Caterpillar 3056E Engines Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Caterpillar 3056E Engines, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
3056E Engine for Caterpillar Built Machines & 3056E Industrial Engines workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 1,433 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
RENR2425 - Schematic (Caterpillar 3056E Industrial Engine Electrical System)
RENR2416 - Systems Operation (3056E Engines for Caterpillar Built Machines).pdf
RENR2428 - Specifications (3056E Industrial Engine).pdf
RENR2401 - Specifications (3056E Engine for Caterpillar Built Machines).pdf
RENR2427 - Systems Operation (3056E Industrial Engine).pdf
RENR2427 - Testing & Adjusting (3056E Industrial Engine).pdf
RENR2416 - Testing & Adjusting (3056E Engines for Caterpillar Built Machines).pdf
RENR2400 - Disassembly and Assembly (3056E Engine for Caterpillar Built Machines).pdf
RENR2426 - Disassembly and Assembly (3056E Industrial Engine).pdf
RENR2417 - Troubleshooting (3054E and 3056E Industrial Engines and Engines for Caterpillar Built Machines).pdf
MAIN SECTIONS
RENR2400 - Disassembly and Assembly (3056E Engine for Caterpillar Built Machines)..............1
Fuel Priming Pump - Remove and Install..............4
Fuel Filter Base - Remove and Install..............7
Fuel Injection Lines - Remove..............10
Fuel Injection Lines - Install..............13
Fuel Injection Nozzles - Remove..............16
Fuel Injection Nozzles - Install..............18
Fuel Injection Pump - Remove..............21
Fuel Injection Pump - Install..............25
Turbocharger - Remove..............28
Turbocharger - Install..............31
Exhaust Manifold - Remove and Install..............33
Inlet Manifold - Remove..............35
Inlet Manifold - Install..............37
Inlet and Exhaust Valve Springs - Remove and Install..............39
Inlet and Exhaust Valves - Remove and Install..............43
Inlet and Exhaust Valve Guides - Remove and Install..............48
Inlet and Exhaust Valve Seat Inserts - Remove and Install..............51
Engine Oil Filter Base - Remove and Install..............55
Engine Oil Cooler - Remove..............58
Engine Oil Cooler - Install..............61
Engine Oil Bypass Valve - Remove..............64
Engine Oil Bypass Valve - Install..............67
Engine Oil Pump - Remove..............70
Engine Oil Pump - Install..............73
Water Pump - Remove and Install..............76
Water Temperature Regulator - Remove and Install..............79
Water Outlet Manifold - Remove and Install..............82
Flywheel - Remove..............85
Flywheel - Install..............88
Crankshaft Rear Seal - Remove..............91
Crankshaft Rear Seal - Install..............93
Flywheel Housing - Remove and Install..............97
Vibration Damper and Pulley - Remove..............101
Vibration Damper and Pulley - Install..............103
Crankshaft Front Seal - Remove..............105
Crankshaft Front Seal - Install..............107
Front Cover - Remove and Install..............109
Gear Group (Front) - Remove..............112
Gear Group (Front) - Install..............115
Housing (Front) - Remove..............118
Housing (Front) - Install..............120
Valve Mechanism Cover - Remove and Install..............123
Rocker Shaft and Pushrod - Remove..............126
Rocker Shaft - Disassemble..............128
Rocker Shaft - Assemble..............130
Rocker Shaft and Pushrod - Install..............132
Cylinder Head - Remove..............134
Cylinder Head - Install..............137
Lifter Group - Remove and Install..............140
Camshaft - Remove and Install..............142
Camshaft Gear - Remove and Install..............145
Camshaft Bearings - Remove and Install..............148
Engine Oil Pan - Remove and Install..............151
Cylinder Liner - Remove..............154
Cylinder Liner - Install..............156
Piston Cooling Jets - Remove and Install..............159
Pistons and Connecting Rods - Remove..............162
Pistons and Connecting Rods - Disassemble..............164
Pistons and Connecting Rods - Assemble..............167
Pistons and Connecting Rods - Install..............170
Connecting Rod Bearings - Remove..............173
Connecting Rod Bearings - Install..............175
Crankshaft Main Bearings - Remove..............177
Crankshaft Main Bearings - Install..............180
Crankshaft - Remove..............183
Crankshaft - Install..............187
Crankshaft Gear - Remove and Install..............192
Bearing Clearance - Check..............195
Atmospheric Pressure Sensor - Remove and Install..............198
Coolant Temperature Sensor - Remove and Install..............200
Engine Oil Pressure Sensor - Remove and Install..............202
