Caterpillar 3606 and 3608 Engines Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Caterpillar 3606 and 3608 Engines, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Caterpillar 3606 and 3608 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.
RENR2458 - Schematic (3600 Diesel Marine Monitoring System Electrical System)
RENR2459 - Schematic (3606;3608;3612;3616 Diesel Marine Monitoring System II Generator Monitoring System)
RENR2458 - Schematic (3600 Diesel Marine Monitoring System Electrical System).pdf
RENR2459 - Schematic (3606;3608;3612;3616 Diesel Marine Monitoring System II Generator Monitoring System).pdf
RENR2491 - Systems Operation (3606; 3608; 3612 and 3616 Engines and C280-12; C280-16; C280-6 and C280-8 Marine Engines Generator Monitoring System).pdf
RENR2491 - Testing and Adjusting (3606; 3608; 3612 and 3616 Engines and C280-12; C280-16; C280-6 and C280-8 Marine Engines Generator Monitoring System).pdf
RENR2491 - Troubleshooting (3606; 3608; 3612 and 3616 Engines and C280-12; C280-16; C280-6 and C280-8 Marine Engines Generator Monitoring System).pdf
RENR2493 - Systems Operation (3606; 3608; 3612 and 3616 Engines and C280-12; C280-16; C280-6 and C280-8 Marine Engines Control Panel).pdf
RENR2493 - Testing and Adjusting (3606; 3608; 3612 and 3616 Engines and C280-12; C280-16; C280-6 and C280-8 Marine Engines Control Panel).pdf
RENR2495 - Service Manual (3606; 3608; 3612; 3616 and 3618 Engines and C280-12; C280-16; C280-6 and C280-8 Marine Engines Panel View Monitor).pdf
RENR5851 - Service Manual (3606; 3608; 3612; 3616 and 3618 Engines Tachometer).pdf
RENR5889 - Systems Operation (3606; 3608; 3612 and 3616 Engines and C280-12; C280-16; C280-6 and C280-8 Marine Engines Standby Pump Panel).pdf
RENR5889 - Testing and Adjusting (3606; 3608; 3612 and 3616 Engines and C280-12; C280-16; C280-6 and C280-8 Marine Engines Standby Pump Panel).pdf
SENR3598 - Specifications (3606 and 3608 Engines).pdf
SENR3599 - Systems Operation (3606 and 3608 Engines).pdf
SENR3599 - Testing and Adjusting (3606 and 3608 Engines).pdf
SENR3600 - Disassembly and Assembly (3606 and 3608 Engines).pdf
PRODUCT DETAILS:
Total Pages: 1,623 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
RENR2458 - Schematic (3600 Diesel Marine Monitoring System Electrical System)....1
Collage....1
Main....16
RENR2459 - Schematic (3606;3608;3612;3616 Diesel Marine Monitoring System II Generator Monitoring System)....18
Collage....18
Main....44
RENR2491 - Systems Operation (3606; 3608; 3612 and 3616 Engines and C280-12; C280-16; C280-6 and C280-8 Marine Engines Generator Monitoring System)....46
General Information....47
Configuration....53
Engine Control Panel....66
Feature Configuration....77
Remote Operation....80
Customer Options....83
Display....87
Alarms and Shutdowns....105
Programmable Logic Controller....120
Contactors....124
Thermocouples....125
Resistance Temperature Detectors....126
Transducers....128
Engine Speed Switch....129
Engine Speed Sensor....133
Related Components....135
RSView Software for Optional Computer....143
RENR2491 - Testing and Adjusting (3606; 3608; 3612 and 3616 Engines and C280-12; C280-16; C280-6 and C280-8 Marine Engines Generator Monitoring System)....161
Overspeed Verification Test....162
System Tests....164
Performance Tests....171
Speed Sensor - Adjust....174
Battery - Replace....176
Input Module and Output Module - Replace....178
Memory Module - Replace....181
Power Supply - Replace....183
Central Processing Unit - Replace....185
Connector Contact Description....187
Signal Listing....189
Reference Parts Information....249
Abbreviations....252
Reference Material....254
Configuration Record....255
RENR2491 - Troubleshooting (3606; 3608; 3612 and 3616 Engines and C280-12; C280-16; C280-6 and C280-8 Marine Engines Generator Monitoring System)....263
General Information....264
Service Tools....265
