Caterpillar C3.6 and C2.8 Engines Repair Service Manual
Complete service repair manual for Caterpillar C3.6 and C2.8 Diesel Engines, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Caterpillar C3.6 and C2.8 Diesel 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.
M0077899 - Systems Operation (C3.6 Engines for Caterpillar Built Machines).pdf
M0077899 - Testing and Adjusting (C3.6 Engines for Caterpillar Built Machines).pdf
M0077903 - Specifications (C3.6 Engines for Caterpillar Built Machines).pdf
M0078100 - Disassembly and Assembly (C3.6 Engines For Caterpillar Built Machines).pdf
M0107642 - Specifications (C3.6 Industrial Engine).pdf
M0107832 - Systems Operation (C3.6 and C2.8 Industrial Engines).pdf
M0107832 - Testing and Adjusting (C3.6 and C2.8 Industrial Engines).pdf
M0107940 - Troubleshooting (C3.6 Engine).pdf
M0108719 - Disassembly and Assembly (C3.6 and C2.8 Industrial Engines).pdf
UENR7549 - Schematic (C3.6 Industrial Engine Electrical System).pdf
PRODUCT DETAILS:
Total Pages: 2,510 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
M0077899 - Systems Operation (C3.6 Engines for Caterpillar Built Machines).......1
Introduction.......2
Basic Engine.......6
Air Inlet and Exhaust System.......13
Clean Emissions Module - Diesel Oxidation Catalyst (DOC); Diesel Particulate Filter (DPF) and Selective Catalytic Reduction (SCR) System.......22
Clean Emissions Module - Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF).......25
DEF Dosing Control System.......27
Cooling System.......51
Lubrication System.......53
Electrical System.......55
Cleanliness of Fuel System Components.......57
Fuel Injection - Engines with a Single Fuel Filter and Electric Fuel Priming Pump.......59
Fuel Injection - Engines with a Single Fuel Filter and Manual Fuel Priming Pump.......70
Fuel Injection - Engines with Two Fuel Filters and Electric Fuel Priming Pump.......81
Electronic Control System.......93
Glossary of Electronic Control Terms.......103
M0077899 - Testing and Adjusting (C3.6 Engines for Caterpillar Built Machines).......111
Fuel System - Inspect.......113
Air in Fuel - Test.......114
Finding Top Center Position for No. 1 Piston.......117
Fuel Injection Timing - Check.......118
Fuel Quality - Test.......120
Fuel System - Prime - Electric Fuel Priming Pump.......122
Fuel System - Prime - Mechanical Fuel Priming Pump.......124
Rear Gear Group - Time.......126
Air Inlet and Exhaust System - Inspect.......128
Turbocharger - Inspect.......130
Exhaust Cooler (NRS) - Test.......133
Compression - Test.......136
Engine Valve Lash - Inspect.......138
Valve Depth - Inspect.......141
Valve Guide - Inspect.......144
Diesel Exhaust Fluid Quality - Test.......146
Aftertreatment SCR System Dosing - Test.......151
Diesel Exhaust Fluid Tank - Flush.......154
Engine Oil Pressure - Test.......159
Excessive Bearing Wear - Inspect.......161
Excessive Engine Oil Consumption - Inspect.......162
Increased Engine Oil Temperature - Inspect.......163
Cooling System - Check.......164
Cooling System - Inspect.......166
Cooling System - Test.......167
Engine Oil Cooler - Inspect.......171
Water Temperature Regulator - Test.......173
Water Pump - Inspect.......174
Position the Valve Mechanism Before Maintenance Procedures.......175
Piston Ring Groove - Inspect.......177
Connecting Rod - Inspect.......180
Cylinder Block - Inspect.......181
Cylinder Head - Inspect.......182
Piston Height - Inspect.......184
Flywheel - Inspect.......187
Gear Group - Inspect.......190
Crankshaft Pulley - Check.......195
Alternator - Test.......196
Battery - Test.......198
Charging System - Test.......199
V-Belt - Test.......200
Electric Starting System - Test.......202
M0077903 - Specifications (C3.6 Engines for Caterpillar Built Machines).......206
Engine Design.......208
Fuel Injection Lines.......211
Fuel Injection Pump.......213
