- Generator Set Engine:
- 3456 (S/N: 9BZ11-240)
Introduction
This procedure is for replacing the front plate and the front gasket on the 3456 engine (S/N: 9BZ11-240). This procedure will fix the problem of a broken bolt between the front plate and the engine block.
You will want to run the Troubleshooting, "Engine Speed/Timing Sensor - Calibrate" in order to ensure correct timing when you complete the following procedure and when the engine is installed.
Note: Please work through your local dealer Technical Communicator to contact the Dealer Service Network (DSN) for assistance if the engine is not marked with an S. The stamped S indicates that new drive gears have been installed in the engine. If the new drive gears have not been installed, this procedure must be modified. Refer to Illustration 1 and 2 for the location of the mark.
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| Illustration 1 | g01074567 |
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| Illustration 2 | g01074568 |
Tools, Special Tools, and Parts that are Required
| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Part Name | Qty |
| A | 9S-9082 | Engine Turning Tool | 1 |
| B | - | Guide Bolt (5/8 inch - 18 NF by 7 inch) |
1 |
| C | 4C-5593 | Anti-Seize Compound | 1 |
| D | 1U-7600 | Slide Hammer Puller Gp | 1 |
| E | 5P-1733 | Seal Locator | 1 |
| F | 5P-1737 | Bolt | 3 |
| G | 9S-8858 | Nut (Seal Installer) | 1 |
| H | 6V-6142 | Seal Installer | 1 |
| J | 154-9731 | Thread Lock Compound | 1 |
| K | 141-5831 | Sealant | 1 |
| L | 9U-7255 | Gear Gauge | 1 |
| M | 9U-7324 | Indicator Bracket (1) | 1 |
| 7H-1942 | Dial Indicator (1) | 1 | |
| 3S-3268 | Indicator Contact Point (1) | 1 | |
| 7H-1940 | Universal Attachment (1) | 1 | |
| N | 9U-6896 | Guide Bolt | 1 |
| ( 1 ) | Part is from 9U-7530 Engine Tool Group . |
| Required Parts | ||
|---|---|---|
| Qty | Part Number | Part Name |
| 1 | 166-9144 | Gasket |
| 1 | 4N-1151 | Gasket |
| 1 | 142-5867 | Crankshaft Seal Gp |
| 1 | 155-9524 | Integral Seal |
| 1 | 159-8524 | Adapter assembly |
| 1 | 159-1533 | Sealing Plate |
| 1 | 117-8801 | O-ring Seal |
| 1 | 5E-8771 | O-ring Seal |
| 1 | 167-8130 | Damper |
| 1 | 227-3704 | Damper Adapter (If needed) |
| 1 | 165-8110 | Plate |
| 1 | 197-4971 | Stub shaft (Cluster) |
| 8 | 5M-2894 | Hard Washer |
| 2 | 9H-8872 | Gasket |
| 9 | 126-1757 | Washer |
| 1 | 144-6142 | Integral Seal |
| 2 | 5P-4142 | Locking Bolts |
| 1 | 8T-9527 | O-ring Seal |
| 1 | 107-5769 | O-ring Seal |
| 2 | 3P-1155 | O-ring Seal |
| 2 | 203-3940 | O-ring Seal |
| 1 | 122-3772 | O-ring Seal |
Front Drive Gears - Remove
Front Support Bracket - Remove
- Use a suitable lifting device in order to support the front of the engine.
- Remove the tubing from the lower part of the water pump.
- Remove the bolts that hold the support bracket on the frame.
- Remove the bolts that hold the support bracket on to the housing (front).
Vibration Damper - Remove
| NOTICE |
|---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
- Remove two bolts (1). Install Tooling (B) .
Note: Check the part number for the damper. The part number should be 167-8130 Damper . Replace the damper during installation if the damper is not the 167-8130 Damper .
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| Illustration 3 | g01052829 |
Typical example | |
- Remove remaining bolts (1). Remove plate (2). Remove vibration damper (3) from adapter (4). The weight of the vibration damper is approximately 15 kg (33 lb).
- Remove Tooling (B) from the crankshaft.
Crankshaft Front Seal - Remove
Note: The crankshaft front seal and the wear sleeve must be replaced at the same time. Once the crankshaft front seal and the wear sleeve are separated, these components can not be used again.
- Use Tooling (D) or a punch and hammer in order to puncture three or more holes in wear sleeve (6) and crankshaft front seal (5) .
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| Illustration 4 | g01183044 |
- Use Tooling (D) to remove the wear sleeve and the crankshaft front seal.
Oil Pan - Remove
- Remove the left dipstick and the right dipstick.
