Testing and Adjusting: 3406 & 3406B Generator Set Engines

Service Information System Page 1 of 20
Testing and Adjusting

3406 & 3406B GENERATOR SET ENGINES
Media Number -SENR2537-02 Publication Date -01/03/1988 Date Updated -11/10/2001
Testing And Adjusting

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Rack Stop
(1) Stop. (2) Spacer.
2. Disconnect the governor control linkage to let the drive group lever move freely through its full
travel.
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Measure Rack Travel

(3) Spacer. (4) 9S7350 Bracket Group. (5) 9S215 Dial Indicator.
3. Install 9S7350 Bracket Group (4) and 9S215 Dial Indicator (5) on the drive housing for the fuel
injection pump.
4. With the drive group lever in the shutoff position (fully clockwise), put spacer (3) of the bracket
group over the rod that will make contact with the rack.
5. Push the hole attachment against the rod to hold the spacer in position.
6. Put the dial indicator on zero and release the hole attachment. Take the spacer away from the rod.
7. Turn the drive group lever slowly in the FUEL ON direction (counterclockwise) until it stops.
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8. Read the measurement on the dial indicator. Look at the Fuel Setting And Related Information
Fiche to find the correct measurement for rack setting.
9. If the measurement is not correct do the steps that follow:
a. Remove cover (9) and the washer.
b. Loosen nut (7) until lock (6) is free of the pin.
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Governor Drive Group

(6) Lock. (7) Nut. (8) Switch assembly. (9) Cover. (10) Terminal. (11) Drive group lever.
c. Turn switch assembly (8), as necessary, to get the correct reading on the dial indicator. Remember
to push the drive group lever (11) counterclockwise when reading the dial indicator.
NOTE: Turn switch assembly (8) clockwise to decrease or counterclockwise to increase the rack
setting.
NOTE: If the pin is not in alignment with one of the notches in lock (6), turn switch assembly (8) to
put the nearest notch in alignment with the pin.
d. Tighten nut (7). Check the adjustment by going through Steps 4 through 9 again. When the
adjustment is correct, install cover (9), the gaskets, spacer (2) and stop (1).
NOTE: To check for full fuel with the engine running connect the 8T500 Circuit Tester between
terminal (10) of the switch assembly and a good ground. When the rack gets to full fuel the light in
the tester will go on.
Adjusting The High Idle Stop

1. Start the engine and let it run until the coolant temperature is normal.
2. Loosen locknut (3). Turn stop screw (4) counterclockwise approximately two turns.
NOTICE
With the stop screw in this position the engine can overspeed. This can
cause damage to engine components. Be ready to shutdown the engine
if it has an overspeed condition.
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Earlier PSG Governor

(1) Synchronizing motor. (2) Knurled knob. (3) Locknut. (4) Stop screw.
3. Use knurled knob (2) or synchronizing motor (1) to adjust the engine to the desired speed.
4. Turn stop screw (4) clockwise until it stops. Tighten locknut (3).
5. If the engine speed is still correct, the adjustment is correct.
Check Speed Droop

The speed droop can be adjusted between zero and seven percent. The desired speed droop will be
different for different applications. Percent of speed droop is the percent difference between the
engine speed at no load and full load. To calculate speed droop use the formula:
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1. Get the desired speed droop for the application.
2. Multiply the full load speed by the desired speed droop. Add the number from this multiplication to
the full load speed to get the no load speed.
3. Start the engine and let it run until the temperature of the coolant is normal.
4. Adjust the engine speed to get the no load speed from Step 2.
5. Connect a known load to the engine. The load must be less than the full capacity of the engine.
Make a record of the decrease in engine speed.
6. Make a ratio between the load on the engine and the full load capacity of the engine. This ratio
must be the same as the ratio between the decrease in engine speed from Step 5 and the number from
the multiplication in Step 2, For example:
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7. If the ratios are not the same, an adjustment of the speed droop is necessary. Remove the load and
stop the engine. If the engine speed decreased too much according to the ratio, decrease the amount of
speed droop. If the decrease in engine speed is not enough, increase the amount of speed droop. See
Speed Droop Adjustment.
Speed Droop Adjustment

1. Make a mark on cover (1) to show the original position of bracket (3). This will show how much a
change in bracket position changes the speed droop.
2. Loosen knob (2) that holds bracket (3) and speed droop lever (4) in position.
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Earlier PSG Governor

