Desarmado y Armado

3406B DIESEL ENGINE FOR GENERATOR SETS

Fuel Injection Pump Housing And Governor
SMCS - 1286-010
Remove And Install Fuel Injection Pump Housing And
Governor

1. Remove nuts (2) and remove cover (1) from the timing gear cover. Remove the
gasket from cover (1).

2. Remove bolts and washers (3). Remove cover (4).

Remove O-ring seals (5) from cover (4).

Remove bolts (6). Remove ring (7) and the gear.

5. Remove fuel injection lines (9). Put caps and plugs on the openings of the pump and
lines to prevent
contamination from entering the fuel system.
6. Remove tube assembly (8). Remove tube assemblies (11) and fuel manifold (10).
Remove fuel
transfer pump (12).
7. The weight of the fuel injection pump housing and governor is 57 kg (125 lb.). Attach
a hoist to the
fuel injection pump housing, and remove two bolts (16), and two bolts (17).
8. Remove two nuts (13) and bolt (14). Remove fuel injection pump housing and
governor (15).

9. Remove O-ring seals (18) from fuel injection pump housing (15).
NOTE: The following steps are for the installation of the fuel injection pump housing
and governor.
10. Attach a hoist to the fuel injection pump housing and governor (15). Be sure that the
three O-ring
seals are in position on the fuel infection pump housing. Install the fuel injection pump
housing and
governor on the timing gear housing.
11. Install fuel transfer pump (12) and fuel manifold (10). Install tube assemblies (8)
and (11).
12. Install fuel injection lines (9).
13. Put gear (19) in position in the front timing gear cover

14. Install two 3/8"-16 NC × 152.4 mm (6 in.) guide bolts (20) in gear (19) as shown.

15. Install ring (7). Install two bolts (6) finger tight. Remove guide pins (20) and install
the remaining
bolts (6). Tighten bolts (6) to a torque of 3 N·m (27 lb. in.).
16. Put the O-ring seals on cover (4). Lubricate the seals with clean engine oil. Put
cover (4) in postion
on ring (7) and install bolts and washers (3).
17. Put the No. 1 piston at top center on the compression stroke. Make reference to the
topic, Finding
Top Center Compression Position For No. 1 Piston, in Testing And Adjusting. Remove
the timing bolt
from the flywheel, and use tool (A) to rotate the crankshaft clockwise (opposite the
direction of engine
rotation) 45°.

18. Remove the plug from the fuel injection pump housing. Install tool (B) in the fuel
injection pump
housing as shown. Slowly rotate the crankshaft counterclockwise (direction of engine
rotation) until the
timing pin goes into the slot in the fuel injection pump camshaft

NOTICE
Too much pressure on the timing pin can damage the fuel injection
pump or the timing pin

19. Put the timing bolt in the timing hole in the flywheel housing. Rotate the crankshaft
counterclockwise (as viewed from the flywheel end of the engine) until the fuel pump
camshaft is tight
against tool (B). This removes gear clearance from the drive train. If the bolt can be
installed in the
timing hole in the flywheel, the timing of the fuel injection pump is correct.
20. If the timing bolt does not go into the timing hole in the flywheel, the timing is not
correct. Do the
steps that follow to adjust the fuel injection pump timing;
a. Loosen four bolts (6). With tool (B) installed and the timing bolt removed, turn the
flywheel
clockwise (opposite the direction of engine rotation) a minimum of 45°. This removes
the backlash from
the timing gears when the engine is put on top center (TC).
b. Tighten two bolts (6) 180° apart, evenly to a torque of 3N·m (27 lb. in.).
c. Turn the flywheel slowly in the direction of engine rotation until the timing bolt can
be installed in the
flywheel. The No. 1 piston of the engine is now at top center (TC).
d. Tighten four bolts (6) to a torque of 55 ± 7 N·m (41 ± 5 lb. ft.). Remove the timing
bolt from the
flywheel and tool (B) from the fuel injection pump housing.
21. Turn the flywheel clockwise (opposite the direction of normal engine rotation) a
minimum of 45°.
Now, turn the flywheel in the direction of engine rotation until tool (B) drops into the
slot of the pump
camshaft. Now turn the flywheel more, in the direction of normal engine rotation, until
all gear
clearance is removed from the drive train. Check to see that the timing bolt will go into
the flywheel.
22. If the timing is not correct, do the procedure in Steps 20a through 20d again.
23. If the timing is correct, remove the timing bolt from the flywheel and the timing pin
[tool (B)] from
the fuel injection pump housing. Install cover (1) and the plug in the fuel injection pump
housing.

