Caterpillar injection+pump+cat+3406

Manual de bomba caterpillar 3406

1. Cerrar SIS
Cambiar configuración del producto o de la pieza
Modelo:  3406 GEN SET ENGINE 75Z


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2. Desarmado y Armado
3406 ENGINE FOR GENERATOR SET
Automatic Timing Advance
SMCS - 1272-11 ; 1272-12 ; 1272-15 ; 1272-16
Remove Automatic Timing Advance
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1. Remove nuts (1), cover (2) and the gasket from the timing gear cover.
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2. Remove bolts (3), washer (4) and automatic timing advance (5) from the engine.
Install Automatic Timing Advance
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Número de medio -SENR2540-00 Fecha de publicación -01/03/1983 Fecha de actualización -11/10/2001
   
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3. Ver imagen

1. Remove plug (1) from the fuel injection pump housing.
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2. Time the fuel injection pump by turning the camshaft until the notch in the camshaft is in alignment
with the hole in the fuel injection pump housing. Install tool (A) through the housing and into the notch
of the camshaft.
3. Use tool (B) and put the engine at top center compression. See TESTING AND ADJUSTING.
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4. Put automatic timing advance (2) in position on the drive shaft for the fuel injection pump.
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4. 5. Install washer (5) and bolts (4) that hold the automatic timing advance in place. Tighten bolts (4) in
the following sequence.
a) Tighten bolts (4) evenly to a torque of 35 N·m (25 lb.ft.).
b) Tighten bolts (4) evenly to a torque of 70 N·m (50 lb.ft.).
c) Tighten bolts (4) evenly to a final torque of 135 ± 7 N·m (100 ± 5 lb.ft.).
6. Install gasket (6) and cover (3) on the front cover.
7. To check for correct engine timing see INSTALL FUEL INJECTION PUMP HOUSING AND
GOVERNOR.
Disassemble Automatic Timing Advance
START BY:
a) remove automatic timing advance
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1. Remove retainer ring (2). Remove gear (1) from flange.
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5. 2. Remove springs (3) and counterweights (4) from the flange.
3. Remove slides from dowels on the flange.
Assemble Automatic Timing Advance
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1. Install slides (2) on the dowels of flange (3).
2. Put clean SAE 30 oil on the slides and counterweights. Install the counterweights (1) on the flange.
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3. Install springs (4).
4. Install the gear on the flange assembly. Install retainer ring (5) that holds the gear to the flange
assembly.
END BY:
a) install automatic timing advance

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6. Copyright 1993 - 2012 Caterpillar Inc.
Todos los derechos reservados.
Red privada para licenciados del SIS.
  Sat Jan 7 21:43:02 EST 2012
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7. Desarmado y Armado
3406 ENGINE FOR GENERATOR SET
Fuel Transfer Pump
SMCS - 1256-11 ; 1256-12 ; 1256-15 ; 1256-16
Remove Oil Transfer Pump
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NOTE: Put plugs or caps in all fuel line openings.
1. Disconnect fuel supply line (2) and fuel pressure line (1) from fuel transfer pump (3).
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2. Remove two bolts (4) that fasten the fuel transfer pump to the governor drive housing. Remove the
fuel transfer pump.
3. Remove the O-ring seal from the transfer pump and remove the gasket from between the governor
drive housing and transfer pump.
Install Fuel Transfer Pump
1. Clean the contact surfaces of the transfer pump and the governor drive housing.
Número de medio -SENR2540-00 Fecha de publicación -01/03/1983 Fecha de actualización -11/10/2001
   
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8. Ver imagen

2. Install new gasket (1) between fuel transfer pump (2) and governor drive housing. Install an O-ring
seal on the transfer pump and put the pump in position on the housing. Install the two bolts that fasten
the pump to the housing.
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3. Connect fuel pressure line (3) and fuel supply line (4) to the transfer pump.
Disassemble Fuel Transfer Pump
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START BY:
a) remove fuel transfer pump
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9. 1. Remove bolts (1). Remove cover (2) from the fuel transfer pump.
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2. Remove bolt (3). Remove gasket, spring and plunger from under bolt.
3. Remove gear (4).
4. Remove shaft assembly (5).
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5. Remove O-ring seal (7) from body assembly.
6. Install a 5/16"-18 NC forged eyebolt (6) in the plug. Remove plug (8) and O-ring seal. Remove the O-
ring seal from the plug.
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10. 7. Remove valve assembly (9).
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8. Remove two lip seals (10) from the body assembly.
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9. Remove two bearings (11) from the body assembly with tooling (A).
Assemble Fuel Transfer Pump
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11. 1. Install bearings in body (1) with tooling (A). Install bearing on gear end of body to a depth of 0.76 ±
0.51 mm (.03 ± .02 in.) below the surface of the body. Install the bearing on the opposite end of the body
even with the outside surface of the counterbore.
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2. Put 8H5137 Permatex #2 Form-A-Gasket on the outside diameter of the two seals. Use tooling (A)
and install the first seal with the lip of the seal toward the bearings and 10.31 ± 0.25 mm (.406 ± .10 in.)
below the outside surface of the body assembly. Use tooling (A) and install the second seal with the lip
of the seal away from the bearings and even with the outside surface of the body assembly. Put a small
amount of clean fuel on the lip of the seals.
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3. Install the valve assembly in the body assembly with tooling (A) to a depth of 14.5 ± 0.5 mm (.57
± .02 in.).
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12. 4. Install O-ring seal (3) on the plug. Install a 5/16"-18 NC forged eyebolt (2) in the plug. Put a small
amount of clean diesel fuel on the O-ring seal and install plug (4) in the body assembly. Make sure plug
is even with the surface of the body.
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5. Install O-ring seal on the body assembly.
6. Put a small amount of clean diesel fuel on the lip seals. Put tool (B) in position on shaft assembly.
Install shaft assembly (5) in the body assembly.
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7. Install gear (7).
8. Put 8H5137 Permatex #2 Form-A-Gasket on the body assembly surface that makes contact with the
cover. Install cover (6).
NOTICE
Do not allow the sealant to enter into the pump.
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13. 9. Shaft assembly must turn by hand after cover is installed.
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10. Install plunger (8), spring (9), gasket (11) and plug (10) in body assembly. Tighten plug to a torque
of 37 ± 4 N·m (27 ± 3 lb.ft.).
END BY:
a) install fuel transfer pump


Copyright 1993 - 2012 Caterpillar Inc.
Todos los derechos reservados.
Red privada para licenciados del SIS.
  Sat Jan 7 21:44:42 EST 2012
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14. Desarmado y Armado
3406 ENGINE FOR GENERATOR SET
Fuel Injection Lines
SMCS - 1252-11 ; 1252-12
Remove Fuel Injection Lines
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1. Remove nuts (1) and the bolts that hold fuel lines (2) in place on the engine.
2. Use tool (A) and remove fuel injection lines (2) from the fuel injection pump and cylinder head.
3. Put plugs or caps on all fuel line opening.
Install Fuel Injection Lines
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Número de medio -SENR2540-00 Fecha de publicación -01/03/1983 Fecha de actualización -11/10/2001
   
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15. 1. Put fuel injection lines (2) in position on the cylinder head and fuel injection pump. Use tool (A) and
tighten the fuel line nuts to a torque of 40 ± 7 N·m (30 ± 5 lb.ft.).
2. Install the bolts and nuts (1) that hold fuel injection lines (2) in place on the engine.


