Injection Pump Cat 3406

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Modelo: 3406 GEN SET ENGINE 75Z

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Service Information System

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Desarmado y Armado 3406 ENGINE FOR GENERATOR SET Número de medio -SENR2540-00

Fecha de publicación -01/03/1983

Fecha de actualización -11/10/2001

Automatic Timing Advance SMCS - 1272-11 ; 1272-12 ; 1272-15 ; 1272-16

Remove Automatic Timing Advance Ver imagen

1. Remove nuts (1), cover (2) and the gasket from the timing gear cover. Ver imagen

2. Remove bolts (3), washer (4) and automatic timing advance (5) from the engine.

Install Automatic Timing Advance Ver imagen

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Ver imagen

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

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. Ver imagen

4. Put automatic timing advance (2) in position on the drive shaft for the fuel injection pump. Ver imagen



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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 Ver imagen

1. Remove retainer ring (2). Remove gear (1) from flange. Ver imagen



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2. Remove springs (3) and counterweights (4) from the flange. 3. Remove slides from dowels on the flange.

Assemble Automatic Timing Advance Ver imagen

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. Ver imagen

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



Copyright 1993 - 2012 Caterpillar Inc. Todos los derechos reservados. Red privada para licenciados del SIS.

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Sat Jan 7 21:43:02 EST 2012



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Fuel Transfer Pump SMCS - 1256-11 ; 1256-12 ; 1256-15 ; 1256-16

Remove Oil Transfer Pump Ver imagen

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). Ver imagen

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.



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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. Ver imagen

3. Connect fuel pressure line (3) and fuel supply line (4) to the transfer pump.

Disassemble Fuel Transfer Pump Ver imagen

START BY: a) remove fuel transfer pump Ver imagen



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1. Remove bolts (1). Remove cover (2) from the fuel transfer pump. Ver imagen

2. Remove bolt (3). Remove gasket, spring and plunger from under bolt. 3. Remove gear (4). 4. Remove shaft assembly (5). Ver imagen

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 Oring seal from the plug. Ver imagen



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7. Remove valve assembly (9). Ver imagen

8. Remove two lip seals (10) from the body assembly. Ver imagen

9. Remove two bearings (11) from the body assembly with tooling (A).

Assemble Fuel Transfer Pump Ver imagen

Ver imagen



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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. Ver imagen

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. Ver imagen

3. Install the valve assembly in the body assembly with tooling (A) to a depth of 14.5 ± 0.5 mm (.57 ± .02 in.). Ver imagen



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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. Ver imagen

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. Ver imagen

7. Install gear (7).

NOTICE Do not allow the sealant to enter into the pump.

8. Put 8H5137 Permatex #2 Form-A-Gasket on the body assembly surface that makes contact with the cover. Install cover (6).



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9. Shaft assembly must turn by hand after cover is installed. Ver imagen

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


Sat Jan 7 21:44:42 EST 2012



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Fuel Injection Lines SMCS - 1252-11 ; 1252-12

Remove Fuel Injection Lines Ver imagen

Ver imagen

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



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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.


Sat Jan 7 21:45:18 EST 2012



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Fuel Injection Lines SMCS - 1252-11 ; 1252-12

Remove Fuel Injection Lines Ver imagen

Ver imagen

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



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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.


Sat Jan 7 21:45:18 EST 2012



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Fuel Injection Pumps SMCS - 1251-11 ; 1251-12 ; 1251-15 ; 1251-16

Remove Fuel Injection Pumps Ver imagen

START BY: a) remove fuel lines Ver imagen

1. Remove the bolts, clamps and service meter (1) from the accessory drive housing. Ver imagen

2. Remove the bolts, stop (3), spacer (2) and the gasket from the accessory drive housing.



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Ver imagen

3. Install stop (3) without the spacer and the gasket and install two 5/16"-18 NC bolts. Ver imagen

4. Remove bolt (5) and disconnect linkage (4) from the lever on the governor housing. Ver imagen

5. Remove felt washer (6) from the fuel injection pump. Ver imagen



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6. Use tooling (A) and remove the bushing from the fuel injection pump. Ver imagen

7. Remove seal (7) from the fuel injection pump. Ver imagen

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 Ver imagen



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NOTICE The fuel rack must be in the center position before the correct installation of an injection pump is possible.

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. Ver imagen

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. Ver imagen



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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.). Ver imagen

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. Ver imagen

11. Connect linkage (7) to the lever on the governor housing. Ver imagen



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12. Remove stop (8) from the accessory drive housing. Ver imagen

13. Install spacer (9), the gasket and stop (8) on the accessory drive housing. Ver imagen

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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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.

Ver imagen

1. Pull plunger (7), washer (6) and spring (5) out of barrel (4). 2. Remove washer (6) from plunger (7).

NOTICE Do not remove the gear from the plunger. The gear and plunger are assembled and adjusted at the factory.

