Manual Cat Assamble Dis Ass Amble

CAÏERPILLAR' SEN R133
l
Jun e1996
Dnsasscnnbly
&
Asscmnb[y
34O8C & 3412C Marine Engines
r ?ff_u, 3412=
gBR1-UP
u MarineAuxiliary& GeneratorSet Engines

OilBypassValves . . ....... ....,20
OilCooler .........24
O i lF i l t e r s ...........2O
O i lF i l t eBr a s e . . . . . . . . . . . . . . .............21
OilFilterBase,Disassemble & Assemble.......... .... ...22
O i lL e v eG l auge . . . . . . ... . . . . 2 3
O i lP a n . . . . . . .1. .6. 1.
O i lP u m p ...'..162
OilPump,Disassemble & Assemble .. 163
PistonCoolingTubes . ...169
- Rod PinBearingWithStraight
Pistons(Earlier
Sides),
Disassemble & Assemble .....
.....171
Pictnne ll alar - Tanororl Rnd Pin Roarinnc\
, e v q , , , , : , v / ,
Disassemble
& Assemble .....173
....................
Pistons . . . .,.... 1 7 0
Precombustion
Chambers........,............. 144
...........................
-:-^.sraft RearSeal& WearSleeve . . . . . . . I. z ó
. -:er HeadAssemblies ........152 Radiator ..............5
_ âr I rnêre . . . . . . |. /. c RockerShaftAssembly ..............
.. ... ....149
RockerShaftAssembly,Disassemble &
- -=:: lnjection Adapters .. . .............146 Assemble ... . 151
Rarru
WaterPrrmn .........
98
- - : re LiftingBrackets .................. ............... 12 RawWaterPump(Earlier Engines), Disassemble&
:-; ie Support . .. . . . . . . . . . . . . . . . 1 2 Assemble .........99
- ' - a u s t M a n i f o l d ( R e a r ) . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 8 RawWaterPump(LaterEngines), Disassemble&
:'^3uSt ManiÍold(WaterCooled) ......... 130 Assemble .......
104
-(sansionTank& WaterLrnes ...............107
Meter.............
Service .............
38
=al ................. . . . . . . . . . . . . . . . . . . . . .6. . . . . . . . . . . .Snar:cr Plates
vYsvvl . ... 160
= a nB e l t s ............7
= a nD r i v e . . . . . . . . . . . . 8 TimingGears............ .............
116
) =anDive,Disassemble & Assemble..............................
...8 T rr r h n n h a r o a r ..... ..............................29
:an Guard ..........4 Turbocharger, Disassemble & Assemb|e.......................
31
=lywheel .........117
=iywheel Housing ............125 ValveCovers . .. .............
133
= r o nH
t orsinn .....112 ValveGuides .. . . ...158
=r'ont Housing Cover ......... 16 ValveLifters & PushRods.............. ...........
148
:.lel Filter '18 ValveSeatInserts ................
157
.........
=uellnjection Lines............. ............................33 Valves .... ...156
=uelInjectionNozzles& Adapters(Later7000 Vibration Damper& Pulley ........................
109
Series) ............143
FuelInjection Nozzles(Earlier 7000 Series) ......
. .. . 139 WateP r ump ...........................92
Fuellnjection PumpHousing & Governor ......................52WaterPump,Disassemble & Assemble .........................
95
FuelInjection PumpHousing,Disassemble & WaterTemperature Regulators .................
87
Assemble .........78
Fuellnjection Pumps ...........44
FuelInjection Valves(DirectInjection)..........
....... ...138
FuelInjection Valves(Precombustion Chamber) ......136
FuelPrimingPump& FilterBase .. . . ....19
FuelRatioControl(lf Equipped) ................35 Disconnect batteries beÍore perÍormance of any
FuelFatioControl,Disassemble & Assemble..............36 service work.
FuelTransfer Pump.........
-. .................
.. ...... 39
FuelTransferPumo.Disassemble & Assemble...........40
Generator ......
118
GlowPlugs(PrecombustionChambers) ......
...............
135
Disassemble
Governor, & Assemble ................................
55
Governor& FuelPumpDrive ......................47
) Governor& FuelPump Drive,Disassemble &
Assemble .........50
3408C&3412C MarineEngines lndex

Disassembly& Assembly H
b-
Fan Guard
Remove& InstallFan Guard 1360-010
I;Ër
ffi
#
3. Removetwentytwo bolts and washers(3)and -t
removetwo fan guards(4). flp
d
NOTE: To installthe fan orrarclsrÊ\/êrsê
the removal ..;il
steps. :fr
*
#
1. Removetwo boltsand strap(1)fromthe fan guard

assemory.
2. Removetwo boltsand strap (2)fromthe fan guard

assemory.
3408C&3412C MarineEngines Disassembly& Assembly

Radiator
Remove& lnstall Radiator 1353-010
- - ;^^ ^,,^r/-J
-,=rar tvuot u
Care must be taken to ensure that fluids are con-

tand during performance of inspection, mainte-
n rrrce,testing, adjusting and repair oÍ the machine.
8e prepared to collect the Íluid with suitable con- 3. Loosentwo hoseclamps(3).
tàners before opening any compartment or disas-
semblingany component containingfluids. ReÍerto 4. Removeradiatortube (2)fromthe radiator.
.TOOLSAND SHOPPRODUCTGUIDE,NENG2sOO'"
for tools and suppliessuitableto collect and contain
í1uids in Caterpillar machines. Dispose Íluids
according to local regulationsand mandates.
l. l'ain the radiatorintoa suitablecontainer

for
:::Í'ageor disposal.
I
5. Loosentwo hoseclamps(5)on the water
temperature
regulator
housings.
6. Removetwo radiatorbracesí4).
two hoseclamps(1).
2. r-oosen
7. Attachliftingslingsand a suitableliftingdeviceto
radiator(6).Radiator(6)weighsapproximately
186kg (410lb).

Fan FrB
i+rrllr
Remove& InstallFan 1356-010
Stad By:
a. removeradalcÍ'
8 . Removefour bolts(7)fastening
radiator(6)to the
-Ât^+^- ^,,^^^*
rdurdL\Jr >UPPUÍ L.
9. Romnrro r:di:tnr íA\
1. Attacha liftingslingand a suitableliftingdeviceto

fan(1).Fan(1)weights 34 kg (75lb) .
2. Removesix boltsand washers(2).
3. Removefan (1).
NOTE: To installthe fan, reversethe removalsteps.
End By:
removefourrubbermounts(8).
10. lf necessary, a. installradiator
NOTE: To installthe radiator,reversethe stepsfor
removal.
EndBy:
^ i^^+^f f +^^ ^,,^.Á
cl. il tèLdI tdr I vu4r u
Fan Belts lnstall Fan Belts 1357-012
Tools Needed A
1
RemoveFan Belts 1357-01 Bf -33-72C BorroughsBelt TensionGauge 1
: á: I
NOTE: Inspectthe Ían beltsfor damage,cracksor
wear. Beplacewith new beltsiÍ necessary.
-;=- four nuts(1)fastening

the Ían drivebracket
'-::nnino
-
",
,Y,,'v.
1 . Installthreefan belts(2)on the pulleys.
2. Tightenbolt (3)untilfan belts(2)are tightened
3. lf beltsare new,tightenbolt(3)untilfanbelts(2)
reacha tensionof 534 + 22N (120 + 5lb). Use
ToolíA)to determine the belttension.
4. lf beltsare used,tightenbolt(3)untilfanbelts(2)
reacha tensionof 400 + 44 N (90 + 10 lb). Use
Tool(A)todetermine the belttension.
z -rcsen bolt (3)to loosenfan belts(2).
3. =:.novethreefan belts(2).
5. Tightenfour nuts (1)fasteningthe fan driveto the

fronthousing.
End By:
a. installfan

Fan Drive Disassemble& Assemble Fan
Drive 1359-017
Remove& lnstallFan Drive 1359-010
Tools Needed
1P-0510 DriverGroup
Tools Needed A
BS-1378 Stud Removerand ResetterGroup 1
Start by:
Staft By:
a. removefan drive
a. removefan belts
063845
1 . Attacha liftingslingand a suitableliftingdeviceto

fan drive(1)as shown.
2. Removefour nutsand washers(2).
3. Removefan drive(1).Fandriveweighs23 kg
( 5 1r b ) .
D45448
1 . Removetwo boltsand bracket(4)fromthe fan

drivebracketassembly.
2. Femovesix bolts(1)that fastenfan adapter(3)to

pulley(2).
4. Removebracketassembly(3).
l
5. lf necessary,removefour studs (a)withTool (A).
NOTE: To installthe fan drive,reversethe removal

steps.
End By:
a. installfanbelts

0 4 5 445
I -:--- . e two boltsand washer(5)from the fan drive 7. Removelipseal(11)Íromhub (7)

:
06J848
8. Removepulley(2)from fan bracketassembly(12).

t. r'.no\/ê O-rinoseal16)from the fan drivehub.
5 . :emove hub (7)fromthe fan drive.
D 45 4 4 6
D{5450 9. Removespacer(13)from fan bracketassembly

(12).
6. Removebearing(8),spacer(9)andbearing(10)
from hub (7).

06J84
9
10. lf necessary,
removeplug(14)insidefan adapter 13. Installpulley
(2)on bracketassembly(12)
(3)
NOTE: ThefollowingstepsareÍor the assemblyof the

fandrive.
045445
14. UseTool(A)to installlip seal(11)intohub (Z).

D 6 J 89
4 Lubricatethe sealinglip oÍ lip seal(11)with 1P-
0808 Lithium Grease .
11. lf removed,installplug(14)insidefan adapter(3)
045450
045446
15. Installbearing(B),spacer(9)and bearing(10)into
hub (7).
í2. lnstallspacer(13)on fan bracketassembiy(12).
3408C& 3412CMarineEngines '10

Disassembly& Assembly
^ rh í7\ in tho fqn drirra pulley(2)to hub (7),
19. Installsix bolts(1)fastening
C-ringseal(6)on hub (7). 20. lnstallbracketand two bolts(4)on the fan drive
bracketassembly.
21. Fillthefan driveat the greasefittingwith 1P-0808

Lithium Grease.
EndBy:
a. installfan drive
t& -sïallwasherand two bolts(5)in hub (7).
3408C& 3412C Marine Engines 11 Disassembly& Assembly

EngineLiftingBrackets EngineSupport
Remove& Install Engine Lifting Remove & Install Engine
Brackets 1122-O1O Support 1154-010
StartBy: Start By:
a. removeexhaustmanifolds a. removecrankshaftpulley& damper
tl fillFrs
trd
dtlr*r
1 . Removefour boltsand washers(2). 1. Loosenbolt(1)closestto the engineon eachside

of the generator.
2. Removerightsideengineliftingbracket(1).
3 t-
rl
* 5
- ÈË
l-r
r-
2. Attachtwo liftingslingsand a suitableliftingdevice *r

3. Removefour boltsand washers(4). to radiatorsupport(2)as shown.Remove *
eight
bolts,washersand nuts(4)fasteningradiator ïl!
4. Removeleft sideenginebracket(3). support(2)to enginesupport(3).

g'.E
NOTE:For installationof the engineliftingbrackets, 3. Removeradiatorsupport(2).The weightof radiator --a
reversethe stepsÍor removal. support(2)is 25 kg (55 lb).