Fuel Injection Nozzles.......215
Fuel Filter Base - Fuel Filter Base with Electric Fuel Priming Pump.......217
Fuel Manifold (Rail).......220
Lifter Group.......222
Rocker Shaft.......225
Valve Mechanism Cover.......227
Cylinder Head Valves.......228
Cylinder Head.......231
Turbocharger.......236
Exhaust Gas Valve (NRS) - Throttle Valve.......241
Exhaust Gas Valve (NRS).......246
Exhaust Cooler (NRS).......248
Exhaust Manifold.......250
Camshaft.......252
Engine Oil Relief Valve.......254
Engine Oil Cooler.......255
Engine Oil Pressure.......256
Engine Oil Pan - Composite Engine Oil Pan.......257
Crankcase Breather.......260
Water Temperature Regulator and Housing.......264
Water Pump.......266
Cylinder Block.......268
Crankshaft.......270
Connecting Rod Bearing Journal.......272
Main Bearing Journal.......274
Connecting Rod.......275
Piston and Rings.......278
Piston Cooling Jet.......280
Housing (Front).......283
Gear Group (Rear).......285
Flywheel.......287
Flywheel Housing.......290
Crankshaft Pulley.......294
Belt Tensioner.......295
Refrigerant Compressor.......296
Fan Drive.......298
Engine Lifting Bracket.......301
Alternator.......303
Starter Motor.......306
Coolant Temperature Sensor.......310
Engine Oil Pressure Switch.......311
Inlet Manifold Temperature and Pressure Sensor.......312
Temperature Sensor (DPF Inlet).......313
Temperature Sensor (DOC Inlet).......314
Pressure Sensor (NOx Reduction System) - Differential Pressure Sensor.......315
Temperature Sensor (NOx Reduction System).......318
Pressure Sensor (Exhaust Differential).......320
Speed_Timing Sensor.......321
Electronic Control Module.......323
Glow Plugs.......324
M0078100 - Disassembly and Assembly (C3.6 Engines For Caterpillar Built Machines).......327
Exhaust Clamp - Remove and Install - Exhaust Ball Clamps and Exhaust V-Clamps (Slip Clamps).......332
Fuel Priming Pump - Remove and Install - Mechanical Fuel Priming Pump and Primary Filter (Water Separator).......345
Fuel Priming Pump - Remove and Install - Electric Fuel Lift Pump (EFLP) and Primary Filter (Water Separator).......349
Flow Control Valve - Remove and Install.......354
Fuel Filter Base - Remove and Install - Single Secondary Fuel Filter.......359
Fuel Lines - Remove and Install - Low-Pressure Fuel Line.......365
Fuel Pressure Regulator - Remove and Install.......375
Fuel Manifold (Rail) - Remove and Install.......379
Relief Valve (Fuel) - Remove and Install.......388
Fuel Injection Lines - Remove.......393
Fuel Injection Lines - Install.......397
Exhaust Cooler (NRS) - Remove and Install.......402
Throttle Valve (Intake Air) - Remove and Install.......413
Fuel Injection Pump - Remove.......418
Fuel Injection Pump - Install.......423
Fuel Injection Pump Gear - Remove.......428
Fuel Injection Pump Gear - Install.......430
Electronic Unit Injector - Remove.......432
Electronic Unit Injector - Install.......437
Turbocharger - Remove.......444
Turbocharger - Install.......451
Turbocharger Wastegate - Remove and Install.......460
Exhaust Gas Recirculation Valve - Remove and Install.......469
Clean Emissions Module - Remove and Install - Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF).......474
Clean Emissions Module - Remove and Install - Selective Catalyst Reduction (SCR).......479
Diesel Exhaust Fluid Lines - Remove and Install.......484
Diesel Exhaust Fluid Pump - Remove and Install.......491
DEF Injector and Mounting - Remove and Install - Engines With a Balancer.......498
DEF Injector and Mounting - Remove and Install.......509
Diesel Exhaust Fluid Tank - Remove and Install.......523
Manifold (DEF Heater) - Remove and Install.......527
Exhaust Manifold - Remove and Install.......535
Support and Mounting (CEM) - Remove and Install - Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF).......539
Support and Mounting (CEM) - Remove and Install - Selective Catalyst Reduction (SCR).......542
