manual cat.assamble dis ass amble

CAERPILLAR'D

SEN R133 l Jun e1996

Dnsasscnnbly & Asscmnb[y34O8C & 3412C Marine Engines

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3412= gBR1-UP

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MarineAuxiliary Generator Engines & Set

. . ....... ....,20 Valves OilBypass .........24 OilCooler ...........2O O i lF i l t e r s .............21 r O i lF i l t eB a s e . . . . . . . . . . . . . . ... . OilFilter Base, Disassemble & Assemble.......... ...22 . . . . . . ... . . . . 2 3 O i lL e v eG a u g e l . . . . . . .1 . . 1 .6. O i lP a n ...'..162 O i lP u m p .. 163 OilPump,DisassembleAssemble & . ...169 Piston Tubes Cooling (Earlier Rod PinBearing Pistons WithStraight ..... .....171 Sides), Disassemble & AssemblePictnne ll alar - Tanororl Rnd Pin Roarinnc\, e v q , , , , : , v / ,

Radiator ..............5 Rocker Assembly Shaft .............. .. ... ....149 RockerShaftAssembly, Disassemble & Assemble ... . 151 - -=:: lnjection Adapters .. . .............146 Rarru WaterPrrmn ......... 98 RawWaterPump(Earlier Disassemble Engines), & - - : re Lifting Brackets .................. ............... 12 .........99 :-; ie Support . .. . . . . . . . . . . . . . . . 1 2 Assemble Disassemble & - ' - a u s t M a n i f o l d ( R e a r ) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 8 RawWaterPump(LaterEngines), Assemble ....... 104 (Water ......... :'^3uSt Maniold Cooled) 130 -(sansion Tank& WaterLrnes ............... 107 Meter............. Service ............. 38 ........152. . . . . . |. / c ._ âr I rnre

-:-^.sraft RearSeal& WearSleeve . -:er HeadAssemblies

..... 173 Disassemble .................... & Assemble Pistons . . . .,.... 1 7 0 144 Precombustion Chambers ........,............. ............................ . . . . . . I. z

)

= a nB e l t s ............7 = a nD r i v e ............ ............. 116 Gears . . . . . . . . . . . . 8 Timing =anDive,Disassemble ..... ..............................29 & Assemble .............................. T r r r h n n h a r o a r ...8 :an Guard Turbocharger, DisassembleAssemb|e & ....................... 31 ..........4 =lywheel .........117 =iywheel Valve Covers . .. ............. 133 Housing ............125 = r o nH o r s i n n t Valve Guides .. . . ...158 .....112 =r'ont Valve Lifters PushRods.............. & ........... 148 Housing ......... 16 Cover '18 :.lel Filter Valve SeatInserts ................ 157 ......... =uellnjection Valves .... ...156 Lines ............. ............................33 =uelInjection Vibration Damper Pulley & ........................ 109 Nozzles Adapters(Later7000 & Series) ............143 WatePump r ...........................92 (Earlier FuelInjection Nozzles 7000 Series) . .. . 139 ...... Pump, Disassemble & Assemble ......................... 95 Fuellnjection PumpHousing Governor ......................52Water & Water Temperature Regulators ................. 87 FuelInjection PumpHousing, Disassemble & Assemble .........78 Fuellnjection Pumps ...........44 (Direct FuelInjection Valves Injection).......... ...138 ....... (Precombustion FuelInjection Valves Chamber) ...136 ... FuelPriming Pump& Filter Base .. . . ....19 Disconnect batteries beore perormance of any (lf FuelRatio ................ Control Equipped) 35 service work. FuelFatioControl, DisassembleAssemble & ..............36 Fuel Transfer Pump......... -. ................. .. ...... 39 FuelTransfer Pumo.DisassembleAssemble & ...........40 ...... 18 Generator 1 (Precombustion ...... GlowPlugs Chambers) ............... 135 Disassemble & Assemble ................................ Governor, 55 Governor FuelPumpDrive & ......................47 Governor FuelPump Drive,Disassemble & & Assemble .........50

=al .................

. . . . . . . . . . . . . . . . . . . . .6 . . . . . . . . . . .Snar:cr Plates .vYsvvl

. ... 160

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3408C&3412C MarineEngines

lndex

Disassembly Assembly &Fan GuardRemove& InstallFan Guard 1360-010

Hb-

I3. Remove twentytwo bolts and washers(3)and remove two fan guards(4). r\/rs removal the NOTE: To install fan orrarcls the steps.;r ffi # -tflp d ..;il

:fr *#

1. Remove two boltsand strap(1)fromthe fan guard assemory.

)

2. Remove two boltsand strap (2)fromthe fan guard assemory.


Disassembly& Assembly

RadiatorRemove& lnstall Radiator 1353-010

-,=rar tvuot u

-

-

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Care must be taken to ensure that fluids are contand during performance of inspection, mainten rrrce,testing, adjusting and repair o the machine. 8e prepared to collect the luid with suitable contners before opening any compartment or disassemblingany component containingfluids. Reerto .TOOLS AND SHOPPRODUCT GUIDE, NENG2sOO'" for tools and suppliessuitableto collect and contain 1uids in Caterpillar machines. Dispose luids according to local regulationsand mandates.

3. Loosentwo hoseclamps(3). 4. Remove radiator tube (2)fromthe radiator.

l. l'ain the radiator a suitable into container for :::'ageor disposal.

I5. Loosen two hoseclamps(5)on the water temperature regulator housings. 6. Remove two radiator braces4).

2. r-oosen hoseclamps(1). two

7. Attachlifting slingsand a suitable lifting deviceto (6). (6) radiator Radiator weighsapproximately 186kg (410lb).



FanRemove& InstallFan 1356-010Stad By: a. removeradalc'

FrBi+rrllr

I

(6) four bolts(7)fastening radiator to the 8 . Remove-Ât^+^- ^,,^^^* rdurdL\Jr >UPPU L.

9.