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 Ver imagen



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NOTICE Put clean fuel oil on all parts during assembly.

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


Sat Jan 7 21:47:18 EST 2012



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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. Ver imagen

1. Remove fuel lines (1) from the engine. Ver imagen

2. Disconnect tube assembly (3) and wires (2) from the governor. Ver imagen



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3. Remove the bolts, the clamps and service meter (4) from the accessory drive housing. Ver imagen

4. Remove bolts (5) that hold the fuel injection pump housing to the accessory drive housing. Ver imagen

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.). Ver imagen



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7. If necessary remove seals (9) from the fuel injection pump housing.

Install Fuel Injection Pump Housing And Governor Ver imagen

1. Use tool (A) and put engine at top center compression stroke. See TESTING AND ADJUSTING. Ver imagen

2. Remove nuts (1) and cover (2) from the automatic timing advance. Ver imagen

3. Loosen four bolts (2) that hold the automatic timing advance to the drive shaft for the fuel injection



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pump. Ver imagen

4. Remove plug (3) from the fuel injection pump housing. Ver imagen

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. Ver imagen

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. Ver imagen



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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. Ver imagen

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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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. Ver imagen

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. Ver imagen

14. Install gasket (13) and cover (12) to the front cover. Ver imagen



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15. Connect tube assembly (14) and wires (15) to the governor. Ver imagen

16. Install fuel lines (16) to the block and fuel injection pump housing. END BY: a) install fuel lines


Sat Jan 7 21:47:45 EST 2012



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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 Ver imagen

1. Remove four bolts (1) and the retainer that hold the fuel injection pump and governor drive to the timing gear plate. Ver imagen

2. Remove injection pump and governor drive (2) and the gasket from the front cover.



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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. Ver imagen

3. Put the injection pump and governor drive (1) in position in the timing gear. Ver imagen

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 Ver imagen



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START BY: a) remove fuel injection pump and governor drive Ver imagen

1. Remove the shaft (2) from housing (1). Ver imagen

2. Remove O-ring seal (3) and retainer ring (4) from shaft (2). Ver imagen

3. Use a press and tool (A) to remove bearing (5) from the shaft.

Assemble Fuel Injection Pump And Governor Drive https://sis.cat.com/sisweb/sisweb/techdoc/content.jsp?calledpage=/sisweb/sisweb/product... 07/01/2012


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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. Ver imagen

2. Install retainer ring (3) that holds the bearing on the shaft. Install the O-ring seal on the shaft. Ver imagen

3. Install the shaft assembly in housing (4) as shown. END BY: a) install fuel injection pump and governor drive


Sat Jan 7 21:48:13 EST 2012



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Governor (Woodward) SMCS - 1264-11 ; 1264-12 ; 1264-15 ; 1264-16

Remove Governor (Woodward) Ver imagen

1. Remove the bolt and nut and disconnect linkage (1) from the governor. 2. Disconnect tube assembly (3) and wires (2) from the governor. Ver imagen

3. Remove nuts (5), governor (4) and the gasket from the governor drive housing. Ver imagen



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4. Remove coupling (6) from the governor drive.

Install Governor (Woodward) Ver imagen

1. Install coupling (1) on the gear in the governor drive. Ver imagen

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. Ver imagen



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3. Connect linkage (5), wires (4) and tube assembly (6) to the governor.

Disassemble Governor (Woodward) Ver imagen

START BY: a) remove governor Ver imagen

1. Remove screws (2) and motor (1) from the governor. 2. Remove clutch assembly (4) and screw (3) from the governor. Ver imagen



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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. 3. Remove bolts (6), cover assembly (5) and the gasket from the case assembly. Ver imagen

4. Remove spring (7) from the seat. Ver imagen

5. Remove pin (9) and lever (8) from the spring assembly and the link assembly. Ver imagen

6. Remove two bolts (13), shafts (11) and (12) and lever (10) from the case assembly. Ver imagen



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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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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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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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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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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). Ver imagen

26. If necessary, remove spring (51) from ballhead (45).



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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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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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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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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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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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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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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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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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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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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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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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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


Sat Jan 7 21:48:39 EST 2012



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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



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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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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)



Page 4 of 12

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.



Page 5 of 12

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



Page 6 of 12

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



Page 7 of 12

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



Page 8 of 12

(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



Page 9 of 12

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



Page 10 of 12

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



Page 11 of 12

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



Page 12 of 12

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


Sat Jan 7 21:49:20 EST 2012



Page 1 of 20




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



Page 2 of 20

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



Page 3 of 20

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.



Page 4 of 20

Ver imagen

NOTICE Make a note of the correct sequence of parts for the torque group for assembly purposes.

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



Page 5 of 20

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



Page 6 of 20

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



Page 7 of 20

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).