Governor
SMCS - 1264-015; 1264-016
Disassemble Governor

Start By:
a. remove fuel injection pump housing and governor
b. remove fuel transfer pump
NOTE: If it is desired to only remove the governor so the fuel injection pump housing
can be
disassembled, do only Steps 1, 2, 3, 4, 5, 6, 18, 24, 27, 28, 29, 30, 34, 36, and 39.

1. Put the fuel injection pump

housing and governor in position on tool (A).
2. Remove bolt (3) to disconnect the lever and link.
3. Remove bolts (2) and remove control linkage (1) from the governor shaft.

3. Remove bolts (4) and plate (5).

5. Remove cover assembly (6), plate (9), and shutoff solenoid (7) from rear governor
housing (8).
6. Remove the bolts, rear governor housing (8) and gasket from the front
governor housing

7. Remove the governor spring (10) and seat from the guide in the rear governor
housing.
8. Remove bolt (11) that holds lever assembly (12) to the shaft.
NOTE: There is a key in the (slot) groove of the shaft assembly that must be removed
before the shaft
assembly is removed from the rear governor housing.
9. Remove shaft (13), lever (12), lever (14) and the spacer from the rear
governor housing

10. Remove plug (16) and lip-type seal (15) from the housing

NOTE: Spacers (17) and (19) are different sizes. Make sure they are assembled in the
correct position.
11. Use needle nose pliers, and remove the shaft. Remove spacer (17), lever (18) and
spacer (19) from
the governor housing.
12. Remove two setscrews and locknuts (20) if necessary.

13. Release spring (21) from the notch in the housing. Remove snap ring (22), and
remove shaft (23)
from the housing. Remove lever (24) and spring (21).

14. Remove lip-type seal (25) from the housing

15. If necessary, remove the screws, cover (26) and the gasket from the governor
housing
16. Remove high idle cover (27) and three O-ring seals (28).

17. Remove lip-type seal (30), dashpot valve (31), fitting (29), insulator and high idle
adjustment (32)
from the rear housing

18. Remove two bolts (33), housing (34) and the gasket from the fuel pump housing.
19. Remove bolts (35), and remove torque control group (36) from the block.
NOTICE
Depending on the different engine applications, torque control groups
will vary. Inspect all parts for wear and damage, and make a note of
the correct sequence of the parts for assembly purposes

NOTE: For additional information, see Specifications For 3406B Diesel Engine
Generator set.

20. Remove the bolts and block (37) for the full load stop from the housing.

21. Remove the bolt that holds collar (39) to bolt (40).
22. Remove collar (39) and spring (38) from bolt (40). Remove bolt (40) from the
block.
23. If necessary, remove the stop screw and the power setting screw from collar (39).

NOTE: It may be necessary to turn the piston to remove the servo from the rack.
24. Remove the three bolts and governor servo (41) from the fuel injection pump
housing

25. Remove lockring (47), seat (46), spring (45) and sleeve (44) from valve (43).
Remove lockring (42)
from the groove in the center of valve (43).
26. Remove sleeve (48), valve (49) and piston (50) from the governor servo. Remove
O-ring seal (54)
from sleeve (48). Remove pin (51) and lever (52) from cylinder (53).

27. Use tool (C) to hold spring (55) under compression so the ring on the governor shaft
can be
removed.
28. Remove the ring, and carefully remove tool (C).
29. Remove bearing (56) the sleeve and spring (55) from the governor shaft.