Romnrro

r:di:tnr

A\

1. Attacha lifting to slingand a suitable lifting device fan(1).Fan(1)weights kg (75lb) . 34 (2). 2. Remove boltsand washers six 3. Remove (1). fan NOTE: To install fan, reverse removal the the steps. End By: (8). fourrubbermounts 10. lf necessary, remove reverse stepsfor the NOTE: To install radiator, the removal. EndBy:^ cl. i^^+^f f +^^ ^,,^. il tLdI tdr I vu4r u

a. install radiator

Fan Belts1 RemoveFan Belts 1357-01

lnstall Fan Belts 1357-012Tools Needed Bf -33-72C BorroughsBelt TensionGauge A1

:

:

I

the NOTE: Inspect an beltsfor damage,cracksor with new beltsi necessary. wear. Beplace

the -;=- four nuts(1)fastening an drivebracket'-::nnino", ,Y,,'v.

threefan belts(2)on the pulleys. 1 . Install 2. Tightenbolt (3)untilfan belts(2)are tightened bolt(3)untilfanbelts(2) 3. lf beltsare new,tighten reacha tension 534 + 22N (120 + 5lb). Use of the ToolA)to determine belttension. bolt(3)untilfanbelts(2) 4. lf beltsare used,tighten reacha tension 400 + 44 N (90 + 10 lb). Use of the Tool(A)todetermine belttension.

z

fan -rcsen bolt (3)to loosen belts(2).

3. =:.novethreefan belts(2).

the four nuts (1)fastening fan driveto the 5. Tighten fronthousing. End By: a. installfan



Fan DriveRemove& lnstallFan Drive 1359-010Tools Needed BS-1378 Stud Removerand ResetterGroup A1

Disassemble& Assemble Fan Drive 1359-017Tools Needed 1P-0510 Driver Group

Start by:

Staft By: a. removefan belts

a. remove drive fan

063845

lifting 1 . Attacha liftingslingand a suitable deviceto fan drive(1)as shown. 2. Remove four nutsand washers(2). 3. Remove drive(1).Fandriveweighs kg fan 23 ( 5 1r b ) .

D45448

1 . Remove two boltsand bracket(4)fromthe fan drivebracketassembly. 2. Femovesix bolts(1)that fastenfan adapter(3)to pulley (2).

(3). 4. Removebracketassemblyl

remove four studs (a)withTool (A). 5. lf necessary, NOTE: To install fan drive,reverse removal the the steps. End By: belts a. installfan 3408C&3412C MarineEngines Disassembly& Assembly

4 0454 5

I

-:--- . e two boltsand washer(5)from the fan drive :

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

06J848

t. r'.no\/ O-rinoseal16) from the fan drivehub. 5 . :emove hub (7)fromthe fan drive.

pulley(2)from fan bracketassembly (12). 8. Remove

D4 446 5

D{5450

9. Remove spacer(13)from fan bracketassembly (12).

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



06J84 9

10. lf necessary, plug(14)inside adapter remove fan (3) NOTE: Thefollowing stepsareor the assembly the of fandrive.

13. Installpulley on bracket (2) (12) assembly

045445

D 6 J 89 4

14. UseTool(A)to install seal(11)intohub (Z). lip Lubricate sealing o lip seal(11)with 1Pthe lip 0808 Lithium Grease .

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

045450 045446

15. Install (B), bearing spacer(9)and bearing into (10) hub (7). 2. lnstall spacer(13)on fan bracketassembiy (12).

3408C& 3412CMarineEngines

'10

Disassembly Assembly &

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drirra

pulley (2)to hub (7), 19. Install bolts(1)fastening six 20. lnstall bracketand two bolts(4)on the fan drive bracketassembly. fitting with 1P-0808 21. Fillthefan driveat the grease Lithium Grease. EndBy: fan a. install drive

C-ring seal(6)on hub (7).

t&

-sallwasher and two bolts(5)in hub (7).

3408C& 3412C Marine Engines

11


EngineLiftingBracketsRemove& Install Engine Lifting Brackets 1122-O1OStartBy: a. removeexhaustmanifolds

Engine SupportRemove & Install Engine Support 1154-010Start By: pulley damper a. removecrankshaft &

tl

fillFrs

trddtlr*r

1 . Remove four boltsand washers(2). 2. Remove rightsideengine (1). lifting bracket

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

3* -

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rl5

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3. Remove four boltsand washers(4). 4. Remove sideenginebracket(3). left NOTE:For installation the engineliftingbrackets, of reverse stepsor removal. the EndBy:

2. Attachtwo liftingslingsand a suitable liftingdevice to radiator support(2)as shown.Remove eight bolts,washersand nuts(4)fastening radiator support(2)to engine support(3).

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g'.E--a

3. Removeradiator support(2).The weightof radiatorsupport(2)is 25 kg (55 lb).

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a. install exhaustmanifolds


12


=tt

Grankcase BreatherRemove& lnstall Crankshaft Breather 1317-010NOTE: The crankcase removaland breather installation the samefor both crankcase is removal breathers.For simplicity, and installation is shownfor onlvone crankcase breather.

I

:-arnsand a suitable lifting device the to : rg brackets shown. Theweightof the as = aoproximately 3629 kg (8000lb).

1 . Loosenhoseclamp(2). (1). 2. Remove breather

- -3 Cevice.a

r:rrt

the encine with the ChainSand the SUitable

-:-f,ve fourbolts,washers and nuts(6).-.:-lro oinhf hnltc /\

::rove engine support(3).Theweight engine of . -:cort (3)is 25 kg (55 lb) . ' êcessary, placewood blocksunderthe engine ,'.aere front housing the and the oil pan are mated'^ lr rnnnrf f ho onnino

3. Remove O-ringseal(3). NOTE: For installation the crankshaft of breather, reverse removal the steps.

'rlT: To install engine the reverse support, the .--': ral steps.-' Qrl "t.

:

pulley& damper rstallcrankshaft


13


Crankshaft Pulley& DamperRemove & Install Crankshaft& Damper 205-010

Start By: a. removefan belts

-iMovedamper(4)forward enoughto attacha far lifting slingas shown. Attachthe liftrng slingto a suitable lifting device. l*.T.oy" damper(4).Damper(4)weighs29 kg (64 tb).

