BOX AS-CONTROL 1363679 - 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 ETBoth 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
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 2T4889Reference Materials
3406BService Manual, SEBR0544, (S/N: 3ZJ1-16181)Service Manual, SENR5150, (S/N: 4CK1-845)
Disassembly & Assembly, SENR5148
Systems Operation Testing & Adjusting, SENR5146Parts 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)3406CService Manual, SEBR0560, (S/N: 3ZJ16182-UP)Service Manual, 5505, (S/N: 4CK846-UP)
Disassembly & Assembly, SENR5532
Systems Operation Testing & Adjusting, SENR5508Parts 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)MiscellaneousSpecial Instruction, SEHS7083, "Using The 5P-6524 Engine Timing Indicator And Flow Checking Tool Group"Tools And Shop Products Guide, NENG2500Removal 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 1 g00300638
Remove the tube assemblies (1) and (2) from the turbocharger's cartridge assembly (3) .
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.
Remove the turbocharger.
Install new O-Ring Seals on the supply tubes and the drain tubes.
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).
Install the oil supply tubes and the oil drain tubes.Removal And Installation Of New Fuel Nozzles
Illustration 2 g00300502
Use the following Steps in order to remove the