Caterpillar 3408C & 3412C Marine Engines Disassembly & Assembly Manual - PDF DOWNLOAD

CATERPILLAR"

3408C & 3412C Marine Engines

3

Marine Auxiliary & Generator Set Engines

SENR1133 June 1996

Important Safety Information Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous and could resutt in injury or death.

Safety precautions and warnings are provided in this manual and on the product. warnings are not heeded, bodily injury' or dedth could occur to you or other perso "WARNING" as shown below.

A

WARNING

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Operation that may cause product damage are identified by N publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warning in this publication and on the product are therefore not all inclusive. W a tool, procedure, work method or operating technique not specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and others. You should also ensure that the product will not be darnage@ or made unsafe by the operation, lubrication, maintenance or repair procedures you choose% The information, specifications, and illustrations in this publication are on the basis of information available at the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before starting any job. Caterpillar dealers have the most current information available. For a list of the most current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F. ,

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Oil Bypass Valves ..................................................................... 20 Oil Cooler ..................................................................................... 24 Oil Filters ..................................................................................... 20 Oil Filter Base .............................................................................21 Oil Filter Base. Disassemble & Assemble ....................... 22 Oil Level Gauge ......................................................................... 23 Oil Pan ....................................................................................... 161 Oil Pump ................................................................................... 162 Oil Pump. Disassemble & Assemble ............................. 163

Aftercooler ...................................................................................

25 Air Filter ...................................................................................

27 Air Cleaner Assembly ............................................................. 28 Bridge Dowels ........................................................................

159

Camshaft ..................................................................................113 Camshaft Bearings ...............................................................115 Connecting Rod Bearings ............................................. 167 Crankcase Breather .............................................................. 13 Crankshait ............................................................................... 180 Crankshaft Front Seal & Wear Sleeve ........................... 110 Crankshaft Main Bearings .................................................. 178 Crankshaft Pulley & Damper ............................................... 14 Crankshaft Rear Seal & Wear Sleeve ............................ 123 Cylinder Head Assemblies ................................................. 152 Cylinder Liners ........................................................................ 175 -'

Piston Cooling Tubes ........................................................... 169 Pistons (Earlier .Rod Pin Bearing With Straight Sides). Disassemble & Assemble .................................... 171 Pistons (Later .Tapered Rod Pin Bearings).

Disassemble & Assemble ...................................................173 Pistons ....................................................................................... 170 Precombustion Chambers .................................................

144 Radiator ..........................................................................................

5 Rocker Shaft Assembly ....................................................... 149 Rocker Shaft Assembly. Disassemble & Assemble ..................................................................................

151 Raw Water Pump ..................................................................... 98 Raw Water Pump (Earlier Engines). Disassemble & Assemble ..................................................................................... 99 Raw Water Pump (Later Engines). Disassemble & Assemble .................................................................................. 104

Direct Injection Adapters ................................................. 146 Engine Lifting Brackets ........................................................

12 Engine Support ......................................................................... 12 Exhaust Manifold (Rear) ...................................................... 128 Exhaust Manifold (Water Cooled) .................................... 130 Expansion Tank & Water tines ........................................ 107

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Service Meter .............................................................................38 Spacer Plates ..........................................................................160

Fan .................................................................................................... 6 Fan Belts ....................................................................................... 7 Fan Drive ........................................................................

8 Fan Drive. Disassemble & Assemble ..................................8 Fan Guard .....................................................................................4 Flywheel ..................................................................................... 117 Flywheel Housing .................................................................. 125 Front Housing ......................................................................... 112 Front Housing Cover ..............................................................16 Fuel Filter .....................................................................................18 Fuel Injection Lines ..................................................................33 Fuel lnjection Nozzles & Adapters (Later 7000 Series) ........................................................................................ 143 Fuel Injection Nozzles (Earlier 7000 Series) ................. 139 Fuel Injection Pump Housing & Governor ...................... 52 Fuel lnjection Pump Housing. Disassemble & Assemble ..................................................................................... 78 Fuel Injection Pumps ............................................................. 44 Fuel Injection Valves (Direct Injection)............................ 138 Fuel Injection Valves (Precombustion Chamber) ....... 136 Fuel Priming Pump & Filter Base ....................................... 19 Fuel Ratio Control (If Equipped) ......................................... 35 Fuel Ratio Control. Disassemble & Assemble ..............36 Fuel Transfer Pump ................................................................ 39 Fuel Transfer Pump. Disassemble & Assemble ........... 40

Timing Gears ........................................................................... 116 Turbocharger ............................................................................. 29 Turbocharger. Disassemble & Assemble ....................... 31 Valve Covers ........................................................... .......... 133 Valve Guides ...........................................................................

158 Valve Lifters & Push Rods ..................................................148 Valve Seat Inserts ..................................................................

157 Valves .........................................................................................

156 Vibration Damper & Pulley .................................................109 Water Pump ............................................................................... 92 Water Pump. Disassemble & Assemble ......................... 95 Water Temperature Regulators .......................................... 87

Disconnect batteries before performance of any service work

Generator ................................................................................. 118 Glow Plugs (Precombustion Chambers) ...................... 135 Governor. Disassemble & Assemble ................................ 55 Governor & Fuel Pump Drive ............................................... 47 Governor & Fuel Pump Drive. Disassemble & Assemble .....................................................................................50

3408C & 3412C Marine Engines

3

Index

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Disassembly & Assembly Fan Guard Remove & Install Fan Guard 1360-010

3. Remove twenty two bolts and washers (3) and remove two fan guards (4).

NOTE: To install the fan guards, reverse the removal steps.

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1. Remove two bolts and strap (1) from the fan guard assembly.

2. Remove two bolts and strap (2) from the fan guard assembly.

3408C & 3412C Marine Engines

4

Disassembly & Assembly

Radiator -1

\ Remove & Install Radiator 1353-010 Start By: a. remove fan guard

FLUID SPILLAGE CONTAINMENT

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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com~onentcontainina fluids. Refer to 1 1 ~ SHOP ~ PRODUCT ~ ~ GUIDE, ~ NENG250OW, ~ . for tools and supplies suitable to colle& and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

3. Loosen two hose clamps (3).

4. Remove radiator tube (2) from the radiator. ~

~

1. Drain the radiator into a suitable container for storage or disposal.

5. Loosen two hose clamps (5) on the water temperature regulator housings.

6. Remove two radiator braces (4).

2. Loosen two hose clamps (1).

7. Attach .lifting slings and a suitable lifting device to radiator (6). Radiator (6) weighs approximately 186 kg (410 Ib).

3408C & 3412C Marine Engines

5

Disassembly & Assembly

Fan Remove & Install Fan 1356-010 Start By:

a. remove radiator

8. Remove four bolts (7) fastening radiator (6) to the radiator support.

9. Remove radiator (6).

1. Attach a lifting sling and a suitable lifting device to fan (1). Fan (1) weights 34 kg (75 Ib) .

2. Remove six bolts and washers (2).

3. Remove fan (1).

NOTE: To install the fan, reverse the removal steps.

End By:

10. If necessary, remove four rubber mounts (8).

a. install radiator

NOTE: To install the radiator, reverse the steps for removal.

End By:

a. install fan guard

3408C & 3412C Marine Engines

6

Disassembly & Assembly

Fan Belts .

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Install Fan Belts 1357-012 A

Tools Needed

Remove Fan Belts 1357-011

BT-33-72C Borroughs Belt Tension Gauge

1

Start By: a. remove fan

NOTE: Inspect the fan belts for damage, cracks or wear. Replace with new belts if necessary.

1. Loosen four nuts (1) fastening the fan drive bracket to the engine.

1. Install three fan belts (2) on the pulleys.

2. Tighten bolt (3) until fan belts (2) are tightened.

3. If belts are new, tighten bolt (3) until fan belts (2) reach a tension of 534 22 N (120 k 5 Ib). Use Tool (A) to determine the belt tension.

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4. If belts are used, tighten bolt (3) until fan belts (2) reach a tension of 400 44 N (90 10 Ib). Use Tool (A) to determine the belt tension.

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2. Loosen bolt (3) to loosen fan belts (2).

3. Remove three fan belts (2).

5. Tighten four nuts (1)fastening the fan drive to the front housing.

End By:

a. install fan

3408C & 3412C Marine Engines

7

Disassembly & Assembly

Disassemble & Assemble Fan Drive 1359-017

Fan Drive Remove & Install Fan Drive 1359-010 Tools Needed

85-1378 Stud Remover and Resetter Group

Tools Needed

A

A 1

1P-0510 Driver Group

1 Start by:

Start By:

a. remove fan drive

a. remove fan belts

1. Attach a lifting sling and a suitable lifting device to fan drive (1) as shown.

2. Remove four nuts and washers (2).

3. Remove fan drive (1). Fan drive weighs 23 kg (51 Ib) .

1. Remove two bolts and bracket (4) from the fan drive bracket assembly.

2. Remove six bolts (1) that fasten fan adapter (3) to pulley (2).

4. Remove bracket assembly (3).

5. If necessary, remove four studs (4) with Tool (A).

NOTE: To install the fan drive, reverse the removal steps.

End By:

a. install fan belts 3408C & 3412C Marine Engines

8

Disassembly & Assembly

7. Remove lip seal (11) from hub (7).

3. Remove two bolts and washer (5) from the fan drive hub.

18. ~ e m o v epulley (2) from fan bracket assembly (12).

4. Remove O-ring seal (6) from the fan drive hub.

5. Remove hub (7) from the fan drive.

9. Remove spacer (13) from fan bracket assembly 112).

6. Remove bearing (8), spacer (9) and bearing (10) from hub (7).

3408C & 3412C Marine Engines

9

Disassembly & Assembly

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10. If necessary, remove plug (14) inside fan adapter

13. Instdl pulley (2) on bracket assembly (12).

(3).

NOTE: The following steps are for the assembly of the fan drive.

1

14. Use Tool (A) to install lip seal (11) into hub (7).

-Lubricatethe sealing Ilp of lip seal (11) with 1P0808 Lithium Grease .

11. If removed, install plug (14) inside fan adapter (3).

15. Install bearing (8), spacer (9) and bearing (10) into hub (7).

12. Install spacer (13) on fan bracket assembly (12).

3408C & 3412C Marine Engines

10

Disassembly & Assembly

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16. Install hrrBq(T)in jhs fan d$$k.

W. Install six bolts (1) fastening pulley (2) to hub (7).

e m ,

17. Install 0kr7g ae&

(@I dl hub m.

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20. lnstalibracket and tyro bolts (4) on the fan drive bracket assembly.

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21. Fill jhe fan drive at the grease fitting with 1P-0808 Lithiirm Grease.

End By: a. install fan drive

18. Instatl washer $ndbof b.~h (5) in hub (7).

3408C & 3412C Marine Engines

11

Disassembly & Assembly

Engine Lifting Brackets

Engine Support

Remove & Install Engine Lifting Brackets 1122-010

Remove & Install Engine Support 1154-010

Start By:

Start By:

a. remove exhaust manifolds

a. remove crankshaft pulley & damper

1. Remove four bolts and washers (2).

1. Loosen bolt (1) closest to the engine on each side of the generator.

2. Remove right side engine lifting bracket (1).

4. Remove left side engine bracket (3).

2. Attach two lifting slings and a suitable lifting device to radiator support (2) as shown.Remove eight bolts, washers and nuts (4) fastening radiator support (2) to engine support (3).

NOTE: For installation of the engine lifting brackets, reverse the steps for removal.

3. Remove radiator support (2). The weight of radiator support (2) is 25 kg (55 Ib).

3. Remove four bolts and washers (4).

End By: a. install exhaust manifolds

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3408C & 3412C Marine Engines

12 I

Disassembly & Assembly

Crankcase Breather Remove & Install Crankshaft Breather 1317-010 NOTE: The crankcase breather removal and installation is the same for both crankcase breathers.For simplicity, removal and installation is shown for only one crankcase breather.

4. Attach chains and a suitable lifting device to the

engine lifting brackets as shown. The weight of the engine is approximately 3629 kg (8000 Ib).

1. Loosen hose clamp (2).

2. Remove breather (1).

5. Support the engine with the chains and the suitable lifting device.

6. Remove four bolts, washers and nuts (6).

7. Remove eight bolts (5).

8. Remove engine support (3).The weight of engine support (3) is 25 kg (55 Ib) .

9. If necessaw, dace wood blocks under the enaine where the front housing and the oil pan are mvated to support the engine.

3. Remove O-ring seal (3).

NOTE: To install the engine support, reverse the removal steps.

NOTE: For installation of the crankshaft breather, reverse the removal steps.

End By:

a. install crankshaft pulley & damper

3408C & 3412C Marine Engines

13

Disassembly & Assembly

Crankshaft Pulley & Damper Remove & Install Crankshaft & Damper 1205-010 Tools Needed 88-1378 Stud Remover and Resetter Group

A 1

Start By: a. remove fan belts 4. Move dam~er(41forward far enough to attach a

lifting sling 'as s'hbwn. Attach the l'Sng sling to a suitable lifting device.

5. Remove damper (4). Damper (4) weighs 29 kg (64 Ib).

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1. Remove twelve nuts (2).

2. Use two people to remove pulley (1). Pulley (1) weighs approximately 21 kg (46 Ib).

NOTE: Adapter (6) is held in place by twelve bolts @).Whenremoving twelve bolts (5) hold adapter (6) by hand to prevent it from falling.

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6. Hold adapter (6) by hand, remove twelve bolts (5). kc

3. Remove pulley (3).

7. If necessary, remove twelve studs (7) with Tool (A).

3408C & 3412C Marine Engines

14

Disassembly & Assembly

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The following steps are for the instdIatioTof nkshaft pulley and damper. +% -

12. Install pulley (3) on the adapter.

8. If removed, install twelve studs (7) in adapter (6) with Tool (A).

13. Place pulley (1) in position on the adapter.

14. Install twelve nuts (2). Tighten twelve nuts (12) to a torque of 65 +- 10 N*m (48 & 7 Ib ft).

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9. Place adapter (6)in position on the crankshaft.

End By:

10. Install twelve bolts (5).

a. install fan belts

11. Install damper (4) on the adapter.

3408C & 3412C Marine Engines

15

Disassembly & Assembly

~ro-sing

Cover

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Remove & Install Front Housing Cover 1151-010 I

Tools Needed 85-1 378 Stud Remover and Resetter Group

A 1

Start By:

a. remove fan drive 3. If necessary, remove four studs (6) with Tool (A).

4. If necessary, remove three bolts and cover (5).

5. Remove nut (7). w

6. Remove ten bolts (3) and cover (4).

1

1. Remove bolt and hose clip (1).

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7. Remove gasket (9).

8. If necessary, remove stud (8) with Tool (A).

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2. Remove nut and washer (2).

3408C & 3412C Marine Engines

16

Disassembly & Assembly

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9. If necessary, remove five nuts (1O), cover (11) and the gasket.

13. If removed, apply 4C-4032 Thread Sealant to the threads of stud (8) and install with Tool (A).

10. If necessary, remove five studs (12) with Tool (A).

14. lnstall gasket (9).

NOTE: The following steps are for the installation of the front housing cover.

15. If removed, install four studs (6) with Tool (A).

16. lnstall cover (4).

11. If removed, install five studs (12) with Tool (A).

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17. Install nut (7) and ten bolts (3).

12. Install the gasket, cover (1I), and five nuts (10).

Tighten five nuts (10) to a torque of 20 3 N-m (15 f 2 Ib ft).

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3408C & 3412C Marine Engines

18. If removed, install the gasket and cover (5).

17

Disassembly & Assembly

Fuel Filter Remove & Install Fuel Filter 1261-010 Tools Needed

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2P8250

Strap Wrench

A 1

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLSAND SHOP PRODUCT GUIDE, NENG2500". for tools and supplies suitable to collect and contail fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

19. lnstall nut and washer (2).

1

20. lnstall bolt and hose clip (1).

End By:

a. install fan drive

1. Turn the fuel supply valve to the "OFF" position.

2. Use Tool A to remove fuel filter (1).

NOTE: The following steps are for the installation of the fuel filter.

3408C & 3412C Marine Engines

18

Disassembly & Assembly

C

Fuel Priming Pump 8 Filter Base Remove & Install Fuel Priming Pump & Filter Base 1258 & 1262-010 Start By:

a. remove fuel filter

FLUID SPILLAGE CONTAINMENT Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG25W1', for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

3. Lubricate the seal of.fuel filter (1) with clean engine oil prior to installation.

,u '

4. Use Tool (A) to install fuel filter (I). Tiqhten fuel filter (I) 3/4 to I turn after contact with the filter base.

5. Turn the fuel'supply valve to the "ONn position.

1. Turn the fuel supply valve to the "OFF" position.

2. Remove two bolts (2). Remove fuel priming pump (1) and the gasket.

3. Mark two hoses (3) for identification. Disconnect two hoses (3) from filter base (5). Cap and plug all openings immediately.

4. Remove two bolts and nuts (4) from the filter base.

Remove filter base (5).

NOTE: For installation of the fuel priming pump and filter base, reverse the removal steps.

End By: a: install fuel filter

3408C & 3412C Marine Engines

19

Disassembly & Assembly

:

Oil Bypass Valves

Oil Filters

Remove & Install Oil Bypass Valves 1314-010

Remove & Install Oil Filters 1318-010 A

Tools Needed Tools Needed 2P8250

Strap Wrench

1

2P-8250 Strap Wrench

A

c

1

FLUID SPILLAGE CONTAINMENT Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG25001', for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

1. Remove two oil filters (2) from oil filter base (1) with Tool (A).

NOTE: The following steps are for the installation of the oil filters.

2. Lubricate the seals of two oil filters (2) with clean

engine oil.

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3. lnstall two oil filters (2) until contact is made with oil filter base (1).

4. Tighten two oil filters (1) an additional 3/4 turn after

contact with the oil filter base is made.

2. Remove the filter bypass valve from the filter base.

3. Use Tool (A) to remove 011 filter (2).

NOTE: Upon installation, install oil filter (2) according to the instructions given on the filter.

4. Remove cover (3).

5. Remove the oil cooler bypass valve from the cooler bypass line.

NOTE: For installation of the oil bypass valves, reverse the removal steps.

6. Check the engine oil for the corred level. See the Operation & Maintenance Manual.

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3408C & 3412C Marine Engines

20

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isa assembly & Assembly

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Oil Filter Base Remove & Install Oil Filter Base 1306-010 Start By: a. remove oil filters

FLUID SPILLAGE CONTAINMENT

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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing; adjusting and repair of the machine.

Be-preparedto collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500I1, for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

1. Remove bolt (2) holding hose clip (3) in place.

2. Remove eleven bolts (1) holding oil filter base (4) to oil cooler (5) and cylinder block (6).

3. Remove oil filter base (4).

4. Remove the four O-ring seals from oil filter base (4).

NOTE: For installation of the oil filter base, reverse the removal steps.

A -

End By:

a. install oil filters 6. Check the enaine oil for the correct level. See the Operation & ~aintenanceManual.

3408C & 3412C Marine Engines

21

'

Disassembly & Assembly

Disassemble & Assemble Oil Filter Base 1306-017 Start By: a. remove oil filter base

FLUID SPILLAGE CONTAINMENT Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers-before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG250OU, for tools and supplies suitable to collect and contain fluids in caterpillar machines. Dispose fluids according to local regulations and mandates.

There is a small amount of spring force behind cover (4). When two bolts (3) are loosened, the spring force will be released. To prevent possible personal '--'y u ,rn ji loosen bolts (3) slowly and evenly to release the spring force.

2. Remove two bolts (3) slowly and evenly to release the spring force behind cover (4).

3. Remove cover (4).

1. Remove four O-ring seals (1) from oil filter base (2).

4. Remove two springs (5) from oil filter base (2).

3408C & 3412C Marine Engines

22

Disassembly & Assembly

Oil Level Gauge Remove & Install Oil Level Gauge 1326-010

5. Remove two plungers (6) from oil filter base (2).

6. Remove two plugs (7) from oil filter base (2).

NOTE: For assembly of the oil filter base, reverse the disassembly steps. d'

End By:

1. Remove bolt, two washers and nut (1).

a. install oil filter base

2. Remove tube (2) from the engine block.

3. Remove the O-ring seal from tube (2).

NOTE: For installation of the oil level gauge, reverse the steps for removal.

3408C & 3412C Marine Engines

23

Disassembly & Assembly

Oil Cooler Remove & Install Oil Cooler 1378-010 Start By:

a. remove oil filter base

FLUID SPILLAGE CONTAINMENT Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG25001', for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

NOTE: The oil cooler is held in place by six bolts (2).

Hold the oil cooler in place by hand while removing six bolts (2) to prevent the oil cooler from falling.

2. Hold oil cooler (3) in place by hand, remove six bolts (2).

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3. Remove oil cooler (3).

4. Remove the two O-ring seals from the end of oil cooler (3).

5. Remove the gasket where six bolts (2) fasten the oil cooler to the cylinder block.

NOTE: The following steps are for installation of the oil cooler.

NOTE: Check the O-ring seals for damage or wear prior to assembly. Replace with a new gasket if necessary.

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NOTE: Lubricate the O-ring seals with clean engine oil prior to installation.

1. Disconnect tube (1). Cap and plug all openings

immediately.

3408C & 3412C Marine Engines

24

Disassembly 81Assembly

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SS

Aftercooler Remove & Install Aftercooter 1063-010

lgl

tained during performance of inspection, maintenance, testing,-adjusting and repair of themachine.

Be prepared t o collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG250ON, for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

6. Install the gasket between the oil cooler and the cylinder block.

u

7. Install the two O-ring seals on the end of the oil cooler. Lubricate the two O-ring seals with clean engine oil prior to installation of the oil cooler.

8. Place oil cooler (3) in ~ositionand install six bolts (2)

Start By:

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a. remove fuel injection lines

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9. Connect tube (1).

1. Remove plug (5) and drain the coolant from the aftercooler into a suitable container for storage or disposal. Reinstall plug (5).