30. Remove ring (57) and dashpot assembly (58) from the governor shaft.
31. Use tool (B), and remove ring (64) from seat (61).
32. Remove ring (63) and spool (62) from seat (61).
33. Remove seat (61) and spring (60) from shield (59).

34. Remove spring (66), if equipped, and riser (65) from the governor shaft.
NOTE: Later models do not use Over Fueling Spring (66).

35. Remove ring (67), races (68) and bearing (69) from the riser.

36. Remove the bolts and carrier assembly (70) from the fuel injection pump housing.
37. Remove dowels (72) and flyweights (73) from the carrier assembly.
38. Remove dowel (71) from the governor shaft, and remove the governor shaft from
the carrier
assembly.

39. Remove races (74) and (76) and bearing (75) from the camshaft in the fuel injection
pump housing.
Assemble Governor
1. Put the fuel injection pump housing in position on tool (A). Install race (76) bearing
(75) and race
(74) on the end of the camshaft in the fuel injection pump housing.

2. Put flyweights (73) in position on carrier assembly (70), and install dowels (72) to
hold the flyweights
in place. The flyweights must move freely on the dowels and have 0.010 to 0.230 mm
(.0004 to .0090
in.) end play.

3. Install governor shaft (77) on carrier assembly (70).

4. Install dowel (71) in governor shaft (77) and slide carrier assembly (70) down on the
governor shaft
until dowel (71) fits into the slot in the carrier assembly.
5. Install carrier assembly (70) on the end of the camshaft.

6. Install race (68), bearing (69), race (68) and ring (67) on riser (65).

7. Install riser (65) and spring (66), if equipped, on the governor shaft.
8. Install spool (62) and ring (63) on seat (61) and use tool (B) to install ring (64) to
hold them in
position.
9. Install seat (61) on spring (60). Install spring (60) on shield (59).

10. Install dashpot assembly (58) on the governor shaft.

11. Install ring (57) in the groove on the governor shaft. Install sleeve (78), spring (55),
the sleeve and
bearing (56) on the governor shaft.
12. Use tool (C) to hold spring (55) under compression, and install the ring in the
groove on the
governor shaft.

13. Put lever (52) in position on governor servo (53), and install pin (51) to hold the
lever in place. Use a
hammer and chisel to move the metal (stake) four places 90° apart on the outside
surface on both legs of
the governor servo to hold pin (51) in place.
14. Install O-ring seal (54) on sleeve (48). Install piston (50) and sleeve (48) in the
governor servo as
shown.
15. Install valve (49) in the governor servo as shown.
16. Install lockring (42) in the groove near the center of valve (43). Put sleeve (44),
spring (broken link
spring) (45) and seat (46) in position on valve (43), and install lockring (47) to hold
them in place.

17. Put governor servo (41) in position on the fuel injection pump housing with piston
(50) engaged
over the rack. Make sure the lever is engaged in the (slot) groove of riser (65).

18. If dowel (82) was removed, install it in block (83) 31 ± 0.5 mm (1.22 ± .02 in.)
above the outside surface of the block.
19. Install bolt (40) in block (83) and spring (38) on bolt (40).
20. Install stop screw (80) and the locknut on collar (39). Install power setting screw
(81) and the
locknut on the collar.
21. Install collar (39) on bolt (40). Make an alignment of the hole in the collar with the
notch in bolt (40)
and install bolt (79).
22. If the dowels that align block (37) with the front governor housing were removed,
install them 4.0 ±
0.5 mm (.16 ± .02 in.) above the outside surface of the front governor housing.
23. Put block (37) in position on the front governor housing with the holes in the block
in alignment
with dowels in the front governor housing.

24. Install dowel (84) in the front governor housing 6.0 ± 0.5 mm (.24 ± .02 in.) above
the outside
surface of the front governor housing.
25. Assemble torque control group (36) in the correct sequence, and install it on the
block.
 To avoid possible personal injury and damage to the engine when front
governor housing (34) is installed on the fuel injection pump housing,
make sure the flange on bolt (40) is behind the shield of the dashpot. If
the flange on the bolt is installed on the wrong side of the shield, the
riser in the governor will be held in the maximum fuel delivery position.

