3406C (PEEC III) Truck Engines Caterpillar

Piston Rings

The piston grooves and the rings are of the Keystone type. The 1U-6431 Piston Ring Groove Gauge is available to check the top two ring grooves in the piston.

Illustration 1	g00365332
Instructions for 1U-6431 Piston Ring Groove Gauge

Connecting Rods And Pistons

Use the 7M-3978 Ring Expander in order to remove the piston rings. Use the 7M-3978 Ring Expander in order to install the piston rings.

Use the 5P-3526 Piston Ring Compressor in order to install the pistons into the cylinder block.

Tighten the connecting rod nuts in the step sequence that follows:

1. Apply 4C-5593 Anti-Seize Compound to the threads of the bolts and the contact surfaces of the bolt head.

2. Tighten all bolts to the following torque.

   Torque for bolts ... 90 ± 8 N·m (66 ± 6 lb ft)

3. Put an alignment mark on each cap and bolt.

4. Tighten the bolts from the mark to the following value.

   Angle from the mark. ... 90 ± 5 degrees

Connecting Rod Bearings

The connecting rod bearings fit tightly in the bore in the rod. If the bearing joints or backs are fretted, check the bore size. This can be an indication of wear because of a loose fit.

Connecting rod bearings are available with 0.63 mm (0.025 inch) and 1.27 mm (0.050 inch) smaller inside diameter than the original size bearing. These bearings are for crankshafts that have been ground.

Main Bearings

Main bearings are available with a larger outside diameter than the original size bearings. These bearings are available for the cylinder blocks with the main bearing bore that is made larger than the bores' original size. The size that is available has a 0.63 mm (0.025 inch) outside diameter that is larger than the original size bearings.

Cylinder Block

If the main bearing caps are installed without bearings, the bore in the block for the main bearings can be checked. Tighten the nuts that hold the caps to the torque that is shown in the Specifications. Alignment error in the bores must not be more than 0.08 mm (0.003 inch). Refer to the Special Instruction, SMHS7606 for the use of the 1P-4000 Line Boring Tool Group for the alignment of the main bearing bores. The 1P-3537 Dial Bore Gauge Group can be used to check the size of the bores. The Special Instruction, GMGO0981 is with the group.

Illustration 2	g00294303
1P-3537 Dial Bore Gauge Group

Projection Of Cylinder Liners

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Illustration 3	g00557687
Holding The Top Plate To The Cylinder Block (Typical Example) (1) 3H-0465 Push Puller Plate (2) 1P-2396 Adapter Plate (3) 2F-0126 Seal (4) Top plate

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Illustration 4	g00557691
Reworking Of The Old Spacer Plate (5) Sections

Note: On engines with aluminum spacer plates, use care in obtaining liner projection measurements to prevent marring the surface. Use copper washers with the spacer plate bolts in order to prevent damage to the spacer plate. Do not use hardened steel washers. Follow the correct procedure when tightening the spacer plate bolts.

1. Be sure that the top plate (4) and the cylinder liner flange are clean. Install a new top plate gasket, but do not install liner seals when this check is made.

   To increase the accuracy of liner projection measurements, cut figure eight sections from an old spacer plate. Install the figure eight sections below the spacer plate bolts. This helps to prevent damage to engine parts. The figure eight sections are the center ribs from a scrapped 2W-8601 Spacer Plate. Refer to Illustration 4. The top radius and the bottom radius of the figure eight sections should coincide with the radii of the washers.

Note: To keep the movement of the bolts and the washers to a minimum, install two bolts with washers on each side of each cylinder liner.

2. Use 0S-1575 Bolt and two seals (3) on each bolt in order to hold the top plate (4) to the cylinder block. Install two bolts with seals (3) on each side of the cylinder liner. Tighten the bolts in the following manner:
   • Tighten the bolts to 14 N·m (10 lb ft).

   • Tighten the bolts to 35 N·m (25 lb ft).

   • Tighten the bolts to 70 (50 lb ft).

   • Tighten the bolts to 95 N·m (70 lb ft).