;]
EndBy:
:t
a. installexhaustmanifolds
=tt
3408C&3412C MarineEngines 12 Disassembly
& Assembly
GrankcaseBreather
Remove& lnstall Crankshaft
Breather 1317-010
NOTE: The crankcase breatherremovaland
installation
is the samefor both crankcase
breathers.For removaland installation
simplicity, is
shownfor onlvone crankcase breather.
I :-arnsand a suitableliftingdeviceto the

: rg bracketsas shown.Theweightof the
= aoproximately3629 kg (8000lb).
1 . Loosenhoseclamp(2).
2. Removebreather(1).
r:rrt the encine with the ChainSand the SUitable

- -3 Cevice.
a -:-f,ve fourbolts,washersand nuts(6).
-.:-lro oinhf hnltc /Á\
::rove enginesupport(3).Theweightof engine

. -:cort (3)is 25 kg (55 lb) .
' êcessary,placewood blocksunderthe engine
,'.aerethe front housingand the oil pan are mated
'^ lr rnnnrf f ho onnino
3. RemoveO-ringseal(3).
'rlTÊ: To installthe enginesupport,reversethe
NOTE: For installation
of the crankshaftbreather,
.--': ral steps. reversethe removalsteps.
--
' Qrl
"t.
: rstallcrankshaftpulley& damper
3408C&3412C MarineEngines 13 Disassembly& Assembly

Crankshaft Pulley& Damper
Remove & Install Crankshaft&
Damper í205-010
Start By:
a. removefan belts
-i
Movedamper(4)forwardfar enoughto attacha
liftingslingas shown.Attachthe liftrng
slingto a
suitableliftingdevice.
l*.T.oy" damper(4).Damper(4)weighs29 kg
(64 tb).
a
,9
1 . Removetwelvenuts (2).
2. Usetwo peopleto removepulley(1).pulley(1)

weighsapproximatety
Zl kg (46 tb). $
--I
t,
!9If , Adapter(6)is hetdin ptaceby twelvebotts
!5),Whenremovingtwelvebolts(5)hotdadapter(6)by
handto preventit from falling.
6. Hold adapter(6)by hand,removetwelvebotts(S).
3. Removeputtey(3).
7. lf necessary,
removetwelvestuds(7)withTool(A).
I
3408C & 3412CMarine Engines 14 Disassembly& Assembly .iill

',I -: -re followingstepsarefor the installation
of
--,--:shaft
pulleyand damper.
12. Installpulley(3)on the adapter.
=-:i'ed, installtwelvestuds(7)in adapter(6)

'- -:cl (A).
13. Placepulley(1)in positionon the adapter.
nuts(2).Tightentwelvenuts(12)toa
14. Installtwelve
torqueof 65 + 10 N.m (r+8t 7 lb ft).
9 . : ::: adapter(6)in positionon the crankshaft.
End By:
- r'all
10- trrrohro h n l t cL U / 6 \
vvr \v/.
a. installÍanbelts
t l. rstalldamper(4)on the adapter.
}{OSC& 3412C Marine Engines 15 Disassembly& Assembly

FrontHousingGover
Remove& lnstall Front Housing
Cover 1151-010
Tools Needed A
BS-1378 Stud RemoverandResetterGrouo 1
StartBy:
a. removefan drive
'-*
3. lf necessary,removefour studs (6)with Tool(A). I
3?
:irt
4. lf necessary,removethreeboltsand cover(5).
{l z"#
5. Removenut (7). nï
s-
6. Removeten bolts (3)and cover(4).
1. Removebolt and hoseclip (1).
'"t
7. Removegasket(9). ..
. --tt'
8. lf necessary,removestud (B)withTool(A). -t
2. Removenut and washer(2).
3408C&3412C MarineEngines 16 Disassembly& Assembly lrt

: --.'..'emovefivenuts(10),cover(11)and 1 3 . lÍ removed,apply4C-4032Thread Sealant to
':-. thethreadsoÍ stud (8)and installwithTool(A).
- : -::], removefivestuds(12)withTool(A). 14. lncfnll oaekat /O\
- '-' , "rrwino
'"',.Y stensarc fOrthe installation
oÍ
-s ng cover.
15. lf removed,installfour
studs(6)withTool(A).
(4).
16. Installcover
' '-:'roved, installfive
studs(12)withTool(A).
17. Installnut (7)and ten bolts(3).
I gasket,cover(11),andfivenuts(10).
- =:allthe
;'ten five nuts(10)to a torqueof 20 + 3 N.m 18. lf removed,installthe gasketand cover(5).
( 1 s+ 2 l b f t ) .
3108C& 3412CMarineEngines 17 Disassembly& Assembly

Fuel Filter
Remove& InstallFuel Filter 1261-01
Tools Needed
Care must be taken to ensure that fluids are coÍr

tained during performanceof inspection,maint*
19. Installnut and washer(2). nance,testing, adjusting and repair of the machine.
Be prepared to collect the Íluid with suitable corF
tainers before opening any compartment or disas-
semblingany componentcontainingfluids.Referto
"TOOLSAND SHOPPRODUCTGUIDE,NENG2SOO'
fluids in Caterpillar machines. Dispose fluids
and hoseclip(1).
20. Installbolt
End By:
a. installfandrive
1. Turnthe Íuelsupplyvalveto the "OFF"position,
2. UseToolA to removefuelfilter(1).
NOTE: Thefollowingstepsarefor the installation

of
the fuelfilter.
3408C& 3412CMarineEngines '18 -1..3

FuelPrimingPump& Filter
Base
Remove& InstallFuel PrimingPump &
Filter Base 1258& 1262-010
Start By:
a. removefuelfilter
:' :aie the sealof fuelfilter(1)withcleanengine Care must be taken to ensure that fluids are con-
: - :' to installation. tained during performance of inspection, mainte-
-:cl nance,testing, adjusting and repair of the machine.
+ (A)to installfuelfilter(1).Tightenfuelfilter Be prepared to collect the Íluid with suitable con-
: -: to I turn aftercontactwith the filterbase. tainers before opening any compartment or disas-
sembling any component containingfluids. ReÍerto
-- :re Íuelsupplyvalveto the "ON"position. ''TOOLSAND SHOPPRODUCTGUIDE,NENG2sOO",
Íor tools and suppliessuitableto collect and contain
Íluids in Gaterpillar machines. Dispose fluids
1. Turnthe fuelsupplyvalveto the "OFF"position.
2. Removetwo bolts (2).RemoveÍuel primingpump

(1)and the gasket.
3. Marktwo hoses(3)Íor identiÍrcation.

Disconnect
two hoses(3)fromfilterbase(5).Cap and plugall
openingsimmediately.
4. Removetwo bolts and nuts(4)Íromthe filterbase.

Removefilterbase(5).
NOTE: Forinstallation of the fuelprimingpumpand

filterbase,reversethe removalsteps.
End By:
a: installfuel
filter
3408C&U12C MarineEngines 19 Disassembly& Assembly

Oil BypassValves Oil Filters |!l*'
;
Remove& InstallOil Bypass Remove& Installoil Filters 1318-010ïF I
Valves 1314-010 k ":ll
Tools Needed
I
iËd
Care must be taken to ensure that fluids are con- fl5rd

tained during performance of inspection, mainte- .nm f
nance,testing,adjustingand repairof the machine. *tnfl
Be prepared to collect the fluid with suitable con- flF*
tainers before opening any compartment or disas- -'-''frJ
ar*.: al
"TOOLSAND SHOPPRODUCTGUIDE,NENG2sOO", bSA
1 |
Íor tools and suppliessuitableto collect and contain l||||r.s
r
fluids in Caterpillar machines. Dispose fluids --r-Éh
1. Remove (2)Íromoilfilterbase(1)with
two oilfilters
Tool (A).
NOTE: The followingstepsare for the installation

the oilfilters.
of F h
2. Lubricatethe sealsof two oil filters(2)with clean

engineoil.
3. Installtwooilfilters(2)untilcontactis madewith oil

ffi
w
filterbase(1).
4. Tightentwo oil filters(1)an additional3/4turn aller

contactwith the oilÍilterbaseis made.
1. Removecover(1).
2. Removethe filterbypassvalvefrom the filterbase.
3. UseTool (A)to removeoil filter(2).
NOTE: Uponinstallation, installoilfilter(2)according

givenon the filter.
to the instructions
4. Removecover(3).
5. Removethe oil coolerbypassvalvefrom the cooler

bypassline.
of the oil bypassvalves,reverse

NOTE: For installation
tho romnrnl qtonq
6. Checkthe engineoil for the correctlevel.Seethe

& Maintenance
Operation Manual.

Irr r iter Base
rcr -,: , e & l n s t a l l O i l Fi l te r
!-.'r.Ê 1306-010
'- - -i: re taken to ensure that fluids are con-

-.e: :--'rg performance oÍ inspection, mainte-
1. Removebolt(2)holdinghoseclip(3)in place.
:, . ':s:;ng. adjusting and repair of the machine.
t- ;r.*:.r-ed to collect the Íluid with suitable con-
2. Removeelevenbolts(1)holdingoilfilterbase(4)to
-F, :€{3re opening any compartment or disas-
oil cooler(5)and cylinderblock(6).
:,:,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 " , 3. Removeoilfilterbase(4).
- ' : :.:. s : nd supplies suitable to collect and contain
L-',i"; - Caterpillar machines. Dispose fluids
4. Removethe fourO-ringsealsÍromoilfilterbase(4).
' r--'-; to local regulations and mandates.
NOTE: Forinstallation
oÍ the oil filterbase,reversethe
romnrrll ctanc
EndBy:
a. installoil filters
6. Checkthe engineoilfor the correctlevel.Seethe

Operation
& Maintenance Manual,
r108C&3412C MarineEngines 21 Disassembly& Assembly

Disassemble& AssembleOil Filter
Base 1306-017
StartBy:
'#
a. removeoil filterbase I
a

tained during performance oÍ inspection, mainte-
nance,testing, adjustingand repair oÍ the machine.
Be prepared to collect the fluid with suitable con-
sembling any component containing Íluids. ReÍer to
"TOOLSAND SHOPPRODUCTGUIDE,NENG2sOO",
fluids in Caterpillar machines. Dispose fluids There is a small amount of spring force behind cover
according to local regulationsand mandates. (4).Whentwo bolts (3)are loosened,the spring Íorce
will be released.To preventpossiblepersonalinjury,
loosen bolts (3) slowly and evenly to release the
spring Íorce.
2. Removetwo bolts(3)slowlyand evenlyto release

the springforcebehindcover(4).
3. Removecover(4).
06J885
1. Removefour O-ringseals(1)fromoilfilterbase(2).
D63887
4. Removetwo springs(5)from oil filterbase (2).
3408C&3412C MarineEngines 22 Disassembly& Assembly 3108C

Oil LevelGauge
Remove& InstallOil Level
Gauge 1326-010
- -. Jr V
r nU n l r r nrngosrrcè í| \A9\, /fi rl num ail {il+nr l-,aoa /D\
r | | v[ lrrsr uaJË \é/,
PrUr
: 'rrrn nlr rnc /7\ írnm nil Íiltor haco /?\
-' assemblyof the oil filterbase,reversethe

.: - steps.
1. Removebolt,two washersand nut (1).

