3406E AND 3456 ENGINE

TEST AND ADJUST SECTION

FUEL SYSTEM PRIME

1,prime screw

2. pr regulator

If engine has run out of fuel ,

Open fuel pressure regulating valve (2) by two and a half turns. The regulating
valve is located in the integral fuel filter base.

Note: Do not remove the regulating valve completely. Open the valve enough to
allow the air that is trapped in the cylinder head to be purged from the fuel system.

Then crank engine for 30 seconds

Liner projection
Water pump pressure min 15 psi.

Fuel system pressure test

Low fuel pressure

Plugged fuel filters

Debris in the check valves for the fuel priming pump
Debris in the pressure regulating valve
Partially open check valve
Sticking or worn fuel pressure regulating valve in the fuel transfer pump
Severe wear on return fuel pressure regulating valve in the fuel filter base
Worn gears in the fuel transfer pump
Pinched fuel lines or undersized fuel lines
Old fuel lines that have a reduced interior diameter that was caused by swelling
Fuel lines with deteriorating interior surfaces
Pinched fuel line fittings or undersized fuel line fittings
Debris in the fuel tank, fuel lines, or fuel system components that create
restrictions

High fuel pressure

Plugged orifices in the fuel pressure regulating valve, Excessive fuel pressure can
cause fuel filter gaskets to rupture.

Stuck fuel pressure regulating valve in the fuel transfer pump

Pinched fuel return line
 1. Fuel pressure ports.

The typical fuel pressure of the engine at operating temperature can vary. At low
idle, the fuel pressure can be 538 kPa (78 psi). At high rpm, the fuel pressure can
be 641 kPa (93 psi).

Oil pr test port

The inlet fuel temperature to the fuel transfer pump must not exceed 79 °C (175
°F)
When the engine is at operating temperature and the engine is using SAE 10W30
or SAE 15W40 oil, the maximum oil
temperature should be 110 °C (230 °F). This is the temperature of the oil after
passing through the oil cooler.

A small amount of coolant leakage across the surface of the water pump seals is
normal

Com test
This Caterpillar engine uses Keystone piston rings. Keystone piston rings are designed to expand
during the compression
stroke of the engine. At engine cranking speed, the Keystone piston rings do not fully expand.
This results in unstable
readings for cylinder compression. As a result Caterpillar does not recommend performing
compression tests on engines
that use Keystone piston ring

Oil flow

Vacuum test port at air filter-air filter restriction check

 a. Connect the vacuum port of the differential pressure gauge to test location (2). Test
location (2) may be located anywhere along the air inlet piping after air cleaner (1) but
before turbocharger.. Leave the pressure port of the differential pressure gauge open to
the atmosphere.

b. . Start the engine. Run the engine in the no-load condition at high idle.
Record the value.. Multiply the value from Step 4.d by 1.8.

Maximum restriction ... 6.2 kPa (25 in of H2O)

Ex restriction

Connect the pressure port of the differential pressure gauge to test location (2). Test location (2)
can be located anywhere along the exhaust piping after turbocharger (3) but before muffler (1) .

Leave the vacuum port of the differential pressure gauge open to the atmosphere.

Start the engine. Run the engine in the no-load condition at high idle. Record the value
Multiply the value from Step 4 by 1.8.

Maximum back pressure ... 10.0 kPa (40 in of H2O)

The turbocharger compressor wheel pulls inlet air through the air cleaner and into the air inlet.
The air is compressed and heated to about 150 °C (300 °F) before the air is forced to the
aftercooler. The air flows through the aftercooler core and the temperature of the compressed air
lowers to about 43 °C (110 °F).

Inj adjustment

9U-7227 Injector Height Gauge 1

To make an adjustment to the unit injectors on cylinders 3, 5, and 6 use the following procedure:

Put the No. 1 piston at the top center position on the compression stroke

Injector height gauge (4) is used in order to obtain a dimension of 78.0 ± 0.2 mm (3.07 ± 0.01
inch)

Hold the adjusting screw in this position and tighten locknut (3) to a torque of 100 ± 10 N·m (74
± 7 lb ft)

To make an adjustment to the unit injectors on cylinders 1, 2, and 4,

remove the timing bolt. Turn the flywheel by 360 degrees in the direction of engine rotation.

Valve adjustment

Inlet 0.38 ± 0.08 mm (0.015 ± 0.003 inch)

Exhaust 0.76 ± .08 mm (0.030 ± 0.003 inch)

With No. 1 piston at the top center position of the compression stroke, an adjustment can be
made to the valves. Make an adjustment to the valve lash on the inlet valves for cylinders 1, 2,
and 4. Make an adjustment to the valve lash on the exhaust valves for cylinders 1, 3, and 5
Tighten to a torque of 30 ± 7 N·m (22 ± 5 lb ft). Recheck each adjustment.

Remove the timing bolt, and turn the flywheel by 360 degrees in the direction of engine rotation.
This will position the No. 6 piston at the top center on the compression stroke. Install the timing
bolt in the flywheel.

Make an adjustment to the valve lash on the inlet valves 3, 5, and 6

Make an adjustment to the valve lash on the exhaust valves 2, 4, and 6.

ASSY DIS ASSY SECTION

Liner with filler band at top side.

