834B TRACTOR / POWER SHIFT / 92Z00001-UP (MACHINE) POWERED BY 34...

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Shutdown SIS

Previous Screen

Product: WHEEL DOZER

Model: 834B WHEEL DOZER 92Z
Configuration: 834B TRACTOR / POWER SHIFT / 92Z00001-UP (MACHINE) POWERED BY 3408 ENGINE

Disassembly and Assembly

3408 VEHICULAR ENGINE FOR 834B WHEEL TRACTOR AND 836 LANDFIL
Media Number -SENR2604-01 Publication Date -01/08/2003 Date Updated -22/11/2010

SENR26040026

Fuel Injection Pump Housing

SMCS - 1235-16; 1253-15

Disassemble Fuel Injection Pump Housing

START BY:

a) remove fuel injection pump housing and governor

b) remove governor

NOTICE

Be careful not to cause damage to the inlet and outlet ports on the
bottom of the pump housing. The pump housing must be put on wood
blocks before it is disassembled.

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1. Remove bolts (3) and adapter (2) from fuel injection housing (1).

2. Remove two bolts (4) and remove cover (5).

3. Remove bolts (9) that hold retainer (7) and gear (6) to the fuel injection pump camshaft.
Remove the retainer and gear.

4. Remove idler gear (10). Remove drive gear (11) and pinion shaft (8). Use a soft hammer to
push the pinion shaft (8) out of drive gear (11).

NOTE: When pinion gear (8) is removed, make a replacement of gear (11) with a new part.

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5. Remove protective caps (14), felt washers (13) and plug (12).

6. Install tool (A) in the hole with the large diameter end without the taper down. Move the
governor control to the "ON" position until the rack stops against tool (A). The racks are now in
center (zero) position. Hold the rack against tool (A) and carefully remove each fuel injection
pump (15) with tools (B) and (C).

NOTICE

When injection pumps, spacers and lifters are removed from the
injection pump housing, keep the parts of each pump together so they
can be installed back in their original location.

7. Remove bracket assembly (16) and link (17).

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8. Put identification on fuel racks (18) and (19) and remove the fuel racks.

9. Put identification on each spacer (20) and lifter (21) so they can be installed in their original
position.

10. Remove fuel injection pump camshaft (22) from the pump housing.

11. Remove O-ring seal (23).

12. Inspect link pivot shaft (24) and bracket locating dowel (25). Make a replacement by removal
of shaft (24) and dowel (25) with tool (D).

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13. Inspect upper bearing (26) and the lower bearing that hold the pinion gear in the pump
housing.

14. Make a replacement of bearings (26) if necessary.

15. Inspect idler gear shaft (27). If replacement is necessary, remove with tooling (D).

16. Inspect fuel rack bearings (28) and camshaft bearings (29). If replacement is necessary,
remove bearings (28) and (29).

17. Use tool group (E) to remove bearing (29).

18. Remove regulator valve (30).

19. Remove pin (31) to disassemble regulator valve and inspect the components.

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20. Piston (32) must move freely in valve body (30).

21. Make reference to the SPECIFICATIONS for spring (34).

22. Make a replacement of O-ring seals (33).

Assemble Fuel Injection Pump Housing

1. Install spring (4), piston (1) and pin (2) in valve body (3).

NOTICE

Pin (2) must not extend out of either side of valve body (3).

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2. Put clean engine oil on the valve body and O-ring seals (5). Install the oil bypass valve in the
pump housing. Tighten the bypass valve body to a torque of 70 ± 14 N·m (50 ± 10 lb.ft.).

3. Install the camshaft front and rear bearings with tool group (A). Install the front bearing until it
is a distance of 1.0 ± 0.5 mm (.04 ± .02 in.) from the front surface of the pump housing. Install the
rear bearing until it is 4.8 ± 0.5 mm (.19 ± .02 in.) from the rear surface of the pump housing.
Make sure both oil holes in bearing are in alignment with the oil holes in the pump housing.

4. Put tool (B) in on the fuel pump housing with the dowels of tool (B) in alignment with the left
fuel rack bore. Install the bolt that holds the tool in place on the housing.

5. Put new bearings in position with the tab of the bearings up. The bearing tabs must be within
0.05 mm (.002 in.) of a line through the center of the bearing inside diameter and parallel to the
vertical centerline of the fuel injection housing.

