3406E Truck Engines Caterpillar

Connecting Rods And Pistons

Use 149-7179 Ring Expander to install the piston rings. Use the 149-7179 Ring Expander to remove the piston rings.

Use the 149-7180 Ring Compressor to install pistons.

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 1	g00294303
1P-3537 Dial Bore Gauge Group

Projection Of Cylinder Liners

Note: Measuring the cylinder liner projection does not require an "H" bar to hold the cylinder liner down.

The 8T-0455 Liner Projection Tool Group can be used to check the liner projection.

Illustration 2	g00294304
Liner projection components (1) Bolt (2) Washer (3) Washer (4) Spacer plate (5) Block (6) Cylinder liner

Note: A fabric material is used to make the 7K-1977 Washers . These washers are a replaceable item. You may wish to order more washers than the amount that is indicated.

Illustration 3	g00294387

Note: Refer to Reuse and Salvage Guidelines, SEBF9390, "Visual Inspection of Liner Seats for 3400, C15, C16, and C18 Series Engines" for the correct cylinder top deck and spacer plate inspection procedures prior to measuring the liner projection.

1. Install a new spacer plate gasket and a clean spacer plate.

2. Install the cylinder liners in the cylinder block without seals or bands.

3. Install the bolts and washers into the holes with an "X".

4. Install the remaining bolts around the liner.

   Torque for bolts ... 95 N·m (70 lb ft)

5. Use the 8T-0455 Liner Projection Tool Group to measure the liner projection at "A", "B", "C" and "D".

6. Record measurements for each cylinder.

7. Add the four readings for each cylinder. Divide the total by four in order to find the average.

Do not exceed the maximum liner projection of 0.152 mm (0.006 inch). The excessive liner projection will contribute to cracking of the liner flange.

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

Note: Apply liquid soap and/or clean engine oil immediately before assembly. Avoid applying the liquid soap and/or clean engine oil to the seals too early. The seals may swell and the seals may become pinched beneath the cylinder liner during the liner installation.

Final assembly of the cylinder liners into engine block require the following parts to be lubricated: O-ring seals, cylinder block and upper filler band. If the lower O-rings 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. 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.

Flywheel And Flywheel Housing

Face Runout (Axial Eccentricity) Of The Flywheel Housing

Illustration 4	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 5	g00294392
Checking face runout of the flywheel housing (A) Bottom (B) Right side (C) Top (D) Left side

3. Rotate 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 6	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 7	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 7. 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. Rotate the flywheel in order to place the dial indicator in position (A) . Adjust the dial indicator to 0.0 mm (0.00 inch).

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Illustration 8	g00294392
Checking bore runout of the flywheel housing

5. Rotate the flywheel counterclockwise in order to place the dial indicator in position (B) . Write the measurements in the chart.

6. Rotate the flywheel counterclockwise in order to place the dial indicator in position (C) . Write the measurement in the chart.

7. Rotate the flywheel counterclockwise in order to place the dial indicator in 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 9	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. The bore is in alignment when the point of intersection is located in the Acceptable range. The flywheel housing must be changed when the point of intersection is located in the Unacceptable range.

Face Runout (Axial Eccentricity) Of The Flywheel

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Illustration 10	g00294398
Checking Face Runout Of The Flywheel

1. Refer to illustration 10 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. Rotate 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 11	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. Rotate 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 12	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.

Viscous Damper (If Equipped)

Illustration 13	g00294402
Cross section of vibration damper (1) Crankshaft (2) Weight (3) Case

Illustration 14	g00294403
Cross section of vibration damper (1) Crankshaft (2) Weight (3) Case

The vibration damper is installed on the front of the crankshaft (1) . The damper has a weight (2) in a case (3) . The space between the weight and the case is filled with thick fluid. The weight moves within the case. This limits the torsional vibration.

Replace the damper if the damper is leaking, 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.