Caterpillar 3408 3412 Specification Manual Abby

CATERPILLAR S E N R 2 5 6 1 -0 1
BDC From th e L ib ra ry of Barrington Diesel Club
Page 1 of 159 pages
Specification
3408 & 3412 GENERATOR SET ENGINES
S/N: 81Z00001-04999
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3408 & 3412G EN E R ATO R SET ENGINES S E N R256 1-0 1
CATERPILLAR'
Specifications
Media N u m b e r -S E N R 2 5 6 1 -0 1 Publication D ate -0 1 / 0 2 / 2 0 0 1 Date U pdated -1 5 / 1 0 / 2 0 0 1
Introduction
The specifications given in this book are on the basis of information available at the time it was
written. The specifications torques, pressures of operation, measurements, adjustments and other
items can change at any time. These changes can effect the service given to the product. Get the
complete and most current information before you start any job. Caterpillar Dealers have the most
current information which is available. For a list of the most current modules and form numbers
available for each Service Manual, see the SERVICE MANUAL CONTENTS MICROFICHE
REG1139F.
When the words "use again" are in the description, the specification given can be used to determine
if a part can be used again. If the part is equal to or within the specification given, use the part again.
When the word "permissible" is in the description, the specification given is the "maximum or
minimum" tolerance permitted before adjustment, repair and/or new parts are needed.
A comparison can be made between the measurements of a worn part, and the specifications of a
new part to find the amount of wear. A part that is worn can be safe to use if an estimate of the
remainder of its service life is good. If a short service life is expected, replace the part.
N O TE: For Systems Operation and Testing and Adjusting, make reference to 3408 & 3412
Generator Set Engines, Form No. SENR2562.
2
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR'
Specifications
Media N u m b e r -S E N R 2 5 6 1 -0 1 Publication D ate -0 1 / 0 2 / 2 0 0 1 Date Updated -1 5 / 1 0 / 2 0 0 1
Engine Design
(3408)
CYLINDER AND VALVE LOCATION
Bore ... 137.2 mm (5.40 in.)
Stroke ... 152.4 mm (6.00 in.)
Arrangement and Number of Cylinders ... 65° V-8
Valves per Cylinder ... 4
Combustion ... Direct Injection
Firing Order (Injection Sequence) ... 1,8,4,3,6,5,7,2
Rotation of Crankshaft (when seen from flywheel end) ... counterclockwise
Rotation of Fuel Pump Camshaft (when seen from pump drive end) ... counterclockwise
N O TE: Front end of engine is opposite to flywheel end.
3
Left side and right side of engine are as seen from flywheel end.
No. 1 cylinder is the front cylinder on the left side.
No. 2 cylinder is the front cylinder on the right side.
4
CATERPILLAR'
Specifications
Media N u m b e r -S E N R 2 5 6 1 -0 1 Publication D ate -0 1 / 0 2 / 2 0 0 1 Date Updated -1 5 / 1 0 / 2 0 0 1
Engine Design
(3412)
CYLINDER AND VALVE LOCATION
Bore ... 137.2 mm (5.40 in.)
Stroke ... 152.4 mm (6.00 in.)
Arrangement and Number of Cylinders ... 65° V-12
Valves per Cylinder ... 4
Combustion ... Direct Injection
Firing Order (Injection Sequence) ... 1,4,9,8,5,2,11,10,3,6,7,12
Rotation of Crankshaft (when seen from flywheel end) ... counterclockwise
5
Rotation of Fuel Pump Camshaft (when seen from pump drive end) ... counterclockwise
NO TE: Front end of engine is opposite to flywheel end.
Left side and right side of engine are as seen from flywheel end.
No. 1 cylinder is the front cylinder on the left side.
No. 2 cylinder is the front cylinder on the right side.
6
CATERPILLAR'
Specifications
Fuel System Identification

(3408)
FUEL INJECTION PUMP AND GOVERNOR DRIVE
(1) Location of stamped part number on Fuel Injection Pump and Governor Group or Drive.
7
3408 FUEL SYSTEM WITH

CATERPILLAR DASHFOT GOVERNORS
Inj. Pump Inj.
Engine A Pump
Arrangement Gov. Grp. or Dr. Group
1W9405
1W9408
8N9268
1W9417
1W9420
7N6389
1W9404
1W9407
6N9348
1W9416
1W9419
PUMP GROUPS WITH STEEL LIFTERS
1W9398
1W9401 7N8235
2W4981
9N3328
1W9399
1W9402 , 7N8236
2W4980
PUMP GROUPS WITH ALUMINUM LIFTERS
8
FUEL INJECTION PUMP AND GOVERNOR GROUP

WOODWARD PSG GOVERNORS
Inj. Pump Inj.
Engine A Pump
1W9403
1W9406 8N9453
8N3749
1W9415
1W9418
1W9397
1W9400 7N1242 7N1241
2W4982
9
CATERPILLAR'
Specifications
Media N u m b e r -S E N R 2 5 6 1 -0 1 Publication D ate -0 1 / 0 2 / 2 0 0 1 Date U pd ated -1 5 / 1 0 / 2 0 0 1
Fuel System Identification

(3412)
FUEL INJECTION PUMP AND GOVERNOR DRIVE GROUP
(1) Location of stamped part number on Fuel Injection Pump and Governor Group or Drive.
10

CATERPILLAR DASHPOT GOVERNORS
tnj. Pump Inj.
Engine A Pump
1W9597
1W9G00
1W9603 1W4931
1W9604
1W96Q1 1W4932 7N6390
1W9606
1W7561
1W96Q9
1W9607
1W7560
1W9610
•1W9611
1N4752 1N4578
MW9613
PUMP GROUPS w rm STEEL l if t e r s
1W9591
1W9594 7N8240
2W161 7N7577
1W9592
7N8241
1W9595
PUMP QROUPS WITH ALUMINUM LIFTERS
*3412-1200 rpm low speed engine arrangements
11
FUEL INJECTION PUMP AND GOVERNOR GROUP

WOODWARD PSQ GOVERNORS
Inj. Pump Inj.
Engine A Pump
IW9596
1W9599
1W9602
1W2191 1W945
1W9605
1W9608
2W7900
MW9612
•1W9614 1W2193 1W2192

1W9590
1W9593 7N1252 7N1251
2W4011
*3412-1200 rpm low speed engine arrangements
12
CATERPILLAR'
Specifications
Media N u m b e r -S E N R 2 5 6 1 -0 1 Publication D ate -0 1 / 0 2 / 2 0 0 1 D ate Updated -1 5 / 1 0 / 2 0 0 1
Fuel Injection
13
A-5P4158 GAUGE
3408 Firing order (injection sequence) ... 1,8,4,3,6,5,7,2,
Injection timing before TC (top center) ... 28 ± 1°
3412 Firing order (injection sequence) ... 1,4,9,8,5,2,11,10,3,6,7,12
Injection timing before TC (top center):
Standard Engine ... 30 ± 1°
Low Speed Engine ... 22.5 ± 1°
NO TE: Make reference to FUEL SYSTEM CHART in FUEL SYSTEM IDENTIFICATION section
to find specific arrangements.
(1) Torque for bushing ... 205 ± 14 N m (150 ± 10 lb.ft.)
(2) 6N24 Spring:
Length under test force ... 9.53 mm (.375 in.)
Test force ... 56 ± 3 N (12.5 ± .6 lb.)
Free length after test ... 13.03 mm (.513 in.)
14
Outside diameter ... 11.68 ± 0.13 mm (.460 ± .005 in.)
(3) Thickness of spacers:
9N6496 Spacer ... 4.12 mm (.162 in.)
9N6495 Spacer ... 4.22 mm (.166 in.)
5M2697 Spacer ... 4.32 mm (.170 in.)
2M4208 Spacer ... 4.42 mm (.174 in.)
2M4209 Spacer ... 4.52 mm (.178 in.)
2M4210 Spacer ... 4.62 mm (.182 in.)
2M4211 Spacer ... 4.72 mm (.186 in.)
2M4212 Spacer ... 4.83 mm (.190 in.)
5M2691 Spacer ... 4.93 mm (.194 in.)
5S7189 Spacer ... 5.03 mm (.198 in.)
(4) UFTER SPRINGS

Part No. 187392 7N1208
Length under 36.66 mm 29.26 mm
test force (1.522 in.) (1.152 in.)
100 ± 4 N 325 ± 13.3 N
Test force
(22.6 ± 1.1 lb.) (73 ,± 3.65 lb.)
Free length 44.46 mm 46.03 mm
after test (1.751 in.) (1.891 in.)
Outside 25.27 ± 0.13 mm 25.27 ± 0.13 mm
diameter (.995 ± .005 in.) (.995 ± .005 in.)
For use with Aluminum Lifters Steel Lifters
(5) Bores for the racks:
Bore in housing, at the rear (new) ... 12.758 ± 0.038 mm (.5023 ± .0015 in.)
Bearing at the front (after assembly) ... 12.758 ± 0.046 mm (.5023 ± .0018 in.)
Diameter of fuel racks (new) ... 12.662 ± 0.005 mm (.4985 ± .0002 in.)
Maximum permissible clearance between rack and bearings (worn) ... 0.18 mm (.007 in.)
(6) Bore in bearings for the camshaft (after assembly) ... 53.988 ± 0.038 mm (2.1255 ± .0015 in.)
Diameter of bearing surfaces of the camshaft (new) ... 53.899 ± 0.013 mm (2.1220 ± .0005 in.)
15
Maximum permissible clearance between the bearings and the camshaft ... 0.25 mm (.010 in.)
(7) Length of injection pump plunger. See chart that follows.
(8) Timing dimension for fuel injection pumps. See chart that follows.
INJECTIO N PUMP PLUNGER LENG TH AND TIMING DIMENSIONS

3 a El 3412 Stamford S n o t Ertgln*# 3412 U n . Speed
(a * Timing) (30° THnmgi EnOtn*e [225° Timing]
'Injection TH12A1 TN4MS 7311251 7HD3H 1N497V
Phinip Gruufi* 9N332* SHM JS 7N7577 1W W 1W21U
Plunge* Length 66 434 ± 0,03* mm 6 3 .t i e ± 0.038 mm 66.424 ± 0-096 nun 69.116 ± 0-030 n m 6 9 .1IS ± 0 033 mm
(new) (2 0151 ± .0 0 15 m.) (2.7212 ± .0015 ir.) (2 .6 1 5 1 ± .0015 In.) (2.7212 ± .'00:5 r ,) (2.7212 ± .0016 m.)
(7) Min*inFTi
**.335 rtkn 63.050 mm 66-165 mm S3.DBG mm 69 030 mm
Permissible
Plunaer Lsngth (2.6135 ktj (2.7197 irO (2.5135 in.) (2-7197 h .) (2 7 1 9 7 f i .)
On Elnpns 106.30 ± 0.0 6 mm 106.0? ± O.0B mm 104.00 -*■ 0.05 mm 105 71 ± OLOSmm i06.se ± 0,06 -mm
Turtng Dim. (4.135 ± .002 id.) (4.17+ ± .002 ki.) (4.097 ± .002 Hi.} (4 162 + 002 in ) (4 208 z: 002 in.)
(0>
Off Engine 10S 041 ±. 0.0 6 mm 110.335 * 0.05 mm 103.641 i 0,05 mm 110.335 ± 0.05 mm 110.335 * 0 06 mm
Tifing Dim, (4 2772 ± .002 in.) (4-343S ± .002 In.) (4 2772 ± .00? In.} <4 3439 t 002 in.) (4 3439 ± 002 in j
■NOTE: Make reference ha FUEL 3Y5TBYI CHART in FUEL SYSTEM EENTFICfcTlOM section to Hnd * epwdlic engine
(9) Torque for the nuts that hold the fuel injection lines to the nozzles ... 40 ± 7 N m (30 ± 5 lb.ft.)
16
(10) Torque for nuts that hold the nozzles ... 75 ± 7 N m (55 ± 5 lb.ft.)
(11) Body.
(12) Nozzle. Tighten nozzle finger tight on body (11).
N O TE: Make reference to Special Instruction Form No. SEHS7292 for information on testing fuel
injection nozzles.
(13) Put liquid soap (40% solid) in the bore in the cylinder head and on the O-ring seal. Put 5P3931
Anti-Seize Compound on the threads before installation. Torque for direct injection adapter ... 205 ±
14 N m (150 ± 10 lb.ft.)
17
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR'
Specifications
Dashpot Governors
B25038X1
N O TE: Any adjustment to the governor must be made only by a person approved by Caterpillar or by
18
a Caterpillar Dealer.
(1) Torque for nut ... 12 ± 4 N m (9 ± 3 lb.ft.)
(2) Rack stop spring. See MISCELLANEOUS SPRING CHART.
(3) Piston assembly.
(4) Cushion spring for piston assembly. See MISCELLANEOUS SPRING CHART.
MISCELLANEOUS SPRING CHART