3. Use the following parts in order to hold the liner:puller plate (2), three plates (1), 8B-7548 Push-Puller Tool Group and two 2H-3749 Bolt

4. Tighten the bolts in the following manner:
   • Tighten the bolts to 7 N·m (5 lb ft).

   • Tighten the bolts to 20 N·m (15 lb ft).

   • Tighten the bolts to 35 (25 lb ft).

   • Tighten the bolts to 70 N·m (50 lb ft).

   The distance from the bottom edge of 8B-7548 Push-Puller Tool Group to the top plate must be equal on both sides of the cylinder liner.

5. Use a 8T-0455 Liner Projection Tool Group to measure the liner projection. Refer to Special Instruction, SMHS7727 for more information on the measurement procedures.

6. Set the dial indicator to zero.

Note: If the liner projection changes, turn the liner to a new position within the bore. If the liner projection is not correct, move the liner to a different bore.

Note: When the liner projection is correct, put a temporary mark on the liner and the top plate. This allows the liner to be installed in the correct position.

7. The liner projection must be 0.03 to 0.15 mm (.001 to .006 inch). Make the measurement to the top of the liner flange. Do not make the measurements to the inner ring. The maximum difference between the measurements that are made at four places around each liner is 0.05 mm (.002 inch). The average projection of liners next to each other must not be more than 0.05 mm (.002 inch). The maximum difference in the average projection of the cylinder liners under one cylinder head must not be more than 0.10 mm (.004 inch).

   The contact face of the cylinder block can be machined with use of the 8S-3140 Counterboring Tool Group in order to adjust the liner projection.

   2W-3815 Seat Insert and 5N-0093 Seat Insert are available for use after the cylinder block has been counterbored. Refer to Special Instruction, SMHS8222 for the correct installation procedure for the inserts.

When the liner projection is correct, put a temporary mark on the liner and the spacer plate. Set the liners aside.

Flywheel And Flywheel Housing

Face Runout (Axial Eccentricity) Of The Flywheel Housing

Illustration 5	g00294390
8T-5096 Dial Indicator Group

If you use any other method except the method that is given here, always remember that the bearing clearance must be removed in order to receive the correct measurements.

1. Fasten a dial indicator to the flywheel so the anvil of the dial indicator will contact the face of the flywheel housing.

2. Put a force on the crankshaft toward the rear before the dial indicator is read at each point.

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Illustration 6	g00294392
Checking Face Runout Of The Flywheel Housing (A) Bottom. (B) Right side. (C) Top. (D.) Left side.

3. Turn the flywheel while the dial indicator is set at 0.0 mm (0.00 inch) at location (A). Read the dial indicator at locations (B), (C) and (D) .

4. The difference between the lower measurements and the higher measurements that are performed at all four points must not be more than 0.38 mm (0.015 inch), which is the maximum permissible face runout (axial eccentricity) of the flywheel housing.

Bore Runout (Radial Eccentricity) Of The Flywheel Housing

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Illustration 7	g00294390
8T-5096 Dial Indicator Group

1. Fasten a dial indicator to the flywheel so the anvil of the dial indicator will contact the bore of the flywheel housing.

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Illustration 8	g00294394

2. While the dial indicator is in the position at location (C) adjust the dial indicator to 0.0 mm (0.00 inch). Push the crankshaft upward against the top of the bearing. Refer to the illustration 8. Write the measurement for bearing clearance on line 1 in column (C) .

   Note: Write the measurements for the dial indicator with the correct notations. This notation is necessary for making the calculations in the chart correctly.

3. Divide the measurement from Step 2 by two. Write this number on line 1 in columns (B) and (D) .

4. Put the dial indicator at position (A). Adjust the dial indicator to 0.0 mm (0.00 inch).

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Illustration 9	g00294392
Checking Bore Runout Of The Flywheel Housing

5. Turn the flywheel counterclockwise in order to put the dial indicator at position (B). Write the measurements in the chart.

6. Turn the flywheel counterclockwise in order to put the dial indicator at position (C). Write the measurement in the chart.

7. Turn the flywheel counterclockwise in order to put the dial indicator at position (D). Write the measurement in the chart.

