Caterpillar 3408 Injection Pump Service Manual

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Read Book Caterpillar 3408 Injection Pump Service Manual Caterpillar 3408 Injection Pump Service Manual Getting the books caterpillar 3408 injection pump service manual now is not type of inspiring means. You could not without help going similar to book stock. I want to reseal the injection pump on my 3208 cat, the reason is there is a small line coming from the bottom of the pump that leaks fuel. I believe that the back half of this pump is the lift pump portion and if resealed could get me back up and running. The engine will start if you prime with the hand pump but doesn't stay running very long.

Governor & Fuel Injection Pump Housing (Serial Numbers 8RG1-Up & 3JK1-Up)

Remove & Install Governor & Fuel Injection Pump Housing

Start By:

a. remove air separators

b. remove expansion tank

c. drain the coolant from the cooling system

1. Use Tool (A) to remove fuel lines (1) both sides. Disconnect and plug all fuel hose connections (2). At assembly use Tool (A) to torque the fuel line nuts to 41 ± 7 N·m (30 ± 5 lb ft).

2. Disconnect all electrical connections (3) from the governor and housing.

3. Remove four bolts (6) & (8). Remove two tubes (7).

4. Remove mounting bolts (5).

5. Remove nut and washer (9) and remove the timing gear housing (4).

6. Remove four bolts (10) and spacer (12). At assembly, refer to the topic, 'Camshaft Timing For Fuel Injection Pump' in Systems Operation, Testing & Adjusting Manual, SENR5517. Tighten bolts (10) to a torque of 25 N·m (20 lb ft). Tighten bolts (10) to 230 ± 15 N·m (170 ± 11 lb ft).

7. Remove timing gear assembly (11).

8. Loosen bolts (14).

9. Remove two bolts (15).

10. Remove tube assembly (13).

11. Remove governor housing mounting bolts (16) both sides.

12. Attach a hoist and strap (17) to pump housing (18) as shown. Remove the pump. The weight of the pump for the 3412 Marine Engine is 91 kg (200 lb). The weight of the pump for the 3408 Marine Engine is 57 kg (125 lb).

NOTE: Reverse the order of Steps 1 thru 12 for installation.

End By:

a. install expansion tank

b. install air separators

c. fill cooling system with coolant

d. remove (bleed) the air from the fuel system.

Disassemble Governor & Fuel Injection Pump Housing (Serial Numbers 8RG1-Up & 3JK1-Up)

Caterpillar 3408 injection pump service manual pdf

Start By:

a. remove governor and fuel injection pump housing

1. Remove two bolts (2) and remove rotary solenoid (1).

2. Remove seven bolts (3) and cover (5).

3. Remove four bolts (6) and housing (4).

Caterpillar 3408 Service Manual Pdf

4. Remove fuel shut-off solenoid (9) and the seal with Tool (F).

5. Remove retainer nut (8). Remove connector (10).

6. Remove two bolts (11) and lever group (12).

Caterpillar 3408 Injection Pump Service Manual

7. If necessary, remove spring (14) from lever group (13).

8. Remove jam nut (15) with Tool (A).

9. Remove control group (16) from the housing. If necessary, remove and replace the O-ring seal.

10. Remove spring (17) from the control group.

11. Remove retaining ring (20) and shaft (18).

12. If necessary, remove spring (19).

13. If necessary, remove retaining ring (21) and lip-type seal (22).

14. Remove four bolts (24), rotary servo group (23) and the gasket from the housing.

15. Remove two bolts (25), cover (26) and the gasket.

16. Remove spring (27) and valve (28) from the rotary servo body.

17. Remove bolt (29) and body assembly (30).

18. Remove three O-rings (31) and shaft assembly (32).

19. Separate shaft (36) from star gears (33) and (34).

20. Remove key (35) if necessary.

21. Remove two bolts (38) and fuel transfer pump (37).

22. Remove eleven bolts (39) and drive housing (40).

23. Remove bolt and washer (41). Remove rack control bar (42).

24. Remove two bolts (43) and servo piston assembly (44).

25. Remove retaining ring (45), spring seat (46), link spring (47), rack control sleeve (48) and ring (49) from servo piston assembly (44).

