Installation of a 3306 Engine Emissions Upgrade Group for a 816B Landfill Compactor, 815B Soil Compactor, or a 814B Wheel Dozer{1000} Caterpillar

Installation of a 3306 Engine Emissions Upgrade Group for a 816B Landfill Compactor, 815B Soil Compactor, or a 814B Wheel Dozer{1000}

Usage:

816B 15Z

Landfill Compactor:: 816B (S/N: 15Z1-UP)
Soil Compactor:: 815B (S/N: 17Z1-UP)
Wheel Dozer:: 814B (S/N: 16Z1-UP)

Introduction

Note: This Special Instruction can only be used for the machines with certain engine arrangements. Refer to Table 1 for the arrangement numbers that are applicable.

The engine serial number will not change after this procedure is completed. The arrangement number of the engine will change.

Show/hide table

Table 1
Engine Arrangement Numbers
Original	Engine Serial Number	New
9Y-4951	(S/N: 08Z; 6NC)	284-3319
6N-5908	(S/N: 08Z)	284-3320

This Special Instruction provides the information in order to install a 3306 Engine Emissions Upgrade Group (EUG) for a Wheel Tractor. Tier I emission levels can be achieved by replacing certain components on the existing unregulated engine. This Emissions Upgrade procedure should be completed at the time of the engine overhaul.

When the Emissions Upgrade procedure has been completed, a label will be provided by Caterpillar. This label will verify that the Emissions Upgrade procedure has been performed for that individual 3306 Engine.

In order to obtain an Emissions Upgrade Label, the following criteria must be met:

All procedures in this Special Instruction must be completed by a Caterpillar dealer. The Caterpillar dealership will be required to verify the Emissions Upgrade procedure.
The engine that receives the Emissions Upgrade procedure must be tested on a dynamometer. The data will be submitted on the emissions upgrade validation form. The form must be approved by Caterpillar Engineering prior to installing the engine back on the machine.
The EUG must be registered as outlined in Special Instruction REHS5097.

Note: A label will not be issued for the Emissions Upgrade procedure if all of the criteria has not been met.

Return the component cores according to Reman Policies and Core Management, SELD0122. Refer to the following web site for more information.

https://reman.cat.com

This Special Instruction does not include all of the procedures that can be found in your existing manuals. Refer to the original Service Manual, Parts Manual, and Operation and Maintenance Manual for more information.

When you have completed this procedure, prepare the machine for service. Refer to the Operation and Maintenance Manual.

Note: Do not perform any procedure in this Special Instruction until the information has been read and understood.

Reference Service Manual, Parts Manual, Operation and Maintenance Manual, Engine Reusability Guidelines

Register the Retrofit

When performing a retrofit installation, record the vital information in Table 2.

Note: If the procedure is performed by the customer, ask the customer to record the proper information.

Show/hide table

Table 2
Repair Date
Product Serial Number
Service Hours or Service Meter Units
Removed Component Part Number ⁽¹⁾
Removed Component Serial Number ⁽¹⁾
Installed Component Part Number ⁽²⁾
Installed Component Serial Number ⁽³⁾

Show/hide table

^( 1 )	Only applies if a component is replaced by a retrofit component. If the product is an engine, and the product retrofit is a kit for upgrading the engine, disregard the "Removed Component" information. Refer to detailed instructions in Step 3 for more information.
^( 2 )	Record the highest level retrofit kit, arrangement, or group part number.
^( 3 )	Most retrofits will not have a serial number. Exceptions include emissions repower engines and diesel particulate filters.

Update the product configuration by entering the information from Table 2 into SIMSi.

For detailed instructions on updating the product configuration, refer to Special Instruction, REHS5097, "Instructions to Register the Retrofit".

Safety

Show/hide table

Personal injury or death can result from sudden machine movement.
Sudden movement of the machine can cause injury to persons on or near the machine.

To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine.

Show/hide table

Do not attempt to assemble this machine until you read and you understand the assembly instructions.

Improper assembly procedures could result in injury or death.

Show/hide table

Personal injury or death can result from improper lifting or blocking.
When a hoist or jack is used to lift any part or component, stand clear of the area. Be sure the hoist or jack has the correct capacity to lift a component. Install blocks or stands before performance of any work under a heavy component.

Approximate weights of the components are shown. Clean all surfaces where parts are to be installed.