Type (2) Rack Stop (4) Cushion
Part No. 6N8793 6N1777
Length under test 19.1 mm 31,8 mm
force (.75 in.) (1.25 in.)
2.0 ± 0.1 N 4.4 ± 0.5 N
Test Force (1.10 ± .11 lb.)
(.45 ± .03 lb.)
Free length after 41,9 mm 36.8 mm
(1.65 in.) (1.45 in.)
9.4 mm 14.7 mm
Outside diameter (.37 in.) (.58 in.)
Color Code (stripes) none one yellow
Used with these 1N4928 5 7N6852
Governors:
(5) Governor spring. See GOVERNOR SPRING CHART.
aO VERNO fl V R U IC t C H A R T
Sprirtg Per! No iw ie a s 7N12M 7H1235 r 7N4612
C o o t Code one bkfe stripe one end ^ n y one end dark blue one end red
ons red stupe one light green stripe one ora nyp skp e one while singe
h ji a fofte on e p rrg of 22 N 22 N 27 N
(6.0 lb.) <5 0 b . ) (6 .0 lb.] (9 .5 lb.)
Ttien add rw re fore*
to £5.4 mm az.4 mm 14.0 mm 12.7 H i)
make spring d o rte r by (1.00 m ) ■(.ee in,) (.66 in.) ( 50 irr)
Tolal tesl force S3.4 ± 1.D N 66 - 1 N 4B ± 0 .5 N 66.26 ± 1.00 N
<12 rt ,2 IS.) (14-E + 21b.) [10.3 ± .1 lb.) (14 0 -± .2 lb.)
Free length after tost 68 6 ± 0.3 mm 55.8 jl O.S mm 68.G * 0 B mm 0S.6 - O.S mm
(a. 70 ± .03 In.) (2.70 ± ,03 irv) <2.70 ± .5 3 in j (2 70 ± .03 In.)
34.7 mm 35.1 mm 35 . T mnr 35.1 mm
Outside diameter
(1 .3 7 In.) (1 36 in.) (1 .3 6 in.) (.1.38 ir .)
Used iv;thi ttioco Fuat 7NB235 7NB23B
Injecitofi Pumps 0NS2C6
1W7SOO SN9346
and (ijv e m o f 1W4931 1N4752 1W7561
GfWpS 1W4332
7N024O
7NB241
N O TF- Make 'O la r r o e to F U LL S Y S TE M IDENTIFICATION w c lw n to find iha corradl arrengement
(6) Diameter of the outer surface of the cylinder (new) ... 38.100 ± 0.013 mm (1.5000 ± .0005 in.)
Bore in the gear (new) ... 38.151 ± 0.013 mm (1.5020 ± .0005 in.)
19
(7) Put marks in alignment on pinion-stop and gear before installing dowel.
(8) Bore in the bearing (after assembly) ... 22.263 ± 0.038 mm (.8765 ± .0015 in.)
Diameter of the gear, at the hub (new) ... 22.187 ± 0.013 mm (.8735 ± .0005 in.)
*5aicn-lx2
PLATE ASSEMBLY
(9) Distance from the face of the plate to the bearing for the governor drive assembly ... 0.51 ± 0.25
mm (.020 ± .010 in.)
(10) Dowel installation:
Angle A must be ... 54 ± 10°
Dimension B must be ... 7.9 ± 0.5 mm (.31 ± .02 in.)
(11) Install dowels to get a dimension of ... 5.6 ± 0.5 mm (.22 ± .02 in.)
20
1? 13 14
CONTROL SHAFT BEARINGS
(12) Bore in the governor control shaft bearings (after assembly) ... 15.761 ± 0.038 mm (.6205
± .0015 in.)
Diameter of the governor control shaft (new) ... 15.720 ± 0.008 mm (.6189 ± .0003 in.)
(13) Distance between the bearings for the governor control shaft ... 60.58 ± 0.13 mm (2.385 ± .005
in.)
(14) Distance from the face of the housing to the end of the bearing for the governor control shaft ...
43.38 ± 0.15 mm (1.708 ± .006 in.)
21
3408 & 34 12 G EN E RATO R S ET E N G IN ES__________________________________________________________ SE N R2561 -0 1
SHUTOFF SHAFT BEARINGS
(15) Bore in the shutoff shaft bearing (new) ... 12.713 ± 0.013 mm (.5005 ± .0005 in.)
Diameter of the shutoff shaft (new) ... 12.637 ± 0.013 mm (.4975 ± .0005 in.)
(16) Distance from center of bolt hole to outside of sleeve bearing ... 90.25 ± 0.50 mm (3.553 ± .020
in.)
(17) Needle bearing.
(18) Distance from center of bolt hole to outside end of needle bearing (17) ... 21.69 ± 0.50 mm (.854
± .020 in.)
(19) Torque for insulator ... 4.5 ± 0.6 N m (40 ± 5 lb.in.)
Install seals as shown.
22
CATERPILLAR'
Specifications
Governor Linkage
(Woodward PSG)
23
LINKAGE SHOWN FROM RIGHT SIDE OF ENGINE IN SHUTOFF POSITION
NO TE: Move the fuel injection pump control lever and the governor control lever to the shut-off
position. Measure the distance from center to center of the levers to find the correct length of the rod
assembly needed before it is installed.
(1) Torque for studs ... 14 ± 4 N m (10 ± 3 lb.ft.)
24
CATERPILLAR'
Specifications
Woodward PSG Governor

(1W1636)
&33S67X1
25
(1) Torque for sleeves ... 40 N m (30 lb.ft.)
(2) Governor oil pump relief valve must open at ... 1200 kPa (175 psi)
(3) Synchronizing motor rating ... 24 V
(4) Adjust clutch assembly to slip at ... 0.7 ± 0.06 N m (6.0 ± .5 lb.in.)
(5) 3N5723 Return Spring:
Free length ... 104.9 to 108.0 mm (4.13 to 4.25 in.)
Outside diameter ... 25.27 to 25.78 mm (.995 to 1.015 in.)
(6) Torque for nut on pilot valve ... 8 N m (70 lb.in.)
(7) Flyweight rotation as seen from the top ... clockwise
(8) 2N1021 Speeder Spring and Fork Assembly:
Free length ... 24.6 to 26.2 mm (.97 to 1.03 in.)
Outside diameter (large end) ... 24.13 ± 0.25 mm (.950 ± .010 in.)
(9) Diameter of the power piston (new) ... 21.803 to 21.816 mm (.8584 to .8589 in.)
Bore in the bushing (new) ... 21.829 to 21.841 mm (.8594 to .8599 in.)
(10) Diameter of five pilot valve lands (new) ... 6.325 to 6.337 mm (.2490 to .2495 in.)
Bore for pilot valve lands (new) ... 6.350 to 6.363 mm (.2500 to .2505 in.)
(11) Diameter of pilot valve bushing (new) ... 15.847 to 15.855mm (.6239 to .6242 in.)
Bore for pilot valve bushing (new) ... 15.875 to 15.855 mm (.6250 to .6254 in.)
(12) 6L3990 Damper Springs:
Color Code ... one purple stripe
Free length ... 33.3 to 34.8 mm (1.31 to 1.37 in.)
Outside diameter (large end) ... 10.67 ± 0.25 mm (.420 ± .010 in.)
(13) Depth of the counterbore ... 6.680 to 6.693 mm (.2630 to .2635 in.)
Thickness of gears ... 6.647 to 6.660 mm (.2617 to .2622 in.)
(14) Bore in oil pump idler gear ... 7.734 to 7.747 mm (.3045 to .3050 in.)
Diameter of shaft ... 7.709 to 7.717 mm (.3035 to .3038 in.)
Install the shaft with the oil hole as shown.
26
The distance between the top of the shaft and the bottom of the counterbore must be ... 6.40 to 6.45
mm (.252 to .254 in.)
27
CATERPILLAR'
Specifications
(3408) Fuel Injection Pump Housing
(1) Install pin to get a dimension of ... 4.78 ± 0.25 mm (.188 ± .010 in.)
(2) Install dowel to get a dimension of ... 12.19 ± 0.25 mm (.480 ± .010 in.)
(3) Rack bearing alignment - the center of the rack bearing tab must be within 0.05 mm (.002 in.) of a
vertical line that:
(a) goes through the center of the rack bearing

(b) is parallel to the vertical center line of injection pump housing
N O TE: The following tooling is available to position the rack bearings correctly: 5P6217 Fixture and
5P6218 Driver.
The correct bearing depth is controlled when driver is stopped by fixture.
(4) Position of camshaft bearing joints (X) must be limited to area (A) ... 30 ± 1°
N O TE: When viewed from the FRONT of the injection pump housing, the two camshaft bearings
28
must be installed with the bearing joint (X) in an area (A) between a vertical position and a position
30 ± 1° to the RIGHT of vertical. AT the same time, oil hole (Y) in the two bearings must be to the
LEFT of vertical.
(5) Distance from bottom of housing to end of rear hollow dowel ... 1.5 ± 0.3 mm (.06 ± .01 in.)
(6) Maximum distance from bottom of housing to end of front hollow dowel ... 1.0 mm (.04 in.)
(7) Torque for bolts ... 54 ± 7 N m (40 ± 5 lb.ft.)
(8) Distance from rear bearing bore face to installed rear camshaft bearing ... 4.8 ± 0.5 mm (.19 ± .02
in.)
(9) Distance from front bearing bore face to installed front camshaft bearing ... 1.0 ± 0.5 mm (.04
± .02 in.)
PUMP HOUSING USED WITH PSG GOVERNORS SHOWN
(10) Distance from top surface of housing to top of lower governor drive bearing ... 28.4 ± 0.5 mm
29
(1.12 ± .02 in.)
(11) Position the top governor drive bearing (notch end up) with the notch in alignment with the
center of oil hole (Z). A line drawn through the center of the notch and hole (Z) should make an angle
(U) of 10 ± 5° with centerline (W) as shown. Install the bearing even with the top surface of the
housing ... + 0.00 - 0.15 mm (+ .000 - .006 in.)
(12) Install dowel to get a dimension from centerline of fuel injection pump bore to dowel (seal dowel
hole with aluminum ball) ... 14.76 ± 0.10 mm (.581 ± .004 in.)
(13) Distance from end of bearing to face of boss on housing ... 73.03 ± 0.51 mm (2.875 ± .020 in.)
(14) Distance between the bearings for the shaft ... 34.80 ± 0.51 mm (1.370 ± .020 in.)
(15) Install pins until they contact bottom of housing casting.
30
CATERPILLAR'
Specifications
(3412) Fuel Injection Pump Housing
(1) Install pin to get a dimension of ... 4.78 ± 0.25 mm (.188 ± .010 in.)
(2) Install dowel to get a dimension of ... 12.19 ± 0.25 mm (.480 ± .010 in.)
(3) Rack bearing alignment - the center of the rack bearing tab must be within 0.05 mm (.002 in.) of a
vertical line that:
a. goes through the center of the rack bearing.

b. is parallel to the vertical centerline of injection pump housing.
N O TE: The following tooling is available to position the rack bearings correctly: 5P6217 Fixture and
5P6218 Driver.
The correct bearing depth is controlled when driver is stopped by the fixture.
(4) Position of camshaft bearing joints (X) must be limited to area A ... 30 ± 1°
N O TE: When viewed from the FRONT of the injection pump housing, all three camshaft bearings
must be installed with the bearing joint (X) in an area (A) between a vertical position and a position
30 ± 1° to the RIGHT of vertical. At the same time, oil hole (Y) in the two end bearings (center
bearing has no oil hole) must be to the LEFT of vertical.
31
(5) Install dowels to get a dimension of ... 9.7 ± 0.5 mm (.38 ± .02 in.)
(6) Distance from bottom of housing to end of rear hollow dowel ... 1.5 ± 0.3 mm (.06 ± .01 in.)
(7) Maximum distance from bottom of housing to end of front hollow dowel ... 1.0 mm (.04 in.)
(8) Torque for bolts ... 55 ± 7 N m (40 ± 5 lb.ft.)
(9) Distance from rear bearing bore face to installed rear camshaft bearing ... 4.8 ± 0.5 mm (.19 ± .02
in.)
(10) Distance from rear bearing bore face to installed center camshaft bearing ... 127.0 ± 0.5 mm
(5.00 ± .02 in.)
(11) Distance from front bearing bore face to installed front camshaft bearing ... 1.0 ± 0.5 mm (.04
± .02 in.)
(12) Install plug to a depth of ... 1.3 ± 0.5 mm (.05 ± .02 in.)
(13) Pressure oil passage.
(14) Install pins until they contact bottom of housing casting.
32
PUMP HOUSING USED WITH PSG GOVERNORS SHOWN
(15) Distance from top surface of housing to top of lower governor drive bearing ... 28.4 ± 0.5 mm
(1.12 ± .02 in.)
(16) Position the top governor drive bearing (notch end up) with the notch in alignment with the
center of oil hole (Z). A line drawn through the center of the notch and hole (Z) should make an angle
(U) of 10 ± 5° with centerline (W) as shown. Install the bearing eve with the top surface of the
housing ... + 0.00 - 0.15 mm (+ .000 - .006 in.)
(17) Install dowel to get a dimension from centerline of fuel injection pump bore to dowel (seal dowel
holes with aluminum ball) ... 14.76 ± 0.10 mm (.581 ± .004 in.)
(18) Distance from end of bearing to face of boss on housing ... 73.03 ± 0.51 mm (2.875 ± .020 in.)
(19) Distance between the bearings for the shaft ... 34.80 ± 0.51 mm (1.370 ± .020 in.)
33
CATERPILLAR'
Specifications
Media N u m b e r -S E N R 2 5 6 1 -0 1 Publication D ate -0 1 / 0 2 / 2 0 0 1 Date U pd ated -1 5 / 1 0 / 2 0 0 1
Drive And Oil Pump For The Governor

