Usage:
3608 (6MC)
Introduction
This Special Instruction provides the necessary information required to replace the 9Y9345 Rear Gear Group in the 3606 and 3608 Engines listed above.
The information contained in this instruction supersedes the information in the Service Manual. The camshaft must be moved forward 5 to 6 mm (0.20 to 0.24") to provide the necessary clearance to install the cam gear.
Make sure that you read and understand this Special Instruction before proceeding with any disassembly and assembly.
Reference: Service Manual and Parts Manual.
Parts Needed
9Y9345 Gear Group
Seals (As required or specified)
NOTE: Refer to the Parts Manual for part numbers of replacement seals.
Installation
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Be sure the engine cannot be started while service work is being performed. This is very important when the engine is equipped with an Automatic Start-Stop System. On engines equipped with an air starting system, close the air supply valve to the air starting motor before service work is begun. |
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Remove Coupling Guard and Coupling
1. Remove the coupling guard.
2. Scribe a mark along the coupling, driven equipment shaft, and flywheel to define the relationship of components.
3. Remove the coupling.
Install Crankshaft and Camshaft Timing Pins
Use the manual barring group and rotate the engine. Set number 1 piston to top center (TC) and install the camshaft and crankshaft timing pins.
Refer to the topic "Finding Top Center Position For No. 1 Piston" in the Systems Operation Testing and Adjusting, form SENR3599.
NOTE: System Operation Testing and Adjusting is part of the Service Manual.
Loosen Rocker Arm Shafts
1. Remove all the valve covers from the engine.
2. Loosen bolts (1) that hold rocker arm shafts (2) in place until all of the rocker arms are free from the injector and valve bridges.
Remove Camshaft Drive Gear
- 6V6080 Torque Multiplier5P1748 Socket
1. Remove the camshaft drive gear cover from the rear housing.
2. Engage and lock the manual barring group to prevent the engine from rotating when bolt (4) is loosened.
3. Use the torque multiplier and socket to loosen bolt (4).
4. Remove bolt (4) and washer (3).
5. Remove bolts (2) and plate (5).
6. Put washer (3) between the camshaft and plate (5), and install bolt (4).
7. Install bolts (2) finger tight.
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To avoid possible personal injury, be sure bolt (4) is installed to hold camshaft drive gear (1) when it is pulled off the taper of the camshaft. |
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8. Tighten bolts (2) evenly to pull camshaft drive gear (1) off the taper of the camshaft.
* The weight of the camshaft drive gear is 35 kg (77 lb).
9. Fasten a hoist to camshaft drive gear (1). Remove bolts (2) and (4), plate (5) and washer (3). Remove the camshaft drive gear from the rear housing.
10. Remove cam thrust plate.
Remove Governor or Governor Actuator
Remove Governor
1. Mark and disconnect the wires from the wiring harness at the governor.
2. Disconnect rod assembly (3) at the lever on the governor (1).
3. Disconnect tube assembly (2) from the governor.
4. Fasten a nylon strap and hoist to the governor.
5. Remove the four bolts that hold the governor to the governor drive.
6. Lift the governor straight up to disengage the governor drive shaft from the coupling.
* Keep the governor in an upright position to prevent loss of oil.
Remove Governor Actuator
1. Drain the oil from the actuator.
2. Disconnect the wiring harnesses from actuator (1).
3. Disconnect the rod assembly from the lever on the actuator shaft.
4. Fasten a hoist to actuator (1).
5. Remove four bolts (2) that hold the actuator to the governor drive.
* The weight of the actuator is 79 kg (175 lb).
6. Lift the actuator straight up to disengage the actuator drive shaft from the coupling.
7. Remove the O-ring seals and the gasket from the governor drive housing.
Remove Governor Drive
1. Remove coupling (3).
2. Remove the four bolts that hold pinion assembly (2) to rear housing (1).
| NOTICE |
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Do not bend shims (4) when pinion assembly (2) is removed. |
3. Remove pinion assembly (2) and shims (4) from rear housing (1).
4. Remove O-ring seals (5) from pinion assembly (2).
Remove Flywheel
Refer to the topic "Flywheel and Ring Gear Assembly" in the Service Manual for the procedure to use to remove the flywheel.
Remove Rear Housing
Refer to the Service Manual for the procedure to remove the rear housing.