(1) Cover. (2) Knob. (3) Bracket. (4) Speed droop lever. (5) Stop screw.
3. To increase the speed droop turn lever (4) counterclockwise. To decrease the speed droop turn lever
(4) clockwise.
NOTE: If the lever is turned clockwise beyond the point where the speed droop is zero the engine
will hunt a large amount and will not get stability.
4. Tighten knob (2) to hold the lever and bracket in position. After an adjustment is made check the
speed droop. See CHECK SPEED DROOP. Several adjustments can be necessary to get the desired
speed droop.
5. When lever (4) is in the position that gives the desired speed droop, set stop screw (5) against the
pin on lever (4). This will make it easy to return the speed droop lever to the desired position after
disassembly and assembly of the governor.
Pilot Valve Adjustment
The top cover is pushed away from the body of the governor by a strong
spring. Loosen all the bolts that hold the cover in position evenly to
decrease the force of compression of the spring.
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PSG Governor
(1) Inspection opening. Check the adjustment of the pilot valve when the governor is disassembled (linkage and top cover
removed).
1. Remove the pipe plug from inspection opening (1).
2. Use a light to look for the control opening in pilot valve bushing (2) and regulating land (3) on the
pilot valve.
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Control Opening
(1) Inspection opening. (2) Pilot valve bushing. (3) Regulating land. (A) Port opening. (B) Port opening.
3. Push pilot valve (6) in the direction of the drive end as far as possible. Check the length of port
opening (A).
4. Pull the pilot valve in the opposite direction as far as possible. Check the length of port opening
(B).
5. The length of port opening (A) must be the same, within 0.25 mm (.010 in.), as port opening (B).
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PSG Governor
(2) Pilot valve bushing. (3) Regulating land. (4) Locknut. (5) Spring seat. (6) Pilot valve.
6. If the lengths of the port openings are not correct hold spring seat (5) with 1P87 Adjusting Wrench.
Loosen locknut (4). Turn the pilot valve as necessary to get the correct adjustment.
NOTE: Turn the pilot valve clockwise to increase port opening (A) and decrease port opening (B).
Turn it counterclockwise to decrease port opening (A) and increase port opening (B).
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1P87 Adjusting Wrench Used To Hold Spring Seat
7. Tighten locknut (4) and remove the wrench.
8. Check the adjustment according to Steps 3, 4 and 5.
NOTICE
If this adjustment is not correct the engine can have an overspeed
condition. This can cause damage to engine components.
9. When the adjustment is correct, put 5P3413 Pipe Sealant on the threads of the pipe plug and install
it in pipe plug opening.
Air Inlet And Exhaust System

Restriction Of Air Inlet And Exhaust
There will be a reduction of horsepower and efficiency of the engine if there is a restriction in the air
inlet or exhaust system.
Air flow through the air cleaner must not have a restriction (negative pressure difference measurement
between atmospheric air and air that has gone through air cleaner) of more than 762 mm (30 in.) of
water.
Back pressure from the exhaust (pressure difference measurement between exhaust at outlet elbow
and atmospheric air) must not be more than 685 mm (27 in.) of water.
Measurement Of Pressure In Inlet Manifold

The efficiency of an engine can be checked by making a comparison of the pressure in the inlet
manifold with the information given in the Fuel Setting And Related Information Fiche. This test is
used when there is a decrease of horsepower from the engine, yet there is no real sign of a problem
with the engine.
The correct pressure for the inlet manifold is given in the Fuel Setting And Related Information Fiche.
Development of this information is done with these conditions:
a. 747 mm (29.4 in.) of mercury barometric pressure.

b. 29°C (85°F) outside air temperature.
c. 35 API rated fuel
Any change from these conditions can change the pressure in the inlet manifold. Outside air that has
higher temperature and lower barometric pressure than given above will cause a lower horsepower
and a lower inlet manifold pressure measurement than given in the Fuel Setting And Related
Information Fiche. Outside air that has a lower temperature and a higher barometric pressure will
cause higher horsepower and a higher inlet manifold pressure measurement.
A difference in fuel rating will also change horsepower and the pressure in the inlet manifold. If the
fuel is rated above 35 API, pressure in the inlet manifold can be less than given in the Fuel Setting
And Related Information Fiche. If the fuel is rated below 35 API, the pressure in the inlet manifold
can be more than given in the Fuel Setting And Related Information Fiche.
NOTE: Be sure that the air inlet and exhaust do not have a restriction when making a check of
pressure in the inlet manifold.
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Inlet Manifold Plug For Pressure Test
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Aftercooler Housing Plug For Pressure Test
Use the 1U5470 Engine Pressure Group and part of the 6V3121 Multitach Group to check the
pressure in the inlet manifold.
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1U5470 Engine Pressure Group
This tool group has a gauge to read pressure in the inlet manifold. Special Instruction Form
SEHS8524 is with the tool group and gives instructions for its use.
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6V3121 Multitach Group