(3408 & 3412)
PUMP GROUPS USED WITH DASHPOT GOVERNORS
34
B M g lX l
PUMP GROUPS USED WITH PSG GOVERNORS
(1) Torque for oil pump bypass valve body ... 70 ± 14 N m (50 ± 10 lb.ft.)
(2) 7L8696 Spring, inside the valve body (1):
Length under test force ... 28.7 mm (1.13 in.)
Test force ... 31 ± 2 N (7.2 ± .4 lb.)
Free length after test ... 34.8 ± 0.3 mm (1.37 ± .01 in.)
Outside diameter ... 7.4 mm (.29 in.)
(3) Bore in the oil pump idler gear (new) ... 12.512 ± 0.008 mm (.4926 ± .0003 in.)
Diameter of the shaft (new) ... 12.482 ± 0.008 mm (.4914 ± .0003 in.)
(4) Depth of oil pump cover bore ... 9.568 ± 0.013 mm (.3763 ± .0005 in.)
Gear thickness ... 9.525 ± 0.008 mm (.3750 ± .0003 in.)
N O TE: Gear must be pushed against should of pinion shaft at assembly.
Number of teeth on drive gear ... 11
Number of teeth on idler gear ... 9
(5) Bearing diameter (after assembly) ... 19.093 ± 0.038 mm (.7517 ± .0015 in.)
35
NO TE: For bearing installation, see information in FUEL INJECTION PUMP HOUSING section.
Diameter of pinion shaft (new) ... 19.025 ± 0.013 mm (.7490 ± .0005 in.)
(6) Minimum gear clearance (backlash) ... 0.03 mm (.001 in.)
36
CATERPILLAR'
Specifications
Automatic Timing Advance Unit

(9N3959 and 6N3195)
6N3195 SHOWN
NO TE: 9N3959 is used on 3408 engines only.
(1) Weights (two).
37
SPRINGS FOR A U T O M A T IC TIMING ADV AN CE UNIT

Outer Middle Im b w
Part No. <3 (3) (3) (4) (4!
6M M 64 OM6077 5N 9ig3 £445670 B N 3190
LerigHl under 67.D mm 57 .S mm 49.3 rftm 35.2 mm 35.5 mm
test tone# (2.S4 m.) (2.2S in.) (1.94 in.) (1.50 m.) {1.41 in.)
Test lores 52 I 2 N 61 - i O N 72 ± 3 N 35 ± 2 N 10 X 1 N
(11.3 ± .B Iti.l (13.4 ± .68 lb.) <16.3 - .5 lb.) (7.9 4 .4 lb.} (2 ,2 ± ,1 lb.)
F r w i&'ir.rth 06.4 4, Q.fl mm 64.0 ± 0.9 mm 65.1 ± 0.5 m u 42 ^ ^ 0.3 mm 3B.4 J. D.B m n
after leet (3.40 ± .UJ in.) (3.55 + .03 In.) (2 .SB * .03 r } (1.07 ± .03 in.) (1.51 * .03 rv )
OutBWB 25.4 mm 25.4 mm 19.3 m u 13 3 m n 13.7 mm
diameter (1.00 in ) {1.00 n .) (.7 2 In.) (.72 in.) ( 54 in )
Used wrtti: UN3959 6N3195 9N39S9 6N31S5
(5) Torque for the four bolts ... 135 ± 7 N m (100 ± 5 lb.ft.)
38
CATERPILLAR'
Specifications
Automatic Timing Advance Unit

(3412 Low Speed Engine)
(1) Weights (two).
(2) 8N9000 Spring.
Test force ... 44.5 ± 2.2 N (10.0 ± .4 lb.)
39
Free length after test ... 75.2 mm (2.96 in.)
40
CATERPILLAR'
Specifications
Governor And Fuel Pump Drive Gear

(3412 Fixed Timing)
41
CATERPILLAR'
Specifications
Fuel Injection Lines

(3408)
(1) Torque for the nuts that hold the adapter locks ... 14 ± 3 N m (10 ± 2 lb.ft.)
(2) Torque for all bolts that hold the fuel injection line clamps ... 10 ± 3 N m (7 ± 2 lb.ft.)
(3) Torque for nuts that hold the fuel injection lines to the injection pumps and valves ... 40 ± 7 N m
(30 ± 5 lb.ft.)
(4) Torque for nuts that hold the fuel injection lines to the adapter ... 40 ± 7 N m (30 ± 5 lb.ft.)
42
CATERPILLAR'
Specifications
Fuel Injection Lines

(3412)
(1) Torque for the nuts that hold the adapter locks ... 14 ± 3 N m (10 ± 2 lb.ft.)
(2) Torque for all bolts that hold the fuel injection line clamps ... 10 ± 3 N m (7 ± 2 lb.ft.)
(3) Torque for fuel injection line nuts at the fuel injection pumps and fuel injection valves ... 40 ± 7
N m (30 ± 5 lb.ft.)
(4) Torque for fuel injection nuts at the fuel line adapters ... 40 ± 7 N m (30 ± 5 lb.ft.)
43
CATERPILLAR'
Specifications
Fuel Transfer Pump
(1) Diameter of the shaft ... 12.540 ± 0.003 mm (.4937 ± .0001 in.)
Maximum temperature of the gear for installation on the shaft ... 316°C (600°F)
N O TE: For position of gear on shaft, See (5).
44
Bore in the bearings (both) ... 12.581 ± 0.013 mm (.4953 ± .0005 in.)
Maximum permissible clearance between bearings and shaft (worn) ... 0.08 mm (.003 in.)
NO TE: The shaft must rotate freely when the cover bolts are tight.
(2) Clearance between the gears and the cover (new) ... 0.020 to 0.051 mm (.0008 to .0020 in.)
(3) Diameter of the shaft ... 12.482 ± 0.008 mm (.4914 ± .0003 in.)
Bore in the gear ... 12.512 ± 0.008 mm (.4926 ± .0003 in.)
Clearance between shaft and gear (new) ... 0.015 to 0.046 mm (.0006 to .0018 in.)
(4) Depth of the bore in the body (new) ... 12.687 ± 0.008 mm (.4995 ± .0003 in.)
(5) Distance from the gear to the shoulder of the shaft ... 49.71 mm (1.957 in.)
(6) Torque for plug of bypass valve ... 38 ± 4 N m (27 ± 3 lb.ft.)
Pressure of fuel to open the valve ... 230 kPa (33 psi)
(7) 6N1069 Spring for bypass valve:
Test force ... 26 ± 1 N (5.9 ± .3 lb.)
(8) Torque for nut ... 28 ± 7 N m (22 ± 5 lb.ft.)
45
CATERPILLAR'
Specifications
Fuel Transfer Pump Drive
A 2 2 4 9 5 -1 X 1
(1) Bore in bearing (after assembly) ... 11.961 ± 0.033 mm (.4709 ± .0013 in.)
Diameter of shaft (new) ... 11.908 ± 0.005 mm (.4688 ± .0002 in.)
(2) Temperature of the gear for installation on the shaft ... 232°C (450°F)
46
CATERPILLAR'
Specifications
Fuel Filter Base

(3408)
(1) Put 9S3265 Retaining Compound on the tapered end of stud to a distance of ... 7.6 mm (.30 in.)
(2) Distance from sealing surface of base to end of stud ... 24.6 ±1. 3 mm (.97 ± .05 in.)
47
(3) Sealing surface of stud.
N O TE: Do not damage this surface.
(4) Torque for stud ... 70 ± 14 N m (50 ± 10 lb.ft.)
48
CATERPILLAR
Specifications
Media N um ber -S E N R 2 5 6 1 -0 1 Publication Date -0 1 / 0 2 / 2 0 0 1 Date Updated -1 5 / 1 0 / 2 0 0 1
Fuel Filter Base

(3412)
(1) Put 9S3265 Retaining Compound on the tapered end of stud to a distance of ... 7.6 mm (.30 in.)
(2) Distance from sealing surface of base to end of stud ... 24.6 ± 1.3 mm (.97 ± .05 in.)
(3) Sealing surface of stud.
NOTE: Do not damage this surface.
(4) Torque for stud ... 70 ± 14 N m (50 ± 10 lb.ft.)
49
3408 & 3412G EN E R ATO R SET ENGINES SE N R256_ -0 1
CATERPILLAR
Specifications
Valve Covers
(3408)
O ___________ o o
ftZZ*»7X1 '4
(1) Torque for four studs (for locks of fuel injection lines) ... 17 ± 10 N m (12 ± 7 lb.ft.)
(2) Bore for adapter or plug. For installation, clean contact surfaces of bore and adapter or plug with
6V1541 Quick Cure Primer and put 9S3265 Retaining Compound on the surfaces.
A H H 1 I Xt
TIGHTENING SEQUENCE FOR BASE
(3) Tighten the bolts for the base in the number sequence shown to ... 14 ± 4 N m (10 ± 3 lb.ft.)
50
A 50512XI
TIGHTENING SEQUENCE FOR COVER
(4) Tighten the bolts for the cover in the number sequence shown to ... 14 ± 4 N m (10 ± 3 lb.ft.)
51
CATERPILLAR'
Specifications
Valve Covers
(3412)
(1) Torque for the three studs (for locks of fuel injection lines) ... 17 ± 10 N m (12 ± 7 lb.ft.)
(2) Bore for adapter or plug. For installation, clean contact surfaces of bore and adapter or plug with
6V1541 Quick Cure Primer and put 9S3265 Retaining Compound on the surfaces.
52
3408 & 3412 GENERATOR SET ENGINES SENR256_-01
TIGHTENING SEQUENCE FOR BASE
(3) Tighten the bolts for the base in the number sequence shown to ... 14 ± 4 N m (10 ± 3 lb.ft.)
TIGHTENING SEQUENCE FOR COVER
(4) Tighten the bolts for the cover in the number sequence shown to ... 14 ± 4 N m (10 ± 3 lb.ft.)
53
CATERPILLAR
Specifications
Valve Rocker Arms, Lifters, And Bridges
(1) Bore in rocker arm for shaft (new) ... 24.803 ± 0.013 mm (.9765 ± .0005 in.)
(2) Put 2P2506 Thread Lubricant on the threads of all bolts that hold rocker arms shaft and tighten the
bolts in the step sequence that follows:
Step l.Tighten bolts in number sequence shown to ... 270 ± 25 N m (200 ± 20 lb.ft.)
Step 2. Tighten bolts in number sequence shown to ... 447 ± 20 N m (330 ± 15 lb.ft.)
54
Step 3. Tighten bolts in number sequence shown again to ... 447 ± 20 N m (330 ± 15 lb.ft.)
(3) Torque for locknut for valve adjustment screw ... 28 ± 4 N m (22 ± 3 lb. ft.)
(4) Torque for locknut for bridge adjustment screw ... 28 ± 4 N m (22 ± 3 lb. ft.)
(5) Clearance for valves:
Intake valves ... 0.38 mm (.015 in.)
Exhaust valves ... 0.76 mm (.030 in.)
(6) Height to top of dowel ... 53.3 ± 0.5 mm (2.10 ± .02 in.)
(7) Diameter of dowel (new) ... 11.008 ± 0.003 mm (.4334 ± .0001 in.)
Bore in bridge for dowel (new) ... 11.15 ± 0.05 mm (.438 ± .002 in.)
Bore in head for dowel ... 10.968 ± 0.020 mm (.4318 ± .0008 in.)
(8) Diameter of valve lifter (new) ... 27.8956 ± 0.0127 mm (1.09825 ± .00050 in.)
Bore in block for valve lifter (new) ... 27.9527 ± 0.0190 mm (1.10050 ± .00075 in.)
(9) Guide springs must not be used again. Always install new guide springs.
(10) 2N7229 Spring:
55
Test force ... 45 to 53 N (10 to 12 lb.)
Outside diameter ... 29.7 mm (1.17 in.)
(11) Dowel length above top surface of rocker shaft support to be (both ends) ... 12.7 ± 1.0 mm (.50 ± .04
in.)
(12) Clearance for rocker arms (both ends) ... 0.30 to 1.40 mm (.012 to .055 in.)
(13) Use 2N7228 Washer as needed to get clearance (12).
SEQUENCE FOR ROCKER ARM BOLTS (3412)
SEQUENCE FOR ROCKER ARM BOLTS (3408)
56
CATERPILLAR
Specifications
Valves
NOTE: GUIDELINES FOR REUSABLE PARTS: VALVES AND VALVE SPRINGS, Forms SEBF8002
and SEBF8034, have the procedure and specifications necessary for checking used valves and valve
springs.
(1) 4N5906 Spring for valves (new):
Test force ... 344 ± 34 N (77.3 ± 7.6 lb.)
Use again minimum load at length under test force ... 291 N (65.4 lb.)
57
Length of spring at valve open position ... 42.93 mm (1.690 in.)
Use again minimum load at valve open position ... 817 N (183.6 lb.)
Spring must not be bent more than ... 2.18 mm (.086 in.)
(2) Height to top of valve guide ... 32.3 ± 0.8 mm (1.27 ± .03 in.)
(3) Diameter of valve stem (new) ... 9.441 ± 0.008 mm (.3717 ± .0003 in.)
Use again minimum:
1W3860 Exhaust ... 9.408 mm (.3704 in.)
1W3859 Intake ... 9.408 mm (.3704 in.)
Bore in valve guide with guide installed in the head (new) ... 9.487 ± 0.025 mm (.3735 ± .0010 in.)
Use again dimension for valve guide bore ... 9.538 mm (.3755 in.)
(4) Diameter of valve head:
Exhaust valve ... 41.81 ± 0.13 mm (1.646 ± .005 in.)
Intake valve ... 44.98 ± 0.13 mm (1.771 ± .005 in.)
(5) Angle of exhaust valve face ... 44 1/4 ± 1/4°
Angle of intake valve face ... 29 1/4 ± 1/4°
(6) Depth of bore in head for valve seat insert (new) ... 13.01 ± 0.15 mm (.512 ± .006 in.)
58
(7) Diameter of valve seat insert for exhaust valve ... 42.850 ± 0.013 mm (1.6870 ± .0005 in.)
Bore in head for valve seat insert for exhaust valve ... 42.774 ± 0.025mm (1.6840 ± .0010 in.)
(7) Diameter of valve seat insert for intake valve ... 46.025 ± 0.013 mm (1.8120 ± .0005 in.)
Bore in head for valve seat insert for intake valve ... 45.949 ± 0.025 mm (1.8090 ± .0010 in.)
(8) Angle of face of intake valve seat insert ... 30 1/4 ± 1/2°
Angle of face of exhaust valve seat insert ... 44 3/4 ± 1/2°
(9) Dimension from end of closed valve to machined face of head.
Maximum permissible dimension:
Below (recessed from) machined face ... 1.22 mm (.048 in.)
Above (extended from) machined face ... 0.20 mm (.008 in.)
(10) Outside diameter of the face of the valve seat insert:
Exhaust seat ... 40.41 ± 0.13 mm (1.591 ± .005 in.)
Intake seat ... 44.04 ± 0.13 mm (1.734 ± .005 in.)
(11) "Use again" thickness of valve lip:
Exhaust valve ... 2.03 mm (.080 in.)
Intake valve ... 2.51 mm (.099 in.)
59
CATERPILLAR
Specifications
Camshaft
(1) Maximum permissible temperature of the gear for installation on the camshaft (do not use a torch) ...
315°C (600°F)
(2) Tight fit between the gear and camshaft ... 0.062 to 0.138 mm (.0024 to .0054 in.)
(3) Diameter of the surfaces (journals) for the camshaft bearings (new) ... 69.850 ± 0.013 mm (2.7500 ±
.0005 in.)
Bore in front and rear bearings for the camshaft (after assembly) ... 69.969 ± 0.048 mm (2.7547 ± .0019
in.)
Bore in inner bearings for the camshaft (after assembly) ... 69.982 ± 0.061 mm (2.7552 ± .0024 in.)
(4) Thickness of thrust plate (new) ... 4.65 ± 0.03 mm (.183 ± .001 in.)
End play of the camshaft ... 0.10 to 0.25 mm (.004 to .010 in.)
60
(5) Height of camshaft lobes.
To find lobe height, use the procedure that follows:
A. Measure camshaft lobe height (5).
B. Measure base circle (7).
C. Subtract base circle (STEP B) from lobe height (STEP A.). The difference is actual lobe lift (6).
D. Specified camshaft lobe lift (6) is:
a. Exhaust lobe ... 8.783 mm (.3458 in.)

