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21/1/2014 Water Pump

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008-062 Water Pump
Preparatory Steps
WARNING
Batteries can emit explosive gases. To
reduce the possibility of personal injury,
always ventilate the compartment
before servicing the batteries. To
reduce the possibility of arcing, remove
the negative (-) battery cable first and
attach the negative (-) battery cable last.
WARNING
Coolant is toxic. Keep away from
children and pets. If not reused, dispose
of in accordance with local
environmental regulations.
WARNING
A small amount of coolant can leak
when servicing the coolant filter with the
shutoff valve in the OFF position. To
reduce the possibility of personal injury,
avoid contact with hot coolant.
Disconnect the batteries. Refer to
the original equipment manufacturer
(OEM) service manual.
Drain the cooling system. Refer to
Procedure 008-018 in Section 8.
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Remove
Multiple Turbochargers
Remove the eight allen head capscrews
from the two free-end water pipes
connecting to the water pump .
Push the pipes upward and remove the o-
rings.
Remove the three allen head capscrews
from the lower pump flange.
Loosen and remove the allen head
capscrews that attach the pump to the
free-end housing.
Loosen but do not remove the two upper
capscrews.
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WARNING
This component or assembly weighs
greater than 23 kg [50 lb]. To prevent
serious personal injury, be sure to have
assistance or use appropriate lifting
equipment to lift this component or
assembly.
With an approved lifting device attached to
the pump , remove the two remaining allen
head capscrews (1).
Pull the pump straight forward, slightly, to
remove the spacers (2).
Remove the pump from the engine.
Take care not to allow the pump drive
gear to come into contact with the free-end
housing. Damage to the gear or housing
can occur.
Single Turbocharger
Remove the eight flanged allen head
capscrews from the two free-end water
pipes connecting to the water pump .
Loosen the hose clips and remove the
pipes.
Remove the eight flanged Allen head
capscrews that secure the high
temperature water pipe between the
water pump (1) and the oil cooler (2),
and remove the pipe.
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Loosen and disconnect the oil feed line (1)
to the water pump .
Loosen, but do not remove, the four
flanged allen head capscrews (2) that
secure the water pump to the free-end
casing.
WARNING
This component or assembly weighs
greater than 23 kg [50 lb]. To prevent
serious personal injury, be sure to have
assistance or use appropriate lifting
equipment to lift this component or
assembly.
With an approved lifting device attached to
the pump , remove the two remaining
capscrews.
Remove the pump from the engine.
Take care not to allow the pump drive
gear to come into contact with the free end
housing. Damage to the gear or housing
can occur.
Disassemble
Multiple Turbochargers
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Remove the seven allen head capscrews
and lock washers from the end cover.
Discard the lock washers.
Remove the end cover and o-ring.
Discard the o-ring.
Remove the five allen head capscrews and
locking plate from the pump end of the
shaft.
Remove the low temperature impeller.
NOTE: If the impeller does not loosen,
gently tap it to rotate it on the shaft.
Remove the two locking rings and discard.
Remove the shaft sleeve and seal
assembly.
Remove the rotating half of the mechanical
seal from the sleeve.
Discard the seal.
Remove the seven allen head capscrews
and lock washers that fasten the pump
housing to the gear housing.
Discard the lock washers.
NOTE: Cutouts have been cast into
the housings to allow the use of
levers.
Separate the pump housing from the
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drive housing.
Remove the fixed half of the mechanical
seal from the pump housing.
Discard the seal.
NOTE: If the impeller does not loosen,
gently tap it to rotate it on the shaft.
Remove the high temperature impeller and
four locking rings
Remove the seal spacer from the shaft.
Remove the rotating half of the mechanical
oil seal.
Discard the seal.
Remove the four allen head capscrews
and drive gear locking plate from the drive
end of the shaft.
Remove the drive gear and four locking
rings.
Discard the locking rings.
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Remove the beveled retaining ring from
the drive housing.