Copyright 1993 - 2012 Caterpillar Inc.
Todos los derechos reservados.
Red privada para licenciados del SIS.
  Sat Jan 7 21:45:18 EST 2012
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16. Desarmado y Armado
3406 ENGINE FOR GENERATOR SET
Fuel Injection Lines
SMCS - 1252-11 ; 1252-12
Remove Fuel Injection Lines
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1. Remove nuts (1) and the bolts that hold fuel lines (2) in place on the engine.
2. Use tool (A) and remove fuel injection lines (2) from the fuel injection pump and cylinder head.
3. Put plugs or caps on all fuel line opening.
Install Fuel Injection Lines
Ver imagen

Número de medio -SENR2540-00 Fecha de publicación -01/03/1983 Fecha de actualización -11/10/2001
   
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17. 1. Put fuel injection lines (2) in position on the cylinder head and fuel injection pump. Use tool (A) and
tighten the fuel line nuts to a torque of 40 ± 7 N·m (30 ± 5 lb.ft.).
2. Install the bolts and nuts (1) that hold fuel injection lines (2) in place on the engine.


Copyright 1993 - 2012 Caterpillar Inc.
Todos los derechos reservados.
Red privada para licenciados del SIS.
  Sat Jan 7 21:45:18 EST 2012
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18. Desarmado y Armado
3406 ENGINE FOR GENERATOR SET
Fuel Injection Pumps
SMCS - 1251-11 ; 1251-12 ; 1251-15 ; 1251-16
Remove Fuel Injection Pumps
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START BY:
a) remove fuel lines
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1. Remove the bolts, clamps and service meter (1) from the accessory drive housing.
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2. Remove the bolts, stop (3), spacer (2) and the gasket from the accessory drive housing.
Número de medio -SENR2540-00 Fecha de publicación -01/03/1983 Fecha de actualización -11/10/2001
   
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19. Ver imagen

3. Install stop (3) without the spacer and the gasket and install two 5/16"-18 NC bolts.
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4. Remove bolt (5) and disconnect linkage (4) from the lever on the governor housing.
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5. Remove felt washer (6) from the fuel injection pump.
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20. 6. Use tooling (A) and remove the bushing from the fuel injection pump.
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7. Remove seal (7) from the fuel injection pump.
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8. Move lever (9) forward to move the rack to the center position and use tool (B) and remove fuel
injection pump (8) from the fuel injection pump housing.
Install Fuel Injection Pumps
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21. Ver imagen

1. Put the groove of barrel (2) in alignment with the slot of the gear segment (the slot is on the opposite
side of the gear segment teeth).
2. Move lever (3) forward to move the rack to the center position.
3. Look inside the bore of the injection pump housing to find the dowel. Put groove of the barrel in
alignment with the dowel and put the injection pump straight down into the bore.
4. Use tool (A) and install fuel injection pump (1) in the fuel injection pump housing.
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5. Inspect for wear or damage and make a replacement if necessary of seal (4).
6. Put seal (4) in position on the fuel injection pump.
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NOTICE
The fuel rack must be in the center position before the correct
installation of an injection pump is possible.
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22. 7. Install bushing (5) that holds the fuel injection pump in the fuel injection housing. If the fuel injection
pump is in the correct position, bushing (5) will turn into the fuel injection housing by hand until the top
of the bushing is even with the fuel pump housing.
8. Use tool (B) and tighten bushing (5) to a torque of 200 ± 13 N·m (150 ± 10 lb.ft.).
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9. Put felt washer (6) in position on the fuel injection pump.
10. After each pump has been installed, check total rack travel to make sure each pump has been
installed correctly. See TESTING AND ADJUSTING.
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11. Connect linkage (7) to the lever on the governor housing.
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23. 12. Remove stop (8) from the accessory drive housing.
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13. Install spacer (9), the gasket and stop (8) on the accessory drive housing.
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14. Install service meter (10), the clamps and the bolts on the accessory drive housing.
END BY:
a) install fuel lines
Disassemble Fuel Injection Pumps
START BY:
a) remove fuel injection pumps
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24. Ver imagen

1. Pull plunger (7), washer (6) and spring (5) out of barrel (4).
2. Remove washer (6) from plunger (7).
3. Remove ring (3) and make a separation of barrel (4) from bonnet (1).
4. Remove check valve (9), seat (8) and spring (2) from bonnet (1). If the check valve assembly is
disassembled, do not mix the parts with parts from another check assembly.
Assemble Fuel Injection Pumps
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NOTICE
Be careful when the injection pumps are disassembled. Do not damage
the surfaces of the plungers, barrels and bonnets. Any scratches will
cause leakage inside the fuel injection pump. The plunger and barrel
for each pump are made as a set. Do not put the plunger of one pump
in the barrel of another pump. If one part has wear, install a complete
new pump assembly. Be careful when the plunger is put into the bore
of the barrel.
NOTICE
Do not remove the gear from the plunger. The gear and plunger are
assembled and adjusted at the factory.
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25. 1. Put spring (7), seat (9) and check valve (5) into position in bonnet (8).
2. Install bonnet (8) on barrel (4) and install ring (6) to hold them together. Do not slide bonnet (8)
across barrel (4) because the check valve assembly in the bonnet can cause damage to the face of barrel
(4).
3. Install spring (3) on barrel (4).
4. Install washer (2) on plunger (1) with the flat side toward the gear on the plunger.
5. Install plunger (1) in barrel (4) until washer (2) is engaged in the spring.
END BY:
a) install fuel injection pumps


NOTICE
Put clean fuel oil on all parts during assembly.
Copyright 1993 - 2012 Caterpillar Inc.
Todos los derechos reservados.
Red privada para licenciados del SIS.
  Sat Jan 7 21:47:18 EST 2012
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26. Desarmado y Armado
3406 ENGINE FOR GENERATOR SET
Fuel Injection Pump Housing And Governor
SMCS - 1286-11 ; 1286-12
Remove Fuel Injection Pump Housing And Governor
START BY:
a) remove fuel lines
NOTE: The photographs were taken with a Woodward Governor.
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1. Remove fuel lines (1) from the engine.
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2. Disconnect tube assembly (3) and wires (2) from the governor.
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Número de medio -SENR2540-00 Fecha de publicación -01/03/1983 Fecha de actualización -11/10/2001
   
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27. 3. Remove the bolts, the clamps and service meter (4) from the accessory drive housing.
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4. Remove bolts (5) that hold the fuel injection pump housing to the accessory drive housing.
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5. Fasten strap (7) and a hoist to fuel injection pump housing and governor (6).
6. Remove bolts (8) and fuel injection pump housing and governor (6) from the engine. The weight of
the fuel injection pump housing and governor is 39 kg (87 lb.).
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28. 7. If necessary remove seals (9) from the fuel injection pump housing.
Install Fuel Injection Pump Housing And Governor
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1. Use tool (A) and put engine at top center compression stroke. See TESTING AND ADJUSTING.
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2. Remove nuts (1) and cover (2) from the automatic timing advance.
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3. Loosen four bolts (2) that hold the automatic timing advance to the drive shaft for the fuel injection
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29. pump.
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4. Remove plug (3) from the fuel injection pump housing.
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5. Time the fuel injection pump by turning the camshaft until the notch in the camshaft is in alignment
with the hole in the fuel injection pump housing. Install tool (B) through the housing and into the notch
of the camshaft.
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6. Inspect for wear or damage and make a replacement if necessary of seals (4).
7. Put seals (4) in position on the fuel pump housing.
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30. 8. Fasten strap (6) and a hoist to fuel injection pump housing and governor (5).
9. Install gasket (7) and fuel injection pump housing and governor (5) on the accessory drive housing
and engine block with the bolts that hold it.
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10. Tighten bolts (8) of automatic timing advance (9) in the following sequence.
a) Tighten bolts (8) evenly to a torque of 35 N·m (25 lb.ft.).
b) Tighten bolts (8) evenly to a torque of 70 N·m (50 lb.ft.).
c) Tighten bolts (8) evenly to a final torque of 135 ± 7 N·m (100 ± 5 lb.ft.).
Ver imagen