b. Intake lobe ... 8.100 mm (.3189 in.)
Minimum permissible difference between actual lobe lift (STEP C) and specified lobe lift (STEP D) is
0.13 mm (.005 in.)
61
CATERPILLAR
Specifications
Media N um ber -S E N R 2 5 6 1 -0 1 Publication Date -0 1 / 0 2 / 2 0 0 1 Date Upd ate d -1 5 / 1 0 / 2 0 0 1
Front Timing Gears

(3408)
(1) Fuel injection pump drive gear and timing advance unit.
(2) Camshaft gear.
62
NOTE: Make alignment of "V" marks as shown.
(3) Water pump drive gear.
(4) Gear for attachment drive groups.
(5) Idler gear (small) and balancer gear (large).
(6) Diameter of the shaft (new) ... 63.500 ± 0.013 mm (2.5000 ± .0005 in.)
Bore in the bearing (after assembly) ... 63.602 ± 0.038 mm (2.5040 ± .0015)
Bearing joint must be in center of heavy section of gear at assembly.
(7) End clearance (new) ... 0.28 to 0.35 mm (.011 to .014 in.)
(8) Plate. The lubrication groove must be against the gear.
(9) Crankshaft gear.
(10) Engine oil pump drive gear.
(11) Torque for bolt ... 55 ± 7 N m (40 ± 5 lb.ft.)
63
CATERPILLAR
Specifications
Front Timing Gears

(3412)
(1) Fuel injection pump drive gear and timing advance unit.
64
(2) Camshaft gear.
(3) Water pump drive gear.
(4) Gear for attachment drive groups.
(5) Idler gear assembly.
Bore in bearing (after assembly) ... 63.602 ± 0.038 mm (2.504 ± .0015 in.)
(7) End clearance (new) ... 0.28 to 0.35 mm (.011 to .014 in.)
(8) Plate. The lubrication groove must be against the gear.
(9) Crankshaft gear.
NOTE: Make alignment of "V" mark as shown.
(10) Distance that bearing is installed from the face of idler gear ... 1.12 ± 0.25 mm (.044 ± .010 in.)
Bore in bearing (after assembly) ... 35.034 ± 0.038 mm (1.3793 ± .0015 in.)
(12) Engine oil pump idler gear. Tighten the bolt that holds idler gear to a torque of ... 55 ± 7 N m (40 ± 5
lb.ft.)
(13) Engine oil pump drive gear. Tighten the bolt that holds the drive gear to a torque ... 55 ± 7 N m (40 ±
5 lb.ft.)
65
CATERPILLAR
Specifications
Timing Gear Housing
(1) Torque for stud on back of the housing ... 25 ± 4 N m (20 ± 3 lb. ft.)
(2) Put 9S3263 Thread Lock on the stud threads:
Dimension stud must be extended above timing gear housing ... 73.2 mm (2.88 in.)
(3) Torque for three studs ... 25 ± 4 N m (20 ± 3 lb.ft.)
66
(4) Put 5P3413 Pipe Sealant on the threads of two studs for installation in the housing.
67
CATERPILLAR
Specifications
Cylinder Heads
(3408)
(1) Large bolts (3/4 inch). Put 5P3931 Anti-Seize Compound on all bolt threads and tighten the bolts in
the step sequence that follows:
Step 1. Tighten bolts from 1 to 14 in number sequence to ... 270 ± 25 N m (200 ± 20 lb.ft.)
Step 3. Tighten bolts from 1 to 14 in number sequence again to ... 450 ± 20 N m (330 ± 15 lb.ft.)
Step 4. Install the rocker arms for the engine valves.
Step 8. Tighten the nine small bolts (2) to ... 43 ± 7 N m (32 ± 5 lb.ft.)
(2) Small bolts (3/8 inch). See Step 8, above.
(3) Torque for eight studs in each cylinder head ... 25 ± 4 N m (20 ± 3 lb. ft.)
68
(4) Height of cylinder head (new) ... 112.78 ± 0.25 mm (4.440 ± .010 in.)
69
CATERPILLAR
Specifications
Cylinder Heads
(3412)
(1) Large bolts (3/4 inch). Put 5P3931 Anti-Seize Compound on all bolt threads and tighten bolts in the
step sequence that follows:
Step 4. Install the rocker arms for the engine valves.
Step 8. Tighten the thirteen small bolts (2) to ... 43 ± 7 N m (32 ± 5 lb.ft.)
(2) Small bolts (3/8 inch). See Step 8 above.
(3) Torque for twelve manifold studs in each cylinder head ...25 ± 4 N m (20 ± 3 lb.ft.)
70
71
CATERPILLAR
Specifications
Exhaust Manifolds
3408 TORQUE SEQUENCE
3412 TORQUE SEQUENCE
NOTE: Put 5P3931 Anti-Seize Compound on the threads of all plugs, studs, bolts and nuts for the exhaust
manifolds, couplings, elbows, and turbocharger support, where they become very hot.
(1) Tighten the locknuts for the manifold in the number sequence shown to ... 52 ± 7 N m (38 ± 5 lb.ft.)
72
CATERPILLAR
Specifications
Exhaust Manifolds (Water Cooled)

3408
(1) Elbow. Make sure the cup plug is removed from each cylinder head before the elbows are connected.
(2) Tighten the studs in the flange to a torque of ... 30 ± 5 N m (22 ± 4 lb. ft.)
73
CATERPILLAR
Specifications
Exhaust Manifolds (Water Cooled)

3412
(1) Tighten the studs in the flange to a torque of ... 30 ± 5 N m (22 ± 4 lb. ft.)
(2) Tighten long bolt to a torque of ... 55 ± 7 N m (40 ± 5 lb.ft.)
(3) Elbow. Make sure cup plug is removed from each cylinder head before the elbows are connected.
74
CATERPILLAR
Specifications
Air Lines
(3408)
NOTE: Put 5P3931 Anti-Seize Compound on the threads of all studs, bolts and nuts for the exhaust
manifolds, couplings, elbows and turbocharger support, where they become very hot.
(1) Tighten the taperlock studs in the manifold to a torque of ... 30 ± 5 N m (22 ± 4 lb.ft.)
(2) Tighten the nuts on the studs to a torque of ... 45 ± 7 N m (32 ± 5 lb. ft.)
75
(3) Torque for bolt that holds exhaust manifold support to engine ... 55 ± 7 N m (40 ± 5 lb.ft.)
(4) On earlier engines, apply a thin layer of 2P2333 Manifold Sealer to the outside diameter of male
member of joint before assembly. Remove excess sealer from assembled joint.
NOTE: Put clean engine oil or glycerin on all O-ring seals and in their bores at assembly.
76
CATERPILLAR
Specifications
Air Lines
(3412)
TYPICAL ARRANGEMENT FOR SINGLE TURBOCHARGER
NOTE: Put 5P3931 Anti-Seize Compound on the threads of all studs, bolts and nuts for the exhaust
manifolds, couplings, elbows, turbocharger support, where they become very hot.
(1) Torque for bolt that holds exhaust manifold support to engine ... 55 ± 7 N m (40 ± 5 lb.ft.)
77
TYPICAL ARRANGEMENT FOR TWO TURBOCHARGERS
(2) Plugs.
(3) On earlier engines, apply a thin layer of 2P2333 Manifold Sealer to the outside diameter of male
member of joint before assembly. Remove excess sealer from assembled joint.
NOTE: Put clean engine oil or glycerin on all O-ring seals and in their bores at assembly.
78
CATERPILLAR
Specifications
Turbochargers
(AiResearch TV81 and TW81)
(1) Turbocharger impeller installation at room temperature:
a. Put impeller on shaft.
b. Put a small amount of 2P2506 Thread Lubricant on the threads and impeller face that will be under the
nut.
c. Tighten the nut to ... 14 to 17 N m (125 to 150 lb.in.)
NOTE: Do not bend or add stress to the shaft when the nut is loosened or tightened.
79
d. Loosen th nut on the shaft.
e. Tighten the nut to ... 3.5 N m (31 lb.in.)
f. Tighten the nut more ... 120°
(2) Torque for the bolts that hold the backplate ... 10.2 ± 1.1 N m (90 ± 10 lb.in.)
(3) Torque for the clamp bolts ... 14.0 ± 1.5 N m (124 ± 13 lb.in.)
Lightly hit all around clamp with a soft faced hammer and again tighten to ... 14.0 ± 1.5 N m (124 ± 13
lb.in.)
(4) Bore in the bearings ... 15.921 to 15.931 mm (.6268 to .6272 in.)
Diameter for the surfaces (journals) on the shaft for the bearings ... 15.875 to 15.885 mm (.6250 to .6254
in.)
(5) Bore in the housing ... 24.961 to 24.973 mm (.9827 to .9832 in.)
Outside diameter of the bearings ... 24.846 to 24.859 mm (.9782 to .9787 in.)
(6) Clearance between the ends of the oil seal ring ... 0.20 to 0.38 mm (.008 to .015 in.)
(7) End play for the shaft ... 0.08 to 0.25 mm (.003 to .010 in.)
(8) Torque for bolts and nuts that hold the turbocharger to the exhaustmanifold (put 5P3931 Anti-Seize
Compound on the threads) ... 54 ± 5 N m (40 ± 4 lb.ft.)
80
CATERPILLAR
Specifications
Turbochargers
(AiResearch TV91)
a. Put impeller on shaft.
b. Put a small amount of 2P2506 Thread Lubricant on the threads and impeller face that will be under the
nut.
c. Tighten the nut to ... 31 N m (23 lb.ft.)
NOTE: Do not bend or add stress to the shaft when the nut is loosened or tightened.
81
d. Loosen the nut on the shaft.
e. Tighten the nut to ... 5 N m (4 lb.ft.)
f. Tighten the nut more ... 120°
(2) Torque for the clamp bolt ... 14.0 ± 1.5 N m (10± 1 lb.ft.)
Hit lightly all around clamp with a soft faced hammer and again tighten to ... 14.0 ± 1.5 N m (10 ± 1 lb.ft.)
(3) Bore in the bearings ... 21.585 to 21.595 mm (.8498 to .8502 in.)
Diameter of the surfaces (journals) on the shaft ... 21.539 to 21.549 mm (.8480 to .8484 in.)
(4) Bore in the housing ... 30.594 to 30.607 mm (1.2045 to 1.2050 in.)
Outside diameter of bearings ... 30.467 to 30.480 mm (1.1995 to 1.2000 in.)
(5) Clearance between the ends of oil seal ring ... 0.20 to 0.38 mm (.008 to .015 in.)
(6) End play for the shaft ... 0.165 ± 0.063 mm (.0065 ± .0025 in.)
(7) Torque for the bolts that hold the backplate ... 10 ± 1 N m (7 ± 1 lb. ft.)
Torque for the bolts and nuts that hold the turbocharger to the exhaust manifold (put 5P3931 Anti-Seize
(8) Torque for the bolts that hold the turbine housing to the cartridge housing (put 5P3931 Anti-Seize
82
CATERPILLAR
Specifications
Turbochargers
(Schwitzer F452 and F552)
A526MXJS \ 8
(1) End play for shaft (new) ... 0.114 ± 0.038 mm (.0045 ± .0015 in.)
Maximum permissible end play (worn) ... 0.20 mm (.008 in.)
(2) Thickness of thrust bearing ... 5.36 ± 0.03 mm (.211 ± .001 in.)
(3) Diameter of shaft (new) ... 14.254 to 14.262 mm (.5612 to .5615 in.)
Bore in the bearing (new) ... 14.293 to 14.300 mm (.5627 to .5630 in.)
Maximum permissible clearance between bearing and shaft (worn) ... 0.08 mm (.003 in.)
(4) Tighten band clamps with procedure that follows:
83
a. Tighten to ... 13.6 ± 1.1 N m (120 ± 10 lb.in.)
b. Tap (hit) clamp lightly all around.
c. Tighten again to ... 13.6 ± 1.1 N m (120 ± 10 lb.in.)
(5) Maximum permissible gap of oil seal ring, measured in bore of housing ... 0.23 mm (.009 in.)
a. Put 6V1541 Quick Cure Primer on the nut and the shaft threads to clean them, if necessary.
b. Put a small amount of 9S3265 Retaining Compound on the nut and shaft threads.
NOTICE
Do not let the retaining com pound get into the com pressor wheel bore
or on the shaft, because it can make removal of the com pressor wheel
difficult during future tu rb o ch arg er disassembly.
c. Put a small amount of lubricant, such as Lubriplate, on the nut seat area on the compressor. Do not put
lubricant on the threads.
d. Tighten the compressor wheel retainer nut to a torque of ... 30 ± 3 N m (22 ± 2 lb.ft.)
NOTICE
Do not bend or add stress to the shaft when the nut is tightened.
(7) Bore in housing (new) ... 22.255 to 22.268 mm (.8762 to .8767 in.)
Outside diameter of the bearing (new) ... 22.144 to 22.154 mm (.8718 to .8722 in.)
Maximum permissible clearance between bearing and bore in housing (worn) ... 0.15 mm (.006 in.)
(8) Thickness of each thrust ring ... 2.553 ± 0.013 mm (.1055 ± .0005 in.)
(9) Torque for four nuts (put 5P3931 Anti-Seize Compound on threads) ... 55 ± 5 N m (40 ± 4 lb.ft.)
84
CATERPILLAR
Specifications
Turbochargers
(Schwitzer 4MF and 4MFW)
(1) End play for shaft (new) ... 0.114 ± 0.038 mm (.0045 ± .0015 in.)
Maximum permissible end play (worn) ... 0.20 mm (.008 in.)
(2) Tighten band clamps with procedure that follows:
a. Tighten to ... 13.6 ± 1.1 N (120 ± 10 lb.in.)
b. Tap (hit) clamp lightly all around.
c. Tighten again to ... 13.6 ± 1.1 N (120 ± 10 lb.in.)
85
(3) Thickness of thrust bearing ... 5.36 ± 0.03 mm (.211 ± .001 in.)
(4) Diameter of shaft (new) ... 14.254 to 14.262 mm (.5612 to .5615 in.)
Bore in the bearing (new) ... 14.293 to 14.300 mm (.5627 to .5630 in.)
Maximum permissible clearance between bearing and shaft (worn) ... 0.08 mm (.003 in.)
(5) Maximum permissible gap of oil seal ring, measured in bore of housing ... 0.23 mm (.009 in.)
(6) Bore in housing (new) ... 22.255 to 22.268 mm (.8762 to .8767 in.)
Outside diameter of the bearing (new) ... 22.144 to 22.154 mm (.8718 to .8722 in.)
Maximum permissible clearance between bearing and bore in housing (worn) ... 0.15 mm (.006 in.)
a. Put 6V1541 Quick Cure Primer on the nut and the shaft threads to clean them, if necessary.
b. Put a small amount of 9S3265 Retaining Compound on the nut and shaft threads.
NOTICE
Do not let the retaining com pound get into the com pressor wheel bore
or on the shaft, because it can make removal of the com pressor wheel
difficult during future tu rb o ch arg er disassembly.
c. Put a small amount of lubricant, such as Lubriplate, on the nut seat area on the compressor. Do not put
lubricant on the threads.
d. Tighten the compressor wheel retainer nut to a torque of ... 60 ± 3 N m (44 ± 2 lb.ft.)
NOTICE
Do not bend or add stress to the shaft when the nut is tightened.
(8) Thickness of each thrust ring ... 2.553 ± 0.013 mm (.1005 ± .0005 in.)
(9) Torque for four nuts (put 5P3931 Anti-Seize Compound on threads) ... 55 ± 5 N m (40 ± 4 lb.ft.)
86
CATERPILLAR
Specifications
Turbocharger Oil Lines