Speed_Timing Sensor - Remove and Install..............204
Inlet Air Temperature Sensor - Remove and Install..............206
V-Belts - Remove and Install..............209
Fan - Remove and Install..............211
Fan Drive - Remove and Install..............213
Electronic Control Module - Remove and Install..............215
Alternator - Remove..............217
Alternator - Install..............220
Electric Starting Motor - Remove and Install..............224
RENR2401 - Specifications (3056E Engine for Caterpillar Built Machines)..............227
Engine Design..............229
Fuel Injection Lines..............231
Fuel Injection Pump..............232
Fuel Injection Nozzles..............233
Fuel Lines..............235
Fuel Filter Base..............237
Fuel Priming Pump..............239
Lifter Group..............241
Rocker Shaft..............242
Valve Mechanism Cover..............244
Cylinder Head Valves..............246
Cylinder Head..............250
Turbocharger..............252
Inlet Manifold..............254
Exhaust Manifold..............256
Camshaft..............258
Camshaft Bearings..............261
Engine Oil Filter Base..............262
Engine Oil Filter Bypass Valve..............263
Engine Oil Cooler..............264
Engine Oil Pump..............266
Engine Oil Pressure..............269
Engine Oil Bypass Valve..............270
Engine Oil Pan..............272
Crankcase Breather..............275
Water Temperature Regulator Housing..............277
Water Temperature Regulator..............278
Water Pump..............279
Cylinder Block..............280
Cylinder Liner..............283
Crankshaft..............285
Crankshaft Seals..............289
Vibration Damper and Pulley..............291
Connecting Rod Bearing Journal..............293
Main Bearing Journal..............294
Connecting Rod..............295
Piston and Rings..............299
Piston Cooling Jet..............301
Front Housing and Covers..............303
Gear Group (Front)..............305
Flywheel..............307
Flywheel Housing..............309
Engine Lifting Bracket..............310
Alternator and Regulator..............311
Electric Starting Motor..............315
Coolant Temperature Sensor..............318
Engine Oil Temperature Sensor..............320
Boost Pressure Sensor..............322
Inlet Manifold Temperature Sensor..............324
Electronic Control Module..............326
Speed_Timing Sensor..............327
Air Inlet Heater..............329
RENR2416 - Systems Operation (3056E Engines for Caterpillar Built Machines)..............331
Introduction..............332
Basic Engine..............336
Air Inlet and Exhaust System..............345
Cooling System..............352
Lubrication System..............354
Electrical System..............356
Fuel Injection..............359
Electronic Control System..............375
Power Sources..............381
RENR2416 - Testing & Adjusting (3056E Engines for Caterpillar Built Machines)..............386
Fuel System - Inspect..............388
Air in Fuel - Test..............390
Engine Speed - Check..............393
Finding Top Center Position for No. 1 Piston..............395
Fuel Injection Nozzle - Test..............397
Fuel Injection Timing - Check..............402
Fuel Quality - Test..............406
Fuel System - Prime..............408
Fuel System Pressure - Test..............412
Gear Group (Front) - Time..............414
Air Inlet and Exhaust System - Inspect..............415
Turbocharger - Inspect..............417
Compression - Test..............423
Engine Valve Lash - Inspect_Adjust..............425
Valve Depth - Inspect..............429
Valve Guide - Inspect..............432
Engine Oil Pressure - Test..............434
Engine Oil Pump - Inspect..............438
Excessive Bearing Wear - Inspect..............442
Excessive Engine Oil Consumption - Inspect..............443
Increased Engine Oil Temperature - Inspect..............444
Cooling System - Check..............445
Cooling System - Inspect..............447
Cooling System - Test..............449
Engine Oil Cooler - Inspect..............457
Water Temperature Regulator - Test..............459
Water Pump - Inspect..............461
Piston Ring Groove - Inspect..............462
Connecting Rod - Inspect..............465
Cylinder Block - Inspect..............469
Cylinder Head - Inspect..............470
Cylinder Liner Projection - Inspect..............474
Piston Height - Inspect..............477
Flywheel - Inspect..............480
Flywheel Housing - Inspect..............483
Gear Group - Inspect..............487
Vibration Damper - Check..............489
Air Inlet Heater - Test..............491
Alternator - Test..............495
Battery - Test..............497
Belt Tension Chart..............498
Charging System - Test..............499
Electric Starting System - Test..............500