Inlet and Exhaust Valve Springs - Remove and Install - Cylinder Head Installed On The Engine.......547
Inlet and Exhaust Valves - Remove and Install - Cylinder Head Removed From The Engine.......555
Engine Oil Filter Base - Remove and Install.......562
Engine Oil Cooler - Remove.......569
Engine Oil Cooler - Install.......571
Engine Oil Relief Valve - Remove and Install.......575
Engine Oil Pump - Remove - Fluids Module.......579
Engine Oil Pump - Install - Fluids Module.......582
Water Pump - Remove.......587
Water Pump - Install.......589
Water Temperature Regulator - Remove and Install.......592
Engine Lifting Bracket - Remove.......595
Engine Lifting Bracket - Install.......597
Gear Group (Rear) - Remove and Install.......599
Flywheel - Remove.......611
Flywheel - Install.......615
Crankshaft Rear Seal - Remove and Install.......622
Flywheel Housing - Remove and Install - Flywheel Housing With Power Take Off.......626
Flywheel Housing - Remove and Install - Flywheel Housing Without Power Take Off.......637
Crankshaft Pulley - Remove and Install.......647
Crankshaft Front Seal - Remove and Install.......653
Accessory Drive - Remove and Install - Accessory Drive SAE A.......658
Accessory Drive - Remove and Install - Accessory Drive SAE B.......666
Crankcase Breather - Remove and Install.......674
Valve Mechanism Cover - Remove and Install.......679
Rocker Shaft and Pushrod - Remove.......689
Rocker Shaft - Disassemble.......693
Rocker Shaft - Assemble.......695
Rocker Shaft and Pushrod - Install.......698
Cylinder Head - Remove.......702
Cylinder Head - Install - C3.6 Engines Only.......709
Lifter Group - Remove and Install.......718
Camshaft - Remove and Install.......721
Engine Oil Pan - Remove and Install - Composite Engine Oil Pan.......726
Piston Cooling Jets - Remove and Install.......733
Pistons and Connecting Rods - Remove.......736
Pistons and Connecting Rods - Disassemble.......740
Pistons and Connecting Rods - Assemble.......744
Pistons and Connecting Rods - Install.......750
Connecting Rod Bearings - Remove - Connecting Rods in Position.......754
Connecting Rod Bearings - Install - Connecting Rods in Position.......757
Crankshaft Main Bearings - Remove and Install - Crankshaft in Position.......761
Crankshaft - Remove.......771
Crankshaft - Install.......775
Bearing Clearance - Check.......782
Nitrogen Oxide Sensor - Remove and Install - On Engine Nitrogen Oxide Sensor.......785
Nitrogen Oxide Sensor - Remove and Install - Nitrogen Oxide Sensor in Original Equipment Manufacture (OEM) Exhaust Tube Assembly.......790
Camshaft Position Sensor - Remove and Install.......795
Crankshaft Position Sensor - Remove and Install.......798
Coolant Temperature Sensor - Remove and Install.......801
Engine Oil Pressure Switch - Remove and Install.......804
Fuel Temperature Sensor - Remove and Install.......807
Temperature Sensor (Exhaust) - Remove and Install - Temperature Sensor for Diesel Oxidation Catalyst (DOC); Diesel Particulate Filter (DPF); and (Selective Catalyst Reduction (SCR).......811
Pressure Sensor (DPF) - Remove and Install - Differential Pressure Sensor and Tube Assemblies.......815
Temperature Sensor (Cooled Exhaust Gas) - Remove and Install - Pre-NoX Reduction System (NRS) Cooler.......824
Pressure Sensor (NRS Absolute) - Remove and Install - Differential Pressure and Absolute Pressure Sensor.......827
Inlet Manifold Temperature and Pressure Sensor - Remove and Install.......831
Glow Plugs - Remove and Install.......834
Alternator Belt - Remove and Install.......839
Idler Pulley - Remove and Install - Grooved Idler Pulley.......845
Idler Pulley - Remove and Install - Flat Idler Pulley.......848
Belt Tensioner - Remove and Install.......851
Fan - Remove and Install.......853
Fan - Remove and Install - Fan with Fan Extension.......856
