419-8235 Major Engine Overhaul Kit for 3412D Marine Engines{1000} Caterpillar


419-8235 Major Engine Overhaul Kit for 3412D Marine Engines{1000}

Usage:

3412D REA
Industrial Engine:
3412D (S/N: REA1-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    
3412D     238-8191     S/N:REA1-UP     SEBP3998     RENR1389    
238-8190

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

3412D 419-8235 Major Overhaul Kit Consist

Table 2
419-8235 Major Overhaul Kit Consist    
Gasket Kits    
Part Number     Part Name     Qty    
258-8117     Single Cylinder Liner Gasket Kit     12    
420-0923     After Cooler and Lines Gasket Kit     1    
420-4866     Rear Structure Gasket Kit     1    
281-0029     Single Fuel Injector Gasket Kit     12    
420-4502     Single Cylinder Head Gasket Kit     2    
420-0925     Central and Lower Structure Gasket Kit     1    
421-1305     Fuel System Gasket Kit     1    
420-0926     Front Structure Gasket Kit     1    
421-8976     Oil Cooler and Lines Gasket Kit     1    
6V-0237     Expansion Tank Gasket Kit     1    
Additional Parts Included in This Kit    
Part Number     Part Name     Qty    
1R-0749     Fuel Filter     2    
1R-1808     Engine Oil Filter     2    
2B-2695     Bolt     4    
2F-4967     Spacer     2    
2K-4973     Locknut     1    
2N-2766     Locknut     24    
2N-8109     Clamp     1    
2P-1974     Taperlock Stud     3    
2P-4304     Hollow Stud     1    
2P-8669     Gasket     1    
2S-2760     Spring     1    
2Y-9255     Spacer     2    
3B-1915     Bolt     2    
3E-6773     O-Ring Seal     2    
3G-2292     Locking Bolt     5    
3K-3256     Taperlock Stud     3    
3M-0496     Taperlock Stud     1    
4F-9081     Stud     1    
4M-1336     Ferrule     2    
4N-0342     Plate     1    
4N-0685     Bushing     5    
4N-6658     Bushing     2    
4N-8150     Spring     2    
5F-0304     Plug     5    
5H-8985     Spring Pin     1    
5M-2894     Hard Washer     3    
6F-7012     Taperlock Stud     4    
6K-0806     Cable Strap     6    
6L-4428     Taperlock Stud     3    
6L-8562     Taperlock Stud     8    
6N-0977     Bushing     1    
6N-1027     Thrust Plate     1    
6V-1520     Drain Valve     2    
6V-5063     O-Ring Seal     1    
7C-7407     Stud     1    
7N-2443     Thrust Washer     1    
7W-0316     Clamp     2    
7W-6492     Pipe Plug     2    
7W-6534     Pipe Plug     6    
8M-1047     Taperlock Stud     8    
8M-2296     Full Nut     8    
8N-9758     Clamp     2    
8T-6757     Pipe Plug     6    
8T-6763     Pipe Plug     4    
9S-4190     O-Ring Plug     6    
9Y-2988     Breather As     1    
061-9456     O-Ring Seal     1    
106-1792     Taperlock Stud     24    
111-2721     Felt Plug     1    
112-3540     O-Ring Seal     2    
112-9217     Thrust Plate     1    
114-2687     O-Ring Seal     2    
114-4427     O-Ring Seal     2    
114-9224     Spacer     28    
226-4753     Gasket     2    
248-5513     Temperature Regulator     2    
293-3286     Spacer     4    
305-6843     Guide Spring     24    
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.

3412D Engine Gasket Kit Locations




Illustration 2g03331009

(1) Aftercooler and Lines ( 420-0923 Gasket Kit )

(2) Rear structure ( 420-4866 Gasket Kit )

(3) Single Cylinder Liner ( 258-8117 Gasket Kit )

(4) Single Cylinder Head ( 420-4502 Gasket Kit )

(5) Central and Lower ( 420-0925 Gasket Kit )

(6) Fuel System ( 421-1305 Gasket Kit )

(7) Front Structure ( 420-0926 Gasket Kit )

(8) Expansion Tank ( 6V-0237 Gasket Kit )

(9) Oil Cooler and Lines ( 421-8976 Gasket Kit )

(10) Single Fuel Injector ( 281-0029 Gasket Kit )

Gasket Kit Consists

Single Cylinder Liner (258-8117 Gasket Kit)

Table 3
258-8117 Gasket Kit (Single Cylinder Liner)    
Part Number     Part Name     Qty    
9L-5854     Filler Band     1    
155-0809     Liner Seal     1    
155-0810     Liner Seal     1    
155-2793     Liner Seal     1    

Refer to Illustration 2.