(1) Carrying case. (2) Power cable. (3) Tachometer generator. (4) Tachometer drive group. (5) Multitach.
The 6V3121 Multitach Group can measure engine speed from a tachometer drive on the engine. It
also has the ability to measure engine speed from visual engine parts in rotation.
Special Instruction Form No. SEHS7807 is with the 6V3121 Multitach Group and gives instructions
for the test procedure.
Turbocharger
Every 7200 hours or if any unusual sound or vibration in the turbocharger is noticed, a quick check of
bearing condition can be made without disassembling the turbocharger. This can be done by removing
the piping from the turbocharger and inspecting the compressor impeller, turbine wheel and
compressor cover. Rotate the compressor and turbine wheel assembly by hand and observe by feeling
excess end play and radial clearance. The rotating assembly should rotate freely with no rubbing or
binding. If there is any indication of the impeller rubbing the compressor cover or the turbine wheel
rubbing the turbine housing, recondition the turbocharger or replace with a new or rebuilt one.
End clearance is best checked with a dial indicator. Attach a dial indicator with the indicator point on
the end of the shaft. Move the shaft from end to end making note of the total indicator reading.
End play for the turbocharger should be 0.08 to 0.15 mm (.003 to .006 in.). If end play is more than
the maximum end play, rebuild or replace the turbocharger. End play less than the minimum end play
could indicate carbon build up on the turbine wheel and the turbocharger should be disassembled for
cleaning and inspection.
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Checking Turbocharger Rotating Assembly End Play (Typical Example)
A more reliable check of bearing conditions can be made only when the turbocharger is disassembled
and the bearings, shaft journal and housing bore diameters can actually be measured.
Measurement Of Exhaust Temperature

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6V5000 Infrared Thermometer Group
Use the 6V5000 Infrared Thermometer Group to check exhaust temperature. Special Instruction Form
No. SEHS8149 is with the tool group and gives instructions for the test procedure.
Crankcase (Crankshaft Compartment) Pressure