End By: a. install oil filter base

2. Remove four bolts and washers (2).

3. Remove eighteen bolts (3).

4. Remove bracket (4).

5. Remove aftercooler housing (1).

3408C & 3412C Marine Engines

25

Disassembly & Assembly

9. Remove two O-ring seals (9).

6. Remove gasket (6) from cover (1).

10. Remove two adapters (10).

17. Remove four bolts and washers (7). .

b 8. Remove two elbows (8).

,

1

11. Remove eight bolts (12).

12. Remove cooler element (11).

13. Remove two O-ring seals (13).

14. Remove eight bolts (15), aftercooler housing (14)

and the gasket.

3408C & 3412C Marine Engines

26

Disassembly & Assembly

Air Filter Remove & Install Air Filter 1054-010

15. Remove four O-ring seals (16).

NOTE: The following steps are for installation of the aftercooler. .-

NOTE: Prior to installation, check all O-ring seals for damage or wear and replace if necessary. Coat the seals with clean engine oil.

1. Unlatch six latches (2) and remove cover (1).

NOTE: For installation of the aftercooler, reverse the removal steps.

End By:

a. install fuel injection lines

.

,

2. Remove air filter elekent (3) from the air cleaner assembly. NOTE: To install the air filter element, reverse the removal steps.

3408C & 3412C Marine Engines

27

Disassembly & Assembly

Air Cleaner Assembly Remove & Install Air Cleaner Assembly 1051-010 Start By: a. remove air filter

6. Remove four bolts and washers (8) fastening air cleaner support (7)to the flywheel housing.

NOTE: To install the air cleaner assembly, reverse the removal steps.

End By:

\

a. install air filter

1. Remove bolt, washers and nut (1) from the bracket fastening air cleaner assembly (2) to the engine.

2. Loosen two hose clamps (3).

3. Remove bolt, washers and nut (4) from the bracket fastening air cleaner assembly (2) to the engine.

4. Remove three bolts (6)fastening air cleaner housing

(5) to air cleaner support (7).During assembly, tighten three bolts (6)to a torque of 24 m 7 Nm (18 5 Ib ft).

+

5. Remove air cleaner housing (5).

3408C & 3412C Marine Engines

28

Disassembly & Assembly

tainers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLSAND SHOP PRODUCT GUIDE, NENG25008', for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

8. Attach lifting slings and a suitable lifting device to the turbocharger as shown.

9. Remove four nuts (8).

- d

Start By: a: remove air cleaner

1a. Disconneat.tube [B]; Cap and plug all openings irntvW/&ely.

d 1.

Remove four bolts (1).

2. Disconnect tube (2). Cap and plug all openings immediately.

3. Disconnect tube (3). Cap and plug all openings immediately.

4. Remove two bolts (4).

5. Disconnect tube (5). Cap and plug all openings immediately.

6. Remove two bolts (6).

7. Disconnect tube (7). Cap and plug all openings immediately.

3408C & 3412C Marine Engines

29

Disassembly & Assembly

15. Install gasket (13) and gasket (14)

11. Remove bolt and clip (11).

12. Remove tube (12) and the gasket. Cap and plug all openings immediately.

13. Remove turbocharger (10). The weight of the turbocharger is 47 kg (104 Ib).

16. Attach lifting slings and a suitable lifting device to the turbocharger as shown. Install turbocharger (10) in its original location. The weight of the turbocharger is 47 kg (104 Ib).

17. Place tube (12) in position and install bolt and clip (11).

14. Remove gaskets (13) and (14).

NOTE: The following steps are for the installation of the turbocharger.

18. Connect tube (9) to the cylinder block.

19. lnstall four nuts (8). Do not tighten nuts (8) at this time.

3408C & 3412C Marine Engines

30

Disassembly & Assembly

C

Disassemble & Assemble Turbocharger 1052-017 Start By:

a. remove turbocharger

20. Install four bolts (1) connecting the elbow to the aftercooler.

21. Loosen the V-band clamps attaching the compressor housing and turbine housing to the cartridge enough to allow housings to rotate.

J,

)

22. Position the housings with the air pipes, exhaust pipes, the oil and the water lines so they are all aligned without binding.

1. Loosen clamp (4) and retiiove hose (5).

23. Connect tube (2), (3), (5) and (7).

2. Loosen clamp (2). Upon assembly tlghten ckam~t[2) toatorq~eofi4&IN*ni'(iQ&fI~~)~

24. Install two bolts (4) and (6) connecting the tubes to the turbocharger.

3. Remove compreksor i3) from the cartridge assembly 'and.turbine (I),

25. Tighten the V-band clamps to 14 & 1 N*m (10 1 Ib ft).

'

+

26. Tap the V-band clamps all the way around and retighten to 14 & 1 Nem (10 r 1 Ib ft). Do not overtighten the clamps.

27. Tighten the four nuts (8) fastening the turbocharger to the rear exhaust manifold to a torque of 55 & 5 N-m (41 & 4 Ib ft).

I

w

End By: a: install air cleaner 4. Remove pipe (6) and the two O-ring seals from compressor (3).

5. Remove adapter (7) and the two O-ring seals from pipe (6).

3408C & 3412C Marine Engines

31

Disassembly & Assembly

I

o. Loosen elq-np (Q).Upori a ~ e ~ b ltighten y, clamp (9) to atutque of 14 +, 1 N~rn (10 % 1 Ib ft).

10. Remove three adapters (12).

11. Remove gasket (13).

7. Remob catn'dge assembly (&)from turbine (1).

12. Remove adapter (14).

8. Rernave four bolts and clip^ (I 1).

13. Remove two plugs (15) from exhaust elbow (lo) 9. Remove exhaust elbow (10).

NOTE: Check all O-ring seals for wear or damage and replace with new parts if necessary.

NOTE: For assembly of the turbocharger, reverse the disassembly steps.

-

End By: a. install turbocharger

3408C & 3412C Marine Engines

32

Disassembly & Assembly

.I

Fuel Injection Lines - ,

') Remove Fuel Injection Lines 1252-011 Tools Needed 5P-4996 Plug 5P-0405

L

A B 16

16

Cap

4. Remove tie wraps (4).

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500M, for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

5. Remove bolt, clamps, washers and nuts (5).

e.

6. Loosen eight nuts (6)and eight nuts (7).

7. Remove fuel injection lines (8) as a unit.

1. Remove bolt, clamps, washers and nut (1).

2. Remove bolt, clamps and washers (2).

3. Remove two bolts, clamps, washers and nuts (3).

8. lnstall Tooling (A) in the fuel injection line openings.

9. Install Tooling (6)in the openings of the fuel injection pump and the valve covers.

3408C & 3412C Marine Engines

33

3

-----

Disassembly & Assembly

lnstall Fuel Injection Lines 1252-012 Tools Needed

A B C

5P-4996 Plug

16

5P-0405 Cap 5P-0144 Socket

16 1

5. Install tie wraps (4).

wrc

3

~

~

3

6. lnstall bolt, clamps, washers and nut (5).

1. Remove Tooling (A) from the fuel injection line

openings.

2. Remove Tooling (B) from the openings of the fuel injection pump and the valve covers.

7. Install two bolts, clamps, washers and nuts (3).

8. lnstall bolt, clamp and washers (2).

9. lnstall bolt, clamps, washers and nut (1).

NOTE: If replacement lines are installed, alway: remove the metal identification tags so vibration or tags will not cause worn through fuel lines.

3. lnstall fuel injection lines (8) as a unit.

4. Use Tool C to tighten eight nuts (6) and eight nuts (7) to a torque of 40 +. 7 N-m (30 5 Ib ft).

+

3408C & 3412C Marine Engines

34

Disassembly & Assembly

i

lnstall Fuel Ratio Control (If Equipped) 1278-012

Fuel Ratio Control )

Remove Fuel Ratio Control (If Equipped) 1278-011 FLUID SPILLAGE CONTAINMENT Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500n, for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

1. Put fuel ratio control (1) into position on the governor housing.Make sure bolt (3) engages with stop collar (4) in the governor housing.

2. Install the bolts that hold fuel ratio control (1) to the governor housing.

1. Disconnect line (3) to fuel ratio control (1).

2. Remove bolts (2). Remove fuel ration control (1).

3. Connect the air line at fitting (2).

L,

3408C & 3412C Marine Engines

35

Disassembly & Assembly

Disassemble Fuel Ratio Control 1278-015 Start By: a. remove fuel ratio control

FLUID SPILLAGE CONTAINMENT Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG250OW, for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

5-

Remove the three bolts (9) and cover (10).

6. Remove valve (7),diaphragm (8), retainer and spring

7. Remove pin (12) from valve (7).

8. Remove cover (I 1) from the valve.

1. Remove two bolts (1) and the housing (2).

9. Remove the seal fromcover (1I).

2. Remove valve assembly (3).

3. Remove seal (4) and O-ring seal from valve.

4. Remove the retainer (5) and two springs (6).

3408C & 3412C Marine Engines

36

Disassembly & Assembly

Assemble Fuel Ratio

Control 1278-016 FLUID SPILLAGE CONTAINMENT

I

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE. NENG2500". for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

4.' 'I'&&ll spring

md retdner

(6)in cover (8).

I@) an valve assembly (4) and in

!f& Instiall 'dkphF-kgrn thecover.

-

1. Put clean engine oil on the lip of seal (1). lnstall seal

6. Install covw and three bolts (I 1) that hold covers together.

(1) in cover (2). Install the seal so the lip is toward the inside of the cover.

7. Put clean engine oil on seal and ring seal. lnstall the seals (10) on valve.

8. lnstall the two springs (13), retainer, and valve assembly (12).

9. Install housing (9) and two bolts.

NOTE: Correct adjustment must be made to the fuel ratio control before installation. See the Systems Operation, Testing & Adjusting Manual.

End By:

a. install fuel ratio control 2. lnstall valve (3) into cover (2).

3. lnstall the pin that holds the cover on the valve.

3408C & 3412C Marine Engines

37

Disassembly & Assembly

Service Meter Remove & Install Service Meter 7478-010

NOTE: Lubricate the O-ring seal with clean diesel fuel prior to installation.

3. Lubricate the O-ring seal with clean diesel fuel prior to installation. Install the O-ring seal on service meter (1).

1

-

NOTE: The fuel injection lines have been removed for picture clarity.The fuel injection lines do not have to be removed in order to remove the service meter.

4. Install service meter (1) on fuel transfer pump (3).

Position service meter (1)for viewing from right hand side of the engine.

1. Remove two bolts and clamps (2) that hold service meter (1) to fuel transfer pump (3). Remove service meter (I).

5. Install two bolts and clamps (2) securing service meter (1) to fuel transfer pump (3).

2. Remove the O-ring seal on service meter (1).

NOTE: The following steps are for the installation of the service meter.

3408C & 3412C Marine Engines

38

Disassembly & Assembly

I

Install Fuel Transfer Pump 1256-012

Fuel Transfer Pump Remove Fuel Transfer Pump 1256-011 Start By: a. remove service meter

FLUID SPILLAGE CONTAINMENT Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG25001', for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

1. Install the gasket on fuel transfer pump (2).

2. Put fuel transfer pump (2) in position on the governor.

3. Install two bolts (3).

4. Connect two fuel lines (1)to the transfer pump.

End By:

I

a. install service meter

NOTE: The fuel injection lines have been removed for picture clarity.The fuel injection lines do not have to be removed in order to remove the service meter.

1. Disconnect and cap two fuel lines (1) from fuel transfer pump (2).

2. Remove two bolts (3).

3. Remove fuel transfer pump (2) and the gasket.

3408C & 3412C Marine Engines

39

Disassembly & Assembly

9%

Disassemble Fuel Transfer Pump 1256-015 Start By:

a. remove fuel transfer pump

FLUID SPILLAGE CONTAINMEN1 Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLSAND SHOP PRODUCT GUIDE, NENG25001', for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

4. Remove O-ring seal (7) from fitting (3).

5. Remove three socket head bolts (8).

6. Remove cover (9) from the fuel transfer pump.

1. Remove fittings (3) and (4) from fuel transfer pump (5).

2. Remove gasket (1) and O-ring seal (2) from fuel transfer pump (5).

7. Remove lip seal (10) from cover (9).

3. Remove O-ring seal (6) from fitting (4).

3408C & 3412C Marine Engines

40

Disassembly & Assembly

8. Remove plug (11) from cover (9).

16. Remove gear (23) from shaft (21).

9. Remove O-ring seal (12) from plug (11).

,

10. Remove plug (17), two washers (16), seal (15), spring (14) and plunger (13) from cover (9).

11. If necessary, remove the ferrule.

17. Remove Bearing (24) from body assembly (18).

18. Remove two lip seals (25) from body assembly (18)

12. Remove nut (20) from the shaft.

I '

13. Remove gear (19) and the key from the shaft.

19. Remove valve (26), idler shaft (28), and bearing (27) from body assembly (18).

) 14. Remove shaft assembly (21) from body assembly

-- 1

(18).

15. Remove gear (22) from body assembly (18).

3408C & 3412C Marine Engines

41

Disassembly & Assembly

Assemble Fuel Transfer Pump 1256-016

4. lnstall first lip seal (25) with Tooling (C). lnstall first lip seal (25) until it is 26.19 k 0.13mm (1.031 k .OW in) from the bottom (drive gear) surface and with the lip facing toward bearing (27).

5. lnstall second lip seal (25) with Tooling (D). lnstall second lip seal (25) until it is 14.2 0.5 rnm (.559 '-' k .020 in) from the bottom (drive gear) surface and with the lip facing away from bearing (27).

+

6. lnstall bearing (24) in body assembly (18) with Tooling (E). The bearing (24) must be even with the bottom (drive gear) surface of the pump body.

1. Install valve (26) with Tooling (B).

2. lnstall idler shaft (28) until flush with bottom of body assembly (18).

3. Install bearing (27) with Tooling (A). Bearing (27) must not extend above the (gear) surface of body assembly (18).

7. Heat gear (23)to a maximum of 315" C (600" F). lnstall gear (23) on shaft (21) until dimension (X) is 49.71 k 0.25 mm (1.957 +. .010 in).

3408C & 3412C Marine Engines

42

Disassembly & Assembly

2 +

<

' ,,. .

...:

.I"- " -

.

*

@~)k-@&i m b b (18):

'b%x~lshcdt +... ~ 9 m b j g

a

15. Install lip seal (10) in cover (9) with Tooling (C). lnstall the seal until it is 22.61 0.05 mm (.890 .W2 in) from the top surface of cover (9) and with lip facing toward gears (22) and (23).

+

Ir&all gear (22) on idls~ahaft(28).

+

NOTlCE Do not let the liquid gasket enter the pump during application or assembly.

.

,

10. lnstall gear (193 on the&%,-rn~~.

8

11. Iristall rmf (20)on the sb&&Edy. to a torque 6 4i@% T Nm@[#

RQ)'

T1ghBn nut f $ bft).

16. Put 7M-7260 Liquid Gasket Material on the surface of cover (9).

17. Install cover (9) on body assembly (18).

18. lnstall three socket head bolts (8).

NOTE: The drive shaft must turn freely after sower head bolts (8) are tightened.

12. lnstall O-ring (12) on plug (11).

13. lnstall plug (11) in cover (9).

-

14. lnstall plunger (13), spring (14). seal (15), two washers (16) and plug (17) in cover (9).

3498C 8 3412G Marine Engines

43

Disassembly & Assembly

Fuel lnjection Pumps Remove Fuel Injection Pumps 1251-011 Tools Needed 6V6019

Timing Pin

8T5287

Wrench

852244

Extractor

A B C 1 1 1

19. lnstall O-ring (7) on fitting (3).

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500n, for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

20. lnstall O-ring on fitting (4).

1. Remove the plug from location (1). lnstall Tool (A) in

the hole with the square end down. Move the governor control to the "ON" position until the rack stops against Tool (A). The racks are now in center (zero) position.

21. lnstall fittings (3) and (4) in the fuel transfer pump.

22. lnstall gasket (1) on the fuel transfer pump.

23. lnstall O-ring seal (2) on the fuel transfer pump.

End By:

a. install fuel transfer pump

3408C & 3412C Marine Engines

44

Disassembly & Assembly

2. Disconnect lines (2) from the fuel injection pumps.

Remove washers (3). Put caps on all fuel openings.

8. Remove spacer (8)from the fuel injection pump bore. Keep spacer (8)with respective fuel injection pump.

3. Remove bushings (4) with Tool (6).

4. Remove fuel injection pump with Tool (C). Remove spacer (8).

Install Fuel Injection Pumps 1251-012

NOTE: 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.

Tools Needed

5. Disassemble the fuel injection pump. Remove ring (6). Make a separation of bonnet (5) from the plunger and barrel assembly (7).

NOTICE Be careful when the injection pumps are disassembled. Do not cause damage to the surface on the plunger. The plunger and barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel of another pump. If one part has wear, install a complete new pump assembly. Be careful when the -, pCunger is put into the bore of the barrel.

Timing Pin

8T5287

Wrench

882244

Extractor

1

b

11 1

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500t1, for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

6. Remove the gear segment, washer and spring from the barrel.

7. Remove the ring, spring, collar, and valve from the barrel.

3408C & 3412C Marine Engines

6V6019

A B C

NOTE: Make sure the fuel racks are in the center (zero) position before the fuel injection pumps are installed.

45

Disassembly & Assembly

5. Install seal (1)and bushing (15) in the pump housing bore. If the pump is in the correct position, bushing (15) will turn into the threads of the pump housing with the fingers until it is even with the housing.

Tighten bushing (15) to a torque of 205 14 N-m / (lS0 10 lbaft),

+

+

L

6. Install washers (16).

7. Connect the fuel lines to the injection pumps and tighten the fuel line nuts to a torque of 40 +: 7 Nwm (30 5 Ib ft) with Tool (D).

+

8. Check for correct installation of the injection pumps with the engine stopped. See Injection Pump Installation in the Systems Operation, Testing & Adjusting Manual.

1. Put plunger (1O), washer (5)and spring (9) in position on barrel (4). Put check valve assembly (7), spring (3) and collar (8) in position in bonnet (6).

Connect bonnet (6) and barrel (4) together with ring (2). Keep seal (1) with bonnet for use at installation.

NOTICE If one or more of the injection pumps have been installed wrong, damage to the engine is possible if cautions are not taken when the engine is first started.Make preparation to close off the air intake to stop the engine, if necessary.

2. Put spacer (13) into position in the pump housing bore. Make sure the correct spacer is with each P'J"P. 3. Put the space in gear segment (11) in alignment with the groove in barrel (4).

9. Remove Tool (A) and install the plug in the pump housing.

4. Put the injection pump straight down into the housing bore so the space in gear segment (11) is in alignment with pin (12) and the groove in barrel (4) is in alignment with dowel (14). Use Tool (C) to install the pump.

3408C & 3412C Marine Engines

46

Disassembly & Assembly

Governor & Fuel Pump Drive \

I

Remove & Install Governor & Fuel Pump Drive 1288-010 Tools Needed 98-9082

Engine Turning Pinion

0s-1619

Bolt 3/8-16 NC x 76 mm (3 in) long

A B 1 1

Start By:

a. remove front housing cover

2. Install Tool (A).

3. Remove plug (2).

),

1. Remove cover (1).

4. Install Tool (B).

5. Turn the engine counterclockwise (as seen from the flywheel end of engine) with Tool (A) until No. 1 piston is at top center (TC)on the compression stroke and Tool (B) can be installed in the flywheel.

See Top Center (TC) for No. 1 piston in Testing & Adjusting.

3408C & 3412C Marine Engines

-- ..-- -.------<

MA-

47

Disassembly & Assembly

9. Remove cover (1).

6. Put alignment mark on governor and fuel pump drive (3).

7. Remove four bolts (4) and retainer (5).

10. Install Tool (A).

11. Remove plug (2).

8. Remove governor and fuel pump drive (3).

NOTE: The following steps are for the installation of the governor and fuel pump drive.

12. Install Tool (6).

13. Turn the engine counterclockwise (as seen from the flywheel end of engine) with Tool (A) until No. 1 piston is at top center (TC) on the compression stroke and Tool (6) can be installed in the flywheel.See Top Center (TC) for No. 1 piston in Testing and Adjusting.

34086 & 3412C Marine Engines

48

Disassembly 81Assembly

NOTE: Lubricate the weights and slides inside the governor and fuel pump drive with clean engine oil prior to installation.

NOTE: Inspect gasket (6) for damage or wear, if necessary replace with a new gasket.

15. Install retainer (5) and four bolts (4). Tighten four bolts (4) to a torque of 136 7 N=m(101 +5 Ib ft).

+

16. Install plug (2) and cover (1).

End By: 14. Install governor and fuel pump drive (3) in position

a. install front housing cover

according to the alignment mark.

3408C & 3412C Marine Engines

49

Disassembly & Assembly

Disassemble Governor & Fuel Pump Drive 1288-015 Start By: a. remove governor and fuel pump drive

2. Remove two springs (2) and two weights (3) from drive gear assembly (4).

1. Remove flange assembly (I), -

50

-

Disassembly & Assembly

3. Remove two slides (5)from pistons (6).

4. Separate drive gear assembly (4)from advance sleeve (71-

Install s l i w (5) on pistons (6K

- .

5. Install advance sleeve (7) to drive gear assembly (4).

Assemble Governor & Fuel rump Drive 1288-016 1288-016

6. Install drive gear assembly (4)on flange assembly (1). Make sure slides (5) fit in grooves of the weights.

End By:

,-

-

.