,91 . Remove twelvenuts (2). 2. Usetwo people remove to pulley pulley (1). (1) weighsapproximatety kg (46 tb). Zl

a

$--It,

!9If , Adapter(6)is hetdin ptaceby twelvebotts removing twelvebolts(5)hotdadapter(6)by !5),When handto preventit from falling. 6. Hold adapter(6)by hand,removetwelvebotts(S).

3. Remove puttey (3).

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

I

3408C & 3412CMarine Engines

14


.iill

',I -: -re following stepsarefor the installation of --,--:shaft pulley and damper.

pulley on the adapter. (3) 12. Install

=-:i'ed, install twelve studs(7)in adapter (6) '- -:cl (A).

(1) 13. Placepulley in position the adapter. on 14. Installtwelve (2).Tighten nuts twelvenuts(12)toa torqueof 65 + 10 N.m (r+8t 7 lb ft).9 . : ::: adapter in position the crankshaft. (6) on 10- r'all t r r r o h r o hv n l t c U / 6 \ v r L\v/.

End By: a. installan belts

t l.

rstalldamper(4)on the adapter.

}{OSC& 3412C Marine Engines

15


FrontHousingGoverRemove& lnstall Front Housing Cover 1151-010Tools Needed ResetterGrouo BS-1378 Stud Removerand A 1

StartBy: fan a. remove drive 3. lf necessary, remove four studs (6)with Tool(A). 4. lf necessary, remove threeboltsand cover(5). 5. Remove (7). nutsI '-*3? :irt z"#

{l

n

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

1. Remove bolt and hoseclip (1).

gasket(9). 7. Remove 8. lf necessary, removestud (B)withTool(A).

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'"t. --tt'

2. Removenut and washer(2).


16


lrt

'emove nuts(10), : --.'.. five (1 cover 1)and ':-. - : -::], remove studs(12)withTool(A). five - '-, "rrwinostensarc fOrthe installation ' '"',.Y o -s ng cover.

1 3 . l removed, apply4C-4032Thread Sealant to thethreads stud (8)and install o withTool(A). 14.lncfnll oaekat /O\

15. lf removed, installfour studs(6)withTool(A). ' I '-:'roved, installfive studs(12)with Tool(A). (11), fivenuts(10). thegasket, cover and - =:all fivenuts(10)to a torqueof 20 + 3 N.m ;'ten ( 1 s+ 2 l b f t ) . (4). 16. Installcover 17. Install (7)and ten bolts(3). nut 18. lf removed, install gasketand cover(5). the

3108C 3412CMarineEngines &

17


Fuel FilterRemove& InstallFuel Filter 1261-01Tools Needed

(2). nut 19. Install and washer

Care must be taken to ensure that fluids are cor tained during performanceof inspection,maint* nance,testing, adjusting and repair of the machine. Be prepared to collect the luid with suitable corF tainers before opening any compartment or disassemblingany componentcontaining fluids.Referto AND SHOPPRODUCT GUIDE, NENG2SOO' "TOOLS for tools and suppliessuitableto collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulationsand mandates.

and 20. Installbolt hoseclip(1). End By: a. installfan drive

position, 1. Turnthe uelsupply valve the "OFF" to fuel 2. UseToolA to remove filter(1). NOTE: Thefollowing stepsarefor the installation of the fuelfilter.


'18


-1..3

FuelPrimingPump& Filter BaseRemove& InstallFuel PrimingPump & Filter Base 1258& 1262-010Start By: fuel a. remove filter

:' :aie the sealof fuelfilter withcleanengine (1) : - :' to installation. -:cl (A)to install filter(1). + fuel Tighten filter fuel : -: to I turn aftercontactwith the filterbase. -- :re uelsupply valve the "ON"position. to

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 luid with suitable containers before opening any compartment or disassembling any component containingfluids. Reerto ''TOOLS AND SHOPPRODUCT GUIDE, NENG2sOO", or tools and suppliessuitableto collect and contain luids in Gaterpillar machines. Dispose fluids according to local regulationsand mandates.

1. Turnthe fuelsupply valve the "OFF"position. to

two bolts (2).Remove 2. Remove uel primingpump (1)and the gasket. 3. Marktwo hoses(3)or identircation. Disconnect two hoses(3)fromfilterbase(5).Cap and plugall immediately. openings 4. Remove two bolts and nuts(4)romthe filterbase. Remove filterbase(5). pumpand NOTE: Forinstallation the fuelpriming of filterbase,reverse removal the steps. End By: filter a: installfuel

3408C&U12C MarineEngines

19


Oil BypassValvesRemove& InstallOil Bypass Valves 1314-010

Oil Filters;

|!l*'I ":ll

Remove& Installoil Filters 1318-010F kTools Needed

id

I

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance,testing,adjustingand repairof the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassemblingany componentcontainingfluids.Referto NENG2sOO", AND SHOPPRODUCT GUIDE, "TOOLS or tools and suppliessuitableto collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulationsand mandates. (2)rom oilfilter base(1)with 1. Remove oilfilters two Tool (A). of stepsare for the installation NOTE: The following the oilfilters. the 2. Lubricate sealsof two oil filters(2)with clean engine oil. (2) 3. Installtwo oilfilters untilcontactis madewith oil filter base(1). two oil filters(1)an additional3/4turn aller 4. Tighten baseis made. contact with the oililter

fl5rd

.nm *tnflflF* -'-''frJ ar*.:bSA l||||r.s --r-h

f

al1

|

r

F

ffi w

h

cover(1). 1. Remove the 2. Remove filterbypassvalvefrom the filterbase. 3. UseTool (A)to removeoil filter(2). (2) install oilfilter according NOTE: Uponinstallation, givenon the filter. to the instructions 4. Remove cover(3). the 5. Remove oil coolerbypassvalvefrom the cooler line. bypass reverse of NOTE: For installation the oil bypassvalves,tho romnrnl qtonq

level. Seethe oil 6. Checkthe engine for the correct Manual. & Operation Maintenance