Pistons or piston rings that have damage can be the cause of too much pressure in the crankcase. This
condition will cause the engine to run rough. There will also be more than the normal amount of
fumes coming from the crankcase breather. This crankcase pressure can also cause the element for the
crankcase breather to have a restriction in a very short time. It can also be the cause of oil leakage at
gaskets and seals that would not normally have leakage.
Compression
An engine that runs rough can have a leak at the valves, or have valves that need adjustment. Removal
of the head and inspection of the valves and valve seats is necessary to find those small defects that do
not normally cause a problem. Repair of these problems is normally done when reconditioning the
engine.
Cylinder Head
The cylinder head has valve seat inserts, valve guides, and bridge dowels that can be removed when
they are worn or have damage. Replacement of these components can be made with the tools that
follow.
Valves
Valve removal and installation is easier with use of the 5S1330 Valve Spring Compressor Assembly
and 5S1322 Valve Keeper Inserter.
Valve Seat Inserts
Tools needed to remove and install valve seat inserts are in the 6V4805 Valve Insert Puller Group.
Special Instruction Form No. SMHS7935 gives an explanation for the procedure to remove the valve
seat inserts. For easier installation, lower the temperature of the insert before it is installed in the head.
Valve Guides
Tools needed to install valve guides are the 5P2396 Driver Bushing and 7S8859 Driver. The
counterbore in the driver bushing installs the guide to the correct height. Use a 1P7451 Valve Guide
Honing Group to make a finished bore in the valve guide after installation of the guide in the head.
Special Instruction Form No. SMHS7526 gives an explanation for this procedure. Grind the valves
after the new valve guides are installed.
Checking Valve Guide Bore
Use the 5P3536 Valve Guide Gauge Group to check the bore of the valve guides. Special Instruction
Form No. GMG02562 gives complete and detailed instructions for use of the 5P3536 Valve Guide
Gauge Group.
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5P3536 Valve Guide Gauge Group
Bridge Dowel
Use a 5P944 Dowel Puller Group witha 5P942 Extractor to remove the bridge dowels. Install a new
bridge dowel with a 5P2406 Dowel Driver. This dowel driver installs the bridge dowel to the correct
height.
Bridge Adjustment
When the cylinder head is disassembled, keep the bridges with their respective cylinders. Adjustment
of the bridge will be necessary after the valves are ground or other reconditioning of the cylinder head
is done. The bridge should be checked and/or adjusted each time the valves are adjusted. Use the
procedure that follows to make an adjustment to the bridge.
NOTE: The bridges can be adjusted without removal of the rocker arms and shafts. Valves must be
fully closed when adjustment is made.
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Bridge Adjustment
NOTE: Valves must be fully closed.
1. Put engine oil on the bridge dowel in the cylinder head and in the bore in the bridge.
2. Install the bridge with the adjustment screw toward the exhaust manifold.
3. Loosen the locknut for the adjustment screw and loosen the adjustment screw several turns.
4. Put a force on the bridge with a finger to keep the bridge in contact with the valve stem opposite the
adjustment screw.
5. Turn the adjustment screw clockwise until it just makes contact with the valve stem. Then turn the
adjustment screw 30° more in a clockwise direction to make the bridge straight on the dowel, and to
make compensation for the clearance in the threads of the adjustment screw.
6. Hold the adjustment screw in this position and tighten the locknut to 28 ± 4 N·m (22 ± 3 lb ft).
7. Put engine oil at the point where the rocker arm makes contact with the bridge.
Valve Clearance Setting

NOTE: Valve clearance is measured between the rocker arm and the bridge for the valves.
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Valve Clearance Check
NOTE: When the valve lash (clearance) is checked, adjustment is NOT NECESSARY if the
measurement is in the range given in the chart for VALVE CLEARANCE CHECK: ENGINE
STOPPED. If the measurement is outside this range, adjustment is necessary. See the chart for
VALVE CLEARANCE SETTING: ENGINE STOPPED, and make the setting to the nominal
(desired) specifications in this chart.
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To make an adjustment to the valve clearance, turn the adjustment screw in the rocker arm. It is not
necessary to change the bridge adjustment for normal valve clearance adjustments. Valve clearance
adjustments can be made by using the procedure that follows:
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Valve Adjustment
1. Put No. 1 piston at top center (TC) on the compression stroke. Make reference to Finding Top
Center Compression Position For No. 1 Piston.
2. Make an adjustment to the valve clearance on the intake valves for cylinders 1, 2 and 4. Make an
adjustment to the valve clearance on the exhaust valves for cylinders 1, 3 and 5.
3. After each adjustment, tighten the nut for valve adjustment screw to 28 ± 4 N·m (22 ± 3 lb ft), and
check the adjustment again.
4. Remove the timing bolt and turn the flywheel 360° in the direction of engine rotation. This will put
No. 6 piston at top center (TC) on the compression stroke. Install the timing bolt in the flywheel.
5. Make an adjustment to the valve clearance on the intake valves for cylinders 3, 5 and 6. Make an
adjustment to the valve clearance on the exhaust valves for cylinders 2, 4 and 6.
6. After each adjustment, tighten the nut for valve adjustment screw to 28 ± 4 N·m (22 ± 3 lb ft), and
check the adjustment again.
7. Remove the timing bolt from the flywheel when all valve clearances are correct.
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Cylinder And Valve Location
Lubrication System
One of the problems in the list that follows will generally be an indication of a problem in the
lubrication system for the engine.
Too Much Oil ConsumptionOil Pressure Is LowOil Pressure Is HighToo Much Bearing
WearIncreased Oil Temperature
Too Much Oil Consumption
Oil Leakage on Outside of Engine
Check for leakage at the seals at each end of the crankshaft. Look for leakage at the oil pan gasket and
all lubrication system connections. Check to see if oil comes out of the crankcase breather. This can
be caused by combustion gas leakage around the pistons. A dirty crankcase breather will cause high
pressure in the crankcase, and this will cause gasket and seal leakage.
Oil Leakage Into Combustion Area of Cylinders
Oil leakage into the combustion area of the cylinders can be the cause of blue smoke. There are four
possible ways for oil leakage into the combustion area of the cylinders.
1. Oil leakage between worn valve guides and valve stems.