26. Remove sleeve (52), piston (51) and valve (50) from servo piston assembly (44). Remove the O-ring seal from sleeve (52).

27. Remove two bolts (53) and pump drive gear (54).

28. Remove the bolt and plug (58) and rack link (57).

29. Remove two bolts (56), support assembly (55) and the pin.

30. Loosen twelve washers (59) with Tool (B).

31. Install two rack zero pins, Tool (E) in the pump housing. Hold the racks against Tool (E).

32. Install Tool (C) and compress the fuel pump spring. Remove twelve washers (59).

33. With the regulator racks held against Tool (E) install Tool (G) and remove twelve fuel injection pumps (60).

NOTE: Mark each fuel injection pump so it can be returned to it's original location assembly. Do not handle or mark the internal finishes of the fuel injection pumps. This will cause damage to the pumps.

34. Mark for identification at assembly right and left hand rack regulators (61). Remove the rack regulators.

35. Remove six bolts (62), two bolts (63), the plate assembly and the gasket from the fuel injection housing.


Typical Example

36. Remove bypass valve (64) and the O-ring seal. If necessary, press out adapter (65).

37. Remove bypass valve assembly (66) from valve body (70).

38. Remove O-ring seal (67) from bypass valve assembly (66).

39. Remove spring (68) and bypass valve (69) from housing (70).

40. Use a seal pick to remove valve lifters (71) and the spacers. Put identification on each of the spacers and lifters as to their location in the pump housing.

41. Remove two bolts (72) and the locking tabs.

42. Remove camshaft lock (73).

NOTE: Do not damage the camshaft bearings as the camshaft is removed.

43. Remove camshaft (74) from the fuel injection pump housing.

44. If necessary, use Tool (C) to remove camshaft bearings (75).

45. If necessary, remove fourteen bolts (76), the cover and the gasket from each side of the fuel injection pump housing.

Assemble Governor & Fuel Injection Pump Housing (Serial Numbers 8RG1-Up & 3JK1-Up)

1. If removed, install camshaft bearings (75) with Tool (C). See Specifications Manual, SENR5516 for the proper location and orientation of bearings.

2. If removed, install fourteen bolts (76), the cover and the gasket to each side of the fuel injection pump. Tighten bolts (76) to 14 ± 4 N·m (10 ± 3 lb ft).

3. Install camshaft (74) to the fuel injection pump.

4. Install camshaft lock (73).

5. Install two bolts (72) and the locking tabs.

6. Put clean engine oil on lifters (71). Install lifters (71) and the spacers in their original locations.

7. Coat O-ring seal (67) with clean engine oil. Install O-ring (67) to bypass valve assembly (66).

8. Install spring (68) and bypass valve (69) to valve body (70).

9. Install bypass valve assembly (66) to housing (70).

10. Coat the O-ring seal with clean engine oil. Install the O-ring seal and bypass valve (64). If removed, press in adapter (65).

NOTE: Coat the O-ring seal with clean engine oil.

11. Install the gasket, plate assembly, six bolts (62) and two bolts (63) to the fuel injection pump housing.

12. Put clean engine oil on two rack regulators (61). Install right and left hand rack regulators (61) in their proper locations.

If one or more of the injection pumps have been installed wrong, damage to the engine is possible if cautions are not taken when the engine is first started. Make preparation to close off the air intake to stop the engine if necessary.

13. Use Tool (G) to install fuel injection pumps (60) and the spacers in their original location. For more detail, see the topic, 'Install Fuel Injection Pumps'.