Show/hide table

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 Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

Welding on Electronically Controlled Engines

Proper welding procedures are necessary in order to avoid damage to electronic controls. Perform welding on the engine according to the following procedure.

Set the engine control to the "STOP" mode.

Turn OFF the fuel supply to the engine.

Disconnect the negative terminal from the battery.

Disconnect the electronic components of the engine from the wiring harnesses: ECM, throttle actuator, actuator for the turbocharger compressor's bypass, fuel metering valve and sensors.

Protect the wiring harnesses from welding debris and/or from welding spatter.

Show/hide table

NOTICE

Do NOT use electrical components (ECM or sensors) or electronic component grounding points for grounding the welder.

Connect the ground cable of the welder directly to the engine component that will be welded. Place the clamp as close as possible to the weld in order to reduce the possibility of welding current damage to the engine bearingsto the electrical componentsand to other engine components.

Use standard welding procedures to weld the materials together.

Required Parts

Parts to Order

Refer to TMIweb for the current parts list.

Use the Modification Gp part number in Table 3 as a part number in TMIweb. Each of the components with the set type "PTS-LIST" needs to be ordered. Read the notes for each component as some groups are required for specific serial number ranges only. Components with a set type "MISC REF" should NOT be ordered. In order to have coverage over multiple serial number breaks, some parts from the hardware kit will not be used.

The parts contained within the Modification Gp are for the emissions upgrade only. Additional parts needed for the overhaul, such as a reman cylinder head, gasket kits, etc. need to be ordered as necessary to support the engine arrangement number. Parts availability should be considered prior to the machine arriving at the facility.

Show/hide table

Table 3
Required Parts
Qty	Description	Part Number
1	Modification Gp	284-3288

Under the Modification Gp in TMI, "MISC-REF" part numbers may be used in SISWEB to view illustrations and individual part numbers. Refer to the parts book if further detail is needed.

Note: To install the engine on this machine, the following items in Table 4 must be added to the kit:

Show/hide table

Table 4
Parts List for Engine
Main Component Part Number	Consist Part Number	Name	Qty
6I-2613 Muffler Gp	0L-1352	Bolt	1
	2Y-5829	Nut-Hex	2
	4P-3806	Clamp	1
	6I-2408	Muffler As	1
	6I-2409	Pipe	1
	6I-2614	Support	1
	6I-2615	Support	1
	6V-1820	Bolt	4
	6V-5839	Washer-Hard	10
	6V-5842	Bolt-Hex Head	2
	8T-4184	Bolt	4
	8T-4223	Washer-Hard	4
	8T-4244	Nut-Hex	4
	9S-8752	Nut-Full	1
6I-2701 Air Lines Gp	5L-8854	Ring	1
	5L-8855	Seal-Metal Ring	1
	8T-4986	Clamp-Band	2
	113-1064	Hose	1
132-1427 Air Cleaner Gp	123-7774	Cleaner Gp-Air-B	1

Procedure to Install the Emissions Upgrade Group

Note: Before starting the procedures, refer to the following items:

See your machines Disassembly and Assembly for more information about the removal and installation of the engine.

Component Reusability Guidelines

The following information is used in order to test the original engine components that will be used for the Emissions Upgrade procedure. Examples of the original components that are often used with the Emissions Upgrade Group include the following parts: engine block, engine cylinder head, crankshaft, valve mechanism and gear train. Refer to Table 5 for the correct media number for each part reusability.

Show/hide table

Table 5
Reusability Guidelines Service Manual Numbers
Part Description	Service Manual Media Number
Engine Block	RENR3218 ⁽¹⁾
Cylinder Head	RENR3219 ⁽²⁾
Crankshaft	RENR3223 ⁽³⁾
Valve Mechanism ⁽⁴⁾	RENR3226 ⁽⁵⁾
Gear Train	RENR3227 ⁽⁶⁾

Show/hide table

^( 1 )	The individual sections for the engine block are listed in Table 6.
^( 2 )	The individual sections for the cylinder heads are listed in Table 7.
^( 3 )	The individual sections for the crankshaft are listed in Table 8.
^( 4 )	The camshaft specifications are included in the Valve Mechanism section.
^( 5 )	The individual sections for the valve mechanisms are listed in Table 9.
^( 6 )	The individual sections for the gear train are listed in Table 10.

