Product: ARTICULATED TRUCK
Model: 735 ARTICULATED TRUCK AWR
Configuration: 735 Articulated Truck AWR00001-UP (MACHINE) POWERED BY 3406E Engine
Disassembly and Assembly
3406E and 3456 Engines for Caterpillar Built Machines
Bearing Clearance - Check
SMCS - 1203-535; 1219-535
Measurement Procedure
Table 1 Required Tools
Tool
Plastic Gauge (Green)
to 0.076 mm
to 0.003 inch)
Plastic Gauge (Red)
to 0.152 mm (0.002 to 0.006 inch)
Plastic Gauge (Blue) 0.102 to 0.229 mm (0.004 to 0.009 inch)
Plastic Gauge (Yellow) 0.230 to 0.510 mm (0.009 to 0.020 inch)
Note: Plastic gauge may not be necessary when the engine is in the chassis.
NOTICE
i05977048
Keep all parts clean from contaminants.
Contaminants may cause rapid wear and shortened component life.
Note: Cat does not recommend the checking of the actual bearing clearances particularly on small engines. This is because of the possibility of obtaining inaccurate results and the possibility of damaging the bearing or the journal surfaces. Each Cat engine bearing is quality checked for specific wall thickness.
Note: The measurements should be within specifications and the correct bearings should be used. If the crankshaft journals and the bores for the block and the rods were measured during disassembly, no further checks are necessary. However, if the technician still wants to measure the bearing clearances, Tooling (A) is an acceptable method. Tooling (A) is less accurate on journals with small diameters if clearances are less than 0.10 mm (0.004 inch).
NOTICE
Lead wire, shim stock or a dial bore gauge can damage the bearing surfaces.
The technician must be very careful to use Tooling (A) correctly. The following points must be remembered:
• Ensure that the backs of the bearings and the bores are clean and dry.
• Ensure that the bearing locking tabs are properly seated in the tab grooves.
• The crankshaft must be free of oil at the contact points of Tooling (A).
1. Put a piece of Tooling (A) on the crown of the bearing that is in the cap.
Note: Do not allow Tooling (A) to extend over the edge of the bearing.
2. Use the correct torque-turn specifications in order to install the bearing cap. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed.
Note: Do not turn the crankshaft when Tooling (A) is installed.
3. Carefully remove the cap, but do not remove Tooling (A). Measure the width of Tooling (A) while Tooling (A) is in the bearing cap or on the crankshaft journal. Refer to Illustration 1.
Illustration 1 g01152855
Typical Example
4. Remove all of Tooling (A) before you install the bearing cap.
Note: When Tooling (A) is used, the readings can sometimes be unclear. For example, all parts of Tooling (A) are not the same width. Measure the major width in order to ensure that the parts are within the specification range. Refer to Specifications Manual, "Connecting Rod Bearing Journal" and Specifications Manual, "Main Bearing Journal" for the correct clearances.
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Wed Mar 27 11:12:40 UTC+0530 2024
Product: ARTICULATED TRUCK
Model: 735 ARTICULATED TRUCK AWR
Configuration: 735 Articulated Truck AWR00001-UP (MACHINE) POWERED BY 3406E Engine
Disassembly and Assembly
3406E and 3456 Engines for Caterpillar Built Machines
Camshaft - Install
Installation Procedure
all parts
1. Ensure that the camshaft and camshaft bearings are thoroughly clean. Lubricate the camshaft lobes with a 50/50 mixture of Tooling (K) and clean engine oil. Apply a thin coat of clean engine oil on the camshaft bearings.
1
2
2. Install Tooling (A) on the cylinder head at Location (Y).
Illustration 3
3. Install Tooling (B) on front housing (7). Do not tighten the bolts that hold Tooling (B) to front housing (7) at this time.
4. Use Tooling (H) to align Tooling (B) with the camshaft bearings. Tighten the bolts that hold Tooling (B) to front housing (7). Remove Tooling (H).
Note: Tooling (H) should move freely from the bore of Tooling (B).
Illustration 4
5. Install Tooling (C) in the end of camshaft (8).
Note: Rotate the camshaft during installation. This will prevent the camshaft from binding in the camshaft bearings.
6. Use a suitable lifting device in order to position camshaft (8) into Tooling (B) and the cylinder head. The weight of the camshaft is approximately 39 kg (86 lb).
5
Illustration 6
Note: Tooling (C) must be removed before the camshaft can be completely installed in the cylinder head.
7. Remove the lifting device. Rotate the camshaft during installation. Use care not to allow the end of the camshaft and Tooling (C) to drop. Use Tooling (D) to assist in aligning camshaft (8) with the camshaft bearings.
8. Remove Tooling (C) and finish installing camshaft (8) in the bore.
9. Remove Tooling (A) and Tooling (B).
Illustration 7
Illustration 8
10. Install O-ring seals (5) and (6) in seal assembly (3). Lubricate seal (6) with Tooling (K).
11. Install seal assembly (3). Position adapter (4). Ensure that the dowel in adapter (4) engages the hole in the camshaft.
12. Position thrust plate (1). Apply Tooling (J) to bolts (2). Hold thrust plate (1) in position and install bolts (2). Evenly tighten bolts (2) until seal assembly (3) and O-ring seal (5) are seated against the cylinder head.
Note: Be careful in order to ensure that O-ring seal (5) stays in the groove in seal assembly (3).
End By:
a. Install the rocker arms and the rocker shafts. Refer to Disassembly and Assembly, "Rocker Arm and Shaft - Install".
b. Install the camshaft gear. Refer to Disassembly and Assembly, "Camshaft Gear - Remove and Install".
Alternative Installation Procedure
Table 2