435-8503 Major Engine Overhaul Foundational Kit for 3406E Marine Engines{1000} Caterpillar


435-8503 Major Engine Overhaul Foundational Kit for 3406E Marine Engines{1000}

Usage:

3406E 9WR
Marine Engine:
3406E MARINE (S/N: 9WR1-UP)

Introduction

This Special Instruction is intended to provide information on the Engine Overhaul Kit Consist and detailed information on specific parts that should be used based on engine arrangements.

This Engine Overhaul Kit may contain extra parts and extra quantities due to the variety of engine arrangements assigned to a given kit. Refer to the corresponding Parts Manual or Disassembly and Assembly manual in Table 1.

Note: This Kit may contain upgraded parts. These upgraded part numbers may be different than what you have in the parts manual or engine, but these parts have been technically reviewed for compatibility with your application.

Note: This kit contains gasket kits and includes additional parts needed to perform an engine overhaul.

Note: This kit does not contain rod bearings, main bearings, and thrust plates.

Note: For assistance with technical questions, contact your local Cat dealer.

Note: For more information, visit us at catmarinesupport.com.

Note: For access to our website you can scan the QR code below with a QR enabled device.




Illustration 1g03319969

Reference Material

Table 1
Engine Model     Engine Arrangement     Engine Serial Number Range     Parts Book Media     Disassembly and Assembly Media    
3406E     234-9228     S/N:9WR1-UP     SEBP2555     SENR1169    
255-8712

Note: For ordering reference material contact your local Cat dealer.

3406E 435-8503 Major Overhaul Kit Consist

Table 2
435-8503 Major Overhaul Kit Consist    
Gasket Kits    
Part Number     Part Name     Qty    
349-1530     Rear Structure Gasket Kit     1    
433-7623     After Cooler and Lines Gasket Kit     1    
433-9243     Heat Exchanger Gasket Kit     1    
433-9843     Fuel System Gasket Kit     1    
434-0857     Front Structure Gasket Kit     1    
434-1393     Central and Lower Structure Gasket Kit     1    
433-1394     Oil Cooler and Lines Gasket Kit     1    
438-8574     Single Cylinder Head Gasket Kit     1    
Additional Parts Included in This Kit    
Part Number     Part Name     Qty    
1R-0749     Fuel Filter     1    
1R-1808     Engine Oil Filter     1    
2N-0931     Gasket     4    
2N-2766     Locknut     12    
2N-3350     O-Ring Seal     2    
3G-2292     Locking Bolt     5    
3S-9643     Lip Type Seal     2    
4N-0641     Gasket     1    
4N-0933     Gasket     2    
4N-1156     Regulator Cover Gasket     1    
4N-8150     Spring     2    
5P-5678     Seal     7M    
6V-6609     O-Ring Seal     3    
9X-7378     O-Ring Seal     1    
061-7540     O-Ring Seal     1    
100-7399     Plug     2    
101-8468     Bushing     1    
106-1792     Taperlock Stud     12    
109-0076     O-Ring Seal     2    
124-9052     Gasket     1    
126-1756     Locking Bolt     4    
126-1757     Washer     9    
130-4698     Bushing     1    
131-7123     Bushing     1    
155-9524     Integral Seal     1    
214-7566     O-Ring Seal     1    
214-7568     O-Ring Seal     5    
228-7093     O-Ring Seal     2    
238-5080     O-Ring Seal     5    
238-5081     O-Ring Seal     2    
238-5084     O-Ring Seal     1    
248-5513     Temperature Regulator     2    
268-5589     Seal     1    
392-9208     Valve Plunger     2    

Note: For assistance or technical questions contact your local Cat dealer.

Note: Refer to Illustration 2 for location of gasket kits.