-
_
{;t+^- h^^^
lil LUt udèu 2. Bemovetube (2)Íromthe engineblock.
3. Removethe O-ringsealfromtube (2).
of the oil levelgauge,reverse

NOTE: Forinstallation
tho cïonc fnr rommral
3408C& 3412CMarine Engines 23 Disassembly& Assembly

Oil Gooler
Remove& InstallOil Gooler1378-010
StartBy:
a. removeoilfilterbase

tained during performance of inspection, mainte-
nance,testing, adiusting and repair of the machine.
NOTE:The oil cooleris heldin placeby six bolts(2).
tainers before opening any compartment or disas- Holdthe oil coolerin placeby handwhileremovingsix
semblingany componentcontainingfluids.Referto bolts(2)to preventthe oil coolerfromfalling.
"TOOLSAND SHOPPRODUCTGUIDE,NENG2500",
for tools and suppliessuitableto collectand contain 2. Holdoil cooler(3)in placeby hand,removesix
fluids in Gaterpillar machines. Dispose fluids bolts(2).
accordingto local regulationsand mandates.
3. Removeoil cooler(3).
4. Removethe two O-rinosealsfromthe end of oil

cooler(3).
5. Removethe gasketwheresix bolts(2)fastenthe oil

r:noler tn the r:vlinclerblock. .,
NOTE: The followingstepsare for installation

oÍ the oil
cooler.
NOTE: Checkthe O-ringsealsfor damageor wear

priorto assembly.Replacewith a new gasketif
necessary.
NOTE: Lubricatethe O-ringsealswith cleanengineoil

priorto installation.
tube(1).Cap and plugall openings

1. Disconnect
immediately.
I
3408C&3412C MarineEngines 24 Disassembly& Assembly i1:33
Aftercooler
Remove& lnstall
Aftercooler 1063-010
Care must be taken to ensurethat fluids are con-

tained during performanceof inspection,mainte-
nance,testing,adiustingand repair of the machine.
Be preparedto collect the fluid with suitablecon-
tainers before openingany compartmentor disas-
rrsket betweenthe oil cooler and the semblingany componentcontainingfluids.Referto
^ ^1,
J- n.
''TOOLSAND SHOPPRODUCTGUIDE,NENG2sOO'"
for tools and suppliessuitableto collectand contain
v. O-rinn seals on tte end Of the Oil fluids in Caterpillar machines. Dispose fluids
-:ricatethetwo O-ringsealswithclean accordingto local regulationsand mandates.
- criorto installation
of the oil cooler.
-rolerí3)in nositinn
and install
sixbolts StartBy:
a. removefuelinjection
lines
- '. a:.t lLrv vr vl ^ r o / 1| \

\ / .
: 1 . Removeplug(5)and drainthe coolantfromthe

intoa suitablecontainer
aftercooler for storageor
- - - L 1^ i t í i t + ^ - L ^ ^ ^ plug(5).
disposal.Reinstall
: f,li uil iltlcl udSc
2. Removefour boltsand washers(2).
3. Bemoveeighteenbolts(3).
4. Removebracket(4).
housing(1).
5, Femoveaftercooler

6. Removegasket(6)fromcover(1). 9. Removetwo O-rrngseals(9).
10. Removetwo adapters(10).
7. Removefour boltsand washers(7)
8. Removetwo elbows(B). 1 1 . Removeeightbolts(12),
12. Removecoolerelement(11),
1 3 . Bemovetwo O-ringseals(13).
14. Removeeightbolts(15),aftercooler
housing(14)
and the oasket.
I
-. rlt-
Air Filter
Remove & lnstall Air Filter 1054-010
'a -=-f,ve Íour O-ringseals(16).

-re
Yl -: Íollowingstepsare for installation
of the
{ - - = l .
Yl --: trriorto installation,

checkall O-ringsealsÍor
, i- .l: or wearand replaceif necessary.Coatthe 1. Unlatchsix latches(2)andremovecover('1).
,',:^cleanengineoil.
'gl -l :cr installation
of the aftercooler,reversethe
^. atêne
-::,.
r '-::ariÍuelinjectionlines
2. Removeair filterelement(3)from the air cleaner

assembly.
NOTE: To installthe air filterelement,reversethe

removalsteos.
}fO8C &U12C MarineEngines Disassembly

& Assembly
Air GleanerAssembly trÊccfu
lbr+lr:'r+ I
Remove& InstallAir Cleaner '!!;rfJÍ
Assembly 1051-010
StartBy:
airfilter
a. remove
:-atc Êr-8: !
-- :t-t'íÏ
llre rá-tfr
-l'altg2
, ,24í
rnCt-r; fi
6. Removefourboltsand washers(8)Íastening air -:.:L: r\c
cleanersupport(7)to the flywheelhousing. t:.:l': tt
E
l\t!p t- l
reversethe
NOTE: To installthe aircleanerassembly, ::
f : :fefr;
removalsteps.
End By:
a. installairfilter
1 . Removebolt,washersand nut (1)fromthe bracket
H
air cleanerassembly(2)to the engine.
fastening
2. Loosentwo hoseclamps(3).
3. Removebolt,washersand nut (4)fromthe bracket

air cleanerassembly(2)to the engine.
fastening
r
rtr
i
4. Removethreebolts(6)fasteningair cleanerhousing
(5)to air cleanersuppotl (7).Duringassembly,
tightenthreebolts(6)to a torqueof 24 + 7 Nm
( 1 8+ s l b f t ) .
5. Removeair cleanerhousing(5).
I
l-:: :-:
Turbocharger
lemo v e & I n s t a l l
-.'lóocharger
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 L AttachliÍtingslingsand a suitableliÍtrng
deviceto
-
]OLS AND SHOP PRODUCT GUIDE, NENG25OO'" the tr rrhnr:rarnêr áq qhown.
. ' :cols and supplies suitable to collect and contain
'- ls in Caterpillar machines. Dispose fluids
9. Romnrio ínr rr nr rte /R\
r.::crding to local regulations and mandates.
, èi?&
- ^ r ^l^^^^r
: =r utEdt tel
t!
tt
'' a:
.t
:t\ {
'.r ,1
tube (9).Cap and plugall openings

10. Disconnect
immediately.
- -- r\/ê ínr rr h nlie

vvr\v
/ 1| \
\ /,
. -:nnect tube(2).Cap and plugall openings

---:dief o|rr
-::nnect tube(3).Capand plugallopenings

- -Àia+al',
YUrqLVry.
I =róvê ïrnrn hnlte /á\
- =:onnecttube (5).Cap and plugall openings

--modirtohr
_:mnrro trrrn hnlte íA\
- =:onnecttube (7).Cap and plugall openings

'- modiatohr
vv,e(v,J.
j-108C& 3412C Marine Engines 29 Disassembly& Assembly

i*"'
1 1 . Removeboltand clip(11). gasket(13)andgasket(14).
15. lnstall
12. Rammro ir rkro i 1 ?\ en| rne gasKer./uap

+l-rn aanlzaf -an
anO
anÀ
prug
n
all openingsimmediately.
13. Femoveturbocharger (10).TheweightoÍ the

is 47 kg (104lb).
turbocharger
1 6 . Attachliftingslingsand a suitableliftingdeviceto
the turbocharger as shown.Installturbocharger t
(10)in its originallocation.

Theweightof the
turbocharger is 47 kg (104lb).
1 7 . Placetube(12)in positionand installboltand clip

14. Removegaskets(13)and (14). { 11 ) .
NOTE: The followingstepsarefor the installation

oÍ
fho tr rrhrnnharnar
g
18. Connecttube (9)to the cylinderblock.
1 9 . Insiallfournuts(8).Do not tightennuts(8)at this

time. I
3408C&3412C MarineEngines ?n Disassembly& Assembly ; -':.
Disassemble& Assemble
Turbocharger 1O52-O17
StartBy:
a. removeturbocharger
í a\
,)J rs
/*. , Y ,/"r;t
Y-t;*' //_--\,
r ^stallÍourbolts(1)connecting
the elbowto the
::ercooler.
-trosenthe V-bandclampsattaching the

:f,mpressorhousingand turbinehousingto the
:artridgeenoughto allowhousingsto rotate. 063822
2 :csitionthe housingswiththe air pipes,exhaust

:rpes,the oil and the waterlinesso theyare all 1 . Loosenclamp(4)and removehose(5).
a ignedwithoutbinding.
2. Loosenclamp(2).Uponassemblytightenclamp(2)
23. lonnect tube (2),(3),(5)and (7). t o a t o r q u e o1f 4 + 1 N . m ( 1 0 t 1 l b f t ) .
t{. rstalltwo bolts(4)and (6)connectingthe tubesto 3. Removecompressor (3)fromthe caftridge

'no ir rrl-rnnharnor
and turbine(1).
assembly
Ë- -ightenthe V-bandclampsto 14 + 1 N.m (10 t

1 rb ft).
26. Tap the V-bandclampsall the way aroundand

.etightento 14 + 1 N.m (10 + 1 lb ft). Do not
cvertightenthe clamps.
Z7. Tightenthe four nuts (B)fasteningthe

turbocharger to the rearexhaustmanifoldto a
rorqueof 55 + 5 N.m (41 + 4lb ft).
: By:
, rstallair cleaner D63825
4. Removepipe (6)and the two O-ringsealsfrom

nnmnraqqnr /Q)
5. Removeadapter(7)and the two O-ringsealsfrom

pipe(6).

3 - € l I nj e
eÊ- 3 íe Ft
- rÈs 124
. 0 6J 8 24
6 . Loosenclamp(9).Uponassembly,
tightenclamp(9) 1 0 . Removethreeadapters(12). -
to a torqueof '14 + 1 N.m (10 + 1 lb ft).
:í{ 'S: :
"ar'-tl I -a O
11. Romnrra neckot í1?\
- . : r - , :Ê ::Stll
7. Femovecartridgeassembly(B)from turbine(1), :*- 32;!.31Ê(
12. Removeadapter(14). D€ÍC
-1r-.:/-<
r--: ^3 a'
-
:.: -S AN
':r'::'S ani
t-:s I (
-.á â Í'
lt. - - J :
V'
TF
D6J825
06J827 -
'
:.
fourboltsandclips(11).
8. Remove t- Ll
: r- r-f
13. Removetwo plugs(15)from exhaustelbow(10).
9. Removeexhaustelbow(10).
I
NOTE: Checkall O-ringsealsfor wearor damageand

replacewith new partsif necessary.
NOTE: Forassembly
oÍ the turbocharger,
reversethe
niaa^^^*hl', ^+^^^
urèaèèEr ilury JLUPJ.
EndBy:
a. installturbocharger
3408C&3412C MarineEngines JZ Disassembly& Assembly

FuelInjection Lines
RemoveFuel Injection
Lrnes 1252-011
4. Removetie wraps (4).

lare must be taken to ensure that Íluids are con-
zned during performance of inspection, mainte- 5. Removebolt,clamps,washersand nuts(5).
r.Ílce, testing, adjusting and repair oÍ the machine.
3c prepared to collect the fluid with suitable con-
Sners beÍore opening any compartment or disas-
rmbling any component containingfluids. ReÍer to
TOOLSAND SHOPPRODUCTGUIDE,NENG2sOO",
br tools and suppliessuitableto collect and contain
tuids in Caterpillar machines. Dispose fluids
rccording to local regulationsand mandates.
6. Looseneightnuts (6)and eightnuts(7)
lines(B)as a unit.
7. RemoveÍuelinjectlon
1. Removebolt,clamps,washersand nut (1)
2. Removebolt,clampsand washers(2).
3. Removetwo bolts,clamps,washersand nuts (3).
8. InstallTooling(A)in the fuelinjection

lineopenings.
Tooling(B)in the openingsoÍ the fuel

L Install
injectionpump and the valvecovers.

fnstall Fuel Injection Lines 1252-012 Fuel Ral
Remove F
EquiPPed
.i;'
'
: . . r#*'
_** , lb. 'a):;r'
--re must t
_é" -red durin
1.-.,r..j
06J919 rrrce. testit
3c PrePare<
zrrers beío
5. lnqiall ïio urranq //l rrnbling an
-OOLS AN
6. Installbolt,clamps,washersand nut (5). r:í tools arx

'Lrds in (
xcording t
1 . RemoveTooling(A)fromthe fuelinjection
line
openings. \r-
2. FemoveTooling(B)fromthe openingsof the fuel
injectionpump and the valvecovers,
7. Installtwo bolts,clamps,washersand nuts (3).
8. Installbolt,clampand washers(2).
9. Installbolt,clamps,washersand nut (1).
NOTE: lf replacement linesare installed,always

removethe metalidentification
tags so vibrationof the
tags willnot causewornthroughfuellines.
3. Installfuel lines(8)as a unit.

injection
4. UseToolC to tighteneightnuts(6)and eightnuts

(7)to a torqueoÍ 40 r- 7 N.m (30 t 5lb ft).
3408C&3412C MarineEngines 34 Disassembly& Assembly 3r08

t FuelRatio Gontrol InstallFuel Ratio Gontrol
(lf Equipped) 1278-012
aemoveFuel Ratio Gontrol(lf
!quippedl 1278-011
l:re must be taken to ensure that fluids are con-

:,ned during performanceof inspection,mainte-
'.3nce,testing,adjustingand repairof the machine.
ie preparedto collect the fluid with suitablecon-
.: ners before opening any compartment or disas-
,+mblingany componentcontainingÍluids.Referto
-OOLS
AND SHOPPRODUCTGUIDE,NENG2sOO",
:'tools and suppliessuitableto collectand contain
-ids in Caterpillar machines. Dispose fluids
,:cording to local regulationsand mandates.
Sp * '
#$
:i-
{r
,È w." 1_d
,È
I -'*d
4 t
''í *i
*dr
, 7.
,fi."rr
,. ,b
sl ,
433524P1"
^\:#_
à .
1 . Putfuelratiocontrol(1)intopositionon the
governorhousing.Make surebolt (3)engageswith
stopcollar(4)in the governorhousing.
_f,q.^nnê^t
' lina /?\ tn fr rol ratin nnntrnl / 1\ 2. Installthe boltsthat holdÍuelratiocontrol(1)to the
l^^, 'î^^
vvvvr I rvr I tuuJil tg.
l. iemove bolts(2).RemoveÍuelrationcontrol(1)
3. Connectthe air lineat fitting(2).