11. To check for correct engine timing follow the steps below.
a) Remove tool (B) from the fuel pump housing and the bolt from the flywheel.
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31. b) Turn the flywheel counterclockwise (as seen from the front of the engine) two complete revolutions.
c) If the engine is in correct timing, tool (B) can be installed in the notch of the camshaft in the fuel
injection pump housing and the bolt can be installed in the flywheel.
d) If tool (B) and the bolt can not be correctly installed, the timing is not correct and Step 11 must be
repeated.
NOTE: The flywheel can be out of alignment ± 1° and still be in correct timing.
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12. Remove tool (B) and install plug (10) in the fuel injection pump housing.
13. Install service meter (11) on the accessory drive housing with the clamps and bolts.
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14. Install gasket (13) and cover (12) to the front cover.
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32. 15. Connect tube assembly (14) and wires (15) to the governor.
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16. Install fuel lines (16) to the block and fuel injection pump housing.
END BY:
a) install fuel lines


Copyright 1993 - 2012 Caterpillar Inc.
Todos los derechos reservados.
Red privada para licenciados del SIS.
  Sat Jan 7 21:47:45 EST 2012
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33. Desarmado y Armado
3406 ENGINE FOR GENERATOR SET
Fuel Injection Pump And Governor Drive
SMCS - 1288-11 ; 1288-12 ; 1288-15 ; 1288-16
Remove Fuel Injection Pump And Governor Drive
START BY:
a) remove automatic timing advance
b) remove fuel injection pump housing and governor
c) remove fuel transfer pump
d) remove service meter
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1. Remove four bolts (1) and the retainer that hold the fuel injection pump and governor drive to the
timing gear plate.
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2. Remove injection pump and governor drive (2) and the gasket from the front cover.
Número de medio -SENR2540-00 Fecha de publicación -01/03/1983 Fecha de actualización -11/10/2001
   
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34. Install Fuel Injection Pump And Governor Drive
1. Clean the contact surfaces of the fuel injection pump and governor drive and the front cover.
2. Install a new gasket between the fuel injection pump and governor drive and the front cover.
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3. Put the injection pump and governor drive (1) in position in the timing gear.
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4. Install retainer (2) and the four bolts that hold injection pump and governor drive to timing gear plate.
END BY:
a) install fuel injection pump housing and governor
b) install automatic timing advance
c) install service meter
d) install fuel transfer pump
Disassemble Fuel Injection Pump And Governor Drive
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35. START BY:
a) remove fuel injection pump and governor drive
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1. Remove the shaft (2) from housing (1).
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2. Remove O-ring seal (3) and retainer ring (4) from shaft (2).
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3. Use a press and tool (A) to remove bearing (5) from the shaft.
Assemble Fuel Injection Pump And Governor Drive
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36. Ver imagen

1. Heat bearing (2) to 135°C (275°F) and install on it shaft (1). Install the bearing until it makes contact
with the shoulder on the shaft.
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2. Install retainer ring (3) that holds the bearing on the shaft. Install the O-ring seal on the shaft.
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3. Install the shaft assembly in housing (4) as shown.
END BY:
a) install fuel injection pump and governor drive

Copyright 1993 - 2012 Caterpillar Inc.
Todos los derechos reservados.
Red privada para licenciados del SIS.
  Sat Jan 7 21:48:13 EST 2012
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38. Desarmado y Armado
3406 ENGINE FOR GENERATOR SET
Governor (Woodward)
SMCS - 1264-11 ; 1264-12 ; 1264-15 ; 1264-16
Remove Governor (Woodward)
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1. Remove the bolt and nut and disconnect linkage (1) from the governor.
2. Disconnect tube assembly (3) and wires (2) from the governor.
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3. Remove nuts (5), governor (4) and the gasket from the governor drive housing.
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Número de medio -SENR2540-00 Fecha de publicación -01/03/1983 Fecha de actualización -11/10/2001
   
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39. 4. Remove coupling (6) from the governor drive.
Install Governor (Woodward)
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1. Install coupling (1) on the gear in the governor drive.
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2. Make sure bushing (3) is in correct alignment with the coupling in the governor drive and install the
gasket and governor (2) on the governor drive.
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40. 3. Connect linkage (5), wires (4) and tube assembly (6) to the governor.
Disassemble Governor (Woodward)
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START BY:
a) remove governor
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1. Remove screws (2) and motor (1) from the governor.
2. Remove clutch assembly (4) and screw (3) from the governor.
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41. 3. Remove bolts (6), cover assembly (5) and the gasket from the case assembly.
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4. Remove spring (7) from the seat.
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5. Remove pin (9) and lever (8) from the spring assembly and the link assembly.
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6. Remove two bolts (13), shafts (11) and (12) and lever (10) from the case assembly.
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Spring force is present behind cover assembly (5). To prevent possible
personal injury, carefully loosen all bolts slowly and evenly to decrease
spring force.
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42. 7. Remove nut (16), seat (14) and strut (15) from lever (10).
8. Remove pin (17) from lever (10).
Ver imagen

9. Remove two blocks (19), the pin and washers (18) from the link assembly.
Ver imagen

10. Loosen bolt (21) and remove lever (20) from the shaft.
Ver imagen

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43. 11. Remove adjusting sleeves (24) and (25), the two washers, spring (22), lever (26) and link assembly
(23) from the case assembly.
Ver imagen

12. Remove cotter pin (27) and shaft (28) from lever (26).
Ver imagen

13. Remove nut (32), spacer (29), bolt (30) and shaft assembly (31) from link assembly (23).
Ver imagen

14. Remove nut (33), the washers and the piston stop from the case assembly.
Ver imagen
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44. 15. Remove power piston (34) from the case assembly.
Ver imagen

16. Use tool (A) and remove snap ring (35). Remove spring seat (36), springs (37) and piston (39) from
power piston (38).
Ver imagen

17. Remove spring assembly (40) from the ballhead assembly.
Ver imagen

18. Remove nut (41) from the valve plunger.
Ver imagen
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45. 19. Use a screwdriver to hold valve plunger (43) and remove spring seat (42).
NOTE: Count the number of turns for assembly purposes.
Ver imagen

20. Remove race (44), the bearing and the race from the valve plunger.
Ver imagen

21. Use tool (A) and remove the snap ring and ballhead (45) at the same time.
Ver imagen

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46. 22. Carefully remove cover (46) from the ballhead.
NOTE: If the cover is damaged in any way it must be replaced.
Ver imagen

23. Remove pins (48) and flyweights (47) from the ballhead.
Ver imagen

24. Remove drive cup (49) from ballhead (45).
Ver imagen

25. Remove bearing (50) from ballhead (45).
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26. If necessary, remove spring (51) from ballhead (45).
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47. Ver imagen

27. Remove bolts (54) that hold base (52) to case assembly (53).
Ver imagen

28. Hold case assembly (53) and base (52) together and turn them so the case assembly is on the top as
shown.
29. Remove case assembly (53) from base (52).
Ver imagen

30. Remove valve assembly (56) from the case assembly.
31. If necessary, remove plug (55) from the case assembly. Mark its location for assembly purposes.
Plugs are used for governor rotation and must be installed back into their original position.
Ver imagen
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48. 32. Remove pilot valve bushing (57), idler gear (60) and seal (59) from the base.
33. If necessary, remove plug (58) from the base. Mark the location of plug (58) for assembly purposes.
It must be installed back in its original location.
Ver imagen