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6. Install the bearing with tool (C) until the shoulder of tool (C) makes contact with tool (B).

7. Turn tool (B) and make an alignment of the dowels on tool (B) with the right fuel rack bore.

8. Do Step (7) again for the left fuel rack bearing.

9. Install shaft (6) to a height of 16.8 ± 0.5 mm (.66 ± .02 in.).

10. Make sure the chamfer on the lower bearing for the pinion gear is toward the inside and the
notch is in the location shown. Install the bearing until it is even (flush) to 0.15 mm (.006 in.)
below the lower surface of the bearing bore with tooling (D).

11. Make sure the chamfer on the upper bearing for the pinion gear is toward the inside and the
notch is in the location shown. Use tooling (D) to install the bearing until it is even (flush) to 0.15
mm (.006 in.) below the upper surface of the bearing bore.

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12. Install link pivot shaft (7) to a dimension of 12.19 ± .025 mm (.480 ± .010 in.) above the
finished surface of the pump housing.

13. Install bracket assembly locating dowel (8) to a dimension of 4.78 ± 0.25 mm (.188 ± 0.10 in.)
above the finished surface of the pump housing.

14. Install pinion gear in the pump housing. Put the drive gear in position on pinion gear shaft and
install cover. Install tool (E) and "C" clamp as shown and install pinion gear (9) until drive gear
makes contact with the shoulder of the pinion gear shaft.

15. Remove cover (10) and remove any metal chips or shavings that might have been caused when
the drive gear was installed on the pinion shaft.

16. Install idler gear (11) on the shaft.

17. Install cover (10) and the two bolts that hold it in place.

NOTE: Turn the pump shaft while the bolts are tightened. The pump shaft must turn freely after
the bolts are tightened.

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18. Put clean engine oil on the camshaft bearings and camshaft (12). Install the camshaft in the
pump housing.

19. Install new O-ring seal (13).

20. Install camshaft gear (14) and retainer (15) on the camshaft.

21. Install lifters (16) in their respective bores.

22. Install spacers (17) in their respective bores.

NOTE: If new lifters and/or spacers are installed, make an adjustment to the fuel pump timing
dimension. See SETTING THE INJECTION PUMP TIMING DIMENSION OFF ENGINE in
TESTING AND ADJUSTING.

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23. Put clean engine oil on th fuel racks. Install left fuel rack (18) and right fuel rack (19) in the
pump housing with the groove in the racks engaged with the tab of the rack bearings.

24. Put link (20) in position over the dowel and into the notch in each fuel rack.

25. Install bracket assembly (21).

26. Install gasket and adapter (22) on the fuel injection pump housing.

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Typical Example

27. Install tooling (F) in the end housing as shown to check the rack movement (travel) after each
fuel injection pump is installed.

28. Install tool (G) in the fuel injection pump housing to hold the fuel racks in the center (zero)
position.

29. Turn the camshaft until the respective lobe is at its lowest point.

Typical Example

30. Install tool (H) on fuel injection pump, as shown. Put the groove in the barrel in alignment
with the space in the gear segment.

NOTE: Make sure the racks are held against tool (G) to put the racks in center (zero) position
when the fuel injection pumps are installed.

31. Put the fuel injection pump straight down into the pump housing bore with space in the gear
segment engaged with pin in the lifter and groove in the barrel engaged with dowel in the pump
housing.

Typical Example

32. Put a small amount of diesel fuel on seal (23). Install seal (23) and bushing (24) in the pump
housing bore. If the injection pump is in the correct position, bushing (24) will turn into the thread

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of the pump housing with the fingers until it is even with the pump housing with tool (J). Tighten
the bushings to a torque of 205 ± 14 N·m (150 ± 10 lb.ft.).

Typical Example

33. Install felt washer (26) and 5F2807 Cap (25).

34. Remove tool (G) and check the movement (travel) after the injection pump has been installed.
The total amount of rack travel is approximately 20.32 mm (.800 in.). If the injection pump is
installed wrong, fuel rack movement (travel) will be less than 20.32 mm (.800 in.). For more
detail, see Fuel Rack Travel.

35. Do Steps (28) through (33) again for each of the other fuel injection pumps.

END BY:

a) install governor

b) install fuel injection pump housing and governor

Copyright 1993 - 2019 Caterpillar Inc. Wed Sep 25 04:43:09 UTC+0200 2019
All Rights Reserved.
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