Fan Drive - Remove and Install.......859
Electronic Control Module - Remove and Install - Mounted Off Engine.......861
Alternator - Remove - 150 A Right-Hand Side Alternator.......865
Alternator - Remove - 150 A Left-Hand Side Alternator.......869
Alternator - Remove - 100 A Right-Hand Side Alternator.......874
Alternator - Install - 150 A Right-Hand Side Alternator.......879
Alternator - Install - 150 A Left-Hand Side Alternator.......883
Alternator - Install - 100 A Right-Hand Side Alternator.......887
Electric Starting Motor - Remove and Install.......891
M0107642 - Specifications (C3.6 Industrial Engine).......894
Engine Design.......897
Fuel Injection Lines.......899
Fuel Injection Pump.......901
Fuel Injection Nozzles.......903
Fuel Filter Base - Fuel Filter Base with Electric Fuel Priming Pump.......905
Fuel Filter Base - Secondary Fuel Filter Base.......907
Fuel Filter Base - Fuel Filter Base with a Manual Fuel Priming Pump.......909
Fuel Manifold (Rail).......911
Lifter Group.......913
Rocker Shaft.......914
Valve Mechanism Cover.......916
Cylinder Head Valves.......917
Cylinder Head.......920
Turbocharger.......925
Injector (Diesel Exhaust Fluid).......928
Manifold (Diesel Exhaust Fluid).......929
Diesel Exhaust Fluid Tank.......931
Diesel Exhaust Fluid Pump.......932
Solenoid Valve (DEF Heater Coolant).......933
Exhaust Gas Valve (NRS) - Throttle Valve.......934
Exhaust Gas Valve (NRS).......937
Exhaust Cooler (NRS).......939
Exhaust Manifold.......941
Camshaft.......943
Engine Oil Filter Base.......945
Engine Oil Relief Valve.......947
Engine Oil Cooler.......948
Engine Oil Pressure.......949
Engine Oil Pan - Composite Engine Oil Pan.......950
Engine Oil Pan - Cast Iron Engine Oil Pan with Balancer.......951
Crankcase Breather.......953
Water Temperature Regulator and Housing.......955
Water Pump.......957
Cylinder Block.......959
Crankshaft.......961
Connecting Rod Bearing Journal.......963
Main Bearing Journal.......964
Connecting Rod.......965
Piston and Rings.......968
Piston Cooling Jet.......970
Accessory Drive.......973
Housing (Front).......975
Gear Group (Rear).......977
Gear Group (Rear) - Engines with a Balancer.......979
Flywheel.......981
Flywheel Housing.......983
Flywheel Housing - Engines with a Balancer.......985
Crankshaft Pulley.......987
Belt Tensioner.......988
Refrigerant Compressor.......989
Fan Drive.......990
Engine Lifting Bracket.......991
Engine Lifting Bracket - Top Mounted Aftertreatment on Engines with a Balancer.......992
Alternator.......994
Starter Motor.......1000
Nitrogen Oxide Sensor.......1002
Coolant Temperature Sensor.......1003
Engine Oil Pressure Switch.......1004
Inlet Manifold Temperature and Pressure Sensor.......1005
Temperature Sensor (DPF Inlet).......1006
Temperature Sensor (DOC Inlet).......1007
Temperature Sensor (Exhaust) - Selective Catalytic Reduction (SCR) Temperature Sensor.......1008
Pressure Sensor (NOx Reduction System) - Differential Pressure Sensor.......1009
Temperature Sensor (NOx Reduction System).......1010
Pressure Sensor (Exhaust Differential).......1012
Speed_Timing Sensor.......1013
Electronic Control Module.......1015
Glow Plugs.......1016
M0107832 - Systems Operation (C3.6 and C2.8 Industrial Engines).......1018
Introduction.......1019
Basic Engine.......1027
Air Inlet and Exhaust System.......1034
Clean Emissions Module - Diesel Oxidation Catalyst (DOC); Diesel Particulate Filter (DPF) and Selective Catalytic Reduction (SCR) System.......1043
Clean Emissions Module - Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF).......1046
Clean Emissions Module - Diesel Oxidation Catalyst (DOC); Diesel Particulate Filter (DPF) and Selective Catalytic Reduction (SCR) System - Top Mounted Aftertreatment - Engines with a Balancer.......1048
DEF Dosing Control System.......1051
Cooling System.......1075
Lubrication System.......1077