3406E Engine Gasket Kit Locations




Illustration 2g03402964

(1) Rear Structure ( 349-1530 Gasket Kit )

(2) Single Cylinder Head ( 438-8574 Gasket Kit )

(3) Aftercooler and Lines ( 433-7623 Gasket Kit )

(4) Fuel System ( 433-9843 Gasket Kit )

(5) Heat Exchanger ( 433-9243 Gasket Kit )

(6) Front Structure ( 434-0857 Gasket Kit )

(7) Central and Lower ( 434-1393 Gasket Kit )

(8) Oil Cooler and Lines ( 433-1394 Gasket Kit )

Gasket Kit Consists

Rear Structure (349-1530 Gasket Kit)

Table 3
349-1530 Gasket Kit (Rear Structure)    
Part Number     Part Name     Qty    
2A-1162     Gasket     3    
4H-7869     Gasket     1    
5H-0244     Gasket     1    
9Y-6089     Gasket     1    
142-5868     Crankshaft Seal     1    
155-5619     Gasket     1    
234-8937     Integral Seal     1    
250-0466     O-Ring Seal     1    

Refer to Illustration 2.

Aftercooler and Lines (433-7623 Gasket Kit)

Table 4
433-7623 Gasket Kit (Aftercooler and Lines)    
Part Number     Part Name     Qty    
2M-9780     O-Ring Seal     2    
3P-0654     O-Ring Seal     2    
5M-3038     O-Ring Seal     2    
6L-1650     O-Ring Seal     3    
6V-3917     O-Ring Seal     2    
6V-4365     O-Ring Seal     5    
6V-5048     O-Ring Seal     2    
7D-7111     O-Ring Seal     1    
8L-2786     O-Ring Seal     1    
123-5205     Gasket     2    
130-5694     O-Ring Seal     2    
150-4104     Gasket     1    
214-7568     O-Ring Seal     1    
237-7623     O-Ring Seal     2    

Refer to Illustration 2.

Heat Exchanger (433-9243 Gasket Kit)

Table 5
433-9243 Gasket Kit (Heat Exchanger)    
Part Number     Part Name     Qty    
2N-0931     Gasket     1    
6L-1650     O-Ring Seal     1    
6V-5656     O-Ring Seal     2    
9X-7378     O-Ring Seal     3    
110-7753     O-Ring Seal     2    
136-9486     Liner     4    

Refer to Illustration 2.

Fuel System (433-9843 Gasket Kit)

Table 6
433-9843 Gasket Kit (Fuel System)    
Part Number     Part Name     Qty    
1P-0436     Gasket     3    
6V-5048     O-Ring Seal     5    
6V-6923     Backup Ring     1    
8L-2786     O-Ring Seal     1    
033-6033     O-Ring Seal     1    
107-5769     O-Ring Seal     2    
214-7568     O-Ring Seal     10    
238-5081     O-Ring Seal     1    

Refer to Illustration 2.

Front Structure (434-0857 Gasket Kit)

Table 7
434-0857 Gasket Kit (Front Structure)    
Part Number     Part Name     Qty    
3K-0360     O-Ring Seal     2    
5E-8771     O-Ring Seal     1    
6V-1197     O-Ring Seal     1    
7X-4805     O-Ring Seal     2    
8L-2786     O-Ring Seal     2    
8T-9527     O-Ring Seal     1    
9M-3786     O-Ring Seal     1    
061-9455     O-Ring Seal     3    
103-6045     Seal     1    
107-5769     O-Ring Seal     2    
109-0077     O-Ring Seal     1    
117-8801     O-Ring Seal     1    
122-3772     O-Ring Seal     1    
142-5867     Crankshaft Seal     1    
144-6142     Integral Seal     1    
155-3629     Gasket     1    
166-9144     Gasket     1    
214-7568     O-Ring Seal     1    
250-0466     O-Ring Seal     1    

Refer to Illustration 2.