- Drain the oil from the engine oil pan into a suitable container for storage or disposal.
- Remove the bolts that fasten the oil pan to the engine block or the housing (front).
- Remove engine oil pan.
Front Cover - Remove
| NOTICE |
|---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
- Remove screws (9), bolts (7), and nuts (10) .
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| Illustration 5 | g01052408 |
- Remove front cover (8) .
Finding the Top Center Position for No. 1 Piston
The No. 1 piston at top center (TC) on the compression stroke is the starting point of all timing procedures.
Note: Some engines have two threaded holes in the flywheel. These holes are in alignment with the holes with plugs in the left and right front of the flywheel housing. The two holes in the flywheel are at a different distance from the center of the flywheel so the timing bolt cannot be put in the wrong hole.
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| Illustration 6 | g01052409 |
Locating Top Center (11) Timing bolt (12) Timing bolt location (13) Cover | |
- Timing bolt (11) is a cover bolt. The timing bolt can be installed in either the left side of the engine at location (12) or in the right side of the engine at timing bolt location (12). Remove both bolts (11) and cover (13) from the flywheel housing. Remove the plug from the timing hole in the flywheel housing.
- Put timing bolt (11) (long bolt that holds the cover on the flywheel housing) through the timing hole in the flywheel housing. Tooling (A) and a 1/2 inch ratchet are used in order to turn the engine flywheel. The rotation of the engine is counterclockwise when the engine is viewed from the rear of the engine. Turn the engine flywheel until the timing bolt engages with the threaded hole in the flywheel.
- Remove the front valve mechanism cover from the engine.
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| Illustration 7 | g01183050 |
Using 9S-9082 Engine Turning Tool (11) Timing bolt (A) Tooling | |
Note: If the flywheel is turned beyond the point of engagement, the flywheel must be turned in the opposite direction of normal engine rotation approximately 45 degrees. Then turn the flywheel in the direction of normal rotation until the timing bolt engages with the threaded hole. The procedure will eliminate the backlash that will occur when the No. 1 piston is put on the top center.
- The inlet and exhaust valves for the No. 1 cylinder are fully closed if the No. 1 piston is on the compression stroke and the rocker arms can be moved by hand. If the rocker arms can not be moved and the valves are slightly open the No. 1 piston is on the exhaust stroke.
Note: After the actual stroke position is identified, and the other stroke position is needed, remove the timing bolt from the flywheel. The flywheel is turned 360 degrees in a counterclockwise direction when the engine is viewed from the rear of the engine. The timing bolt is reinstalled.
Camshaft Gear - Remove
- Verify that the timing mark on camshaft gear (14) is aligned with Timing Mark (X) on front housing (16) .
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| Illustration 8 | g01052412 |
- Remove top bolt (15) from camshaft gear (14). Install Tooling (N) in place of the bolt.
- Remove remaining bolts (15) and remove camshaft gear (14) .
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| Illustration 9 | g01183052 |
- Remove Tooling (N) .
| NOTICE |
|---|
Do not turn the crankshaft or the camshaft while the camshaft gear is removed. If the front gear group is not correctly timed during installation, interference can occur between the pistons and the valves, resulting in damage to the engine. |
Inspect the Adapter for the Camshaft gear
- Remove the thrust plate.
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| Illustration 10 | g01076163 |
- Remove the adapter for the cam gear.
- Install a new 159-8524 Adapter As .
- Remove the tension from the camshaft before you install the thrust plate.
- Remove the valve mechanism covers.
Note: When the engine is reassembled you will need to check the engine valve lash. Refer to ""Check the Engine Valve Lash" ".
- Loosen the four bolts for each rocker arm shaft. This will release the tension on the camshaft in order to slide the camshaft back into the correct position.
- Install the thrust plate.
Note: Do not tighten the bolts for the rocker arm shaft until the following items are installed: seal plate, adapter for the camshaft gear and thrust plate.
Housing (Front) - Remove
| NOTICE |
|---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
| NOTICE |
|---|
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
- Remove bolts (18) that fasten front plate (17) to front housing (16) .
| NOTICE |
|---|
Do not turn the crankshaft or the camshaft while the camshaft gear is removed. If the front gear group is not correctly timed during installation, interference can occur between the pistons and the valves, resulting in damage to the engine. |
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| Illustration 11 | g01052414 |
Typical example | |
- Remove bolts (19), nut (21), and nuts (20) from front housing (16) .
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| Illustration 12 | g01052417 |
Typical example | |
- Remove front housing (16) .
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| Illustration 13 | g01052418 |
Typical example | |
Gear Group (Front) - Remove
| NOTICE |
|---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
| NOTICE |
|---|
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
- Remove bolts (23), plate (24), and adjustable idler gear (22) .