Electrical System.......1079
Cleanliness of Fuel System Components.......1081
Fuel Injection - Engines with a Single Fuel Filter and Electric Fuel Priming Pump.......1083
Fuel Injection - Engines with a Single Fuel Filter and Manual Fuel Priming Pump.......1094
Fuel Injection - Engines with Two Fuel Filters and Electric Fuel Priming Pump.......1105
Electronic Control System.......1117
Glossary of Electronic Control Terms.......1130
M0107832 - Testing and Adjusting (C3.6 and C2.8 Industrial Engines).......1138
Fuel System - Inspect.......1140
Air in Fuel - Test.......1141
Finding Top Center Position for No. 1 Piston.......1144
Fuel Injection Timing - Check.......1145
Fuel Quality - Test.......1147
Fuel System - Prime - Mechanical Fuel Priming Pump.......1149
Rear Gear Group - Time.......1151
Air Inlet and Exhaust System - Inspect.......1153
Turbocharger - Inspect.......1155
Exhaust Cooler (NRS) - Test.......1160
Compression - Test.......1163
Engine Valve Lash - Inspect.......1165
Valve Depth - Inspect.......1168
Valve Guide - Inspect.......1171
Diesel Exhaust Fluid Quality - Test.......1173
Aftertreatment SCR System Dosing - Test.......1178
Diesel Exhaust Fluid Tank - Flush.......1181
Engine Oil Pressure - Test.......1186
Excessive Bearing Wear - Inspect.......1188
Excessive Engine Oil Consumption - Inspect.......1189
Increased Engine Oil Temperature - Inspect.......1190
Cooling System - Check.......1191
Cooling System - Inspect.......1193
Cooling System - Test.......1194
Engine Oil Cooler - Inspect.......1198
Water Temperature Regulator - Test.......1200
Water Pump - Inspect.......1201
Position the Valve Mechanism Before Maintenance Procedures.......1202
Piston Ring Groove - Inspect.......1204
Connecting Rod - Inspect.......1207
Cylinder Block - Inspect.......1208
Cylinder Head - Inspect.......1209
Piston Height - Inspect.......1211
Flywheel - Inspect.......1214
Gear Group - Inspect.......1217
Gear Group - Inspect - Engines with a Balancer.......1222
Crankshaft Pulley - Check.......1227
Alternator - Test.......1228
Battery - Test.......1230
Charging System - Test.......1231
V-Belt - Test.......1232
Electric Starting System - Test.......1234
M0107940 - Troubleshooting (C3.6 Engine).......1238
General Information.......1243
Welding Precaution.......1246
Electronic Service Tools.......1248
System Overview.......1254
Component Location.......1257
Diesel Particulate Filter Regeneration.......1266
Engine Monitoring System.......1267
Diagnostic Capabilities.......1269
Configuration Parameters.......1271
Diagnostic Trouble Codes.......1274
Acceleration Is Poor or Throttle Response Is Poor.......1293
Alternator Problem - Charging Problem and_or Noisy Operation.......1300
Battery Problem.......1303
Clean Emissions Module Has High Oxygen Level.......1305
Coolant Contains Oil.......1307
Coolant Level Is Low.......1310
Coolant Temperature Is High.......1312
Coolant Temperature Is Low.......1318
Cylinder Is Noisy.......1321
DEF Does Not Purge.......1325
DEF Module Does Not Respond.......1327
DEF Pressure Is High.......1332
DEF Pressure Is Low.......1335
DEF Tank Level Is Low.......1344
DEF Tank Temperature Is High.......1347
DEF Temperature Is Low.......1351
Diesel Oxidation Catalyst Has Incorrect Inlet Temperature.......1355
Diesel Oxidation Catalyst Has Low Conversion Efficiency.......1358
Diesel Particulate Filter Collects Excessive Soot.......1364
Diesel Particulate Filter Has Low Inlet Pressure.......1368
Diesel Particulate Filter Temperature Is Low.......1370
Ether Actuation Occurrence Is Excessive.......1372
Engine Cranks but Does Not Start.......1377
Engine Does Not Crank.......1386
Engine Has Early Wear.......1389
Engine Has Mechanical Noise (Knock).......1392
Engine Misfires; Runs Rough or Is Unstable.......1397
Engine Overcrank Occurrence.......1403
Engine Overspeeds.......1407