Remove the shaft assembly from the drive
housing.
Use appropriate tooling to remove the
bearings from the shaft.
Discard the bearings.
Remove the stationary portion of the
mechanical seal from the drive housing.
Remove the lip seal.
Discard the seals.
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Single Turbocharger
Remove the four allen head capscrews
that secure the end cover to the pump
body.
Remove the end cover and o-ring.
Discard the o-ring.
Remove the five allen head capscrews and
locking plate from the pump end of the
shaft.
Slide the low temperature impeller from the
shaft.
NOTE: If the impeller does not loosen,
gently tap the impeller to rotate the
impeller on the shaft.
Remove the sleeve, and use a small lever
to remove the rotating half of the
mechanical seal assembly.
Discard the seal.
Remove the five allen head capscrews that
fasten the pump housing to the gear
housing.
Separate the pump housing from the
drive housing.
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Discard the o-ring.
Remove the fixed half of the mechanical
seal from the pump housing.
Discard the seal.
Remove the high temperature impeller and
four locking rings.
NOTE: If the impeller does not loosen,
gently tap the impeller to rotate the
impeller on the shaft.
Remove the rotating half of the mechanical
seal from the shaft.
Discard the seal.
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Remove the nine allen head capscrews
and the pressure plate from the drive gear.
Remove the drive gear from the pump
shaft.
Remove the beveled retaining ring from
the drive housing.
Remove the shaft assembly from the drive
housing.
Use appropriate tooling to remove the
bearings from the shaft.
Discard the bearings.
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Remove the stationary portion of the
mechanical seal from the drive housing.
Remove the lip seal from the drive
housing.
Discard the seals.
Clean and Inspect for Reuse
WARNING
When using solvents, acids, or alkaline
materials for cleaning, follow the
manufacturer's recommendations for
use. Wear goggles and protective
clothing to reduce the possibility of
personal injury.
WARNING
Wear appropriate eye and face
protection when using compressed air.
Flying debris and dirt can cause
personal injury.
Clean the components with solvent.
Dry with compressed air.
Inspect the end cover, pump housing, and
drive housing for cracks and other
damage.
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Check the impellers for excessive pitting,
corrosion, and cracked or broken blades.
Inspect the shaft bore of the impellers for
excessive scoring.
Check the drive gear for cracked or broken
teeth.
Inspect the shaft bore of the gear for
excessive scoring.
Check the shaft for excessive pitting,
corrosion, scoring, and other damage.
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Assemble
Multiple Turbochargers
Press the new bearings onto the shaft.
Check to make sure they rotate freely after
installation.
Install a new lip seal into the bearing
housing.
Use clean engine oil to lightly lubricate the
shaft assembly and lip seal in the drive
housing.
Install the shaft assembly into the drive
housing.
Install the beveled retaining ring into the
drive housing.
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Check to be sure that the shaft turns freely.
Use clean engine oil to lubricate the drive
gear bore and locking rings.
NOTE: Check that the locking rings
are positioned as shown.
Install the drive gear, new locking rings,
and gear retainer onto the shaft until the
assembly makes contact with the bearing
inner race.
For water pump s installed with the
double-shoulder retaining flange, the flange
must be installed with the largest diameter
flange (1) towards the water pump drive
gear.
Apply Loctite 243 to the capscrew
threads.
Install the four capscrews and tighten in
a diametrically opposite pattern in three
stages.
Torque Value:
1. 5 n.m [44 in-lb]
2. 15 n.m [133 in-lb]
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3. 33 n.m [24 ft-lb]
For water pump s installed with the
single-shoulder retaining flange (1), the
flange must be installed with the shoulder
(1) towards the water pump drive gear.
Apply clean engine oil to the flange head
screws.
Do not apply Loctite to the capscrew.
Install the four flange head screws and
tighten in a diametrically opposite pattern
in three stages.