(3408)
87
1 /TTTTQ
(1) Put 5P3931 Anti-Seize Compound on the threads of taperlock stud and tighten the stud in the exhaust
manifold to a torque of ... 30 ± 5 N m (20 ± 3 lb.ft.)
(2) Put 5P3931 Anti-Seize Compound on the threads of the stud and tighten the nut to a torque of ... 45 ±
7 N m (32 ± 5 lb.ft.)
(3) Put 5P3931 Anti-Seize Compound on the threads and tighten the bolt and nut to a torque of ... 45 ± 7
N m (32 ± 5 lb.ft.)
88
89
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ - 0 1
CATERPILLAR
Specifications
Turbocharger Oil Lines

(3412)
(1) Put 5P3931 Anti-Seize Compound on the threads of taperlock stud and tighten the stud in the exhaust
manifold to a torque of ... 30 ± 5 N m (20 ± 3 lb.ft.)
(2) Put 5P3931 Anti-Seize Compound on the threads of the stud and tighten the nut to a torque of ... 45 ±
7 N m (32 ± 5 lb.ft.)
90
(3) Put 5P3931 Anti-Seize Compound on the threads and tighten the bolt and nut to a torque of ... 45 ± 7
N m (32 ± 5 lb.ft.)
91
92
CATERPILLAR
Specifications
Oil Filter Base
3408 OIL FILTER BASE SHOWN
(1) Bypass valve for the oil cooler.
(2) Bypass valve for the oil filter.
(3) Torque for the two center studs under the filter base [put 9S3263 Thread Lock on last 7.6 mm (.30 in.)
of thread at base end of studs] ... 80 ± 14 N m (60 ± 10 lb.ft.)
NOTE: Put clean engine oil on the filter seals. Put the filters in position on stud (3) and tighten until the
seals make contact with the base. Turn the filters 270° (3/4 of one turn) more.
(4) 4N8150 Spring for either bypass valve (1) or (2):
Test force ... 75 ± 5 N (17 ± 1.3 lb.)
Pressure difference to open either bypass valve ... 255 ± 20 kPa (37 ± 3 psi)
93
CATERPILLAR
Specifications
Oil Pan
(1) Torque for three plugs with round head and square boss ... 80 ± 11 N m (60 ± 8 lb.ft.)
94
CATERPILLAR
Specifications
Oil Breather Cap
(1) Breather assembly.
(2) Torque for clamp ... 4.5 ± 0.6 N m (40 ± 5 lb.in.)
95
CATERPILLAR
Specifications
Oil Pump
NOTE: Make reference to Timing Gears to find oil pump drive gear.
(1) Diameter of drive shaft (new) ... 22.217 ± 0.005 mm (.8747 ± .0002 in.)
Bore in bearings for drive shaft (new) ... 22.258 ± 0.008 mm (.8763 ± .0003 in.)
Diameter of idler shaft (new) ... 22.217 ± 0.005 mm (.8747 ± .0002 in.)
Bore in bearings for idler shaft (new) ... 22.258 ± 0.008 mm (.8763 ± .0003 in.)
(2) Length of gears (new) ... 79.375 ± 0.025 mm (3.1250 ± .0010 in.)
Depth of bores for gears (new) ... 79.502 ± 0.020 mm (3.1300 ± .0008 in.)
(3) 2S2760 Spring (oil pressure relief):
96
Test force ... 490 ± 27 N (110 ± 6 lb.)
NOTE: 3412 Low Speed oil pump arrangement does not use spacer behind pressure relief spring.
PUMP COVER
ROTATION OF PUMP DRIVE
97
PUMP BODY
(4) Bearing junction.
(5) Position of bearing junction from the centerline through bearing bores ... 30 ± 15°
Install bearings so they are even with outside of pump body and even with FACE A of pump cover.
98
CATERPILLAR
Specifications
Radiator
TYPICAL EXAMPLE
TIGHTENING SEQUENCE FOR TYPICAL TWO-ROW TANK
99
(1) Cap (6L8617, 6L9850, or 4N3311 Pressure Cap).
(2) Torque for bolts that hold the guard* ... 20 ± 4 N m (15 ± 3 lb.ft.)
*4 bolts on smaller radiators, and 8 bolts on larger radiators.
NOTE: Use the tightening sequence shown to install top and bottom tanks to radiator core.
100
CATERPILLAR
Specifications
Pressure Cap Of Cooling System
A 2 £492X1
PRESSURE CAPS
Part No. fll_af3t7 6L985Q 4N 3311
Pressure that opens the cap 45 to 55 kPa 22 1o 28 kPa 40 1o 55 fcPa

roiief valve (6 5 to S psi) (3.5 to 4 psi) (6 to 8 psi)
Maximum vacuum that opens 7 kPa 7 kPa 7 kPa
the suction valve (1 psi) (1 psi) (1 psi)
101
CATERPILLAR
Specifications
Water Pump
3408 & 3412 Standard Engine
„ A22501X3
(1) Torque for three long studs in cylinder block ... 25 ± 4 N m (20 ± 3 lb.ft.)
Put 9S3263 Thread Lock on threads of short stud in front housing.
(2) Oil seal. Put glycerin or clean engine oil on the lip of the seal. Assemble with the lip toward the
bearings.
(3) Seal. Put a light amount of clean engine oil in the bore for the seal.
102
(4) Ring and water seal.
a. Put clean water on the seal and ring.
b. Use the seal installation tool (part of the replacement seal assembly) and hand pressure to install the
seal and ring as a unit in the housing bore. Make sure the shiny face of the ceramic ring is toward carbon
seal assembly (5).
(5) Seal Assembly:
a. Remove the spring from the seal assembly.
b. Put clean water inside the seal assembly.
c. Use the seal installation tool (part of the replacement seal assembly) and hand pressure to install the seal
assembly on the shaft until the carbon face makes light contact with the shiny face of the ceramic seal.
d. Install the spring.
(6) Torque for the bolt that holds the impeller ... 39 ± 3 N m (28 ± 2 lb. ft.)
(7) Clearance between the impeller and the housing ... 0.56 to 1.50 mm (.022 to .059 in.)
3412 Low Speed Engine
B25O40X1 ^
(1) Oil seal. Put glycerin or clean engine oil on the lip of the seal. Assemble with the lip toward the
103
bearings.
(2) Seal. Put a light amount of clean engine oil in the bore for the seal.
(3) Ring and water seal.
a. Put clean water on the seal and ring.
b. Use the seal installation tool (part of the replacement seal assembly) and hand pressure to install the
seal and ring as a unit in the housing bore. Make sure the shiny face of the ceramic ring is toward carbon
seal assembly (4).
(4) Seal Assembly:
a. Remove the spring from the seal assembly.
b. Put clean water inside the seal assembly.
c. Use the seal installation tool (part of the replacement seal assembly) and hand pressure to install the seal
assembly on the shaft until the carbon face makes light contact with the shiny face of the ceramic seal.
d. Install the spring.
(5) Torque for the bolt that holds the impeller ... 39 ± 3 N m (28 ± 2 lb. ft.)
(6) Clearance between the impeller and the housing ... 0.56 to 1.50 mm (.022 to .059 in.)
104
CATERPILLAR
Specifications
Water Temperature Regulators
Temperature when completely open ... 92°C (197°F)
Minimum opening distance at 92°C (197°F) ... 9.53 mm (.375 in.)
105
CATERPILLAR
Specifications
V-Belt Tension Chart
V B E L T TENSIO N C H A R T
B E L T TENSIO N B E L T TEN SIO N
W IDTH TO P “ Li-SEiy”
"'B im A L "' n n B R A tir.H R D A IIR F NLJHRFR3
B E L T SIZE WtDTH OP P U LL E T
B E L T TO P GROOVE G A U G E READING G A U G E f lE A d N G
mm in. mm in. N <1. N lb. O LD G A U G E NO, N EW G A U G E NO.
3/fl 10,72 422 9 85 360 145 ± 22 1O0± 5 400 ± 22 90 4: 3 BT-33-73F BT-33-95
1/2 13.69 .5*7 12.70 .500 59* + 22 1 2 0 -5 400 * 4 4 90 a ID B T -33-96-4-16 ST-33-95
5V 15. B0 .325 15.24 .600 534 T 22 ISO = £ 400 ± 44 M t 10 ST-33-T2-4-15 0T-33-72C

11/16 17.44 .038 15.88 625 534 1 22 120 - 5 + » ± 44 90 a 10 ST-33-72-4-15 BT-33-72C
3/i 19.05 ■7M 17.53 .690 53* ± 22 120 ± 5 400 r 44 SO * 10 0T-33-72-4-15 BT-33-72C
15/16 23 S3 .936 22 30 .078 53* 1 22 120 A 5 4O0 ± 44 90 ± 10 ST-33-72-4-15 B T-TJ-7 2 C
M EASURE TENSIO N O f S E LT F A R T H E S T FRO M TH E ENGINE
INITIAL1- B E L T T E N S IO N is for anew M L