Engine Shutdown Occurs Intermittently.......1411
Engine Shutdown While Idling.......1414
Engine Stalls at Low RPM.......1416
Engine Top Speed Is Not Obtained.......1420
Engine Vibration Is Excessive.......1427
Exhaust Has Excessive Black Smoke.......1430
Exhaust Has Excessive White Smoke.......1435
Exhaust System Contains Coolant.......1441
Exhaust System Contains Oil.......1444
Exhaust Temperature Is High.......1447
Fuel Consumption Is Excessive.......1450
Fuel Contains Water.......1455
Fuel Rail Pressure Problem.......1458
Fuel Temperature Is High.......1464
Inlet Air Is Restricted.......1468
Intake Manifold Air Pressure Is High.......1470
Intake Manifold Air Pressure Is Low.......1473
Intake Manifold Air Temperature Is High.......1477
NOx Conversion Is Low.......1481
NRS Exhaust Gas Temperature Is High.......1490
NRS Mass Flow Rate Problem.......1493
Oil Consumption Is Excessive.......1499
Oil Contains Coolant.......1503
Oil Contains Fuel.......1506
Oil Level Is Low.......1510
Oil Pressure Is Low.......1512
Power Is Intermittently Low or Power Cutout Is Intermittent.......1517
SCR Catalyst Has Incorrect Inlet Temperature.......1521
SCR Warning System Problem.......1525
Transmission Oil Temperature Is High.......1536
Valve Lash Is Excessive.......1538
CAN Data Link - Test.......1540
Coolant Diverter - Test.......1545
Cooling Fan Control - Test.......1551
Cooling Fan Speed - Test.......1556
Data Link Configuration Status - Test.......1559
DEF Injector - Test.......1562
DEF Line Heater - Test.......1568
DEF Pump Motor - Test.......1575
DEF Pump Pressure Sensor - Test.......1582
DEF Return Valve - Test.......1589
DEF Tank Sensor - Test.......1597
Electrical Power Supply - Test.......1602
Engine Speed - Test.......1606
Ether Starting Aid - Test.......1610
Fuel Control - Test.......1614
Fuel Transfer Pump - Test.......1620
Glow Plug Starting Aid - Test.......1625
Idle Validation - Test.......1632
Indicator Lamp - Test.......1640
Injector Data Incorrect - Test.......1644
Injector Solenoid - Test.......1648
Mode Selection - Test.......1655
Motorized Valve - Test.......1659
NOx Sensor Supply - Test.......1668
Relay - Test - Start Relay.......1671
Relay - Test - SCR Main Relay.......1675
Sensor Calibration Required - Test.......1680
Sensor (Data Link Type) - Test.......1684
Sensor Signal (Analog; Active) - Test.......1689
Sensor Signal (Analog; Passive) - Test.......1698
Sensor Supply - Test.......1707
Speed Control (Analog) - Test.......1710
Speed Control (PWM) - Test.......1718
Speed_Timing - Test.......1725
Switch Circuits - Test - Engine Oil Pressure Switch.......1730
Switch Circuits - Test - Air Filter Restriction Switch.......1736
Switch Circuits - Test - Multiposition Throttle Switch.......1740
Valve Position - Test.......1744
Water in Fuel - Test.......1752
Service Tool Features.......1758
Service Tool Error Identifiers.......1802
Customer Passwords.......1811
Factory Passwords.......1812
ECM Will Not Accept Factory Passwords.......1814
Electronic Service Tool Does Not Communicate.......1815
Test ECM Mode.......1818
ECM Software - Install.......1820
ECM - Replace.......1822
DEF Pump - Replace.......1825
Electrical Connectors - Inspect.......1828
Cooling Fan - Calibrate.......1833
Injector Code - Calibrate.......1835
SCR Inducement Emergency Override.......1838
Turbocharger - Clean.......1841
M0108719 - Disassembly and Assembly (C3.6 and C2.8 Industrial Engines).......1850
Exhaust Clamp - Remove and Install - Exhaust Ball Clamps and Exhaust V-Clamps (Slip Clamps).......1855
Fuel Priming Pump - Remove and Install - Mechanical Fuel Priming Pump and Primary Filter (Water Separator).......1868
Fuel Priming Pump - Remove and Install - Electric Fuel Lift Pump (EFLP) and Primary Filter (Water Separator).......1872
Flow Control Valve - Remove and Install.......1877