Í
DisassembleFuel Ratio k:r*rrC'e
'i
Controf 1278-015 l.-:r-r? :'
Start By;
a. removeÍuelratiocontrol

-:r,r-: :\l
nance, testing, adjustingand repair of the machine.
Be prepared to collect the Íluid with suitable con- -.,t:.r-i !-t:
tainers before opening any compartment or disas- Removethe threebolts(9)and cover(10).

"TOOLSAND SHOPPRODUCTGUIDE,NENG2sOO', 6. Removevalve(7),diaphragm(8),retainer
and
for tools and suppliessuitableto collectand contain spring
@g
YT
*" *J
#.,3&
q'-
#xa@Ë@
M,i
: ..:a,
-#,'o
85843P1.
7. Removepin (12)fromvalve(7).
8. Removecover(11)fromthe valve.
two bolts(1)andthe housing(2).
1. Remove
9. Removethe sealfromcover(11).
f;) a9
ï o'fuffi
I
TU
85837P1-
2. Removevalveassembly(3).
3. Removeseal(4)and O-ringsealfromvalve.
4. Removethe retainer(5)and two springs(6).

AssembleFuel Ratio
(bntrof 1278-016
( 4l
\-,/
I
I
--re Ir
must be taken to ensure that Íluids are con-
Y
-r€d during performance oÍ inspection, mainte- {. tu
rÍrce, testing, adjusting and repair of the machine. Li
}r prepared to collect the Íluid with suitable con-

-rers before opening any compartment or disas- 85840P1'
rmbling any component containingÍluids. Refer to
bí tools and suppliessuitableto collect and contain
trds in Gaterpillar machines. Dispose fluids Installspring(7)and retainer(6)in cover(8),
5. Installdiaphragm(5)on valveassembly(4)and in
ïne cover.
85842P1'
'?. :,-rtcleanengineoil on the lip of seal(1).Installseal

'r in cover(2).Installthe sealso the lip is toward 6. lnstallcoverand threebolts(11)that holdcovers
:ie insideof the cover. together.
7. Put cleanengineoil on sealand ringseal.Installthe

eorlc
vvq|v
/1O\ nn rnhra
\
8. Installthetwo springs(13),retainer,
and valve
assembly(12).
9. lnstallhousing(9)andtwo bolts,
NOTE: Correctadjustmentmust be madeto the Íuel

ratiocontrolbeforeinstallation.
Seethe Systems
Operation,Testing& AdjustingManual.
EndBy:
a. 'instdlfuel ratiocontrol
Installvalve(3)into cover(2).
Installthe pin that holdsthe coveron the valve.

Service Meter f-L€l Trat
Remove& lnstallService tnove F

Meter 7478-O1O tunp 12
-.:r -;St t
:tr€ :unr
NOTE: Lubricate the O-rinqsealwith cleandieselfue 'r-r:a l?stÍ
priorto installation.
tr recare<
:r.*Ys 5€Íc
3. Lubricate the O-ringsealwith cleandieselfuelprior aÍ
fdng
to installation.
Installthe O-rinqsealon service .l.aS AN
meter(1). t:í -.:rS an
'rrrS 1 |
NOTE: Thefuelinjection lineshavebeenremovedÍor 4. Installservicemeter(1)on fueltransÍerpump (3). r:r:Êí: Ín9 |
pictureclarity.The
fuelinjection
linesdo not haveto be Positionservicemeter(1)for viewingfrom right
removedin orderto removethe servicemeter. handsideof the engine.
1. Femovetwo boltsand clamps(2)that hold service 5. Installtwo boltsand clamps(2)securingservice -

meter(1)tofueltransfer
pump(3).Removeservice meter(1)tofueltransfer pump(3). I
meter{l ). .;
t
I
2. Removethe O-ringsealon servicemeter(1). ï
\
NOTE: Thefollowingstepsarefor the installation
of
the servicemeter.
:.9:-Í
FuelTransfer Pump Install Fuel TransferPump 1256-012
RemoveFuel Transfer
hrnp 1256-011
r ...--JVeservrcemeter
ie must be taken to ensure that fluids are con-

-red during performance of inspection, mainte-
rmce, testing, adjusting and repair oÍ the machine.
3t prepared to collect the fluid with suitable con-
-rers beÍore opening any compartment or disas-
1 . Installthe gasketon fueltransferpump(2).
rmbling any component containingÍluids. ReÍerto
2. Putfueltransferpump(2)in positionon the
bí tools and suppliessuitableto collect and contain governor.
trds in Gaterpillar machines. Dispose Íluids
3. lnstalltwobolts(3).
4. Connecttwo Íuellines(1)to the transferpump.
End By:
a. installservicemeter
'.JTE: The fuel injectionlineshavebeen removedfor

::rre clarity.The
fuelinjection
linesdo not haveto be
=-cved in orderto removethe servicemeter.
1. Jisconnectand cap two fuellines(1)fromfuel

'rrnqfar nr rmn /?\
2 iemove two bolts(3).
3. Removefueltransferpump (2)and the gasket.

DisassembleFuel Transfer .- Ó-.'
Pump 1256-015 alD
" -.ac
Start By: \q
t
a. removefueltransferoumo
aJ

nance,testing, adjusting and repair of the machine.
tainers beÍore opening any compartment or disas- 4. RemoveO-ringseal(7)fromfitting(3).
semblingany componentcontainingÍluids.Referto
"TOOLSAND SHOPPRODUCTGUIDE,NENG2sOO'"
for tools and suppliessuitableto collectand contain
fluids in Caterpillar machines. Dispose Íluids
5. Removethreesockethead bolts(8).
6. Removecover(9)from the fueltransferpump.
1 . Removefittings(3)and (4)fromfueltransferpump
(5)
2. Bemovegasket(1)and O-ringseal(2)fromfuel
tnnqfor n r r mI rnv / 6 \
yur \v/.
7. Removelip seal(10)from cover(9).
D63927
3. RemoveO-ringseal(6)fromfitting(4).
3408C&3412C MarineEngines 40 Disassembly& Assembly -; -.:l

-W
(}.:
v
D639J5
:^roveplug(11)fromcover(9). 16. Removegear(23)from shaft(21).
:^roveO-ringseal(12)fromplug(11).
- ::move plug(17),two washers(16),seal(15),

. : r i n g( 1 4 ) a n dp l u n g e(r1 3 ) f r o m
c o v e r( 9 ) .
' ' lecêssan/removethe ferrule.
J ' ' v " ' v Y e
06J936
1 7 . Removebearing(24)Írom body assembly(18).
1 8 . Removetwo lip seals(25)frombodyassembl,

(18)
' 2 . lemove nut (20)fromthe shaft.
.?
Removegear(19)and the keyfromthe shaft.
D639J7
19. Removevalve(26),idlershaft(28),and bearing

(27)Írombodyassembly(18).
14. Removeshaftassembly(21)frombodyassembly
(18).
15. Removegear(22)from body assembly(18).

Assemble Fuel TransÍer
Pump 1256-016
Tools Needed A B c D E
1P0529 Handle 1 1 1 1 1
1P0456 DrivePlate
1P0458 DrivePlate 1
1P0462 Drive Plate 1
1P0463 Drive Plate 1
1P0467 Drive Plate
4. Installfirstlip seal(25)withTooling(C),Installfirst
seal(25)untilit is 26.19+ 0.í3mm (1.031I
.005 in) from the bottom(drivegear)surfaceand
withthe lipfacingtowardbearing(27).
5. Installsecondlip seal(25)withTooling(D).Install
secondlip seal(25)untilit is 14.2 + 0.5 mm (.559
+ .020in)from the bottom(drivegear)surface a.
with the lip facingawayfrom bearing(27).
6. lnstallbearing(24)in bodyassembly(18)with
T n n l i n n / t r \ T| |h' va lv -v rs rai lor vr i n n ( 2 4 \ m t r S t h e e v e n w i t h t h =
\L./,
063937 bottom(drivegear)surface
of the pr:mpbody
1 . Installvalve(26)withTooling(B).
2. Installidlershaft(28)untilflushwithbottomof body
assembly(18).
3. Installbearing(27)withTooling(A).Bearing(27)
must not extendabovethe (gear)sudaceof body
assembly(18).
D6J9J5 b
b
I
7. Heatgear(23)to a maximumof 315" C (600' F).
Installgear(23)on shaft(21)untildimension
(X)is
49.71 + 0.25 mm (1.957+ .0í0 in).
3408C&3412C MarineEngines â
+z Disassembly& Assembly . ,:.
D 6J 9 3 2
(21)in bodyassembly
r:aft assembly (18). lipseal(10)in cover(9)withTooling(C).
í5. Install
Installthesealuntilit is 22.61 + 0.05 mm (.890
-^-- /4.\ ^^ iir^- ^À^+ i2Rl + .002in) fromthe top surJace
--at \aa) ur I rurvr Jr tdtL \--l. of cover(9)and
withlip facrngtowardgears(221and ,23)
NOTICE
Do not let the liquid gasket enter the pump during
applicationor assembly.
- - rr:ll qhaff qqqamhlrr

aoar ll O\ nn iho
v v q | \ | q 9 9 v | | | v | j .
^stallnut (20)on the shaftassembly.

Tightennut
20)to a torqueof 30 + 7 N.m (22 + 5 lb ft).
063929
16. Put 7M-7260 Liquid Gasket Material on the

sudaceof cover(9).
'p
P (il
17. lnstallcover(9)on bodyassembly(18).
%4 [P o 18. Installthreesocketheadboltsí8).
NOTE: The driveshaftmust turn freelyaftersocket

";M r ,// /" headbolts(B)aretightened.
: r3931
O-ring(12)on plug(11).
1 2 . Install
' 3 . Install
plug(11)in cover(9).
plunger(13),spring(14),seal(15),two
Install
washers(16)and plug(17)in cover(9).
:408C&3412C MarineEngines 43 Disassembly& Assembly