26. Install the gasket and front governor housing (34) on the fuel injection pump
housing. Make sure the
flange on bolt (40) is behind the shield of dashpot (58).

27. Check the seal on dashpot valve (31) for damage or wear, and make a replacement if
necessary.
28. Install dashpot valve (31), insulator (85), fitting (29) high idle screw (32) and the
locknut in rear
governor housing (8). Tighten insulator (85) to a torque of 4.5 ± 0.5 N·m (40 ± 4.4
lb.in.).

29. Use tool group (D), and install seal (30) with the lip of the seal down as shown. Put
clean engine oil
on the lip of the seal. Install high idle screw cover (27) and O-ring seals (28).
30. Install the lip-type seals in housing (8) with tool group (D) as shown.

31. Install the gasket and cover (26) in the governor housing.

32. Put clip (86) in position on shaft (23), and install shaft (23) into the housing through
spring (21) and
lever (24). Put the key in the lever in alignment with the keyway in the shaft.
33. Install clip (22) on the shaft, and install screw (87) and the locknut on the lever. Put
the end of the
spring in position in the notch in the housing as shown.

34. Install screws (89) and locknuts (20) on lever assembly (18). Tighten locknuts (65)
to a torque of
1.70 ± 0.25 N·m (15 ± 3 lb.in.).

35. Install shaft (90) in the housing. Install long spacer (19), lever assembly (18) and the
short spacer on
shaft (90).
36. Check the condition of the O-ring seal on the plug. Lubricate the O-ring seal with
clean engine oil,
and install the plug to hold shaft (90) in position.

37. Install lever assembly (12) on shaft assembly (13). Be sure the alignment marks on
the components
are in alignment with each other.
38. Install shaft (13) into the housing. Put washer (91) and lever (14) in position on the
shaft. Put key
(92) in the keyslot on shaft (13), and install lever (12) over the key on the shaft. Align
the bolt hole in
lever (12) with the groove in the shaft (13), and install the bolt.

To avoid possible personal injury and damage to the engine when rear
governor housing (8) is installed on the fuel injection pump housing,
make sure the flyweights are toward the fuel injection pump housing. If
the flyweights are extended out too far, the riser in the governor will be
held in the maximum fuel delivery position.
Typical Example
40. Install gasket (95) and rear governor housing (8) on the front governor housing.
41. Make the governor adjustments. See Governor Adjustments in Testing And
Adjusting.
42. Hold shaft (13) in the fuel off position, and install shutoff solenoid (7).
End By:
a. install fuel transfer pump
b. install fuel injection pump housing and governor

Fuel Injection Pumps

SMCS - 1251-010; 1251-011; 1251-012
Remove Fuel Injection Pumps

Start By:
a. remove fuel injection lines
b. disassemble governor *
*Only disassemble the governor enough so that tooling (D) of Install Fuel Injection
Pump can be
installed
1. Remove the plug, and move the rack until tool (A) can be installed to hold the rack in
the center
position. The rack must be in the center position to remove the fuel injection pumps.

To prevent possible personal injury carefully follow the steps below.

2. Put tooling (B), except for the 8S4613 Wrench, in position on the fuel pump housing
as shown.
Lower the handle to center the adjusting screw with the fuel line seat. With the handle
down in the
locked position, the adjusting screw must just be in contact with fuel line seat (1). If
force is needed to
lower the handle or there is a gap, remove the tooling, and make an adjustment to the
screw.
3. Loosen bushing (2) 1/4 of a turn.
4. Put tooling (B) in position on the pump housing with the handle down in the locked
position as
shown.
5. Remove bushing (2) from the pump housing.
6. Carefully and slowly lift the handle to release the spring force. Remove the tooling.
7. Install tool (C) on fuel pump (4) as shown.
8. Remove seal (3) and fuel pump (4) from the fuel pump housing.