NOTE: Do not remove the turbocharger. Instead, disconnect and remove the turbocharger oil return line.
Remove Rear Idler Gears (Old Gear Train)
* The weight of the idler gear assembly is 54 kg (119 lb).
1. Fasten a hoist to idler gear assembly (2). Remove retainer (1), and remove idler gear assembly (2) from the shaft.
2. Remove thrust washer (3).
* The weight of the shaft is 25 kg (55 lb).
3. Fasten a hoist to shaft (4). Remove bolts (5), and remove shaft (4) from the cylinder block.
Remove Crankshaft Rear Gear
- 8T0914 Guide Pins (2)
1. Install the 8T0914 Guide Pins in the rear of the crankshaft.
NOTE: Crankshaft rear seal should have been removed with rear housing.
2. Remove four bolts (3) that hold adapter (2) and gear (1) in place. The weight of the adapter is approximately 67 kg (147 lb).
3. Fasten a hoist to adapter (2). Remove adapter (2) and gear (1) from the crankshaft.
4. Remove the O-ring seals from gear (1).
Install Rear Idler Gears (New Gear Train)
1. Fasten a hoist to shaft (4). Put shaft (4) in position on the cylinder block, and install bolts (5). Tighten the bolts to a torque of 270 ± 25 N·m (200 ± 18 lb ft).
2. Install thrust washer (3).
3. Assemble idler gear assembly (2) as follows:
a. Install bearing (6) 2.5 ± 0.5 mm (0.098 ± 0.02") below the surface of gear (7). The inside diameter of the bearing should be 106.0 ± 0.016 mm (4.173 ± 0.0006") after assembly.
b. Position gear (2) on gear (7), and install bolts (8).
4. Fasten a hoist to idler gear assembly (2). Install the idler gear assembly on shaft (4), and install retainer (1).
Install Crankshaft Rear Gear
- 8T0914 Guide Pins (2)
1. Install new O-ring seals on each side of gear (1).
* Fasten a hoist to gear (1).
2. Align the four unevenly spaced holes in gear (1) with the four threaded holes in the crankshaft, and install gear (1) on the 8T0914 Guide Pins with the gear teeth away from the crankshaft.
* Fasten a hoist to adapter (2).
3. Align the four unevenly spaced bolt holes in adapter (2) with the holes in gear (1) and install adapter.
4. Install bolts (3).
Install Rear Housing
Refer to the Service Manual for the procedure to install the rear housing.
Install New Crankshaft Seal
Refer to the Service Manual for the procedure to install the seal.
Install Flywheel
Refer to the Service Manual for the procedure to install the flywheel.
Install Coupling
Install the coupling being careful to align the scribed marks to maintain correct relationship of components.
Remove Camshaft Timing Pin
Remove the camshaft timing pin.
Remove Side Cam Cover
Remove number six side cam cover on six cylinder engines or number eight side cam cover on eight cylinder engines.
Use a bar and move the camshaft forward 5 to 6 mm (0.20 to 0.24") to provide the necessary clearance to install the camshaft drive gear.
| NOTICE |
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Be careful when moving the camshaft to avoid damaging the cam lobes. |
Install Camshaft Drive Gear
- 6V6080 Torque Multiplier5P1748 Socket
1. Put plate (3) in position on camshaft drive gear (2) and install bolts (4).
2. Put 2P2506 Thread Lubricant on the threads of bolt (6).
3. Fasten a hoist to camshaft drive gear (2). Put the camshaft drive gear in position on the camshaft, aligning the holes in the gear with the top and bottom bolt holes for the cam thrust plate. Install washer (5) and bolt (6). Tighten bolt (6) by hand.
Slide Camshaft Rearward
| NOTICE |
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Be careful when moving the camshaft to avoid damaging the cam lobes. |
Slide the camshaft rearward, back into position.
Install Thrust Plate
1. Install the thrust plate using the access holes in the cam gear to install the bolts.
2. Rotate the crank, turning the camshaft gear until all three thrust plate bolts can be installed and tightened.
3. Rotate the camshaft until the camshaft timing pin can be installed.
4. Install camshaft timing pin.
NOTE: A pry bar may be inserted between the camshaft section bolts to adjust the camshaft position as needed.
