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


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

Usage:

3406B 3ZJ

Information for equipment:


ELECTRICAL AND STARTING SYSTEM
ELECTRONICS GP-ENGINE

New Personality Modules Require New Service Program Modules 1990/03/01
New Dynamic Fuel Ratio Control (FRC) Settings Provide Improved Engine Response 1993/11/01
8T-8697 Electronic Control Analyzer Programmer (ECAP) Improved 1993/11/01
Engine Control Module (ECM) Hotline Is Now Available {1901} 2015/07/24
Cold Weather Operation Reminder {1000, 1250, 1350, 1355, 1450, 1453, 1456} 2007/07/01
A New Version of Caterpillar Electronic Technician (ET) is Now Available {0785, 1900, 7610} 2008/05/01
Setting Modifications for the Messenger Display that Is Used With On-Highway Truck Engines in South America and Venezuela {1901, 1920, 7490} 2008/12/01

New Service Information Tool for CAT Dealers is Now Available {1000} 2002/06/01
Engine Harness Assembly (Bypass) Flashes Messenger When Communication Through the Service Connector is Not Possible {0779, 0781} 2004/04/01
A New Electronic Control Module Wash Out Process {1901, 1920} A New Electronic Control Module Wash Out Process {1901, 1920}
New CAT Inspect Form Available for EMCP Troubleshooting and Inspection {0374, 4490, 7451, 7620} New CAT Inspect Form Available for EMCP Troubleshooting and Inspection {0374, 4490, 7451, 7620}

Cold Weather Recommendation Charts Cold Weather Recommendations for On-Highway Diesel Truck Engines

"A Series" Governor And Air/Fuel Ratio Control Response And Low Power Test{0374} "A Series" Governor And Air/Fuel Ratio Control Response And Low Power Test{0374}
Using the 8T8697 Electronic Control Analyzer Programmer (ECAP){0781, 0782} Using the 8T8697 Electronic Control Analyzer Programmer (ECAP){0781, 0782}
Procedures To Install a 3406C Electronic Engine, And Reprogram The Electronic Control Module (ECM), In a Truck Chassis Formerly Equipped With a 3406B PEEC Engine{1000, 1900} Procedures To Install a 3406C Electronic Engine, And Reprogram The Electronic Control Module (ECM), In a Truck Chassis Formerly Equipped With a 3406B PEEC Engine{1000, 1900}
Installation Of Governor Spring Guide{1264} Installation Of Governor Spring Guide{1264}
Instruction For Increasing The Horsepower Rating On The 3406B Truck Engines And The 3406C Truck Engines{1901} Instruction For Increasing The Horsepower Rating On The 3406B Truck Engines And The 3406C Truck Engines{1901}
Diagnostic Code Information for Caterpillar <SUP>&reg;</SUP> Electronic Control {1901, 1927, 1948, 3168, 4348, 4802, 4808, 4810, 5511, 5701, 7490, 7494, 7601, 7602, 7610, 7610, 7610} Diagnostic Code Information for Caterpillar ® Electronic Control {1901, 1927, 1948, 3168, 4348, 4802, 4808, 4810, 5511, 5701, 7490, 7494, 7601, 7602, 7610, 7610, 7610}
Procedure to Install Fluid Property Sensor on All Caterpillar<SUP>&reg;</SUP> and Non-Caterpillar Diesel Engines {1348, 1403, 1439} Procedure to Install Fluid Property Sensor on All Caterpillar® and Non-Caterpillar Diesel Engines {1348, 1403, 1439}

Ether Starting Aid 3406B DIESEL TRUCK ENGINE
Ether Starting Aid 3406C DIESEL TRUCK ENGINE
Ether Starting Aid 3406C DIESEL TRUCK ENGINE

APPEARANCE CHANGE ON REMAN SHORT BLOCKS APPEARANCE CHANGE ON REMAN SHORT BLOCKS

Fuel Ratio Control For Use With Earlier Engines 3406B DIESEL TRUCK ENGINE
Fuel Ratio Control For Use With Later Engines 3406B DIESEL TRUCK ENGINE

New Dynamic Fuel Ratio Control (FRC) Settings Provide Improved Engine Response{1278} 1993/11/09
Updated Flash Procedure for All Caterpillar Products {1920, 7610, 7620} 2014/09/16


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

Tools For The Fuel Flow Timing Method

  • 1P-0540 Fuel Flow Checking Tool Group

  • 6V-2023 Fuel Flow Checking Adapter Group

Table 1
Part Numbers For The Kits With The Corresponding Engine Serial Numbers    
Part Number     Engine Serial Number    
0R-9050     (S/N: 3ZJ1-16247)    
0R-9051     (S/N: 3ZJ16248-31974)    
0R-9051     (S/N: 3ZJ31975-38395) (1)    
0R-9052     (S/N: 3ZJ31975-38395) (1)    
0R-9052     (S/N: 3ZJ38396-UP)    
0R-9053     (S/N: 4CK1-UP)    
( 1 ) Performance Specification Number 2T4889

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.