20


Irr r iter Basercr -,: , e & l n s t a l l O i l Fi l te r !-.'r. 1306-010

- -i: re taken to ensure that fluids are con'-.e: :--'rg performance o inspection, mainte. ':s:;ng. adjusting and repair of the machine. :, t- ;r.*:.r-ed to collect the luid with suitable con-F, :{3re opening any compartment or disas:,:,r'-.1 3ny component containing fluids. Referto " , - r - S A N D S H O P P R O D U C TG U I D E ,N E N G 2 5 0 0 " , - ' : :.:. s : nd supplies suitable to collect and contain L-',i"; - Caterpillar machines. Dispose fluids r--'-; to local regulations and mandates. '

1. Remove (2)holding bolt hoseclip(3)in place. 2. Remove eleven bolts(1)holding filterbase(4)to oil (5) oil cooler and cylinder block(6). 3. Remove oilfilter base(4). 4. Remove fourO-ring the romoilfilterbase(4). seals NOTE: Forinstallation the oil filterbase,reverse o theromnrrll ctanc

EndBy: a. install filters oil 6. Checkthe engine for the correct oil level. Seethe Operation Maintenance & Manual,

r108C&3412C MarineEngines

21


Disassemble AssembleOil Filter & Base 1306-017StartBy: a. remove filterbase oil

'#

I

a

Care must be taken to ensure that fluids are contained during performance o inspection, maintenance,testing, adjustingand repair o the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing luids. Reer to AND SHOPPRODUCT GUIDE, NENG2sOO", "TOOLS for tools and suppliessuitableto collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulationsand mandates.

There is a small amount of spring force behind cover (4).Whentwo bolts (3)are loosened,the spring orce will be released.To preventpossiblepersonalinjury, loosen bolts (3) slowly and evenly to release the spring orce.

to 2. Remove two bolts(3)slowlyand evenly release the spring forcebehind cover(4).

3. Removecover(4).

06J885

1. Remove four O-ring seals(1)fromoilfilter base(2).

D63887

4. Remove two springs(5)from oil filterbase (2).


22


3108C

Oil LevelGaugeRemove& InstallOil Level Gauge 1326-010

a - - J Vn n l r r nrn o rrc \ 9\, /fi r n m | | v [i l {l irlr+ n r l -aa o a / D \ . rr U PrUr gs l ur sr u , J \/, |A : 'rrrn nlr rnc /7\ rnm nil iltor haco /?\

-' assembly the oil filter of base,reverse the .: - steps. 1. Remove bolt,two washers and nut (1)._ {;t+^- h^^^ lil LUt udu

tube (2)romthe engine 2. Bemove block. the 3. Remove O-ringsealfromtube (2). gauge, reverse NOTE: Forinstallation the oil level oftho conc fnr rommral

3408C& 3412CMarine Engines

23


Oil GoolerRemove& InstallOil Gooler1378-010StartBy: a. remove filter oil base

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance,testing, adiusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassemblingany componentcontaining fluids.Referto AND SHOPPRODUCT GUIDE, NENG2500", "TOOLS for tools and suppliessuitableto collectand contain fluids in Gaterpillar machines. Dispose fluids accordingto local regulations and mandates.

NOTE:The oil cooleris heldin placeby six bolts(2). Holdthe oil coolerin placeby handwhileremoving six the fromfalling. bolts(2)to prevent oil cooler 2. Holdoil cooler(3)in placeby hand,remove six bolts(2). 3. Remove cooler(3). oil sealsfromthe end of oil 4. Remove two O-rino the (3). cooler 5. Remove gasketwheresix bolts(2)fastenthe oil ther:noler tn the r:vlinclerblock.

.,

NOTE: The following stepsare for installation the oil o cooler. NOTE: Checkthe O-ring sealsfor damage wear or priorto assembly. Replace with a new gasketif necessary. NOTE: Lubricate O-ring the sealswith cleanengine oil priorto installation. tube(1).Cap and plugall openings 1. Disconnect immediately.

I3408C&3412C MarineEngines

24


i1:33

AftercoolerRemove& lnstall Aftercooler 1063-010

rrsket betweenthe oil cooler and the^ ^1,J- n.

v. O-rinn seals on tte end Of the Oil

-:ricatethetwo O-ring seals withclean - criorto installation the oil cooler. of -roler3)in nositinn install bolts and six

Care must be taken to ensurethat fluids are contained during performanceof inspection,maintenance,testing,adiustingand repair of the machine. Be preparedto collect the fluid with suitablecontainers before openingany compartmentor disassemblingany componentcontaining fluids.Referto ''TOOLS AND SHOPPRODUCT GUIDE, NENG2sOO'" for tools and suppliessuitable collectand contain to fluids in Caterpillar machines. Dispose fluids accordingto local regulations and mandates.

StartBy: fuelinjection lines a. remove

- '. a:.t

lLrv v v ^ r o / 1| \ rl\

/ .

:- - - L 1^ i t i t + ^ - L ^ ^ ^ : f,li uil iltlcl udSc

plug(5)and drainthe coolant 1 . Remove fromthe into aftercooler a suitable container storage for or plug disposal. Reinstall (5). (2). 2. Remove four boltsand washers 3. Bemove eighteen bolts(3). 4. Removebracket(4). (1). aftercooler housing 5, Femove


25


gasket(6)fromcover(1). 6. Remove

seals(9). two 9. Remove O-rrng (10). two 10. Remove adapters

7. Remove four boltsand washers(7) 8. Remove two elbows(B). eightbolts(12), 1 1 . Remove (1 12. Remove coolerelement 1), seals(13). two O-ring 1 3 . Bemove

(14) housing aftercooler eightbolts(15), 14. Remove and the oasket.

I-. rlt-


26


Air FilterRemove & lnstall Air Filter 1054-010

'a

-=-f,ve our O-ring (16). seals -re- - = l .