RENR2417 - Troubleshooting (3054E and 3056E Industrial Engines and Engines for Caterpillar Built Machines)..............504
System Overview..............508
Glossary..............513
Electronic Service Tools..............519
Indicator Lamps..............525
Replacing the ECM..............529
Self-Diagnostics..............532
Sensors and Electrical Connectors..............533
Engine Wiring Information..............538
Programming Parameters..............547
Factory Passwords..............548
Flash Programming..............550
System Configuration Parameters..............552
Alternator Noise - Noisy Operation..............554
Alternator Will Not Charge - Charging Problem..............556
Battery..............557
Can Not Reach Top Engine RPM..............559
Coolant in Engine Oil..............562
Coolant Temperature Is Too High..............564
ECM Will Not Accept Factory Passwords..............567
ECM Will Not Communicate with Other Systems or Display Modules..............569
Electronic Service Tool Will Not Communicate with ECM..............570
Engine Cranks but Will Not Start..............572
Engine Has Early Wear..............576
Engine Misfires; Runs Rough or Is Unstable..............578
Engine Oil in Cooling System..............582
Engine Stalls at Low RPM..............584
Engine Vibration..............586
Engine Will Not Crank..............588
Excessive Black Smoke..............591
Excessive Engine Oil Consumption..............594
Excessive Valve Lash..............597
Excessive White Smoke..............599
Intake Air Temperature Is Too High..............602
Intermittent Engine Shutdown..............604
Intermittent Low Power or Power Cutout..............607
Low Engine Oil Pressure..............610
Low Power_Poor or No Response to Throttle..............613
Mechanical Noise (Knock) in Engine..............618
Noise Coming from Cylinder..............620
Diagnostic Code Cross Reference..............621
CID 0041 FMI 03..............624
CID 0041 FMI 04..............625
CID 0091 FMI 02..............626
CID 0091 FMI 03..............628
CID 0091 FMI 04..............630
CID 0091 FMI 08..............632
CID 0091 FMI 12..............634
CID 0100 FMI 03..............635
CID 0100 FMI 04..............636
CID 0100 FMI 10..............637
CID 0102 FMI 03..............639
CID 0102 FMI 04..............640
CID 0102 FMI 10..............641
CID 0105 FMI 03..............642
CID 0105 FMI 04..............643
CID 0110 FMI 03..............644
CID 0110 FMI 04..............645
CID 0174 FMI 02..............646
CID 0247 FMI 09..............648
CID 0253 FMI 02..............649
CID 0262 FMI 03..............650
CID 0262 FMI 04..............651
CID 0320 FMI 02..............652
CID 0320 FMI 11..............653
CID 0342 FMI 02..............654
CID 0774 FMI 02..............655
CID 0774 FMI 03..............657
CID 0774 FMI 04..............659
CID 0774 FMI 08..............661
CID 0774 FMI 12..............663
CID 1627 FMI 03..............665
CID 1684 FMI 00..............666
CID 1684 FMI 02..............668
CID 1684 FMI 03..............670
CID 1684 FMI 04..............672
CID 1684 FMI 05..............673
CID 1684 FMI 07..............674
CID 1684 FMI 08..............675
CID 1684 FMI 09..............678
CID 1684 FMI 10..............680
CID 1684 FMI 11..............682
CID 1684 FMI 12..............684
CID 1684 FMI 14..............686
CID 1743 FMI 02..............688
CID 1894 FMI 02..............689
CID 1895 FMI 02..............690
Event Codes..............691
E015 High Engine Coolant Temperature Derate..............692
E016 High Engine Coolant Temperature Shutdown..............693
E017 High Engine Coolant Temperature Warning..............694
E025 High Inlet Air Temperature Derate..............695
E027 High Inlet Air Temperature Warning..............696
E040 Low Engine Oil Pressure Shutdown..............698
E054 High Fuel Temperature Derate..............699
E056 High Fuel Temperature Warning..............701
E100 Low Engine Oil Pressure Warning..............703
E190 Engine Overspeed Warning..............706
5 Volt Engine Pressure Sensor Supply Circuit - Test..............707
Air Inlet Heater Circuit - Test..............715
Analog Throttle Position Sensor Circuit - Test..............723
CAN Data Link Circuit - Test..............733
Data Link Circuit - Test..............746
Digital Throttle Position Sensor Circuit - Test..............759
Electrical Connectors - Inspect..............771
Electrical Power Supply Circuit - Test..............783
Engine Pressure Sensor Open or Short Circuit - Test..............790
Engine Temperature Sensor Open or Short Circuit - Test..............801
Fuel Injection Pump Circuit - Test..............809
Indicator Lamp Circuit - Test..............825
Mode Selection Circuit - Test..............831
