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Specification
3408 & 3412 GENERATOR SET ENGINES
S/N: 81Z00001-04999
CATERPILLAR'
Specifications
3408 & 3412 GENERATOR SET ENGINES
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.
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3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR'
Specifications
3408 & 3412 GENERATOR SET ENGINES
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)
Rotation of Fuel Pump Camshaft (when seen from pump drive end) ... counterclockwise
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3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
Left side and right side of engine are as seen from flywheel end.
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3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR'
Specifications
3408 & 3412 GENERATOR SET ENGINES
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)
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3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
Rotation of Fuel Pump Camshaft (when seen from pump drive end) ... counterclockwise
Left side and right side of engine are as seen from flywheel end.
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3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR'
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
(1) Location of stamped part number on Fuel Injection Pump and Governor Group or Drive.
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3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
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3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
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3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR'
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
(1) Location of stamped part number on Fuel Injection Pump and Governor Group or Drive.
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3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
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3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
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3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR'
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
3408 & 3412G EN E R ATO R SET ENGINES S E N R256 1-0 1
A-5P4158 GAUGE
NO TE: Make reference to FUEL SYSTEM CHART in FUEL SYSTEM IDENTIFICATION section
to find specific arrangements.
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3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
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.)
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3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
Maximum permissible clearance between the bearings and the camshaft ... 0.25 mm (.010 in.)
(8) Timing dimension for fuel injection pumps. See chart that follows.
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.)
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3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
(10) Torque for nuts that hold the nozzles ... 75 ± 7 N m (55 ± 5 lb.ft.)
(11) Body.
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
3408 & 3412 GENERATOR SET ENGINES
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
Dashpot Governors
B25038X1
N O TE: Any adjustment to the governor must be made only by a person approved by Caterpillar or by
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3408 & 3412G EN E R ATO R SET ENGINES S E N R256 1-0 1
a Caterpillar Dealer.
(4) Cushion spring for piston assembly. See MISCELLANEOUS 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.)
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3408 & 3412G EN E R ATO R SET ENGINES S E N R256 1-0 1
(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.)
(11) Install dowels to get a dimension of ... 5.6 ± 0.5 mm (.22 ± .02 in.)
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3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
1? 13 14
(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.)
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3408 & 34 12 G EN E RATO R S ET E N G IN ES__________________________________________________________ SE N R2561 -0 1
(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.)
(18) Distance from center of bolt hole to outside end of needle bearing (17) ... 21.69 ± 0.50 mm (.854
± .020 in.)
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3408 & 3412G EN E R ATO R SET ENGINES S E N R256 1-0 1
CATERPILLAR'
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
Governor Linkage
(Woodward PSG)
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3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
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.
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3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR'
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
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3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
(2) Governor oil pump relief valve must open at ... 1200 kPa (175 psi)
(4) Adjust clutch assembly to slip at ... 0.7 ± 0.06 N m (6.0 ± .5 lb.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.)
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.)
(14) Bore in oil pump idler gear ... 7.734 to 7.747 mm (.3045 to .3050 in.)
26
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
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.)
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3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR'
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
(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:
N O TE: The following tooling is available to position the rack bearings correctly: 5P6217 Fixture and
5P6218 Driver.
(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
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3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
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.)
(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.)
(10) Distance from top surface of housing to top of lower governor drive bearing ... 28.4 ± 0.5 mm
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3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
(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.)
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3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR'
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
(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:
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.
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3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
(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.)
(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.)
32
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
(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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR'
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
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3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
B M g lX l
(1) Torque for oil pump bypass valve body ... 70 ± 14 N m (50 ± 10 lb.ft.)
Free length after test ... 34.8 ± 0.3 mm (1.37 ± .01 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.)
(5) Bearing diameter (after assembly) ... 19.093 ± 0.038 mm (.7517 ± .0015 in.)
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3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
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.)
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3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR'
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
6N3195 SHOWN
37
3408 & 3412G EN E R ATO R SET ENGINES S E N R256 1-0 1
(5) Torque for the four bolts ... 135 ± 7 N m (100 ± 5 lb.ft.)
38
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR'
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
39
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
(3) Torque for the four bolts ... 135 ± 7 N m (100 ± 5 lb.ft.)
40
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR'
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
(1) Torque for the four bolts ... 135 ± 7 N m (100 ± 5 lb.ft.)
41
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR'
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
(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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR'
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
(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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR'
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
(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)
44
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
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.)