Yl -:{

ollowing stepsare for installation the of

Yl --: trrior installation, to checkall O-ring seals or , i- .l: or wearand replace necessary. if Coatthe ,',:^clean engine oil. 'gl -l -::,. r '-::ari uelinjection lines^. atne

(2)andremove 1. Unlatch latches six cover('1).

:cr installation the aftercooler, reverse of the

(3) 2. Remove filterelement from the air cleaner air assembly. NOTE: To install air filterelement, the reverse the removal steos.

}fO8C &U12C MarineEngines


Assembly Air GleanerRemove& InstallAir Cleaner Assembly 1051-010StartBy: a. remove filter air

trccfulbr+lr:'r+ '!!;rfJ I

:-atc -llre -l'altg2 ,

r-8: :t-t' r-tfr

!

,24 fi

(8)astening air fourboltsand washers 6. Remove (7) housing. cleaner support to the flywheel reverse the the assembly, NOTE: To install aircleaner steps. removal End By: air a. install filter and nut (1)fromthe bracket bolt,washers 1 . Remove (2) air assembly to the engine. fastening cleaner

rnCt-r;

-:.:L: r\ct:.:l': t: :fefr; tt l ::

E l\t!p f

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

Hri

rtrhousing air threebolts(6)fastening cleaner 4. Remove (5)to air cleaner suppotl (7).Duringassembly, tightenthreebolts(6)to a torqueof 24 + 7 Nm ( 1 8+ s l b f t ) . (5). housing air 5. Remove cleaner

I3408C&3412C MarineEngines 28 Disassembly& Assemblyl-:: :-:

Tu rbochargerlemo v e & I n s t a l l -.'locharger 1052-010

l:'e must be taken to ensure that fluids are con.r' red during performance of inspection, mainte'.i-ce. testing, adjusting and repair of the machine. l-: erepared to collect the fluid with suitable con.i -ers before opening any compartment or disas;-:r bling any component containing fluids. Refer to ]OLS AND SHOP PRODUCT GUIDE, NENG25OO'" . ' :cols and supplies suitable to collect and contain '- ls in Caterpillar machines. Dispose fluids r.::crding to local regulations and mandates.

L Attachliting slings and a suitable litrng to devicethe tr rrhnr:rarnr q qhown.

9.

Romnrio

nr rr nr rte /R\

, i?&: ^ r =r ^l^^^^r utEdt tel

t! tt '' a:

.t'.r ,1:t\

{

10. Disconnect tube (9).Cap and plugall openings immediately.

- - - r \ / n r r r hv n\ l i e v r v

/ 1| \\

/,

. -:nnect tube(2).Cap and plugall openings---:dief o|rr

-::nnect tube(3). Capand plugallopenings-ia+al', YUrqLVry. I =rv

rnrn

hnlte

/\

- =:onnect tube (5).Cap and plugall openings--modirtohr _:mnrro trrrn hnlte A\

- =:onnect tube (7).Cap and plugall openings'- modiatohr vv,e(v,J.

j-108C 3412C Marine Engines &

29


i*"'1 1 . Remove and clip(11). bolt 12.+l-rn aanlzaf /Rammro ir rkro i 1 ?\ en| rne gasKer.a n anOn uap a n prug all openings immediately.

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

(10). 13. Femove turbocharger Theweighto the turbocharger 47 kg (104lb). is

1 6 . Attachlifting slings and a suitable lifting device to the turbocharger shown.Install as turbocharger (10)in its original location. weightof the The turbocharger 47 kg (104lb). is gaskets (13)and (14). 14. Remove NOTE: The following stepsarefor the installation ofho tr rrhrnnharnar

t

1 7 . Place tube(12)in position and install and clip bolt { 11 ) .

g

18. Connect tube (9)to the cylinder block. 1 9 . Insiallfour nuts(8).Do not tighten nuts(8)at this time.

I; -':.


?n


Disassemble& Assemble Turbocharger 1O52-O17StartBy: turbocharger a. remove

a\

,)J rs /*. , Y ,/"r;tr

^stallour the bolts(1)connecting elbowto the ::ercooler. the -trosen V-bandclamps attaching the housing the to :f,mpressor housing turbine and to :artridge to enough allowhousings rotate.

Y-t;*' //_--\,

063822 1 . Loosenclamp(4)and removehose(5). tightenclamp(2) 2. Loosenclamp(2).Uponassembly t o a t o r q u e o1 4 + 1 N . m ( 1 0 t 1 l b f t ) . f (3)fromthe caftridge compressor 3. Remove (1). and assembly turbine

2

:csitionthe housings exhaust withthe air pipes, so :rpes,the oil and the waterlines theyare all a igned withoutbinding.

23. lonnect tube (2),(3),(5)and (7). the t{. rstalltwo bolts(4)and (6)connecting tubesto'no ir rrl-rnnharnor

to - -ightenthe V-bandclamps 14 + 1 N.m (10 t 1 rb ft). 26. Tap the V-bandclampsall the way aroundand .etighten 14 + 1 N.m (10 + 1 lb ft). Do not to cvertighten clamps. the the Z7. Tighten four nuts (B)fastening the manifold a to turbocharger the rearexhaust to rorque 55 + 5 N.m (41 + 4lb ft). of : By: , rstallair cleanerD63825

pipe (6)and the two O-ringsealsfrom 4. Removennmnraqqnr /Q)

5. Remove adapter(7)and the two O-ringsealsfrom pipe(6).

3408C&U12C MarineEngines

31


3 - l I nj e- rs

e- 3 e Ft

124

.06 82 J 4

6 . Loosen clamp(9).Uponassembly, tighten clamp(9)

to a torqueof '14 + 1 N.m (10 + 1 lb ft).

(12). 1 0 . Remove threeadapters 11.Romnrra neckot 1?\

:{

-

'S:

:

(B) (1), 7. Femove cartridge assembly from turbine (14). 12. Remove adapter

"ar'-tl - . : r - , : :*-

I -a O ::Stll

32;!.31( DC

r--: ^3 a' :.: -S AN':r'::'S t-:slt. -. J - -

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NOTE: Lubricate lip seals(116)and (119)with two clean engine priorto rnstallationshaft(111). oil of 7 . I n s t as lh a f ( 1 1 1 ) . l t (113) shaft 8. Installthe woodruff and lever key on (1 1). 1 l r 9 . I n s t ablo l t( 1 1 2 i)n l e v e( 1 1 3 ) .

