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CASE 580SK Injector Pump Rebuild *in the nick of time* !

Discussion in 'Tractor/Loader/Backhoes' started by AU.CASE, Sep 22, 2018.

  1. AU.CASE

    AU.CASE Well-Known Member

    Joined:
    May 7, 2010
    Messages:
    164
    Occupation:
    Grazier // Rancher remote NSW
    Location:
    NSW Australia
    Hello all,

    Our superb CASE 580SK (XP Series / EU make with side shift) has been progressively wetting down the "Bosch VE" (I think that is the make / model anyway) injector pump for the Cummins 4T-390 powerplant, to the point where fuel would drip occasionally running or not.

    Imminent failures averted (so far):
    • When I removed it, there was a shock to find that the main shaft nut was only hand tight and the spring washer was collapsed.
    • Our pump guru in our local town has called me to collect the rebuilt pump after warning that the main springs inside it were broken and that it could have destroyed itself.
    • Also; That the throttle stop (and some other?) had been changed since built by previous CASE service provider for QR (Queensland Rail / previous owner) ?
    • He has to tell me what to change on it if the machine won't start when I assemble next week (scary part for sure :eek:).
    • He also said that I don't need the pump lock, only the timing chest lock to rebuild as the timing should be correct due to the shaft key (I am still learning here and welcome comment).
    More later; For now, here is a picture of our 'hoe marooned in front of our workshop in drought ridden inland Australia.

    DSC05751.jpg
     
  2. thepumpguysc

    thepumpguysc Senior Member

    Joined:
    Mar 18, 2010
    Messages:
    5,343
    Occupation:
    Master Inj.Pump rebuilder
    Location:
    Sunny South Carolina
    IF you DIDNT time the pump w/ the pin under the pump OR lock the pump w/ the locking bolt.. U should be able to slide the key in the gear & line up the lines.. BUT that's not to proper way..
    The pump should have been timed before removal w/ the pin under the pump & the pump locked.. THEN the pump should come back locked & it would slide right on..
    Your gonna run into trouble.. I can see that from here..

    He told u what parts to change if "no start"???
    On the pump?? the pump he JUST repaired?? WTF??
     
  3. AU.CASE

    AU.CASE Well-Known Member

    Joined:
    May 7, 2010
    Messages:
    164
    Occupation:
    Grazier // Rancher remote NSW
    Location:
    NSW Australia
    Thanks; I should be alright to install.

    The CASE service provider for QR (Queensland Rail) had adjusted the idle and full throttle stops to compensate for the crippled springs.

    Our Pump guru said has has never seen these broken and it was fortunate the cam didn't dislodge and destroy more with it; Also the starting would improve markedly with this repair.

    As for setup he advised me how to 'undo' the changes to the idle and throttle stops within reason and if out of range to adjust the top spline on the rack arm to align it with the centre marks he scribed on it before tear down.

    Pictures will tell a story and I might try to install tomorrow depending on other commitments.

    NO; I didn't say parts to change ??? Adjust only !

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    CASE-580SK.INJECTOR.PUMP_FAULT_240918-DSC05752.JPG

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    CASE-580SK.INJECTOR.PUMP_FAULT_240918-DSC05754.JPG

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    CASE-580SK.INJECTOR.PUMP_FAULT_240918-DSC05761.JPG

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  4. thepumpguysc

    thepumpguysc Senior Member

    Joined:
    Mar 18, 2010
    Messages:
    5,343
    Occupation:
    Master Inj.Pump rebuilder
    Location:
    Sunny South Carolina
    They break ALL THE TIME.. in that application & changed the part # of the springs..
    Glad u got it sorted out..
     
  5. AU.CASE

    AU.CASE Well-Known Member

    Joined:
    May 7, 2010
    Messages:
    164
    Occupation:
    Grazier // Rancher remote NSW
    Location:
    NSW Australia
    Oh ok thank you for the tip; I guess it is the pulse speed on them from the face cam which breaks them.

    The pump looks excellent so when I have time and if the pesky Wild Dogs leave my sheep alone I will re-assemble.