Torque Value:
1. 5 n.m [44 in-lb]
2. 10 n.m [89 in-lb]
3. 25 n.m [221 in-lb]
Use a soapy solution to wet the drive
housing seal bore and stationary half of the
mechanical seal.
Install the seal in the bore by pressing
evenly with finger pressure.
Wipe the face of the seal with a lint-free
cloth to remove any oil.
NOTE: Do not touch the seal face. If
contact is made, clean the seal with a
lint-free cloth to remove any oil.
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Use a soapy solution to wet the seal area
of the shaft.
Install the rotating half of the mechanical
seal onto the shaft.
Install the seal spacer.
Use clean engine oil to lubricate the shaft
and locking rings.
Install the high temperature impeller and
four new locking rings onto the shaft as
shown.
Use a soapy solution to wet the pump
housing seal bore and stationary half of the
mechanical seal.
Install the seal in the bore by pressing
evenly with fingers.
Wipe the face of the seal with a lint-free
cloth to remove any oil.
NOTE: Do not allow the seal face of
the mechanical seal to make contact
with the shaft. If contact is made, clean
the seal with a lint-free cloth to remove
any oil.
Install the o-ring onto the drive housing.
Install the pump housing onto the drive
housing.
Install the Allen head capscrews with new
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lock washers and tighten.
Torque Value: 22 n.m [195 in-lb]
Use a soapy solution to wet the seal area
of the shaft sleeve.
Install the rotating half of the mechanical
seal onto the shaft.
Install the shaft sleeve and seal assembly.
Use clean engine oil to lubricate the shaft
and impeller locking rings.
Install the low temperature impeller and two
new locking rings onto the shaft as shown.
Lubricate the threads of the five allen head
capscrews and install.
Tighten the capscrews in a criss-cross
pattern.
Torque Value: 17 n.m [150 in-lb]
Install a new end cover and new o-ring.
Install the seven allen head capscrews with
new lock washers and tighten.
Torque Value: 22 n.m [195 in-lb]
Single Turbocharger
Press the new bearings onto the shaft.
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Check to make sure they rotate freely after
installation.
Install a new lip seal into the bearing
housing.
Use clean engine oil to lightly lubricate the
shaft assembly and lip seal in the drive
housing.
Install the shaft assembly into the drive
housing.
Install the beveled retaining ring into the
drive housing.
Check to be sure the shaft turns freely.
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Use clean engine oil to lubricate the drive
gear bore and locking rings.
Install the drive gear, locking rings, and
gear retainer onto the shaft.
Position the gear on the shaft so that a
measurement of 103 mm [4.05 inch] is
obtained between the pump side of the
drive gear and the mounting face of the
drive housing of the pump .
Install the nine allen head capscrews and
tighten in the order shown.
NOTE: Repeat each step of the
tightening until each step torque value
is achieved on all capscrews.
Torque Value: 5 n.m [44 in-lb]
Check gear spacing.
Torque Value:
1. 10 n.m [89 in-lb]
2. 17 n.m [150 in-lb]
Use a soapy solution to wet the drive
housing seal bore and stationary half of the
mechanical seal.
Install the seal in the bore by pressing
evenly with finger pressure.
Wipe the face of the seal with a lint-free
cloth to remove any oil.
NOTE: Do not touch the seal face. If
contact is made, clean the seal with a
lint-free cloth to remove any oil.
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Use a soapy solution to wet the seal area
of the shaft.
Install the rotating half of the mechanical
seal onto the shaft.
Install the seal spacer.
Use clean engine oil to lubricate the shaft
and locking rings.
Install the high temperature impeller and
four new locking rings onto the shaft as
shown.
Use a soapy solution to wet the pump
housing seal bore and stationary half of the
mechanical seal.
Install the seal in the bore by pressing
evenly with finger pressure.
Wipe the face of the seal with a lint-free
cloth to remove any oil.
NOTE: Do not allow the seal face of
the mechanical seal to make contact
with the shaft. If contact is made, clean
the seal with a lint-free cloth to remove
any oil.