34. Use tool (A) and remove snap ring (63) from pilot valve bushing (57).
35. Remove bushing (62) and pilot valve plunger (61) from pilot valve bushing (57).
Assemble Governor (Woodward)
Ver imagen

Ver imagen

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49. 1. Check the seal on plug (1) for wear or damage and make a replacement if necessary.
2. Plug (1) is used for governor rotation and must be installed back into its original location. Install plug
(1) into base (2).
3. Check seal (3) for wear or damage and make a replacement if necessary.
4. Install seal (3) on base (2) as shown.
Ver imagen

5. Install pilot valve plunger (5), bushing (6) and use tool (A) to install snap ring (7) in pilot valve
bushing (4).
Ver imagen

6. Install pilot valve bushing (4) and idler gear (8) in base (2) as shown.
Ver imagen

7. Put washer (10) in position on valve (11) and install valve (11) in case assembly (9).
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50. Ver imagen

8. Check the seal on plug (12) for wear or damage and make a replacement if necessary.
9. Plug (12) is used for governor rotation and must be installed back in its original location. Install plug
(12) in the case assembly.
Ver imagen

10. Put case assembly (9) in position on base (2).
Ver imagen

11. Hold the case assembly and base together and turn them around. Install three bolts (13) that hold the
base to the case assembly.
Ver imagen
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51. 12. Put spring (14) in position on ballhead (15) with the tang end of the spring up as shown. Make an
alignment and bend the end of the spring (not shown) in the groove (slot) of the ballhead (not shown).
Make sure the spring is even (flush) with the outside surface of the ballhead to prevent movement of the
spring end when the cover is installed.
Ver imagen

13. Install bearing (16) in ballhead (15). Make sure the red die side of the bearing is toward the ballhead.
Ver imagen

14. Put drive cup (17) in position on ballhead (15). Make sure the tang of the spring fits in the groove
(slot) of the drive cup.
15. Move the cup drive and the ballhead from stop to stop for correct movement.
Ver imagen
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52. 16. Put flyweights (18) in position on the ballhead and install pins (19) that hold the flyweights in place.
Ver imagen

17. Make sure cover (20) is not damaged. Install ballhead (15) in cover (20) until the lip of the cover is
even with the outside surface of the ballhead.
18. After the ballhead assembly is completed, make the following final checks.
a) The flyweights should pivot freely.
b) Move the ballhead slightly with your fingers and let go. If the spring tang is correctly installed in the
groove (slot) of the drive cup, the ballhead will move back into its original position.
Ver imagen

19. Put ballhead (15) in position on pilot valve bushing (4) and use tool (A) to install the snap ring that
holds the ballhead in place.
Ver imagen
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53. 20. Install race (23), bearing (22) and race (21) in the ballhead.
Ver imagen

21. Install spring seat (24) on pilot valve plunger (5). Use a wrench or 1P87 Adjusting Wrench to hold
the spring seat and a screwdriver to center the pilot valve plunger. For the correct centering adjustment
of the pilot valve plunger, see TESTING AND ADJUSTING.
Ver imagen

22. After pilot valve plunger has been centered, install locknut (25) and tighten it to a torque of 8 N·m
(70 lb.in.).
23. Install spring assembly (26) on the ballhead.
Ver imagen
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54. 24. Install spring (28), piston (29), spring (30), spring seat (31) and use tool (A) to install snap ring (32)
in power piston (27).
Ver imagen

25. Put power piston (27) in position in the case assembly as shown.
Ver imagen

26. Install piston stop (28) in the case assembly as shown and install the washers and the nut that hold it.
Ver imagen

27. Put lever assembly (30) in position on link assembly (29). Install the bolt, spacer (31) and nut (32).
Ver imagen
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55. 28. Install lever (35) on shaft (34). Install cotter pin (33) that hold the lever and the shaft together.
Ver imagen

29. Put spring (36) on shaft (34). Make sure spring end (37) is installed in the hole in lever (35).
30. Put link assembly (29) and lever (35) in position in the case assembly.
31. Install washers (38) and (40) on adjusting sleeves (39) and (41).
32. Install adjusting sleeves (39) and (41) in the case assembly that hold the lever and the link assembly.
Ver imagen

33. Put lever (42) in position on the shaft and tighten bolt (45).
34. Install the pin, two washers (44) and two blocks (43) on link assembly (29) as shown.
Ver imagen
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56. 35. Install pin (47) in lever (46) with the hole in the pin as shown.
Ver imagen

35. Install strut (48) in lever (46).
Ver imagen

36. Install seat (49) on strut (48) as shown.
Ver imagen

37. Install nut (50) on the strut.
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57. Ver imagen

38. Lift link assembly (29) and put lever (46) in position in the case assembly. Make sure blocks (43) are
installed in the grooves (slots) of the lever.
Ver imagen

39. Put shafts (51) and (52) in position in the case assembly that holds lever (46) in place.
Ver imagen

40. Install bolts (53) that hold the shafts in place.
Ver imagen
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58. 41. Put lever (55) with the 45° notch up in position with the forks of lever (55) between pin (54) and the
lever between the two washers. Put the opposite end of lever (55) on the spring assembly. Install pin
(56) that holds lever (55) to the spring assembly and bend it to hold it in place.
Ver imagen

42. Put gasket (59) and spring (58) in position on the case assembly and install cover assembly (57).
Ver imagen

43. Install clutch assembly (62), screw (61) and motor (60) on the governor. For the correct governor
adjustment see TESTING AND ADJUSTING.
END BY:
a) install governor

Copyright 1993 - 2012 Caterpillar Inc.
Todos los derechos reservados.
Red privada para licenciados del SIS.
  Sat Jan 7 21:48:39 EST 2012
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60. Desarmado y Armado
3406 ENGINE FOR GENERATOR SET
Governor Drive Housing (Woodward)
SMCS - 1288-11 ; 1288-12 ; 1288-15 ; 1288-16
Remove Governor Drive Housing (Woodward)
START BY:
a) remove governor
Ver imagen

NOTE: The rack extension is connected to the lever on governor drive housing (2). Carefully remove
the governor drive housing.
1. Remove bolts (1), governor drive housing (2) and the gasket from the fuel injection pump housing.
Ver imagen

2. Remove bolts (4) and support (3) from the fuel injection pump housing.
Ver imagen
Número de medio -SENR2540-00 Fecha de publicación -01/03/1983 Fecha de actualización -11/10/2001
   
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61. 3. Remove gear (5) from support (3).
Ver imagen

4. If necessary remove dowels (7) and bearing (6) from support (3).
Install Governor Drive Housing (Woodward)
Ver imagen

Ver imagen

1. Use tool group (A) and install dowels (1) in support (2) 3.81 ± 0.508 mm (.15 ± .02 in.) above the
outside surface.
2. Remove plug (3) from support (2) so that bearing (4) can correctly be installed.
3. Use tool group (A) and install bearing (4) even with the outside surface of support (2) and the oil
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62. supply hole in the bearing centered in the hole of the support.
4. Install plug (3) in support (2) and tighten the plug to a torque of 4.5 ± 0.6 N·m (40 ± 5 lb.in.).
Ver imagen

5. Put gear (5) into position in support (2) as shown.
Ver imagen

6. Put support (2) in position on fuel injection pump housing and install the bolts.
Ver imagen

7. Put gasket (8) and governor drive housing (9) in position on the fuel injection pump housing. Make
sure rack extension (6) is installed in the fork of lever (7).
END BY:
a) remove governor
Disassemble Governor Drive Housing (Woodward)
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63. START BY:
a) remove governor drive housing
Ver imagen

