Disassembly, Assembly, and Installation of the Oil Heater Pumps and Seals for Certain 3600 and C280 Engines{1333} Caterpillar

Engine:

3612 (S/N: 9RC1-UP)

3616 (S/N: 1PD1-UP)

C280-16 (S/N: NKB1-UP; TDX1-UP)

Marine Engine:

C280-12 (S/N: TSJ1-UP; RDW1-UP)

Introduction

Do not perform any part of this procedure until you have read and understand the information. This procedure covers the disassembly, assembly, and installation of the oil heater pump and seal.

Identify the Pump

Identify the pump by measuring the inlet or outlet port of the pump.

The following pumps have 1 inch inlet and outlet ports :

• 304-4382

• 445-1356

The following oil heater pumps have 1.5 inch inlet and outlet ports :

• 197-2033

• 218-0248

• 445-1354

• 445-1355

Illustration 1	g03464299
(1) Inlet port of the pump (2) Pressure relief valve

Orientation of the pump is of importance. The pressure relief valve should be pointed toward the inlet side of the pump. Note the motor rotation relative to the pump intake as shown in Illustration 1. The seal, shaft, and seal bore are independent of pump rotation, however the pump must be reassembled in correct orientation.

Oil Heater Pump Seal Parts

The oil heater pumps have similar designs. The shaft that couples the pump to the motor has the same outside diameter of 1 7/16 inches, regardless of pump model. Each pump uses the same replacement seals, the difference is orientation from which the seals are installed and removed.

Illustration 2	g03464500
304-4385 Seal As 445-1356 Oil Pump (1) Pump housing seal (2) Pump rotor

Illustration 2 shows the location where seals are removed and installed from the C-face motor mounting adapter flange.

Illustration 3	g03464531
197-2033 Oil Pump As 218-0248 Oil Pump As 445-1354 Oil Pump 445-1355 Oil Pump (3) Pump housing seal (4) Pump rotor

Illustration 3 shows the location where seals are removed and installed from inside the pump cavity.

Disassembly of the Pump

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

Removal and Disassembly of the Pump

1. Remove the pump from the motor.

   1. Remove the four cap screws and use three as jackscrews in the threaded holes of the pump from the motor shaft.

      Note: If the pump has a valve, the valve must be removed first to have room for the jackscrews.

2. Remove the pump head.

   1. Mark the head and casing before disassembly to make sure that the parts are reassembled correctly.

   2. The idler pin, which is offset in the pump head, must be aligned to allow for the flow of liquid through the pump.

      Note: The idler pin should be of equal distance between the port connections.

   3. If disassembly is necessary to inspect the pump, remove the head cap screws first. And remove the head by tapping lightly to remove the lugs.

3. Remove the head gaskets.

   Note: If a new set of gaskets is not available, the original gaskets can be reused if undamaged.

4. Remove the idler bushing from the idler pin.

   Note: If the idler pin is worn, then replace the head, idler pin, and idler bushing. If the idler bushing is worn, replace with a new bushing.

   1. If the new bushing is carbon graphite, special care must be taken while pressing the bushing into the idler. An arbor press must be used and the bushing must be straight.

      Note: Do not stop the pressing operation until the bushing is in the proper location. Carbon graphite is brittle. Starting and stopping during the pressing operation may result in cracking. Cracking will cause disintegration of the part.

5. Remove the rotor from the casing.

   1. The rotor can be removed by pressing the end of the hollow drive end, unless there is a mechanical seal. The spring and rotary member of the mechanical seal will come out with the rotor on the following pumps.
      • 197-2033 Oil Pump As

      • 218-0248 Oil Pump As

      • 445-1354 Oil Pump

      • 445-1355 Oil Pump

   2. Models with mechanical seals will need an arbor press with an arbor of 34.93 mm (1.375 inch) to press out the seal. The seal will remain in the casing.

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Illustration 4	g03467238
(1) Retaining snap ring

6. Remove the mechanical seal or lip seal.

   1. Remove the snap ring (1) in the casing and the complete seal can be removed from the flange end.

   2. Remove the spring and rotary member from the rotor, seal seat and/or lip seals from the pump end of the casing.

Oil Heater Pump Seal Replacement Procedure

If the seal for the oil heater pump is leaking, replace with a new seal. The procedure that follows is for replacing the seal.

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Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Place a Do Not Operate tag at the Start/Stop switch location to inform personnel that the equipment is being worked on.