Show/hide table

Table 6
Engine Block Reusability
Title	Media Number
"Cylinder Block Salvage Procedure Using Belzona Ceramic R Metal"	REHS2133
"Using 1P-3537 Dial Bore Gauge Group to Check Cylinder Bore Size"	GMGO0981
"Use of 1P-4000 Line Boring Tool Group"	SMHS7606
"Using LOCK-N-STITCH Procedures for Casting Salvage"	SEBF8882
"Salvage Weld Procedure for Cast Iron Cylinder Blocks"	SEHS8919
"Installation of 1N-3574 or 1N-3576 Cylinder Block Service Group (Spacer Plate) as a Replacement for the Former Counterbored Cylinder Block"	SMHS7541
"Specifications to Salvage Cylinder Block Contact Surfaces"	SEBF8076

Show/hide table

Table 7
Cylinder Head Reusability
Title	Media Number
"Specifications to Measure and Salvage Cylinder Head Assemblies and Related Components"	SEBF8162
"Using the 9U-5383 Vacuum Tester"	SEHS9498
"Specifications for Cylinder Head Assemblies 3300 Engines"	SEBF8375

Show/hide table

Table 8
Crankshaft Reusability
Title	Media Number
"Crankshaft Measurement"	SEBF8041
"Procedure to Measure and Straighten Bent Crankshafts"	SEBF8054
"Main and Connecting Rod Bearings"	SEBF8009
"Visual Inspection of Crankshafts"	SEBF8043
"Inspection of Crankshafts for Cracks"	SEBF8039
"Procedure to Polish Crankshafts"	SEBF8042

Show/hide table

Table 9
Valve Mechanism Reusability
Title	Media Number
"Camshaft Measurement"	SEBF8097
"Visual Inspection of Camshafts"	SEBF8146
"Slipper Followers and Camshaft Roller Followers"	SEBF8067
"Valve and Valve Spring Specifications"	SEBF8034
"Valves, Valve Springs, Valve Rotators, and Locks"	SEBF8002

Show/hide table

Table 10
Gear Train Reusability
Title	Media Number
"Timing Gears For All Engines"	SEBF8045

Show/hide table

Table 11
Miscellaneous
Title	Media number
"Kidney Loop Filtration Process For Rebuilt Engines"	SEBF8405

When you have completed this procedure, prepare the machine for service. Refer to the Operation and Maintenance Manual.

Installation of the Emissions Upgrade Components

The following is a detailed procedure used to install the following emissions critical components: Cylinder Pack Gp, Fuel Injection Pump Gp, Fuel Injection Nozzles, and Turbocharger Gp. The installation of the remaining emissions and non-emissions critical components should be completed per the Disassembly and Assembly Manual. A recommended outline of some of these extra steps is included in this document.

Disassembly and Inspection of the Engine

Disassemble the engine according to the Disassembly and Assembly Manual for your machine.

Clean the block and inspect for erosion in the cylinder liner seal location and deck at the cylinder liner seat location.

Check Cylinder Liner Projection

Note: Do not install liner seals for this step.

Note: The following procedure alleviates the need for the crossbar to hold the cylinder liners during cylinder liner projection measurements.

Clean the cylinder liner flange and the cylinder block surface. Remove any nicks on the top of the cylinder block.

Install clean cylinder packs without the rubber seals or the filler band. Install a new spacer plate gasket and the clean spacer plate.

Show/hide table

Table 12
Required Components
Item	Part Number	Part Description	Quantity For One Cylinder	Quantity For Six Cylinders
1	0S-1589	Bolt	6	36
2	2S-0736	Washer	6	36
3	8F-1484	Washer	6	36
4	7K-1977	Washer	6	36

Show/hide table




Illustration 1	g00544054

Install the bolts and washers in the order that is shown in Illustration 1 in order to seat the cylinder liner in the block. Tighten bolts (1) evenly to a torque of 95 N·m (70 lb ft).

Show/hide table




Illustration 2	g00544478
(5) Bolt (6) Dial Indicator (7) Gauge Body (8) Gauge

Loosen bolt (5) until dial indicator (6) can be moved. Place gauge body (7) and dial indicator (6) on the long side of gauge (8) .

Slide dial indicator (6) into position until the point contacts gauge (8). Slide dial indicator (6) until the needle of the dial indicator makes a quarter of a revolution clockwise. The needle should be in a vertical position. Tighten bolt (5) and zero dial indicator (6) .