JS E O " B E L T TEN B fDN is for a belt wrucfi tias mora fian 30 minutes of operation al rated speed pi engine, A10232-1 XI
106
CATERPILLAR
Specifications
Pulley And Damper
(1) Adapter.
(2) Damper.
(3) Tighten the bolts that hold the adapter to the crankshaft to a torque of ... 200 ± 25 N m (150 ± 20
lb.ft.)
(4) Tighten nuts that hold damper to adapter to a torque of ... 135 ± 14 N m (100 ± 10 lb.ft.)
(5) Tighten studs in adapter to a torque of ... 55 ± 7 N m (40 ± 5 lb.ft.)
107
CATERPILLAR
Specifications
Rear Drive Gear
(1) Camshaft.
(2) Torque for four bolts ... 25 ± 4 N m (20 ± 3 lb.ft.)
108
CATERPILLAR
Specifications
R e a r B a la n c e r
(3408)
(1) Bore in the bearing (after assembly) ... 50.902 ± 0.048 mm (2.0040 ± .0019 in.)
Diameter of the shaft (new) ... 50.800 ± 0.013 mm (2.0000 ± .0005 in.)
(2) End play (new) ... 0.15 to 0.36 mm (.006 to .014 in.)
109
CATERPILLAR
Specifications
Cylinder Block
12 13 A22990-1X1
(1) Torque for three studs to hold the water pump ... 25 ± 4 N m (20 ± 3 lb.ft.)
(2) Plug (two on front and two on rear). See note after Step 17.
(3) Length of dowels (four) out of the block face ... 18.5 ± 0.5 mm (.73 ± .02 in.)
(4) Thickness of the gasket between the cylinder block and top plates ... 0.20 ± 0.03 mm (.008 ± .001 in.)
(5) Thickness of the top plates ... 8.59 ± 0.03 mm (.338 ± .001 in.)
(6) Make reference to CYLINDER LINER PROJECTION, for the height of the liner.
(7) Bores in the block for the camshaft bearings ... 76.835 ± 0.018 mm (3.0250 ± .0007 in.)
(8) Torque for one plug on front and two on rear of the block (see note after Step 17) ... 80 ± 14 N m (60 ±
10 lb.ft.)
110
(9) Bore in the block for the main bearings:
Standard, original size (new) ... 129.891 ± 0.013 mm (5.1138 ± .0005 in.)
0.64 mm (.025 in.) larger than original size ... 130.526 ± 0.013 mm (5.1388 ± .0005 in.)
(10) Length of dowels (four) out of the front and rear faces of the block ... 19.0 ± 0.5 mm (.75 ± .02 in.)
(11) Width of slot for bearing cap ... 215.900 ± 0.013 mm (8.5000 ± .0005 in.)
Width of bearing cap ... 215.900 ± 0.025 mm (8.5000 ± .0005 in.)
Clearance between slot and bearing cap ... 0.038 mm (.0015 in.) tight to ... 0.038 mm (.0015 in.) loose
(12) Torque for the bolts that hold the piston cooling tubes ... 24 ± 7 N m (18 ± 5 lb.ft.)
(13) Torque for the bolts that hold the caps for the main bearings:
Install the main bearing caps with the marks (arrow) toward the front of the engine. Each cap has a
number on the bottom and must be installed in the same position as the correct number on the left side of
the block pan rail.
a. Put 2P2506 Thread Lubricant on the threads of the bolts.
b. Tighten the bolts on left side to ... 260 ± 14 N m (190 ± 10 lb.ft.)
c. Tighten the bolts on right side to ... 260 ± 14 N m (190 ± 10 lb.ft.)
d. Put a mark on each bolt and cap.
e. Tighten the bolts on right side, from the mark ... 120 ± 5°
f. Tighten the bolts on left side, from the mark ... 120 ± 5°
111
(14) Dimension (new) from the centerline of crankshaft bearing bore to top of block (top deck) ... 419.10
± 1.15 mm (16.500 ± .006 in.)
(15) Dimension (new) from centerline of crankshaft bearing bore to bottom of block (pan rails) ... 165.10
± 0.10 mm (6.500 ± .004 in.)
RIGHT SIDE OF ENGINE
(16) Put 9S3263 Thread Lock on two plugs located at front and rear of right cylinder bank before
installing.
(17) Put 9S3265 Retaining Compound on plug before installing.
NOTE: Put 9S3263 Thread Lock on the threads of all plugs installed without a seal.
112
CATERPILLAR
Specifications
Cylinder Liners
(1) Bore in liner (new) ... 137.19 ± 0.03 mm (5.401 ± .001 in.)
Maximum permissible bore when measured near upper end of the wear surface of the cylinder liner
(worn) ... 137.36 mm (5.408 in.)
"Use again" maximum bore (when measured near upper end of the wear surface of the cylinder liner) ...
137.29 mm (5.405 in.)
(2) Thickness of flange on liner ... 8.890 ± 0.020 mm (.3500 ± .0008 in.)
(3) Filler Band.
Installation procedure:
Put liquid soap on seals, liner grooves and bore in cylinder block. Install seals on bottom of liner. Put filler
band in SAE 30 oil for a moment, then install it on the liner. Install the liner in the cylinder block
immediately after the band is installed on the liner (before expansion of the band).
NOTE: Make reference to GUIDELINE FOR REUSABLE PARTS: PISTONS AND CYLINDER
LINERS, FORM NO. SEBF8001.
113
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 - 0 1
CATERPILLAR
Specifications
Cylinder Liner Projection
Make reference to CYLINDER LINER PROJECTION in Testing and Adjusting for complete procedure.
1. Install gasket (10) and spacer plate (9) with bolts (1). Tighten bolts (1) evenly in four steps.
1st step ... 14 N m (10 lb.ft.)
2nd step ... 35 N m (25 lb.ft.)
3rd step ... 70 N m (50 lb.ft.)
4th step ... 95 N m (70 lb.ft.)
2. Install tooling as shown. Tighten bolts (4) evenly in four steps.
1st step ... 7 N m (5 lb.ft.)
2nd step ... 20 N m (15 lb.ft.)
3rd step ... 35 N m (25 lb.ft.)
4th step ... 70 N m (50 lb.ft.)
3. Measure cylinder liner projection with dial indicator (3) in 1P2402 Gauge Body (2) as shown. Measure
at four places around each cylinder liner near the clamped area.
Cylinder liner projection measurements for any cylinder liner must be ... 0.025 to 0.152 mm (.0010 to
114
.0060 in.)
Maximum permissible difference between all four measurements ... 0.05 mm (.002 in.)
Maximum permissible difference between average projection of any two cylinder liners next to each other
... 0.05 mm (.002 in.)
Maximum permissible difference between average projection of all cylinder liners under one cylinder
head:
3408 engines ... 0.08 mm (.003 in.)
3412 engines ... 0.10 mm (.004 in.)
4. Minimum permissible depth to machine counterbore to adjust cylinder liner projection ... 0.76 mm (.030
in.)
Maximum permissible depth to machine counterbore to adjust cylinder liner projection ... 1.14 mm (.045
in.)
SHIM THICKNESS, COLOR CODE, AND PART NUMBER

0.18 mm 0.20 mm 0.23 mm 0.38 mm 0.76 mm
(.007 in.) (.008 in.) (.009 in.) (.015 in.) (.030 in.)
BLACK FED GREEN BROWN BLUE
538138 538139 5S8140 5S8141 5S8142
Install a 0.76 mm (.030 in.) shim plus any added shims necessary to get the correct cylinder liner
projection.
NOTE: Be sure that the 0.76 mm (.030 in.) shim is directly under the cylinder liner flange.
(5) 3H465 Plate.
(6) 8B7548 Push-puller Crossbar.
(7) 1P2396 Adapter Plate.
(8) 3H465 Plate (installed upside down).
115
CATERPILLAR
Specifications
Pistons And Rings

For additional information, make reference to the GUIDELINE FOR REUSABLE PARTS:
Pistons and Cylinder Liners, Form No. SEBF8001.
Pistons, Form No. SEBF8049.
Piston Pins and Retaining Rings, Form No. SEBF8051.
(1) Top ring.
(2) Intermediate ring.
(3) Oil control ring.
(4) Bore in piston for pin ... 50.815 ± 0.008 mm (2.0006 ± .0003 in.)
Clearance between pin and bore in piston ... 0.008 to 0.028 mm (.0003 to .0011 in.)
Maximum permissible clearance (worn) ... 0.05 mm (.002 in.)
Pin diameter ... 50.795 ± 0.005 mm (1.9998 ± .0002 in.)
116
PISTO NS A W PISTON FUNGS

(1 ) TOP WNG* (2 ) INTERM EDIATE RING* (3) OIL C O N TR O L BiN0 ‘ ■
Width ot groove in piston far AM
3.18& - 0.013 mm
piston ring (new). ( 1255 ± .0005 in.)
«ee W
Thickness of piston ring (new). 3.137 + 0.013 mrr
(.1235 ± 0005 in )
Clearance between groove 0.U51 ± 0.025 mm
and pislon ring (new). (,DD2D ± .0010 in.)
Maximum permissible Clearance ++*
0,15 mm
(warn). (.oce In.)
Clearance between ends of
piston ring (new) when installed 0.72$ ^ 0. I&1 mm 1 0S0 ± 0. IS1 mm 0,572 ± 0-191 mm
in a cylinder liner with a bore (.0285 * .0075 in.) (.0426 ± .0075 in.) (.0225 ± .0075 in.)
3iM Of 137. to mm (5.400 In.)
increase n daarancu between
ends of piston rim lor each 0.03 0,08 im t
mm (.001 In,) increase in cylin (.003 IP.)
der frnw bore sice
install piston rings with " L F " side toward top of piston.
NOTE: Top Fbng (1 ) has Ity rm ar*. "U P -1 ".
r.tetiitHfdinto Ring (2 ) has the merit "UP-2".
^ n s ia il Cw Control FHno (3 ) with the g&p in fh» spring 1 8 0 ° aw ay from this gap n tae ring
■Keystone" style paton rngs a id grooves in ptslrms Tho 504812 K EYSTO NE P1STOM FH»3 GROOVE GAUGE Is necessary lot
m&awnng ih w a g r p o v « . Pul t o pin (A) of ^ u g o **V* in t o groove at tour place® arowid 1he circumforenca. Do Hiia to both
grooves. The Hat edge (B> at the gauge must be between grooves ( ! ) and (2). If there is clearance between the flat (b> gf the
gauge Hud the fusion ari aH test locations, far twth grooves, ghston is reusable, ft the flart edge (B ) is in contact with t o pi9lonr a*
any of m s tsat locations, t o piston a not feuHBbfc. Install a ngw piston.
117
CATERPILLAR
Specifications
Connecting Rods
Asamxl 5 6
(1) Bore in connecting rod for piston pin bearing ... 55.436 ± 0.013 mm (2.1825 ± .0005 in.)
Tight fit between connecting rod eye and piston pin bearing ... 0.05 to 0.10 mm (.002 to .004 in.)
NOTE: Connecting rod must be heated for installation of piston pin bearing. Do not use a torch.
Heat connecting rod to temperature of ... 177 to 260°C (350 to 500°F)
Position of pin bearing:
118
AtlOHXl
MARKS FOR TIGHTENING CONNECTING ROD BOLTS
Bearing junction and locating hole are 180° apart (directly across from each other). Bearing junction and
locating hole must be assembled within either area "A" (90 ± 10° from centerline through the connecting
rod bores) as shown.
Make reference to Special Instruction Form No. SMHS7295 for use of pin bearing removal and
installation tools and procedures.
(2) Bore in connecting rod for bearing with nuts tight to specifications (6) ... 103.500 ± 0.013 mm (4.0748
± .0005 in.)
(3) Distance between center of bearings ... 261.62 ± 0.05 mm (10.300 ± .002 in.)
(4) Bore in bearing for piston pin (new) ... 50.830 ± 0.008 mm (2.0012 ± .0003 in.)
Diameter of piston pin (new) ... 50.795 ± 0.005 mm (1.9998 ± .0002 in.)
Maximum permissible clearance between bearing and piston pin (worn) ... 0.08 mm (.003 in.)
(5) Bore in bearing for crankshaft ... 97.119 to 97.175 mm (3.8236 to 3.8258 in.)
119
Clearance between bearing and crankshaft (new) ... 0.071 to 0.168 mm (.0028 to .0066 in.)
Maximum permissible clearance between bearing and crankshaft (worn) ... 0.25 mm (.010 in.)
NOTE: Bearings are available in 0.64 mm (.025 in.) and 1.27 mm (.050 in.) smaller than original size.
(6) Tightening procedure for connecting rod bolts:
a. Put 2P2506 Thread Lubricant on bolt threads and contact surfaces of nut and cap.
b. Tighten both nuts to ... 80 ± 8 N m (60 ± 6 lb.ft.)
c. Put a mark on each nut and end of bolt as shown.
d. Tighten each nut from mark ... 120 ± 5°
NOTE: The connecting rod must be installed so the chamfer on the edge of bore (5) is near the corner on
the crankshaft. The side opposite the chamfered edge must be against the other connecting rod on the
same crankshaft pin.
Side clearance between two connecting rods on same crankshaft pin (new) ... 0.28 to 0.84 mm (.011 to
.033 in.)
Make reference to Special Instruction Form Nos. GMG02394 & SMHS7366 for information to check and
recondition connecting rods.
120
CATERPILLAR
Specifications
Bearings For Connecting Rods And Mains

Make reference to GUIDELINES FOR REUSABLE PARTS: MAIN BEARINGS AND CONNECTING
ROD BEARINGS, Form No. SEBF8009, and GUIDELINES FOR REUSABLE PARTS: CRANKSHAFT
MEASUREMENT, Form No. SEBF8041.
C O N N E C TIN G ROD Bf-AHINfiS

