Instruction For Increasing The Horsepower Rating On The 3406B Truck Engines And The 3406C Truck Engines{1901} Caterpillar

Truck Engines:

3406B (S/N: 3ZJ1-16181; 4CK1-845)

3406C (S/N: 3ZJ16182-UP; 4CK846-24722)

Introduction

This Special Instruction gives the procedures for increasing the horsepower rating of the 3406B and the 3406C engines. The customer that is servicing the engine is responsible for ensuring that the chassis is capable of operating with the additional horsepower. Caterpillar Inc. takes on no responsibility for drive trains, components, exhaust systems, water systems, and/or air systems that are not capable of operating with a higher horsepower.

The entire Special Instruction should be read and understood before beginning work on the engine.

Required Tools And Parts

Mechanical Engines

• 8T-5246 Engine Timing Indicator Group

• 8T-5300 Engine Timing Indicator Group

• 8T-5301 Diesel Engine Timing Adapter Group

• 6V-6070 Governor Adjusting Tool Group

• 8T-0500 Continuity Tester

Electronic Engines

• JEBD3003 CAT ET

Both Engines

• 5P-5195 Fuel Line Wrench

• 5P-0144 Fuel Line Socket

• 1B-4206 Nut

• 9U-5840 Spanner Wrench

• 6V-6983 Adapter

• 8T-3199 Puller Screw

• 8T-3198 Puller Tube

Tools For The Fuel Flow Timing Method

• 1P-0540 Fuel Flow Checking Tool Group

• 6V-2023 Fuel Flow Checking Adapter Group

Reference Materials

3406B

Service Manual, SEBR0544, (S/N: 3ZJ1-16181)

Service Manual, SENR5150, (S/N: 4CK1-845)

• Disassembly & Assembly, SENR5148

• Systems Operation Testing & Adjusting, SENR5146

Parts Manual, SEBP1991, (S/N: 4CK1-845)

Parts Manual, SEBP1992, (S/N: 4CK1-845)

Parts Manual, SEBP1958, (S/N: 3ZJ1-16181)

Parts Manual, SEBP1959, (S/N: 3ZJ1-16181)

3406C

Service Manual, SEBR0560, (S/N: 3ZJ16182-UP)

Service Manual, 5505, (S/N: 4CK846-UP)

• Disassembly & Assembly, SENR5532

• Systems Operation Testing & Adjusting, SENR5508

Parts Manual, SEBP2011, (S/N: 4CK846-UP)

Parts Manual, SEBP2013, (S/N: 3ZJ16182-60112)

Parts Manual, SEBP2014, (S/N: 3ZJ16182-60112)

Parts Manual, SEBP2380, (S/N: 3ZJ60113-UP)

Miscellaneous

Special Instruction, SEHS7083, "Using The 5P-6524 Engine Timing Indicator And Flow Checking Tool Group"

Tools And Shop Products Guide, NENG2500

Removal And Installation Of The Turbocharger

Note: If the engine has a turbocharger that is mounted low, refer to the engine parts' manual for the correct oil drain, supply tubes, and gaskets. Care must be taken in order to ensure that the fluids are contained during inspection, maintenance, testing, adjusting and repair of the engine. Suitable containers should be handy before disassembling components that may contain fluids. Dispose of all fluids according to local regulations and laws. Refer to the Tools And Shop Products Guide, NENG2500 for tools and supplies that are suitable for collecting fluids.

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Illustration 1	g00300638

1. Remove the tube assemblies (1) and (2) from the turbocharger's cartridge assembly (3) .

2. Attach a strap to the turbocharger in order to hold the turbocharger in position. Remove the four bolts that hold the turbocharger onto the exhaust manifold.

3. Remove the turbocharger.

4. Install new O-Ring Seals on the supply tubes and the drain tubes.

5. Install the new turbocharger from the kit with the four new 2N-2765 Bolts . Apply 5P-3931 Anti-Seize Compound to the bolts. Tighten the bolts to a torque of 55 ± 5 N·m (40 ± 4 lb ft).