9. Remove spacers (5) from the pump housing.

NOTE: There must be a pump installed on either side of the pump to be removed to
install tooling (B).

If there is no pump, take a pump already removed, and remove the spring so there will
be no spring
force, and install it in the pump housing. See the topic, Install Fuel Pump.
NOTE: Spacers (5) are the same thickness for each fuel injection pump so they can be
mixed. The fuel
injection pump plungers and barrels are sets and cannot be mixed.
Install Fuel Injection Pumps
1. Install spacers (5) in the fuel pump housing.
2. Move the rack until tool (A) can be installed to hold the rack in the center position.
The rack must be
in the center position to install the fuel injection pumps.
3. Install a fuel pump without its spring so that tool (B) can be installed. See Step 5 for
correct fuel
pump installation.

4. Install tool (C) on the bonnet of the fuel pump as shown.

5. Install the fuel pump in the pump housing with the saw cut (slot) (9) in the gear in
alignment with
small pin (6) in the lifter assembly and groove (8) in the barrel in alignment with large
pin (7) in the
pump housing.
6. Install the seal and bushing (2) on the fuel pump.
7. Put tooling (B) in position on the fuel pump housing as shown.
8. Lower the handle slowly and carefully. If the fuel pump is not installed correctly, the
handle will not
go all the way down. Do not try to use force on it. Remove and install the tooling and
the fuel pump
again.
9. Make sure the seal is in its correct position, and start to tighten bushing (2). Remove
the tooling, and
tighten the bushing to a torque of 215 ± 15 N·m (160 ± 11 lb.ft.).

Typical Example
10. After each fuel pump has been installed, follow the steps below to check total rack
travel to make
sure each pump has been installed correctly.
a. Install tooling (D) on the fuel pump housing as shown and zero the dial indicator.
b. Remove tool (A) from the fuel pump housing.
c. Move rack (10) in and out of the fuel pump housing to measure rack travel. Rack
travel is
approximately 9.62 mm (.379 in.) in the plus (full fuel) direction and 10.40 mm (.410
in.) in the minus
(shutoff) direction. If this measurement is not obtained, center the rack, install tool (A),
and remove and
install the fuel pump again.
NOTE: One tooth off and rack travel is approximately 6.35 to 6.82 mm (.250 to .269
in.) in the plus
direction and 7.02 to 7.05 mm (.276 to .278 in.) in the minus direction.
a. assemble governor
b. install fuel injection lines
Disassemble and Assemble Fuel Injection Pumps
Start By:
a. remove fuel injection pumps

NOTICE
Be careful when the injection pumps are disassembled. Do not damage
the surfaces of the plungers, barrels and bonnets. Any scratches will
cause leakage inside the fuel injection pump. The plunger and barrel
for each pump are made as a set. Do not put the plunger of one pump
in the barrel of another pump. If one part has wear, install a complete
new pump assembly. Be careful when the plunger is put into the bore
of the barrel.

NOTE: Do not remove the gear from the plunger. The gear and plunger are assembled
and adjusted at
the factory.
1. Pull plunger (4) and washer (3) out of barrel (1) and spring (2).
2. Remove spring (2) from barrel (1).
3. Use the following procedure to put the fuel pump in position on tooling (A):
a. Select the correct turret position.
b. Place a barrel assembly into the turret.
c. Loosen the nut on the clamp.
d. Adjust clamp end (6) until the bonnet is almost touching the barrel when the clamp
handle is in the
locked position.
e. Tighten the nut on the clamp.

4. Use tool (B) to expand ring (5), and carefully lift it off the fuel pump.
5. Slowly release the clamp handle of tooling (A), and remove the lockring.
6. Remove bonnet (7), spring (8) and valve (9) from barrel (1).
NOTE: The following steps are for assembly of the fuel injection pumps.

NOTICE
Put clean fuel oil on all parts during assembly.