Place gauge body (7) on the spacer plate with the dial indicator point on the cylinder liner flange. Read the dial indicator in order to find the amount of liner projection. Check the liner projection at four locations (every 90 degrees) around each cylinder liner.

Show/hide table

Table 13
Specifications
Liner Projection	0.033 mm (.0013 inch) to 0.175 mm (.0069 inch)
Maximum Variation in Each Cylinder	0.051 mm (.0020 inch)
Maximum Average Variation Between Adjacent Cylinders	0.051 mm (.0020 inch)
Maximum Variation Between All Cylinders	0.102 mm (.0040 inch)

If the cylinder liner projection is out of specifications, rotate the cylinder liner in the bore and repeat the procedure. If the cylinder liner is still out of specifications, install the cylinder liner into a different cylinder bore.
Note: Do not exceed the maximum liner projection of 0.175 mm (0.0069 inch). Cracking in the flange of the cylinder liner results from excessive cylinder liner projection measurements.

If the maximum variation between cylinder liners is greater than the recommended specification, counterbore as needed. Clean the block to remove metal shavings and debris. Use shims in order to reach the correct specification.

When the cylinder liner projection for each cylinder liner is within the recommended specification, mark each cylinder liner for the proper location in the bore. Remove the cylinder liners.
Refer to the Disassembly and Assembly manual for this model to complete the following steps:
- Install the crankshaft

Installation of the Cylinder Pack Gp

The Cylinder Pack Gp contains three procedures for installation. The following procedures are included: cylinder liner, pistons and connecting rods and connecting rod bearings.

Installation of the Cylinder liners

Show/hide table

Table 14
Required Tools
Tool	Part Number	Part Description	Qty
A	8T-0455	Liner Projection Tool	1
B	2P-8260	Cylinder Liner Installation Tool	1

Lubricate the O-ring seals, the cylinder liner, and the upper filler band before installation.
Note: If the lower O-ring seals are black in color, apply liquid soap on the lower O-ring seals and the cylinder block. Use clean engine oil on the upper filler band.
Note: If the lower O-rings are brown in color, apply engine oil on the lower O-ring seals, the cylinder block, and the upper filler band.

Show/hide table

NOTICE

Apply 5P-3975 Rubber Lubricant and/or clean engine oil immediately before assembly. If the 5P-3975 Rubber Lubricant or engine oil is applied too early, the filler bands and/or O-ring seals may swell and the filler bands and/or O-ring seals may be pinched under the cylinder liner during installation.

Show/hide table




Illustration 3	g00544889

Apply liquid soap on the bottom cylinder liner bore in the cylinder block. Apply liquid soap on the grooves of the cylinder liner and on O-ring seals (4). Install O-ring seals (4) on the cylinder liner.

Lubricate filler band (5) with clean engine oil and install filler band (5) on cylinder liner (6). Install cylinder liner (6) into the engine block immediately after you lubricate the cylinder liner. The lubricant helps to prevent swelling of the filler band.

Show/hide table




Illustration 4	g00478920

Ensure that the mark on the cylinder liner is in alignment with the mark on the cylinder block. Use Tool (B) to press each of the cylinder liners into position.

Installation of the Pistons and Connecting Rods

Show/hide table

Table 15
Required Tools
Tool	Part Number	Part Description	Qty
A	5P-3525	Piston Ring Compressor	1

Show/hide table

NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Refer to your Disassembly and Assembly in order to remove the existing pistons and connecting rods.

Rotate the crankshaft until the bearing journals are at the bottom center. The bearing journals that are at the bottom center are for the piston installation.

Put clean engine oil on the crankshaft journals and on the inside of the cylinder liners. Put clean engine oil on the piston rings and the connecting rod bearings.

Move the piston rings on the pistons until the ring openings are separated by approximately 120 degrees.

Show/hide table




Illustration 5	g00483337

Put the piston in the cylinder liner with the "V" mark on the piston in alignment with the "V" mark on the cylinder block. Put tool (A) in position on the cylinder block and compress the piston rings.

Show/hide table

NOTICE

The "V" mark must be visible on the piston and the cylinder block. If the "V" mark is not visible, the piston must be installed with the relief for the valve positioned toward the pushrod opening in the cylinder block. Damage may result if the pistons are not installed properly.

Push the piston into the cylinder liner and out of the ring compressor.

Show/hide table




Illustration 6	g00483701

Guide connecting rod (1) into position on the crankshaft.