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| Illustration 14 | g01183798 |
Typical example | |
- Remove bolts (26), plate (27), and idler gear (25) .
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| Illustration 15 | g01183801 |
Typical example | |
- Remove bolts (29), plate (30), and cluster gear (28) .
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| Illustration 16 | g01183802 |
Typical example | |
- Remove bolts (31) and stub shaft (32) from the engine block.
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| Illustration 17 | g01183809 |
Typical example | |
Fuel Transfer Pump - Remove
- Remove the two bolts (33) that hold the fuel transfer pump onto the pump drive gp .
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| Illustration 18 | g01182670 |
Fuel transfer pump | |
- Separate the fuel transfer pump from the pump drive gp .
- Remove the three bolts (35) that hold the pump drive gp .
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| Illustration 19 | g01182721 |
Pump drive gp | |
- Remove nut (34) that holds the pump drive gp to the front plate .
Front Plate and Gasket - Remove
- Remove nuts (37) .
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| Illustration 20 | g01182908 |
Typical example | |
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| Illustration 21 | g01184817 |
Note: If necessary, support the water pump before removing the front plate from the engine.
- Remove two bolts (36) .
- Remove the eight bolts (38) that hold the front plate onto the engine block.
- Separate the old front plate (17) from the front of the engine block.
- Remove the studs from the old front plate (17) .
Installation Procedure
Front Plate and Gasket - Install
- Install 155-9524 Integral Seal (41) to the front of the engine block.
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| Illustration 22 | g01182802 |
Front view | |
Note: Make sure that the face of the engine block is cleaned thoroughly. The face of the engine block must be free of oil, fuel, water, dirt, assembly compounds, and any other contaminants during assembly.
- Install 156-5198 O-Ring Seal (40) to the water pump.
- Clean bolts (32) with a wire brush. Apply Tooling (J) to bolts (32) after the bolts have been cleaned.
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| Illustration 23 | g00537659 |
Bolt tightening sequence for stub shaft (39) | |
- Install new 197-4971 Stub shaft (39). Tighten bolts (32) to a torque of 55 ± 10 N·m (41 ± 7 lb ft) in a sequence (1, 3, 4, 5, 2, 1, 2, 3, 4, 5, 1). Refer to illustration 23.
- Tighten the bolts (32).
- Clean the old studs from the old front plate (17) with a wire brush. Apply Tooling (J) to the serrated part of the studs.
- Install the studs from the old front plate (17) into the new front plate (43) .
- Install new 165-8110 Front Plate (44) to the front of the engine block.
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| Illustration 24 | g01184823 |
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| Illustration 25 | g01184845 |
- Apply Tooling (J) to the eight 5P-4255 Locking Bolts .
- Install the eight 5P-4255 Locking Bolts and 5M-2894 Hard Washers (38) in order to secure the front plate to the front of the engine block.
- Install a new 159-1533 Sealing Plate to the front plate (43) .
- Apply Tooling (J) to the threads of the studs. Install washers and nuts (37) that hold the two idler shafts to the front plate.
- Install two new 5P-4142 Locking Bolts (44) in order to secure the two idler shafts to the front plate.
Fuel Transfer Pump - Install
- Install new 8T-9527 O-Ring Seal (45) onto the pump drive gp .
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| Illustration 26 | g01183120 |
Pump drive Gp | |
- Install the three bolts (35) that hold the pump drive gp .
| | |
| Illustration 27 | g01182721 |
Pump drive gp | |
- Install nut (34) that holds the pump drive gp to the front plate .
- Install new 107-5769 O-Ring Seal (46) onto the pump drive gp .
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| Illustration 28 | g01183133 |
- Install the two bolts (33) that hold the fuel transfer pump onto the pump drive gp .
| | |
| Illustration 29 | g01182670 |
Fuel transfer pump | |
Gear Group (Front) - Install
| NOTICE |
|---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
- Clean the front of the gear plate.
- Put 187-8979 Cluster Gear (28) on stub shaft (39). Ensure that timing Marks (V) are aligned on cluster gear and the crankshaft gear. Clean the threads of bolts (29) with a wire brush. Apply Tooling (J) to bolts (29) after the bolts have been cleaned. Install plate (30) and bolts (29). Tighten bolts (29) to a torque of 30 ± 7 N·m (22 ± 5 lb ft).
| | |
| Illustration 30 | g01183802 |
Typical example | |
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| Illustration 31 | g00516404 |
Typical example | |
- Put idler gear (25) on the fixed idler stub shaft. Apply Tooling (K) to bolts (26). Install plate (27) with the oil groove toward the gear face. Clean the threads of bolts (26) with a wire brush. Apply Tooling (J) to bolts (26). Install bolts (26) and tighten to a torque of 30 ± 7 N·m (22 ± 5 lb ft).