.1 - ^ T^^r /n\ +^ i^^+^r bearino .1 5) to q clenth il rv I uul Lw ll lLqll uqqr Lv a uu|!,r of \u,/ \ | r u/

(1 - se Tool(D)to install bearing 1B)untiloutward ',:ing surface bearing (118) 110.84t of is 0.50 mm (4.340 + .020 in) from the bottomof (1 :earing 15). - se Tool(D)to install seal(.1 untilseated lip 16) -'mly against counterbore with lipacing face the :re counterbore sudace. Jse Tool(D)to install seal(119) lip untilseated 'rrmly (1 against bearing 1B)with lip sealfacingaway 'rombearing (118). ,/ ,--/ (4) D63910 (107) 1 0 . Install lever and (109). 1 1 . Install socketheadbolts(108)fastening four levers (107) and (109) shaft(111). to gasket(110) adapter group(4). 12. lnstall on


ot


t'ffi&''t'*r!l$*:::1r:l

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ffi",..-*-ri",,

,

I

. .-

1na

13. lf removed, install dowel(106) plateassembly in (105). plug(107) 14. Install

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

18. Install stop (1OO)in bolt cover(99). (105)in position adapter 1 5 . Put plateassembly on group(4). 1 6 . Install bolt,washers and nut (104). 19. Install washer and nut (101)on boltstop (100). NOTE: Wiretie (102) can onlybe installed afterfinal adjustments havebeenmade to the governor.

20.


68


D6J901

2. Install O-ring two seals(95)on cytinder (92).

NOTE: Lubricate entire the cylinder the O-ring and seals with 1P-0808Lithium Greasepriorto installation plategroup(71). in (92) 22. Install cylinder in plategroup(71). plug(91)in plategroup(71). 23. Install 24. UseTool(D)to install (93)untilit is 0.51 + bearing + 0.25 mm (.O2O4 .0100 in) betow the top surface of plate group (7). 20. Installtwo gaskets (98), (97), two covers cover (99)and fourbolts(96), gasket (89)on plategroup(71). 25. lnstall


69


o^9

I

(80) 33. Put bracket in position plategroup(71). on (80)to 34. Install threebolts(79)fastening bracket 26. lf a replacement the dowelsin plategroup(71) of is necessary, the illustration correct see for installation dimensions. plate group(71). gear(75). 35. Install pin retaining (81)on gear 36. UseTool(C)to install (75)a:

.-:-

.- :

I(80). 27. PUIlever(82)in position bracket on pin (80). 28. lnstall (83)in bracket gurde (77)on plategroup(71), 37. lnstall (85). 29. Install O-ring seal(84)onsleeve 38. Install dowel(78)in guide(77). valve(87)in piston(88). 30. Install pin (80)andengage 31. Install (86)in bracket with lever(82). piston(BB)with (86). pin 32. Engage


70


I

-E: Makesureto alignmarkson stop (76)and - 75)during assembly, :'3. nstall stop (76)in gear(75). Alignalignment marks proper ro ensure assemoty

NOTE: Makesurethe rack is heldln ihe "zero" position withTool(A)during installatron plategroup of (71). (82)engages Makesurelever withthe rackduring installation. 42. ?laceplategroup(71)in position the fuel on pumphousing. injection 43. lnstallfour plategroup71)to bolts(72)fastening pumphousing. the fuelinjection

40. Install (73) driveassembly in gear(75). pin 4 1 . lnstall assembly in gear(75). (74) Ensure the (74) endso pin assembly areengaged the in groveof the gear. zl4. lnstall governor weight(69)on plategroup (71).

\

45. Install (70) lockring on governor weight(69). Ensure endso lockring are engaged the (70) in the oovernor weioht. 3408C&3412C MarineEngines 71 Disassembly Assembly &

3t!

nt

',i'-' 't

retaining (63)securing ring 51. UseTool(B)to install the springseatto the gutde.

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D63891

46. lnstall bolt stop (64)in springseat (65), 47. Install bearing(67)in springseat (65). u18.Install ring retaining (68)in springseat (65). spacer(66)in springseat (65). 49. lnstall (62)on the boltstop. spring 52. Install spool(61)on the boltstop. 53. Install

seat 50. Installspring (65)andboltstop (64)onthe plategroup as shown.

g.

ring(60)on the bolt stop. Install spacer spacerring(60)to the spool.

retaining (59)fastening ring 55. UseTool(B)to install


IZ


I

:6. Install spring(58)and spring seat(57).

442791P10-

(53)in the housing, valve 60. lnstall (52).Dimension (D) 6 1 . UseTooling to install bearing "2" is 43.38+ 0.015mm (1.708 + .0006in). 62.I l s e T o o l n o i D ) t o i n s t a l lh e a r i n n / 5 1 ) n i m n s i o n' ' Y

"X" is 25.35 r- 0.13 mm (.998 -r .005 in),

\u/

Lv

i7

Inctell )-rinn

coal /${) On Valve (55).

"Y" "Y". 63. Checkdimension Dimension mustbe 60.58 + 0.13 mm (2.385+ .005 in).

58. Install O-ringseal(56)on valvebody(53). 59. Install valve(55)in valvebody (56).

D6J957

two 64. UseTool(D)to install lip seals(49)until they areflushwiththe outside faceof the housing and with the lipsof both sealsfacingtowardsthe inside. NOTE: Lubricate borewithcleanenoine beore the oili n c t a l l i n In t nlr rn /O\|/ruv \vv./.

plug(50)and O-ringseal. 65. Install the


73


06J955

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

69. lnstall washer42\ on the shaft. felt 70. Install bracket(43)and two sockethead bolts1:-

(46) 67. Put lever assembly in position the housing in and install shaft(47). 68. Install (46) bolt (45)in leverassembly

71. Install highidlescrew(39)the samenumber o turnsas duringremoval. 72. Install idlescrew(41)the samenumber low of turnsas duringremoval. gasket(40)on the housing. 73. Install'l

a-,

- -9. T

31 &


74


th

I

06J950

85. lnstallguide(22),quadrant controlQa), nub Q5), (26)and bracket ratchet (17)on the shaft.