FuellnjectionPumps
Remove Fuel Injection
Pumps 1251-01 1
Tools Needed A BC
6V6019 TimingPin
8T5287 Wrench 1
852244 Extractor
D6J928
19. InstallO-ring(7)on fitting(3).
Gare must be taken to ensure that fluids are con

tained during performance of inspection, mainte
nance,testing, adjustingand repair oÍ the machine
Be prepared to collect the Íluid with suitable cor>
tainers beÍore opening any compartment or disas.
sembling any component containing fluids. Refertc
"TOOLSAND SHOPPRODUCTGUIDE,NENG2sOO'
D6J927
20. InstallO-ringon fitting(4).
f,c
1. Removethe plugfromlocation(1).InstallTool (A)in

the holewith the squareend down. Movethe
063925 governorcontrolto the "ON" positionuntilthe rack
stops againstTool(A).The racksare now in center
/zorn\ nnciiinn
pump
(3)and(4)in thefueltransfer
21. lnstallfittings
22. Installgasket(1)on the fueltransferpump.
23. lnstallO-ringseal(2)on the Íueltransferpump.
EndBy:
transferpump
a. installfuel
)
3408C& 3412CMarine Engines 44 Disassembly& Assembly É:"3(

w-'
:
'::l:'
i:
lines(2)fromthe fuelinjection
Z --:isconnect pumps. 8. Removespacer(8)fromthe fuelinjectionpump
-emovewashers(3).Put capson allfuelopenings. bore.Keepspacer(8)with respectivefuel inlection
pumo.
3. lemove bushings(a)withTool(B).
{. iemove fuelinjectionpumpwithTool(C).Remove
scacer(B).
Install Fuel Injection Pumps 1251-012
'.lTE: Wheninjectionpumps,spacers
and liftersare
:-ovêd fromthe injection pump housing,keepthe Tools Needed A B c
::s of eachpumptogetherso theycan be installed 6V6019 TimingPin 1
,,:< in theiroriginallocation.
8T5287 Wrench 1
5. lisassemblethe fuelinjection
pump.Removering 852244 Extractor
6). Makea separationof bonnet(5)fromthe
clungerand barrelassembly(7),
NOTICE
3e carefulwhen the injectionpumps are disassem- Care must be taken to ensure that fluids are con-
: ed. Do not cause damageto the surfaceon the tained during performance of inspection, mainte-
: unger.The plungerand barrelfor each pump are nance,testing, adjusting and repair oÍ the machine.
-ade as a set. Do not put the plungerof Be prepared to collect the fluid with suitable con-
one pump in
're barrelof anotherpump.lf tainers before opening any compartment or disas-
one parthaswear,install
: completenew pump assembly.Be carefulwhenthe sembling any component containingfluids. ReÍerto
:rungeris put intothe bore of the barrel. ''TOOLSAND SHOPPRODUCT
GUIDE,NENG2sOO",
Íluids in Gaterpillar machines. Dispose fluids
b. Removethe gearsegment,washerand springfrom according to local regulationsand mandates.
the barrel.
7 . Removethe ring,spring,collar,and valvefromthe

NOTE: Makesurethe Íuel racksare in the center
oarret. (zero)positionbeforethe fuel injectionpumpsare
installed.
3408C& 3412CMarineEngines Ê
3overnot
415874P2'
??? ? ?
$f,-.##f$
:ernove &
a-ílp Driv
*f i7T
óó à ó óó
seal(1)and bushing(15)in the pumphous-

5. Install
bore.lÍ the pumpis in the correctposition,bushr
(15)willturnintothe threadsoÍ the pumphousing
withthe frngersuntilit is evenwiththe housing.
Tightenbushing(15)to a torqueof 205 -r 14 N.m
(150 + 10 tb ft).
6. lnstallwashers(16).
7. Connectthe fuellinesto the injection

pumpsand
tightenthe Íuellinenutsto a torqueof 40 + 7 N.m
(30 -f 5lb ft) withToot(D).
8. Checkfor correctinstallation pumps

of the injection
1 . Put plunger(10),washer(5)and spring(9)in withthe enginestopped.See Injection Pump
positionon barrel( ). Put checkvalveassembly(7), lnstallation
in the SystemsOperation,Testing&
spring(3)and collar(8)in positionin bonnet(6). AdjustingManual.
Connectbonnet(6)and banel(4)together with ring
(2).Keepseal(1)with bonnetfor useat installatron,
NOTICE
2. Put spacer(13)intopositionin the pumphousing lf one or more of the injectionpumps have been
bore.Makesurethe correctspaceris with each installedwrong,damageto the engineis possibleiÍ
DUMO. cautionsare not takenwhen the engineís first start-
ed.Makepreparation to closeoff the air intaketo stop
3. Put the spacein gearsegment(11) in alignment the engine,if necessary.
with the groovein banel(4).
9. RemoveTool(A)and installthe plugin the pump

nousrng.
4. Putthe injection pumpstraightdown intothe

housingboreso the spacein gearsegment(11)is
in alrgnment withpin (12)andthe groovein barrel
(4)is in alignmentwith dowet(14).UseToot(C)to
lnstallthe oumo.
3408C&3412C MarineEngines z+o Disassembly& Assembly :-:: i
3overnor& Fuel Pump Drive
8.*.nove& Install Governor& Fuel
a-mp Drive 1288-010
EngineTurningPinron
'9 Bolt 3/8-16NC x 76 mm (3 in)long
L.
-:ve fronthousingcover
2. Installlool(A).
3. Removepiug(2).
::'nove cover(1),
(B).
4. lnstallTool
5. Turnthe enginecounterclockwise (asseenÍromthe

flywheelend of engine)withTool(A)untilNo. 1
pistonis at top centerf-C) on the compression
strokeand Tool(B)can be installed in the flywheel.
SeeTop Center(TC)for No. 1 pistonin Testing&
Adiustino.
H08C &3412C MarineEngines 47 Disassembly& Assembly

--------
'r'
. -f.
il
6. Put alignment
markon governorand fuelpump 9. Removecover(1).
.'l
drive(3).
7. Removefour bolts(4)and retainer(5).
1 0 . InstallTool
(A).
1 1 . Removeplug(2).
8. Removegovernorand fuelpumpdrive(3),
NOTE: ThefollowingstepsareÍor the installation

of
the governorandfuelpumpdrive.
12. InstallTool(B).
1 3 . Turnthe enginecounterclockwise
(asseenfrom
the flywheelend of engine)with Tool(A)untilNo. 1
pistonis at top center[iC) on the compression
ÁD
strokeand Tool (B)can be installedin the
flywheel.See Top Center(1-C)for No. 1 pistonin
Testingand Adjusting.
3408C&3412C MarineEngines 48 Disassembty& Assembly

'llTE: Lubricate the weightsand slidesinsidethe
; ..3rnorand fuelpumpdrivewithcleanengineoil
-' :'to installation.
'vJTE: lnspectgasket(6)fordamageor wear,if
'--:ee2n/ ronlano a l i i h a newgasKer.
r..,.,,
(5)and fourbolts(4).Tightenfour
15. Installretainer
bolts(4)to a torqueoÍ 136 + 7 N.m (101 +
5 rb ft).
16. Installplug(2)and cover(1).
EndBy:
t4. Installgovernorand fuelpump drrve(3)in position
a. installfront
housingcover
according to the alignment
mark.

lss€mb
Èwe 1
:-
A22493P2' ---
: j.
PumP
DisassembleGovernor& Fuel
Drive 1288-015 1- - -
:-
Starl BY:
L
pump drive
a. removegovernorand fuel
weights(3)Írom
2. Removetwo springs(2)and two
drivegearassemblY(4)'
c40806P1'
(1)'
1. RemoveflangeassemblY
DisassemblY& AssemblY
50
ga08O& 3412CMarineEngines
c40808P1',
: -:r.rovetwo slides(5)Írom pistons(6). 4. Use1P-008GeneralPurposeLubricantto hold

slides(5)in positionon drivegearassembly(4).
I :=paratedrivegearassembly(4)fromadvance Installslides(5)on pistons(6).
.:eve (7).
5. lnstalladvancesleeve(7)to drivegearassembly(4).
AssembleGovernor& Fuel Pump

Drive 1288-0161288-016
4 3 8 16 6 P 1 '
6. Installdrivegearassembly(4)on flangeassembly
(1).Makesureslides(5)fitin groovesof the
weights,
End By:
1 . Putweights(3)in positionin flangeassembly
(1)as
shown. governorand fuelpumpdrive
a. rnstall
2. Installsprings(2)in flangeassembly(1).
3408C& 3412CMarineEngines Disassembly& Assembly

Fuel InjectionPump Housing&
Governor
RemoveFuel InjectionPump Housing
& Governor 1253&1264-011
Start By:
a. removefuelinjection
lines
b. removegovernor& fuelpump drive
2. Removetwo bolts,washersand spacers(2). a--
Gare must be taken to ensure that Íluids are con-

tained during perÍormance of inspection, mainte-
nance, testing, adjusting and repair of the machine.
tr€,€,
"TOOLSAND SHOPPRODUCTGUtDE,NENG2500",
w t/J
, ,,,
?
$,/
3. Removetwo bolts,washersand spacers(3).
two fuellines(1)to the fueltransfer

1. Disconnect
pump.Cap or plugimmediately
4. Bemovethreeboltsand washers(4)
5. Removebracket(51.

ï;
wr
:-l
:rcve two boltsand washers(6) 9. Attacha liftingslingand a suitableliftingdeviceto

Íuelinjectionpump housing& governor(9)as
:^rovebracket(7). shown.
\ 10. MoveÍuelinjectionpump housing& governor(9)

, backtowardsthe rearoÍ the engineuntilclearof
a the governorand fuelpumpdrivehousing.
a
Ëg, 11. Removefuelinjectionpumphousing& governor
iét,",#
-
(9).Theweightof the fuelinjection
pump housing
- '','t'f & governoris 56 kg (125lb).
.l$,.,r,
ï, ':\ê",
.:t .= 12. Removethe two O-ringsealson the bottomof the
?r,È
-,i,iF
:14!::l pump housing& governor.
Íuelinjection
'.i:,.:,
.:::lil= 13. Removethe O-ringsealon the frontof the fuel
pump housing& governor.
injection
lisconnecttwo hoses(B).Cap and plugall

:peningsimmediately.
i-108C&3412C MarineEngines Disassembly& Assembly

InstallFuel InjectionPump Housing&
Governor 1253& 1264-012 j
NOTE: Inspectall O-ringsealspriorto installation
for
wearor damage.lf necessary,replacewithnew O-ring
seals.
NOTICE
Makesurethereis no paint,dirt or otherÍoreignmate-
rial on the machinedsurfacesof the engineor fuel
injectionpump housing.Be carefulnot to damagethe
O-ringsealsfor the oil inletand oil outletas the pump
is put into positionon the engine.
6. Connecttwo hoses(8)to the fuelinjection
pump
housing.
1. lnstallthe O-ringseallocatedon the frontof the fuel

injectionpump housingand governor. 7. Put bracket(7)in positionand installtwoboltsand
washers(6).
2. Installthetwo O-ringsealslocatedon the bottomoÍ -
pumphousingand governor,
the fuelinjection r
Ë
3. Put a lightlayerof 5P-0960Multi-Purpose
Grease on the O-ringseallocatedat the front of
.T
the fuelinjectionpumphousingand governorand
on the two O-ringsealsfound on the bottomof the
fuelinjectionpumphousingand governor(oilinlet i
and oil outlet). I

l
4. Attacha liftingslingand a suitableliftingdeviceto ,-

fuelinjectionpumphousingand governor(9)as '-à
shown.
5. Putfuelinjectionpumphousingand governor(9)in
positionon the cylinderblock.
8. Put bracket(5)in positionand installthree

boltsand
washers(4).
- a_l
Governor
DisassembleGovernor 1264-015
Tools Needed A B c
6 V - 6 0 1 9 T i m i n gP i n 1
1P-1856 RetainingRingPliers 1
1P-1855 RetainingRingPliers 1
i -stalltwobolts,washersand spacers(3),
nance,testing, adjustingand repair of the machine.
tainers before opening any compaftment or disas-
semblingany componentcontainingÍluids.ReÍerto
"TOOLSAND SHOPPRODUCTGUIDE,NENG2sOO",
Íluids in Caterpillar machines. Dispose Íluids
NOTE: Thefuelinjectionpumphousing& governor

does not haveto removedÍrom the engineto
disassemble the governor, pump
Thefuelinjection
housing& governorhavebeenremovedfrom the
.rstalltwo bolts,washersand spacers(2). engineto disassemblethe governorfor photographic
ourooses.
'11.Connecttwo Íuellines(1)to the fueltransfer

pump. pump
1. Removeplug(1)fromthe fuelinjection
- nousng.
-rd By:
a. installgovernor& fuelpumpdrive
injectionlines
o. installfuel

--
2. InstallTool(A)intothe fuelinjectionpumphousing 5. Removegasket(6)fromhousingassembly(5).

withthe souareend down,Usea smallamountof
handforceto pushdownon Tool (A)whilethe fuel
controlleveris movedforwardto the "FUELON" n*rÊ l5 :
nnsition r rntil Tnol /A\ seats itsolf The Ír rcl rack will
á -€ad I
y v v l l | v | v v | \ , 1 /
stop in the center"zero"position.