Fuel Filter Base - Remove and Install - Single Secondary Fuel Filter.......1882
Fuel Lines - Remove and Install - Low-Pressure Fuel Line.......1888
Fuel Pressure Regulator - Remove and Install.......1898
Fuel Manifold (Rail) - Remove and Install.......1902
Relief Valve (Fuel) - Remove and Install.......1911
Fuel Injection Lines - Remove.......1916
Fuel Injection Lines - Install.......1920
Exhaust Cooler (NRS) - Remove and Install.......1925
Throttle Valve (Intake Air) - Remove and Install.......1936
Fuel Injection Pump - Remove.......1941
Fuel Injection Pump - Install.......1946
Fuel Injection Pump Gear - Remove.......1951
Fuel Injection Pump Gear - Install.......1953
Electronic Unit Injector - Remove.......1955
Electronic Unit Injector - Install.......1960
Turbocharger - Remove.......1967
Turbocharger - Install.......1974
Turbocharger Wastegate - Remove and Install.......1983
Exhaust Gas Recirculation Valve - Remove and Install.......1992
Clean Emissions Module - Remove and Install - Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF); Engines With a Balancer.......1997
Clean Emissions Module - Remove and Install - Selective Catalyst Reduction (SCR); Engines With a Balancer.......2002
Clean Emissions Module - Remove and Install - Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF).......2009
Clean Emissions Module - Remove and Install - Selective Catalyst Reduction (SCR).......2014
Diesel Exhaust Fluid Lines - Remove and Install.......2019
Diesel Exhaust Fluid Pump - Remove and Install.......2026
DEF Injector and Mounting - Remove and Install - Engines With a Balancer.......2033
DEF Injector and Mounting - Remove and Install.......2044
Diesel Exhaust Fluid Tank - Remove and Install.......2058
Manifold (DEF Heater) - Remove and Install.......2062
Exhaust Manifold - Remove and Install.......2070
Support and Mounting (CEM) - Remove and Install - Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF).......2074
Support and Mounting (CEM) - Remove and Install - Selective Catalyst Reduction (SCR).......2077
Support and Mounting (CEM) - Remove and Install - Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF); Engines With a Balancer.......2082
Support and Mounting (CEM) - Remove and Install - Selective Catalyst Reduction (SCR) Engines With a Balancer.......2088
Inlet and Exhaust Valve Springs - Remove and Install - Cylinder Head Installed On The Engine.......2093
Inlet and Exhaust Valves - Remove and Install - Cylinder Head Removed From The Engine.......2101
Engine Oil Filter Base - Remove and Install.......2108
Engine Oil Cooler - Remove.......2115
Engine Oil Cooler - Install.......2117
Engine Oil Relief Valve - Remove and Install.......2121
Engine Oil Pump - Remove - Fluids Module.......2125
Engine Oil Pump - Install - Fluids Module.......2128
Water Pump - Remove.......2133
Water Pump - Install.......2135
Water Temperature Regulator - Remove and Install.......2138
Engine Lifting Bracket - Remove.......2141
Engine Lifting Bracket - Remove - Engines With a Balancer.......2143
Engine Lifting Bracket - Install.......2145
Engine Lifting Bracket - Install - Engines With a Balancer.......2147
Gear Group (Rear) - Remove and Install.......2149
Flywheel - Remove.......2161
Flywheel - Install.......2165
Crankshaft Rear Seal - Remove and Install.......2172
Flywheel Housing - Remove and Install - Flywheel Housing With Power Take Off.......2176
Flywheel Housing - Remove and Install - Flywheel Housing Without Power Take Off.......2187
Flywheel Housing - Remove and Install - Flywheel Housing With Power Take Off; Engines With a Balancer.......2207
Crankshaft Pulley - Remove and Install.......2218
Crankshaft Front Seal - Remove and Install.......2224
Accessory Drive - Remove and Install - Accessory Drive SAE A.......2229
Accessory Drive - Remove and Install - Accessory Drive SAE B.......2237
Crankcase Breather - Remove and Install.......2245