5. Remove the crankshaft timing pin from the timing location.
6. Turn the flywheel opposite the direction of normal rotation a maximum of 20°.
7. With bolt (6) hand tight, turn the flywheel in the direction of normal engine rotation until the crankshaft timing pin can be reinstalled in the crankshaft.
* This procedure holds the backlash in the timing gears in the direction of normal engine rotation.
| NOTICE |
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If the crankshaft timing pin location is missed, do not turn the flywheel in the opposite direction to install the crankshaft timing pin. If the crankshaft timing position is missed, repeat Steps 6 and 7. |
8. Remove the camshaft timing pin.
9. Use the torque multiplier and the socket to tighten bolt (6) to a torque of 2000 ± 275 N·m (1480 ± 200 lb ft).
10. Carefully hit bolt (6) with a hammer, and repeat Step 9. Repeat this procedure until the bolt torque does not change.
11. Remove the crankshaft timing pin.
12. Verify the correct camshaft timing. See the topic, Camshaft Timing Check in Testing and Adjusting for 3606 and 3608 Diesel Engines, form SENR3599.
Install Governor Drive
- 8S2328 Dial Indicator Test Group
1. Move the camshaft to the rear against plate assembly (9).
2. Put shims (4) in position on pinion assembly (2), and install new O-ring seals (5). Put clean engine oil on the O-ring seals.
NOTE: Refer to the Parts Manual for part numbers of replacement seals.
3. Put pinion assembly (2) in position in rear housing (1), and install the four bolts that hold it in place.
| NOTICE |
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Be sure the camshaft is all the way to the rear against the plate assembly and the pinion is forced upward against the plate assembly when checking the backlash between the two gears. If the camshaft is forward when the backlash is set, there will not be enough clearance between the gears when the camshaft moves to the rear. |
4. Use the 8S2328 Dial Indicator to check the backlash between the pinion gear and the governor drive gear. Add or remove shims (4) as needed to obtain a backlash of 0.3 ± 0.1 mm (0.12 ± 0.04").
NOTE: If old shims are used, this step is not required.
5. Install coupling (3).
Install Governor or Install Governor Actuator
Install Governor
1. Inspect the drive coupling, and replace if necessary.
2. Replace four O-ring seals (4). Be sure the O-ring seal is installed on governor housing that engages with the governor drive.
NOTE: Refer to the Parts Manual for part numbers of replacement seals.
| NOTICE |
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Do not force the governor in position in the coupling. |
3. Move the governor to an upright position and engage the governor drive shaft with the coupling. Do not force the governor into position in the coupling.
4. Install the four bolts that hold the governor to the governor drive.
5. Connect tube assembly (2) to governor (1).
6. Connect rod assembly (3) to the lever on the governor.
7. If the oil was drained from the governor, remove the plug on top of the governor and fill the governor with 1.9 liter (2 quarts) of SAE 40 grade CD motor oil.
8. Check the governor control linkage for correct adjustment. See the topic "Injector Synchronization" in Testing and Adjusting Service Manual for 3606 and 3608 Diesel Engines, form SENR3599.
Install Governor Actuator
1. Put the O-ring seals and gasket in position on the governor drive housing.
NOTE: Refer to the Parts Manual for part numbers of replacement seals.
2. Fasten a hoist to actuator (1).
| NOTICE |
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Do not force the governor actuator into position in the coupling. |
3. Align the splines on the actuator drive shaft with the coupling in the governor drive and install the actuator on the governor drive.
4. Install four bolts (2).
5. Connect the rod assembly to the lever on the actuator shaft.
6. Connect the wiring harnesses to actuator (1).
7. Adjust the governor actuator linkage. See the topic, "Governor Actuator Linkage" in Testing and Adjusting Service Manual for 3606 and 3608 Diesel Engines, form SENR3599.
8. See the topic "EGB29P Actuator Start Up Procedure" in the 2301 Governor Service Manual.
Retorque Rocker Arm Shafts
Tighten the bolts that hold the rocker arm shaft in position.
Reset Valve Lash and Injector Time Adjustments
Perform a complete valve lash and injector timing adjustment. Refer to the Service Manual Systems Operation Testing and Adjusting for the procedure.
Install All Covers
Install all covers previously removed. Make sure that the camshaft and crankshaft timing pins are in their proper storage locations.