1. Loosen nut (3) and remove lever (1) and the key from the shaft.
2. If necessary, remove linkage (4) from lever (1).
3. Remove stud (2) from the shaft.
Ver imagen

4. Remove bolt (8) and plate (7) from the governor drive housing.
5. Remove the wire, bolt (5) and cover (6) from the governor drive housing.
Ver imagen

6. Remove switch (9) from the governor drive housing.
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64. Ver imagen

7. If necessary, remove lock (11) and nut (10) from switch (9).
Ver imagen

8. Remove pin (12) and, if necessary, dowel (13) from the governor drive housing.
Ver imagen

9. Bend lock (17) away from bolts (16) and remove bolts (16), shaft (14) and plate (15) from the
governor drive housing.
Ver imagen

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65. 10. Remove ring (18) from the shaft.
Ver imagen

11. Move lever (22) away from the spring so it is disconnected from sleeve (21).
12. Turn shaft (19) so bolt (20) can be seen for removal as shown. Remove bolt (20).
Ver imagen

13. Remove shaft (19), sleeve (21), spring (23) and lever (22) from the governor drive housing.
Ver imagen

14. Bend lock (26) away from bolts (25) and remove bolts (25) and plate (24) from lever (22).
Ver imagen
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66. 15. If necessary, remove bearings (27) and dowel (28) from the governor drive housing.
Ver imagen

16. If necessary remove seals (30) and bearings (29) from the governor drive housing.
Assemble Governor Drive Housing (Woodward)
Ver imagen

Ver imagen

1. Use tool group (A) and install bearing (3) in the governor drive housing to a diameter of 72.14 mm
(2.84 in.) from the inside face of counterbore (1) to inside face of bearing (3). Make sure the bearing is
pushed on the stamped side only.
2. Use tool group (A) and install bearing (5) in the governor drive housing to a dimension of 130.56 mm
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67. (5.14 in.) from outside surface (2) of the governor drive housing to inside face of bearing (5). Make sure
the bearing is pushed on the stamped side only.
3. Install dowel (6) in the goveror drive housing to a dimension of 28.45 mm (1.12 in.) from inside
surface (4) of the governor drive housing to the end of dowel (6).
Ver imagen

4. Use tool group (A) and install bearing (7) in the governor drive housing to a dimension of 13.46 mm
(.53 in.) from the inside face of counterbore (1) (see picture B65771X1) to the inside face of bearing (7).
Make sure the bearing is pushed on the stamped side only.
5. Use tool group (A) and install bearing (10) in the governor drive housing to a dimension of 14.73 mm
(.58 in.) from outside surface (2) of the governor drive housing to inside face of bearing (10). Make sure
the bearing is pushed on the stamped side only.
6. Use tool group (A) and install seal (8) with the lip toward the inside as shown to a dimension of 1.27
mm (.05 in.) from the inside face of counterbore (1) (see picture B65771X1) to inside face of seal (8).
7. Use tool group (A) and install seal (9) with the lip toward the inside as shown to a dimension of 2.032
mm (.08 in.) from outside surface (2) of governor drive housing to inside face of seal (9).
8. After seals (8) and (9) have been installed, put clean engine oil on the lips of the seals.
Ver imagen

9. Put plate (14) in position on lever (11) and install lock (13) and bolts (12) as shown.
10. Bend lock (13) against the flat side of the bolts as shown.
Ver imagen
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68. 11. Put spring (16) in position on sleeve (15) and make an alignment of the bolt holes as shown.
12. Put sleeve (15) and lever (11) in position in the governor drive housing and install shaft (17) as
shown.
Ver imagen

13. Make an alignment of the bolt holes in the spring, the sleeve and the shaft and install the washer and
bolt (18).
Ver imagen

14. Turn shaft (17) until lever (11) can be connected to sleeve (15).
Ver imagen
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69. 15. Install ring (19) on the shaft.
Ver imagen

16. Put shaft (20) and plate (21) in position in the governor drive housing. Make sure dowel (6) is in the
notch of plate (21).
Ver imagen

17. Install lock (23) and bolts (22) that hold the plate to the shaft.
18. Bend lock (23) against the flat side of bolts (22) as shown.
Ver imagen
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70. 19. Install pin (24) in the governor drive housing to a dimension of 1.575 mm (.062 in.) above the
outside surface.
Ver imagen

20. Install pin (25) in the governor drive housing with the chamfered end installed first and the collar
end last.
Ver imagen

21. Install lock (28) and nut (27) on switch (26).
22. Install switch (26) in the governor drive housing.
Ver imagen
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71. 23. Install cover (29) and bolt (30) in the governor drive housing.
Ver imagen

24. Install plate (34) and the bolt on the governor drive housing.
25. Install linkage (32) on lever (31).
26. Install the key and lever (31) on shaft (17) as shown.
27. Install stud (33) on the shaft.
28. See TESTING AND ADJUSTING for the correct governor drive adjustment.
END BY:
a) install governor drive housing


Copyright 1993 - 2012 Caterpillar Inc.
Todos los derechos reservados.
Red privada para licenciados del SIS.
  Sat Jan 7 21:49:20 EST 2012
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72. Desarmado y Armado
3406 ENGINE FOR GENERATOR SET
Governor (Hydramechanical)
SMCS - 1264-15 ; 1264-16
Disassemble Governor (Hydramechanical)
Ver imagen

Ver imagen

1. Remove the bolt, cover (1) and the gasket from the housing assembly.
2. Remove the bolts, nuts, covers (3) and the gaskets from plate assembly (2).
3. Remove the bolts, plate assembly (2) and the gasket from the cover assembly.
Ver imagen
Número de medio -SENR2540-00 Fecha de publicación -01/03/1983 Fecha de actualización -11/10/2001
   
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73. 4. Remove idle screw (4), bolt (6), cover assembly (7) and gasket (8) from housing assembly (5).
Ver imagen

5. Remove strainer assembly (10) and insulator (9) from cover assembly (7).
Ver imagen

6. Bend locks (12) and (15) away from bolts (11) and (16).
7. Remove bolts (11) and (16) and remove levers (13) and (14) from shaft (17).
8. Remove shaft (17) from cover assembly (7).
Ver imagen
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74. 9. Remove seals (18) and (19) from cover assembly (7).
Ver imagen

10. Remove bearings (20) and (21) from cover assembly (7).
Ver imagen

11. Remove screw (24) and collar (23) from bolt (22).
Ver imagen

12. Remove bolts (25), housing assembly (5) and the gasket from the fuel injection pump housing.
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75. Ver imagen

13. Remove torque control group (27) and valve body (26) from housing assembly (5).
Ver imagen

14. Remove seal (28) and valve (30) from valve body (26).
15. Remove seal (29) from valve (30).
Ver imagen

16. Bend lock (33) away from bolt (34) and remove the bolt from shaft (31).
17. Remove shaft (31) and lever (32) from the housing assembly.
Ver imagen
NOTICE
Make a note of the correct sequence of parts for the torque group for
assembly purposes.
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76. 18. Remove seal (35) from housing assembly (5).
Ver imagen

19. If necessary, remove plug (36) from housing assembly (5).
Ver imagen

20. Remove bearings (37) from housing assembly (5).
Ver imagen

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77. NOTE: For the correct procedure to remove the spring guide see SPECIAL INSTRUCTION Form
SMHS7356.
21. Use tooling (A) and remove the spring guide from housing assembly (5).
Ver imagen

