3412 Generator Set Engine 2WJ00001-UP(SEBP2268 - 42) - Documentation Page 1 of 6

Shutdown SIS

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Product: GEN SET ENGINE

Model: 3412 GEN SET ENGINE 2WJ
Configuration: 3412 Generator Set Engine 2WJ00001-UP

Disassembly and Assembly

3412 GENERATOR SET ENGINES
Media Number -SENR4628-02 Publication Date -01/05/2003 Date Updated -26/06/2015

SENR46280040

Fuel Injection Pumps

SMCS - 1251-011; 1251-012

Remove Fuel Injection Pumps

Start By:

a. remove fuel lines

1. Use tool (F) and remove the shutdown solenoid (1).

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2. Remove two bolts (2) and remove actuator solenoid (3) from the fuel injection pump housing.

3. Remove two rack zero plugs (4).

Typical Example

4. Push the rack servo (5) toward the rear of the engine. Install tools (A) in the rack zero pin holes.
Push the rack servo (5) toward the front of the engine and install tool (B) to hold the rack against the
rack zero pin.

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5. Use tool (C) to loosen bushing (6).

6. Install tool (E) and compress fuel pump spring. Hold tool (E) in position and remove bushing (6).

Typical Example

7. Remove fuel injection pump with tool (D).

NOTICE

When injection pumps, spacers and lifters are removed from the
injection pump housing, keep the parts of each pump together so they
can be installed back in their original location.

8. Disassemble the fuel injection pump. Remove ring (8). Make a separation of bonnet (7) from the
plunger and barrel assembly (9).

NOTICE

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Be careful when the injection pumps are disassembled. Do not cause

damage to the surface on the plunger. 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.

9. Remove the gear segment, washer and spring from the barrel.

10. Remove the ring, spring, collar and valve from the barrel.

Typical Example

11. Remove spacer (10).

Install Fuel Injection Pumps

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Typical Example

NOTE: Make sure the fuel racks are in the center (zero) position before the fuel injection pumps are
installed.

1. Install plunger (10) and gear segment (11), washer (5) and spring (9) in position on barrel (4). Put
check valve assembly (7), spring (3) and collar (8) in position in bonnet (6). Connect bonnet (6) and
barrel (4) together with ring (2). Keep seal (1) with bonnet for use at installation.

2. Put spacer (13) into position in the pump housing bore. Make sure the correct spacer is with each
pump.

3. Put the space in gear segment (11) in alignment with the groove in barrel (4).

4. Put the injection pump straight down into the housing bore so the spacer in gear segment (11) is in
alignment with pin (12) and the groove in barrel (4) is in alignment with dowel (14). Use tool (C) to
install the pump.

5. Install seal (1) and bushing (16) in the pump housing bore. If the pump is in the correct position,
install tool (D) with bushing (16). Compress fuel injection pump spring with tool (D) and hand start
the bushing threads to a torque of 245 ± 15 N·m (180 to 10 lb ft) with tool (B).

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6. Check for correct installation of the injection pumps with the engine stopped. See the topic,
INJECTION PUMP INSTALLATION in TESTING AND ADJUSTING.

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.

7. Remove the timing pin [Tool (A)] and install the plug in the injection pump housing.

End By:

a. install fuel lines

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