Put clean engine oil (SAE 30) on the lower half of the connecting rod bearing and on the connecting rod bolts.

Show/hide table

NOTICE

When the connecting rod caps are installed, ensure that the identification marks are aligned.

Install connecting rod cap (2) and the nuts that secure the connecting rod cap. Torque both of the nuts to 40 ± 4 N·m (30 ± 3 lb ft). Mark the position of the nuts. Tighten each nut for an additional 90 degrees (1/4 turn).

Repeat Steps 1 through 9 for the remainder of the piston and connecting rods.

Installation of the Connecting Rod Bearings

Show/hide table

Table 16
Tool	Part Number	Part Description	Qty
A	-	Plastigage	-

Show/hide table

NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Note: Install the connecting rod bearings dry when the clearance checks are made. Put clean engine oil on the connecting rod bearings for final assembly.

Install the upper half of the connecting rod bearing in the connecting rod.

Install the lower half of the connecting rod bearing in the connecting rod.
Note: Align the tabs on the back of the connecting rod bearings with the tab grooves in the connecting rod.

Show/hide table




Illustration 7	g00487493

In order to check the connecting rod bearing clearance, put Tool (A) on the connecting rod bearing, as shown.

Put clean engine oil (SAE 30) on the connecting rod bolts.

Show/hide table

NOTICE

When the connecting rod caps are installed, ensure that the identification marks are aligned.

Show/hide table




Illustration 8	g00487412

Note: Do not turn the crankshaft when Tool (A) is positioned.

Ensure that connecting rod (3) is in position on the crankshaft. Install connecting rod cap (2) and connecting rod nuts (1) on connecting rod (3) .

Show/hide table




Illustration 9	g00287852

Tighten the connecting rod nuts to a torque of 40 ± 4 N·m (30 ± 3 lb ft). Mark the position of the nuts. Tighten each nut for an additional 90 degrees (1/4 turn).

Remove the connecting rod cap. Measure Tool (A) on the bearing surface before Tool (A) is removed. The clearance between the connecting rod bearing and a new crankshaft should be 0.076 to 0.168 mm (.0025 to .0066 inch). The clearance between the connecting rod bearing and a used crankshaft should be 0.25 mm (0.01 inch).

Install connecting rod cap (2) and connecting rod nuts (1) on connecting rod (3). Repeat Step 6 in order to tighten the nuts.

Repeat Steps 1 through 8 for the remaining connecting rod bearings.

Refer to the Disassembly and Assembly manual for this model to complete the following steps:

Install rear housing and flywheel
Install front plate
Install camshaft
Install front gears
Install lifters
Install spacer plate gasket and spacer plate
Install head gasket and ferrules
Install cylinder head. Follow torque procedures and specs listed in current model specifications.

Note: Do not install injection nozzles until after the fuel pump is installed.

Install push tubes and rocker arm assemblies. Follow torque procedures and specs listed in current model specifications.
Adjust valves

Installation of a Governor and Fuel Injection Pump Gp

Show/hide table

Table 17
Required Tools
Tool	Part Number	Part Description	Qty
A	5P-7307	Engine Turning Tool	1
B	4C-9874	Spanner Wrench	1
C	6V-4186	Fuel Pump Timing Pin	2

Show/hide table

NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Note: The No. 1 piston must be set at the top center position (TC) in order to perform all of the timing procedures.

Note: The engine is seen from the flywheel end when the direction of the crankshaft rotation is given.

Remove the existing fuel pump from the engine. Refer to the Disassembly and Assembly for your machine for more information.

Show/hide table




Illustration 10	g00460164

Remove the electric starting motor.

Install Tool (A) into the flywheel housing, as shown.

To find the TC position for the No. 1 piston, perform the following procedure:
1. Turn the flywheel clockwise or turn the flywheel in the opposite direction of the engine rotation for approximately 30 degrees. This procedure will remove all play from the timing gears.
  Note: If you go past the bolt hole, repeat Step 4.a.
1. Remove plugs (1) and (2) .
1. Turn the flywheel counterclockwise until a 3/8-16 X 3 1/2 NC bolt (4) can be installed in the flywheel through the hole in the flywheel housing. The No. 1 and No. 6 pistons are now at the TC position. Plug (2) was removed for viewing through inspection hole (3) .
1. In order to check the position of the inlet and exhaust valves, remove the valve mechanism cover. Refer to your machines Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install".