Page 8 of 20

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



Page 9 of 20

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



Page 10 of 20

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



Page 11 of 20

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



Page 12 of 20

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



Page 13 of 20

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



Page 14 of 20

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



Page 15 of 20

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



Page 16 of 20

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



Page 17 of 20

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



Page 18 of 20

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



Page 19 of 20

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.


Sat Jan 7 21:50:01 EST 2012



Page 20 of 20



Page 1 of 12




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.



Page 2 of 12

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



Page 3 of 12

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



Page 4 of 12

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



Page 5 of 12

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.



Page 6 of 12

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



Page 7 of 12

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.



Page 8 of 12

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



Page 9 of 12

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



Page 10 of 12

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

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).

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).



Page 11 of 12

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.

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.

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



Page 12 of 12

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)


Sat Jan 7 21:50:44 EST 2012



Page 1 of 4




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



Page 2 of 4

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



Page 3 of 4

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



Page 4 of 4

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


Sat Jan 7 21:51:09 EST 2012


Page 1 of 1

Ver imagen Gráfio y contenido

GRAFICO #1 c236476

https://sis.cat.com/sisweb/sisweb/partlist/consistlistimagesframe.jsp?calledpage=/sisweb/... 07/01/2012

Page 1 of 1

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. Grp

NPR Nota NPR

No. de pieza

Nombre de la pieza

7N-1219

PUMP GP-FUEL INJECTION

PIEZAS INDIVIDUALES Ref. Cant.

NPR Nota

No. de pieza

Cant. Nombre de la pieza req.

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

NPR CL

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

NPR C

7N-1066

1

WASHER-RETAINER

Abreviaturas: CL - Pieza Classic disponible C - CHANGE FROM PREVIOUS TYPE


Sat Jan 7 21:54:57 EST 2012

https://sis.cat.com/sisweb/sisweb/partlist/consistlist.jsp?calledpage=/sisweb/sisweb/produ... 07/01/2012

Page 1 of 1

https://sis.cat.com/sisfiles/c21/768/c217681.gif

07/01/2012

Page 1 of 1

Ver imagen Gráfico sólo

GRAFICO #1 c222742


Page 1 of 1


GRAFICO #1 c413079


Page 1 of 2

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. Grp

NPR Nota NPR

No. de pieza

Nombre de la pieza

7N-1256


PIEZAS INDIVIDUALES Ref. Cant.

NPR Nota

No. de pieza

Cant. Nombre de la pieza req.

1

NPR

1M-1077

6

SEAL-O-RING

2

NPR

2M-4314

6

BUSHING

3

NPR

8H-9204

6

WASHER-FELT

4

NPR B

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

NPR Y

7N-1219

6


10

NPR

4N-7353

1

PLATE-THRUST

11

NPR C

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

GEAR-GOVERNOR DRIVE (72 TEETH) SPRING-LEAF YOKE PIN-SPRING PIN

NPR

4N-0629

1

16

NPR

4N-2483

1

17

NPR

4N-4051

1

18

NPR

6D-9953

2

19

NPR

4N-0627

1

20

NPR

6N-1483

1

CAMSHAFT AS-PUMP

NPR

9F-7882

1

PIN-SPRING

22

NPR

6N-4448

1

HOUSING AS-FUEL PUMP

23

NPR

4B-9782

1

BALL

21


Page 2 of 2

24

NPR

4M-1474

3

25

NPR

9S-4160

1

26

NPR

1S-1953

1

27

NPR

1P-0232

6

NPR

1P-0234

6

28

NPR

1S-7101

2

29

NPR C

9F-2247

1

30

NPR

9S-9702

2

31

NPR

1S-7103

1

32

NPR

5M-6214

3

PIN-LIFTER GUIDE BEARING-SLEEVE BEARING-RACK BALL DOWEL BEARING-SLEEVE PLUG DOWEL BEARING-SLEEVE PLUG-PIPE (PIPE)

- OR -

NPR C

1N-5999

3

PLUG (STR THREAD)

NPR C

7J-0204

3

SEAL-O-RING

33

NPR B

4N-9837

6

NPR B

4N-9838

6

NPR B

4N-9839

6

NPR B

4N-9840

6

NPR B

4N-9841

6

NPR B

4N-9842

6

NPR B

4N-9843

6

SPACER 4.96MM(.195IN)THK SPACER 5.06MM(.199IN)THK SPACER 5.16MM(.203IN)THK SPACER 5.26MM(.207IN)THK SPACER 5.36MM(.211IN)THK SPACER 5.47MM(.215IN)THK SPACER 5.57MM(.219IN)THK

Abreviaturas:

B - USE AS REQUIRED C - CHANGE FROM PREVIOUS TYPE Y - SEPARATE ILLUSTRATION


Sun Jan 8 17:38:37 EST 2012


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GRAFICO #1 c182354


Injection Pump Cat 3406

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