Set Speed Circuit - Test..............838
Speed_Timing Sensor Circuit - Test..............847
Throttle Switch Circuit - Test..............853
RENR2425 - Schematic (Caterpillar 3056E Industrial Engine Electrical System)..............861
Collage..............861
Main..............881
RENR2426 - Disassembly and Assembly (3056E Industrial Engine)..............883
Fuel Filter Base - Remove and Install..............886
Fuel Transfer Pump - Remove and Install..............889
Fuel Injection Lines - Remove and Install..............892
Fuel Injection Nozzles - Remove..............895
Fuel Injection Nozzles - Install..............897
Fuel Injection Pump - Remove..............900
Fuel Injection Pump - Install..............903
Turbocharger - Remove..............906
Turbocharger - Install..............908
Exhaust Manifold - Remove and Install - Three-Piece Exhaust Manifold..............911
Exhaust Manifold - Remove and Install - Two-Piece Exhaust Manifold..............914
Air Inlet Heater - Remove and Install..............917
Inlet Manifold - Remove..............920
Inlet Manifold - Install..............923
Inlet and Exhaust Valve Springs - Remove and Install..............926
Inlet and Exhaust Valves - Remove and Install..............930
Inlet and Exhaust Valve Guides - Remove and Install..............935
Inlet and Exhaust Valve Seat Inserts - Remove and Install..............938
Engine Oil Filter Base - Remove and Install..............942
Engine Oil Cooler - Remove..............945
Engine Oil Cooler - Install..............947
Engine Oil Relief Valve - Remove and Install..............950
Engine Oil Pump - Remove..............958
Engine Oil Pump - Install..............961
Water Pump - Remove and Install..............965
Water Temperature Regulator - Remove and Install..............968
Water Outlet Manifold - Remove and Install..............971
Flywheel - Remove..............974
Flywheel - Install..............977
Crankshaft Rear Seal - Remove..............980
Crankshaft Rear Seal - Install..............982
Crankshaft Wear Sleeve (Rear) - Remove..............985
Crankshaft Wear Sleeve (Rear) - Install..............987
Flywheel Housing - Remove and Install..............989
Vibration Damper and Pulley - Remove..............993
Vibration Damper and Pulley - Install..............995
Crankshaft Front Seal - Remove..............997
Crankshaft Front Seal - Install..............999
Front Cover - Remove and Install..............1001
Idler Gear - Remove and Install..............1004
Housing (Front) - Remove..............1008
Housing (Front) - Install..............1011
Accessory Drive - Remove and Install..............1014
Crankcase Breather - Remove and Install..............1018
Valve Mechanism Cover - Remove and Install..............1021
Rocker Shaft and Pushrod - Remove..............1024
Rocker Shaft - Disassemble..............1026
Rocker Shaft - Assemble..............1028
Rocker Shaft and Pushrod - Install..............1030
Cylinder Head - Remove..............1032
Cylinder Head - Install..............1035
Lifter Group - Remove and Install..............1040
Camshaft - Remove and Install..............1042
Camshaft Gear - Remove and Install..............1046
Camshaft Bearings - Remove and Install..............1049
Engine Oil Pan - Remove and Install..............1052
Cylinder Liner - Remove..............1057
Cylinder Liner - Install..............1059
Piston Cooling Jets - Remove and Install..............1062
Pistons and Connecting Rods - Remove..............1066
Pistons and Connecting Rods - Disassemble..............1068
Pistons and Connecting Rods - Assemble..............1070
Pistons and Connecting Rods - Install..............1074
Connecting Rod Bearings - Remove..............1077
Connecting Rod Bearings - Install..............1079
Crankshaft Main Bearings - Remove..............1081
Crankshaft Main Bearings - Install..............1085
Crankshaft - Remove..............1090
Crankshaft - Install..............1095
Crankshaft Timing Ring - Remove and Install..............1101
Crankshaft Gear - Remove and Install..............1104
Bearing Clearance - Check..............1107
Coolant Temperature Sensor - Remove and Install..............1110
Engine Oil Pressure Sensor - Remove and Install..............1112
Speed_Timing Sensor - Remove and Install..............1114
Boost Pressure Sensor - Remove and Install..............1116
Inlet Air Temperature Sensor - Remove and Install..............1118
Jacket Water Heater - Remove and Install..............1120
V-Belts - Remove and Install..............1125
Fan - Remove and Install..............1127
Fan Drive - Remove and Install..............1130
Electronic Control Module - Remove and Install..............1132
Voltage Load Protection Module - Remove and Install..............1134
Alternator - Remove..............1136