1. Put weights (3) in position in flange assembly (1)as shown.

a. install governor and fuel pump drive

2. Install springs (2) in flange assembly (1).

3408C & 3412C Marine Engines

51

Disassembly & ~ssembly

Fuel lnjection Pump Housing & Governor Remove Fuel Injection Pump Housing & Governor 1253 & 1264-011 Start By:

a. remove fuel injection lines b. remove governor & fuel pump drive

FLUID SPILLAGE CONTAINMENT

2. Remove two bolts, washers and spacers (2).

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500I1, for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

3. Remove two bolts, washers and spacers (3).

L

1. Disconnect two fuel lines (1) to the fuel transfer pump. Cap or plug immediately

4. Remove three bolts and washers (4).

5. Remove bracket (5).

I

3408C & 3412C Marine Engines

52

Disassembly & Assembly

.I

6. Remove two bolts and washers (6).

7. Remove bracket (7).

9. Attach a lifting sling and a suitable lifting device to fuel injection pump housing &governor (9) as shown.

10. Move fuel injection pump housing & governor (9) back towards the rear of the engine until clear of the governor and fuel pump drive housing.

w

11. Remove fuel injection pump housing & govemor (9). The weight of the fuel injection pump housing & governor is 56 kg (125 Ib). .Lr 12. Remove the two O-ring seals on the bottom of the fuel injection pump housing & govemor.

13. Remove the O-ring seal on the front of the fuel injection pump housing & governor.

-'?

8. Disconnect two hoses (8). Cap and plug all openings immediately.

3408C & 3412C Marine Engines

Disassembly & Assembly

Install Fuel Injection Pump Housing & Governor 1253 & 1264-012 NOTE: Inspect all O-ring seals prior to installation for wear or damage. If necessary, replace with new O-ring seals.

NOTICE Make sure there is no paint, dirt or other foreign material on the machined surfaces of the engine or fuel injection pump housing. Be careful not to damage the O-ring seals for the oil inlet and oil outlet as the pump is put into position on the engine.

6. Connect two hoses (8) to the fuel injection pump housing.

1. Install the O-ring seal located on the front of the fuel injection pump housing and govemor.

7. Put bracket (7) in position and install two bolts and washers (6).

2. Install the two O-ring seals located on the bottom of the fuel injection pump housing and governor.

3. Put a light layer of 5P-0960 Multi-Purpose Grease on the O-ring seal located at the front of the fuel injection pump housing and governor and on the two O-ring seals found on the bottom of the fuel injection pump housing and governor (oil inlet and oil outlet).

4. Attach a lifting sling and a suitable lifting device to fuel injection pump housing and govemor (9) as shown.

5. Put fuel injection pump housing and governor (9) in position on the cylinder block.

8. Put bracket (5) in position and install three bolts and washers (4).

3408C & 3412C Marine Engines

54

Disassembly & Assembly

Governor Disassemble Governor 1264-015 Tools Needed 6V-6019 Timing Pin

A 6 C 1 1

1P-1856 Retaining Ring Pliers

1

1P-1855 Retaining Ring Pliers

9. Install two bolts, washers and spacers (3).

1

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing,-adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500N, for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and manbates.

NOTE: The fuel injection pump housing & governor does not have to removed from the engine to disassemble the governor. The fuel injection pump 1.housing & governor have been removed from the engine to disassemble the governor for photographic 1 I. purposes.

1

10. Install two bolts, washers and spacers (2).

"

11. Connect two fuel lines (1) to the fuel transfer Pump.

1. Remove plug (1) from the fuel injection pump housing.

End By:

a. install governor & fuel pump drive b. install fuel injection lines

34086 & 3412C Marine Engines

55

Disassembly & Assembly

5. Remove gasket (6) from housing assembly (5).

2. Install Tool (A) into the fuel injection pump housing with the square end down. Use a small amount of hand force to push down on Tool (A) while the fuel control lever is moved forward to the "FUEL ON" position until Tool (A) seats itself. The fuel rack will stop in the center "zero" position.

6. Remove seven bolts (7) fastening housing assembly (5) to plate group (8).

3. Remove wire tie (2).

4. Remove five bolts and washers (3) fastening adapter group (4) to housing assembly (5).

3408C & 3412C Marine Engines

56

Disassembly & Assembly

L

10. Remove gasket ( I3) from the bottom af housing (5).

There is spring force under collar (9). Remove socket head bolt (10) slowly while holding collar (9) in place to allow the spring force to be released gradually.

7. Remove socket head bolt (10) from collar (9) while holding collar (9) in place to prevent sudden release of the spring force.

8. Remove spring (11).

11. Remove locknut (14).

9. If necessary, remove nut and screw (12) from collar (9).

12. Remove cotter pin and pin (15).

34086 & 3412C Marine Engines

57

Disassembly & Assembly

13. Remove throttle control rod (16) from bracket (17).

Shaft (20) is under spring force. Remove shaft (20) from handle (21) slowly while holding shaft (29) in place to prevent possible personal injury. . . /

16. Remove shaft (20) from handle (21) by turning counterclockwise.

17. Remove the spring from shaft (20).

18. Remove handle (21) from guide (22).

19. Remove two screws (23) from bracket (17).

14. Remove locknut (18) from throttle control rod (16).

15. Fiemove spacer and spring (19) from throttle cantrol rod (16).

20. Remove guide (22), quadrant control (24), hub (25), ratchet (26) and bracket (17) from the shaft.

3408C & 3412C Marine Engines

58

Disassembly & Assembly

-

C

32. Remove gasket (40).

NOTE: Mark locations af idle screws (39) and (41) prior to removal from the housing.

33. Make alignment mark an high idle screw (39) and remove high idle screw (39) counting the number of turns until removed.

34. Makg qrirnent mark oQ~;ltw/dlescrew (41) and rern6~~.5&~~&&fBwr$lJcounting the number

of turn@ k@i iemb@d.

',

'

. .

21. Remove two socket head bolts (27).

22. Remove lock (28).

-'

23. Remove retainer (29).

24. Remove insulator (30).

35. Remove two socket head screws (44) fastening bracket (43) to the housing.

25. Remove contact (31).

36. Remove felt washer (42) from the shaft.

26. Remove retainer (32).

27. Remove shim (33).

28. Remove bar (34).

29. Remove insulator (35).

30. Remove cover (36).

-331. Remove bolt (37) and cover (38).

3408C & 3412C Marine Engines

59

Disassembly & Assembly

41. Remove two seals (49) from both sides of the housing.

37. Remove bolt (45).

38. Remove shaft (47) and lever assembly (46).

42. If necessary, remove plug (50) and the O-ring seal.

Pin (48) has a large amount of spring force behind it.

The spring force will not release slowly during removal of pin (48). Remove pin (48) very carefully to avoid possible personal injury.

39. Remove pin (48) slowly and carefully due to the large spring force behind it.

40. Remove the spring and the stop plunger inside lever assembly (46).

45. Remove valve (55) from valve body (53).

46. Remove O-ring seal (54) from valve (55).

47. Remove O-ring seal (56) from valve body (53).

3408C & 3412C Marine Engines

60 !

Disassembly & Assembly

C

,A'

48. Remove seat (57) and spring (58).

52. Use Tool (6) to remove retaining ring (63).

49. Use Tool (B) to remove retaining ring (59).

53. Remove spring seat (65) and bolt stop (64) from the governor.

50. Remove spacer ring (60).

51. Remove spool (61) and spring (62).

3408C & 3412C Marine Engines

61

Disassembly & Assembly

56. Remove governor weight (69) from the governor.

54. Disassemble spring seat (65) and bolt stop (64) as follows:

L

a. Remove retaining ring (68) from spring seat (65).

57. Remove four bolts (72).

b. Remove bearing (67) from spring seat (65).

58. Remove adapter plate (71)from the fuel injection pump housing.

c. Remove bolt stop (64) from spring seat (65). d. Remove spacer (66)from spring seat (65).

59. Remove pin assembly (74) fastening drive assembly (73)to gear (75).

55. Remove lockring (70) from governor weight (69).

3408C & 3412C Marine Engines

60. Remove drive assembly (73) from gear (75)

62

Disassembly & Assembly

NOTE: Make a note of alignment marks on stop (76) used for installation purposes.

65. Turn adapter plate (71) over

66. Use Tool (C) to remove retaining ring (81) from gear (75).

61. Remove stop (76) from gear (75).

67. Remove three bolts (79) and bracket assembly (80) from adapter plate (71).

62. Remove dowel (78) from guide (77).

63. Remove guide (77) from adapter plate (71).

68. Disassemble bracket assembly (80) as follows: 64. Remove the O-ring seal inside guide (78). a. Remove piston (88).

b. Remove valve (87). c. Remove pin (86). d. Remove sleeve (85).

e. Remove O-ring seal (84)from sleeve (85).

f. If necessary, remove dowel (83) and lever (82).

--

3408C & 3412C Marine Engines

63

--

isa assembly& Assembly

69. Remove gasket (89) from adapter plate (71).

76. Remove four bolts (96) from adapter group (4).

70. Remove plug (91) from adapter plate (71).

77. Remove two covers (97) from adapter group (4).

71. Remove two dowels (90) from adapter plate (71).

72. Remove cylinder (92) from adapter plate (71).

73. Remove dowel (94) from adapter plate (71).

74. Remove bearing (93) from adapter plate (71).

78. Remove two gaskets (98) from adapter group (4).

75. Remove two O-ring seals (95) from cylinder (92).

79. Remove cover (99) from adapter group (4).

I

3408C & 3412C Marine Engines

64

Disassembly & Assembly

a1

80. Remove wire tie (102) from bolt stop (100).

87. If necessary, remove dowel (106) and plug (107) from plate assembly (105).

*.

81. Remove nut and washer (101) from bolt stop 82. Remove bolt stop (100) from cove; (99).

)i:

~

aa. Remove gasket ( T I 0) f r h adapter. group (4).

L

89. Remove four sbcket head bolts (108).

-4

83. Remove gasket (103) from adapter group (4).

90. Remove lever (107) and (109).

84. Turn adapter group (4) over.

91. Remove bolt (112), lever (113) and the woodruff key.

85. Remove bolt and washer (104) from adapter group (4).

92. Remove shaft (111) from adapter group (4).

--i 86. Remove plate assembly (105) from adapter group (4).

a d 8 a~341% Marine Engines

65

Disassembly & Aseembly

Assemble Governor 1264-Of 6 Tools Needed 6\1-6019 Timing Pin 1P-1856 Retaining Ring Pliers 1P-1855 Retaining Ring Pliers 1P-0510 Driver Group

NOTE: Inspect all parts of governor for wear of damage prior to assembly. If necessary, replace any worn or damaged part with a new part. Lubricate all O-ring seals with clean engine oil prior to assembly.

93. Remove insulator (114) from adapter group (4).

94. Remove two bearings (115) and (118) from adapter group (4).

95. Remove two lip seals (116) and (119) from adapter group (4).

96. Remove valve (117). Remove the 0;ring seal from valve (117). -

1. Install valve assembly (120) in adapter group (4).

97. Remove valve assembly (120).

3408C & 3412C Marine Engines

66

Disassembly & Assembly

2. Install insulator (114) in adapter group (4). Tighten insulator (114) to a torque of 4.52 r 0.60 Nm (40.000 r 5.000 Ib in).

NOTE: Lubricate two lip seals (116) and ( I19) with clean engine oil prior to installation of shaft (111).

7. lnstall shaft (111).

NOTE: All measurements involving bearing (115) are taken at the cen'ter of the bearing.

8. Install the woodruff key and lever (1 13) on shaft (11I),

3

3. Use Tool (D) to instatf (115) to a depth of 2.13 & 0.10 h m l0.084 .004 in) from the outside face of adapter group (4).

a.

Instal bolt (112) in lever (113). .

-. ,

.

4. Use Tool (D) to install bearing (118) until outward facing surface of bearing (118) is 110.84 & 0.50 mm (4.340 & .020 in) from the bottom of bearing (115). .

)

I

5. Use Tool (D) to install lip seal (116) until seated firmly against the counterbore face with lip facing the counterbore surface.

6. Use Tool (D) to install lip seal (119) until seated firmly against barina (118) with lip seal facing away from bearing ($18).

10. Install lever (107) and (109).

11. Install four socket head bolts (108) fastening levers (107) and (109) to shaft (111).

12. lnstall gasket (110) on adapter group (4).

3408C & 3412C Marine Engines

67

Disassembly & Assembly

13. If removed, install dowel (106) in plate assembly (105).

17. Put gasket (103) in position on adapter group (4).

14. Install plug (107)

18. Install bolt stop (100) in cover (99).

19. Install washer and nut (101) on bolt stop (100).

15. Put plate assembly (105) in position on adapter group (4)-

NOTE: Wire tie (102) can only be installed after final adjustments have been made to the governor.

16. Install bolt, washers and nut (104).

3408C & 3412C Marine Engines

68

Disassembly & Assembly

L

21. lnstall two O-ring seals (95) on cylinder (92).

I

NOTE: Lubricate the entire cvlinder and the 0-rina seals with 1P-0808Lithium Grease prior to installation in plate group (71). v

22. lnstall cylinder (92) in plate group (71).

23. lnstall plug (91) in plate group (71).

24. Use Tool (D)to install bearing (93) until it is 0.51 0.25 mm 1.0204 2 .0100in) below the top surface & plate group (71).

20. lnstall two gaskets (98), two covers (97), cover

25. lnstall gasket (89) on plate group (71).

(99) and four bolts (96).

3408C & 3412C Marine Engines

+

69

Disassembly & Assembly

.22 in.

(5.58 mm)

1.

33. Put bracket (80) in position on plate group (71).

34. lnstall three bolts (79) fastening bracket (80) to plate group (71).

26. If a replacement of the dowels in plate group (71) is necessary, see the illustration for correct installation dimensions.

35. lnstall gear (75).

36. Use Tool (C) to install retaining pin (81) on gear

27. Put lever (82) in position on bracket (80).

28. lnstall pin (83) in bracket (80).

37. lnstall guide (77) on plate group (71). rv. lnstall O-ring seal (84) on sleeve (85).

38. lnstall dowel (78) in guide (77).

30. lnstall valve (87) in piston (88).

31. lnstall pin (86) in bracket (80) and engage with lever (82).

32. Engage piston (88) with pin (86).

3408C & 3412C Marine Engines

70

Disassembly & Assembly

i

NOTE: Make sure to align marks on stop (76) and gear (75) during assembly.

NOTE: Make sure the rack is held in the "zero" position with Tool (A) during installation of plate group (71). Make sure lever (82) engages with the rack during installation.

39. Install stop (76) in gear (75). Align alignment marks to ensure proper assembly

42. Place plate group (71) in position on the fuel injection pump housing.

43. lnstall four bolts (72) fastening plate group 71) to the fuel injection pump housing.

40. lnstall drive assembly (73) in gear (75).

J

41. lnstall pin assembly (74) in gear (75). Ensure the ends of pin assembly (74) are engaged in the grove of the gear.

44. lnstall governor weight (69) on plate group (71).

45. Install lockring (70) on governor weight (69).

Ensure the ends of lockring (70) are engaged in the governor weight.

3408C & 3412C Marine Engines

71

Disassembly & Assembly

51. Use Tool (B) to install retaining ring (63) securing the spring seat to the guide.

46. lnstall bolt stop (64) in spring seat (65).

47. lnstall bearing (67) in spring seat (65).

48. lnstall retaining ring (68) in spring seat (65).

52. lnstall spring (62) on the bolt stop.

49. lnstall spacer (66) in spring seat (65).

53. lnstall spool (61) on the bolt stop.

50. Install spring seat (65) and bolt stop (64) on the plate group as shown.

54. lnstall spacer ring (60) on the bolt stop.

55. Use Tool (B) to install retaining ring (59) fastening spacer ring (60) to the spool.

3408C & 3412C Marine Engines

72

Disassembly & Assembly

L

56. lnstall spring (58) and spring seat (57).

60. lnstall valve (53) in the housing.

61. Use Tooling (D) to install bearing (52). Dimefision '$7 is 43.38 & 0.015 rnrn (1.708 2 .0006 in).

62. Use Tooling (D) to install bearing (51). Dimension X' is 25.35 & 0.13 rnm (.998 & .005 in). ,)

63. Check dimension "r'.

Dimension "Y" must be 60.58 & 0.13 rnrn (2.385 & .005 in).

57. lnstall O-ring seal (54) on valve (55).

58. Install O-ring seal (56) on valve body (53).

59. lnstall valve (55) in valve body (56).

64. Use Tool (D) to install two lip seals (49) until they are flush with the outside face of the housing and with the lips of both seals facing towards the inside.

NOTE: ~ubricatethe bore with clean engine oil before installing plug (50).

65. lnstall plug (50) and the O-ring seal.

3408C & 3412C Marine Engines

73

Disassembly & Assembly

66. Install the stop plunger, spring and pin (48) in lever assembly (46).

69. Install felt washer (42) on the shaft.

70. lnstall bracket (43) and two socket head bolts (44).

67. Put lever assembly (46) in position in the housing and install shaft (47).

71. lnstall high idle screw (3) the Same number of turns as during removal.

68. lnstall bolt (45) in lever assembly (46)

72. Install low idle screw (41) the same number of turna w during removal.

73. lnstall gasket (40) an the housing,

3408C & 3412C Marine Engines

74

Disassembly & Assembly

85. lnstall guide (22), quadrant control (24), hub (25), ratchet (26) and bracket (17) on the shaft.

86. lnstall two screws (23)fastening bracket (17),to the housing.

064050

87. lnstall the spring,<govemorcontrol shaft (20) and handle (21).

74. lnstall cover (38) and bolt (37).

75. lnstall cover (36).

76. lnstall insulator (35).

77. lnstall bar (34).

78. lnstall shim (33).

19. lnstall retainer (32).

80. lnstall contact (31).

81. lnstall insulator (30).

82. lnstall retainer (29).

88. lnstall spring (19) and locknut (18) on throttle control rod (16).

83. lnstall lock (28).

3

84. lnstall two socket head bolts (27).

--./

3408C & 3412C Marine Engines

75

Disassemblv & Assembly

89. Install throttle control rod (16) in bracket (17).

92. Install gasket (13) on the bottom of housing (5).

90. Install pin and cotter pin (15) fastening the throttle control rod to the quadrant.

93. Install screw and nut (12) in collar (9).Tighten nut (12) to a torque of 12 4 Nm (106.8 35.6 Ib in).

+

L

+

91. lnstall locknut (14) on the throttle control rod.

94. lnstall spring (1I), collar (9) and socket head bolt (10).

I 3408C & 3412C Marine Engines

76

Disassembly & Assembly

-

!'

95. Put housing (5) in position on plate group (8).

NOTE: Do not install wire tie (2) until after adjustments to the governor have been made.

96. Install seven bolts (7) fastening housing (5) to plate

100. Remove Tool (A).

97. Install gasket (6) on top of housing (5).

101. Install plug (I).

98. Put adapter group (4) in position on housing (5).

99. Install five bolts and washers (3).

. 3408C & 34126 Marine Engines -------.

.-

Disassembly & Assembly

Disassemble Fuel Injection Pump Housing 1253-015

Start By: a. remove fuel injection pump housing and governor

2. Remove shafl(6) from rear cover (2). Remove the gear from shaft (6). Remove the bushing from rear cover (2).

b. remove governor

3. Remove retainer (4). Remove gear (5).

FLUID SPILLAGE CONTAINMENT 4. Remwe oil pump cover (3).

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG25001', for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

NOTICE Be careful not to damage the inlet and outlet ports on the bottom of the pump housing. The pump housing A13CIJJl?lnbly. must be put on blocks before c';c-reab

5. Remove idler gear (7)-Remove pinion gear a ~ ~ m b(3) l yfrom tha pump housing with a soft hammer eras shown. Remove drive gear (8).

/

u

N m C W e n piniofl gear assembly @) iis removed, make a repkmsment af drive gear (8)with a new part.

1. Remove bolts (1) from rear cover (2). Remove cover (2) and the gasket.

3408C & 3412C Marine Engines

78

Disassembly & Assembly

10. Install Tool (D) in the pump housing with the square end down (end with taper will be up). Hold the racks against Tool (D) and remove each of the injection pumps (18) with Tool (B). For more details, see the topic "Remove Fuel Injection Pumps*.

7. Remove the bolts from levers (14) and (11). Remove shaft (16), lever (14), lever (1I), bearing (15) and spring washer (12). ,-

NOTE: Step (7) is only necessary on earlier fuel systems. Later systems have shutoff in governor housing.

8. Remove bypass valve (13). Remove the O-ring seal, pin, piston, and spring from the valve body.

._

11. Remove bolt (19) that holds bracket (23) to the fuel injection pump housing. Remove bracket (23) and link (20).

12. Put identification on the left rack (21) and right rack (22).Remove racks (21) and (22).

9. Remove the felt washer from bushing (17). Remove

bushing (17) from each of the injection pumps with Tool (A).

3408C & 3412C Marine Engines

79

Disassembly & Assembly

13. Ranowe!sp&c.ere t24) an& IIWrs' (25) from the injsdbn p m p hoU&ng; P u t k3#%R@tion.oneach ' csP the spmers and liftdm as toa"'th3rdw&imln the pump hoosit-f~.

15. Remove dowel (27), shaft (28) and dowel (29) with Tool (C).

16. Remove lower and upper bearings (30) that are supports for the pinion assembly.

17. Remove bearing (31) and the lip seal. Remove bearing (32) andthe lip seal.

NOTICE Be careful not to damage the camshaft bearings as the camshaft is removed.

3408C & 3412C Marine Engines

--.

0

18. Remove the rack bearings from locations (33).

19. Remove the camshaft bearings with Tool (E).

80

4

Disassembly & Assembly

Assemble Fuel Injection Pump Housing 1253-016

1. Put fixture assembly (3) (part of Tool (A)) on the pump housing with the dowels in fixture (3) engaged in the right ~ a c kbore. Install bolt (4).

2. Put a new bearing (2) in position between fixture (3) and the rack bore with..the tab of the bearing up.

Install the bearing with driver (1) until the shoulder of the driver makes contact with the fixture.

3. Turn the fixture and make alignment of the dowels Install the right on the fixture with the left ra~k~bore. wek'bedng ack@&Qg ..i to * the instk~ctions 2.

.