0.64 mm (.025 ID.1 1.77 mm (.050 in.)
U N D tH S I^E UNDERSIZE
ORIGINAL W t {SM ALLER ] (S M A LLER )
JOURNAL JOURNAL JOURNAL
□lamcier ol cranksliatt jour-sl 97 0P3 * 0.020 n'dl 06.300 - 0 020 mm 95.758 1 0.020 mm
(bflarng airlaoe) 1ar connecting rad. (3.B2D0 ± .0006 n j (3 7950 = .O003 n j (3.7700 ± OOOfl in.)
Clearance between bearing and 0.07 1 1o 0. 166 i n '1
iCJT'ial ir«w ). ( 0028 to 0060 ii.)
Maximum pennisaitJe clearance 0.P5 mm
eelwetfl bearing and journal. (.010 m.)
MAIN BEARING3
0.54 mm 1-035 in.) 1.27 mm (josO in.j
UNDERSIZE UNDERSIZE
ORIGINAL SIZE (S M A LLER ) (SM ALLER )
JO UR NAL JO UR NAL JOURNAL
Oipneler gl craakgtiaft journal 120.650 * 0 020 mm 120.015 ± 0,020 mm 119.330 ± 0.020 mm

(bearing surface) tor man bearings (4.7530 ± jOOOfl inj (4.725C I .0006 ) (4 7000 ± .0006 ai.)
Clearance between bearing anc 0 09 t (0 0, IB6 mm
jPLiral (new]. (.0036 lu .0073 in.)
Maximum pormissfefc clearanca 0 25. mm
belweeii bearing And journal. (0 1 0 In.)
121
CATERPILLAR
Specifications
Crankshaft
3408 CRANKSHAFT SHOWN
(1) Maximum length of pin out of crankshaft face ... 6.4 mm (.25 in.)
(2) Thrust plates, at center main bearing.
(3) End play for the crankshaft (new) ... 0.15 to 0.50 mm (.006 to .020 in.)
(4) Minimum torque for five plugs ... 23 N m (17 lb.ft.)
"Stake" (make a mark with a punch) the crankshaft to hold the plug tight.
(5) Length of dowel out of the crankshaft ... 4.1 ± 0.5 mm (.16 ± .02 in.)
(6) Maximum permissible temperature of the gear for installation on the crankshaft ... 232°C (450°F)
NOTE: Install gear with "V" mark to the outside.
122
(7) Rear wear sleeve and seal. For installation procedure, see (10).
(8) Make reference to CONNECTING ROD BEARINGS.
(9) Make reference to MAIN BEARINGS.
(10) Front wear sleeve and seal:
Remove wear sleeves with 5P7318 Distorter Group. Install front and rear wear sleeves and seals as
follows:
a. Clean the outer surface of the crankshaft with 6V1541 Quick Cure Primer.
b. Install the sleeve and seal as a unit on the crankshaft with the correct tooling.
NOTE: See Special Instruction Form SMHS7100 for the necessary tools and complete procedure for
installation of wear sleeves and seals.
123
CATERPILLAR
Specifications
Flywheel
TYPICAL ILLUSTRATION
Make reference to FLYWHEEL RUNOUT for the correct method of flywheel inspection.
(1) Gear. Maximum temperature for installation ... 316°C (600°F)
NOTE: Install gear with chamfer on teeth in direction shown.
124
(2) Put 2P2506 Thread Lubricant on all the bolts that hold the flywheel to the crankshaft and tighten them
to a torque of ... 270 ± 27 N m (200 ± 20 lb. ft.)
NOTE: Service flywheels may include two dowels. Do NOT install these dowels in flywheel of 3412
Engines.
125
CATERPILLAR
Specifications
Flywheel Runout
Face Runout (Axial Eccentricity) of the Flywheel:
CHECKING FACE RUNOUT OF THE FLYWHEEL
1. Install the dial indicator as shown. Put a force on the flywheel toward the rear.
2. Set the dial indicator to read 0.0 mm (.000 in.)
3. Turn the flywheel and read the indicator every 90°. Put a force on the flywheel to the rear before each
reading.
4. The difference between the lower and higher measurements taken at all four points must not be more
than 0.15 mm (.006 in.) which is the maximum permissible face runout (axial eccentricity of the flywheel).
Bore Runout (radial eccentricity) of the Flywheel:
126
CHECKING FLYWHEEL BORE
CHECKING FLYWHEEL CLUTCH PILOT BEARING BORE
1. Install the dial indicator (3) and make an adjustment of the universal attachment (4) so it makes contact
as shown.
2. Set the dial indicator to read 0.0 mm (.00 in.)
127
3. Turn the flywheel and read the indicator every 90°.
4. The difference between the lower and higher measurements taken at all four points must not be more
than 0.15 mm (.006 in.), which is the maximum permissible bore runout (radial eccentricity) of the
flywheel.
5. Runout (eccentricity) of the bore for the pilot bearing for the flywheel clutch, must not exceed 0.13 mm
(.005 in.)
128
CATERPILLAR
Specifications
Flywheel Housing
(8N3738)
129
TORQUE SEQUENCE
See FLYWHEEL HOUSING RUNOUT and FLYWHEEL HOUSING BORE for the correct methods of
flywheel housing inspection.
(1) Torque the bolts that hold the flywheel housing to the block in the sequence that follows:
a. Tighten bolts 1 thru 8 in number sequence to ... 135 ± 14 N m (100 ± 10 lb.ft.)
b. Tighten bolts 9 thru 20 in number sequence to ... 55 ± 7 N m (40 ± 5 lb.ft.)
c. Again tighten bolts 1 thru 8 in number sequence to ... 135 ± 14 N m (100 ± 10 lb.ft.)
d. Again tighten bolts 9 thru 20 in number sequence to ... 55 ± 7 N m (40 ± 5 lb.ft.)
NOTE: After assembly, cut the gasket off even with the bottom of the flywheel housing.
(2) Plug (two). Tighten each plug to a torque of ... 54 ± 14 N m (40 ± 10 lb.ft.)
130
CATERPILLAR
Specifications
Flywheel Housing
(4N2931 &2W3218)
131
A6020BX1 8 *
TORQUE SEQUENCE
See FLYWHEEL HOUSING RUNOUT and FLYWHEEL HOUSING BORE for the correct methods of
flywheel housing inspection.
(1) Put 5P3413 Pipe Sealant on the four bolts for installation of housing to engine block.
Tighten the bolts that hold the flywheel housing to the block in the sequence that follows:
a. Tighten bolts 1 thru 8 in number sequence to ... 135 ± 14 N m (100 ± 10 lb.ft.)
b. Tighten bolts 9 thru 20 in number sequence to ... 55 ± 7 N m (40 ± 5 lb.ft.)
c. Again tighten bolts 1 thru 8 in number sequence to ... 135 ± 14 N m (100 ± 10 lb.ft.)
d. Again tighten bolts 9 thru 20 in number sequence to ... 55 ± 7 N m (40 ± 5 lb.ft.)
NOTE: After assembly, cut the gasket off even with the bottom of the flywheel housing.
(2) Put 5P3413 Pipe Sealant on the stud threads. Install the studs until they extend from the housing a
distance of ... 25.4 ± 1.5 mm (1.00 ± .06 in.)
132
CATERPILLAR
Specifications
F ly w h e e l H o u s in g R u n o u t
F a c e R u n o u t (a x ia l e c c e n tr ic ity ) o f th e F ly w h e e l H o u s in g :
8S2328 DIAL INDICATOR GROUP INSTALLED (TYPICAL EXAMPLE)
1. Fasten a dial indicator to the crankshaft flange so the anvil of the indicator will touch the face of the
flywheel housing.
2. Put a force on the crankshaft toward the rear before reading the indicator at each point.
133
C (T O P )
A (B O T T O M )
3. With dial indicator set at 0.0 mm (.000 in.) at location (A), turn the crankshaft and read the indicator at
locations (B), (C), and (D).
4. The difference between lower and higher measurements taken at all four points must not be more than
0.30 mm (.012 in), which is the maximum permissible face runout (axial eccentricity) of the flywheel
housing.
134
CATERPILLAR
Specifications
Flywheel Housing Bore
C fTOP )
A (BOTTOM)
135
NOTE: Write the dial indicator measurements with their positive (+) and negative (-) notation (signs).
This notation is necessary for making the calculations in the chart correctly.
1. Fasten the dial indicator to the flywheel so the anvil of the indicator will touch the flywheel housing
bore. With the dial indicator in position at (C), adjust the dial indicator to "0" (zero). Push the crankshaft
up against the top bearing. Write the measurement for bearing clearance on line 1 in column (C).
2. Divide the measurement from Step 1 by 2. Write this number on line 1 in columns (B) & (D).
3. Turn the crankshaft to put the dial indicator at (A). Adjust the dial indicator to "0" (zero).
4. Turn the crankshaft counterclockwise to put the dial indicator at (B). Write the measurement in the
chart.
5. Turn the crankshaft counterclockwise to put the dial indicator at (C). Write the measurement in the
chart.
6. Turn the crankshaft counterclockwise to put the dial indicator at (D). Write the measurement in the
chart.
7. Add lines I and II by columns.
8. Subtract the smaller number from the larger number in line III in columns (B) & (D). The result is the
horizontal "eccentricity" (out of round). Line III, column (C) is the vertical eccentricity.
136
CHART fo r d i a l in d ica to r m e a s u r e m e n t s
Position of
dial indicator
Lina
No. A a c D
C o rrectio n fo r bearing clearance \ 0
Dial in d icato r R eading II 0

U » It ■*
T otal of Line 1 & 2 III 0
*T otal V ertical eccen tricity (out of ro u n d ).

" S u h t r a c t the sm aller Mo. from the larger No. The d ifference is
th e to tal h o rizo n tal eccentricity
9. On the graph for total eccentricity find the point of intersection of the lines for vertical eccentricity and
horizontal eccentricity.
10. If the point of intersection is in the range marked "Acceptable" the bore is in alignment. If the point of
intersection is in the range marked "Not Acceptable" the flywheel housing must be changed.
137
CATERPILLAR
Specifications
Alternators And Regulators
138
AllcrnatDra (pelco-Rettty M -S IJ
Vollage Rutins 1ZV 24V
CHtgrp4l3r Number 7 0 /3 8 3 ON9204 ST6352 5N6692
rjettoflamy Numbor 117641 1117640 1117647 1117042
Polarity
Negalfrd grQ.rwt
Rotation
Erih&r ttroclron
Speed fer testing [rpmfl 2000 e&oo 2000 6500 2600 BEOO 2500 6500
2SA gsa 1SA 05A ISA
Output (ouid; ■35A 12 A 4SA
a: at at ftt ml a: el at
14V 14V 23V 23V 20V 23V 26V 26V
fTflied output [hof>
at man. speed bo a 3£ A 45,A
IFietd current at rated
voltage and 0CFF (27°G1 7.0 to 0 □ A 2.6 to 3.2 A
PostNe output
e 2 to 3.0 N m
ierninaf torquE
{S5 to 71 IP in.)
( i ] Ground
1.7 Id 2.0 N « 1
Is'irttwl torque
(16 to lb. n .)
(21 Shaft nut torque 95 to 109 N-m
(70 to 30 |p. f O
Reg ulster untide Alter [UlOfS'l
RaguLKpr 90S235 376353
Voltage setting
No adjustment
Keriniasiple vottsge range 13 to- 1b V 26 10 30 V
139
Alternators (Delco-Rem 25-SI)
Voltage Rating 12V
Caterpillar Number 5S6698

1117227
Delco-rlemy Number 1117228
1117242
Polarity Negaiive ground
' Rotation Either direction

""11■
Sueed tot testing 5 0 0 0 rpm
Output (cold) 70A
Rated output (hot) 75A

at max. speed --------------------- —
Field current at rated 4 1 tO
voltage and 3 0 T (27 PC) 4 5A
95 to 109 N m
(1 ) Torque for nut
(7 0 to B0 lb. f t )
(2 ) Torque tor output 12 to 15 N m

terminal <9 lo 11 lb. ft.)
Regulators (Inside Alternators)
Regulator 7N 284
Voltage setting range 13 to 15 V
'Adjust voltage setting to: 14V
Then increase speed 75A

to get max output of:
'Two types o* adjustment: One type adjustment made by removing
pipe alug and turning adjusting screw one or two notches clockwise
lo raise vollage setting and one or two notches counterclockwise to
lower voltage setting. Second type adjusted simifiar except remove
end cover to expose a potentiometer for adjustment.
140
141
( D e lo p -R a m y 3 0 -S t) tBrLBhlftSB)
V o lla gH llst.n o
24V 32V
C m flrp lla r Num ber
■1N3S00 4N 35B7
' D e i o A l e m y Num ber
1117734 1117733
RCtarity
Insulated ground
R ntal la^
Eiltifff rSrectton
S p e e d for tesling (r p m ) 2600 esoo 2W O B&OG
46A 60A 25.4 60A
O utput (C O W ) at at ■if at
2BV 26V 36V 36V
H a le d output ( h c t ) at m a* upHed
S tlA
R e id Current at ra lo d MiJtHge and 3 C JF (2 7 " O 2 .2 10 2. 7 A 3 4 to 3 7 A
( 1 ) {Jbeft nul LCigue £)£ to 109 N m
(7 C to 9 0 H) ft.)
[ 2 ) T o rq iw for output lerm ixnl 6 B to 3 0 M m
(£ 0 to 72 Ih in )
A e g u lo lD r tln n id c A lte r n a to r )
R egulator
376354
V nlrn ge s e llin g ranfie
■36 lo 3 0 V - 3 3 to 3 9 V
R e le d voltage
?6V 37 5 V
f.’irJi.ne ...ki.___ ■ -- . .
' A d M t v o t a n u Wirti 4 - p O H i ™ c a p (A ): higti; r « d . h ig h -3 : m ed. lo w -2 flfd luw. .
pOsilion IS for 16 celll battery S ys le m {3 2 V ). f a 15 cell h a lta ry syste m , pull r ^ t t a p (A ) and c n a n y t Id [HJa-tior a lor 3 0 V
142
CATERPILLAR
Specifications
Alternators
143
Alternator* (Bosch)
Voltage Rating 24V
Caterpillar Number 6N9294 7N9720
Bosch Number 0122469001
Polarity Negative ground
Rotation Either direction
Speed for testing 4 0 0 0 rpm
Output (cold) 47A
Output (hot) 37 A
Field current at rated 1.8A

voltage and 7 7 * F (2 5 ° C )
9 5 to 109 N m
(1 ) To rqu e for pulley nut
(7 0 to 8 0 lb. ft.)
(2 ) To rqu e for output 7 .5 to 10,0 N m

terminal (5 5 to 7.4 lb. ft.)
144
Alternator* (Motorola)
Voltage Rating 24V
Caterpillar Number 2N6398
Motorola Number 8M H3005F
Polarity Insulated
Rotation (a s seen from Either

drive end)
Testing Spe e d (rp m ) 1800 2500
'2 1 .5 A '3 1 A
Output (cold) at 2 8 V at 28V
Rated output **31.2A
Field current at rated 3 0 A Maximum

voltage and 8 0 SF ( 2 7 ° C )
5 3 to 67 N m
(1 ) To rq u e for pulley nut (4 0 to 5 0 lb. ft.)
1.7 to 2.2 N
(2 ) Tension Brush Spring (6 to 8 o z .)
I .. ..
'6 .5 to 9 .3 % higher with no regulator.

