Guide For Conversion Of Remanufactured 3406 Engine (Part Number 0R2519, Arrangement Number 1W2434) To Specific Truck Engine Arrangements.{1000} Caterpillar

BEFORE DOING ANY WORK ON THE ENGINES:

* Find the part number and the arrangement number of the remanufactured (new) engine on the caution and information plate on the left side of the cylinder block, just above the governor.

* Find the arrangement number of the core (old) engine in the caution and information plate on the left side of the cylinder block, just above the governor.

* Make the conversion according to the instructions opposite the old engine arrangement number in the left column.

* Read the conversion instructions carefully. Since one remanufactured engine arrangement is a replacement for several old engine arrangements, some item exchanges will not be necessary. Example: If the flywheel housing number in the new engine arrangement is different than the flywheel housing number on your old engine, the conversion instructions will tell you to exchange the housings. Check the housings carefully. An exchange may not be necessary in your specific application.

BEFORE RETURN SHIPMENT OF THE OLD ENGINE TO THE FACTORY:

* Remove the drain plugs. Make sure all of the coolant is removed from the engine. Do not install the plugs back in the engine. Make a package for storage of the plugs. Use wire to fasten the package to the engine.

* All parts removed from the new engine must be installed on the old engine.

IMPORTANT: Before upgrading engine horsepower, first check the truck's drive lines and engine cooling system to insure that they are capable of supporting the increased horsepower.

The new engine as sent from the factory will not necessarily have the same BHP (brake horsepower) as your old engine. The correct low-idle and high idle rpm, and fuel rack settings are in the book, FUEL SETTING INFORMATION.

NOTE: Conversion Instructions for PCT/DIT to DITA exchanges and PCTA/DIT exchanges are not provided because of anticipated low demand. If such conversion information is desired please contact your Parts & Service Sales Division Manager.

Old engine arrangements need additional parts that are not on the new engine. Remove these parts from your old engine and install them on the new engine.

For maximum life of the Caterpillar remanufactured engine, be sure that the following components are checked during installation:

Air Compressor

As the air compressor uses engine oil, be sure it is clean inside. Foreign material from the former engine can decrease engine life.

Air Cleaner

Install new element in the air cleaner. Install hoses and clamps. Inspect all of the tubes for leaks.

Radiator

Make sure that the radiator is clean inside and outside. Install new hoses and clamps. Check for leaks.

For easy reference of related engine parts, fold out last page.

3406 Series

Remanufactured Engine Part Number 0R2519 - Arrangement Number 1W2434

A, B, C & D OIL LEVEL GAUGE LOCATIONS

1. FUMES DISPOSAL TUBE

2. HOSE

3. BREATHER

4. FILLER CAP

5. REAR VALVE COVER

6. FRONT VALVE COVER

7. DAMPER ASSEMBLY

8. FLYWHEEL HOUSING

9. COVER (OIL FILLER)

10. OIL FILTER

11. OIL FILTER SHIELD

12. OIL FILTER BASE

13. TURBOCHARGER

14. AIR TRANSFER PIPE

15. TURBO OIL LINES

16. TURBO OUTLET LINE ELBOW

17. TURBO INLET LINE CONNECTOR

18. MANIFOLD SHIELD

19. EXHAUST MANIFOLD

20. AIR TRANSFER PIPE ELBOW

21. FUEL FILTER

22. SUPPLY LINE

23. FUEL HOSE

24. ELBOW

25. DAMPER

26. ALTERNATOR SUPPORT

27. FRONT LIFTING EYE

28. GOVERNOR CONTROL LEVER

29. GOVERNOR DRIVE COVER

30. ALTERNATOR MOUNTING BAR

31. SUPPLY LINE NUT & UNION

32. SUPPLY LINE ELBOW

33. TURBO EXHAUST SUPPORT

34. OIL PAN DRAIN PLUG

35. AIR COMPRESSOR GROUP

36. WATER PUMP COVER

37. REAR LIFTING EYE

38. OIL COOLER

39. COVER (OIL FILLER)