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500M, for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

3408C & 3412C Marine Engines

:,."

.-i

*.

4. Install O-ring seal (5).

81

Disassembly & Assembly

5. lnstall the camshaft Tront bearing (7) with Tool (6). lnstall the bearing until tt is 1.02 0.51 mm (.040 r .020 in) from front surface (6)of the pump housing.

8. Install the lower and upper bearings for the pinion gear assembly with Tool (C). lnstall the upper bearing until it is even with the top of the bearing bore and the bottom bearing until it is even with the bottom of the bearing bore.

+

NOTE: lnstall a camshaft beadngs with the bearing joint in area 'X".

This will put the oil hole in area "Y".

For more complete illustration of bearing installation, make reference to the Specifications Manual.

9. Install shaft (11) in the pump hausing until it is extended 16.76 r 0.51 mm (.SO & ,020 in) from the top of the pump housing.lnstal1 dowel (12) until it is extended 11.18 r 0.51' mm (A40 r .026 in) from the top of the pump housing.

NOTE: Steps 10 thru 13 and Step 24 apply only to earlier fuel systems with fuel shutoff shaft in injection pump housing.

6. lnstall center bearing (9) with Tool (6)until the rear edge of the bearing is 127.00 r 0.51 mm (5.000 r .020 in) from rear surface (8) of the pump housing.

7. lnstall rear bearing (I 0) with Tool (B) until it is 4.83 r 0.51 mm (.I90 2 .020 in) from rear surface (8).

3408C & 3412C Marine Engines

82

Disassembly & Assembly

14. Put clean engine oil on the camshaft bearings and on camshaft (17),lnstall camshaft (17) as shown.

)

10. lnstall bearing (13) with Tool (D) until dimension "Z" is 38.23 & 51 mm (1.505 & .MO in) Dimension "Z" is taken from the end of bearing (13) to the outer face of the pump housing boss.

15. Put clean engine oii on lifters (19.). lnstall lifters (19) and spacers (18) for each af'the injection pumps.

Be sure the lifters and spacers are put in their original location in the pump housing.

11. lnstall seal (14) with Tool (D). lnstall the seal even

with the surface of the housing and with the lip toward the outside as shown.

12. lnstall bearing (15) with Tool (D) until dimension "R" is 34.80 & 0.51 mm (1.370 & .020 in).

Dimension "R" is the distance between bearings.

16. Put clean engine oil fuel racks (20) and (22). Install left rack (22) in the pump housing with the groove in the rack engaged with the tab of the rack bearing. lnstall right rack (20) with the groove in the rack engaged with the tab of the rack bearing.

NOTE: The right rack has a notch (21) cut into the rear end of the rack:

13. lnstall seal (16) with Tool (E). lnstall the seal until it is even with the surface of the pump housing and with the lip toward the outside as shown.

3408C & 3412C Marine Engines

83

Disassembly & Assembly

17. lnstall dowel (23) in the pump housing until it is extended 12.2 +. 0.5 mm (.48 .02) from the surface of the pump housing.

20. lnstall pinion gear (29) in the pump housing. Use ' an 11/16".Socket and a "C" clamp with a minimum opening of 22.9 cm (9 inches) and install pinion gear (29) until the pump drive gear makes contact with the shoulder of the pinion gear shaft.

+

18. lnstall link (25) and brac'ket (26). Tighten bolt (24) to standard torque. Be careful so bracket (26) does not turn as bolt (24) is tightened.

/

-.

7

L

21. lnstall spring (30) and piston (32) in valve body (34). lnstall pin (33). lnstall seal (31).

19. lnstall idler gear (27) on the shaft. Put drive gear (28) in position with the bevel side of the gear down. Make sure the teeth of the idler gear and drive gear are in alignment and install the pump cover.

NOTE: Pin (33) must not extend out from either side of valve body (34).

" L

22. Put clean engine oil on valve body (34) and seal (31). lnstall the oil bypass valve in the pump housing.

3408C & 3412C Marine Engines

84

Disassembly & Assembly

L

26. Install cover (45).

27. Install Tool (F) in the injection pump housing with the fat end down. Use a punch or a screwdriver to push the rack into housing. At the same time, push down on Tool (F) until it engages in slot (groove) in the rack. The rack is now centered (in the zero position) and the fuel injection pump can he installed.

23. Remove pump cover (40) and clean the metal clips from the fuel injection pump housing. lnstall pump cover (40).

24. Put lever (35) bearing and spring washer (37) into position in the pump housing. lnstall shaft (38). lnstall lever (39). lnstall bolts (41).

25. Put gear (42) and retainer (43) into position in the pump housing.lnstall bolts (44) and tighten to standard torque.

28. Put the space in gear segment (47) alignment with the groove in pump barrel (46). Put the injection pump straight down into the housing bore with the space in gear segment (47) engaged with the pin in the lifter and the groove in barrel (36) engaged with the dowel in the pump housing. Use Tool (H) to install the pumps.

V

3408C & 3412C Marine Engines

85

Disassembly & Assembly

33. Heat gear (52) t~a ~ i m u temperature m of 2SaC(45O0F).lnsWIthe gear on shaft (51) until it

29. Install bushing (48) in the pump housing bore. If

the injection pump is in the correct position, bushing (48) will turn into the threads of the pump housing with the fingers until it is even with The housing.

makes contact with the shoulder of the shaft.

34. Put rear cover (4 into )position on the pump houshg with sh&-f6t) in alignment with hole (53).

30. Tiahten bushinas 1481to 205 k 14 Nem (150 +16 lb ft) with ~&l' (G;).Install the felt wasier for each injection pump. For more detail see Install Fuel Injection Pumps.

31. Check the rack movement {lmvel)bwith Tool (K) after each pump b installedeSee Injection Pump Installation in the Systems Qperattan, Testing & Adjusting Manual.

35. Install bolts (54).

End By: a. install governor b. install fuel injection pump housing and governor 32. Install bearing (50) in rear cover (49) with Tool (J).

3408C & 3412C Marine Engines

86

Disassembly & Assembly

-,

Water Temperature Regulators Remove Water Temperature Regulators 1355-011 FLUID SPILLAGE CONTAINMENT

I

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine..

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500n, for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

<

5. Remove two gaskets (7).

6. Remove two bolts (5).

7. Remove water temperature regulator housing (6).

.EF 1. Drain the coolant from the radiator until the coolant level is below the water temperature regulator housings.

8. Remove tube (8).

9. Remove two gaskets (9).

2. Loosen the hose clamp and disconnect radiator hose (1).

10. Remove two bolts (1I ) , water connector (10) ana the gasket.

3. Remove four bolts (2) and tube (4).

4. Remove tube (3).

Disassembly & Assembly

3408C & 3412C Marine Engines

--

-

11. Loosen the hose clamp and disconnect hose (12).

17. Remove two gaskets (19).

12. Remove two bolts (13) and disconnect tube (14) from water temperature regulator housing (15).

18. Remove two bolts (21), water connector (20) and the gasket.

13. Remove tube (16).

-

NOTE: The removal of the water tem~eraturereaulator from the regulator housing is the same for both housings (7) and (15). For simplicity, only the removal of one water temperature regulator from the regulator housing is shown. ,

14. Remove two gaskets (17).

15. Remove three bolts (18).

16. Remove water temperature regulator housing (15).

3408C & 3412C Marine Engines

19. Remove gasket (22) from the water temperature regulator housing.

88

Disassembly & Assembly

Install Water Temperature Regulators 1355-012

1

FLUID SPILLAGE CONTAINMENT

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500I1, for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

20. Remove water temperature regulator (23)from the water temperature regulator housing.

NOTE: The installation of the water temperature regulator is the same for both water temperature regulator housings. For simplicity, the installation of only one water temperature regulator is shown.

NOTE: Ensure all gasket material is removed and all mating surfaces are free of dirt, oil and grease. R~place any damaged or worn gaskets or O-ring seals with a new part if necessary.

21. Remove O-ring seal (24) from water temperature regulator (23).

1. Install O-ring seal (24) on water temperature regulator (23).

3408C & 3412C Marine Engines

89

Disassembly & Assembly

5. Put the gasket and water connector (20) in position on the cylinder head.

NOTICE If the water temperature regulator is installed incorrectly, the engine will over heat.

6. Install two bolts (21) fastening water connector (20) to the cylinder head.

2. Install water temperature regulator (23) in the water temperature regulator housing.

7. Put two gaskets (19) into position on water connector (20).

3. Install gasket (22) on the water temperature regulator housing.

8. Put water temperature regulator housing (15) in position on the water connector.

j '

<

V

9. Install three bolts (18) fastening water temperature regulator housing (15) to the water connector.

4. Repeat steps 1 through 3 for the other water temperature regulator housing.

10. Put two gaskets (17) into position on water temperature regulator housing (15).

3408C & 3412C Marine Engines

90

Disassembly & Assembly

I

/

11. Put tube (14) into position on water ternpe~ature regulator housing (15) and install two bolts (13).

16. Put water temperature regulator housing (7) in position on the water connector.

12. Connect radiator hose (12) and tighten the hose clamp.

17. lnstall two bolts (5) fastening water temperature regulator housing (6) to the water connector.

13. Put the gasket and water connector (10) in ,position on the cylinder head. lnstall two bolts (11) fastening water connector to the cylinder head.

18. Install tube and two bolts (3).

-- \14.

19. Put tube (4) and the gaskets in position and install four bolts (2).

Install two gaskets (9) on the watek connector.

20. Connect radiator hose (1) and tighten the hose clamp.

'd 15. Connect tube (8)to the water connector.

3408C & 3412C Marine Engines --.-. ---.

4-

Disassembly & Assembly

91 -

-

I

Water Pump Remove Water Pump 1361-011

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

3. Remove four bolts (3) and tube (4).

NOTE: For clarity, the radiator has been removed for removal of the water pump. The radiator does not have to be removed to remove the water pump.

4. Remove two gaskets (5).

1. Drain the coolant from the cooling system into a

suitable container for storage or disposal.

2. Remove two hose clamps (1) and hose (2).

5. Remove five bolts (7) and water pump cover (8).

C

3408C & 3412C Marine Engines

92

Disassembly & Assembly

'

-

Install water Fump 1361--012

6. Remove four bolts (9).

7. Remove two O-ring seals (10).

I. Put water pump (14) in position on the front housing. Install the nuts and one bolt (13) that hold pump (14) to the front housing.

8. Remove two bolts (1I), elbpw (12) and the gaskets.

..

2. Put clean engine oil on the O-rings inside elbow (12). Install the gaskets on elbow (12).

3. Install elbow (12) in the oil cooler.

4. Install two bolts (11).

9. Remove one bolt and four nuts (13).

10. Remove water pump (14) from the front housing.

z 5

3408C & 3412C Marine Engines

93

---

j- ---A-

- -...

~ i s a s s e m b l bly $ ~ ~ .

-

- <-

.,-A

-.

----wp

5. Install four bolts (9) fastening the water pump to elbow (12).

9. Install two gaskets (5).

6. lnstall two O-ring seals (10). Lubricate two O-ring seals with clean engine oil.

10. lnstall tube (4) and four bolts (3).

7. Put water pump cover (8) in position.

8. lnstall five bolts (7).

11. lnstall tube (2) and two hose clamps (1).

.

.

-

.

3408e & 3412C Marine Engines

94

Disassembly & Assembly

L

Disassemble Water Pump 1361-015 Tools Needed

A B

892264

Puller Group

1PO456

Drive Plate

1

4B3903

Bolt

2

9M1974

Flat Washer

4

1P2320

Puller Assembly

1

9S9155

Step Plate

1

1

Start By:

4. Remove impeller (4)from the water pump housing with Tool (A).

a. remove water pump

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG25001', for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

5. Remove seal assembly (5). Remove rirrg and seal (6).

1. Remove O-ring seal (1) from adapter (2).

2. Remove ada~ter(2) with a screwdriver. Remove the seal from the edgk 'of adapter (2).

6. Remove the bolt and washer that hold gear (7) on the water pump shaft.

3. Remove bolt (3) and the washer.

7. Remove gear (7) with Tool (B).

8. Remove bolts and retainer (9).

9. Remove O-rings seal (8).

3408C & 3412C Marine Engines

95

Disassembly & Assembly

10. Remove shaft (10) and bearings ae a unit.

1. Put clean oil or glycerin on the lip of seal (1). Install seal (1) as shown with Tool (A).

11. Remove bearing - .(1I), . spacer (12) and bearing - (13) from shaft (10).

12. Remove the R p seal from the gear side of the water pump, Fiemtive.flng grid mal from the impeller side of the wa* pump.

Assemble Water Pump -1361-016 Tools Needed

A

1PO529

Handle

1

1PO479

Drive Plate

1

1PO469

Drive Plate

1

2. lnstall bearing (4), spacer (3) and bearing (5) on shaft (2). lnstall shaft (2) in the pump housing.

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500M, for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

3. lnstall retainer (7) and O-ring seal (8).

4. lnstall gear (6). lnstall the washer and bolt that hold gear (6) to shaft (2).

3408C & 3412C Marine Engines

96

Disassembly & Assembly

7. Install impeller (14) and the washer and nut (13)that hold 'the inpell6r to tfe'pump 9ha:ft.

8. Tighten nut (13) tb a torque of 39 1 Ib ft).

5. Put clean water on seal (9). Install seal (9) and ring

(10) together in the housing bore with the shiny face of ring (10) toward the outside.

i N-rn (28 +

d

9. Put clean engine oil or glycerin on O-ring seals (15).

Install the O-ring seals on adapter (16).

6. Remove spring (1I ) from seal (12). Put clean water on the inside of seal (12). Push the seal on the shaft until the carbon face makes contact with the shiny face or ring (10). Install spring (11).

10. Install adapter (16) in the pump housing with the notch in alignment with dowel (17).

a

End By: a. install water pump

3408C & 3412C Marine Engines

97

Disassembly & Assembly

Raw Water Pump

Install Raw Water Pump 1371-012

Remove Raw Water Pump 1371-011 Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500H, for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG250O1', for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

1. Put raw water pump (2) into position on the engine.

Install the nuts and washer for studs (1).

1. Remove the inlet and outlet water lines to pump (1).

2. Install the oil supply line between raw water pump (2) and the side of the cylinder block.

2. Remove oil supply line (2).

3. Connect the inlet and outlet water lines to raw water pump (2).

3. Remove nuts (3). Remove raw water pump (1).The weight of the raw water pump is 27 kg (60 Ib).

3408C & 3412C Marine Engines

98

L

Disassembly & Assembly

Disassemble Raw Water Pump (Earlier Engines) 1371-015

1. Remove bolt and washw @I from raw water pump shaft. Remove gear 43)).with Tool (F).

2. Remove housing (q,. \

-J

Tools Needed 1U7600

Puller Group

H 1

=

3, Remove cFmp (1): t%mov& md cpver (7). Remove plate (5) fr@m the en&wvkr.

4. Remove the auer pin, nut (6)and &&her. Remove impeller with Tool (A) h d tho 8 mm bolts 5b.8 m e, [S~bI) long or tap the hole9 and u$e two 5116-4%' nc 5Q1 mm (2 in) la@ bolts. a

"P1@

Start By: a. remove raw water pump

*'"

,*

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

5. Remove O-ring seal (8) and ring (10).

Remove washer (9) and key (11). Remove plate (12).

3408C & 3412C Marine Engines -

-

Disassembly & Assembly

11. Remove snap ring (19) with Tool (D).

7. Remove nuts (14) that hold body (13) to housing (15).

8. Use a press to remove housing (15) and shaft (16) from body (13).Remove seal (17).

12. Bend back the l o ~ fram k nut (21). Remove nut.

(21) with Tool (C). Remove the bck.

9. Remove the ceramic ring from the body (13) with Tool (B) and a press.

13. Remove spacer (20).

14. Remove shaft (16) from housing (15) with a press.

Do not let the shaft drop as it is removed.

10. Remove the rubber washer from shaft (16).

Remove seal (18) with Tool (H).

15. Remove the bearing from shaft (16) with a press.

16. Remove bearing retainer (22). Remove the bearing from housing (15) with Tool (E) and a press.

17. Remove bearing race (23) with Tool (G).

3408C & 3412C Marine Engines

100

Disassembly & Assembly

L

2. Install the double roller-bearing (2) in housing (1) with Tool (C) and a press. Install the bearing until it is against the shoulder in housing (1).

FLUID SPILLAGE CONTAINMENT -

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG250OU, for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

I

*

$

3. lnstall single roller $&ring (4) on shaft (3) until it is against the should of shaft (3).

4. Put 9s-3265 Retaining Compound to the inside diameter of collar (5) and on shaft (3). Install collar (5) until it makes contact with bearing (4). Remove any excess compound.

1. Install the bearing race in housing (1) with Tool (B).

Install bearing until it is against the shoulder in housing (1).

3408C & 3412C Marine Engines

101

Disassembly & Assembly

5. lnstall retainer (6) on housing (I ta )hold the double roller bearing (2) in position.

6. Install shafi (3)and bearing (4) in housing (1) as a unit. Ee sure that shaft 43) is in alignment with bearing (2)and bearing ((4)is also in alignment with it respective outer rmG.

8. lnstall seal (8) With Tool (F) until it makes contact with sndp ring (7). lnstall rubber washer (9) (thrower) on shaft (3).

C

7. lnstall snap ring (3with Tool (D).

9. Put clean water on the ceramic ring (10). lnstall ceramic ring (10) with Tool (A)and hand pressure. lnstall the ring with the bevel side down.

3408C & 3412C Marine Engines

102

Disassembly & Assembly

1

10. lnstall body (13)on housing (1).lnstall nuts (15) ,. ,ma-lpcks.'*J , +;; ' .%; . *, a

% -*

*

' , . " I -

16. Instdl the original shims (20)if available or shims of a thickness of 0.51 mm (.(MO in) as a place to start.

=.T+

,%

iki

ll.'lktan t h i sfiacsr, lodk amfnt$bn'tl% g & ~ of the pump shaft.Tighten tha nut to a torque of 95 to I t 0 N e r n (70 to 1bfi), and bend the tab of the look in the groDve.of the.nut.

17. Use a micrometer and measure the thickness of the impeller (18) and the width of ring (14) to find the difference in dimensions. This difference is used to flnd the ahims needed to get the same amount of clearance on each side of the impeller when it is installed in the pump.

12. Put @lean,wateron seal (16). Install seal,,(l6)on the pump shaft with large seaG suhce against the ceramic ring. Use hand prrssure-only to install seal (16). . a .

- -.

18. Install key (19) and impeller (181.0~ the pump shaft.

NOTE: Make a replacement d both seal (16) and ceramic ring (10) if either is damaged or worn.

NOTE: lnstall the impeller with the threaded puller holes toward the outside.

13. lnstall washer (I 1)on the pump shaft. ./

14. lnstall plate (17) in body (13) with tabs (12) in alignment with the notches in body (13).

15. Install the O-ring seal around ring (14).

3408C & 3412C Marine Engines

103

Disassembly & Assembly

Disassemble & k m b l e Raw Watet Pump (Later Engines) 1371-017

Start By:

a. remove raw water pump 19. Install the washer and nut (22). Tighten the nut to a torque of 6P qo 70 N N (45 . ~ to 5;0 Ib ft). lnstall the cotter pin to hold the nut after Step 20.

20. Use a feeler gauge to check the clearance behind the impeller at four locations the same distance apart. Use the average of the four measurements.

The correct clearance is 0.20 0.03 rnm (.008 -t- ,001 in). Make an adjustment to the shims if necessary.

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG250OU, for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

+

21. Install plate (21) in cover (24) with the tabs of the plate in alignment with the notches of cover (24).

22. lnstall ring (14) and O-ring seal (23) in cover (24).

1. Prior to disassembly, mark all components for the

assembly procedure.

23. lnstall housing (26) on the pump.

24. lnstall gear (27) and the washer and bolt (28).

Tighten the bolt to a torque of 55 r 7 Nem (40 & 5 Ib ft). Use a hammer and punch and hit the bolt. Tighten the bolt again to the same torque.

2. Remove two bolts (1) and nuts.

3. Remove clamp assembly (2).

25. lnstall cover (24) and clamp (25) on the pump.

4. Separate body (3) from body (4).

End By: a. install raw water pump

3408C & 3412C Marine Engines

104

Disassembly & Assembly

C

5. Remove ring (5).

6. Remove seal (6).

NOTE: Check seal (6) for damage or wear. Replace if necessary.

L

9. Bend tab on lockwasher (10) for removal.

10. Use Tool (6) to remove nut (9).

NOTE: Whem installing nut (9), tighten to a torque of 135 to 200 Nern (100 to 150 Ib ft).

11. Remove lackwasher (10).

7. Use Tool (A) to remove impeller (7).

12. Remove collar (1I ) and seal (12).

8. Remove washer (8).

1.3. Remove four bolts (13) and washers. .

NOTE: Wheq hsta!lin$ balts (13), tighten to a torque fi& ' of 34 N-rn p 3 Ibi *

NOTE:

Keep washer (8) free of ail and grease contaminates.

.%

i

14. Separate hoking(14) from body (3).

3408C & 3412C Marine Engines

105

Disassembly & Assembly

19. Use Tool (D) to remove snap ring (18).

15. Remove plate (15).

16. Remove seal group (16).

20. Place housing (14) in a press @ndremove shaft (19).

NOTE: Seal group (16) may separate when plate (15) is removed.

.. .

17. Inspect seal (17) for damage or wear. Replace if necessary.

.

M Remove bearing (20) from shaft (19) if necessary. . .

NOTE: If bearing (20) is removed, upon installation heat bearing in oven to 117 "C (275 "F).

18. Use Tool (C) to remove seal (16).

NOTE: Seal (16) in the step above is part of the seal group in Step (16).

3408C & 3412C Marine Engines

106

Disassembly & Assembly

Expansion Tank & Water Lines R e ~ w e r ~ ~ t l sTank i o n& WLMr Lines 12@4-011

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG25001', for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.1.