6. Install the oil supply tubes and the oil drain tubes.

Removal And Installation Of New Fuel Nozzles

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Illustration 2	g00300502

1. Use the following Steps in order to remove the valve covers (2) .

   1. If necessary, remove the breather tube (3) .

   2. Remove the six bolts (1) and the covers (2). Replace the seal under the valve cover if the seal is worn.

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Illustration 3	g00305866

2. Remove the bolts (4) that hold the valve cover bases (5) to the cylinder head. Remove the valve cover bases (5) .

3. If the engine is equipped with a Jacobs Brake, use the following steps in order to remove the Jacobs Brake Assembly.
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   Illustration 4	g00305923

   1. Remove the nuts (6), washers, and bolts (7) that hold the Jacobs Brake Housing Assembly (8) in place.

   2. Remove the Jacobs Brake Housing Assembly (8) .

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Illustration 5	g00306006

4. Use a 5P-0144 Fuel Line Socket in order to loosen the inner fuel injection line (9) from the fuel injection nozzle (11) and from the retainer (10) .

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Illustration 6	g00305947

5. Use a 5P-5195 Fuel Line Wrench (12) in order to loosen the nut at the end of the fuel injection line adapter. Remove the inner fuel injection lines (9). Install caps and plugs on all fuel injection line openings in order to keep dirt out of the fuel system.

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Illustration 7	g00306006

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Illustration 8	g00306065

6. Use the 9U-5840 Spanner Wrench in order to remove the retainer (10) from the adapter.

7. Use the following Steps in order to remove the injection nozzles:

   1. Install the 6V-6983 Adapter and the 8T-3199 Puller Screw into the nozzle assembly (11) .

   2. Install the 8T-3198 Puller Tube over the 8T-3199 Puller Screw .

   3. Use the 1B-4206 Nut on the 8T-3199 Puller Screw in order to pull the fuel injection nozzle from the adapter.

8. Put the new fuel injection nozzle from the kit into the correct position inside the adapter. Install the retainer (10) .

9. Use the 9U-5840 Spanner Wrench in order to tighten the retainer (10) to a torque of 40 ± 7 N·m (30 ± 5 lb ft).

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Illustration 9	g00306074

10. Install the inner fuel injection lines (9). Use the 5P-5195 Fuel Line Wrench in order to tighten the nuts (13) of the fuel injection line adapter to a torque of 40 ± 7 N·m (30 ± 5 lb ft).

11. Use the 5P-0144 Fuel Line Socket in order to tighten the nut (14) of the fuel injection line to a torque of 40 ± 7 N·m (30 ± 5 lb ft).

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Illustration 10	g00305866

12. Install the valve cover bases (5) on the cylinder head assembly. Install the bolts (4) that hold the valve cover bases in place. Tighten the bolts (4) to a torque of 14 ± 3 N·m (10 ± 2 lb ft).

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Illustration 11	g00300502

13. Install the valve cover. Tighten the six bolts to a torque of 18 ± 3 N·m (13 ± 2 lb ft). If necessary, install the breather tube.

Power Setting

In order to set the power level, the first step is comparing the current rating of the engine to the desired rating. The current rating is displayed in the Performance Specification on the information plate which is located on the upper, right, rear corner of the cylinder block. The details of the Performance Specification can be obtained from the Technical Marketing Information's screen. There will be several screens of data.

Two Tables have been provided in order to assist you in comparing performance specifications. The first Table has been completed as an example. The second Table has blank spaces in order to be used as a worksheet. Once the information is found in the Technical Marketing Information, fill in the column on the worksheet that represents the engine which is being worked on. The rows on the Tables are in the same order as the information on the screen of the Technical Marketing Information.

Note: If the engine which is being worked on is an electronic engine, advance to the ""Electronic Engine" " section of this Special Instruction.