*D:€ to
rrlhr
;. ï
:5;.eF"'Ï
t#,,-3
iË ,*,,',
6. Removesevenbolts(7)fastening
housingassembly
(5)to plategroup(B).
3. Removewiretie (2).
4. Removefive boltsand washers(3)fastening

adaptergroup(4)to housingassembly(5)
3408C&3412C MarineEngines cb Disassembly& Assembly ;':

(13)
-t I
,È
'*a
i ïï,,',
tfl
063944
10. Femovegasket(13)from the bottomoÍ housing

(5)
-lrere
is spring force under collar (9).Removesock-
:t head bolt (10) slowly while holding collar (9) in
:iace to allow the springÍorce to be releasedgrad-
-ally.
f emovesocketheadbolt(10)fromcollar(9)while
roldingcollar(9)in placeto preventsuddenrelease
rí iho cnrinn fnrno
f,. lemovespring(11).
D 6 3 954
locknut(14).
11. Remove
9. lÍ necessary,
removenut and screw(12)from collar
(e)
12. Removecotterpin and pin (15)

.-.-.-
l a',- \
v
_1Q /
i$::i:=
:!444
'í
ïF
,
';:.;s
: r951
13. Removethrottlecontrolrod (16)frombracket(i7)
Shaft (20) is under spring force. Remove shaft (20

from handle (21) slowly while holding shaft (29) ir
place to prevent possible personal injury.
1 6 . Femoveshaft(20)from handle(21)by turning

counterclockwise.
1 7 . Removethe springfrom shaft(20).
18. Femovehandle(21)Írom guide(22).
1 9 . Removetwo screws(23)from bracket(17). I

-
14. Removelocknut(18)fromthrottlecontrolrod (16).
1 5 . Removespacerand spring(19)Íromthrottle
controlrod (16).
1.t =
Lr.
zz'
:
23'
a4
L+,
za'
20. Removeguide(22),quadrantcontrol(24),hub 26'

(25),ratchet(26)and bracket(17)fromthe shaft,
^?
zr,
28
rI 3

i't.'
,-- i
\ ri
:
\
::,: t
*.....--a*s
:63951 063952
32. Removegasket(40).
NOTE: Marklocationsof idlescrews(39)and(41)

priorto removalfromthe housing.
28
29 33. Makealignment markon highidlescrew(39)and
removehighidlescrew(39)countingthe number
30 of turnsuntilremoved.
11
34. Makealignment markon low idlescrew(41)and

z?
removelow idlescrew(41)countingthe number
of turnsuntilremoved.
D64050
21. Removetwo socket head bolts (27).
22. Removelock (28). 06J953
23. Removeretainer(29).
35. Removetwo socketheadscrews(44)fastening
(30).
24. Removeinsulator bracket(a3)to the housing.
25. Removecontact(31). 36. Removefelt washer(42)f romthe shaft.
26. Removeretainer(32).
27. Removeshim(33).
28. Removebar (34),
(35).
29. Removeinsulator
30. Removecover(36).
31. Removebolt (37)andcover(38).
3408C& 3412CMarineEngines Disassembly& Assembly

ry *i* *'
.@
;"*** "
S ,1,
L- *
*3* .*-
%.-..-l
- M - \, I Ii
-#,*\ s
: i.i.
rjql E .':
, :; ^' ',;s !:.
.1. .r'
0 6 J 95 4 06J957 -'it*i.;l
ï'
ré
37. Removebolt(45). 41. Removetwo seals(49)from both sidesoÍ the
nousrng.
38. Removeshaft(47)and leverassembly(46)
removeplug(50)andthe O-ringsea
42. lf necessary,
F.
ll
fl-r,.
l
D6J955 J13
43. Removebearingsleeve(51)and (52)
4. Removevalvebody(53)fromthe housing.
Pin (a8)has a large amount oÍ spring force behind it.
The spring Íorce will not release slowly during
removalof pin (zA).Removepin (rt8)very careÍullyto
avoid possible personal iniury.
39. Removepin (48)slowlyand carefully

due to the
largespringÍorcebehrndit.
40. Femovethe springand the stopplungerinside

leverassemb! (aO).
t
:1
06J958
45. Removevalve(55)fromvalvebody (53).
46. RemoveO-ringseal(54)fromvalve(55).
47. RemoveO-ringseal(56)fromvalvebody (53).
3408C&3412C MarineEngines bU Disassembly& Assembly

lemove seat(57)andspring(SB). 52. UseTool (B)to removeretainingring(63)
:9. UseTool(B)to removeretaining

ring(59). 53. Removesprrngseat (65)and bolt stop (64)from
rnegovernor.
i0. Removespacerring (60).
51, Removespool(61)and spring(62)

I
a
(t
06J891
56. Removegovernorweight(69)from the governor
54. Disassemble
springseat (65)and bolt stop (64)as
follows:
ring(68)fromspringseat(65).
a. Removeretaining 57. Removefour bolts(72).
b. Removebearing(67)fromspringseat(65). 58. Removeadapterplate(71)fromthe fuelinjection
pumpnousrng.
c. Removeboltstop (64)fromspringseat(65).
1).
d. Removespacer(66)fromspringseat(65).
t3
59. Removepin assembly(74)fastening

drive
assembly(73)to gear(75).
55. Removelockring(70)fromgovernorweight(69). 60. Removedriveassembly(73)fromgear(75)
3408C&3412C MarineEngines 62 Disassembly& Assembly 310

I ,w
*p
lr.:i
{:. -j ,
.{mt
(-.,::
#i
- at897
,ITE: Makea noteoÍ alignment

markson stop (76) 65. Turnadapterplate(71)over.
-
: J- ílÔ
.
Í il ^Í ^l +S^ tl li^l+l iladn L l OI Ínp' U' r: ' p O S e S .
66. UseTool(C)to removeretaining
ring(Bl)from
:1. Removestop (76)Írom gear(75). gear(75).
67. Removethreebolts(79)and bracketassembly

(80)fromadapterplate(71).
62. Removedowel(78)fromguide(77),
63. Removeguide(77)fromadapterplate(71)
bracketassembly(80)as follows:
68. Disassemble
64. Removethe O-ringsealinsideguide(78).
a. Removepiston(BB).
b. Removevalve(87).
c. Removepin (BO).
d. Removesleeve(85).
e. RemoveO-ringseal(84)fromsleeve(85).
f. lf necessary,removedowel(83)and lever(82).
3408C&3412C MarineEngines 63 Disassembty E Assenbrr

I
76. Removefour bolts(96)fromadaptergroup(4)' G

69. Removegasket(89)fromadapterplate(71).
70. Removeplug(91)fromadapterplate(71). 77. Removetwo covers(97)fromadaptergroup(4) r
71. Removetwo dowels(90)fromadapterplate(71).
72. Removecylinder(92)from adapterplate(71).
73. Bemovedowel(94)fromadapterplate(71).
74. Removebearing(93)fromadapterplate(71).
'1,-
J.' * i
::,'.t
. tlil
D63904
78. Femovetwo gaskets(98)fromadaptergroup (4).
a).
D6J901
75. Removetwo O-ringseals(95)fromcylinder(92)'
D63905
79: Removecover(99)fromadaptergroup (4).
ar
I
t
ïI
I
:r: :3movewiretie (102)from
bottstop(1OO). 87. lf necessary,
removedowel(106)and ptug(i OZ)
r:.nove nut and washer(101)from Írom plateassemblv(10S).
-t0). boltstop
::move boltstop (t OO)from

cover(99).
,/
f\/t
(4)
'r
D63910
)
88. Removegasket(110)fromadaptergroup(4).
89. Removefoursocketheadbotts(1OB).
lemove gasket(103)fromadaptergroup(4). 90. Removelever(107)and (109).
D6J911
u. Turnadaptergroup (4)over. 9 1 . Femovebolt (112),iever(113)and the woodr--

key.
85. Removeboltand washer(104)fromadapter
group(4). 92. Removeshaft(111)fromadapte.j.:.-: -
86. Removeplateassembly(t 0b) from adaptergroup
(4).
3408C&3412C MarineEngines 65 grJd->:-rt-

Assemble Governor 1264-016
.. 'l I
6V-6019 TimingPin
Tools Needed
1P-1856 RetainingRingPliers
1P-1855 RetainingRingPliers
1P-0510 DriverGroup
A
1
B c 't
l,
#_,re-
NOTE: Inspectall paftsof governorÍor wearof

^^-^^^ ^-i^- +^ ^^^^rhhr
063913 udr I rdvu p r r u r L L ,d J ) u r I r u r y . il {l |n nt un nuoËn ba n5rd t y . tr nËnpl nt d
^5
uv q
a 6t i ' )
worn or damagedpart with a new paft. Lubricateal

qaalq
í)-rinn rrriih nla:n , oUnrnl i9nloÍ l e nOi ll l nprlilnOr r +LAr Ja
.ó.c
ssemDly,
93. Removeinsulator
(114)from adaptergroup(4).
,- 1Ï
94. Removetwo bearings(115)and (11B)from
aÀ^^+^. ^.^, '^ | À\
q uqvLsr vr wuP \a/.
95. Removetwo lipseals(116)and (119)from adapter

group(4).
96. Removevalve(117).Removethe C-ringsealfrom

valve(117).
1. Installvalveassembly(120)in adaptergroup(4).
97. Removevalveassembly(120)
^.?
3408C& 3412C MarineEngines oo Disassembly& Assembly

I ,ï
" -------_......
A
\ ..-,/
'/\
+---{113)
D6J9l1 \-./
-srallinsulator
(114)in adaptergroup(4).Tighten NOTE: Lubricate two lip seals(116)and (119)with
=rlator(114)to a torqueof 4.52 r- 0.60 Nm cleanengineoil priorto rnstallation
of shaft(111).
140.000 + 5.000lb in).
7 . I n s t asl lh a f (t 1 1 1 ) .
-E:
- All measurements involvingbearing(.115)are
- at the centerof the bearinq. 8. Installthewoodruffkeyand lever(113)on shaft
( 111 ) .
- ^ T^^r /n\ +^ i^^+^r bearino í.1.15) to a
- >g I uul \u,/ Lw ll lèLqll uqqr il rv \ | r u/ L v q clenth
uu|!,r of
2.13 -r 0.10 mm (0.084+ .004in)Írom the 9 . I n s t abl lo l t( 1 1 2 i)n l e v e(r1 1 3 ) .
-tsidefaceoÍ adaptergroup(4).
- se Tool(D)to installbearing(11B)untiloutward
',:ing surface of bearing(118)is 110.84t
0.50 mm (4.340 + .020 in) from the bottomof
:earing(115).
- se Tool(D)to installlip seal(.1

16)untilseated
-'mly againstthe counterbore facewith lipÍacing
:re counterbore sudace.
Jse Tool(D)to installlip seal(119)untilseated ,/

'rrmlyagainstbearing(11B)with lip sealfacingaway
,--/
'rombearing (118). (4)
-
D63910
lever(107)and (109).
1 0 . Install
1 1 . Installfoursocketheadbolts(108)fastening
levers
(107)and (109)to shaft(111).
12. lnstallgasket(110)on adaptergroup(4).
3408C&3412C MarineEngines ot Disassembly& Assembly

t'ffi&'Íï't'*
r!l$*:::1r:l
-.@ I
ffi"È ,€
,..-*-ri",,
. .- 1na
13. lf removed,installdowel(106)in plateassembly 17. Put gasket(103)in positionon adaptergroup(4

(105).
plug(107)
14. Install
18. Installboltstop (1OO)in

cover(99).
washerand nut (101)onboltstop (100).

19. Install
1 5 . Put plateassembly(105)in positionon adapter
group(4). NOTE: Wiretie (102)can onlybe installed
afterfinal
adjustmentshavebeenmade to the governor.
1 6 . Installbolt,washersand nut (104).
20.