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| Illustration 32 | g01183801 |
Typical example | |
Housing (Front) - Install
| NOTICE |
|---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
- Thoroughly clean the old gasket material from front housing (16) and install front housing (16) on the two dowel pins.
| | |
| Illustration 33 | g01052418 |
Typical example | |
- Install bolts (19), nut (20), and nuts (21) on front housing (16) .
| | |
| Illustration 34 | g01052417 |
Typical example | |
- Install bolts (18) that fasten front plate (17) to front housing (16) .
| | |
| Illustration 35 | g01052414 |
Typical example | |
Static Check Of The Timing Gear Position
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| Illustration 36 | g01183870 |
Front gear group (V) Timing mark (X) Timing mark (14) Camshaft gear (22) Adjustable idler gear (27) Idler gear (30) Cluster gear (47) Crankshaft gear (48) Oil pump gear | |
The basis for the correct fuel injection timing and the valve mechanism operation is determined by the alignment of the timing marks for the front gear group. Timing marks (X) and timing marks (V) are aligned in order to provide the correct relationship between the piston movement and the valve movement.
Cam Gear - Install
| NOTICE |
|---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
- Install Tooling (N) in the top hole in the camshaft.
| | |
| Illustration 37 | g01183052 |
| NOTICE |
|---|
Do not turn the crankshaft or the camshaft while the camshaft gear is removed. If the front gear group is not correctly timed during installation, interference can occur between the pistons and the valves, resulting in damage to the engine. |
- Align the hole in the back of camshaft gear (14) with the dowel in the adapter. Install 244-1640 Cam Gear (14) over Tooling (N) .
- Verify that the timing mark on camshaft gear (14) is aligned with timing mark (X) on front housing (16) .
| | |
| Illustration 38 | g01052412 |
Note: Camshaft timing is critical. The timing mark on the camshaft gear must be aligned with the timing mark on the front cover when the No. 1 piston is at the top center of the compression stroke. Refer to Testing and Adjusting, "Gear Group (Front) - Time".
- Install bolts (15). Remove Tooling (N) and install remaining bolt (15) .
- Tighten bolts (15) in a numeric sequence 1, 4, 2, 5, 3, 6, 1, 4 to a torque of 240 ± 40 N·m (180 ± 30 lb ft). Refer to illustration 39.
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| Illustration 39 | g00593987 |
- Check the backlash between the camshaft gear and the adjustable idler gear. The backlash should be 0.216 ± 0.114 mm (0.0085 ± 0.0045 inch). Refer to Testing and Adjusting, "Gear Group (Front) - Time" for the backlash adjustment procedure.
Gear Group (Front) - Time
Setting Backlash For Camshaft And Adjustable Idler Gear
- Remove the adjustable idler gear from stub shaft (50). Stub shaft (50) is held in position with five nuts (49) and bolt (49). Loosen five nuts (49) and loosen bolt (51) .
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| Illustration 40 | g01183894 |
Loosen stub shaft assembly. (49) Nuts (50) Stub shaft | |
- Refer to Illustration 39 in order to position Tooling (L). Move Tooling (L) to the left and to the right. Lightly tighten nuts (49) and bolt (51). Once the nuts and the bolt are tightened, lightly tap Tooling (L) with a rubber mallet on the sides. This will ensure that the tool is properly seated. Tooling (L) must be free to move in and out without any binding. Tighten the nuts and the bolt to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
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| Illustration 41 | g01183896 |
Installation of the adjustable idler assembly (L) Gear gauge (49) Nuts (51) Bolt | |
- Install Tooling (M) on the timing gear housing. When idler gear assembly (24) is held stationary, the backlash between the camshaft gear (14) and the idler gear (24) is 0.216 ± 0.114 mm (0.0085 ± 0.0045 inch).
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| Illustration 42 | g01183905 |
Checking backlash (M) Indicator assembly (14) Camshaft gear (24) Idler gear assembly | |
- If necessary, repeat step 1 through step 3 in order to obtain the proper backlash.
Cover (Front) - Install
| NOTICE |
|---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
- Inspect seal (52). If seal (52) is worn or damaged, replace the seal. Install seal (52) in front cover (8) .
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| Illustration 43 | g01183908 |
- Install front cover (8), screws (9), bolts (7), and nuts (10) .
| | |
| Illustration 44 | g01052408 |
Typical example | |
- Tighten bolts (7) and nuts (10) .