.

. s .

22. Remove bearing (21) if necmary.

NOTE: lf bearing (21) is removed, upon installation cool the bearing and insure it is seated against the counterbore in housing (14).

Drain the coolant from the expansion tank into a suitable container for storage or disposal.

NOTE: If race (22) is removed, up@ninstallation cool the race and tnsurcii it is seated against the counterbore in housing (14).

2. Fiemove the four botts from the tank drain.elbow. %$

NOTE: Be sure all parts of the mw water pump are thorou~hlyclean and free of d ' i and debris prior to

assembly.

-1

NOTE: For assembly of the raw water pump, reverse the dSassembly steps.

End By:

'

a. install raw water pump

3. Remove hose (1) from the top of the expansion tank. Disconnect llne (2) to the turbocharger cooling line. Remove bolt (4).

4. Remove bolts (3) from the temperature regulator housings.

5. Fasten a hoist to the expansion tank. Remove bolts (5). Remove bolts (5). Remove expansion tank. The weight of the tank is 77 kg (170 b).

3408C & 3412C Marine Engines

107

Disassembly & Assembly

lnstall Expansion Tank & Water Lines 1354-012 FLUID SPILLAGE CONTAINMENT

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be DreDared to collect the fluid with suitable containers' before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG25001', for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

I

6. Remove water line (6) and elbows. Remove tem erature re ulator housi

?meT b C ?'%a

nHammLAeLI&&%-

m

r

n

I

:,'.$i,&

7. Remove elbows (8).

1. lnstall water line (2) and elbows, lnstall elbows (3).

8. Remove water line (11) and elbows. Remove water line (9) and elbows. Remove elbows (10).

2. lnstall water line (4) and elbows.

3. lnstall elbows (1).

4. lnstall water temperature regulator housing (6). lnstall water line (5) and elbows.

3408C & 3412C Marine Engines

108

Disassembly & Assembly

Vibration Damper & Pulley Remove Vibration Damper & Pulley 1205-011 A

Tools Needed Guide Bolt1/2-13 NC x 127 mm (5 in) long

2

5. Fasten a hoist to the expansion tank. Put the tank into position on the engine. Install four bolts (10).

6. Install bolts (11) into the temperature regulator

housings.

d 7.

Connect hose (7) to the expansion tank and line (8) to the turbocharger cooling line.

8. l n e l l hose clhnlp a i d bolt (9). .$it.

1. Remove four nuts (2)that hold pulley (1) to the vibration damper adapter. Remove pulley (1).

Q

9. Install four bolts (12).

10. Fill the cooling system with coolant to the correct

level.

2. Remo* two of the bolts that hold vibration damper (3) to damper adapter (5). Install Tool (A). Remove the remainder of the bolts that hold damper (3) to adapter (5).

3. Fasten a hoist to damper (3). Remove damper (3).

The weight of the damper is 31 kg (68 lb).

4. Remove spacer (6).

5. Remom bolts (4) that hold adapter (5) to the crankshaft. Remove adapter (5).

3408C & 3412C Marine Engines

109

Disassembly & Assembly

lnstall Vibration Damper & Pulley 1205-012

Crankshaft Front Seal & Wear Sleeve

Tools Needed

A

Guide Bolt 1/2-13 NC x 127 mm (5 in) long

Remove Crankshaft Front Seal & Wear Sleeve 1160-011

2

1U7600

Tools Needed Puller Group

5P7312

Distorter

5P7314

Ring

A B C 1

1 1

Start By: a. remove vibration damper and pulley

1. Put 5P-3931 Anti-Seize Compound on bolts (1). lnstall vibration damper adapter (2) and bolts (1).

2. Install spacer (3) on adapter (2).

3. Put Tool (A) into position in adapter (2).

FRONT

REAR

NOTICE The crankshaft front seal and wear sleeve come as a set and must be installed as a set. If a replacement of the seal is to be made, a replacement of the wear sleeve must also be made.

J

4. Put damper (4) into position on Tool (A). lnstall bolts (5). Remove Tool (A) and install the last two bolts (5). Tighten bolts (5) to 135 k 14 N-m (100 10 Ib ft).

+

5. Put the pulley into position on studs (6). lnstall the nuts that hold the pulley to adapter (2).

1. Make at least three holes in seal (1) with a hammer and sharp punch.

2. Use Tool (A) to remove seal (1).

3408C & 3412C Marine Engines

110

Disassembly & Assembly

C

3. Install Tool (C) in the seal bore.

1. Install the front crankshaft and wear sleeve with Tooling (A). Use the procedure that follows.

4. Install Tool (6)between Tool (C) and wear sleeve (2). Turn Tool (B) until the tool makes a dent

a. Clean and prepare the inside diameter of the wear sleeve and the outside of the crankshaft by appling 6\1-1541 Quick Cure Primer. Apply 9s-3265 Retaining Compound to the outside diamter of the crankshaft before the wear sleeve is installed on the crankshaft. Do not let any Quick Cure Primer or'Retaining Compond get on the lip of the seal.

(crease) in wear sleeve (2).Do this in three or more places until the wear sleeve is loose.

5. Remove Tools (6) and (C), and remove wear sleeve (2) from the crankshaft.

b. Install locator (3) and bolts (4) on the crankshaft.

Install Crankshaft Front Seal & Wear Sleeve 1160-012

c. Seal (1)and wear sleeve (2) must be installed dry.

Tools Needed 5P-1733

Locator

5P-1737

Bolt

NOTICE Make sure the seal is installed with the part number and the arrows showing crankshaft rotation toward the outside.

98-8858 Nut 6\1-6142

-

Installer

d. Put wear sleeve (2) and seal (1) as a unit in position on locator (3).

NOTICE The crankshaft seal and wear sleeve come as a set and must not be separated from each other at any time. Carefully read Special Instruction, SMHS8508, that is included with each seal and wear sleeve before any handling of the seal group is made.

e. Put installer (5) in position on locator (3). f. Put clean engine oil on the face of nut (6) and its contact area on installer (5). Install nut (6) on locator (3). g. Tighten nut (6) until the inside surface of installer (5) comes in contact with locator (3).

NOTICE The front and rear seals and wear sleeves have different sprial grooves in the seal. Because of this type of design, the front seal group for an engine is different from the rear seal group. If a seal group is installed on the wrong end of the engine, oil can actually be taken out of the engine instead of moving the oil back into the engine.

h. Remove Tooling (A) from the crankshaft seal and wear sleeve. Tooling (A) will install the seal and wear sleeve to the correct depth on the crankshaft.

End By: a. install vibration damper and pulley

3408C & 3412C Marine Engines

111

Disassembly & Assembly

Front Housing

lnstall Front Housing 1151-012 Tools Needed

Remove Front Housing 1151-011 Tools Needed

85-1378 StudPuller 5P-9736

A B 1

88-1378 StudPuller 5P-9736 Link Bracket

A 6

2

1

Link Bracket

2

NOTE: Thoroughly clean the mating surfaces of botn the front cover and the cylinder block of any old gasket material. The mating surfaces must be free of all oil, dirt or other contaminants prior to assembly.

Start By: a. remove crankshaft front seal & wear sleeve

b. remove governor & fuel pump drive c. remove water pump d. remove oil pan e. Remove the engine front support.

1. If removed, put 9s-3265 Retaining Compound on the front housing and cylinder block studs and install with Tool (A).

2. Put clean engine oil on the O-ring seal for the fuel injection pump housing.

3. lnstall Tool (B) on front housing (1).

4. Put a new gasket and front housing (1) into position on the front of the cylinder block.

1. lnstall Tool (B) as shown. Attach a suitable lifting device to Tool (B).

2. Remove five nuts (2) and cover (3).

. 5. lnstall bolts (4) that hold front housing (1) to the cylinder block.

3. Remove five bolts (4) that hold front cover (1) to the cylinder block.

-

6. lnstall cover (3) and nuts (2) on the front housing.

7. Remove Tool (B).

4. Remove front cover (1) and the gasket.

8. Cut the front housing gasket even with the bottom of the cylinder block.

5. Use Tool (A) to remove the studs from the front cover and the cylinder block.

End By:

a. install front engine supprt b. install oil pan c. install water pump d. install governor & fuel pump drive e. install crankshaft front seal & wear sleeve.

3408C & 3412C Marine Engines

112

Disassembly & Assembly L

Camshaft Remove Camshaft Tools Needed 4B4277

Washers (5116 in)

989082

Engine Turning Pinion

1PO478

Driver Plate

Start By: 2. Turn the engine with Tool (B) until the bolts in camshaft rear gear (3) are visible. Remove the four bolts.

a. remove front housing b. remove valve lifters

3. Tum the engine until the "V" marks on the fron? timing *gearsare in alignment. Install Tool (A) through the flywheel housing and into gear (3).

NOTE: Tool (A) must be used to keep the rear camshaft gear in position when the camshaft is removed. :?

4. Tighten Tool (A) evenly to free the rear camshaft gear from the camshaft.

1. Remove turbocharger drain tube (1) and elbow from the flywheel housing. Remove two studs (2).

5. Remove two bolts (5) and plate (4).

6. Remove camshaft and gear from the cylinder block.

The weight of the camshaft is approximately 26 kg (58 Ib).

NOTICE Be careful not to cause damage to the camshaft bearings as the camshaft is removed.

7. If necessary, remove camshaft gear with Tool (C) and a press.

3408C & 3412C Marine Engines - .

-

-

,----

- --

--

*-

-

113

Disassembly & Assembly

Install Camshaft 1210-012 Tools Needed 484277

Fiat Washer (5/16 in)

989082

Engine Turning Pinion

885467

Dial Test Indicator Group

4. Loosen the two bolts from Tool (A) to make alignment of gear (5) and the camshaft. lnstall one bolt through gear (5) to hold the gear in position.Remove Tool (A).

1. Heat gear (2) to a maximum temperature of 315°C (6W°F).lnstall gear (2) on camshaft (1).

5. Turn the engine with Tool (B) until all of bolts (7) are installed.Tighten the bolts evenly to 25 4 W-m (20 30 Ib ft). Tighten the bolts again to 25 4 N-m (20 k 3 Ib ft).

+

+

+

6. Check the camshaft end play with Tool (C). End play must be 0.10 to 0.25 mm(.004 to .010 in).

L/

7. lnstall two studs (6) until they are extended 25.4 + 1.5 mm (1.00 & .06 in) from the surface of the flywheel housing. Put 95-3263 Thread Lock on the studs before installation.

2. Put clean engine oil on the lobes and journals of camshaft (1) and on the camshaft bearings. lnstall the camshaft with the "V" mark on gear (2) in alignment with the 'V mark on gear (4).

8. lnstall the oil drain tube for the turbocharger.

3. lnstall plate (3) and bolts.

End By: a. install valve lifters b. install front housing

3408C & 3412C Marine Engines

114

Disassembly & Assembly

Camshaft Bearings )

Remove Camshaft Bearings 1211-011 Tools Needed 882241

Camshaft Bearing Removal 8 InstallationTool Group

888293

Extension

5P1667

Spacer Tube

lnstall Camshaft Bearings 1211-012 Tools Needed 832241

Camshaft Bearing Removal & InstallationTool Group

858293

~xtenion

5P1667

Spacer Tube

Start By: a. remove camshaft b. remove flywheel housing c. remove pistons

1. Install the rear camshaft bearing and three internal camshaft bearings with Tool (A). lnstall the bearings from the rear of the block bore. lnstall the bearings until the front edge of the bearing is even with the front surface (1) of the block bore.

1. Remove the rear camshaft bearing with Tool (A).

NOTICE Be sure each bearing is in alignment with the cylinder block before the bearing is installed. lnstall the bear15 degrees ing with the oil hole in the bearing 90 from the oil hole in the block bore.

+

2. Remove the remainder of the camshaft bearings with Tool (A). Start at the rear of the engine block and move toward the front.

3408C & 3412C Marine Engines

Disassembly & Assembly

1

Timing Gears Remove Timing Gears 1206-011

c

Tools Needed

L1774

Spacer

1P2321

Puller Assembly

1PO531

Handle

Start By:

a. remove front housing b. remove camshaft

Install the front camshaft bearing with Tool (A) until it is 7.34 r 0.10 mm (.2%9 r .004 in) from the machined surface on the front of the cylinder block as shown.

End By:

a. install pistons b. install camshaft c. install flywheel housing

1. Remove four bolts (1) and plate (2). Remove front idler gear (3).

2. Remove bearing from gear (3) with Tool (B) and a press.

3. Remove crankshaft gear (4) with Tool (A).

34086 & 3412C Marine Engines

116

Disassembly & Assembly

I

lnstall Timing Gears 1206-012

Flywheel

Tools Needed

A

1PO491

Drive Plate

1PO487

Drive Plate

1

1PO531

Handle

1

1

Remove Flywheel 1156-011 Tools Needed

6V2157 081624

Lifting Bracket Bolt 518-1 1 NC x 25 mm (1 in) long Guide Bolt 5/8-18 NF x 203 mm (8 in) Long

--

,

.

1. lnstall the bearing' in front idler gear (1) with Tool (A) as shown.

1. Remove two flywheel bolts from the crankshaft. lnstall Tool (B) in the crankshaft.

2. lnstall Tooling (A) in flywheel (2). Attach a suitable lifting device to Tooling (A). Remove the remainder of bolts (1).

3. Remove flywheel (2). The weight of flywheel (2) is 84 kg (185 Ib).

4. If necessary, remove the ring gear from flywheel (2) using a punch and hammer.

2. Heat crankshaft gear (2) to a maximum temperature of 204°C (400°F). lnstall gear (2) with notch (4) in alignment with the pin on the crankshaft.

3. lnstall gear (1). Make sure the "V" mark on gear (1) is in alignment with the "V" mark on gear (2).

4. lnstall plate (3) with the groove towards gear (1). lnstall the four bolts that hold plate (3).

End By: a. install camshaft

b. install front housing .--

\

3408C & 3412C Marine Engines -

Disassembly & Assembly

Install Flywheel 1156-012 Tools Needed

Generator A 6

6V2157

Lifting Bracket

1

OS1624

Bolt 518-11 NC x 25 mm (1 in) Long

1

Guide Bolt 5/8-18 NF x 203 mm (8 in) Long

Remove Generator 1404-011 Tools Needed

2 2J-3505

1. Heat rina aear (3)to a maximum temperature of 315" C (660" i) 'and install it on flywheel (2), so the chamfer of the gear teeth will be toward the starter pinion when the flywheel is installed.

A

Eyebolt (7/8 in)

1

Nut (718 in)

1

1. Remove five bolts and spacers (1).

2. Remove cover (2).

1. Install Tool (B) in the crankshaft.

3. Remove four bolts (3) and two guards (4).

2. Fasten a hoist and Tool (A) to flywheel (1). Put flywheel (1) into position on Tool (B).

3. Put clean engine oil or 5P-0960 Multipurpose Grease on the threads of bolts (2). Install bolts (2).

Remove Tool (B). Install the last two bolts. Tighten bolts (2) to a torque of 270 +: 40 N-m (200 & 30 Ib ft).

4. Check the run out (eccentricity) of the flywheel. See the topic "Flywheel & Flywheel Housing" in the Systems Operation, Testing & Adjusting Manual.

3408C & 3412C Marine Engines

118

Disassembly & Assembly

c

4. Attach lifting chains and a suitable lifting device to the engine lifting brackets as shown to support the engine. The weight of the 3408 Engine is approximately 3629 kg (8000 Ib). The weight of the 3412 Engine is approximately 5443 kg (12,000 Ib).

7. Install Tool (A) to generator (5). Attach a lifting sling and a suitable lifting device to Tool (A). The generator weighs approximately 1270 kg (2800 Ib).

Y

\

8. Remove sixteen bolts (7) that hold generator (5) to ,. the flywheel housing.

5. Remove, four bolts, washers and nuts (6) that hold , geneiator (5) to the frame.

9. Remove six bolts (8) that hold generator fan-(9) to the flywheel. '

lo. Remove generator (5) from the engine by moving the generator away from the engine.

6. Support the engine and put blocks underneath the oil pan to support the engine's weight as shown.

11. Remove eight bolts (11) and shim pack (10).

3408C & 3412C Marine Engines

119

'

Disassembly & Assembly

lnstall Generator 1404-012 Tools Needed Eyebolt (718 in) 2J-3505

Nut (718 in)

83-5467

Dial Indicator Test Group

A B

1 1 1

NOTICE Do not start the alignment procedure until the electric set is permanently installed. If the electric set is moved to a different location, check the alignment and make any necessary corrections. Alignment between the generator and the engine must be correct to get the maximum performance and the longest life from the electric set.

2. Position shim pack (10) in the bore of.the flywheel housing to check for clearance before installing on generator (5). There must be clearance between the outside of the shim pack and the inside diameter of the bore in the flywheel.

NOTE: Remove all dirt, burrs and paint from the contact sufaces of the generator supports and the base. All contact surfaces of the engine, the coupling and the generator must be completely clean.

3. lnstall a full shim pack (10) on generator (5).

--.

??-,

4. lnstall six bolts (11) holding the shim pack to the generator.

Typical Example

5. lnstall two 5/8-11 NC Guide Bolts in the flywheel as shown.

1. lnstall Tool (B) on the crankshaft pulley as shown.

The tip of the indicator must touch the face of crankshaft pulley (12). Use a bar placed between the flywheel and the flywheel housing to push the crankshaft toward the flywheel to remove all the end play. Put the dial indicator in the "zero" position. Move the crankshaft to its forward position and make a record of the total indicator reading FIR). The TIR is the end play of the crankshaft.

u

NOTICE Damage to the engine and-or generator can result if the electric set is run with a shim pack that does not have the proper clearance as described in Step 2.

3408C & 3412C Marine Engines

120

Disassembly & Assembly

11. Use Tool (B) to check the crankshaft end play (do

not use force to hold the crankshaft in position if the original crankshaft TIR is not the same. If the TIR is less than the original value, remove the generator and remove only enough shims (10) to - get the original amount of end play as shown in Step 1.

12. If adjustments were made to the shim pack, initall the generator and again check the crankshaft end play

-

(I"? .?

)

6. Attach Tool (A) to generator (5). Attach lifting strap to Tool (A). Attach appropriate lifting device to the lifting strap. The generator weighs 1270 kg (2800 Ib).

7. Install the generator. Use the guide bolts to align shim pack (lo), generator fan (9) with the flywheel.

8. Install four bolts (8). Remove the guidebolts and install the last two bolts (8).

,

,

9. Install sixteen bolts (7) holding the generator to the flywheel housing.

10. Remove Tool (A).

NOTE: The total thickness of shim pack (10) must not cause a reduction of crankshaft end play as measured in setp (1).

3408C & 3412C Marine Engines

121

Disassembly & Assembly

16. Install two guards (4).

17. Install four bolts (3).

13. Support the engine from the engine lifting brackets with chains and a suitable lifting device. The weight of the 3408 Engine is approximately 3629 kg (8000 Ib). The weight of the 3412 Engine is approximately 5443 kg (12,000 Ib).

18. lnstall guard (2) and five bolts, spacers and washers (1).

14. Remove the wood blocks from under the oil pan.

15. Install four bolts, washers and nuts (6) holding generator (5) to the frame.

3408C & 3412C Marine Engines

122

Disassembly & Assembly

5

- , '

Crankshaft Rear Seal & Wear Sleeve Remove Crankshaft Rear Seal & Wear Sleeve 1161-011 1U7600

Tools Needed Puller Group

5P7312

Distorter

5P7314

Ring

A B C 1 1

1

Start By:

2. Install Tool (C) in the rear seal bore.

a. remove flywheel

3. Install Tool (B) between Tool (C) and the wear sleeve. Turn Tool (B) until the edge of the tool makes a flat plate (crease) in the wear sleeve. Do this in two or more places until the wear sleeve is loose.

4. Remove Tool (C) and the wear sleeve by hand.

1. Put holes (2) evenly around seal (1) with a sharp

punch as shown. Remove seal (1) and Tool (A).

NOTE: When a replacement of the earlier type rear seal is made, a replacement of the wear sleeve is to be made also. Later type seals and wear sleeves come as a set and must be replaced as a set. . /

3408C & 3412C Marine Engines

123

Disassembly & Assembly

c. For ,earliertype seals, put clean engine oil on the seal lip of the seal and on the outside diameter on wear sleeve. Make sure the lip of the seal is toward the inside of the engine and the outside diameter bevel of wear sleeve is toward the outside of the engine.

Install Crankshaft Rear Seal & Wear Sleeve 1161-012 Tools Needed

1

5P1733

Locator

5P1737

Bolt

6V6143

Installer

988858

Nut

6V6142

Installer

A B 1 1 3 3 111 1 1 1 1

C

NOTE: Later type seals and wear sleeves cannot be used again after the seals and wear sleeves are separated. d. Put the wear sleeve and seal in position on locator (2) as a unit.

NOTICE On later type seals,make sure the seal is installed with the part number and the arrows showing crankshaft rotation toward the outside.

NOTICE On later type seals, the front and rear seals and wear sleeves have different spiral grooves in the seal.

Because of this type of design, the front seal group for an engine is different from the rear seal group. If a seal group is installed on the wrong end of the engine, oil can actually be taken out of the engine instead of moving the oil back into the engine. e. Put the correct installer (4) in position on locator (2). f. Put clean engine oil on the face of nut (3) and its contact area on installer (4). Install nut (3) on locator (2). g. Tighten nut (3) until the inside surface of installer (4) comes in contact with locator (2).

1. Install earlier crankshaft rear seals and wear sleeves with Tool (A) or later crankshaft rear sleeves with Tool (A) or later crankshaft rear seals and wear sleeves with Tool (B) as follows:

W

NOTICE On some early engines with lip seals, if the seals goes against the bottom of the bore, a resistance (increase in torque) will be felt on nut (3). Do not tighten nut (3) too tight or the case (body) of the seal will be damaged.

a. Install locator (2) and the bolts on the rear of the crankshaft. b. Clean and prepare the wear sleeve inside diameter and crankshaft outside diameter with 6\1-1541 Quick Cure Primer. Apply 98-3265 Retainer Compound to the crankshaft outside diameter and wear sleeve inside diameter before wear sleeve is installed on the crankshaft.

h. Remove Tool (A) or (B).