D6J901
2í. Installtwo O-ringseals(95)on cytinder(92).
NOTE: Lubricate the entirecylinderand the O-ring

sealswith 1P-0808Lithium Greasepriorto
in plategroup(71).
installation
22. Installcylinder(92)in plategroup(71).
23. Installplug(91)in plategroup(71).
24. UseTool(D)to installbearing(93)untilit is 0.51 +

0.25 mm (.O2O4+ .0100 in) betow the top
surface of plate group (7í).
20. Installtwogaskets(98),two covers(97),cover
(99)andfourbolts(96), 25. lnstallgasket(89)on plategroup(71).

o^9
I
33. Put bracket(80)in positionon plategroup(71). .-
34. Installthreebolts(79)fastening
bracket(80)to a:
-:-
of the dowelsin plategroup(71)

26. lf a replacement plategroup(71). .- :
is necessary,seethe illustration
for correct
installation
dimensions. 35. Installgear(75).
36. UseTool(C)to installretainingpin (81)on gear

(75)
I
27. PUIlever(82)in positionon bracket(80).
28. lnstallpin (83)in bracket(80).

37. lnstallgurde(77)on plategroup(71),
29. InstallO-ringseal(84)onsleeve(85).
38. Installdowel(78)in guide(77).
30. Installvalve(87)in piston(88).
31. Installpin (86)in bracket(80)andengagewith

lever(82).
32. Engagepiston(BB)withpin (86).

I
-E:
Makesureto alignmarkson stop (76)and NOTE: Makesurethe rack is heldln ihe "zero"
- 75)duringassembly, positionwithTool(A)duringinstallatron
of plategroup
(71).Makesurelever(82)engageswiththe rackduring
:'3. nstallstop (76)in gear(75).Alignalignment
marks installation.
ro ensureproperassemoty
42. ?laceplategroup(71)in positionon the fuel
injectionpumphousing.
43. lnstallfourbolts(72)fastening
plategroup71)to
pumphousing.
the fuelinjection
40. Installdriveassembly(73)in gear(75).
4 1 . lnstallpin assembly(74)in gear(75).Ensurethe

endsoÍ pin assembly(74)areengagedin the
groveof the gear.
zl4. lnstallgovernorweight(69)on plategroup (71).
\ 45. Installlockring(70)on governorweight(69).

Ensurethe endsoÍ lockring(70)are engagedin
the oovernorweioht.

3t!
n
',Íi
't t
'-'
ring(63)securing
51. UseTool(B)to installretaining $
the springseatto the gutde.
D63891
46. lnstallbolt stop (64)in springseat (65),
47. Installbearing(67)in springseat (65).
u18.Installretainingring(68)in springseat (65). 52. Installspring(62)on the boltstop.

ê
49. lnstallspacer(66)in springseat (65). 53. Installspool(61)on the boltstop.
seat(65)andboltstop (64)onthe
50. Installspring g. Installspacerring(60)on the bolt stop.
plategroup as shown.
ring(59)fastening
55. UseTool(B)to installretaining
spacerring(60)to the spool.
3408C&3412C MarineEngines IZ Disassembly& Assembly

I
:6. Installspring(58)and springseat(57).
442791P10-
60. lnstallvalve(53)in the housing,
6 1 . UseTooling(D)to installbearing(52).Dimension
"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 ê n s i o n
' ' Y \u/ Lv
"X" is 25.35 r- 0.13 mm (.998 -r .005 in),
i7 Inctell í)-rinn coal /${) On Valve (55). 63. Checkdimension "Y" mustbe
"Y".Dimension
60.58 + 0.13 mm (2.385+ .005 in).
58. InstallO-ringseal(56)on valvebody(53).
59. Installvalve(55)in valvebody (56).
D6J957
64. UseTool(D)to installtwo lip seals(49)untilthey

areflushwiththe outsidefaceof the housingand
with the lipsof both sealsfacingtowardsthe
inside.
NOTE: Lubricate
the borewithcleanenoineoil beÍore
i n c t a l l i n Int nlr rn /ÁO\
|/ruv \vv./.
65. Installplug(50)andthe O-ringseal.

06J955
66. Installthe stop plunger,springand pin (48)in lever 69. lnstallfelt washer42\ on the shaft.
assembly(46).
70. Installbracket(43)and two sockethead bolts1:-
67. Put leverassembly(46)in positionin the housing

and installshaft(47). 71. Installhighidlescrew(39)the samenumberoÍ
turnsas duringremoval.
68. Installbolt (45)in leverassembly(46)
72. Installlow idlescrew(41)the samenumberof
'l
turnsas duringremoval.
73. Installgasket(40)on the housing. a

-,
-Ê
-9.
31
&

th I
06J950
85. lnstallguide(22),quadrantcontrolQa), nub Q5),

ratchet(26)and bracket(17)on the shaft.
28
29
30
a..l
??
D63949
)
86. lnstalltwo screws(23)fasteningbracket(17)to
the housing.
064050
87. Installthe spring,governorcontrolshaft(20)and
handle(21).
74. lnstallcover(38)and bolt (37).
75. Installcover(36).
76. Installinsulator
(35).
77. Installbar (34).
78. Installshim
(33).
79. Installretainer(32)
80. lnstallcontact(31).
81. Installinsulator
(30).
82. Installretainer(29) 88. Installspring(19)and locknut(18)on throttle

controlrod (16).
83. Installlock(28).
84. Installtwosocketheadbolts(27).

tl* 't:*
--:\
1j
ï"'f
tl
l _ ^ . , ,i-a
t"
--'
89. Installthrottlecontrolrod (16)in bracket(17). (13)on the bottomof housing(5).
92. Installgasket É
':'--
Ë
D6J959
90. Installpin and cotterpin (15)fastening

the throttle 93. lnstallscrewand nut (12)in collar(9).Tightennut
controlrod to the quadrant. (12)toa torqueoÍ 12 + 4 Nm (106.8+
35.6lb in).
91. lnstalllocknut{14)on the throttlecontrolrod.

94. lnstallspring(11),collar(9)and socketheadbolt
(10). 98

t5. Puthousing(5)in positionon ptategroup(B). NOTE: Do not installwiretie (2)untitafter
ad;ustments
to the governorhavebeenmade.
36. Installsevenbolts(7)Íastening
housing(5)to plate
group(B).
100. RemoveTool (A).
97. Installgasket(6)on top of housing(5).
plug(1).
10í. Install
98. Put adaptergroup (4)rn positionon housing(5).
99. Installfive
boltsand washers(3).

DisassembleFuel Injection Pump
Housing 1253-0í5
*J a
Tools Needed A B c D E
&
,l
8f5287 Wrench
852244 ExtractoÍ 1
5P0944 Dowel PullerGrouo 1
6V6019 TiminoPin
852241 Camshaft Bearing Removal 1
& InstallationGrouo -
À 3 4 5 17 P 1
StartBy:
pump housingand governor
a. removefuelinjection Removeshaft(6)fromrearcover(2).Removethe 7 . R e m c 't '
gearfrom shaft(6).Removethe bushingfrom rear shaft
o. removegovernor cover(2). sPring
3. Removeretainer(4).Removegear (5). \OTE: S

:.>LVrr'"
- : Jslng '
4. Removeoil pumpcover(3).
tained during performance oÍ inspection, mainte- 8. Rerr:
nance, testing, adjusting and repair of the machine. pln.c
tainers beÍore opening any compartment or disas-
sembling any component containingfluids. ReÍerto
,TOOLSAND SHOPPRODUCTGUIDE,NENG2sOO",
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
assembly(9)fromthe pump housingwitha soft
hammeras shown.Removedrivegear(8).
Àir
NOTE: Whenpiniongearassembly(9)is removed,

oÍ drivegear (8)with a new part.
makea replacement
6. Removecover(10).
434469P1'
1. Femovebolts(1)from rearcover(2).Removecover
(2)and the gasket.

'
iemove the boltsfrom levers(14)and(11).Remove 10. InstallTool(D)in the pump housingwiththe
sraft(16),lever(14),lever(11),bearing
(1S)and squareend down (endwith taperwillbe up).Hold
scringwasher(12). the racksagainstTool (D)and removeeachof the
injectionpumps(18)withTool(B).Formore
. iTE: Step(7)is onlynecessary
on earlierfuel details,seethe topic"RemoveFuelInjection
.::ms. Latersystemshaveshutoffin governor Pumps".
-sing.
3. ?emovebypassvalve(.13). Removethe O-ringseal,

cin,piston,and springfromthe valvebody.
*%
&
@
ffi
434520P1',
1 1 . Removebolt (19)that hotdsbracket(23)to the

Íuelinjection
pumphousing.Removebracket(23)
and link(20).
9. Removethe felt washerfrom bushing(17).Remove 12. Put identification
on the left rack(2j) and rioht
bushing(17)fromeachof the injection
pumpswith rack (22).Remove
racks(21) and(22).
Tool (A).
3408C& 3412CMarine Engines 79 Disassembly& Assembly

lssemb
r ous i ng
#€fi -s&
#,'7": * @ &" A.oal
t
ffi:, l
^t9
434542P1- 434522P1"
13. Removespacers(24)and lifters(25)from the 1 5 . Removedowel(27),shaft(28)and dowel(29)wr:

injectionpump housing.Put identification on each Tool (C).
of the spacersand liÍtersas to theirlocationin the
pumpnousrng. 1 6 . Removelowerand upperbearings(30)thatare
supportsfor the pinionassembly.
1 7 . Removebearing (3i)and the lipseal.Remove

@,r 1*n
bearing(32)andthelip seal.
ffi
;
i9
tI
t|.q.
|
|
,: . 4 r".
I * 7 S#fi l": * - ,
ffi,ë i pt-"-ffi
f,=
ru iËLi
Sr; w-r '*b'-
: l1'l:t:1À.::::=
_ 1. t,
|t "
{ *=rr.,
t:.
A34521P1" I
I are
'Jrn€
-3nc
14. Removecamshaft(26)fromthe pumphousing.
3'e ;
'JríX
lem
NOTICE ,To
Be careful not to damage the camshaft bearingsas 18. Removethe rack bearingsfrom locations(33).
or r I
the camshaftis removed.
1 9 . Removethe camshaftbearingswith Tool (E).

lssemble Fuel lnjection Pump
ltousing 1253-016
>].159 Drive Plate

'='-1455
Drive Plate
1 . Put Íixtureassembly(3)(partoÍ Tool (A))on the

pump housingwiththe dowelsin fixture(3)
engagedin the rightrackbore.Installbolt(4).
2. Put a new bearing(2)in positionbetweenfixture(3)

and the rack borewith the tab of the bearingup.
Installthe bearingwithdriver(1)untiltheshoulderof
the drivermakescontactwith the fixture.
3. Turnthe fixtureand makealignmentof the dowels

on the frxturewith the left rack bore.Installthe right
rackbearingaccordingto the instructions in Step2.
350240 Rack PositionTool Grouo

tained during performance oÍ inspection, mainte-
nance,testing, adjusting and repair oÍ the machine.
Be prepared to collect the Íluid with suitable con-
tainers beÍore opening any compartment or disas-
semblingany component containingfluids. Refer to
.TOOLSAND SHOPPRODUCTGUIDE,NENG2sOO",
434525P1-
4. InstallO-ringseal(5).