22. Remove seat (39) and spring (38) from seat assembly (40).
Ver imagen

23. Use tool (B) and remove ring (42), piston assembly (41) and seat assembly (40) from the guide.
Ver imagen

24. Remove spacer (43), piston assembly (41) and spring (44) from the seat assembly.
Ver imagen
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78. 25. Remove spring (44) from piston assembly (41).
Ver imagen

26. Use tool (B) and remove ring (47) from piston assembly (41).
27. Remove ring (46) and spool (45) from piston assembly (41).
Ver imagen

28. Remove ring (49) and bearing (48) from the seat assembly.
Ver imagen

29. Remove bolt (50) from piston assembly (40).
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79. Ver imagen

30. Bend the tabs of lock (51) away from bolts (52).
31. Remove bolts (52) and piston assembly (53) from the fuel injection pump housing.
Ver imagen

32. Remove dowel (54) and guide (55) from the weight assembly.
Ver imagen

33. Remove lock (56) that holds weight assembly (57) to piston assembly (53).
34. Remove weight assembly (57) from piston assembly (53).
Ver imagen
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80. 35. Remove dowels (59) and weights (58) from the weight assembly.
Ver imagen

36. Remove valve (61) from the piston.
37. Remove sleeve (60) from piston assembly (53).
Ver imagen

38. Remove piston (62) and seal (63) from sleeve (60).
Assemble Governor (Hydramechanical)
Ver imagen
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81. Ver imagen

1. Put 1P808 General Purpose Lubricant in the seal groove of sleeve (2) and on seal (3).
2. Install seal (3) on sleeve (2).
3. Install piston (1) in sleeve (2) as shown.
Ver imagen

4. Install sleeve (2) and the piston in piston assembly (4).
Ver imagen
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82. 5. Install valve (5) in piston (1).
Ver imagen

6. Put weights (6) in position on weight assembly (8) and install pins (7).
7. Use a punch and move the metal (stake) around each dowel (7) to hold them in place.
8. Check to make sure weights (6) move (pivot) freely and have an end play of 0.025 to 0.178 mm (.001
to .007 in.) on dowels after assembly.
Ver imagen

9. Put weight assembly (8) in position on piston assembly (4) and install lock (9) that holds them
together.
Ver imagen
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83. 10. Put guide (10) in position on valve (5) and install the dowel that holds them together.
Ver imagen

11. Put piston assembly (4) and lock (11) in position on the fuel injection pump housing and install bolts
(12). Bend the tabs of lock (11) against the flat side of bolts (12).
Ver imagen

12. Install bolt (13) in seat assembly (14).
Ver imagen

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84. 13. Install bearing (15) and ring (16) in seat assembly (14).
Ver imagen

14. Install spool (17), ring (20) and use tool (A) to install ring (18) on piston assembly (19).
Ver imagen

15. Install spring (22) on piston assembly (19).
16. Install spring (22) on seat assembly (14).
17. Install spacer (21) in seat assembly (14).
Ver imagen

18. Put seat assembly (14) in position on weight assembly (8) and use tool (A) to install the ring that
holds the two together.
Ver imagen
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85. 19. Install spring (23) and seat (24) on seat assembly (14).
Ver imagen

NOTE: For the correct procedure to install the spring guide, see SPECIAL INSTRUCTION Form No.
SMHS7356.
20. Use tooling (B) and a press to install the spring guide in housing (25).
Ver imagen

NOTE: For the correct procedure to swage (change shape of) the end of the stem in the chamfer of the
bore in the housing see SPECIAL INSTRUCTION Form No. SMHS7356.
21. Use tooling (C) and a press to swage (change shape of) the end of the stem in housing (25).
Ver imagen
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86. 22. Use tool group (D) and install bearing (26) in housing (25) to dimension (Y) or 43.38 ± 0.15 mm
(1.708 ± .006 in.). After assembly the inside diameter of the bearing must be 15.761 ± 0.038 mm (.620
± .001 in.).
23. Use tool group (D) and install bearing (27) in the housing to dimension (X) or 60.58 ± 0.13 mm
(2.385 ± .005 in.). After assembly the inside diameter of the bearing is 15.761 ± 0.038 mm (.620 ± .001
in.).
24. Use tool group (D) and install plug (28) in housing (25) as shown.
Ver imagen

25. Use tool group (D) and install seal (29) with the lip of the seal toward the inside as shown and even
with the outside surface of the housing. Put clean engine oil on the lip of the seal.
Ver imagen
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87. 26. Put lever (31) in position in the housing and install shaft (30). Install lock (32) and bolt (33) that
hold the shaft and the lever in place. Bend the tab of the lock against the flat side of the bolt as shown.
Ver imagen

27. Inspect seals (34) and (36) for wear or damage and make a replacement if necessary.
28. Install seal (34) on body (35) and seal (36) on valve (37).
29. Install valve (37) in body (35).
Ver imagen

30. Put clean engine oil in the valve body bore of the housing and install body (35) and the valve in the
housing.
Ver imagen
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88. 31. Install torque control group (38) on housing (25). Make sure the tabs of the lock are bent against the
flat side of the bolts.
Ver imagen

32. Install the gasket and housing (25) on the fuel injection pump housing.
Ver imagen

33. Install spring (40) and collar (39) on bolt (13).
Ver imagen
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89. 34. Install seal (48) in the housing with the lip of the seal toward lever (47).
35. Use tool group (D) and install bearing (49) in the housing to dimension (O) or 92.862 mm (3.656 in.)
from the center of bore to the outside edge of the bearing as shown.
36. Use tool group (D) and install bearing (43) in the housing to dimension (P) or 98.68 mm (3.885 in.)
from the outside edge of bearing (49) to the inside edge of bearing (43).
Ver imagen

40. Install strainer (50) in cover assembly (51) as shown.
Ver imagen
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90. 41. Install gasket (52) and cover assembly (51) on housing (25).
Ver imagen

42. Inspect seal (53) for wear or damage and make a replacement if necessary.
43. Put seal (53) in position on idle adjustment screw (54) and install it in cover assembly (51).
Ver imagen

44. Install the gaskets, plate assembly (56), cover (55) and cover (57) as shown.
45. Make adjustments to the governor. See GOVERNOR ADJUSTMENTS in TESTING AND
ADJUSTING.

Copyright 1993 - 2012 Caterpillar Inc.
Todos los derechos reservados.
Red privada para licenciados del SIS.
  Sat Jan 7 21:50:01 EST 2012
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91. Page 20 of 20Service Information System
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92. Desarmado y Armado
3406 ENGINE FOR GENERATOR SET
Fuel Injection Pump Housing
SMCS - 1253-15 ; 1253-16
Disassemble Fuel Injection Pump Housing
Ver imagen

START BY:
a) remove fuel injection pump housing and governor
b) remove governor drive housing (Woodward Governor only)
c) remove governor (hydramechanical only)
1. Remove the protection caps and the felt washers from the pumps.
2. Use tool (A) to remove the bushing that holds the pumps in the fuel injection pump housing.
Ver imagen

3. Remove seal (1) from the fuel injection pump housing.
Número de medio -SENR2540-00 Fecha de publicación -01/03/1983 Fecha de actualización -11/10/2001
   
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93. Ver imagen

4. Install tool (C) on the end of the fuel injection pump housing as shown.
Ver imagen


Woodward Governor Shown
5. Move the adapter and rack (Woodward Governor) or rack (hydraulic governor) against tool (C) to
center the rack and use tool (B) to remove fuel injection pump (2) from the fuel injection pump housing.
Ver imagen