7. Put spring (8) and valve (9) in bonnet (7).

8. Put bonnet (7) barrel (1) and ring (5) in position on tool (A).
9. Put the barrel assembly in position on tooling (A). Lower the handle on tool group
(A) to hold the fuel
pump together.
10. Use tool (B), and lower ring (5) on to the barrel and the bonnet to hold them
together.
11. Remove the barrel assembly from tooling (B).
12. Install spring (2) on barrel (1).
13. Install washer (3) on plunger (4). Make sure the spring seat on the washer is away
from the gear on
the plunger.
14. Install plunger (4) in barrel (1). Make sure spring (2) is engaged in the spring seat on
washer (3).
End By:
a. install fuel injection pumps

Disassemble Fuel Injection Pump Housing

Start By:
a. disassemble governor
b. remove fuel injection pumps
1. Remove rack (1) from the fuel pump housing.

2. Remove six lifters (2) from the fuel pump housing. Put identification marks on the
lifters for
installation purposes.

3. Remove camshaft (3) from the fuel pump housing. It may be necessary to use a soft
hammer to push
the camshaft out of the governor end of the fuel pump housing.
4. Remove races (4) and bearing (5) from the camshaft. Remove ring (6) if necessary.

5. Remove rack bearing (7) from both ends of the housing and dowel (8) if necessary.

6. Use tooling (A), and remove three camshaft bearings (9).

7. Remove the bolts, cover (10) and the gasket.

8. Remove pins (12), the seal and dowels (11) if necessary. Pins (12) must be pushed
from the inside
out.
Assemble Fuel Injection Pump Housing

1. Clean and inspect all parts. Make a replacement of all parts that are worn or damaged.
2. Lubricate the seal with clean engine oil, and install pin (12). Pin (12) must protrude
into the pump
bore 2.15 ± .05 mm (.085 ± .002 in.).
3. Install dowel (11) so that it protrudes into the pump bore 1.93 ± 0.05 mm (.076 ± .002
in.).

4. Install the gasket, cover (10) and the bolts.

5. Install the rack bearing with tooling (B). Install the bearing until the driver comes in
contact with the
plate. The bearing should be installed to a depth of 83.0 ± 0.5 mm (3.27 ± .02 in.) from
the fuel pump
mounting face.

6. Measure rack bearing (7). Dimension (X) must be 11.178 ± 0.05 mm (.4400 ± .002
in.). Diameter (W)
must be 12.767 ± 0.058 mm (.5026 ± .0022 in.).

7. Install dowel (8). Dowel (8) must protrude 6.0 ± 0.5 mm (.24 ± .02 in.) from the fuel
pump housing
face.
8. Install the rear rack bearing with tooling (C) to a depth of 7.16 ± 0.13 mm (.282 ±
.005 in.) below the
fuel pump housing surface. The inside diameter of the rear rack bearing must be 12.746
± 0.045 mm
(.5018 ± .0017 in.).
9. Use tooling (D), and install three camshaft bearings (9).
NOTE: Oil holes (13) in the camshaft bearings must be positioned 30° ± 3° above the
horizontal
centerline toward the engine side of the fuel pump housing. The outer bearings must be
installed 1.0 ±
0.5 mm (0.04 ± 0.02 in.) below the surface marked (Z). The inner bearing must be
installed 218.0 ± 0.3
mm (8.58 ± .012 in.) below the front surface (Y). Diameter (XX) must be 68.339 ±
0.038 mm (2.6905
± .0015 in.) after assembly.

10. Install ring (6) races (4) and bearing (5) on the camshaft.
11. Lubricate cam bearings (9) and the camshaft bearing journals with clean engine oil.
12. Install camshaft (3) into the fuel pump housing.

NOTICE
The notch in the lifter must be in line with the dowel in the lifter bore.
The lifter must slide up and down freely in the bore. If it does not,
check the dowel for proper installation depth.

13. Lubricate lifters (2) with clean engine oil, and install them in their original lifter
bores.

14. Lubricate the rack bearings and rack (1) with clean engine oil.

NOTICE
The rack must slide freely in the rack bearings after installation.

15. Install rack (1). The flat on the rack must line up with the flat on the front rack
bearing.
End By:
a. install fuel injection pumps
b. assemble governor.