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You must read and understand the warnings and instructions contained in the Safety section of this manual before performing any operation or maintenance procedures.For most users of 3406 Marine Engines, a top end overhaul is not needed until the major OVERHAUL interval of Every 10,000 Hours or fuel consumption interval for your engine.A top end overhaul is generally indicated by increased fuel consumption and reduced power. This option consists of completely reconditioning your cylinder head, but the cylinder components are not worn enough to need repair.Expected engine life (time to overhaul) can be expressed in terms of liters (gallons) of fuel consumed and can generally be predicted by the average power demanded of the engine over a period of time. Reduced hours of operation at full throttle and/or operating at reduced throttle settings result in lower average power demand and should increase the length of operating time before an engine overhaul is required. Other factors, such as how conscientiously preventive maintenance has been performed, fuel quality, operating conditions, S O S results, etc., are important in deciding when to perform an overhaul.Overhaul Programs
Your Caterpillar dealer may be offering a variety of options regarding overhaul programs and Caterpillar recommends that an Overhaul be performed at this maintenance interval.Overhaul Options
Caterpillar Dealer - Contact your Caterpillar dealer to schedule a Before Failure Overhaul. Overhaul Kit - This useful kit was developed for those users that prefer to perform their own overhaul. This kit includes a combination of new, reused and Remanufactured parts. Also included is a step-by-step instruction regarding how to perform an overhaul. An Overhaul Kit simplifies parts ordering, helps speed repairs and reduces parts costs.Contact your local Caterpillar dealer for information regarding the Overhaul Kit.Overhaul Recommendation
Overhaul programs vary from dealer to dealer. Therefore, Caterpillar recommends that you confer with your dealer to obtain specific information regarding the types of programs offered and overhaul services provided for extending the life of your engine.After Failure Overhaul
If you experience a major engine failure which requires removal of the engine, there are also many After Failure Overhaul options available. An overhaul should be performed if your block or crankshaft needs to be repaired.If the block and/or crankshaft is repairable, then the cost of an overhaul should be between 40 and 50 percent of the cost of a new engine (with like exchange core).This lower cost can be attributed to Caterpillar "designed-in" features that include regrindable crankshaft, undersize bearings, if needed and Cat dealer and Caterpillar Remanufactured exchange components.The following is a list of (R) Remanufactured components that can be found in the Parts Manual and currently being offered by Caterpillar* in many countries:* Short block* Cylinder pack1* Cylinder head - bare casting* Cylinder head - assembled* Crankshaft - undersized*** Crankshaft - upgrade to new* Complete turbocharger* Turbocharger Piece Parts* Turbocharger Cartridges* Water pump* Oil pump* Fuel injectors (when applicable)* Alternator* Starting motor If the component you need is not listed here, contact your Caterpillar dealer to see if it is offered under