Central and Lower (434-1393 Gasket Kit)

Table 8
434-1393 Gasket Kit (Central and Lower Structure)    
Part Number     Part Name     Qty    
2P-3760     Gasket     2    
2P-4305     Gasket     4    
3J-1907     O-Ring Seal     1    
3J-7354     O-Ring Seal     2    
4N-0699     Gasket     3    
4N-0933     Gasket     1    
4N-1151     Gasket     1    
5K-9090     O-Ring Seal     4    
5P-5846     O-Ring Seal     2    
5P-8068     O-Ring Seal     3    
5P-8210     O-Ring Seal     2    
6V-3683     O-Ring Seal     1    
6V-5048     O-Ring Seal     3    
7M-8485     O-Ring Seal     2    
8C-0624     O-Ring Seal     1    
8C-3445     Dust Cap     2    
8J-4351     O-Ring Seal     2    
9X-7378     O-Ring Seal     1    
109-0072     O-Ring Seal     1    
109-0073     O-Ring Seal     2    
109-0077     O-Ring Seal     1    
109-0078     O-Ring Seal     1    
109-7425     Cover Seal     1    
114-4427     O-Ring Seal     1    
118-5068     O-Ring Seal     2    
126-4935     Integral Seal     1    
214-7566     O-Ring Seal     2    
214-7568     O-Ring Seal     2    

Refer to Illustration 2.

Oil Cooler and Lines (434-1394 Gasket Kit)

Table 9
434-1394 Gasket Kit (Oil Cooler and Lines)    
Part Name     Part Number     Qty    
1J-9671     O-Ring Seal     2    
1W-2636     Gasket     1    
2N-3350     O-Ring Seal     4    
2P-3760     Gasket     2    
4L-1267     Gasket     1    
4N-0641     Gasket     1    
4N-0933     Gasket     1    
109-0073     O-Ring Seal     2    
109-0076     O-Ring Seal     4    
109-0077     O-Ring Seal     3    
109-0078     O-Ring Seal     3    
214-7567     O-Ring Seal     2    

Refer to Illustration 2.

Single Cylinder Head (438-8574 Gasket Kit)

Table 10
438-8574 Gasket Kit (Single Cylinder Head)    
Part Number     Part Name     Qty    
1W-2636     Gasket     1    
2M-9780     O-Ring Seal     1    
2N-2766     Locknut     4    
3E-6772     Seal     24    
3K-0360     O-Ring Seal     1    
3S-9643     Lip Type Seal     1    
4N-0641     Gasket     1    
4N-1156     Regulator Cover Gasket     1    
5P-0840     O-Ring Seal     2    
5P-7530     O-Ring Seal     1    
6I-2517     Gasket     1    
6J-2245     O-Ring Seal     1    
6L-1650     O-Ring Seal     1    
6L-8562     Taperlock Stud     4    
6V-0128     O-Ring Seal     1    
6V-1197     O-Ring Seal     1    
6V-4365     O-Ring Seal     5    
6V-4367     O-Ring Seal     1    
6V-5050     O-Ring Seal     1    
7D-7111     O-Ring Seal     1    
7M-7273     Gasket     1    
8L-2777     O-Ring Seal     12    
8L-2786     O-Ring Seal     3    
9X-7430     O-Ring Seal     6    
061-8639     O-Ring Seal     6    
109-0072     O-Ring Seal     2    
109-0073     O-Ring Seal     1    
109-0077     O-Ring Seal     1    
114-2687     O-Ring Seal     1    
114-4427     O-Ring Seal     1    
117-8801     O-Ring Seal     1    
124-9052     Gasket     1    
129-9452     Exhaust Manifold Gasket     6    
142-2329     Seal     1    
166-2904     O-Ring Seal     12    
214-7568     O-Ring Seal     4    
227-1204     Gasket     1    
242-9537     Valve Cover Seal     3    
243-1159     Fastener     12    
272-0390     Seal     1    
272-2583     O-Ring Seal     1    
359-0908     Cylinder Head Gasket     1    

Refer to Illustration 2.

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