If the No. 1 piston is not on the compression stroke, remove bolt (4) and turn the flywheel for 360 degrees counterclockwise. Install bolt (4). The No. 1 piston is now at the TC position.

Show/hide table




Illustration 13	g00460258
Typical example

Install Tool (C) in the fuel injection pump housing, as shown. Push Tool (C) and turn fuel injection pump camshaft (8). When Tool (C) engages the groove (slot) in the camshaft, the fuel injection pump is in the TC position for the No. 1 piston.

Note: Check the condition of the O-ring seals. Replace the O-ring seals, if necessary.

Ensure that O-ring seals (5), (6), (7) and (9) are in position on the fuel injection pump housing and the governor. Put clean engine oil on the seals.

Show/hide table




Illustration 14	g00460259

Attach a hoist and put the fuel injection pump housing and the governor in position on the timing gear plate and the oil manifold. Install three nuts (11), two bolts (10) and the washers. Ensure that Tool (C) remains in place.

Show/hide table




Illustration 15	g00460341

Install washer (12) with the large side outward. Install bolt (13) finger tight. Ensure that Tool (C) is in the notch in the camshaft of the fuel injection pump.

Show/hide table




Illustration 16	g00460342

Install Tool (B) on the fuel pump drive gear. Apply 68 N·m (50 lb ft) of force to the fuel pump drive gear with timing bolt (3) in position in the flywheel and Tool (C) in position in the fuel system. Apply this force in a clockwise direction when the engine is viewed from the front. Use Tool (B) and a suitable torque wrench. Hold the 68 N·m (50 lb ft) of force on Tool (B) and torque the drive gear bolt to a torque of 270 ± 25 N·m (200 ± 18 lb ft). Remove Tool (B) and Tool (C) from the fuel pump and remove bolt (3) from the flywheel.

Use Tool (A) and turn the flywheel for two complete revolutions. When bolt (3) goes in the hole in the flywheel and Tool (C) is installed in the notch in the camshaft, the timing is correct.

Install plugs (1) and (2) .

Remove Tool (A). Install the electric starting motor.

Install the valve mechanism cover. Refer to Disassembly and Assembly, "Valve Mechanism Cover - Remove and Install".

Show/hide table




Illustration 17	g00460343

Put cover (14) and the gasket in position. Install four bolts (15) .

Put the fuel filter base, the gasket, and fuel filter (16) in position. Install two bolts (19) and the washers.

Install tube assemblies (21) and (22). Connect wire (20). Connect hoses (17) and (18) .

Show/hide table




Illustration 18	g00589938

Install the gasket, the oil inlet line, and the bolts. Install the O-ring seal on oil drain line (25). Apply clean engine oil to the O-ring seal and install the gasket. Connect oil drain line (25) and install the bolts. Install the clamps on the oil line.

Show/hide table




Illustration 19	g00460346

Put cover (24) in position. Install nuts (23) and six washers. Tighten nuts (23) to a torque of 27 ± 7 N·m (20 ± 5 lb ft).

Refer to the Disassembly and Assembly manual for this model to complete the following step:

Install the fuel lines from the pump to the cylinder head adaptor
Install the governor and fuel pump drive gear

Installation of the Fuel Injection Nozzle As

Show/hide table

Table 18
Required Tools
Tool	Part Number	Part Description	Qty
A	6V-4979	Carbon Seal Installation Tool	1
B	8S-2245	Injector Cleaning Tool	1
C	6V-4089	Reamer	1

Show/hide table

NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Show/hide table




Illustration 20	g00448903

Use the Disassembly and Assembly for your machine in order to remove the original fuel injection nozzle assemblies.

Put carbon dam seal (1) on the small end of Tool (A). Expand carbon dam seal (1) by sliding carbon dam seal (1) to the large end of Tool (A). Put Tool (A) against the fuel injector nozzle. Slide carbon dam seal (1) from Tool (A) to the fuel injector nozzle. Slide carbon dam seal (1) into position in the groove of the fuel injector nozzle, as shown. Use Tool (A) in order to install carbon dam seal (1).

To clean the fuel injector nozzles, refer to Special Instruction, SEHS7292 for the use of Tool (B) .

Install a new compression seal (2) on the fuel injector nozzle.

Show/hide table




Illustration 21	g00448904

Use Tool (C) in order to clean the bore in the cylinder head for the fuel injector nozzle. Use a wrench in order to turn Tool (C) .