1. Lock out the system at the service panel.

2. Identify the pump liquid. Read and understand the MSDS for the liquid identified. Take appropriate precautions necessary to handle the liquid safely and avoid hazardous exposure to the liquid. The liquid may be hot. Hot liquid can burn and scald.

3. Before opening any pump liquid chamber, relieve the pressure in the system. Completely vent the suction lines, discharge lines, and other appropriate openings or connections. Isolate and drain the fluid from the intake lines and heater tank.

4. Remove the plumbing from the pump. Be careful of fluid exposure and contact.

5. Unbolt and slide the pump from the motor shaft. Use jackscrews if needed then remove the pump.

6. Identify the pump model. If the pump has a lip seal, the pump is one of the following model numbers.
   • 445-1354 Oil Pump

   • 445-1355 Oil Pump

   • 445-1356 Oil Pump

   If the pump has a mechanical seal, the pump is one of the following model numbers.

   • 197-2033 Oil Pump As

   • 218-0248 Oil Pump As

   • 304-4382 Oil Pump

7. Disassemble and remove the pump.

8. Remove the seals from the pump.

   Note: The 304-4382 Oil Pump has a snap ring that must be removed before removing the seals.

9. If the pump previously had lip seals, inspect the shaft for grooves. If grooves are found in the shaft, replace the pump. If the shaft is not grooved, then only a 445-1357 Seal is required.

   Note: Mechanical seals are less likely to cause shaft damage.

10. Install the new seal into the pump housing using the following procedure.

    1. Press the seal into the housing with the seal spring facing the pump rotor.

    2. Use an arbor press of 55.58 mm (2.188 inch) in diameter to press the seal in the casing. Press the seal as far into the casing as possible, except with the 304-4382 Oil Pump .

       The 304-4382 Oil Pump has a small lip inside the housing bore that the seal stops against. If pressed too hard, the seal casing will deform and the seal will need to be replaced.

11. Lightly lubricate the seal lips with clean engine oil.

12. Install the pump rotor into the pump housing. Turn the shaft back and forth when installing, taking care not to fold the lip of the seal under.

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Illustration 5	g03465006
(1) Socket screw

13. Assemble the remainder of the pump. Note the pump orientation. The pressure relief points toward the intake side of the pump.

14. The socket screw (1) shown in Illustration 5 must be removed on the pump intake side. This hole lubricates the seal while the pump operates.

15. The clearance between the pump rotor and housing machined surface must fall in a specific tolerance.

    Note: The seal kits include two gasket kits for each style of pump. Choose the gaskets that best fit the pump. The clearance is attained by trial and error with the gaskets from both kits.

    1. The clearance should be between 0.08 mm (0.003 inch) and 0.13 mm (0.005 inch). Use a 0.13 mm (0.005 inch) feeler gauge to measure the gap.

    2. Install gaskets until the rotor clearance is 0.13 mm (0.005 inch) with the pump head bolts hand tight.

    3. Replace the 0.13 mm (0.005 inch) feeler gauge with a 0.08 mm (0.003 inch) feeler gauge.

    4. Check for resistance while applying final tightening to the head screws. The 0.08 mm (0.003 inch) feeler gauge should slide freely after the head screws are tightened.

16. Install the pump back on the motor. Install the fittings and fasteners back on the motor.

17. Refill the pump and tank with oil.

18. Purge the air from the tank and pump prior to operation. If the tank has an air pocket, then element damage and failure can occur. Air can be bled by loosening hose connections until all air is evacuated.

Assembly of the Pump

The following procedure covers the assembly of the pump. Clean all parts thoroughly and replace parts that show signs of excessive wear or damage.

Assembly of the 304-4382 Oil Pump and 445-1356 Oil Pump

Illustration 6	g03468507
Exploded view of 304-4382 Oil Pump or 445-1357 Seal (1) Key for motor shaft (2) Snap ring (mechanical seal only) (3) 304-4385 Seal As (4) 445-1357 Seal (5) Casing (6) Cap screws (7) Relief valve or cover plate gasket (8) Relief valve (9) Relief valve or cover plate cap screw (10) Pipe plug (11) Machine screw (12) Rotor (13) Idler (14) Idler bushings (15) Head gasket (16) Idler pin (17) Head (18) Head cap screws

Illustration 7	g03468508
Cross section view of 304-4382 Oil Pump or 445-1357 Seal (19) Idler (20) Mounting flange (21) Crescent (22) Head (23) Rotor (24) Lip seal

1. Install the lip seals.

   1. Install the lip seals one at a time in the casing from the large flange end. The sealing lips must face away from each other.