14. Install bushing (59) and the seal in the pump housing bore. If the injection pump is in the correct position, bushing (59) will turn into the threads of the pump housing with the fingers until it is even with the housing. Use Tool (A) to tighten bushing (59) to a torque of 245 ± 15 N·m (180 ± 10 lb ft). Install the washers.

15. Check the rack movement (travel) with Tool (H), after each pump is installed. See the topic, 'Injection Pump Installation' in Systems Operation, Testing & Adjusting Manual, SENR5517.

16. Repeat Steps 13 thru 16 for the remaining pumps and bushings.

17. Install rack link (57), plug (58) and the bolt.

18. Install both Tools (E) and hold the racks against the pins.

19. Rotate plug (58) to equalize bank to bank rack setting, then tighten bolt.

20. Install the pin, support assembly (55) and two bolts (56).

21. Install pump drive gear (54) and two bolts (53).

Service

22. Install the O-ring seal on sleeve (52). Install valve (50), piston (51) and sleeve (52) in servo piston assembly (44).

Caterpillar

NOTE: Lubricate the seal and the cylinder with clean engine oil prior to assembly. Assemble with the sleeve and the cylinder aligned as shown.

23. Install retaining ring (45), spring seat (46), link spring (47), rack control sleeve (48) and ring (49) to servo piston assembly (44).

24. Install two bolts (43) and servo piston assembly (44).

25. Install rack control bar (42). Install bolt and washer (41).

Cat 3408 Service Manual

26. Install eleven bolts (39) and drive housing (40).

27. Install key (35).

28. Install shaft (36) to star gears (33) and (34).

29. Install three O-rings (31) and shaft assembly (32).

30. Install bolt (29) and body assembly (30).

31. Install spring (27) and valve (28) to rotary servo body.

32. Install two bolts (25), cover (26) and the gasket.

33. Install fuel transfer pump (37) and two bolts (38).

34. Install four bolts (24), rotary servo group (23) and the gasket to the fuel injection pump housing.

35. If removed, lubricate lip-type seal (22) lightly with clean engine oil. Install lip-type seal (22) and retaining ring (21).

36. If removed, install spring (19).

37. Install retaining ring (20) and shaft (18).

38. Install spring (17) to the control group.

39. If removed, install the O-ring seal. Install control group (16) to the housing assembly.

40. Install and tighten jam nut (15) with Tool (A) to 55 ± 7 N·m (41 ± 5 lb ft).

Cat 3408 Injection Pump

NOTE: With rack pinned at 'zero' position adjust sensor output as required. With timing pin in timing hole in fuel pump housing and timing slot in camshaft and No. 1 cylinder at top center, compression stroke static timing is 19.5 BTC.

41. If removed, install spring (14) to lever assembly (13).

42. Install lever group (12) with two bolts (11).

43. Install connector (10) with retaining nut (8).

44. Use Tool (F) to install the seal and shutoff solenoid (9). Lubricate the seal lightly with glycerin. Tighten solenoid assembly (9) to 70 ± 10 N·m (50 ± 7 lb ft).

45. Install housing (4) with four bolts (6) and a new gasket.

Caterpillar 3408 Injection Pump Service Manual

46. Install cover (5) with seven bolts (3).

47. Install rotary solenoid (1). Install two clamps and tighten bolts (2).

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NOTICE

Make sure the lever on the solenoid engages correctly in the sleeve on the rack servo. If the lever is not engaged in the sleeve the engine may over speed or may fail to start.

Caterpillar 3408 Fuel Injection Pump

If assembly is not correct, damage to the engine is possible if cautions are not taken when the engine is first started. Make preparation to close off the air intake to stop the engine if necessary.

End By:

3408 Caterpillar Truck Engine

a. install governor and fuel injection pump housing

Caterpillar 3408 Injection Pump Service Manual Transmission

b. calibrate rack position sensor (see Systems Operation, Testing & Adjusting Manual SENR5517 for this procedure)