2. Worn or damaged piston rings, or dirty oil return holes.
3. Compression ring and/or intermediate ring not installed correctly.
4. Oil leakage past the seal rings in the impeller end of the turbocharger shaft.
Too much oil consumption can also be the result if oil with the wrong viscosity is used. Oil with a
thin viscosity can be caused by fuel leakage into the crankcase, or by increased engine temperature.
Measuring Engine Oil Pressure

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An oil pressure gauge that has a defect can give an indication of low oil pressure.
The 1U5470 Engine Pressure Group can be used to check engine oil pressure.
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1U5470 Engine Pressure Group
The 1U5470 Engine Pressure Group can be used to measure the pressure in the system. This tool
group has a gauge to read pressure in the oil manifold. Special Instruction Form SEHS8524 is with
the tool group and gives instructions for its use.
1. Be sure that the engine is filled to the correct level with SAE 10W-30 oil. If any other viscosity of
oil is used, the information in the Engine Oil Pressure Graph does not apply.
2. Connect the 1U5470 Engine Pressure Group to the main oil manifold at location (1).
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Oil Manifold
(1) Pressure test location.
3. Operate the engine to get it up to normal operating temperature.
4. Keep the oil temperature constant with the engine at its rated rpm, and read the pressure gauge.
NOTE: Make sure engine oil temperature does not go above 115°C (239°F).
5. On the Engine Oil Pressure Graph, find the point that the lines for engine rpm and oil pressure
intersect (connect).
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Engine Oil Pressure Graph
6. If the results do not fall within the "ACCEPTABLE" pressure range given in the graph, find the
cause and correct it. Engine failure or a reduction in engine life can be the result if engine operation is
continued with oil manifold pressure outside this range.
NOTE: A record of engine oil pressure, kept at regular intervals, can be used as an indication of
possible engine problems or damage. If there is a sudden increase or decrease of 70 kPa (10 psi) in oil
pressure, even though the pressure is in the "ACCEPTABLE" range on the graph, the engine should
be inspected and the problem corrected.
Copyright 1993 - 2018 Caterpillar Inc. Thu Oct 25 2018 07:03:03 GMT-0700 (Pacific Daylight Time)
All Rights Reserved.
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Service Information System Page 1 of 20

Testing and Adjusting

Testing And Adjusting

Measure Rack Travel

9. If the measurement is not correct do the steps that follow:

a. Remove cover (9) and the washer.

b. Loosen nut (7) until lock (6) is free of the pin.

Governor Drive Group

Adjusting The High Idle Stop

Earlier PSG Governor

5. If the engine speed is still correct, the adjustment is correct.

Check Speed Droop

1. Get the desired speed droop for the application.

Speed Droop Adjustment

Earlier PSG Governor

Pilot Valve Adjustment

1. Remove the pipe plug from inspection opening (1).

1P87 Adjusting Wrench Used To Hold Spring Seat

7. Tighten locknut (4) and remove the wrench.

8. Check the adjustment according to Steps 3, 4 and 5.

Air Inlet And Exhaust System

Measurement Of Pressure In Inlet Manifold

a. 747 mm (29.4 in.) of mercury barometric pressure.

Inlet Manifold Plug For Pressure Test

Aftercooler Housing Plug For Pressure Test

1U5470 Engine Pressure Group

6V3121 Multitach Group

Checking Turbocharger Rotating Assembly End Play (Typical Example)

Measurement Of Exhaust Temperature

6V5000 Infrared Thermometer Group

Crankcase (Crankshaft Compartment) Pressure

Valve Seat Inserts

Checking Valve Guide Bore

5P3536 Valve Guide Gauge Group

NOTE: Valves must be fully closed.

Valve Clearance Setting

Valve Clearance Check

Cylinder And Valve Location

Too Much Oil Consumption

Oil Leakage on Outside of Engine

Oil Leakage Into Combustion Area of Cylinders

1. Oil leakage between worn valve guides and valve stems.

Measuring Engine Oil Pressure

1U5470 Engine Pressure Group

3. Operate the engine to get it up to normal operating temperature.

Engine Oil Pressure Graph

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