8. Add the lines together in each column.

9. Subtract the smaller number from the larger number in column B and column D. Place this number on line III. The result is the horizontal eccentricity (out of round). Line III in column C is the vertical eccentricity.

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Illustration 10	g00294396
Graph For Total Eccentricity (1) Total vertical eccentricity. (2) Total horizontal eccentricity. (3) Acceptable value. (4) Unacceptable value.

10. On the graph for total eccentricity, find the point of intersection of the lines for vertical eccentricity and horizontal eccentricity.

11. If the point of intersection is in the "Acceptable" range, the bore is in alignment. If the point of intersection is in the "Unacceptable"range, the flywheel housing must be changed.

Face Runout (Axial Eccentricity) Of The Flywheel

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Illustration 11	g00294398
Checking Face Runout Of The Flywheel

1. Refer to illustration 11 and install the dial indicator. Always put a force on the crankshaft in the same direction before the dial indicator is read. This will remove any crankshaft end clearance.

2. Set the dial indicator to read 0.0 mm (0.00 inch).

3. Turn the flywheel at intervals of 90 degrees and read the dial indicator.

4. Take the measurements at all four points. Find the difference between the lower measurements and the higher measurements. This value must not exceed the maximum permissible face runout (axial eccentricity) of the flywheel.

Bore Runout (Radial Eccentricity) Of The Flywheel

Illustration 12	g00294400
Checking Bore Runout Of The Flywheel (1) 7H-1945 Holding Rod. (2) 7H-1645 Holding Rod. (3) 7H-1942 Indicator. (4) 7H-1940 Universal Attachment .

1. Install the 7H-1942 Dial Indicator (3). Make an adjustment of the 7H-1940 Universal Attachment (4) so that the dial indicator makes contact on the flywheel.

2. Set the dial indicator to read 0.0 mm (0.00 inch).

3. Turn the flywheel at intervals of 90 degrees and read the dial indicator.

4. Take the measurements at all four points. Find the difference between the lower measurements and the higher measurements. This value must not exceed the maximum permissible bore runout (radial eccentricity) of the flywheel.

   Flywheel without BrakeSaver ... 0.15 mm (0.006 inch)

   Flywheel with BrakeSaver ... 0.25 mm (0.010 inch)

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Illustration 13	g00294401
Flywheel Clutch Pilot Bearing Bore

5. Take the measurements at all four points. Find the difference between the lower measurements and the higher measurements. This value must not exceed the maximum permissible pilot bore runout of the flywheel.

   Flywheel without BrakeSaver ... 0.13 mm (0.005 inch)

   Flywheel with BrakeSaver ... 0.25 mm (0.010 inch)

Vibration Damper

Damage to the damper or failure of the damper will increase vibrations. This will result in damage to the crankshaft.

The force from combustion in the cylinders will cause the crankshaft to twist. This is called torsional vibration. If the vibration is too great, the crankshaft will be damaged. The vibration damper limits the torsional vibrations to an acceptable amount. This prevents damage to the crankshaft.

Replace the damper if the damper is bent or damaged. Replace the damper if the bolt holes are oversize. Replacement of the damper is also needed at the time of a crankshaft failure due to torsional forces.

Illustration 14	g00557731
Vibration Damper (1) Alignment marks

The vibration damper has marks (1) on the hub and the ring. These marks give an indication of the condition of the vibration damper. If the marks are not in alignment, the rubber part of the vibration damper has separated from the ring and/or the hub. Install a new vibration damper.

A used vibration damper can have a visual wobble on the outer ring. The following procedure will check the vibration damper:

1. Install a dial indicator, a contact point and other parts in order to hold the dial indicator stationary. The contact point must be perpendicular to the face of the outer ring of the damper. The contact point must make contact approximately at the center of the outer ring.

2. Push on the front end of the crankshaft so the end play (free movement on the centerline) is removed.

3. Adjust the dial indicator to zero.

4. Turn the crankshaft through 360 degrees and watch the dial indicator. A total indicator reading of 0.00 to 2.03 mm (.000 to .080 inch) is acceptable.