Alternator - Install..............1138
Electric Starting Motor - Remove and Install..............1140
Air Compressor - Remove and Install..............1143
Air Compressor Idler Gear - Remove and Install..............1148
RENR2427 - Systems Operation (3056E Industrial Engine)..............1152
Introduction..............1153
Basic Engine..............1157
Air Inlet and Exhaust System..............1166
Cooling System..............1173
Lubrication System..............1175
Electrical System..............1177
Fuel Injection..............1180
Electronic Control System..............1196
Power Sources..............1202
Glossary of Electronic Control Terms..............1207
RENR2427 - Testing & Adjusting (3056E Industrial Engine)..............1211
Fuel System - Inspect..............1213
Air in Fuel - Test..............1215
Engine Speed - Check..............1218
Finding Top Center Position for No. 1 Piston..............1220
Fuel Injection Nozzle - Test..............1222
Fuel Injection Timing - Check..............1227
Fuel Quality - Test..............1231
Fuel System - Prime..............1233
Fuel System Pressure - Test..............1237
Gear Group (Front) - Time..............1239
Air Inlet and Exhaust System - Inspect..............1240
Turbocharger - Inspect..............1242
Compression - Test..............1248
Engine Valve Lash - Inspect_Adjust..............1250
Valve Depth - Inspect..............1254
Valve Guide - Inspect..............1257
Engine Oil Pressure - Test..............1259
Engine Oil Pump - Inspect..............1263
Excessive Bearing Wear - Inspect..............1267
Excessive Engine Oil Consumption - Inspect..............1268
Increased Engine Oil Temperature - Inspect..............1269
Cooling System - Check..............1270
Cooling System - Inspect..............1272
Cooling System - Test..............1274
Engine Oil Cooler - Inspect..............1282
Water Temperature Regulator - Test..............1284
Water Pump - Inspect..............1286
Piston Ring Groove - Inspect..............1287
Connecting Rod - Inspect..............1290
Cylinder Block - Inspect..............1294
Cylinder Head - Inspect..............1295
Cylinder Liner Projection - Inspect..............1299
Piston Height - Inspect..............1302
Flywheel - Inspect..............1305
Flywheel Housing - Inspect..............1308
Gear Group - Inspect..............1312
Vibration Damper - Check..............1314
Air Inlet Heater - Test..............1316
Alternator - Test..............1320
Battery - Test..............1322
Belt Tension Chart..............1323
Charging System - Test..............1324
Electric Starting System - Test..............1325
RENR2428 - Specifications (3056E Industrial Engine)..............1329
Engine Design..............1331
Fuel Injection Lines..............1333
Fuel Injection Pump..............1334
Fuel Injection Nozzles..............1335
Fuel Lines..............1337
Fuel Filter Base..............1339
Fuel Priming Pump..............1341
Lifter Group..............1343
Rocker Shaft..............1344
Valve Mechanism Cover..............1346
Cylinder Head Valves..............1348
Cylinder Head..............1352
Turbocharger..............1354
Inlet Manifold..............1356
Exhaust Manifold..............1358
Camshaft..............1360
Camshaft Bearings..............1363
Engine Oil Filter Base..............1364
Engine Oil Filter Bypass Valve..............1365
Engine Oil Cooler..............1366
Engine Oil Pump..............1368
Engine Oil Pressure..............1371
Engine Oil Bypass Valve..............1372
Engine Oil Pan..............1374
Crankcase Breather..............1377
Water Temperature Regulator Housing..............1379
Water Temperature Regulator..............1380
Water Pump..............1381
Cylinder Block..............1382
Cylinder Liner..............1385
Crankshaft..............1387
Crankshaft Seals..............1391
Vibration Damper and Pulley..............1393
Connecting Rod Bearing Journal..............1395
Main Bearing Journal..............1396
Connecting Rod..............1397
Piston and Rings..............1401
Piston Cooling Jet..............1403
Front Housing and Covers..............1405
Gear Group (Front)..............1407
Flywheel..............1409
Flywheel Housing..............1411
Belt Tension Chart..............1412
Engine Lifting Bracket..............1413
Alternator and Regulator..............1414
Electric Starting Motor..............1418
Coolant Temperature Sensor..............1421
Engine Oil Temperature Sensor..............1423
Boost Pressure Sensor..............1425
Inlet Manifold Temperature Sensor..............1427
Speed_Timing Sensor..............1429
Electronic Control Module..............1431
Air Inlet Heater..............1432
Caterpillar 3056E Engines Repair Service Manual