    Illustration 1g00300638

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

  1. 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.

  1. Remove the turbocharger.

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

  1. 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).

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

Removal And Installation Of New Fuel Nozzles




    Illustration 2g00300502

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

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

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



    Illustration 3g00305866

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

  1. If the engine is equipped with a Jacobs Brake, use the following steps in order to remove the Jacobs Brake Assembly.



      Illustration 4g00305923

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

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



    Illustration 5g00306006

  1. 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) .



    Illustration 6g00305947

  1. 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.



    Illustration 7g00306006



    Illustration 8g00306065

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

  1. 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) .

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

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

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

  1. 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).



    Illustration 9g00306074

  1. 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).

  1. 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).



    Illustration 10g00305866

  1. 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).



    Illustration 11g00300502

  1. 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.

Table 2
Information On The Power Setting    
Part Number Of The Kit     0R-9050     0R-9051     0R-9052     0R-9053    
350 HP Performance Specification     0T-9548     2T-4519     2T-5598     2T-5039    
425 HP Performance Specification     0T-9539     0T-9539     2T-5197     2T-4748    
High Idle Speed     2220 rpm     2120 rpm     2220 rpm      (2)    
FL Static Fuel Setting (350 HP)    
3.05 mm (0.120 inch)    

3.30 mm (0.130 inch)    

4.80 mm (0.189 inch)    
   
FL Static Fuel Setting (425 HP)    
3.51 mm (0.138 inch)    

3.51 mm (0.138 inch)    

4.55 mm (0.179 inch)    
-54 (1)    
Adjusting The Power    
+ 0.46 mm (+ 0.018 inch)
Turn the power screw 1/2 turn counterclockwise.    

+ 0.20 mm (+ 0.008 inch)
Turn the power screw 1/4 turn counterclockwise.    

- 0.25 mm (- 0.010 inch)
Turn the power screw 1/3 turn clockwise.    
 (2)    
FL Static Fuel Setting (350 HP)    
3.91 mm (0.154 inch)    

3.99 mm (0.157 inch)    

5.06 mm (0.199 inch)    
   
FL Static Fuel Setting (425 HP)    
4.19 mm (0.165 inch)    

4.19 mm (0.165 inch)    

4.80 mm (0.189 inch)    
+22 (1)    
Adjusting The Torque    
+ 0.28 mm (+ 0.011 inch)
Turn the torque screw 1/3 turn counterclockwise.    

+ 0.20 mm (+ 0.008 inch)
Turn the torque screw 1/4 turn counterclockwise.    

- 0.25 mm (- 0.010 inch)
Turn the torque screw 1/3 turn clockwise.    
 (2)    
Static Timing Before Top Center (350 HP)     10 degrees     11 degrees     11 degrees      (2)    
Static Timing Before Top Center (425 HP)     10.4 degrees     10.4 degrees     11 degrees      (2)    
Advance (425 HP)     11.9 degrees     11.9 degrees     9.1 degrees      (2)    
Part Number (350 HP Torque Spring)     8N-7520     8N-7520     8N-7520      (2)    
Part Number (425 HP Torque Spring)     8N-7518     8N-7518     8N-7520      (2)    
Part Number (350 HP Spacer For The Torque Spring)     7N-1796 (3)     7N-1796 (3)     1P-6452      (2)    
Part Number (350 HP Spacer For The Torque Spring)     7W-8405     7W-8405     7W-8405      (2)    
Part Number (350 HP Spacer For The Torque Spring)     1P-6452     1P-6452     7N-1796      (2)    
Part Number (425 HP Spacer For The Torque Spring)     1P-6452     1P-6452     1P-6452      (2)    
Part Number (425 HP Spacer For The Torque Spring)     7W-8405     7W-8405     7W-8405      (2)    
Part Number (425 HP Spacer For The Torque Spring)             7N-1796      (2)    
Part Number (425 HP Advance Spring)     4P-8248     4P-8248     4P-8248      (2)    
Advance Start (425 HP)     1290 rpm     1290 rpm     1225 rpm      (2)    
Part Number (350 HP Governor Spring)     8L-9790     8L-9790     8L-9790      (2)    
Part Number (425 HP Governor Spring)     9M-9141     8L-9790     8L-9790      (2)    
( 1 ) This is the FLS/FTS number that is entered into the ECM.
( 2 ) Controlled by the Personality Module
( 3 ) Remove the spacer that is 0.061 inches thick.