Aftercooler and Lines (420-0923 Gasket Kit)

Table 4
420-0923 Gasket Kit (Aftercooler and Lines)    
Part Number     Part Name     Qty    
3E-6773     O-Ring Seal     2    
4N-2564     Gasket     1    
4N-4307     Gasket     1    
7C-0307     Gasket     1    
109-0076     O-Ring Seal     6    
112-3258     O-Ring Seal     3    
112-3259     O-Ring Seal     2    
112-8186     O-Ring Seal     2    
173-2086     Gasket     1    

Refer to Illustration 2.

Rear Structure (420-4866 Gasket Kit)

Table 5
420-4866 Gasket Kit (Rear Structure)    
Part Number     Part name     Qty    
2A-1162     Gasket     5    
2M-5446     Gasket     1    
4N-0933     Gasket     2    
5F-3144     O-Ring Seal     2    
9L-6924     Gasket     1    
9Y-6089     Gasket     1    
112-3540     O-Ring Seal     2    
114-4427     O-Ring Seal     2    
126-2702     Integral Seal     2    
142-5868     Crankshaft Seal     1    
161-7293     Cylinder Gasket     1    
198-6068     Integral Seal     2    
214-7568     O-Ring Seal     4    
226-4753     Gasket     2    

Refer to Illustration 2.

Single Fuel Injector (281-0029 Gasket Kit)

Table 6
281-0029 Gasket Kit (Single Fuel Injector)    
Part Number     Part Name     Qty    
7W-4487     Special Washer     1    
9L-9098     Carbon Stop Seal     1    
114-3362     O-Ring Seal     1    
271-2489     Washer Seal     1    

Refer to Illustration 2.

Single Cylinder Head (420-4502 Gasket Kit)

Table 7
420-4502 Gasket Kit (Single Cylinder Head)    
Part Number     Part Name     Qty    
1J-9671     O-Ring Seal     1    
3E-6772     Seal     24    
3S-9643     Lip Type Seal     1    
4N-0933     Gasket     1    
4N-1684     Gasket     1    
4N-4307     Gasket     1    
4N-6295     Return Sleeve     1    
4N-7253     Chamber Gasket     6    
5P-5678     Seal     7M    
5P-8119     O-Ring Seal     6    
5P-8356     O-Ring Seal     2    
6V-3831     O-Ring Seal     1    
6V-3917     O-Ring Seal     4    
7C-0307     Gasket     4    
7J-2036     O-Ring Seal     4    
7L-4774     O-Ring Seal     6    
7M-7273     Gasket     1    
8H-9204     Felt Washer     6    
8L-2779     O-Ring Seal     6    
109-0076     O-Ring Seal     6    
109-0078     O-Ring Seal     5    
112-3258     O-Ring Seal     2    
112-3540     O-Ring Seal     2    
126-2702     Integral Seal     1    
129-9452     Exhaust Manifold Gasket     6    
198-6068     Integral Seal     1    
214-7568     O-Ring Seal     1    
225-3099     Cylinder Head Gasket     1    
225-3101     Plate Gasket     1    
229-5332     Exhaust Seal     2    
272-2583     O-Ring Seal     3    

Refer to Illustration 2.

Central and Lower (420-0925 Gasket Kit)

Table 8
420-0925 Gasket Kit (Central and Lower Structure)    
Part Number     Part Name     Qty    
2P-3760     Gasket     1    
2P-4305     Gasket     4    
4N-2630     Spark Ignited Access Gasket     4    
6N-0824     Gasket     1    
6V-5048     O-Ring Seal     1    
6V-5063     O-Ring Seal     1    
8C-3445     Dust Cap     1    
8J-4351     O-Ring Seal     1    
109-0076     O-Ring Seal     3    
109-0078     O-Ring Seal     3    
114-4427     O-Ring Seal     8    
118-5068     O-Ring Seal     1    
165-6170     Plug     3    
198-1517     Gasket     1    
214-7568     O-Ring Seal     1    
239-5572     Integral Seal     5    
343-8888     Gasket     2    
353-1648     Oil Pan Gasket     1    

Refer to Illustration 2.