A34526P1.
5. Installthe camshaftÍrontbearing(7)withTool(B). for the pinio'

8. Installthe lowerand upperbearings
lnstallthebearinguntilit is '1.02+ 0.51 mm (.040 near asscmhlv rnrithTnol /C) Instell
,, ,e(q,, the
( , , v rrngg;
uvF
+ .020 in) from front surface(6)oÍ the pump bearinguntilit is evenwith the top of the bearing
nousrng. boreand the bottombearinguntilit is evenwith :
bottomoÍ the bearingbore.
NOTE: Installa camshaftbearingswiththe bearing \
jointin area"X".Thiswillput the oil holein area"Y". 9. Installshaft(11)inthe pumphousinguntilit is
Formorecompleteillustration of bearinginstallation, extended16.76 + 0.51 mm (.660 + .020in) frc
makereÍerence to the Specifications Manual. thetop of the pumphousing.lnstall
dowel(12)unr
it is extended11.18 + 0.51 mm (.4+Ot- .020 in)
fromthe top of the pump housing.
NOTE: Steps10 thru 13 and Step24 applyonlyto

earlierfuelsystemswith fuel shutoffshaftin inlection
pumpnousrng.
.,2,
6. lnstallcenterbearing(9)withTool(B)untilthe rear
edgeof the bearingis 127.00+ 0.51 mm (5.000
+ .020 in) from rearsurface(B)of the pump
nousrng,
7. Installrearbearing(10)withTool(B)untilit is 4.83
+ 0.51 mm (.190 + .020 in) from rearsurface(B). !r
t
I ,í
^1
3408C&34'l2C MarineEngines 82 Disassembly& Assembly

434541P1',
14. Putcleanengineoil on the camshaftbearingsand

on camshaft(17).lnstall
camshaft(17)as shown.
-$
.!
*:,
"Z"
1 0 . lnstallbearing(13)withTool(D)untildimension
is 38.23+ 51 mm (1.505+ .020in) Dimension 434542P2.
"2" is takenÍromthe end oÍ bearing(13)to the
outerfaceof the pumphousingboss.
15. Putcleanengineoil on lifters(19).Installlifters(19)
seal(14)withTool(D),Installthesealeven
1 1 . Install and spacers(18)for eachoÍ the injectionpumps.
withthe surfaceoÍ the housrng
and withthe lip Be surethe liftersand soacersare out in their
towardthe outsideas shown. orlginallocationin the pump housing.
12. Installbearing(15)withTool(D)untildimension 16. Putcleanengineoilfuelracks(20)and (22).Install

"R" is 34.80 + 0.51 mm (1.370+ .020in). leftrack (22)in the pump housingwith the groove
Dimension "R" is the distancebetweenbearinqs. in the rack engagedwith the tab of the rack
bearing.lnstallrightrack(20)withthe groovein
the rackengagedwiththe tab of the rackbearing.
NOTE:The rightrackhasa notch(21)cut intothe

rearend of the rack:
13. lnstallseal (16)withTool(E).Installthe

sealuntilit
is evenwith the suffaceof the pump housingand
with the lip towardthe outsideas shown.

&,, @
ffi
w J
$
A
s
s
@
" i
434520P2- A41520P2'
1 7 . Installdowel(23)in the pump housinguntilit is 20. Installpiniongear(29)in the pumphousing,Use

extended12.2 + 0.5 mm (.+8 +.02) from the an 11/16"Socket and a "C" clampwith a
surfaceof the pumphousing. minimumopeningoÍ 22.9cm (9 inches)and
installpiniongear(29)untilthe pumpdrivegear
1 8 . Installlink(25)and bracket(26).Tightenbolt (24) makescontactwiththe shoulderof the oinion
to standardtorque.Be carefulso bracket(26) gearshaft.
does not turnas bolt(24)is tightened.
ï
ffi*
,í
@
A15889P3-
441519P2-
21. lnstallspring(30)and piston(32)in valvebody

19. lnstallidlergear(27)on the shaft.Put drivegear (34).lnstallpin (33).Installseal
(3'1).
(28)in positionwiththe bevelsideof the gear
down. Makesurethe teeth of the idlergearand NOTE: Pin (33)must not extendout from eitherside
drivegearare in alignment and installthe pump of valvebody (3a).
cover.
22. Puï cleanengineoil on valvebody (3a)andseal
(31).Installthe oil bypassvalvein the pump
housino.

26. lnstallcoverí45).
27. InstallTool (F)in the injection

pump housingwith
the flatend down.Usea punchor a screwdriver
to pushthe rackintohousing.At the sametime,
pushdownon Tool(F)untilit engagesin slot
(groove)in the rack.The rack is now centered(in
the zeroposition) pumpcan
and the fuelinjection
be installed,
t 23. Removepump cover(40)and cleanthe metal

pumphousing.Install
clipsfromthe fuelinjection
nnmn nnr rar /ulA\
vur I r|./ vvvgr
) \av,/.
24. Put lever(35)bearingand springwasher(37)into

positionin the pump housing.Installshaft
(38)
lnstalllever(39).Installbolts(41).
25. Put gear(42)and retainer(43)into positionin the

pumphousing.lnstdl
bolts(44)and tightento
standardtoroue.
28. Putthe spacein gearsegment(47)alignmeni with
the groovein pump banel(46).Put the injection
pump straightdown intothe housingborewith the
spacein gearsegment(47)engagedwith the pin
in the lifterand the groovein barrel(36)engaged
withthe dowelin the pumphousing.UseTool(H)
to installthepumps.

''
frater
Semove
a.egulat<
1..q,
I
t,
\;:::::
l%
'#r lre mus
:rned du
434470P2"
rrfr-Cg. tgl
3á crepa
-J 1€rs E)
29. Installbushing(48)in the pump housingbore.lf 33. Heatgear(52)to a maximumtemperatureof r.í110lln g

-COLS
pumpis in the correctposition,
the ,njection 232C (450'F).lnstall
the gearon shaft(51)unti
bushing(48)willturnintothe threadsof the pump makescontaciwiththe shoulderoÍ the shaft. i:í tOols
.,- ds ll
housingwiththe fingersuntilit is evenwiththe
nousrng. 34. Put rearcover(49)into positionon the pump r=ordir
housingwithshaft(51)in alignment with hole(53
30. Tightenbushings(48)to 2OS! 14 N.m (150 +
10 lb ft) withTool(G).Installthe feltwasherfor
eachinjectionpump.Formoredetailsee Install
FuelInjection Pumps.
3 1 . Checkthe rack movement(travel)with Tool (K)

aftereachpump is installed.
See Injection
Pump "i
Installation
in the SystemsOperation,
Testing& d",
AdjustingManual. .::
9r
'.' o @ Ë -
. @; ;: )
.:*
;' :'ài'.1
ffi'r ]
35. Installbolts(54).
End By: 4
a inctell ^n\/êrn^r )
434549P1-
b. installÍuel pump housingand governor
injection
32. Installbearing(50)in rearcover(49)with Tool (J)
I
Js
WaterTemperatureRegulators
?emoveWater Temperature
legulators 1355-011
lare must be taken to ensure that fluids are con-

:ined during performanceoÍ inspection,mainte-
-€nce,testing,adjustingand repair of the machine.
3'e prepared to collect the fluid with suitable con-
':iners beÍore opening any compartment or disas-
:emblingany componentcontainingÍluids.Referto 5. Removetwo gaskets(7).
'cr tools and suppliessuitableto collect and contain 6. Removetwo bolts(5).
quids in Caterpillar machines. Dispose fluids
rccordingto local regulationsand mandates. 7. Removewatertemperature housing(6)
regulator
'l. Jrainthe coolantfromthe radiatoruntilthe coolant

levelis belowthe watertemperaturereoulator
housings.
8. Removetube (B).
9. Removetwo gaskets(9).
10. Removetwo bolts(11),waterconnector(10)and

2 . I oosenthe hoser:lamrland disconnect
radiator the gasket.
hose(1).
3. Removefour bolts (2)and tube (4).
4. Removetube (3).

TemperatureRegulators
Water Temperature
ors 1355-011
must be taken to ensure that fluids are con-

during performance oÍ inspection, mainte-
, testing, adjusting and repair oÍ the machine.
gepared to collect the fluid with suitable con-
beÍore opening any compadment or disas-
any component containingfluids. ReÍerto 5. Removetwo gaskets(7).
AND SHOPPRODUCTGUIDE,NENG2sOO",
bols and suppliessuitableto collect and contain 6. Removetwo bolts(5).
in Caterpillar machines. Dispose fluids
IÊoíding to local regulationsand mandates. 7. Removewatertemperatureregulatorhousing(6).
t l'ain the coolantfrom the radiatoruntilthe coolant

=. el is belowthe watertemperaturereoulator
-:usings.
8. Removetube (8).
9. Removetwo gaskets(9).
10. Removetwo bolts('11),

waterconnector(10)and
-oosenthe hose clampand disconnectradiator the gasket.
rose (1).
lemove four bolts (2)and tube (4).
Removetube (3).

Manual Cat Assamble Dis Ass Amble

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CAÏERPILLAR' SEN R133

u MarineAuxiliary& GeneratorSet Engines

3408C&3412C MarineEngines lndex

1. Removetwo boltsand strap(1)fromthe fan guard

2. Removetwo boltsand strap (2)fromthe fan guard

3408C&3412C MarineEngines Disassembly& Assembly

Care must be taken to ensure that fluids are con-

l. l'ain the radiatorintoa suitablecontainer

3408C&3412C MarineEngines Disassembly& Assembly

9. Romnrro r:di:tnr íA\

1. Attacha liftingslingand a suitableliftingdeviceto

2. Removesix boltsand washers(2).

NOTE: To installthe fan, reversethe removalsteps.

-;=- four nuts(1)fastening

2. Tightenbolt (3)untilfan belts(2)are tightened

z -rcsen bolt (3)to loosenfan belts(2).

5. Tightenfour nuts (1)fasteningthe fan driveto the

3408C&3412C MarineEngines Disassembly& Assembly

1 . Attacha liftingslingand a suitableliftingdeviceto

2. Removefour nutsand washers(2).

1 . Removetwo boltsand bracket(4)fromthe fan

2. Femovesix bolts(1)that fastenfan adapter(3)to

NOTE: To installthe fan drive,reversethe removal

3408C&3412C MarineEngines Disassembly& Assembly

I -:--- . e two boltsand washer(5)from the fan drive 7. Removelipseal(11)Íromhub (7)

8. Removepulley(2)from fan bracketassembly(12).

5 . :emove hub (7)fromthe fan drive.

D{5450 9. Removespacer(13)from fan bracketassembly

3408C&3412C MarineEngines Disassembly& Assembly

NOTE: ThefollowingstepsareÍor the assemblyof the

14. UseTool(A)to installlip seal(11)intohub (Z).

11. lf removed,installplug(14)insidefan adapter(3)

3408C& 3412CMarineEngines '10

21. Fillthefan driveat the greasefittingwith 1P-0808

t& -sïallwasherand two bolts(5)in hub (7).

3408C& 3412C Marine Engines 11 Disassembly& Assembly

a. removeexhaustmanifolds a. removecrankshaftpulley& damper

1 . Removefour boltsand washers(2). 1. Loosenbolt(1)closestto the engineon eachside

2. Attachtwo liftingslingsand a suitableliftingdevice *r

4. Removeleft sideenginebracket(3). support(2)to enginesupport(3).

reversethe stepsÍor removal. support(2)is 25 kg (55 lb).

I :-arnsand a suitableliftingdeviceto the

r:rrt the encine with the ChainSand the SUitable

a -:-f,ve fourbolts,washersand nuts(6).

-.:-lro oinhf hnltc /Á\

::rove enginesupport(3).Theweightof engine

3408C&3412C MarineEngines 13 Disassembly& Assembly

2. Usetwo peopleto removepulley(1).pulley(1)

6. Hold adapter(6)by hand,removetwelvebotts(S).

3408C & 3412CMarine Engines 14 Disassembly& Assembly .iill

12. Installpulley(3)on the adapter.

=-:i'ed, installtwelvestuds(7)in adapter(6)

13. Placepulley(1)in positionon the adapter.

t l. rstalldamper(4)on the adapter.

}{OSC& 3412C Marine Engines 15 Disassembly& Assembly

1. Removebolt and hoseclip (1).

2. Removenut and washer(2).

3408C&3412C MarineEngines 16 Disassembly& Assembly lrt

3108C& 3412CMarineEngines 17 Disassembly& Assembly

Care must be taken to ensure that fluids are coÍr

1. Turnthe Íuelsupplyvalveto the "OFF"position,

NOTE: Thefollowingstepsarefor the installation

3408C& 3412CMarineEngines '18 -1..3