   2. Use an arbor press with an arbor of 55.58 mm (2.188 inch) diameter and press the seals as far as possible. Refer to Illustration 7 for a cross section view of the lip seal.

2. Install the rotor.

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   NOTICE
   Turn the rotor back and forth while pushing through the lip seal to the bottom of the casing. Be careful not to fold the lip of the seal under.

   1. Flush the rotor hub with light oil and insert the rotor in the casing with the hub through the lip seals.

3. Install the idler. Install the idler with the bushings on the idler pin.

4. Place the head gaskets on the pump head.

   1. Use the proper amounts of gaskets to provide necessary end clearance within in the pump so the pump turns freely.

      ReferenceRefer to Table 1 that contains the normal amounts of gaskets needed to achieve proper clearance with no appreciable end play.

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      Table 1

      Pump Model	Normal Thickness Used	Contents of Single Gasket Set
      304-4382 445-1356	0.254 - 0.381 mm (0.010 - 0.015 inch)	Two 0.127 mm (0.005 inch) Plastic gaskets
      		Three 0.051 mm (0.002 inch) Plastic gaskets

5. Bolt the valve into the casing.

   Note: The adjusting screw of the relief valve must point toward the suction port of the pump.

   1. Place the valve and gasket or cover plate on the pump and fasten with four cap screws.

6. Assemble the pump on the motor.

   1. Install the full length key in the keyway of the motor shaft.

      Note: The key must be full length to avoid misalignment of the pump rotor. Rotor misalignment can damage the pump.

   2. Slide the pump on the motor shaft and fasten with four cap screws.

Assembly of the 197-2033 Oil Pump As , 218-0248 Oil Pump As , 445-1354 Oil Pump and 445-1355 Oil Pump

Illustration 8	g03469001
Exploded view of 197-2033 Oil Pump As , 218-0248 Oil Pump As , 445-1354 Oil Pump or 445-1355 Oil Pump (1) Key for motor shaft (2) Cap screws (3) Casing (4) Pipe plugs (5) Machine screw (6) Relief valve or cover plate gasket (7) Relief valve (8) Relief valve or cover plate cap screws (9) 197-2034 Seal (10) 445-1357 Seal (11) Rotor (12) Idler (13) Idler Bushing (14) Head gasket (15) Idler pin (16) Head (17) Head cap screws

Illustration 9	g03469003
Cross section view of 197-2033 Oil Pump As , 218-0248 Oil Pump As , 445-1354 Oil Pump or 445-1355 Oil Pump (18) Mounting flange (19) Idler (20) Head (21) Crescent (22) Rotor (23) Lip seal

1. Install the lip seals.

   1. Install the lip seal in the casing one at a time from the head end. The sealing lips must face away from each other.

   2. Use an arbor press and an arbor of 55.58 mm (2.188 inch) diameter and press the seal in the casing as far as possible.

2. Use clean engine oil and lubricate the lip seals.

3. Install the rotor.

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   NOTICE
   Turn the rotor back and forth while pushing through the lip seal to the bottom of the casing. Be careful not to fold the lip of the seal under.

   1. Flush the rotor hub with clean light oil and insert the rotor in the casing with the hub through the lip seals.

4. Install the idler with the bushings on the idler pin.

5. Assemble the head on the pump.

   1. Slightly tilt the top of the head away from the pump until the crescent enters the inside diameter of the rotor.

   2. Rotate the idler until the teeth mesh with the rotor teeth.

      Note: Do not damage the head gaskets. Note the correct position of the idler and crescent, refer to Illustration 9.

   3. Tighten the head cap screws and check for the end clearance.

6. Check pump end clearance.

   1. Measure the clearance between the back of the rotor and the machined surface of the casing. Measure the clearance using feeler gauges through the port opening, this measurement is the end clearance.

   2. Normal clearance is between 0.076 ± 0.127 mm (0.003 - 0.005 inch), add, or remove gaskets until the proper measurement is reached.

      ReferenceRefer to Table 1 for the normal amounts of gaskets needed to achieve proper clearance with no appreciable end play.

7. Bolt the valve to the casing.

   1. Place the gasket and valve or cover plate on the pump and fasten using four cap screws.

      Note: The adjusting screw of the relief valve must point toward the suction port of the pump.

8. Assemble the pump on the motor.

   1. Install the full length key in the keyway of the motor shaft.

      Note: The key must be full length to avoid misalignment of the pump rotor. Rotor misalignment can damage the pump.

   2. Slide the pump on the motor shaft and fasten with four cap screws.