NOTE: For more information on the crankshaft seal installation, see Special Instruction, SMHS7100 (for earlier lip seals), and SMHS8508 (for later seal groups with hydrodynamic grooves).

End By: a. install flywheel

3408C & 3412C Marine Engines

124

Disassembly & Assembly

Flywheel musing

7 Remove Flywheel Housing

1157-011

Tools Needed 5P9736

Lifting Bracket

OS1594

Bolt 3/8-16 NC x 25 mrn (1 in) long

A

2 2

Start By:

a. remove rear exhaust manifold

4. Remove four bolts and washers (5) and fuel filter bracket (6).

b. remove crankshaft rear seal

c. remove oil pan

I.Remove six bolts (2) and turbocharger mounting bracket (1).

2. Remove turbocharger drain line (3).

5. Attach Tooling (A), lifting slings and a suitable lifting

device to the flywheel housing as shown. The weight of the flywheel housing is approximately 191 kg (425 Ib).

6. Remove eight bolts (7),two nuts (8), two covers (9) and the gaskets.

7. Remove twenty bolts (10).

3. Remove two bolts and washers (4).

8. Remove flywheel housing (1 1) and the gasket.

3408C & 3412C Marine Engines

125

---- -

$

--

-aL

--

Disassembly & Assembly

Install Flywheel Housing 1157-012 Tools Needed

A

5P9736

Lifting Bracket

2

OS1594

Bolt 3/8-16 NC x 25 mm (1 in) long

2

NOTE: Ensure front face of the flywheel housing, both sides of the flywheel housing gasket and the rear face of the cylinder block are completely free of all oil, fuel, water, gasket adhesive, assembly compounds and any other contaminants prior to assembly.

NOTE: See the topics "Flywheel Housing Runout" and "Flywheel Housing Bore" in the Specifications Manual for the correct methods of flywheel housing inspection.

1. Install the flywheel housing and cylinder block gasket.

2. Apply 8T-9022 RTV Silicone-Blue sealant to fill the space at the cylinder block, flywheel housing and oil pan joint.

. '

3. Attach Tooling (A), lifting slings and a suitable lifting device to the flywheel housing as shown. The weight of the flywheel housing is approximately 191 kg (425 Ib).

4. Install flywheel housing (11).

5. Apply 4C-4030 Thread Sealant to the threads' of twenty bolts (10).

3408C & 3412C Marine Engines

126

Disassembly & Assembly

f

11. lnstall two bolts and washers (4).

')

6. lnstall twenty bolts (10). Tighten in numerical sequence as shown to a torque of 40 + 10 N=m (30 +- 7 Ib ft).

12. lnstall turbocharger drain line (3).

13. lnstall turbocharger mounting bracket (1) and six bolts (2).

7. Tighten twenty bolts (10) again in numerical sequence shown to a torque of 40 + 10 Nem (30 r 7 lb ft).

End By:

8. lnstall two covers (9) and the gaskets.

a. install oil pan

9. lnstall eight bolts (7) and two nuts (8).

b. install crankshaft rear seal

V

c. install rear exhaust manifold

10. Place fuel filter bracket (6) in position and install four bolts and washers (5).

-3

3408C & 3412C Marine Engines

127

Disassembly & Assembly

Exhaust Manifold (rear) Remove Exhaust Manifold (rear) 1059-011

1

FLUID SPILLAGE CONTAINMENT

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of €he machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG25001', for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

3. Remove eight bolts, washers and nuts (3).

4. Remove two elbows (4) and the gaskets.

Start By:

a. remove turbocharger

5. Remove six bolts, washers and nuts (7) securing rear exhaust manifold (5) to both water cooled exhaust manifolds.

6. Attach lifting slings and a suitable lifting device to the rear exhaust manifold.

7. Remove four nuts (6).

1. Remove four bolts (2) that secure two elbows (1) to the cylinder heads. Some of the bolts (2) are too long to be removed completely, ensure they will not bind on the cylinder head during removal of the rear exhaust manifold.

v

8. Remove rear exhaust manifold (5) and the gaskets.

2. Remove the two gaskets from two elbows (1).

3408C & 3412C Marine Engines

128

Disassembly & Assembly

i

4. Install two elbows (4).

.

5.

,

, , , I eigM bo&,washergand OjS 131securvxJ

.two &ows

($)to the exhaust manifold.

-GF==?, .

tbe.s~skefb dat~isg6or wear prior a -k 14 any gasket is damaged worn. f&

-

0'

a new gasket.

End By:

_ h a \ \ six bolts and nuts

m.

a. install turbocharger /

<.

'

, ,'

L,

Exhaust Manifold (Water Cooled) Remove Exhaust Manifold (Water Cooled) 1059-011 Start By: 1

a. remove rear exhaust manifold

-

FLUID SPILLAGE CONTAINMENT

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG250On, for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

1

3. Remove O-ring s e a l cooled exhaust r

n

4. Attach lifting slings a-

the water cooled - xe

6. Remove left side w -at

and the gaskets.

7. Loosen bolt (6) to allow -ca 1. Remove two bolts (1) and tube (21. .,

8. Loosen two bolts (7).

2. Remove the gasket and the O-ring seal from tube (2).

3408C & 3412C Marine Engines

9. Disconnect tube (8) fromh -t exhaust manifold.

130

-3C

Disass -.---

----

5

-.-

_ I

a

I

-

5. Remove eight nuts, vr

a

Cooled) 1059-012

I

FLUID SPILLAGE CONTAINMENT

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing,-adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers'before opening any compartment or disassembling any component containing fiuids. Refer to "TOOLS AND SHOP PRODUCT GUIDE. NENG2500n, for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

10. Remove O-ring seal (I 1)from water cooled exhaust manifold (10).

i:. d 3' r 2-

11. Attach lifting slings and a suitable lifting device to the water cooled exhaust manifold as shown.

u

NOTE: Inspect all gaskets and O-ring seals for damage or wear. Replace with a new gasket or a new O-ring seal if necessary.

12. Remove eight nuts, washers and spacers (9).

11. Remove right side exhaust manifold (10) and the gaskets.

NOTE: Ensure all of the old gasket material is removed prior to installation of the new exhaust manifold gaskets.

1. Put the new gaskets in place and install right side exhaust manifold (10).

2. Put 4C-5598 Anti-Seize Compound on the studs.

Install eight spacers, washers and nuts (9).

131

3408C & 3412C Marine Engines

-

----. ,,

--- - - .----

&---

+----

.-

----- - .

I

Disassembly & Assembly

gd

3. Tighten nuts (9) in the number sequence shown to a torque of 38 r 6 N-m (28 r 4 Ib ft).

9. Tighten nuts (4) in the number sequence shown to a torque of 38 -1- 6 N-m (28 4 Ib ft).

4. lnstall O-ring seal (11).

10. Install O-ring seal (3).

+

-,

5. lnspect gasket (12) for damage or wear, replace

with a new gasket if necessary. ,

11. lnspect the gasket for tube (2) for damage or wear, replace with a new gasket if necessary.

-.

12. Apply clean engine oil to O-ring (3) prior to installation of tube (2).lnstalltube 2.

4. Apply clean engine oil to O-ring seal (10) on the right side exhaust manifold prior to installation of tube (7). lnstall tube (7).

w

13. lnstall two bolts and washers (1).

5. If necessary, install new gasket (12) prior to

installation of the elbow and bolts (7). Install two bolts (7)

End By: a. install rear exhaust manifold

6. lnstall bolt (6).

NOTE: Ensure all of the old gasket material is removed prior to installation of the new exhaust manifold gaskets.

7. Put the new gaskets in place and install left side exhaust manifold (5).

8. Put 4C-5598 Anti-Sieze Compound on the studs. lnstall eight spacers, washers and nuts (4).

3408C & 3412C Marine Engines

132

Disassembly & Assembly

-

b

3. Remove bolt, washer and clip (5) from right side valve cover (4).

1. Remove nine bolts (1) from left side valve cover (2).

Remove left side valve cover (2).

4. Remove eight remaining bolts (6).

I

5. Remove right side valve cover (4).

6. Remove the gasket from right side valve cover (4);

'd

2. Remove gasket (3) from left side valve cover (2).

3408C & 3412C Marine Engines

133

Disassembly & Assembly

lnstall Valve Covers 1107-012 1. lnstall the gasket in the right side valve cover.

6. lnstall gasket (3) in left side valve cover (2).

2. lnstall right side valve cover (4).

3. lnstall eight of the nine bolts (6) leaving one opening where the fuel line is clamped to the valve cover.

7. Install left side valve cover (2).

8. lnstall nine bolts (1) and tighten to a torque of 14 & 4 N-m (10 3 Ib ft).

+

1

End By: a: install instrument'panel

4. lnstall bolt, washer and clamp (5).

5. Tighten eight bolts (6) and bolt (5) to a torque of 14 4 N-m (10 3 Ib ft).

+

+

3408C & 3412C Marine Engines

134

Disassembly & Assembly

L

Glow Plugs (Precombustion

i

Install Glow Plugs 1412-012 Tools Needed

Chambers' Remove Glow Plugs

1412-01 1

Tools Needed 5P0127

5P0127

A

Socket

Start By

a. remove valve covers

1

A 1

Socket

1. Put 5P-3931 Anti-Seize Compound threads of glow plug (1).

2. lnstall glow plug (I) and tighten to a torque of 14 a 3 N-m (10 2 Ib ft).

+

NOTICE Be sure glow plug wire is away from the valve spring when it is installed on the glow plug.

End By: a. install valve covers.

- .

-

.

i

,

1. Disconnect glow plug wire (1) from the glow plug.

2. Remove the glow plug with tool (A).

3408C 8.3412C Marine Engines

Disassembly & Assembly

=uel Injection Valves :PrecombustionChamber) Remove Fuel Injection Valves (Precombustion Chamber) 1254-011 Tools Needed 5P0144

Socket

5P6229

Extractor

A B 1 1

Start By: 1. Disconnect the glow plug wire from the glow plug and clip (2) from fuel line (1). Remove line (1) with Tool (A).

a. remove valve covers

1

FLUID SPILLAGE CONTAINMENT

1 NOTICE Put protective caps on all fuel line openings.

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

34086 & 3412C Marine Engines

,-

L

2. Remove nut (5) that holds valve (3) in precombustion chamber (4).

3. Remove valve (3) with Tool (B).

136

Disassembly & Assembly

lnstall Fuel Injection Valves (Precombustion Chamber) 1254-012 Tools Needed 5P0144

Socket

A 1

FLUID SPILLAGE CONTAINMENT Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500i1, for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

,.

3. lnstall nut (3) in the precombustion chamber and tighten to 75 7 N-m (55 5 Ib ft).

+

+

4. Install fuet line (5). Tighten the fueGline?nGts to 40,f 7 N-m (30 f 5 Ib ft) witR Tool (A).

5. Connect the glow plug wire to the glow plug and clip (4) on the fuel line. Be sure the wire is clear of the valve spring.

End By:

a. install valve covers

1. lnstall nozzle (2) on valve body (1) finger tight. <

'

'2. lnstall the valve body in the precombustion

-L

chamber. Be sure the grooves (serrations) on body (1) are in alignment with the grooves (serrations) in the precombustion chamber.

3408C & 3412C Marine Engines

137

Disassembly & Assembly

Fuel lnjection Valves (Direct Injection)

Install Fuel lnjection Valves (Direct Injection) 1254-012 P Tools Needed

Remove Fuel lnjection Valves (Direct Injection) 1254-011 Tools Needed 5P0144

Socket

5P6229

Extractor

5P0144

Socket

5P6229

Extractor

6W025

Sleeve

A B 1

1

FLUID SPILLAGE CONTAINMENT start By:

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500" for tools and supplies suitable to collect and containfluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

a. remove valve covers

FLUID SPILLAGE CONTAINMENT Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500M, for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

-

..,/ %

1. If the seal on the direct injection valve has been

removed, install a new seal as follows:

M

a. Put a new seal on Tool (C). b. Put Tool (C) over valve body (1).

1. Remove fuel line (1) with Tool (A).

c. Push the seal into position on the valve body

NOTICE Put protective caps on all fuel line openings.

;

2. Remove nut (3) that holds the fuel valve in adapter (2).

3. Remove the fuel injection valve with Tool (6).

3408C & 3412C Marine Engines

138

Disassembly & Assembly

!

Remove Fuel Injection Nozzles (Earlier 7000 Series) 1254-011 Tools Needed

A

5P0144

Socket

1

5P5195

Fuel Line Wrench

1

6V6070

Nozzle Puller Group

B

1

NOTE: This procedure is for earher 7000 series fuel injection nozzles with 55.12 mm (2.170 in) adapter bores.

2. Install nozzle (2) on valve body (1) finger tight.

Start By: a. remove valve covers

\

FLUID SPILLAGE CONTAINMENT

'

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG25001', for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

3. mshei tfi6fhel injeation MI* h dhed injection adlawer p).Make sur6?tTe.grodves (seifationsjon , valve body 11) are in alignment with the grooves ,. , + gckafiter (3). .. a*

(&$$t@wfi .

L ' k . c

a

..

++*

,

s : .*, -

.

4. Installc>fienut that hold the fuel injection valve in ' *&aqIwhten . . . CI-B ~WWI76 ~ ~ .+: ~ -

~cl& .@$$ -

.

*

r

n

% "

, t ~ 6 o f i eline j (4)?,~ i $ b p nihe otiitl$ezide~ line to a t 6 7 l of 48.,& -%:m&.@8 '16 lb ft] with Tdol

NOTICE Do not let the tops of the fuel nozzles turn when the fuel lines are loosened.The nozzles will be damaged if the top of the nozzles turn in the body.

(4.

End By:

a. in&aIl valve covers

1. Use Tool (A) to loosen fuel injection line (1)at the fuel injection nozzle.

3408C & 3412C Marine Engines

139

Disassembly & Assembly

6. Remove bolt (7) that holds clamp (6).

2. Disconnect fuel injection line nut (2) from head adapter nut (3).

7. Remove fuel injection nozzle (8) with Tool (6)as follows:

3. Remove adapter nut (3) and the O-ring seal.

4. Move adapter (4) out of valve cover base, and remove fuel injection line (1).

3. If necessry, remadf'M[5] fromYud in]ection.lihe

- '{4.

, . 3iS,-";2;<3,-+

"

4.*,

.. :- &:,/

-

+

-5 ?.

1 *-

,/

NOTE: Clmp (6)")"B & q e W d U i ~ fGel fl injediori n-6 (@'is lR-Z%iipSiimdTy 25:O min * (1*00in).

.

<?,

-9. " .* ,

% ', *'

.

i,

- -:,

.%Y$-

8e-,;2y

3,s=.J-7fgv --%,.

;.#-+J.&&&C:..;

\

1,.

-

a. Install 6\1-6983 Adapter and 6\1-4152 Screw (9) part of Tool (B) into fuel injection nozzle (8). b. Install 6\1-6982 Tube Assembly (11) over the 6\1-4152 Screw. Use 28-5658 Washer and 18-2406 Nut (10) on the 6\1-4152 Screw to pull fuel injection nozzle (8) from the adapter.

Items (10) and (1 1) are part of Tool (B).

3408C & 3412C Marine Engines

140

Disassembly & Assembly

NOTE: Earlier fuel injection nozzles are installed in adapters that are below the surface of the cylinder head.

I

NOTICE A replacement of compression seal washer (13) and of carbon dam seal (12) must be made each time the fuel injection nozzle is removed.Be sure that the replace.merit compression seal washer (13) is the same color code and part number as the original compression seal washer. If the wrong thickness washer is used, engine damage could occur. See the Specifications Manual for more detailed information.

-

1. Use Tool (A) to clean adapter bore (1) for fuel

injection nozzle. Use a tap driver to turn Tool (A).

8. Remove carbon dam seal (12) and compression seal washer (13) from fuel injection nozzle (8).

Install Fuel Injection Nozzles (Earlier 7000 Series) 1254-012 Tools Needed

,4

l ~ l ~ l c l ~ l 1

6V4979

Seal Tool*

5P0144

Socket

1

5P5195

Fuel Line Wrench

1

-852245 6V4089

Cleaning Tool Group Reamer Assembly

2. Install compression seal washer (3) on fuel injection nozzle (41. ., 3. Use Tool (A) to install carbon dam seal (2) on fuel injection nozzle (4). Refer to Special Instruction SEHSl292 for the use of Tool (C).

1 1

* Part of 88-2245 Cleaning Tool Group

FLUID SPILLAGE CONTAINMENT

'

I

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG250On, for tools and supplies suitable t o collect and contain fluids in Caterpillar machines. Dispose fluids , according to local regulations and mandates.

3408C & 3412C Marine Engines

141

Disassembly & Assemblv

NOTICE Do not let the tops of the fuel nozzles turn when the fuel lines are tightened. The nozzles will be damaged if the top of the nozzles turn in the body.

7. Use Tool (6) to tighten the inner fuel line nuts to a torque of 41 +. 7 N-m (30 5 Ib ft).

+

4. lnstall fuel injection nozzle (4) and clamp (5) as a unit. lnstall the bolt through the clamp into the adapter.

8. Put clean diesel fuel oil on O-ring seal (10). lnstall O-ring seal (10) and nut (9). Tighten nut (9) to a torque of 30 r 5 N-m (22 r 4 Ib ft).

#k the lnstall nut (8) for the fuel injection line, and tighten fuel injection line nut to a torque of 41 rt 7 N-rn .

&A

(30rt5Ibft).

10. After installation of the valve covers, bleed remove the air from the fuel system. See the Systems Operation, Testing & Adjusting Manual for the correct procedure.

5. lnstall O-ring seal on fuel injection line (6), and put clean diesel fuel on it.

End BY: a. install valve covers

6. lnstall fuel injection line (6). Move adapter (7) into position in the rocker a n cover base.

-- 3408C & 3412C Marine Engines

142

Disassembly & Assembly

Fuel Injection Nozzles 8 Adapters (Later 7000 Series) Remove & Install Fuel Injection Nozzles & Adapters (Later 7000 Series) 1254 & 1106-010

NOTE: This procedure is for later 7000 Series Fuel Injection ~ozzleswith 40.45 mm (1.593 in) adapter bores.

Start By:

a. remove valve covers -

FLUID SPILLAGE CONTAINMENT Care must be taken to ensure that fluids areRmntained during performance of inspection, r n s t e nance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opeqing any compartment or disasany component containing fluids. Refer to - . sembling "TOOLS AND SHOP PRODUCT GUIDE, NENG2500H, , , for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to lbcal regulations and mandates.

1. Use Tool (A), and discohect fuel line (1) at both ends. Remove the fuel line from the engine. Cap and plug all openings immediately.

2. Use Tool (B) and remove retainer (2)from the adapter.

d

1 &J

3. Remove the fuel injectio" nozzles with Tool (C) as follows.

:

1

a. lnstall the 6\1-6983 Adapter and the 8T-3199

I

Screw into nozzle assembly (3).

b. Install the 8T-3198 Tube over the 8T-3199 Screw.

a

._ k

c. Use the 18-4206 Nut on the 8T-3199 Screw to pull the fyel injection noqle from the adapter

.

"

6 a r 4. Remove compression seal (4) 4 d carbon dam seal (8) from fuel injection nozzle ($ 2.

S 0 8 C & 3412C Marine Engines

-

143

5% ~isassembl$%Assembiy

5. Use Tool (A), and remove adapter (6) from the cylinder head.

Precombustion Chambers

6. Remove gasket (7) and seal (5) from adapter (6).

Remove Precombustion Chambers 1106-011

NOTE: The following steps are for installation of the fuel injection nozzles and adapters.

7. Use Tool (E) to clean the bore in adapter (6). Use an open end wrench or tap driver to turn Tool (E).

8. Inspect seal (5) for damage or wear. Replace the seal if necessary.

9. Put washer (7) and seal (5) in position on adapter (6).

Lever Assembly

880225

PrecombustionChamber Wrench

A

6

1 1

Start By: a. remove glow plugs b. remove fuel injection valves.

10. Put liquid soap in the bores of the and in seals (5) in the adapters.

11. Put 5P-3931 Anti-Seize Compound & the threads of adapter (6), and install the adapter in the cylinder head asspmbly.

..

12. Use Tool (A), and tighten the adapter to a torque of 205 14 N-m (150 10 Ib ft)

+

+

Tools Needed FT1322

NOTICE the correct compression seal washer (4) is nozzle assembly is installed in the copper washers are to be used with this?'

4

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the flu@ with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT4GUIDE,NENG25001', for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and-mandates.

f-

adagter.

- * 13. Install compression seal washer (4) and use Tool (F) to install carbon dam seal (8) on the fuel injection nozzle.

rain the coolant from the cylinder heads into a uitable container for storage or disposal.

14. Put fuel injection nozzle (3) in position in the adapter, and install retainer (2).

15. Use ~ool'(6) to tighten retainer (2) to a torque of 48 7 N-m (35 5 Ib ft).

+

+

16. Install fuel line (1). Tighten the nuts on the fuel line with Tool (A) to a torque of 40 2 7 N-m (30 5 Ib ft).

+

End By: a. install valve covers 2. Make separation between the push rod rocker arms with Tool (A). Move the rocker arms to one

I

1

1

- ,

1. Put liquid soap on the bore of the cylinder head and on seal (2).

3. Remove valve bridges (1).

4. Remove precombustion chambers with Tool (B).

-

2. Put 5P-3-1 Anti-Seize Compound on thethreads-of precombustion chamber (1). Install chamber (1) and gasket (3) in the chamber head.

Tighten the precombustion chamber with Tool (B) to a torque of 205 2 14 N-m (150 & 10 Ib ft).