Show/hide table




Illustration 22	g00448905

Show/hide table




Illustration 23	g00448906

Align notch (3) in fuel injector nozzle (5) to the tab in clamp (4) during installation.
Note: Refer to Special Instruction, SEHS7292 for more information about cleaning and installing the fuel injector nozzles.

Install fuel injector nozzle (5). Ensure that the notch in the injector is aligned with the tab in clamp (4) .

Installation of the Aftercooler Gp

Show/hide table

NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. 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 Tools and Shop Products Guide", for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose of all fluids according to local regulations and mandates.

Show/hide table

At operating temperature, the engine coolant is hot and under pressure.
Steam can cause personal injury.
Check the coolant level only after the engine has been stopped and the fill cap is cool enough to touch with your bare hand.
Remove the fill cap slowly to relieve pressure.

Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury.

Note: Put identification on all lines, hoses, wires, and tubes for installation purposes. Use caps and plugs on all lines, hoses, and tubes in order to prevent fluid loss or contamination of the systems.

Show/hide table




Illustration 24	g00336668

Install a new gasket on the air inlet heater (9) .

Show/hide table




Illustration 25	g00336663

Install the aftercooler cover (7) .

Install all 24 bolts (6) .

Connect tube (5) to the aftercooler.

Connect coolant line (4) to the aftercooler. Install four bolts (3) .

Show/hide table




Illustration 26	g00336658

Connect tube (2) to the aftercooler. Install four bolts (1) .

Fill the cooling system. Refer to the Operation and Maintenance Manual for the correct procedure.

Refer to the Disassembly and Assembly manual for this model to complete the following steps:

Install valve covers. Follow torque procedures and specs listed in current model specifications.
Install fuel lines
Install front cover, engine support, and dampers (if applicable)

Installation of the Transmission Oil Cooler Gp

Show/hide table

NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Note: Before assembly, check the condition of the gaskets and the O-ring seals. If the gaskets or the O-ring seals are worn or damaged, use new parts for replacement.

Show/hide table




Illustration 27	g00470817

Install bonnet (3), two elbows (2) and pipe (1) on oil cooler core (4) .

Show/hide table

NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Note: Check the condition of the gaskets. If the gaskets are worn or damaged, use new parts for replacement.

Show/hide table




Illustration 28	g00468428

Install engine oil cooler (2) and three bolts (4). Connect clip (3) for the engine oil level gauge. Connect hose assembly (5) .

Show/hide table




Illustration 29	g00468427

Tighten two hose clamps (1) .

Installation of the Oil Filter Base Gp

Show/hide table

NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Show/hide table




Illustration 30	g00500559

Show/hide table




Illustration 31	g00500551

Install plunger (7), plunger (4) and springs (5) .
Note: Plunger (7) is for the engine oil cooler bypass. Plunger (4) is for the oil filter bypass.

Note: Check the condition of the O-ring seals and gaskets. If the seals or gaskets are worn or damaged, use new parts for replacement.

Install two gaskets (6), two covers (3), four bolts (2) and O-ring seals (1) .

Show/hide table

Table 19
Required Tools
Tool	Part Number	Part Description	Qty
A	2P-8250	Strap Wrench Assembly	1

Show/hide table

NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Show/hide table




Illustration 32	g00499568

Note: Coat all of the O-ring seals with clean engine oil prior to installation.

Put the O-ring seals on engine oil filter base (1). Install engine oil filter base (1) on the cylinder block with four bolts (2) .

Put the O-ring seal and the gasket in position on tube assembly (4). Install tube assembly (4) on the cylinder block. Install the bolts that hold tube assembly (4) in position.

Put the O-ring seal and the gasket in position on tube assembly (3). Fasten the clip to tube assembly (4). Position tube assembly (3) onto the cylinder block and install bolts (5).

Show/hide table




Illustration 33	g00499430

Install engine oil filter (1) with Tool (A) .
Note: Follow the installation procedure on the engine oil filter in order to install the engine oil filter on the engine oil filter base.

Show/hide table




Illustration 34	g02154325
For engines equipped with the air compressor, relocate the Governor As (D) to the new locations as shown. (D) Governor (E) Hose

Refer to the Disassembly and Assembly manual for this model to complete the following steps:

Install oil pump and lines
Install oil pan

Installation of the Turbocharger Gp

Show/hide table

NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Remove the existing turbocharger from your engine. Refer to the Disassembly and Assembly for your machine.