Table 3
Information On The Power Setting    
Part Number Of The Kit     0R-9050     0R-9051     0R-9052     0R-9053    
350 HP Performance Specification                    
425 HP Performance Specification     0T-9539     0T-9539     2T-5197     2T-4748    
High Idle Speed     2220 rpm     2120 rpm     2220 rpm      (2)    
FL Static Fuel Setting (350 HP)                    
FL Static Fuel Setting (425 HP)    
3.51 mm (0.138 inch)    

3.51 mm (0.138 inch)    

4.55 mm (0.179 inch)    
-54 (1)    
Adjusting The Power    
+ 0.46 mm (+ 0.018 inch)
Turn the power screw 1/2 turn counterclockwise.    

+ 0.203 mm (+ 0.008 inch)
Turn the power screw 1/4 turn counterclockwise.    

- 0.25 mm (- 0.010 inch)
Turn the power screw 1/3 turn clockwise.    
 (2)    
FL Static Fuel Setting (350 HP)                    
FL Static Fuel Setting (425 HP)    
4.19 mm (0.165 inch)    

4.19 mm (0.165 inch)    

4.80 mm (0.189 inch)    
+22 (1)    
Adjusting The Torque    
+ 0.28 mm (+ 0.011 inch)
Turn the torque screw 1/3 turn counterclockwise.    

+ 0.203 mm (+ 0.008 inch)
Turn the torque screw 1/4 turn counterclockwise.    

- 0.25 mm (- 0.010 inch)
Turn the torque screw 1/3 turn clockwise.    
 (2)    
Static Timing Before Top Center (350 HP)                  (2)    
Static Timing Before Top Center (425 HP)     10.4 degrees     10.4 degrees     11 degrees      (2)    
Advance (425 HP)     11.9 degrees     11.9 degrees     9.1 degrees      (2)    
Part Number (350 HP Torque Spring)                  (2)    
Part Number (425 HP Torque Spring)     8N-7518     8N-7518     8N-7520      (2)    
Part Number (350 HP Spacer For The Torque Spring)                  (2)    
Part Number (350 HP Spacer For The Torque Spring)                  (2)    
Part Number (350 HP Spacer For The Torque Spring)                  (2)    
Part Number (425 HP Spacer For The Torque Spring)     1P-6452     1P-6452     1P-6452      (2)    
Part Number (425 HP Spacer For The Torque Spring)     7W-8405     7W-8405     7W-8405      (2)    
Part Number (425 HP Spacer For The Torque Spring)             7N-1796      (2)    
Part Number (425 HP Advance Spring)     4P-8248     4P-8248     4P-8248      (2)    
Advance Start (425 HP)     1290 rpm     1290 rpm     1225 rpm      (2)    
Part Number (350 HP Governor Spring)                  (2)    
Part Number (425 HP Governor Spring)     9M-9141     8L-9790     8L-9790      (2)    
( 1 ) This is the FLS/FTS number that is entered into the ECM.
( 2 ) Controlled by the Personality Module

Replacement Of The Automatic Timing Advance Spring

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



    Illustration 12g00301285

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



    Illustration 13g00301286

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

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

  1. 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.

  1. 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.

  1. 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




    Illustration 14g00306076

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

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



    Illustration 15g00306606

  1. 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.



    Illustration 16g00306663

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



    Illustration 17g00302826

  1. 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.

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



    Illustration 18g00306710

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



    Illustration 19g00306711

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

  1. Make the governor adjustments.

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




    Illustration 20g00306717

  1. 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.



    Illustration 21g00306722

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

  1. Make adjustments to the fuel ratio control.

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

  1. 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




    Illustration 22g00306763

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

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

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

  1. 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.

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

  1. 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 23g00302125



Illustration 24g00302126
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