Install Precombustion Chambers 1106-012 Tools Needed FT1322

850225

Lever Assembly PrecombustionChamber Wrench

A B 1 1

s -

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG250OU, for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

3. Install bridges (4).

4. ~ a k a e connection between push rods and rockers

arms with Tool (A).

5. Check the level of the coolant in the engine.

End By: a. install fuel injection lines b. install glow plugs

3408C & 3412C Marine Engines

145

Disassembly & Assembly

Direct Injection Adapters Remove Direct lnjection Adapters 1106-011 Tools Needed FT1322

Lever Assembly

5P0961

Fuel Valve Adapter Wrench

5P0125

Precombustion Chamber Wrench

A B C 1 1 1

Start By: 4. Loosen adapters (2) with the correct Tool (B) or (C).

Remove the adapters from the cylinder head.

a. remove fuel injection nozzles

FLUID SPILLAGE CONTAINMENT

Install Direct Injection Adapters 1106-012

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG25001', for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

A B C

Tools Needed

1

FT1322

Lever Assembly

5P0961

Fuel Valve Adapter Wrench

5P0125

Precombustion Chamber Wrench

1

1

FLUID SPILLAGE CONTAINMENT 1. Drain the coolant from the cylinder heads into a suitable container for storage or disposal.

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG25001' for tools and supplies suitable to collect and contail., fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

2. Separate the push rods and rocker arms with Tool (A). Move the rocker arms to one side.

3. Put identification marks on valve bridges (1) as to their location on the head. Remove valve bridges (11.

3408C & 3412C Marine Engines

146

Disassembly & Assembly

1. Put liquid soap on the bore of the cylinder head and on seal (1).

3. Install valve bridges (4) in their correct locations/ 4. Connect the push rods and rocker arms with Tool (A)"

5. Check the level of the coolant in thb engine.

End By: a. install fuel injection nozzles

2. Put 5P-3931 Anti-Seize Compound on the threads of adapter (2). Install adapter (2) and gasket (3) in the cylinder head. Tighten the adapters to the correct torque as follows: a. Use Tool (B) and tighten 2W-9757 Adapters to a torque of 205 14 N-m (150 2 10 Ib ft) , 4W-5733 Adapters to a torque of 135 + 7 Nom (100 10 Ib ft).

+

L

+

b. Uee Tool (C) and tighten 7W-1902 Adapkrs to a torque of 205 2 14 N-m (150 2 10 Ib ft).

3408C & 3412C Marine Engines

147

Disassembly & Assembly

Valve Lifters & Push Rods

Install Valve Lifters & Push Rods 1209 8~1208-012

C

Remove Valve Lifters & Push Rods 1209 & 1208-011 Tools Needed FT1322

Lever Assembly

5P2401

Tool Assembly

989082

Engine Turning Pinion

NOTE: Install a new guide spring on the valve lifter any time the lifters are removed from the engine.

Start By:

a. remove valve covers

1. Install a new guide spring on the valve lifter with Tool (A), Tool (B) and a Mft hammer.

1. Turn the crankshaft with Tool (C) until there is no

C

pressure on rocker arm (2).

2. Make a separation between rocker arm (2) and push rod (1) with Tool (A). Remove push rod (1).

NOTE: Put identification on each push rod as to its location in the cylinder head.

3. Remove valve lifter (3) with Tool (B).

4. Remove spring (4) from lifter (3).

3408C & 3412C Marine Engines

148

Disassembly & Assembly

I

Rocker Shaft Assembly

Remove Rocker Shaft Assembly 1102-011

A B

Tools Needed

1

FT1~322 Lever Assembly 5P0144

1

Socket

Start By:,

a. rernoiie 'valve 'kov6rs

I

.

.

FLUID SPILLAGE CONTAINMENT

tained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassemblina anv com~onentcontainina fluids. Refer to "TOOLS-AND SHOP PRODUCT GUIDE.NENG250OM, for tools and supplies suitable t o colle,& and contain fluids in Caterpillar machines. is pose fluids according to local regulations and mandates.

2. Remove lifter from Tool (A). Put clean engine oil on the lifter. Put lifter into position in the cylinder block with spring (2) in alignment with the hole in the cylinder block. Push the lifter out of Tool (B) with Tool (D).

j

3. Install the push rod for each lifter. Make a connection between the rocker arms and push rods with Tool (C).

End By:

-

a. install valve covers

.

1. Remove fuel line (2) with Tool (B). Put protective caps on all fuel openings.

2. Make a separation between rocker arm (1) and the push rod with Tool (A). Put identification on each valve bridge as to its location. Remove valve bridges (3).

3408C & 3412C Marine Engines

.----

-

-

---.-.-

.-- - - - --

- -

-.- -

---

Disassembly & Assembly

3. Disconnect fuel lines (4) from fuel line adapters (5).

Remove locks (6). Remove adapters (5).

4. Remove bolts (8)that hold the rocker shaft assembly (7) to the cylinder head. Remove rocker shaft assembly (7).

Install Rocker Shaft Assembly 1102-012 Tools Needed

I

FT1322

Lever Assembly

5P0144

Socket

A B 1

FLUID SPILLAGE CONTAINMENT

1

1

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500I1, for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

1. Put rocker shaft assembly (2) into position on the head.

2. Put clean engine oil on the threads of bolts (1) and install the bolts to hold rocker shaft assembly.

Tighten the bolts as follows:

a. Tighten bolts 1 through 6 in number sequence 25 N-m (200 & shown to a torque of 270 20 Ib ft).

+

L

b. Tighten bolts 1 through 6 in number sequence 20 N-m shown again to a torque of 447 (330 15 Ib ft).

+

+

c. Tighten bolts 1 through 6 in number sequence 30 N-rn shown again to a torque of 447 (330 15 Ib ft).

+

3408C & 3412C Marine Engines

150

+

Disassembly & Assembly

A 1

Tools Needed 5P0944

Puller Group

Start By: a. remove rocker shaft assembly

3. Put clean engine oil on the O-ring for adapter (5).

Install adapters (5) and locks.

A

e

.

.*

*

4. Connect fuel lines.(3) to adabters'(5). Tighten fuel line nuts to 40 -t-. 7 Nm@l -c 5 Ib ft) ~ f i Tool h , (B) i

5. ~ut':cleanengine oil Bj7 the vdve bridge dowels.

Install valve bridges (7) in their correct locations on the cylinder head.

NOTE: Adjustment of the bridge is necessary only if valve grinding or other reconditioning of the cylinder head has been done. See the topic "Bridge Adjustment" in the Systems Operation, Testing and Adjusting Manual for this procedure.

1. Remove retainer (1) from the shaft

.

2. Remove the washers and rocker arm (2).

6. Put clean engine oil on the valve bridges. Make connection between the rocker arms (4) and push rods with Tool (A).

I*.

7. Make an adjustment of the valve to have a clearance of .038mm (.015 in) for intake and 0.76 mm (-030 in) for exhaust. See the topic "Valve Clearance Settingnin the Systems Operation, Testing & Adjusting Manual.

8. Install the fuel lines to fuel valves (6). Tighten the fuel line nuts to 40 k 7 Nmm (30 k 5 Ib ft) with Tool (B).

,

End By:

3. Use Tool (A) to m o v d ths pin t h d holds bracket (3) to the rocker arm shaft.

a. install valve covers

4. Remove bracket (3), rocker a m (4) and the spring.

5. Remove the remainder d the rocker arms.

NOTE: The center brackets do not have pins.

3408C & 3412C Marine Engines

151

Disassembly & Assembly

Cylinder Head Asse-

Assemble Rocker Shaft Assembly 1102-016

Remove Cylinder Head Assemblies 1100-011

NOTE: Make sure all parts of the rocket shaft assembly are clean before assembly.

Start By: a. remove rocker shaft assembly

b. remove exhaust manifold

1. put olean engine oil on shaft (3).

2. Ihstall the center springs, ro"oakrarms and bracket.

3. Install spring (I), rocker arm (4) and bracket (2).

1. Disconnect wires (2) from the valve cover bases.

Remove glow plug harnesses (1).

4. Put tape around the shaft on each side of bracket

(2) as shown. Put the hole in bracket (2) in alignment with the hole in shaft (3)).

Put a mark on each piece of tape in alignment with the hole in bracket (2).

2. Remove valve cover bases (3).

5. Install pin (5) until it is Mended Ef.6 mm(s34in) above the surface of bracket (2). Make sure pin (5) is in alignment With the ma& ~FI tape b&cTre pin B installed. Remove th@ t q ~ .

6. lnstall rocker arm (6), washers (7) and retainer (8).

NOTE: Install enough washers until the end play on each end of the shaft is 0.12 to l.Olmm (.MEto .Oe0 in).

End By: a. install rocker shaft assembly .-

~ t 3 &23412C Man; ~ n ~ i n e s

152

Disassembly & Assembly

C

-

-

NOTICE Do not put the cylinder head down on a flat surface.

Direct injection nozzles extend out from the bottom surface of the cylinder head and will be damaged by the weight of the head.

NOTE: A new spacer plate gasket must be installed when the cylinder head is removed. See Remove & Install Spacer Plate.

Install Cylinder Head Assemblies 1100-012 Tools Needed FT1322

Lever Assembly

5P0144

Socket

A 6 1 1

1. Thoroughly clean the spacer plateand bottom surface of the cylinder head. Install. a new head gasket and water seals. Do not use any adhesives.

NOTE: A new spacer plate gasket must be used when the cylinder head is installed. See Remove & lnstall Spacer Plate.

3. Disconnect elbow (4) to temperature regulator housing (7).

4. Remove bracket (5) and bracket (6). Remove bracket (8). Remove the remainder of the (3/8in) head bolts.~emovelifting bracket (9).

5. Install three 5/16 in-18 NC Forged Eyebolts in the cylinder head. Fasten a hoist to the cylinder head.

2. Put the cylinder head into position on the spacer

plate. Be careful not to damage the head gasket or water seals.

6. Remove cylinder head bolts (10). Remove the cylinder head. The weight of the cylinder head is approximately 90 kg (198 Ib) for the 3408 engine and approximately 172 kg (380 Ib) for the 3412 engine.

3408C & 3412C Marine Engines

-

-- -

-

-.

-

-

-.

.-

-

153

Disassembly & Assembly

5. Put rocker shaft assembly (4) into position on the cylinder head. Put 5P-3931 Anti-Seize Compound on bolts (3). Install rocker shaft assembly bolts and washers. Tighten the bolts as follows:

a. Tighten bolts 21 through 26 in number

i/

sequence to 270 +. 25 N-m (200 & 20 Ib ft).

b. Tighten bolts 21 through 26 in number sequence to 447 & 20 N-m (330 & 15 Ib ft). c. Tighten bolts 21 through 26 in numbers 20 N-m (330 +. 15 Ib ft). sequence to 447

+

3. Put 5P-3931 Anti-Seize Compound on the threads of head bolts (1). Install the cylinder head bolts and washers and tighten as follows:

a. Tighten bolts 1 through 20 in number sequence to 270 & 25 N-m (200 +. 20 Ib ft). b. Tighten bolts 1 through 20 in number sequence to 447 & 20 N-m (330 & 15 Ib ft).

c. Tighten bolts 1 through 20 in number sequence again to 447 +. 20 Nem (330 & 15 Ib ft.

4. Install glow plug harness (2).

3408C & 3412C Marine Engines

154

Disassembly & Assembly

)

6. lnstall bracket (6) and spacer (5) on the cylinder head. Tighten bolts (9) finger tight. lnstall the bolt that holds bracket (6) to the automatic timing advance housing and tighten to standard torque.

Tighten bolts (9) to 43 k 7 N-m (32 5 Ib ft).

+

13. lnstall valve cover base (21) on the cylinder head.

Tighten the bolts in the sequence shown.

7. lnstall bracket (8). Tighten bolts (11) finger tight.

Tighten bolts (7) to standard torque. Tighten bolts (11) to43 & 7 N-m (32 Ibft).

14. Put clean engine oil or glycerin on the O-ring seal for adapter (19). lnstall adapter (19) and lock (16).

+

15. Connect fuel line (17) to adapter (19). Tighten the fuel line nut to 40 7 N-m (30 k 5 Ib ft) with Tool (B).

8. Follow Step 6 for bracket (12).

+

9. Put 5P-3931 Anti-Seize Compound on the remainder of 3/8" head bolts (10) and tighten to 43 7 N-m (32 zk 5 Ib ft).

16. lnstall fuel line (20). Tighten the fuel line nuts to 40 2 7 N-m (30 5 Ib ft) with Tool (B).

+

+

10. lnstall lifting bracket (14).

17. Connect elbow (18) to the temperature regulator housing

11. Put clean engine oil on the bridge dowels and on valve bridges (15).lnstall the valve bridges in their correct locations on the cylinder head.

End By:

a. install exhaust manifold

12. Make a connection between rocker arms (13) and the push rods with Tool (A). Make an adjustment of the valves to have a clearance of 0.38 mm (.015 in) for inlet and 0.76 mm (.030 in) for exhaust. See the topic "Valve Clearance Setting" in the Systems Operation, Testing & Adjusting Manual.

3408C & 3412C Marine Engines

b. install rocker shaft assembly

155

Disassembly & Assembly

Valves Remove Valves 1105-011 Tools Needed

5S1330

Valve Spring Compressor

8S2263

Valve Spring Tester

A 6 1 1

Start By: a. remove cylinder head assemblies

4. Check the spring force with tool (B).Mah reference to the Specifications Manual to find the correct -ling specificattons.

b. remove precombustion chambersldirect injection adapters

5. Do Steps 1 through 4 agein for the remainder of the ,valves. \ \J

Install Valves 1105-012 Tools Needed

5S1330

Valve Spring Compressor

A

1

1. Put springs (1) in compression with Tool (A).

2. Remove locks from valves.

3. Remove Tool (A), rotocoil, spring and valve.

NOTE: If valves can be used again, put identification on the valves for location at installation.

1. Put clean engine oil on the valve stem. Install spring (2), rotocoil (1) and valve.

3408C & 3412C Marine Engines

156

Disassembly & Assembly

Valve Seat Inserts Remove Valve Seat Inserts 1103-011 Tools Needed

A

983095

Handle Assembly

953081

Extractor (Inlet)

1 1

983089

Extractor (Exhaust)

1

Start By: a. remove valves

2. Put the springs in compression with Tool (A).

3. Install locks (3) with the thick end up.

Locks can be thrown from the valve when the spring compressor is released if the locks are not in their correct position.

4. Remove compressor and hit valve with a soft hammer to be sure the locks are in their correct position.

'j

'

1. Remove valve seat inserts with Tool (A).

5. Do Steps 1 through 4 again for the remainder of the valves.

2. Clean and remove burns from the valve seat bore.

End By: a. install precombustion chambersldirect injection adapters

b. install cylinder head assemblies

d

3408C & 3412C Marine Engines

157

Disassembly & Assembly

Install Valve Seat Inserts 1103-012 983095

Tools Needed Handle Assembly

953081

Extractor (Intake)

983089

Extractor (Exhaust)

Remove Valve Guides 1104-011 Tools Needed 9117349

Driver

A 1

Start By: a. remove valves

1. Remove valve guides with Tool (A).

1. Lower the temperature of the valve and seat inserts and install them with Tool (A).

NOTICE Do not make the diameter of the extractor in valve seat insert larger when theinsert is installed in the cylinder head.

2. Grind vale seat insert according to the specifications given in the Specifications Manual.

End By:

a. install valves

3408C & 3412C Marine Engines

158

Disassembly & Assembly

Bridge Dowels

Install Valve Guides 1104-012 Tools Needed 9U7349

Driver

5P2396

Bushing

A

1 1

1. Put clean engine oil on the outside of the valve guides.

Remove Bridge Dowels 1121-011 Tools Needed

A

5P0944

Dowel Puller Group

1

5P0942

Extractor

1

Start By: a. remove valves

)

2. Use Tool (A) to install valve guides. Guides must be extended 32.3 2 0.8 mm (1.27 2 .03 in) from the surface of the head. The inside diameter of the guides must be 9.487 to 0.025 mm (.3735 2 .W10 in). The maximum diameter for used guides is 9.545 mm (.3758 in).

1. Remove dowels (1) with Tool (A).

End By:

a. install valves

3408C & 3412C Marine Engines

Disassembly & Assembly

Install Bridge Dowels 1121-012 Tools Needed 5P2406

Spacer Plates A

Dowel Driver

Remove Spacer Plates 1221-011

1

Start By:

a. remove cylinder head

1. Install dowels with Tool (Al. Dowels must be extended 53.3 0.5 mm (2.10 & .02 in) above the head surface.

+

1. Remove seals (1) from the spacer plate.

End Bv:

a. install valves

' . /

2. Install six 318"-16 NC Forcing Screws (3) in the spacer plate. Tighten the screws evenly until the plate is free of the dowels on the cylinder head.

NOTICE Do not damage dowels (2) as the plate is removed.

3408C & 3412C Marine Engines

160

Disassembly & Assembly

I I'

-I

Install Spacer Plates 1221-012

Oil Pan

1. Make sure the spacer plate and the machined surface (3) of the cylinder block are clean and free of dirt and foreign material.

Remove<Oil Pan 1302-011

2. lnstall O-ring seals (1).

3. Put a new gasket into position over dowels (2) on the cylinder block.

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG250OU, for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

1. Drain the oil from the oil pan into a suitable container for storage or disposal.

4. lnstall spacer plate (4).

)

NOTICE Both surfaces of the spacer plate, gasket and the top of the cylinder block must be clean. Do not use a gasket adhesive or other substances on these surfaces.

5. lnstall new water seals in the spacer plate.

6. Check the cylinder liner projection. See lnstall Cylinder Liners. _-

2. Remove bolts (1) from around the oil pan. Use two people to remove the oil pan. The weight of the oil pan is approximately 14 kg (31 Ib) for the 3408 engine and approximately 27 kg (60 Ib) for the 3412 engine.

End By: a. install cylinder head

3408C & 3412C Marine Engines

161

Disassembly & Assembly

Install Oil Pan 1302-012

Oil Pump Remove Oil Pump 1304-011

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared t o collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500M, for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

Start By: a. remove oil pan

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500n, for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids,_ according to local regulations and mandates.

1.. Put a new into p ~ l t i o n 'qf~the oil pan. Use two people to put th@03 p a ' hta p m i o n on the engine.

2. Install the bolts that hold pan (1) to the cylinder block.

1. Remove four bolts (1). Remove bolt (3) and washer Remove oil suction bell (5),bracket (4) and tube (2).

-

2. Remove one bolt and washer that hold tube (8) to oil pump (7).Removetube (8).

3. Remove three bolts (6). Remove oil pump (7).

3408C & 3412C Marine Engines

Disassembly & Assembly

Install Oil Pump 1304-012 FLUID SPILLAGE CONTAINMENT

Disassemble Oil Pump 1304-015

I

Care must be taken to ensure that fluids are contained during performance of inspection, rnaintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500I1, for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

Start By: a. rermle oil pump

1

FLUID SPILLAGE CONTAINMENT

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG25001', for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

1. Put pump (2) into position on the engine block.

Install bolts (1).

2. Put clean engine oil on the O-ring seals for the bell tube and supply oil tube. Install the suction bell tube and supply oil tube.

3. Install two bolts at locations (3)for the suction bell bracket.

End By: a. install oil pan 1. Remove the bolt and washer that hold gear (1) on

the pump shaft.

2. Remove drive gear (1) with Tool (A). Remove the key from the shaft. Put marks on the pump bodies so they can be assembled in the correct position.

3408C & 3412C Marine Engines

Disassembly 81Assembly -- - .- -.

-

-.

-

--

-

-

I

6. Remove gears

3. Remove retainer (3) for the bypass valve. Remove 5,'

.%-'

r).

Put marks on the gears so they can be assembled in the same position.

the spring- and bypzss valve. <,

4. &mbve Jx~lts %%it ka@ @Wi@ @$thyf2) ta the main pump body. Remuve€fiep h p body.

7. Remove spacer (6) from the main pump body (5).

R6rnowa the baring8 from spacer (8) with Tool (C).

5. Remove the bmrhgs from pump body (2)with Tool

& Rmov8 the gmrs from main puiilp body (6).

(El.

.

'Ll

% Removethe be&ngs Worn the m i n pump body with Tool1(C).

34086 & 3412C Marine Engines

164

!

Disassembly & Assembly

Assemble Oil Pump 1304-016

FLUID SPILLAGE CONTAINMENT

-

I

Care must be taken to ensure that fluids are contained during performance of inspection, rnaintenance, testing, adjusting and repair of the machine.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "TOOLS AND SHOP PRODUCT GUIDE, NENG2500I1, for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations and mandates.

1. Use Tool (A) to install bearings (2) until they are even with the outside surface of main pump body (1). lnstall bearings (2) so the junctions in the bearings are 30 -1- 15 degrees from the center line of the M q g bares and tgward the oil pump outlet passage as shown.

2. lnstall bearings (3) in the spacer with Taol (A). lnstall the bearings until they are in position the same distance in from each side of the spacer. Install the bearings with the oil holes in the bearing in alignment with the oil holes in the spacer and the junctions in the bearings in alignment with the cavity in the spacer as shown. - . %

3. Put clean engine oil small gears and bearings before they are assembled in the oil pump. Install the idler and drive gears (5) in the main pump body.

4. lnstall spacer (4) on the gear shafts with the smaller

cavity and the oil holes in spacer toward the pump outlet passage as shown.

3408C & 3412C Marine Engines -

-

-

-

165

Disassembly & Assembly

BEARING JUNCTION

9. Install gear (13) on the shaft. lnstall the washer and bolt that hold gear (13) on the ehaft. Be wre the pump turns freely after assembly.

5. Use Tool (8)to install bearings (6) in the pump body (7) until they are 1.52 f 0.25 mm (.060 f .001 in) from the inside edge of the bearing bores. Install the bearings so the junctions in the he bearings are 30 f 15 degrees from the center line of the bearing bores and toward the outlet passage. The outlet passage has a cavity between the bearing bores.

