Installation of a 3306 Engine Emissions Upgrade Group Retrofit for Select Industrial Engines{1000} Caterpillar

Engine:

3306 (S/N: 64Z1-UP)

3306B (S/N: 7JB1-UP)

Introduction

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

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

Note: Prior to upgrade, refer to the engine specifications table in the Testing and Adjusting section of this document to assure that the upgraded specification number will meet the requirements of the customer. In some applications the power may change slightly after the upgrade is complete.

This Special Instruction provides the information in order to install a 3306 Engine Emissions Upgrade Group (EUG) Retrofit for certain Industrial Engines. 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.

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

Because retrofits to a prime product will change the configuration of the product, updating the configuration in SIMSi to important. If the retrofit information is not provided, Caterpillar will not be able to provide important product updates.

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

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   ( 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.

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

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

Safety

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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.

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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.

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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.

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.

1. Set the engine control to the "STOP" mode.

2. Turn OFF the fuel supply to the engine.

3. Disconnect the negative terminal from the battery.

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

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

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

6. Connect the welder ground cable 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.

7. 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.

Note: A reference engine arrangement may be shown with set type "PTS - List" but should not be ordered. The upgrade engine arrangement is for reference.

The parts contained within the Modification Gp are for the emissions upgrade only. Additional parts needed for the overhaul need to be ordered as necessary. Examples are a cylinder head and gaskets. Consider parts availability prior to the machine arriving at the facility.

Note: Be sure to read the notes and order governor springs as required.

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.

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 4 for the correct media number for each part reusability.

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

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

2. 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.

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

2. Install clean cylinder packs without the rubber seals or the filler band. Install a new spacer plate gasket and the clean spacer plate.
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   Table 11

   Required Components
   Item	Part Number	Part Description	Qty For One Cylinder	Qty 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

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Illustration 1	g00544054

3. 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).

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

4. 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) .

5. 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) .

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.
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   Table 12

   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)

7. 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.

8. 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.

   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

1. When the projection for each cylinder liner is within the recommended specification, mark each cylinder liner for the proper location. Then remove the cylinder liners.

2. Lubricate the o-ring seals, the cylinder liner, and the upper filler band before installation.

   Note: Refer to the information included in the gasket kit for correct lubrication procedure.

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Illustration 3	g00478920

3. 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

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

2. 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.

3. 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.

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

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Illustration 4	g00483337

5. 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.

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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.

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

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Illustration 5	g00483701

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

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

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

9. 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).

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

Installation of the Connecting Rod Bearings

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.

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

2. 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.

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Illustration 6	g00487493

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

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

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

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Illustration 7	g00487412

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

5. 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) .

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Illustration 8	g00287852

6. 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).

7. 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).

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

9. 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

Note: Prior to installation of governor, verify that the correct governor spring is installed based on upgrade test specifications.

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.

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

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Illustration 9	g00460164

2. Remove the electric starting motor.

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

4. 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. The rotation removes all play from the timing gears.

      Note: If you go past the bolt hole, repeat Step 4.a.

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   Illustration 10	g00460248

   2. Remove plugs (1) and (2) .
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   Illustration 11	g00460252

   3. 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) .

   Note: The No. 1 piston is on the compression stroke when the valves of the No. 1 cylinder are closed. The rocker arms for the inlet valves and for the exhaust valves must have slight side-to-side movement.

   4. 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".

5. 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.

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Illustration 12	g00460258
Typical example

6. 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.

7. 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.

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Illustration 13	g00460259

8. 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.

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Illustration 14	g00460341

9. 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.

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Illustration 15	g00460342

10. 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.

11. 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.

12. Install plugs (1) and (2) .

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

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

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Illustration 16	g00460343

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

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

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

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Illustration 17	g00589938

18. 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.

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Illustration 18	g00460346

19. 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

Illustration 19	g00448903

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

   Note: The nozzles are shipped with seal (1).

2. Verify that carbon dam seal (1) is installed on each nozzle. Tooling (A) is required if seal (1) is not installed on any of the nozzles.

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

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

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Illustration 20	g00448904

5. 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) .

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Illustration 21	g00448905

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Illustration 22	g00448906

6. 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.

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

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

• Install aftercooler (if applicable)

• 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)

• Install oil pump and lines

• Install oil pan

Installation of the Turbocharger Gp

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

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Illustration 23	g00537495
Typical turbocharger

2. 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.

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Illustration 24	g00537468
Typical turbocharger

3. 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. Use a calibrated dyno and fuel flow meters that can provide accurate measurements.

Single HP Instructions

1. 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.
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   Table 18

   Engine Specifications
   Original Specification Number	Upgraded Specification Number
   2T-7769	2T-9891 (1)
   0T-7178
   0T-7046
   0T-9485	2T-8169 (1)
   0T-6728	2T-8625
   0T-7379
   0T-7242	2T-8369
   0K-1351
   2T-8156
   0T-6727
   2T-4549
   2T-5394
   0T-7244	2T-8475
   0T-8000
   0T-6520
   0T-7360
   0T-7361

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   ( 1 )

   These specifications require the governor spring to be changed.

2. 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.

3. Submit a Validation Form with this information.

   Note: Do not remove the engine from the dyno until the validation form has been received and approved by Caterpillar engineering. Leaving the engine in place will reduce delays to the customer as adjustments to the engine settings are sometimes required. Caterpillar engineering is not authorized to provide the emissions upgrade label until all of the parameters listed above are within specifications.

Installation of the Fuel Pump Protection Gp

Illustration 25	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 25 for the location of the Fuel Pump Protection Gp. Lockwire (4) must be installed through bolt (1) and bolt (2). Use wire seal (3) in order to 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.

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

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

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

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

5. Under the "Emissions Upgrade Group", select the "EUG Validation Form" option.

6. Complete the validation form.

7. 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.

Illustration 26	g02446916

EUG Registration

SIMSi 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 SIMSi correctly, new labels will be sent.

Information Label

Replace the existing information label with the information label that is sent after the validation form is approved.

Emissions Label

Illustration 27	g02455156
(1) Typical engine valve cover and emissions label

Attach the emissions label (1) to the engine valve cover.