Valve Mechanism Cover - Remove and Install.......2250
Rocker Shaft and Pushrod - Remove.......2260
Rocker Shaft - Disassemble.......2264
Rocker Shaft - Assemble.......2266
Rocker Shaft and Pushrod - Install.......2269
Cylinder Head - Remove.......2273
Cylinder Head - Remove - Engines With a Balancer and Engine Mounted Aftertreatment.......2280
Cylinder Head - Install - Engines With a Balancer and Engine Mounted Aftertreatment.......2289
Cylinder Head - Install - C3.6 Engines Only.......2298
Lifter Group - Remove and Install.......2307
Camshaft - Remove and Install.......2310
Engine Oil Pan - Remove and Install - Composite Engine Oil Pan.......2315
Engine Oil Pan - Remove and Install - Cast Iron Oil Pan With Balancer.......2322
Piston Cooling Jets - Remove and Install.......2333
Pistons and Connecting Rods - Remove.......2336
Pistons and Connecting Rods - Disassemble.......2340
Pistons and Connecting Rods - Assemble.......2344
Pistons and Connecting Rods - Install.......2350
Connecting Rod Bearings - Remove - Connecting Rods in Position.......2354
Connecting Rod Bearings - Install - Connecting Rods in Position.......2357
Crankshaft Main Bearings - Remove and Install - Crankshaft in Position.......2361
Crankshaft - Remove.......2371
Crankshaft - Install.......2375
Bearing Clearance - Check.......2382
Nitrogen Oxide Sensor - Remove and Install - On Engine Nitrogen Oxide Sensor.......2385
Nitrogen Oxide Sensor - Remove and Install - Nitrogen Oxide Sensor in Original Equipment Manufacture (OEM) Exhaust Tube Assembly.......2390
Camshaft Position Sensor - Remove and Install.......2395
Crankshaft Position Sensor - Remove and Install.......2398
Coolant Temperature Sensor - Remove and Install.......2401
Engine Oil Pressure Switch - Remove and Install.......2404
Fuel Temperature Sensor - Remove and Install.......2407
Temperature Sensor (Exhaust) - Remove and Install - Temperature Sensor for Diesel Oxidation Catalyst (DOC); Diesel Particulate Filter (DPF); and (Selective Catalyst Reduction (SCR).......2411
Temperature Sensor (Exhaust) - Remove and Install - Temperature Sensor for Diesel Oxidation Catalyst (DOC); Diesel Particulate Filter (DPF); and (Selective Catalyst Reduction (SCR); Engines With a Balancer.......2415
Pressure Sensor (DPF) - Remove and Install - Differential Pressure Sensor and Tube Assemblies.......2419
Pressure Sensor (DPF) - Remove and Install - Differential Pressure Sensor and Tube Assemblies; Engines With a Balancer.......2428
Temperature Sensor (Cooled Exhaust Gas) - Remove and Install - Pre-NoX Reduction System (NRS) Cooler.......2441
Pressure Sensor (NRS Absolute) - Remove and Install - Differential Pressure and Absolute Pressure Sensor.......2444
Inlet Manifold Temperature and Pressure Sensor - Remove and Install.......2448
Glow Plugs - Remove and Install.......2451
Alternator Belt - Remove and Install.......2456
Idler Pulley - Remove and Install - Grooved Idler Pulley.......2462
Idler Pulley - Remove and Install - Flat Idler Pulley.......2465
Belt Tensioner - Remove and Install.......2468
Fan - Remove and Install.......2470
Fan - Remove and Install - Fan with Fan Extension.......2473
Fan Drive - Remove and Install.......2476
Electronic Control Module - Remove and Install - Mounted Off Engine.......2478
Alternator - Remove - 150 A Right-Hand Side Alternator.......2482
Alternator - Remove - 150 A Left-Hand Side Alternator.......2486
Alternator - Remove - 100 A Right-Hand Side Alternator.......2491
Alternator - Install - 150 A Right-Hand Side Alternator.......2496
Alternator - Install - 150 A Left-Hand Side Alternator.......2500
Alternator - Install - 100 A Right-Hand Side Alternator.......2504
Electric Starting Motor - Remove and Install.......2508
UENR7549 - Schematic (C3.6 Industrial Engine Electrical System).......2511
Caterpillar C3.6 and C2.8 Engines Repair Service Manual