    Cheers.
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    CASE-580SK.INJECTOR.PUMP_FAULT_240918-DSC05763.JPG

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    CASE-580SK.INJECTOR.PUMP_FAULT_240918-DSC05764.JPG

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    CASE-580SK.INJECTOR.PUMP_FAULT_240918-DSC05766.JPG

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  6. 544D10

    544D10 Well-Known Member

    Joined:
    Sep 8, 2004
    Messages:
    166
    Occupation:
    Lucas & Mercier Construction Co.
    Location:
    Oceanside, CA
    I rebuilt the VE in my 1st Gen Dodge with a Cummins 6BT myself. Just measured every thing that could be measured before taking it off and put it all back exactly as I found it. I also took about 100 pictures during disassembly to reference.

    Put it back in the truck, bled everything and she's been purring like a kitten for 2 years now. All told, it cost $12.00 for the gaskets.
     
  7. AU.CASE

    AU.CASE Well-Known Member

    Joined:
    May 7, 2010
    Messages:
    164
    Occupation:
    Grazier // Rancher remote NSW
    Location:
    NSW Australia
    Super; You are right it can be done, although I have always been wary of injector pumps, hygiene and messing it up somehow.

    Over time I have only had two into our local Diesel Guru and the first one is working superbly; Maybe tomorrow I will fit this second one to our backhoe as stock work needs to be done and it is THE machine for it.

    The cost you mention is interesting and I reckon we had a discount this time ($425 AUD is very generous for the due diligence shown to service our pump - methinks.) as all of our State is in Drought and the community is being very kind to keep us from imminent poverty.

    Global Warming and Climate Change have transformed our ability to raise stock in Australia and we must all think and act smarter to keep back from the cliff; So as to speak.

    Cheers.
     
  8. AU.CASE

    AU.CASE Well-Known Member

    Joined:
    May 7, 2010
    Messages:
    164
    Occupation:
    Grazier // Rancher remote NSW
    Location:
    NSW Australia
    In an hour of workshop 'rehab' I turned out this CASE Barring tool for the bell housing on our Backhoe.

    Thanks to Bob (our Diesel Guru) for the donated starter motor from a Ford V8; Most appreciated.

    It is quite amazing how easy it is to turn the engine with this, even by hand with the rear socket sleeve, it can be turned very slowly.

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    CASE-580SK.BARRING_TOOL_250918-DSC05788.JPG

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    CASE-580SK.BARRING_TOOL_250918-DSC05792.JPG

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    CASE-580SK.BARRING_TOOL_250918-DSC05800.JPG


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    CASE-580SK.BARRING_TOOL_250918-DSC05798.JPG

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    This tool is really simple to make at 29MM shaft turn down x 50MM to the shoulder for depth of the pinion.

    It (the pinion) isn't an exact mesh (there is some backlash) being possibly a tooth smaller but it doesn't affect its ability to turn the Cummins.

    I also made a tool to remove the timing gear from the mainshaft and will depict it later with some dimensions and thread sizes.
     
  9. AU.CASE

    AU.CASE Well-Known Member

    Joined:
    May 7, 2010
    Messages:
    164
    Occupation:
    Grazier // Rancher remote NSW
    Location:
    NSW Australia
    Hi all, luckily it was raining here at times today so I decided to rebuild between showers (not enough to really alter the drought but better than nowt').

    All went well and after a little priming and cranking we had ignition.

    As Bob tipped the main rack shaft might need trimming and as there was no idle and top revs' was 1750, so I advanced the spline one increment and had 825 and 2230 RPM approximately.

    Back to work.

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    DSC05804.JPG

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  10. AU.CASE

    AU.CASE Well-Known Member

    Joined:
    May 7, 2010
    Messages:
    164
    Occupation:
    Grazier // Rancher remote NSW
    Location:
    NSW Australia
    I made a tool to remove the timing gear.

    Just a simple plate of 8MM steel would do by two 10mm drill holes at 34MM centres; The bolt is just 35MMx8MM in HT does the job.

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    CASE-580SK.INJECTOR.GEAR.PULLER_260918-DSC05811.JPG

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    CASE-580SK.INJECTOR.GEAR.PULLER_260918-DSC05814.JPG

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  11. thepumpguysc

    thepumpguysc Senior Member

    Joined:
    Mar 18, 2010
    Messages:
    5,343
    Occupation:
    Master Inj.Pump rebuilder
    Location:
    Sunny South Carolina
    You guys do what ya gotta do over there.. HERE, we just buy the tools.. 30.00 each{US}