Fuel System (421-1305 Gasket Kit)

Table 9
421-1305 Gasket Kit (Fuel System)    
Part Number     Part Name     Qty    
1J-9671     O-Ring Seal     1    
1P-0436     Gasket     1    
1S-0004     O-Ring Seal     2    
2P-8643     Gasket     2    
2P-8669     Gasket     1    
2P-8697     Gasket     1    
3D-2824     O-Ring Seal     3    
3J-1907     O-Ring Seal     10    
3J-7354     O-Ring Seal     3    
3K-0360     O-Ring Seal     1    
4J-7533     O-Ring Seal     1    
4M-8303     O-Ring Seal     3    
4N-1104     Gasket     1    
4N-1105     Gasket     1    
4N-1868     Gasket     1    
4N-1870     Housing Gasket     1    
4N-7465     Gasket     1    
5F-9144     O-Ring Seal     1    
5L-8991     Cover Gasket     1    
5P-0796     Lip Type Seal     2    
5P-5601     O-Ring Seal     2    
5P-8119     O-Ring Seal     12    
6H-9691     O-Ring Seal     1    
6J-2419     O-Ring Seal     1    
6N-2508     Gasket     1    
6V-4314     O-Ring Seal     1    
6V-8977     Lip Type Seal     1    
7J-0204     O-Ring Seal     1    
8H-9204     Felt Washer     14    
8L-2779     O-Ring Seal     8    
8L-3873     Gasket     2    
114-8718     O-Ring Seal     12    
214-7568     O-Ring Seal     3    

Refer to Illustration 2.

Front Structure (420-0926 Gasket Kit)

Table 10
420-0926 Gasket Kit (Front Structure)    
Part Number     Part Name     Qty    
4N-1156     Regulator Cover Gasket     2    
5F-3144     O-Ring Seal     1    
6N-2508     Gasket     1    
9X-7371     O-Ring Seal     1    
112-1579     O-Ring Seal     1    
112-1580     O-Ring Seal     1    
142-5867     Crankshaft Seal     1    
166-9145     Cylinder Block Gasket     1    
193-9155     Gasket     1    
214-7568     O-Ring Seal     1    
234-8937     Integral Seal     1    

Refer to Illustration 2.

Oil Cooler and Lines (421-8976 Gasket Kit)

Table 11
421-8976 Gasket Kit (Oil Cooler and Lines)    
Part Name     Part Number     Qty    
2P-3760     Gasket     1    
4N-0933     Gasket     1    
4N-1156     Regulator Cover Gasket     2    
4N-1684     Gasket     1    
4N-1946     Gasket     1    
4N-2199     Gasket     2    
5F-0149     O-Ring Seal     2    
6N-0824     Gasket     1    
7C-0307     Gasket     3    
109-0072     O-Ring Seal     4    
109-0074     O-Ring Seal     1    
109-0076     O-Ring Seal     3    
109-0077     O-Ring Seal     2    
109-0078     O-Ring Seal     4    
343-8888     Gasket     1    

Refer to Illustration 2.

Expansion Tank (6V-0237 Gasket Kit)

Table 12
6V-0237 Gasket Kit (Expansion Tank)    
Part Number     Part Name     Qty    
1L-8212     Gasket     1    
2N-0931     Gasket     4    
3S-9643     Lip Type Seal     2    
4L-3862     Gasket     4    
4N-1156     Regulator Cover Gasket     2    
4N-1946     Gasket     1    
4N-3858     Gasket     2    
7C-0307     Gasket     4    
9H-2282     Starting Motor Gasket     1    
109-0072     O-Ring Seal     4    
109-0074     O-Ring Seal     1    
109-0075     O-Ring Seal     2    
109-0079     O-Ring Seal     2    
110-7752     O-Ring Seal     4    
110-7753     O-Ring Seal     2    
343-8888     Gasket     1    

Refer to Illustration 2.

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