainer (18) to compensator valve (22). Install spring (19) to compensator valve (22). Install retainer (20) to compensator valve (22).
Install compensator valve (22) to head (7).
Install O-ring seal (16) to test port (15). Install test port (15) to head (7).
Install O-ring seal (14) to relief valve (13). Install relief valve (13) to head (7).
Install O-ring seal (12) to head (7).
Illustration 38 g00875055
Install port plate (11) to head (7).
Install O-ring seal (9) to head (7).
Illustration 39 g00875035
Install coupler (9).
Install head (7) to housing (4).
Install bolts (8) to head (7).
Illustration 40 g00895998
Install flange (6) to housing (4).
Install bolts (5) to flange (6).
Illustration 41 g00895996
Install servo valve (1) to housing (4).
Install bolts (2) and (3) to servo valve (1).End By:
Install the piston pump.