Install the o-ring onto the drive housing.
Install the pump housing onto the drive
housing.
Install the five allen head capscrews and
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tighten.
Torque Value: 14 n.m [124 in-lb]
Use a soapy solution to wet the seal area
of the shaft sleeve.
Install the rotating half of the mechanical
seal onto the shaft.
Install the shaft sleeve and seal assembly.
Use clean engine oil to lubricate the shaft
and impeller locking rings.
Install the low temperature impeller onto
the shaft.
Lubricate the threads and heads of the five
Allen head capscrews and install.
Tighten the capscrews in a criss-cross
pattern.
Torque Value: 17 n.m [150 in-lb]
Install a new end cover and new o-ring.
Install the four allen head capscrews and
tighten.
Torque Value: 14 n.m [124 in-lb]
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Install
Multiple Turbochargers
WARNING
The orifice must be installed prior to
installing the Gilkes pump . Failure to
do so will result in a decrease of oil
pressure and lubrication to the pump .
NOTE: The orifice installation is only
required when changing from a
Kolmeks Pump (old type) to the new
Gilkes Pump (present production).
Apply several drops of Loctite 270 to the
orifice, Part Number 4010851, and install it
in the water pump oil supply passage.
Install three new o-rings on the pump . Use
petroleum jelly on the o-rings to hold them
in place during installation.
WARNING
This component or assembly weighs
greater than 23 kg [50 lb]. To prevent
serious personal injury, be sure to have
assistance or use appropriate lifting
equipment to lift this component or
assembly.
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Install the pump onto the free end
housing. Install the spacers and the two top
allen head capscrews and hand tighten.
Install the remaining capscrews in the
pump and lower flange.
Tighten the mounting capscrews.
Torque Value: 80 n.m [59 ft-lb]
Install two new o-rings and lower the
water pipes to the flanges and install the
eight allen head capscrews.
Tighten the capscrews.
Torque Value: 80 n.m [59 ft-lb]
Single Turbocharger
WARNING
This component or assembly weighs
greater than 23 kg [50 lb]. To prevent
serious personal injury, be sure to have
assistance or use appropriate lifting
equipment to lift this component or
assembly.
Install the coolant pump onto the engine.
Take care not to allow the pump drive
gear to come into contact with the free end
housing. Damage to the gear or housing
can occur.
Use an approved lifting device to install the
coolant pump .
Install the four mounting flange head
capscrews. Hand-tighten only.
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Connect the oil feed line (1) to the water
pump and tighten.
Tighten the four coolant pump flange
head mounting capscrews (2).
Torque Value: 80 n.m [59 ft-lb]
Remove the STORM plug (1) from the side
of free end housing and use a dial
indicator tool to check the backlash
between the pump drive gear and the
crankshaft gear.
Crankshaft Gear Backlash
mm in
0.125 MIN 0.005
0.38 MAX 0.015
Install the high temperature water pipe
between the water pump (1) and the
lubricating oil cooler (2).
Install the eight flange head capscrews and
tighten.
Torque Value: 195 n.m [144 ft-lb]
Install the two free end water pipes to the
coolant pump .
Install and tighten the eight flange head
capscrews.
Torque Value: 195 n.m [144 ft-lb]
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Finishing Steps
WARNING
Batteries can emit explosive gases. To
reduce the possibility of personal injury,
always ventilate the compartment
before servicing the batteries. To
reduce the possibility of arcing, remove
the negative (-) battery cable first and
attach the negative (-) battery cable last.
Fill the high-temperature and low-
temperature cooling systems. Refer
to Procedure 008-018 in Section 8.
Connect the batteries. Refer to the
OEM service manual.
Operate the engine until normal
operating temperatures and
pressures are obtained and check
for leaks.
Last Modified: 18-Jan-2013
Copyright 2000-2010 Cummins Inc. All rights reserved.