Note: Do not tighten screws (9) until bolts (7) and nuts (10) have been properly tightened.
- Tighten button head screw (9) in the numerical sequence that is shown in Illustration 45 to the torque of 13 ± 3 N·m (10 ± 2 lb ft).
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| Illustration 45 | g00563307 |
Tightening sequence for screws | |
Crankshaft Seal (Front) - Install
| NOTICE |
|---|
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
Note: The crankshaft front seal and the wear sleeve must be replaced at the same time. Once the crankshaft front seal and the wear sleeve are separated, these components cannot be used again.
Note: Do not use any type of lubricant during the installation of the crankshaft front seal and the wear sleeve.
- Fasten Tooling (E) to the crankshaft with Tooling (F) .
 | |
| Illustration 46 | g01183072 |
- Position wear sleeve (6) and crankshaft front seal (5) on Tooling (H). Install Tooling (H) on Tooling (E). Lubricate the face of the washer on Tooling (G). Install Tooling (G) on Tooling (E) .
Note: Install the crankshaft front seal with the arrow that shows the direction of crankshaft rotation toward the front of the engine.
- Tighten Tooling (G) until Tooling (H) contacts Tooling (G) .
- Remove Tooling (G), and Tooling (H) from Tooling (G) .
- Remove Tooling (E) and Tooling (F) from the crankshaft.
Vibration Damper - Install
- Install Tooling (B) in the crankshaft.
Note: Check the part number for the damper. The part number should be 167-8130 Damper . Replace the damper during installation if the damper is not the 167-8130 Damper .
| | |
| Illustration 47 | g01052829 |
Typical example | |
- Install 227-3704 Damper Adapter (3) on Tooling (B).
- Install 167-8131 Damper (4) on Tooling (B). The weight of the vibration damper is approximately 15 kg (33 lb).
- Install 6N-7654 Spacer (2) on Tooling (B) .
- Apply Tooling (C) to bolts (1). Install the bolts. Remove Tooling (B) and install the remaining bolts.
Check the Engine Valve Lash
| Valve Lash | |
| Valves | Gauge Dimension |
| Inlet | 0.38 mm (0.015 inch) |
| Exhaust | 0.76 mm (0.030 inch) |
- Make an adjustment to the valve lash on the inlet valves 1, 2, and 4.
- Loosen the valve adjustment locknut.
- Place the appropriate feeler gauge between the inlet rocker arm and the inlet valve bridge. Turn inlet adjustment screw while the valve adjustment locknut is being held from turning. Adjust the valve lash until the correct specification is achieved.
- After each adjustment, tighten the valve adjustment locknut while valve adjustment screw is being held from turning. Tighten to a torque of 30 ± 7 N·m (22 ± 5 lb ft). Recheck each adjustment.
- Make an adjustment to the valve lash on the exhaust valves 1, 3, and 5.
- Loosen the valve adjustment locknut .
- Place the appropriate feeler gauge between the exhaust rocker arm and the exhaust valve bridge. Turn exhaust adjustment screw while the valve adjustment locknut is being held from turning. Adjust the valve lash until the correct specification is achieved.
- After each adjustment, tighten the valve adjustment locknut while valve adjustment screw is being held from turning. Tighten to a torque of 30 ± 7 N·m (22 ± 5 lb ft). Recheck each adjustment.
- Remove the timing bolt, and turn the flywheel by 360 degrees in the direction of engine rotation. This will position the No. 6 piston at the top center on the compression stroke. Install the timing bolt in the flywheel.
- Make an adjustment to the valve lash on the inlet valves 3, 5, and 6.
- Loosen the valve adjustment locknut.
- Place the appropriate feeler gauge between the inlet rocker arm and the inlet valve bridge. Turn inlet adjustment screw while the valve adjustment locknut is being held from turning. Adjust the valve lash until the correct specification is achieved.
- After each adjustment, tighten the valve adjustment locknut while valve adjustment screw is being held from turning. Tighten to a torque of 30 ± 7 N·m (22 ± 5 lb ft). Recheck each adjustment.
- Make an adjustment to the valve lash on the exhaust valves 2, 4, and 6.
- Loosen the valve adjustment locknut .
- Place the appropriate feeler gauge between the exhaust rocker arm and the exhaust valve bridge. Turn exhaust adjustment screw while the valve adjustment locknut is being held from turning. Adjust the valve lash until the correct specification is achieved.
- After each adjustment, tighten the valve adjustment locknut while valve adjustment screw is being held from turning. Tighten to a torque of 30 ± 7 N·m (22 ± 5 lb ft). Recheck each adjustment.