6. Remove spacer (3) from the fuel injection pump housing.
7. Repeat Steps 1-6 for removal of the remaining fuel pumps.
NOTE: Put identification on the injection pumps and spacers as to their location in the pump housing.
Ver imagen
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94. 8. Remove adapter (7) and the rack from the fuel injection pump housing (Woodward Governor only).
Remove the rack from the fuel injection pump housing (hydramechanical governor only).
9. Bend tabs of lock (5) away from bolts (4). Remove bolts (4) and guide (6) from the fuel injection
pump housing (Woodward governor only).
Ver imagen

10. Remove adapter (7) and spring (8) from rack (9) (Woodward Governor only).
Ver imagen

11. Remove lifters (10) from the fuel injection pump housing.
NOTE: Keep lifters together with identification as to their location in the pump housing.
Ver imagen
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95. 12. Bend lock (12) away from bolts (11). Remove bolts (11), locks (12), the sleeves and gear (13) from
the camshaft.
Ver imagen

13. Remove pin (16) and spring (14) from gear (13).
14. Remove pin (17) and yoke (15) from spring (14).
Ver imagen

15. Remove plate assembly (18) and the gasket from the fuel injection pump housing.
Ver imagen

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96. 16. If necessary, remove bushing (19) from the plate assembly.
Ver imagen

17. Remove bolts (21) plate (23) and spacer (22) that hold camshaft (20) in the fuel injection pump
housing.
18. Remove camshaft (20) from the fuel injection pump housing.
Ver imagen

19. If necessary use tool group (D) and remove the camshaft bearing from the automatic timing advance
end of the fuel injection pump housing.
20. If necessary, remove rack bearing (24) from the automatic timing advance end of the fuel injection
pump housing.
Ver imagen

21. If necessary remove rack bearing (25) and dowels (26) from the governor drive housing end of the
fuel injection pump housing.
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97. 22. If necessary, use tool group (D) and remove camshaft bearing (27) from the governor drive housing
end of the fuel injection pump housing and the center bearing in the fuel injection pump housing.
Assemble Fuel Injection Pump Housing
Ver imagen

Ver imagen

1. Use tooling (A) to install the camshaft bearings in fuel injection pump housing (1). Install the
camshaft bearings so that the bearing joints are ± 15° from the vertical centerline of the bores. Install the
front and rear camshaft bearings even with the outside surfaces of fuel injection pump housing (1).
Install the center camshaft bearing to a distance of 122.2 ± 0.5 mm (4.81 ± .02 in.) from rear face (X).
After assembly the inside diameter of the camshaft bearings must be 53.988 ± 0.038 mm (2.125 ± .01
in.).
Ver imagen
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98. 2. Use tooling (B) and install the rack bearing even with the outside surface of fuel injection pump
housing (1). Make sure the tab in the rack bearing is installed toward the inside and within .05 mm (.003
in.) of the vertical center line of the bearing bore. After assembly the inside diameter of the rack bearing
must be 12.758 ± 0.046 mm (.502 ± .002 in.).
Ver imagen

3. Use tool group (C) to install the rear rack bearing. Install the rack bearing to a depth of 7.16 ± 0.13
mm (.282 ± .005 in.) below the outside surface. The small holes in the rear rack bearing must be
installed parallel to the vertical centerline of the bearing bore. After assembly the inside diameter of the
bearing must be 12.746 ± .046 mm (0.502 ± 0.002 in.).
4. Install dowels (2) in the fuel injection pump housing 15.7 ± 0.5 mm (0.618 ± 0.02 in.) above the
outside surface.
Ver imagen

5. Put clean engine oil on camshaft (3) and carefully install it in the fuel injection pump housing.
6. Install spacer (4), plate (5) and the bolts that hold camshaft (3) in place.
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99. Ver imagen

7. Make sure all gasket surfaces are clean and free of dirt.
8. Put gasket (6) in position on the fuel injection pump housing.
Ver imagen

9. Use tool group (C) and install bushing (8) in plate assembly (7) even with outside surface (X).
10. Put plate assembly (7) in position on the fuel injection pump housing as shown.
Ver imagen

11. Install yoke (10) on spring (9) and install the pin that holds them together.
12. Install spring (9) on gear (11) and install the pin that holds them together.
Ver imagen
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100. Woodward Governor Shown
NOTE: Steps 13, 18, 20, 22, 23, 28, and 29 have the guide shown for Woodward Governor only.
13. Install gear (11), lock (14) and the bolts on the end of the camshaft. Bend lock (14) against the bolts.
14. Install guide (12), lock (13) and the bolts on the plate assembly. Bend the tabs of lock (13) against
the bolts (Woodward Governor only).
Ver imagen

15. Install spacers (15) with their respective lifters (16) in the pump housing. If new lifters and/or pumps
are to be installed, make adjustment of the fuel pump timing dimension. See SETTING THE
INJECTION PUMP TIMING DIMENSION: OFF ENGINE TESTING AND ADJUSTING.
Ver imagen

16. Install spring (17) and adapter (18) on rack (19) (Woodward Governor only).
Ver imagen
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101. 17. Put adapter (18) and the rack in position in the fuel injection pump housing (Woodward Governor
only).
18. Put the rack in position in the fuel injection pump housing (hydramechanical governor only).
Ver imagen

19. Install tool (D) on the fuel injection pump housing.
Ver imagen

20. Move adapter (18) and the rack against tool (D) to center the rack (Woodward Governor only).
21. Move the rack against tool (D) to center the rack (hydramechanical governor only).
NOTICE
The plunger from one pump can not be installed in another pump. Do
not install the pumps until the rack is in center position (centered).
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102. 22. Use tool (E) and install fuel pump (21) in its respective bore in the fuel injection pump housing.
23. Make sure groove (slot) (24) in the gear and groove (23) in the barrel are in alignment with pin (20)
in the lifter and dowel (22) in the fuel injection pump housing.
Ver imagen

24. Inspect seal (25) for wear or damage and make a replacement if necessary.
25. Install seal (25) in the fuel injection pump housing.
Ver imagen

26. Put pressure by hand on tool (E). Tighten bushing (26) by hand (finger tight only) until the bushing
is even with the top of the fuel injection pump housing. If the bushing can not be installed by hand,
remove the bushing and the fuel pump and repeat Steps 20-25.
27. If the rack movement (travel) is correct (see Step 28). Use tool (F) to tighten bushing (26) to a torque
of 200 ± 13 N·m (150 ± 10 lb.ft.).
Ver imagen
NOTICE
Do not put force on bushings with a wrench to make them even with
pump housing. Pump is not installed correctly if a force has to be used
to install bushing.
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103. 28. Use tooling (G) to check the rack movement (travel) after each fuel pump is installed. Total rack
movement (travel) must be 20.32 mm (.800 in.). See INSTALLATION OF FUEL INJECTION PUMPS
in TESTINA AND ADJUSTING.
29. Install felt washer (27) and protective cap (28) on the fuel pumps.
30. To install remaining fuel pumps repeat Steps 20-29.
END BY:
a) install fuel injection pump housing
b) install governor drive housing (Woodward Governor)
c) assemble governor (hydramechanical governor)


Copyright 1993 - 2012 Caterpillar Inc.
Todos los derechos reservados.
Red privada para licenciados del SIS.
  Sat Jan 7 21:50:44 EST 2012
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104. Desarmado y Armado
3406 ENGINE FOR GENERATOR SET
Fuel Injection Valves
SMCS - 1254-11 ; 1254-12
Remove Fuel Injection Valves
Ver imagen

START BY:
a) remove valve cover bases
Ver imagen

1. Use tool (A) to disconnect the fuel line assemblies from the cylinder head.
2. Disconnect fuel line assemblies (1) from the fuel injection valves and remove them from the engine.
Install covers on all fuel line connections to keep dirt or foreign material out of the fuel system.
Ver imagen
Número de medio -SENR2540-00 Fecha de publicación -01/03/1983 Fecha de actualización -11/10/2001
   