Replacement Of The Automatic Timing Advance Spring

1. Put the number one piston at the top center position.

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Illustration 12	g00301285

2. Remove the cover (1) and the eight nuts (2) .

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Illustration 13	g00301286

3. Remove the eight nuts (4) from the retainer (3) .

4. Replace the original Automatic Timing Advance Spring with the Automatic Timing Advance Spring from the kit.

5. Position the retainer (3) and install the nuts (4) .

   Note: When you are installing the retainer (3), ensure that the new spring from the kit properly engages the retainer's adjustment screw.

6. Measure the distance from the top of the large adjustment screw (5) to the top base of the retainer (3). The distance should be corrected to a length of 38.1 mm (1.50 inch). The distance to the setscrew from the top of the large adjustment screw (5) should be corrected to 8.0 mm (0.32 inch) with an 11 degree timing advance. The distance to the setscrew from the top of the large adjustment screw (5) should be corrected to 9.0 mm (0.37 inch) with a 10 degree timing advance.

7. Install the cover (1) and the eight nuts (2) .

Determine if the governor spring and the torque spring require replacement. If the springs need to be replaced, continue to the ""Replacement Of The Governor Spring And Torque Spring" " section. Otherwise advance to the rack setting procedure.

Replacement Of The Governor Spring And Torque Spring

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Illustration 14	g00306076

1. Remove the bolts, the fuel ratio control valve (1), and the shutoff solenoid (3) from the rear governor housing (2) .

2. Remove the bolts, the rear governor housing (2), and the gasket from the front governor housing.

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Illustration 15	g00306606

3. Remove the governor spring (4) from the guide (5) in the rear governor housing (2). Replace the existing governor spring with the governor spring that is provided in the kit.

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Illustration 16	g00306663

4. Remove the bolts (6) in order to remove the torque control group (7) from the front governor housing.

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Illustration 17	g00302826

5. Remove the two bolts (6) in order to remove the torque spring (8). Replace the current torque spring with the torque spring that is provided in the kit.

6. Install the two bolts (6) that hold the torque spring (8) in place.

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Illustration 18	g00306710

7. Install the torque control group (7) on the front governor housing (9) .

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Illustration 19	g00306711

8. Install the gasket (10) and the rear governor housing (2) on the front governor housing (9) .

9. Make the governor adjustments.

   Reference: Consult the Systems Operation Testing & Adjusting, SEBR0544, "Fuel Ratio Control And Governor Check" for more information.

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Illustration 20	g00306717

10. Put the fuel ratio control (1) in position. Ensure that the flange on the end of the fuel ratio control (1) is behind the slot in the lever assembly.

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Illustration 21	g00306722

11. Hold the fuel lever in the off position. Install the shutoff solenoid (3) .

12. Make adjustments to the fuel ratio control.

    Reference: Consult the Systems Operation Testing & Adjusting, SEBR0544, "Fuel Ratio Control Adjustment" for more information.

13. If the engine speed-timing requires a change, the engine must be timed by checking the flow. Refer to the Special Instruction, SEHS7083, "Using The 5P-6524 Engine Timing Indicator And Flow Checking Tool Group".

Electronic Engine

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Illustration 22	g00306763

1. Remove the four bolts (2) from the personality module (1). Remove the personality module (1) and seal.

2. Replace the personality module with the new personality module from the kit.

3. Connect the ECAP or the CAT ET to the ECM.

4. Obtain the factory passwords.

   Note: In order to obtain the factory passwords, continue through the procedure on the ECAP or the CAT ET. At a certain point, the ECAP or the CAT ET will request the factory passwords. This screen will also display most of the information that is required in order to obtain the passwords.

5. Reset the Full Load Setting, the Full Torque Setting, and the Top Engine Limit to the values that were recorded in Table 3.

6. Select 425 at the 2000 RPM Low Torque rating.

Information Plate And EPA Decal

Whenever an engine's horsepower rating has been modified, a new information plate and a new EPA film must be attached to the engine for future servicing identification. An example of both of the information plates has been included in this Special Instruction in order to assist you in creating the plate with the required information. Both the information plate and the EPA film have been included in the kit.

Illustration 23	g00302125

Illustration 24	g00302126