Show/hide table




Illustration 35	g00537495
Typical turbocharger

Install oil drain tube (7) on the engine. Position the gasket and turbocharger (5) on top of the exhaust manifold and install four bolts (6) and the nuts.

Show/hide table




Illustration 36	g00537468
Typical turbocharger

Install the gasket and two bolts (3) that hold the oil drain tube to the turbocharger. Put the oil supply tube in position and install the gasket and two bolts (1) that hold the oil supply tube to the turbocharger. Tighten nut (4) .

Testing and Adjusting

ReferenceRefer to Testing and Adjusting, SENR5594, "Governor - Adjust".

Engine Settings

An engine performance validation run MUST be performed on a dyno upon completion of the emissions upgrade. If possible, confirm that the dyno and fuel flow meter have been calibrated before the EUG engine is connected to the dyno. Per EPA requirements, the following parameters must fall within the ceiling/floor ranges specified in the designated test spec in order to receive an engine label:

High Idle Speed
Low Idle Speed
Full Load Speed
Power at Full Load Speed
Fuel Burn Rate at Full Load Speed
Torque Check Speed
Torque at Torque Check Speed
Fuel Burn Rate at Torque Check Speed

If any of these parameters do not fall within the specifications, the FLS/FTS settings should be adjusted until all specifications are met. A label can only be issued once all of the above mentioned parameters are within the specifications.

Note: The values from the dyno tests will be included on the engine labels. For this reason, it is important to have a calibrated dyno and fuel flow meters that can provide accurate measurements for the engine rating being tested.

Single HP Instructions

After the installation of the Emission Upgrade Group, set the engine to the reference FLS/FTS settings included in the test specifications. Refer to the following test specification in the Technical Marketing Information (TMI) for the correct engine specifications.
Show/hide table
Table 20
Engine Specifications

Engine Serial Number Specification Number

S/N:08Z OK-7532

S/N:6NC OK-7533

Perform a dyno test. Adjust fuel pump/governor settings in order to get the above listed parameters to fall within the ceiling/floor range on the test spec.

Submit a Validation Form with this information.
Note: It is recommended that the engine is not removed from the dyno until the validation form has been received and approved by Caterpillar engineering. This will reduce delays to the customer as adjustments to the engine settings are sometimes required. Caterpillar engineering is not authorized to provide an emissions upgrade label until all of the parameters listed above are within specifications.

Installation of the Fuel Pump Protection Gp

Show/hide table




Illustration 37	g01193830
(1) 128-7794 Tamperproof Bolt (2) 128-7796 Tamperproof Bolt (3) 8S-8158 Wire Seal (4) 8C-4983 Lockwire (30 cm (11.8 inches))

After the engine has been set on the dyno, the Fuel Pump Protection Gp must be installed. Refer to Illustration 37 for the location of the Fuel Pump Protection Gp. Lockwire (4) must be installed through bolt (1) and bolt (2) and sealed with wire seal (3). These steps will prevent tampering with the settings of the fuel pump.

3306 Engine Emissions Upgrade Group Caterpillar Validation Form

In order to satisfy EPA requirements, a validation form MUST be submitted and approved upon completion of the emissions upgrade. The validation form for the emissions upgrade is found on the Caterpillar Emissions Solutions web site.

The following steps will take the requestor to the emissions upgrade validation form.

Go to https://dealer.cat.com. On the top of the page, select the "Product Support" tab.

In the left-hand column of the dealer page, select the "Parts Products" tab.

Within the "Parts Products" tab, select the "Emissions Solutions" option.

Under the"Retrofit Solutions" column on that page, select the "Machine Emissions Solutions" option.

Under the "Emissions Upgrade Group", select the "Submit a validation form" option.

Complete the validation form.

Select "Submit" in order to submit the validation form for approval.
Note: The following includes a portion of the information required to complete an on-line validation form. This reduced format includes all the information related to the engine and required results.

Show/hide table




Illustration 38	g02446916

EUG Registration

SIMS and DBS MUST be updated with the emissions upgrade information as specified in the material referenced below.

ReferenceRefer to the Procedure to Register a Serialized Component, REHS5097, "Instructions to Register the Retrofit".

Labels

After the validation form has been approved by Caterpillar engineering, and the emissions upgrade has been registered in SIMS and DBS correctly, new labels will be sent.