Inj o rings

Tighten the bolt for the electronic unit injector to 50 ± 10 N·m (37 ± 7 lb ft)

Conrod-piston

Tighten the bolts to a torque of 90 ± 8 N·m (65 ± 6 lb ft). Tighten each bolt for an additional 90
± 5 degrees (1/4 turn).

Position the piston on connecting rod. Ensure that bearing tab slot and the identification marks
are on the same side as the "V" mark on the top of the piston

Fly hsg

In a numerical sequence, tighten bolt 1 through bolt 9.- Torque for bolts ... 100 ± 20 N·m (74 ±
15 lb ft)

In a numerical sequence, tighten bolt 10 through bolt 24.

Torque for bolts ... 40 ± 10 N·m (30 ± 7 lb ft)

In a numerical sequence, again tighten bolt 1 through bolt 9.

Torque for bolts ... 135 ± 20 N·m (100 ± 15 lb ft)
In a numerical sequence, again tighten bolt 10 through bolt 24.
Torque for bolts ... 55 ± 10 N·m (41 ± 7 lb ft)

Main bearings

Thrust washer at 4th cap. Install the thrust plates for the No. 4 main bearing with the words "Block
Side" toward the cylinder block.

torque of 260 ± 14 N·m (190 ± 10 lb ft). additional 120 ± 5 degrees (2 flats)

Crankshaft end play (new thrust plates) ... 0.15 to 0.55 mm (0.006 to 0.022 inch)
Maximum permissible crankshaft end play (used thrust plates) ... 0.89 mm (0.035 inch)

Cam gear

Tighten the bolts in a numeric sequence 1, 4, 2, 5, 3, 6, 1, 4 to a torque of 240 ± 40 N·m (175 ±

30 lb ft)
Check the backlash between the camshaft gear and the adjustable idler gear. The backlash should
be 0.216 ± 0.114 mm (0.0085 ± 0.0045 inch).

inj sleeve

Head
The bolts that are Marked "X" are 216 mm (8.5 inch) long. The remainder of the bolts are 194
mm (7.6. inc h) in length

In a numerical sequence, tighten bolts 1 through 26 to a torque of 270 ± 15 N·m (200 ± 11 lb ft)

In a numerical sequence, again tighten bolts 1 through 26 to a torque of 450 ± 15 N·m (330 ± 11
lb ft)

valve cover

Tighten bolts (1) to a torque of 18 ± 3 N·m (13 ± 2 lb ft)

Flywheel

Tighten bolts (1) to a torque of 270 ± 40 N·m (200 ± 30 lb ft).

Front hsg
Valve mechanism cover
Tighten bolts (4) to a torque of 18 ± 3 N·m (13 ± 2 lb ft)

rocker arm and shaft

Install rocker shaft (3) with the flat side facing upward. install bolts and tighten to a torque of 50
± 5 N·m (37 ± 4 lb ft). Turn bolts for an additional 45 ± 5
degrees.

Note: Do not reuse the O-ring seals on the rocker arm adjustment screws if the buttons have
been removed from the adjustment screws.

oil pump
Gear group front
Install a new gasket (25) on the cylinder block.
Install plate (23) and bolts (24) –front plate

Tighten bolts (24) to 55 ± 10 N·m (41 ± 7 lb ft)

Install shaft assembly (20). Apply thread lock compound to the studs and the bolt
for the shaft assembly. Tighten the nuts and the bolt for the shaft assembly to a
torque of 55 ± 10 N·m (41 ± 7 lb ft).

Note: The backlash for the camshaft gear and the adjustable idler gear will need
to be readjusted if shaft
assembly (19) has been removed, loosened, or moved in any way. The camshaft
gear must be installed and the
adjustable idler gear must be removed in order to perform the backlash
adjustment procedure.
Install shaft assembly (19). Do not tighten the nuts and the bolt for shaft assembly
(19) at this time. The nuts and the bolt for shaft assembly (19) will need to be
tightened when the backlash is adjusted.

Apply thead loack compound to bolts (22). Install shaft (21). Tighten bolts (22) to
a torque of 55 ± 10 N·m (41 ± 7 lb ft) in

Put cluster gear (15) on shaft (21). Ensure that timing Marks (V) are aligned on cluster gear and
the crankshaft gear. Apply thead lock compound to bolts (17). Install plate (17) and bolts (16).
Tighten bolts (16) to a torque of 30 ± 7 N·m (22 ± 5 lb ft)
Put idler gear (11) on shaft (20). Apply Tooling (B) to bolts (12). Install plate (13) with the oil
groove toward the gear face. Install bolts (12) and tighten to a torque of 30 ± 7 N·m (22 ± 5 lb ft)

Note: Skip Step 12 if shaft assembly (19) has been removed, loosened, or moved in any way.
The backlash for
the camshaft gear and the adjustable idler gear will need to be readjusted. The camshaft gear
must be installed and
the adjustable idler gear must be removed in order to perform the backlash adjustment procedure.
Refer to
Testing and Adjusting, "Fuel System".
step 12

12. Put adjustable idler gear (7) on shaft assembly (19). Apply Tooling (B) to bolts (8). Install
plate (9) and bolts (8).
Tighten bolts (8) to a torque of 30 ± 7 N·m (22 ± 5 lb ft)

Check all gear bush for worn before install

Ex manifold

Damper-pulley

Fuel filter hsg