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.)
Pressure of fuel to open the valve ... 230 kPa (33 psi)
45
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR'
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
A 2 2 4 9 5 -1 X 1
(1) Bore in bearing (after assembly) ... 11.961 ± 0.033 mm (.4709 ± .0013 in.)
(2) Temperature of the gear for installation on the shaft ... 232°C (450°F)
46
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR'
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
(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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
48
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
(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.)
49
3408 & 3412G EN E R ATO R SET ENGINES SE N R256_ -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
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
(3) Tighten the bolts for the base in the number sequence shown to ... 14 ± 4 N m (10 ± 3 lb.ft.)
50
3408 & 3412G EN E R ATO R SET ENGINES SE N R256_ -0 1
A 50512XI
(4) Tighten the bolts for the cover in the number sequence shown to ... 14 ± 4 N m (10 ± 3 lb.ft.)
51
3408 & 3412G EN E R ATO R SET ENGINES SE N R256_ -0 1
CATERPILLAR'
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
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
(3) Tighten the bolts for the base in the number sequence shown to ... 14 ± 4 N m (10 ± 3 lb.ft.)
(4) Tighten the bolts for the cover in the number sequence shown to ... 14 ± 4 N m (10 ± 3 lb.ft.)
53
3408 & 3412G EN E R ATO R SET ENGINES SE N R256_ -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
(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
3408 & 3412G EN E R ATO R SET ENGINES S E N R256 1-0 1
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.)
(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.
55
3408 & 3412G EN E R ATO R SET ENGINES S E N R256 1-0 1
(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.)
56
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
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.
Use again minimum load at length under test force ... 291 N (65.4 lb.)
57
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
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.)
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.)
(6) Depth of bore in head for valve seat insert (new) ... 13.01 ± 0.15 mm (.512 ± .006 in.)
58
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
(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°
59
3408 & 3412G EN E R ATO R SET ENGINES S E N R256 1-0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
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
3408 & 3412G EN E R ATO R SET ENGINES S E N R256 1-0 1
C. Subtract base circle (STEP B) from lobe height (STEP A.). The difference is actual lobe lift (6).
Minimum permissible difference between actual lobe lift (STEP C) and specified lobe lift (STEP D) is
0.13 mm (.005 in.)
61
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
(1) Fuel injection pump drive gear and timing advance unit.
62
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
(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)
(7) End clearance (new) ... 0.28 to 0.35 mm (.011 to .014 in.)
63
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
(1) Fuel injection pump drive gear and timing advance unit.
64
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
(6) Diameter of the shaft (new) ... 63.500 ± 0.013 mm (2.5000 ± .0005 in.)
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.)
(10) Distance that bearing is installed from the face of idler gear ... 1.12 ± 0.25 mm (.044 ± .010 in.)
(11) Diameter of the shaft (new) ... 34.943 ± 0.013 mm (1.3757 ± .0005 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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
(1) Torque for stud on back of the housing ... 25 ± 4 N m (20 ± 3 lb. ft.)
Dimension stud must be extended above timing gear housing ... 73.2 mm (2.88 in.)
66
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
(4) Put 5P3413 Pipe Sealant on the threads of two studs for installation in the housing.
67
3408 & 3412G EN E R ATO R SET ENGINES S E N R256 1-0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
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 2. Tighten bolts from 1 to 14 in number sequence to ... 450 ± 20 N m (330 ± 15 lb.ft.)
Step 3. Tighten bolts from 1 to 14 in number sequence again to ... 450 ± 20 N m (330 ± 15 lb.ft.)
Step 5. Tighten bolts from 15 to 18 in number sequence to ... 270 ± 25 N m (200 ± 20 lb.ft.)
Step 6. Tighten bolts from 15 to 18 in number sequence to ... 450 ± 20 N m (330 ± 15 lb.ft.)
Step 7. Tighten bolts from 15 to 18 in number sequence again to ... 450 ± 20 N m (330 ± 15 lb.ft.)
Step 8. Tighten the nine small bolts (2) to ... 43 ± 7 N m (32 ± 5 lb.ft.)
(3) Torque for eight studs in each cylinder head ... 25 ± 4 N m (20 ± 3 lb. ft.)
68
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
(4) Height of cylinder head (new) ... 112.78 ± 0.25 mm (4.440 ± .010 in.)
69
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
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 1. Tighten bolts from 1 to 20 in number sequence to ... 270 ± 27 N m (200 ± 20 lb.ft.)