28 29 30a..l

??

D63949

) 86. lnstall screws(23)fastening two (17)to bracket the housing. governor 87. Install spring, the control shaft(20)and (21). handle 74. lnstall cover(38)and bolt (37). 75. Install cover(36). 76. Install (35). insulator 77. Install (34). bar 78. Installshim (33). 79. Install (32) retainer 80. lnstall contact(31). 81. Install (30). insulator (29) 82. Install retainer 83. Install lock(28). 84. Installtwo socketheadbolts(27). (19)and locknut 88. Install (18)on throttle spring control (16). rod

064050



1j

--:\ t 't:* l*

"'ftl

l _ ^ . , ,i-a

t"(17). throttle rod 89. Install control (16)in bracket (13) (5). 92. Installgasket on the bottomof housing --' ':'--

D6J959

pin the 90. Install and cotterpin (15)fastening throttle controlrod to the quadrant.

(9). nut 93. lnstall screwand nut (12)in collar Tighten (12)toa torque 12 + 4 Nm (106.8+ o 35.6lb in).

rod. locknut control 91. lnstall {14)on the throttle 94. lnstall spring(11),collar(9)and socketheadbolt (10).98 m


76


t5. Puthousing in position ptate (5) group(B). on 36. Install sevenbolts(7)astening (5) housing to plate group(B).

NOTE: Do not install wiretie (2)untitafter ad;ustments the governor to havebeenmade.

100. Remove Tool (A). gasket(6)on top of housing 97. Install (5).

plug(1). 10. Install 98. Put adaptergroup (4)rn positionon housing(5). 99. Installfive (3). boltsand washers

)


77


DisassembleFuel Injection Pump Housing 1253-05Tools Needed 8f5287 852244 5P0944 852241 Wrench Extracto Dowel PullerGrouo Camshaft Bearing Removal & Installation Grouo A B,l

*J a

c D E

1 1 1

6V6019 TiminoPin

& 3 4 5 17 P 1 -

StartBy: pump housing a. remove fuelinjection and governor o. removegovernor

Remove shaft(6)fromrearcover(2).Remove the gearfrom shaft(6).Remove bushing the from rear cover(2). (4). 3. Removeretainer Removegear (5).

7 . R e m c 't ' shaft sPring

\OTE: S:.>LVrr'"

4. Remove pumpcover(3). oilCare must be taken to ensure that fluids are contained during performance o inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers beore opening any compartment or disassembling any component containingfluids. Reerto ,TOOLSAND SHOPPRODUCT GUIDE, NENG2sOO", for tools and suppliessuitableto collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulationsand mandates.

- : Jslng '

8. Rerr: pln.c

NOTICE Be carefulnot to damagethe inlet and outlet ports on the bottom of the pump housing. The pump housing must be put on blocks beforedisassembly.

5. Removeidlergear(7).Removepiniongear (9)fromthe pump housing assembly witha soft hammeras shown.Remove drivegear(8). gearassembly is removed, NOTE: Whenpinion (9) makea replacement drivegear (8)with a new part. o 6. Remove cover(10).

ir

434469P1'

1. Femovebolts(1)from rearcover(2).Remove cover (2)and the gasket.


78


'

iemove the boltsfrom levers (14)and(11).Remove sraft(16), (14), lever (11), lever (1S) bearing and scring (12). washer

. iTE: Step(7)is onlynecessary earlier on fuel .::ms. Latersystemshaveshutoffin governor -sing. 3. ?emove bypass valve(.13). Remove O-ringseal, the cin,piston, and spring fromthe valvebody.

10. InstallTool in the pump housing (D) withthe square end down (endwith taperwillbe up).Hold the racksagainst Tool (D)and removeeachof the injection pumps(18)with Tool(B).Formore details, the topic"Remove see FuelInjection Pumps".

*% &@ ffi434520P1',

1 1 . Remove bolt (19)that hotdsbracket(23)to the uelinjection pumphousing. Remove (23) bracket and link(20). 9. Remove felt washerfrom bushing the (17).Remove (17) bushing fromeachof the injection pumpswith Tool (A).

12. Put identification the left rack(2j) and rioht onrack (22).Remove racks(21) and(22).

3408C& 3412CMarine Engines

79


lssemb r ous i ng #fi

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434542P1

434522P1"

13. Remove spacers(24)and lifters(25)from the pump housing. identification each Put injection on of the spacers and liters to theirlocation the as in pumpnousrng.

1 5 . Remove dowel(27), shaft(28)and dowel(29)wr: Tool (C). 1 6 . Remove lowerand upperbearings thatare (30) for supports the pinion assembly. (3i)and the lipseal. 1 7 . Remove bearing Remove (32) bearing andthe seal. lip

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ffi ;

i9t It|.q.

|

|

, . 4 r". :

If,=

i w-r Sr; ru iLi ffi,| t{

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7 S#fi

l": * - ,

:

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A34521P1"

t:. I

(26)from pumphousing. 14. Remove camshaft the

I are 'Jrn -3nc 3'e ;'JrX

NOTICE Be careful not to damage the camshaft bearingsas the camshaftis removed.

lem

(33). 18. Remove rack bearings the from locations 1 9 . Remove camshaft the bearings with Tool (E).

,To

or r I


80


lssemble Fuel lnjection Pump ltousing 1253-016

>].159 Drive Plate '='-1455 Drive Plate

(3) 1 . Put ixture assembly (parto Tool (A)) the on pump housing (3) withthe dowelsin fixture engaged the rightrackbore.Install (4). in bolt (2) 2. Put a new bearing in positionbetween fixture(3) and the rack borewith the tab of the bearing up. Install bearing (1) the withdriver untiltheshoulder of the drivermakescontactwith the fixture.