"1n air temperature of 77 DF (2 5 ° C ); Speed 5 0 0 0 rpm; and temperature
and output constant.
145
CATERPILLAR
Specifications
Regulators
Re gulatoro for Alternators (Boach)
Caterpillar Bosch Voltage Voltage

Polarity Setting Max, Oulput
Number Number Rating at » V
Range
9G756? tm ?0530l0 Negative

28V 28.7 to 2B 3V 40A
ground
146
147
CATERPILLAR
Specifications
Electric Starter Motors
D E LC O -F E M V S T A R T E R M Q T O n S _
| ■fit)
Torque for
K re a i
| bolding
No Load
Clearance
Pi Ition Current Cw iaum p- betwaan pinion
(11 hfluama
Rotation Hon (D raw ) wilti and Housing
Spe ed Torque lw to lever
DelCO- as EBHT) solenoid » t __V* (pinion clearance)
ie-minal nut* ho us him
Caterpillar Remv from drive m m (in .)
Min. May. N-m (lb .ft) N-m (lb.ft )
Number Numbnr end Min.
24 Volt Starter Motors [DdPfrFlerny - Enclosed Lever - Heavy Doty)
1 1 14115 ■OSA 125A

e N ie e s
n Has i
7C 30
27.0 tu 33.8 17.810 23.0 6.3 to 9 9 ,
11D9979 120 A
5N9677 cw tw o (20 to PS) (13 tc 17) (.33 to .39)
1 109775
3l2t!49 1114984
9000 70A I IDA
11148(9 ------- ■
32 Vo It Starter Motors (Dsileo-Pemy - Enclosed Lever - Heavy d u ly )
9LB2G7 i tir-ifltia
4N6471 ’ ’ 14719 32K 4CH>3 7£A USA
27.0 to 33-8 17.6 lo £3.0 3.3 10 9.9
6N-30&7 1113880
(PO to 25) (1 3 to 17) (.3 3 (0 .3 9 )
SN3?£fi 1 109769
1109282 7600 105-30 100 A 125A
3T 2773
3 T2 7 7 J 11 09 2 8 1 ; - . . ------ i
'2i-V Starter moiots adsrvsic ?.l ?0V
32V Starter frot-as sdetrcic f t 2-S'V.
148
9G5584 24V (Prestolite Number MES650 1D)
Rotation as seen from drive end ... clockwise
Current consumption (draw) at 20 V with no load and a minimum speed of 6500 rpm ... 77A
(1) Torque for housing bolts ... 11 N.m (8 lb. ft.)
(2) Torque for terminal nuts ... 27 to 33.8 N.m. (20 to 25 lb. ft.)
(3) Clearance between pinion and housing (pinion clearance) ... 0.51 to 1.27mm (.020 to .050 in.)
149
CATERPILLAR
Specifications
Starter Magnetic Switches
9F3099 24V (Delco-Remy Number 0001481)

Current consumption (draw) both windings at 24 V ... .83 to .89 A
.10 7 0 / 'X 2
(1) Torque for large terminal nuts ... 4.0 ± 0.6 N m (35 ± 5 lb.in.)
150
CATERPILLAR
Specifications
Starter Solenoids
-------- ._
SlaMer Solenoid* (Delco-FemyJ
I 11) (2)
' Torque Torque
Terminal Terminal
Nu1* Screw*
Caterpillar 0 slrro -He m* VollH^O Current CansumpUsn (D n w |
Mm N-m
Number Humber Rating Pull in Wmdmgt rtold-m winding* (fc.1t.) lltrin.l
5L3&3& r . f l s B.jA 4.3 to 5 3A
al BV ar 2!jv
32V
STS051 11 15560 7 to 8 3A J Id 5.3A
af liJV 31 2BV
25 to 36 t 8 10 2.4
1119332
4M 1#l 1J5 10 lo 1 1 .5 A a (2G to 26) (16 ;o 30)
1119343 at C,V at 29 10 24V
24V
JT3431 1116659 9 to 11 Sit G.BA mar
------------ at SV at 20V
151
Startler Solenoids (Preilolite)

Current Consumption [CrAwl
Caterpillar Prestunte Voltage 01 31*C (70'F|
N um btr Number Ruling Pull-In Winding HoW-in Winding
as 132ft SAT-4 101
9K7375 SAT-4103
£4V 23 2 la 2£.CA 4 1 t(J 4.SA
araaws &4T-4105 at 1T i A T 12V
3T8035 S a t -4107
152
CATERPILLAR
Specifications
Shut-Off Solenoids
B38989X1
153
£hUl-Dff Solenoid* (D a lco -D u a l CoilJ

Caterpillar Number 2N 2384 3 1 2 385
1 ' tSSS.S
□aleo-Kcm y Number 1 119S30
f 1 15523-H
24V
Vnhege rtnling 12V □j
3SV
P iilin a ,4 tn 9 .5 A 5 5 l!t 6 3A
Windings- at 6V at t)V
Current 12.2 10 1 6 W
Pt*Hn fG .3 Ifl 22 ESA
Cnr'RunnpHoii at 2C to 24V
WindrtQS at 10 to 12V
■ (Draw l
Hnlri-ir
1A at 10 lo 12V .4 5 A at 2 0 Id 24V
Windlnas
(t) 1.23 to 1.92 N-m [ 1 1 lo 17 lb in.]
Tnr-qua lor terminal nutg
iJ-tS9tS2 Of 1/ 8 mm
3NG40 Shaft (.7 0 In.J
<2)
Distanrfl iTtini T L S l f B S h F .tr 29. J 10 S i -S m n (,1.t7 to 1.20 fn.l
shsfr shoulder 27.3 rr.m
to plunger T 0 2 6 Shaft — (1 .1 0 m.]
plate'
0*1124 i a * n 24 4 min ( 9G ir.)
(3)
Distance- ot pinnae* travel
1 $ T m m ( 62 in.)
[start with dimension of
11.2 m n (.44 In.] at J]
'On engine lesl can show n w d dor mors adjustment
Hold in tesl on ongiit must take less thar 2A.
''Uasii a?1 engine Hitipped wilh Woodward PEiG gdvsrnofs.
Shut-Off glenoid* (Li*K-3inglE Uoil)

Activated to:
Caterpillar LMk Vollspe Coil Rniriinc*
NuWbCf Numbtr Rating ■t iSrC (I7^F] Run shut-orl'
a e in w toeo 2 X
24 ta O^V 3.3 la 4. 1 Ohms
uteiao IV 1121-2 X
'Duty-iutafmHtBtil, 2.5 minutes- man "3 0 ".
154
CATERPILLAR
Specifications
Pressure Regulating Valve For Air Starting Motor
(1) Adjusting bolt.
(2) Inlet pressure ... 1725 kPa (250 psi)
Maximum permissible pressure ... 3100 kPa (450 psi)
(3) Maximum permissible outlet pressure ... 1030 kPa (150 psi)
Minimum outlet pressure ... 620 kPa (90 psi)
155
CATERPILLAR
Specifications
Air Starting Motors
(3408)
6N4147 & 6N4148 (IngersoU-Rand Number 150 BMP-E78RH-54)
Output torque (minimum) ... 70 N m (50 lb.ft.)
with motor at ... 2240 rpm
at a pressure of ... 830 kPa (120 psi)
6N4147 SHOWN
(1) Tighten the bolts in steps to a torque of ... 25 to 35 N m (20 to 25 lb.ft.)
(2) Clearance between rotor and end plate ... 0.81 mm (.032 in.)
(3) Tighten the bolts in steps to a torque of ... 11.3 N m (100 lb.in.)
(3412)
3N9413 (Ingersoll-Rand No. VRSM 110/3N9413), 6N4562
(IngersoU-Rand No. VRSM 110/6N4562)
156
(1) Torque for bolts ... 25 to 35 N m (20 to 25 lb.ft.)
(2) Pinion retainer screws:
Step 1. Tighten screws evenly in small increases until torque is ... 11.3 N m (100 lb.in.)
Step 2. Hit retainer with hammer.
Step 3. Torque screw again to ... 11.3 N m (100 lb.in.)
(3412)
5N8788 (IngersoU-Rand No. SS800R/5N8788), 5N8789
(IngersoU-Rand No. SS800R/5N8789)
(1) Cover.
157
Put 2P2506 Thread Lubricant on the threads of the bolts that hold cover and housing to the case at
assembly.
Tighten the bolts evenly in small increases until the torque is ... 80 N m (60 lb.ft.)
(2) Torque for bolts ... 36 N m (28 lb.ft.)
(3) Torque for bolt ... 78 N m (57 lb.ft.)
(4) Torque for bolt that holds pinion ... 110 N m (80 lb.ft.)
(5) Rotor clamp nut.
Tighten nut until clearance between rear end plate and rotor is ... 0.03 to 0.08 mm (.001 to .003 in.)
Check clearance again after the bolt for the clamp nut is tightened.
(6) Torque for bolt that holds rotor ... 120 N m (90 lb.ft.)
158
CATERPILLAR
BDC From the Library of Barrington Diesel Club
Specification
S/N: 81Z00001 -04999
END OF FILE - Page 159 of 159
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CATERPILLAR S E N R 2 5 6 1 -0 1

BDC From th e L ib ra ry of Barrington Diesel Club

Page 1 of 159 pages

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CYLINDER AND VALVE LOCATION

Bore ... 137.2 mm (5.40 in.)

Stroke ... 152.4 mm (6.00 in.)

Arrangement and Number of Cylinders ... 65° V-8

Valves per Cylinder ... 4

Combustion ... Direct Injection

Firing Order (Injection Sequence) ... 1,8,4,3,6,5,7,2

Rotation of Crankshaft (when seen from flywheel end) ... counterclockwise

N O TE: Front end of engine is opposite to flywheel end.

No. 1 cylinder is the front cylinder on the left side.

No. 2 cylinder is the front cylinder on the right side.

CYLINDER AND VALVE LOCATION

Bore ... 137.2 mm (5.40 in.)

Stroke ... 152.4 mm (6.00 in.)

Arrangement and Number of Cylinders ... 65° V-12

Valves per Cylinder ... 4

Combustion ... Direct Injection

Firing Order (Injection Sequence) ... 1,4,9,8,5,2,11,10,3,6,7,12

Rotation of Crankshaft (when seen from flywheel end) ... counterclockwise

NO TE: Front end of engine is opposite to flywheel end.

No. 1 cylinder is the front cylinder on the left side.

No. 2 cylinder is the front cylinder on the right side.

Fuel System Identification

FUEL INJECTION PUMP AND GOVERNOR DRIVE

3408 FUEL SYSTEM WITH

FUEL INJECTION PUMP AND GOVERNOR GROUP

3406 FUEL SYSTEM WITH

Fuel System Identification

FUEL INJECTION PUMP AND GOVERNOR DRIVE GROUP

3412 FUEL SYSTEM WITH

FUEL INJECTION PUMP AND GOVERNOR GROUP

3412 FUEL SYSTEM WITH

PUMP GROUPS WITH STEEL LIFTERS

3408 Firing order (injection sequence) ... 1,8,4,3,6,5,7,2,

Injection timing before TC (top center) ... 28 ± 1°

3412 Firing order (injection sequence) ... 1,4,9,8,5,2,11,10,3,6,7,12

Injection timing before TC (top center):

Standard Engine ... 30 ± 1°

Low Speed Engine ... 22.5 ± 1°

(1) Torque for bushing ... 205 ± 14 N m (150 ± 10 lb.ft.)

(2) 6N24 Spring:

Length under test force ... 9.53 mm (.375 in.)

Test force ... 56 ± 3 N (12.5 ± .6 lb.)

Free length after test ... 13.03 mm (.513 in.)

Outside diameter ... 11.68 ± 0.13 mm (.460 ± .005 in.)

(3) Thickness of spacers:

9N6496 Spacer ... 4.12 mm (.162 in.)

9N6495 Spacer ... 4.22 mm (.166 in.)

5M2697 Spacer ... 4.32 mm (.170 in.)

2M4208 Spacer ... 4.42 mm (.174 in.)

2M4209 Spacer ... 4.52 mm (.178 in.)

2M4210 Spacer ... 4.62 mm (.182 in.)

2M4211 Spacer ... 4.72 mm (.186 in.)

2M4212 Spacer ... 4.83 mm (.190 in.)

5M2691 Spacer ... 4.93 mm (.194 in.)

5S7189 Spacer ... 5.03 mm (.198 in.)

(4) UFTER SPRINGS

(5) Bores for the racks:

(7) Length of injection pump plunger. See chart that follows.