SEAL RING KIT FOR NON-WARRANTABLE REPAIRS OF E-TECH ELECTRONIC UNIT PUMPS (EUP) PRE-CCRS AND CCRS ENGINES

Transcription

1 SERVICE BULLETIN (Also applies to Mack Trucks Australia) NUMBER: SB DATE: 7/16/02 MODEL: E-Tech Pre-CCRS and CCRS SEAL RING KIT FOR NON-WARRANTABLE REPAIRS OF E-TECH ELECTRONIC UNIT PUMPS (EUP) PRE-CCRS AND CCRS ENGINES A seal ring kit (part No. 935-F00HN37759) is available through the MACK Parts System to repair fuel leakage that may be experienced at the joint between the stator and body on E- Tech pre-ccrs and CCRS electronic unit pumps. This kit should only be used to repair unit pumps that are out of warranty. For leaking unit pumps within the warranty period, the entire unit pump must be replaced. The seal ring kit includes the following: 1 Figure 1 Seal Ring Kit Part No. 935-F00HN Retaining screws, stator-to-pump body 2. O-ring, thin, unit pump body, upper 3. O-ring, thick, unit pump body, lower 4. Seal ring, spacer plate 5. Stop retainer plate SB Page 1 of 9 SERVICE PUBLICATIONS, ALLENTOWN, PA MACK TRUCKS, INC. 2002

2 Procedures for installing the seal ring kit are as follows: 1. Remove the unit pump from the engine. To avoid the possibility of serious injury when removing the unit pump from the engine, use the proper service procedures as described in the engine service manual. When servicing a unit pump, take care not to damage any machined or threaded surfaces. Work should be performed on a clean, non-metallic surface. 2. Clean the unit pump with a suitable non-flammable solvent to remove all grease, oil and road dirt, then use a small wire brush to remove any loose paint from the statorspacer-pump body interfaces. It is not necessary to completely remove all the paint, only the loose paint so that pieces of paint will not contaminate the pump during reassembly. 2 Figure 2 Removing Loose Paint from Unit Pump Surfaces 3. Place the pump, with the stator nameplate facing up, on a work bench that has been covered with a clean, lint-free cloth. SB Page 2 of 9

3 4. Remove and discard the four stator retaining screws. The stator screws are tamper resistant Torx -head fasteners and require a special Torx Plus 201PR tamper-resistant screw bit (part No. 935-F00E740012), available through the MACK Parts System, to remove. 3 Figure 3 Removing Stator Screws 5. Separate the stator, spacer, pump body and stop retainer plate and discard the stop retainer plate. 4 Figure 4 Unit Pump Exploded View 1. Nameplate 2. Stator 3. Seal ring, spacer plate 4. Spacer plate 5. Unit pump body 6. Stop retainer plate SB Page 3 of 9

4 The spacer must remain with the pump body from which it was removed. The pump may not function properly if reassembled with a different spacer plate. 6. Remove and discard the two rectangular seal rings from the spacer plate. The lower seal ring may stick to the pump body upon separation. This is normal. 5 Figure 5 Spacer Plate Seal Ring on Unit Pump Body 7. Clean the front and back faces of the spacer plate to make sure they are free of dirt and loose paint. SB Page 4 of 9

5 8. Install the two rectangular seal rings included in the seal ring kit, into the grooves in the spacer plate. These seal rings are rectangular in shape and cross section. MACK O-ring Lubricant (part No. 243SX41) may be applied to the seal rings to aid in holding the rings in place during assembly. 6 Figure 6 Installing Spacer Plate Seal Rings 9. Clean the pump body face to be sure it is free of dirt and loose paint. 10. Install the spacer plate onto the pump body. It is critical to install the spacer plate with the notched face against the pump body, and the notches over the tabs of the metal stamping below the armature. The armature must be positioned the long way with respect to the pump body (refer to the following illustration). 7 Figure 7 Installing Spacer Plate onto Pump Body SB Page 5 of 9

6 11. Place the stator onto the spacer with the electrical contacts facing the top of the pump as shown in the following illustration. Make sure the stator face is clean and free of dirt and loose paint Place the nameplate on the stator. 9 Figure 8 Placing Stator onto Spacer Figure 9 Placing Nameplate on Stator SB Page 6 of 9

7 13. Install the four new tamper-resistant stator screws included with the seal ring kit through the nameplate, stator, spacer plate and pump body. 10 Figure 10 Installing Stator Screws 14. Place the new stop retainer plate included with the seal ring kit on the back of the pump body. The holes in the stop retainer plate must align with the stator screws. 11 Figure 11 Installing Stop Retainer Plate SB Page 7 of 9

8 15. Using a crisscross tightening sequence, pre-tighten the four stator screws to 17.7 lb-in (2.0 N m), then, using the same sequence, tighten the four screws to the following torque value: 12 Pre-CCRS unit pumps (part No. 313GC5227M, MX) lb-in ( N m) CCRS unit pumps (part No. 313GC5230M, MX) lb-in ( N m) Figure 12 Stator Screw Tightening Sequence 16. Remove and discard the two O-rings from the unit pump body. 17. Using a clean, lint-free shop cloth, clean the pump to remove all dirt, grease and loose paint. ItiscriticalthattheO-ringgroovesinthepumpbodyareclean. SB Page 8 of 9

9 18. Install the new O-rings included in the seal ring kit to the grooves in the unit pump body. Do not over-stretch the O-rings as they are being installed. Two different O-rings are used on the pump body, and it is important that the O-rings are installed in the proper groove. The thin O-ring is installed in the upper O-ring groove, just below the unit pump mounting flange. The thick O-ring is installed in the lower O-ring groove. An O-ring is not used in the center O-ring groove. Refer to the following illustration for proper O-ring installation. After the O-rings have been installed, check to make sure they are not twisted. 13 Figure 13 Pump Body O-Ring Installation 19. Apply a thin film of clean engine oil to the O-rings before installing the unit pumps in the engine. SB Page 9 of 9