Step 2. Tighten bolts from 1 to 20 in number sequence to ... 450 ± 20 N m (330 ± 15 lb.ft.)
Step 3. Tighten bolts from 1 to 20 in number sequence again to ... 450 ± 20 N m (330 ± 15 lb.ft.)
Step 5. Tighten bolts from 21 to 26 in number sequence to ... 270 ± 27 N m (200 ± 20 lb.ft.)
Step 6. Tighten bolts from 21 to 26 in number sequence to ... 450 ± 20 N m (330 ± 15 lb.ft.)
Step 7. Tighten bolts from 21 to 26 in number sequence again to ... 450 ± 20 N m (330 ± 15 lb.ft.)
Step 8. Tighten the thirteen small bolts (2) to ... 43 ± 7 N m (32 ± 5 lb.ft.)
(3) Torque for twelve manifold studs in each cylinder head ...25 ± 4 N m (20 ± 3 lb.ft.)
70
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
71
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
Exhaust Manifolds
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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
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) 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.)
(3) Tighten the locknuts for the manifold in the number sequence shown to ... 52 ± 7 N m (38 ± 5 lb.ft.)
73
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
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 studs in the flange to a torque of ... 30 ± 5 N m (22 ± 4 lb. ft.)
(3) Elbow. Make sure cup plug is removed from each cylinder head before the elbows are connected.
(4) Tighten the locknuts for the manifold in the number sequence shown to ... 52 ± 7 N m (38 ± 5 lb.ft.)
74
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
(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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
Air Lines
(3412)
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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
(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
3408 & 3412G EN E R ATO R SET ENGINES S E N R256 1-0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
Turbochargers
(AiResearch TV81 and TW81)
b. Put a small amount of 2P2506 Thread Lubricant on the threads and impeller face that will be under the
nut.
NOTE: Do not bend or add stress to the shaft when the nut is loosened or tightened.
79
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
(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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
Turbochargers
(AiResearch TV91)
b. Put a small amount of 2P2506 Thread Lubricant on the threads and impeller face that will be under the
nut.
NOTE: Do not bend or add stress to the shaft when the nut is loosened or tightened.
81
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
(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.)
(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
Compound on the threads) ... 54 ± 5 N m (40 ± 4 lb.ft.)
(8) Torque for the bolts that hold the turbine housing to the cartridge housing (put 5P3931 Anti-Seize
Compound on the threads) ... 20 ± 2 N m (15 ± 1 lb.ft.)
82
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
Turbochargers
(Schwitzer F452 and F552)
A526MXJS \ 8
(1) End play for shaft (new) ... 0.114 ± 0.038 mm (.0045 ± .0015 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.)
83
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
(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
3408 & 3412G EN E R ATO R SET ENGINES S E N R256 1-0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
Turbochargers
(Schwitzer 4MF and 4MFW)
(1) End play for shaft (new) ... 0.114 ± 0.038 mm (.0045 ± .0015 in.)
85
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
(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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
87
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
89
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ - 0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
(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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
(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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
92
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
(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.
Pressure difference to open either bypass valve ... 255 ± 20 kPa (37 ± 3 psi)
93
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
Oil Pan
(1) Torque for three plugs with round head and square boss ... 80 ± 11 N m (60 ± 8 lb.ft.)
94
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
95
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
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.)
96
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
NOTE: 3412 Low Speed oil pump arrangement does not use spacer behind pressure relief spring.
PUMP COVER
97
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
PUMP BODY
(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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
Radiator
TYPICAL EXAMPLE
99
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
(2) Torque for bolts that hold the guard* ... 20 ± 4 N m (15 ± 3 lb.ft.)
NOTE: Use the tightening sequence shown to install top and bottom tanks to radiator core.
100
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
A 2 £492X1
PRESSURE CAPS
Part No. fll_af3t7 6L985Q 4N 3311
101
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
Water Pump
„ A22501X3
(1) Torque for three long studs in cylinder block ... 25 ± 4 N m (20 ± 3 lb.ft.)
(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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
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).
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.
(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.)
B25O40X1 ^
(1) Oil seal. Put glycerin or clean engine oil on the lip of the seal. Assemble with the lip toward the
103
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
bearings.
(2) Seal. Put a light amount of clean engine oil in the bore for the seal.
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).
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.
(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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
105
3408 & 3412G EN E R ATO R SET ENGINES S E N R256 1-0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
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
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
106
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
(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.)