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105. 3. Remove nut (2) that holds the fuel injection valve to the adapter assembly.
Ver imagen

4. Use tool (B) to remove the fuel injection valves.
5. If the fuel injection valves can not be removed with tool (B), use tooling (C).
Ver imagen

6. Remove nozzles assembly (3) from body (4).
7. Remove seal (5) from the body.
Install Fuel Injection Valves
Ver imagen
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106. Ver imagen

1. Use tool (A) to install seal (2) on valve body (1).
Ver imagen

2. Install nozzle assembly (3) on the valve body. Tighten nozzle finger tight only.
3. Put a small amount of clean diesel fuel on the seal and install the fuel injection valves in the adapter
assemblies.
4. Install the nut that holds the fuel injection valves and tighten to a torque of 75 ± 7 N·m (55 ± 5 lb.ft.).
Ver imagen
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107. 5. Remove the covers from the fuel line connections. Put fuel line assemblies (4) in position on the
engine. Use tool (B) to tighten the fuel line nuts on the cylinder head adapter assembly.
Ver imagen

6. Use tool (C) to tighten fuel line nuts to a torque of 40 ± 7 N·m (30 ± 5 lb.ft.).
END BY:
a) install valve covers and bases


Copyright 1993 - 2012 Caterpillar Inc.
Todos los derechos reservados.
Red privada para licenciados del SIS.
  Sat Jan 7 21:51:09 EST 2012
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108. Ver imagen


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109. 3406 GENERATOR SET ENGINE
Número de medio - SEBP1369-00     |     Fecha de publicación -
01/03/1983     |     Fecha de actualización - 06/10/2001
   
7N1219 FUEL INJECTION PUMP GROUP
PART OF 7N1256 FUEL INJECTION PUMP GROUP SHOWN ON PAGE 178
 GRUPO ENTERO
 Ref.Cant.  NPRNota  No. de pieza   Nombre de la pieza  
 Grp   NPR   7N-1219    PUMP GP-FUEL INJECTION
 
 PIEZAS INDIVIDUALES
Ref.Cant.  NPRNota  No. de pieza
Cant.
req.
Nombre de la pieza  
 1    NPR   9L-6892  1 COLLAR-CHECK VALVE  
 2    NPR   6N-0024  1 SPRING  
 3    NPR   9L-6893  1 BONNET-VALVE  
 4    NPR   9N-0593  1 CHECK AS-PUMP  
 5    NPRCL  7W-1927  1 RING-RETAINER  
 CL   NPR   387-2935  1
    RING-RET-CLA
    
 
 6    NPR   7N-1220  1 PLUNGER AS-PUMP  
 7    NPR   7N-1208  1 SPRING-LIFTER  
 8    NPRC  7N-1066  1 WASHER-RETAINER  
 
 Abreviaturas:  
 
 CL - Pieza Classic disponible  
 C - CHANGE FROM PREVIOUS TYPE  

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Todos los derechos reservados.
Red privada para licenciados del SIS.
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GRAFICO #1
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113. 3406 GENERATOR SET ENGINE
Número de medio - SEBP1369-00     |     Fecha de publicación -
01/03/1983     |     Fecha de actualización - 06/10/2001
   
7N1256 FUEL INJECTION PUMP GROUP
PART OF 7N1258 & 7N1259 GOVERNOR & FUEL INJECTION PUMP GROUPS
SHOWN ON
PAGES 171 & 172. 7N1219 PUMP PARTS ARE SHOWN ON PAGE 182
 GRUPO ENTERO
 Ref.Cant.  NPRNota  No. de pieza   Nombre de la pieza  
 Grp   NPR   7N-1256    PUMP GP-FUEL INJECTION
 
 PIEZAS INDIVIDUALES
Ref.Cant.  NPRNota  No. de pieza
Cant.
req.
Nombre de la pieza  
 1    NPR   1M-1077  6 SEAL-O-RING  
 2    NPR   2M-4314  6 BUSHING  
 3    NPR   8H-9204  6 WASHER-FELT  
 4    NPRB  4N-9844  6 
SPACER
5.67MM(.223IN)THK
 
 5    NPR   4N-7354  1 SPACER  
 6    NPR   9S-4181  1 PLUG-O-RING  
 7    NPR   7M-8485  1 SEAL-O-RING  
 8    NPR   2P-8617  1 RACK-REGULATOR  
 9    NPRY  7N-1219  6 PUMP GP-FUEL INJECTION  
 10    NPR   4N-7353  1 PLATE-THRUST  
 11    NPRC  4W-0736  6 LIFTER AS  
 12    NPR   0S-1618  4 BOLT  
 13    NPR   7F-8036  1 LOCK  
 14    NPR   9M-1974  2 WASHER  
     NPR   6N-1172  2 SLEEVE  
 15    NPR   4N-0631  1 GEAR AS-FLEXIBLE DRIVE  
     NPR   4N-0629  1 
    GEAR-GOVERNOR DRIVE
    
    (72 TEETH)
 
 16    NPR   4N-2483  1 
    SPRING-LEAF
    
 
 17    NPR   4N-4051  1 
    YOKE
    
 
 18    NPR   6D-9953  2 
    PIN-SPRING
    
 
 19    NPR   4N-0627  1 
    PIN
    
 
 20    NPR   6N-1483  1 CAMSHAFT AS-PUMP  
 21    NPR   9F-7882  1 
    PIN-SPRING
    
 
               
 22    NPR   6N-4448  1 HOUSING AS-FUEL PUMP  
 23    NPR   4B-9782  1 
    BALL
 
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114.     
 24    NPR   4M-1474  3 
    PIN-LIFTER GUIDE
    
 
 25    NPR   9S-4160  1 
    BEARING-SLEEVE
    
 
 26    NPR   1S-1953  1 
    BEARING-RACK
    
 
 27    NPR   1P-0232  6 
    BALL
    
 
     NPR   1P-0234  6 
    DOWEL
    
 
 28    NPR   1S-7101  2 
    BEARING-SLEEVE
    
 
 29    NPRC  9F-2247  1 
    PLUG
    
 
 30    NPR   9S-9702  2 
    DOWEL
    
 
 31    NPR   1S-7103  1 
    BEARING-SLEEVE
    
 
 32    NPR   5M-6214  3 
    PLUG-PIPE
    
    (PIPE)
 
  - OR -   
     NPRC  1N-5999  3 
PLUG
(STR THREAD)
 
     NPRC  7J-0204  3 SEAL-O-RING  
 33    NPRB  4N-9837  6 
SPACER
4.96MM(.195IN)THK
 
     NPRB  4N-9838  6 
SPACER
5.06MM(.199IN)THK
 
     NPRB  4N-9839  6 
SPACER
5.16MM(.203IN)THK
 
     NPRB  4N-9840  6 
SPACER
5.26MM(.207IN)THK
 
     NPRB  4N-9841  6 
SPACER
5.36MM(.211IN)THK
 
     NPRB  4N-9842  6 
SPACER
5.47MM(.215IN)THK
 
     NPRB  4N-9843  6 
SPACER
5.57MM(.219IN)THK
 
 
 Abreviaturas:  
 
 B - USE AS REQUIRED  
 C - CHANGE FROM PREVIOUS TYPE  
 Y - SEPARATE ILLUSTRATION  

Copyright 1993 - 2012 Caterpillar Inc.
Todos los derechos reservados.
Red privada para licenciados del SIS.
  Sun Jan 8 17:38:37 EST 2012
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