3. Turnthe fixtureand makealignment the dowels ofon the frxture with the left rack bore.Install right the rackbearing according the instructions Step2. to in350240 Rack PositionTool Grouo

Care must be taken to ensure that fluids are contained during performance o inspection, maintenance,testing, adjusting and repair o the machine. Be prepared to collect the luid with suitable containers beore opening any compartment or disassemblingany component containingfluids. Refer to .TOOLS AND SHOPPRODUCT GUIDE, NENG2sOO", or tools and suppliessuitableto collect and contain fluids in Caterpillar machines. Dispose luids according to local regulationsand mandates.

434525P1

4. Install O-ring seal(5).


81


A34526P1.

(7) 5. Install camshaft the rontbearing withTool(B). lnstallthe bearing untilit is '1.02+ 0.51 mm (.040 + .020 in) from front surface(6)o the pump nousrng. NOTE: Install camshaft a withthe bearing bearings jointin area"X". Thiswillput the oil holein area"Y". illustration bearing Formorecomplete installation, of makereerence the Specifications to Manual.

the 8. Install lower and upperbearings the pinio' fornear asscmhlv rnrith Tnol /C) Instell the rrngg; (, ,v uvF ,, ,e(q,,

bearing untilit is evenwith the top of the bearing boreand the bottombearing untilit is evenwith : bottomo the bearing bore. \ (11)in pumphousing it is 9. Installshaft the until extended 16.76 + 0.51 mm (.660 + .020in) frc thetop of the pumphousing.lnstall (12)unr dowel tit is extended 11.18 + 0.51 mm (.4+O .020 in) fromthe top of the pump housing. NOTE: Steps10 thru 13 and Step24 apply onlyto earlier systems fuel with fuel shutoffshaftin inlection pumpnousrng.

.,2, (9)withTool(B)untilthe rear 6. lnstall centerbearing is edgeof the bearing 127.00+ 0.51 mm (5.000 + .020 in) from rearsurface of the pump (B) nousrng, (10)with 7. Install rearbearing Tool(B)untilit is 4.83 + 0.51 mm (.190 + .020 in) from rearsurface(B).

!r

t,

I

^13408C&34'l2C MarineEngines 82 Disassembly& Assembly

434541 P1',

14. Putcleanengine on the camshaft oil bearings and (17).lnstall (17) on camshaft camshaft as shown.

.!

-$

*:, "Z" 1 0 . lnstall (13) bearing withTool(D)untildimension is 38.23+ 51 mm (1.505+ .020in) Dimension "2" is takenromthe end o bearing to the (13) outerfaceof the pumphousing boss.434542P2.

1 1 . Install seal(14)with Tool(D),Installthe sealeven

withthe surface the housrng withthe lip o and towardthe outsideas shown. (15)with 12. Install Tool(D)untildimension bearing "R" is 34.80 + 0.51 mm (1.370+ .020in). "R" Dimension is the distance between bearinqs.

15. Putcleanengine on lifters (19).Install (19) oil lifters (18)for eacho the injection pumps. and spacers Be surethe lifters and soacersare out in their orlginal location the pump housing. in 16. Putcleanengine fuelracks(20)and (22). oil Install leftrack (22)in the pump housing with the groove in the rack engaged with the tab of the rack bearing. rightrack(20)withthe groove lnstall in the rackengaged withthe tab of the rackbearing. NOTE:The rightrackhasa notch(21)cut intothe rearend of the rack:

(16)with 13. lnstallseal Installthe until Tool(E). seal it is evenwith the suffaceof the pump housing and with the lip towardthe outside shown. as


83


&,,$A

@

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@

w

s434520P2A41520P2'

s

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J

untilit is 1 7 . Install dowel(23)in the pump housing extended12.2 + 0.5 mm (.+8 +.02) from the surface the pumphousing. of (26). Tighten bolt (24) 1 8 . Install (25)and bracket link to standardtorque.Be carefulso bracket(26) does not turnas bolt(24)is tightened.

pinion gear(29)in the pumphousing, 20. Install Use an 11/16"Socket and a "C" clampwith a minimum opening 22.9cm (9 inches)and o pinion gear(29)untilthe pumpdrivegear install makescontact withthe shoulder the oinion of gearshaft.

,

ffi*

@A15889P3441519P2-

19. lnstall idlergear(27)on the shaft.Put drivegear (28)in position withthe bevelsideof the gear down. Makesurethe teeth of the idlergearand the and drivegearare in alignment install pump cover.

(30)and piston(32)in valvebody 21. lnstall spring pin (34).lnstall (33). (3'1). Installseal NOTE: Pin (33)must not extendout from eitherside of valvebody (3a). 22. Pu cleanengine on valve oil body (3a)andseal (31).Install oil bypass the valvein the pump housino.


84


26. lnstall cover45). 27. InstallTool in the injection (F) pump housing with the flatend down.Usea punchor a screwdriver to pushthe rackintohousing. the sametime, At pushdownon Tool(F)untilit engages slot in (groove) the rack.The rack is now centered in (in the zeroposition) the fuelinjection pumpcan and be installed,

t )

pump cover(40)and cleanthe metal 23. Remove pumphousing. clipsfromthe fuelinjection Installnnmn nnr rar vur I r|./ vvvgr /ulA\ \av,/.

24. Put lever(35)bearing and springwasher(37)into position the pump housing. (38) in Installshaft lnstall lever(39).Install bolts(41). (43) 25. Put gear(42)and retainer into positionin the pumphousing.lnstdl (44)and tighten bolts to standard toroue. 28. Putthe spacein gearsegment (47)alignmeni with the groovein pump banel(46).Put the injection pump straight down intothe housingborewith the spacein gearsegment(47)engaged with the pin in the lifterand the groovein barrel(36)engaged withthe dowelin the pumphousing. Tool(H) Use pumps. to installthe


85


frater1..q,I t,

''

Semove a.egulat

manual cat.assamble dis ass amble

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