107
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
(1) Camshaft.
108
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
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.)
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.
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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
(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.)
(16) Put 9S3263 Thread Lock on two plugs located at front and rear of right cylinder bank before
installing.
NOTE: Put 9S3263 Thread Lock on the threads of all plugs installed without a seal.
112
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
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.)
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
3408 & 3412 GENERATOR SET ENGINES
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
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.
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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
.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:
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.)
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.
115
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
(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.)
116
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
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.
118
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
AtlOHXl
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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
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.
a. Put 2P2506 Thread Lubricant on bolt threads and contact surfaces of nut and cap.
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
3408 & 3412G EN E R ATO R SET ENGINES S E N R256 1-0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
□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
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3408 & 3412G EN E R ATO R SET ENGINES S E N R256 1-0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
Crankshaft
(1) Maximum length of pin out of crankshaft face ... 6.4 mm (.25 in.)
(3) End play for the crankshaft (new) ... 0.15 to 0.50 mm (.006 to .020 in.)
"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)
122
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
(7) Rear wear sleeve and seal. For installation procedure, see (10).
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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
Flywheel
TYPICAL ILLUSTRATION
Make reference to FLYWHEEL RUNOUT for the correct method of flywheel inspection.
124
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
(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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
Flywheel Runout
1. Install the dial indicator as shown. Put a force on the flywheel toward the rear.
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).
126
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
1. Install the dial indicator (3) and make an adjustment of the universal attachment (4) so it makes contact
as shown.
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3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
Flywheel Housing
(8N3738)
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3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
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:
c. Again tighten bolts 1 thru 8 in number sequence to ... 135 ± 14 N m (100 ± 10 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.)
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3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
Flywheel Housing
(4N2931 &2W3218)
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3408 & 3412G EN E R ATO R SET ENGINES S E N R256 1-0 1
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:
c. Again tighten bolts 1 thru 8 in number sequence to ... 135 ± 14 N m (100 ± 10 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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
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 :
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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
C fTOP )
A (BOTTOM)
135
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
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.
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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
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
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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
138
3408 & 3412G EN E R ATO R SET ENGINES S E N R256 1-0 1
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
3408 & 3412G EN E R ATO R SET ENGINES S E N R256 1-0 1
140
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
141
3408 & 3412G EN E R ATO R SET ENGINES S E N R256 1-0 1
( 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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
Alternators
143
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
Alternator* (Bosch)
Voltage Rating 24V
Output (hot) 37 A
144
3408 & 3412G EN E R ATO R SET ENGINES S E N R256 1-0 1
Alternator* (Motorola)
Voltage Rating 24V
Polarity Insulated
'2 1 .5 A '3 1 A
Output (cold) at 2 8 V at 28V
145
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
Regulators
146
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
147
3408 & 3412G EN E R ATO R SET ENGINES S E N R256 1-0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
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)
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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
Current consumption (draw) at 20 V with no load and a minimum speed of 6500 rpm ... 77A
(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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R256_ -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
.10 7 0 / 'X 2
(1) Torque for large terminal nuts ... 4.0 ± 0.6 N m (35 ± 5 lb.in.)
150
3408 & 3412G EN E R ATO R SET ENGINES S E N R256 1-0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
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
3408 & 3412G EN E R ATO R SET ENGINES S E N R256 1-0 1
152
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
Shut-Off Solenoids
B38989X1
153
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
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.
154
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
(3) Maximum permissible outlet pressure ... 1030 kPa (150 psi)
155
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
CATERPILLAR
Specifications
3408 & 3412 GENERATOR SET ENGINES
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
(3408)
6N4147 & 6N4148 (IngersoU-Rand Number 150 BMP-E78RH-54)
Output torque (minimum) ... 70 N m (50 lb.ft.)
6N4147 SHOWN
(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
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
Step 1. Tighten screws evenly in small increases until torque is ... 11.3 N m (100 lb.in.)
(3412)
5N8788 (IngersoU-Rand No. SS800R/5N8788), 5N8789
(IngersoU-Rand No. SS800R/5N8789)
(1) Cover.
157
3408 & 34 12 G EN E RATO R S ET E N G IN ES SE N R2561 -0 1
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.)
(4) Torque for bolt that holds pinion ... 110 N m (80 lb.ft.)
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
Specification
3408 & 3412 GENERATOR SET ENGINES
h t t p i 0 e n g i n e. o d . net