End By: a. install oil pump

6. lnstall pump gears (8) on the oil pump shafts in their original position.

7. lnstall pump body (10). lnstall bypass valve (9), spring (11) and retainer (12).

8. lnstall the key on the shaft.

3408C & 3412C Marine Engines

166

Disassembly & Assembly

I

Connecting Rod Bearings

NOTICE Be careful not to damage the crankshaft journals. Do not turn the crankshaft while any of the connecting rod cam are removed.

-

Remove 8 Install Connecting Rod Bearings 1219-010 989082

Tools Needed Engine Turning Pinion

NOTE: The following steps are for the installation of the connecting rod bearings.

A 1

Start By: a. remove oil pump

NQTE: If the bearing.clearances are to be checked with Plastiggge, do not put oil on the parts until the bearing clearance has been checked.

)

5. Install the upper bearings in connecting rods. Put clean engine oil on the bearings and on the crankshal? journals. Slowly pull the connecting rods on the crankshaft.

1. Check each connecting rod cap for its location on the crankshaft. Each cap must have a number (1)

which is the same as the number on the connecting rod. Do not mix bearings.

6. Put clean oil on the lower bearings. Install the lower bearings in the connecting rod c-aps.

2. Use Tool (A) to turn the crankshaft until two of the pistons are at bottom center.

NOTE: Be sure tab (3)on the back af the bearings fits in the groove of the Caps and connecting rods.

3. Remove connecting rod caps (2). Remove the lower bearing from the connecting rod caps.

---

NOTE: When connecting rod caps are installed, make ~ the cap is next to, and sure the number on the s i d of respective with, the number on the side of the connecting rod.

4. Push the connecting rods away from the crankshaft and remove the upper bearings from the connecting rods.

3408C & 3412C Marine Engines

167

Disassembly & Assembly

NOTICE Do not use an impact wrench to tighten the nuts the additional 120 degrees (1/3of a turn).

8. Remove the cap and measures the Plastigage. The rod bearing clearance for new bearings must be 0.071 to 0.168 mm (.0028 to .0066 in).The maximum clearance for used bearings is 0.25 rnrn (.010 in).

9. Put bearing cap (2) in position and tighten the bolts as in Step 7.

10. Do steps 1 through 9 for the other connecting rod bearings.

End By: a. install oil pump

7. Make a check of the bearing clearance with Plastigage (4). Put clean engine oil on bolt threads (5). Put caps (2) in position on the connecting rods and install the nuts. Tighten the nuts with the procedure that follows: a. Tighten each nut (6) to a torque of 80 2 9 N-m (60 6 Ib ft).

+

b. Put a mark across the nuts and bolts. Tighten the nuts 120 degrees (1/3 of a turn) more.

3408C & 3412C Marine Engines

168

Disassembly & Assembly

C

Install Piston Cooling Tube 1331-012

Piston cooling Tubes

1. Put the cooling tube in position on the cylinder block and install the screw that holds the cooling tube to the block.

] Remove Piston Cooling Tubes 1331-011

Tools Needed

989082

Engine Turning Pinion

2. Tighten the screw to a torque of 24 2 7 N*m (18 +5 Ib ft).

A

1

Start By: a. remove oil pump 1. Use Tool (A) to tum the crankshaft until pistons are clear of the cooling tube to be removed.

3. With the piston at the bottom of the bore, check the clearance between piston and wlirrg tube with a piece of wire (1) 0.62 mm (.025 in) thick. If the clearance is less than 0.63 mm (.250 in) , make a replacement of'the tube.

NOTICE The cooling tubes must fit evenly against the cylinder block. If they do not, it will cause an oil loss in the engine oil system.

2. Remove screw (1) that holds the piston cooling tube. Remove the piston cooling tube.

V

End By.

NOTICE Do not remove the adapters for No. 1 and No. 12 piston cooling tubes on engines with Serial Numbers 38S1 through 383890. The engine cylinder blocks that use the adapters are identified by a 10-24 threaded screw hole next to the piston cooling tube mounting hole.

3408C & 3412C Marine Engines

a. install oil pump

169

Disassembly & Assembly

Pistons Remove Pistons 1214-01 1 Tools Needed 989082

Engine Turning Pinion

A 1

Start By: a. remove cylinder head assemblies b. remove oil pump 4. Push the pistons up until the piston rings are clear of the cylinder liner. Remove pietons (2).

c. remove piston cooling tubes

NOTE: Keep each cap with the respective connecting rod.

NOTICE If the piston cooling tubes are not removed, it is possible for the connecting rod to hit the piston cooling tubes. This can move the piston cooling tube out of alignment. A piston cooling tube that is not in alignment will not direct the lubricant to the correct location. The result can be piston seizure.

L

NOTICE Da m a t turn the crankshaft while any oF the connecting r d a are in the engine wIthd* the Wips installed.

LW mat; dmthe cb&tSngtubes v&h'&ntRe p~stcms aua removed.

I.Remove the carbon from the top inside surface of the cylinder liners.

5. Do Steps 1 through 4 for the remainder of the pistons.

2. Turn the crankshaft with Tool (A) until two pistons

are at bottom center.

3. Remove bearing caps (1) from the two connecting rods. Put pieces of rubber hose or tape on the threads of the connecting rod bolts as protection for the crankshaft.

3408C & 3412C Marine Engines

170

Disassembly & Assembly

(c

Install Pistons 1214-012

S F"-] + 7 & ",, t

)'

Tools Needed 5P3526

NOTICE Do not use an impact wrench to tighten the nuts the additional 120 degrees (1/3of a turn) more.

-1

Piston Ring Compressor

A 1

5. Check the side clearance between two connecting rods on the same crankshaft journal. Clearance must be 0.28 0.84 mrn (.011 t o .033in) for new rods.

1. Put clean engine oil on the piston rings, connecting rod bearings and cylinder liners.

6. Do Steps 1 through 5 for the remainder of the pistons.

End by: a. install piston cooling tubes b. install oil pump

c. install cylinder head assemblies

Disassemble & Assemble Pistons (Earlier - Rod Pin Bearing With Straight Sides) 1214-017

-/

2. Put two pistons in position opposite of each other in the correct bore of the block. lnstall pistons (1) with tool (A).

Start By: a. remove pistons

NOTICE Be sure that the pistons are installed with flat surfaces (2) of the connecting rods toward each other and the chamfered sides (4) toward the crankshaft.

1. Remove the bearings from the connecting rod and connecting rod cap.

NOTE: For more detail about checking bearing clearances and installation of connecting rod bearings, see Remove & Install Connecting Rod Bearings.

3. Check the bearing clearances with Plastigage.

9

4. Put 2P-2506 Thread Lubricant on bolts (5). Install caps (3) and nuts finger tight. Tighten each nut to a torque of 80 & 8 N m (60 k Ib ft). Put a mark across the nut and bolts. Tighten each nut 120 degrees (1/3 of a turn) more.

3408C & 3412C Marine Engines

171

Disassembly & Assembly

8, Put cannecting rod (4) in position on the base plate of Tool (fjr. Put a new rod pin bearing (5) on the adapter part of Tool (B). Make sure that the joint in the rod pin bearing is a 10 degrees from a cmwr line through the crankshaft and pin bearing bores.

2. Remove retainer ring (1) with Tool (C).

3. Remove pin (2) and the connecting rod (4) from the piston (3).

+

4. Remove the piston rinas from the piston with Tool

(A). Clean the piston ring grooves on the pistons with an acceptable ring groove cleaning rod.

3. Instail the pusher adapter (7) and pusher (8), part of Tool (B), on the adapter.

NOTE: See Use of Pistons Pin Bearing Removal & InstallationTools, Special Instruction, SMHS7295.

-

NOTE: The old bearing is pushed out by Tool (B) as 0 the new bearing is installed.

5. Heat the connecting rod in an oven to a temperature of 177" to 22O0C(350to 500°F).

Never use a direct flame to heat a connecting rod.

8. Use Tool (B) to push the new bearing into the connecting rod until the push adapter of Tool (B) makes full contact with the connecting rod surface.

9. . Use a pin boring machine to make the rod pin bearing the correct size. The bore ih the new rod 0.008 mm pin bearing must be 58.830 (2.0012 .W03 in).

+

+

10. Check the clearance between the ends of piston rings. See the topic "Pistons & Ringsnin the Specificatians Manual.

NOTE: The following steps are for the assembly of the pistons.

11. Install the oil ring spring in the oil ring groove of the piston.

3408C & 3412C Marine Engines

172

Disassembly & Assembly

f-

Disassemble & Assemble Pistons (Later - Tapered Rod Pin Bearings) 1214-017

NOTE: The oil ring is to be installed over the spring with the oil ring end gap of 180 degrees from the oil ring spring joint.

-

-

Start By: 12. lnstall the oil ring on the piston with Tool (A).

a. remove pistons

13. lnstall the second (intermediate) piston ring with the side that has the identification "UP-2" toward the top of the piston with Tool (A).

14. lnstall the first (top) piston ring with the side that has the identification "UP-1" toward the top of the piston with Tool (A).

)

NOTE: After the installation of all three piston rings, put the piston rings in position so the end gaps are 120 degrees apart.

1. Remove bearinis (3)from the cannecting rod and connecting r6d mp.

2. Remove retainer ring (lrwith Tool (A).

3. Remove pin (2) and connecting ~ o (4) d from the i piston.

15. Put piston (3) in position on connecting rod (4).

Put clean engine oil on pin (2) and install the pin. lnstall retainer rings (1) with Tool (C). Make sure the retainer rings are in grooves of the piston.

16. lnstall the bearings in the connecting rod and connecting rod cap.

End By:

-3 -

a. install pistons

34086 & 3412C Marine Engines

--

C

---

-- -

-

---

- -.

173

Disassembly & Assembly

8. Use a pin boring machine to make the rod pin bearing the correct size. The bore in the new rod pin bearing must be 50.830 0.008 mm (2.0012 .0003 in).

+

+

9. Check the clearance between the ends of the piston rings. See the topic "Pistons & Rings" in the Specifications Manual.

NOTE: The following steps are for the assembly of the pistons.

10. Install the oil ring spring in the oil ring groove of the piston.

4. Remove piston ring (5) from the piston with Tool (B).

NOTE: The oil ring is to be installed over the spring with the oil ring end gap 180 degrees from the oil ring spring joint.

Clean the piston ring grooves on the pistons with an ircc~ptablering groove cleaning tool.

NOTE: See U,se of Piston Pin searing Removal & Installation Tools, Special Ir-structions, SMHS7295.

11. tne&ll the oil ring on the piston with taol (6).

12. Install the second [hterrnediate) pMan ring with the side that has the identifieationUUP-2"twmd ths tap of the piston with Tool (B).

. -.

13. IhsMr the firat (tap) piston ring with the side that has the Idenflimtion "UP-1" toward the top of theu piston with Toql (B).

NOTE ~ f k the c installation of d l three piston rings,

put th& piston r i g s in positron so the end gaps are

5. Heat the connecting rod (4) in an oven to a temperature of 177" to 260°C (350°to 500°F).

18Udeg~eesapart.

Never use a direct flame to heat a connecting rod.

6. Put connecting rod (4) in position on the base plate of Tool (C). Put a new rod pin bearing (6) on the adapter part of Tool (C).

NOTE: The old bearing is pushed out by Tool (C) as the new bearing is installed.

7. Use Tool (C) to push the new bearing into the connecting rod until the push adapter of Tool (C) makes full contact with the connecting rod surface.

3408C & 3412C Marine Engines

174

Disassembly & Assembly

-.

Cylinder Liners Remove Cylinder Liners 1216-011 Tools Needed 5P8665

A 1

Cylinder Liner Puller

Start By:

a. remove spacer plates b. remove pistons 14. Put the in position on connecting rod (4).

Put clean engine ail pin (2) and install the pin.

Install retainer rihgs (1)with Tool (A). Make sure the retainer rings are in the grooves of the pistons.

W

15. ln&&ll bearings (3) in the connecting rod and connectind rod cap.

End By:

a. instan pistons

1. Make an adjustment of the legs on Tool (A) for the length of the cylinder liner.

NOTE: Be careful not to damage cooling tube at the bottom of the cylinder liner.

2. Turn the nut on Tool (A) until cylinder liner (1) is free of the cylinder block.

3408C & 3412C Marine Engines

Disassembly & Assembly

3. Remove seals (3) and filler band (2) from the cylinder liner.

a. lnstall four bolts (4) and eight seals (washers)

from Tool (A) around each cylinder liner as shown. Tighten the bolts evenly, in four steps: 14 N-m (5 Ib ft) ,35 Nom (25 Ib ft) , 7 0 N-m (50 Ib ft) and then to 95 N-m (70 Ib ft).

lnstall Cylinder Liners 1216-012

-

'./

NOTE: To keep from moving bolts and seals as each

liner is checked, install two bolts with seals on each side to each cylinder liner, along the complete length of the top plate. b. lnstall plate (3), crossbar (6), plates (5) from Tool (A) and bolts (2) and washers from Tool (C). Be sure the crossbar is in position at the center of the liner and the liner surface is clean. Tighten the bolts evenly, in four steps: 7 N-m (5 Ib ft) , 20 N-m (15 Ib ft) ,35 N-m (25 lb ft) , and then to 70 N-m (50 Ib ft). c. Check the distance from the bottom edge of crossbar (6) to the top edge of the spacer plate.The distance on each end of the crossbar must be the same.

1. lnstall the gasket and spacer plate.

2. Clean the cylinder liners and liner bores in the cylinder block.

d. Check the liner projection with Tool (B) at four 'locations around the liner flange. Liner projectiomust be 0.03 to 0.15 mm (.DO1 to .006 in).

The difference between the four measurements on the same liner must not be more than 0.05 mm (.022 in). The difference between average liner projection for liners next to each other must not be more than 0.05 mm (.002 in). The maximum difference in the average projection of the cylinder liners under each cylinder head must not be more than 0.10 mm (.OM in).

NOTE: If the liner projection changes too much from point to point around the liner, turn the liner to a new position in the bore. If the projection measurements are still within specifications, move the liner to a different bore in the cylinder block and check the projection again.

3. lnstall the cylinder liners (1) in the cylinder block without seals or bands.

4. Check the cylinder liner projection as follows:

3408C & 3412C Marine Engines

176

Disassembly & Assembly

C

>

5. If a liner does not measure with the correct projection specifications, the projection can be changed with a counterbore operation to the top surface of the cylinder block. The counterbore depth must be a range from a minimum of 0.76 mm (.030 in) to a maximum of 1.14 mrn(.045 in).

Shims are available to then adjust the liner to the correct projection.

NOTE: See Special Instruction, FM055228 for procedure to use the 8s-3140 Cylinder Block Counterboring Tool Arrangement.See the topic "Cylinder Liner Projectionnin the Systems Operation, Testing &Adjusting Manual to find shim thickness, part number and installation.

8. Put liquid soap on seals (8), grooves of the liner and the bore of the block. Install the sears on the cylinder liner.

ti.put a@r: M(f3; in cban SAP ~ I 6il J .For a sh~rt .- frirre, &dl .,

fat ' '

-

'the niter b&ndbn the liner.

l&$M fke liner imMmdfately after the flller band is i w ~ * - g a ksure e the mark on liner b in @i&m3&twTfkthe ark on the blcuck. Use;Tdql )(: t o . p ~ ~_ ~ & l f n i net r~ pasition. .

I-.As

,b . *.

1I,- .M &$is ?'thou& l&ftqr the u$ngTnder.b the %

I

'

e

I&$r&.

)

c

,

6. Put a mark (7) on the cylinder liners and block so the liners can be installed in same position.

a. install pistons

7. Remove Tool (A) and Tool (B). Remove one liner.

a. install spacer plates

3408C & 3412C Marine Engines

.

.P" ~ni:k~ <

177

Disassembly & Assembly

Crankshaft Main Bearings Remove & Install Crankshaft Main Bearings 1203-010 Tools Needed 2P5518

Bearing Tool

A B C 1

Plastigage 885467

Indicator Group

1

Start By: a. remove oil pump

NOTICE If the crankshaft is turned in the wrong direction, the tab of the bearing will be pushed between the crankshaft and the cylinder block. This will cause damage to the crankshaft and block.

1. Check each main bearing cap (2) for its location on the engine. Each cap has an arrow (1) which points to the front of the block and a number (3) which gives the location of that cap.

2. Remove No. 2 through NO. 6 main bearing caps from the engine. Remove the lower bearings from the caps.

4. Turn the crankshaft until Tool (A) can be installed in oil hole (4).Turn the crankshaft in the direction which will push the upper main bearing out, tab end first.

3. Remove the thrust plate from each side of the No. 4 upper main bearing.

NOTE: The following steps are for the installation of the crankshaft main bearings.

3408C & 3412C Marine Engines

178

(-

u

Disassembly & Assembly

-

NOTICE Make sure the upper and lower halves of bbarings are installed so bearing tabs (5) fit into the notch in cylinder block and bearing caps.

w NOTE: Do not put oil on the parts until the bearing clearance has been checked.

5. Put clean enginb OH on the lower. Install lower b&rings in the be&ng caps, 6. Put clean engine oil on the upper bearings. Install upper bmings in the cflnder block with Tool (A). ,

8.

P,ulk @$be of the Plastigag&on the surface of the Iowdr bearing half.

b. int&gdl ;the main bearing caps with arrow (6) toward the front of the cylinder block. Each cap has a number (7) on the bottom surface and must be installed in the same position as the correct number on the left side of the cylinder block. c, Put 28-2506 Thread ~ubricknton the threads Of the cap bolts. Instdl the cap bolts finger tight.

d. Tighten the bolts on the tab end of the caps first to a torque of 260 r 14 N-m (190 f 10 Ib ft). e. Tighten the bolts on the other end of the caps to atorque of 260 k 14 N-m (196 10 Ibft).

+

f.

3408C & 3412C Marine Engines

Put's mark across the bolt head and cap.

Tighten the bolts opposite the tab end 120 degrees (1/3of a turn). Tighten the bolts on the tab end of the cap 120 degrees (1/3of a turn).

Disassembly & Assembly

179

--

-

7--

-

-

- - ~~-- - - -. k

.

s*,:

8-

Crankshaft

NOTICE Do not use an impact wrench to tighten the bolts the additional 120 degrees (113 of a turn).

Remove Crankshaft 1202-011

8. Remove the caps and measure the Plastigage. The clearance for new bearings must be 0.091 to 0.018 mm (.0036 to .0073 in). The maximum clearance for used bearings is 0.25 mm(.010 in).

Tools Needed

9. Install a thrust plate (8) on each side of the No. 4 upper bearing.lnstall the thrust plates with the side marked "Block Side" toward the cylinder block.

10. Install again the No. 2 through No. 6 main bearing caps. Follow the tightening procedure in Step 7.

A 6

1P2322

Puller Assembly

1

5P4170

Step Plate

1

5P0944

Puller Group

1

5P0941

Extractor

1

5P0939

Extractor

1

Start By: a. remove oil pump

11. Do Steps, 2,4,5,6,7 and 8 for the No. 1 and No. 7 main bearing caps.

b. remove front housing c. remove flywheel housing

d. remove pistons NOTE: For more detail about removal of main bearings see the topic "Remove & Install Crankshaft Main Bearings".

12. Check the crankshaft end play with Tool (C). The end play is controlled by the thrust plates on the center main bearing. Make sure the dial indicator is against a machined surface. End play for new thrust plates must be 0.15 to 0.51 mm (.006 to .020 in). The maximum end play with used thrust plates is 0.89 mm (.035 in).

1. Check each bearing cap (1) for its location on the engine. Each cap has an arrow which is toward the front of the block and a number which gives the location of that cap. Keep each bearing with the correct cap.

End By:

2. Remove bearing caps No. 2 through No. 6.

Remove thrust plates from No. 4 upper bearing.

a. install oil pump

3408C & 3412C Marine Engines

3. lnstall one of the flywheel bolts in each end of the crankshaft.Fasten a hoist to the crankshaft as shown. Remove No. 1 and No. 7 main bearing caps. Remove the crankshaft. The weight of the crankshaft is approximately 143 k g (315 Ib) for the 3408 engine and approximately 180 k g (400 Ib) for the 3412 engine.

180

Disassembly & Assembly

c

NOTICE Be careful not to damage the crankshaft journals when the crankshaft is removed.

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3. Heat crankshaft gear (3) to a maximum temperature of 232°C [4W°F). Install gear (3) on the crankshaft with groove (4) in alignment with dowel (2).

4. Make sure the upper main bearings are clean. Put clean oil on the upper main bearings and journals of the crankshaft.

4. Remove crankshaft gear (2) with Tool (A).

5. Remove dowel and pin from the crankshaft with Tool (B).

lnstall Crankshaft 1202-012 A

Tools Needed 885467

Dial Test Indicator Group

1

5. lnstall one of the flywheel bolts in each end of the crankshaft. Fasten a hoist to the crankshaft and put it in position in the block.

NOTICE Use care to prevent damage to the crankshaft journals. Make sure the "V" mark on the crankshaft gear is in alignment with the "V" mark on the idler gear.

NOTE: For more detail about installation of main bearings, see the topic "Remove & lnstall Crankshaft Main Bearings".

1. lnstall pin (1) in the crankshaft end until it is extended from the surface a distance of 6.4 0.5 mm (.25 f .02 in).

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3

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6. Check the bearing clearances with Plastigage.

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7. Put 2P-2506 Thread Lubricant on the bolts for caps No. 1 and No. 7 , lnstall No. 1 and No. 7 caps with the bolts finger tight. Make sure the arrows on the caps are toward the front of the block.

2. lnstall dowel (2) until it is extended from the surface a distance of 4.1 & 5.0 mm (.I6 .02 in).

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3408C & 3412C Marine Engines

181

Disassembly & Assembly