System Power....267
System Inoperable....272
Using LED Indicators to Troubleshoot Modules....275
Central Processing Unit Fault....291
Central Processing Unit Communications Error....295
Central Processing Unit Major Fault....299
Central Processing Unit Cannot Find Active Nodes....303
Central Processing Unit Fatal Error....306
Low Battery Power....310
Resistance Temperature Detector Module....314
Thermocouple Module....316
Analog Input Module....319
Low Battery Alarm Module....321
Digital Input Card....323
Digital Output Card....325
Engine Speed Switch....327
Contactor....331
Transducer....334
Thermocouple Sensor....340
Resistance Temperature Detector....342
Pressure Sender (Starting Air)....348
PLC Diagnostics....349
RENR2493 - Systems Operation (3606; 3608; 3612 and 3616 Engines and C280-12; C280-16; C280-6 and C280-8 Marine Engines Control Panel)....354
General Information....355
Component Location....359
Normal Operation....373
Alarm Mode....376
Shutdown Mode....379
Customer Options....381
Configuration....384
Programmable Logic Controller....386
Senders....390
Sensors....392
Switches....395
Contactors....407
Detectors....417
Timers....420
Potentiometers....425
Solenoids....427
Indicators....432
Gauges....438
Related Components....445
RENR2493 - Testing and Adjusting (3606; 3608; 3612 and 3616 Engines and C280-12; C280-16; C280-6 and C280-8 Marine Engines Control Panel)....446
General Information....447
Service Tools....448
Overspeed Verification Test....450
System Tests....452
Performance Tests....456
Speed Sensor - Adjust....460
Input Module and Output Module - Replace....461
Battery - Replace....463
Central Processing Unit - Replace....465
Setpoints....470
Abbreviations....475
Reference Material....477
Schematics and Wiring Diagrams....478
RENR2495 - Service Manual (3606; 3608; 3612; 3616 and 3618 Engines and C280-12; C280-16; C280-6 and C280-8 Marine Engines Panel View Monitor)....503
General Information....504
Features....506
Dimensions....509
Mounting....510
Connections....516
Setup....524
Initial Operation....529
Battery - Replace....540
Monitor - Clean....541
Memory Module - Replace....542
Board (Backlight) - Replace....546
Diagnostic Indicator Is On - Troubleshoot....547
Troubleshooting Checks....558
RENR5851 - Service Manual (3606; 3608; 3612; 3616 and 3618 Engines Tachometer)....566
Tachometer....567
Component Description....569
Settings....572
Setpoints....574
Configuration....576
General Information....582
Service Tools....585
Installation....586
System - Troubleshoot....588
Setpoint - Check....590
Speed Sensor - Adjust....592
Tachometer - Replace....593
Configuration Table....594
Configuration Record....596
Wiring Diagrams....597
RENR5889 - Systems Operation (3606; 3608; 3612 and 3616 Engines and C280-12; C280-16; C280-6 and C280-8 Marine Engines Standby Pump Panel)....599
General Information....600
Component Description....601
Electrical Connections....608
Basic Operation....612
RENR5889 - Testing and Adjusting (3606; 3608; 3612 and 3616 Engines and C280-12; C280-16; C280-6 and C280-8 Marine Engines Standby Pump Panel)....614
General Information....615
Service Tools....616
Contactor - Test....617
Contactor - Adjust....620
Wiring....623
Reference Material....626
SENR3598 - Specifications (3606 and 3608 Engines)....627
Fuel Injection Lines - Heavy Fuel Oil....630
Fuel Injection Lines - Mechanical Unit Injection....633
Fuel Injection Lines....636
Shutoff (Energize to Run)....638
Shutoff (Energize to Shutdown)....640
Fuel Shutoff....643
Fuel Filter Housing....644
Fuel Transfer Pump....646
Fuel Injector Mechanism....648
Fuel Injector - Distillate Fuel....650
Fuel Injector - Heavy Fuel Oil....652
Governor Drive....654
Fuel Injection Control Linkage....657
Aftercooler....660
Camshaft - Earlier....661
Camshaft....665
Camshaft Bearing Position....670
Valve Mechanism....672
Cylinder Head....674
Cylinder Head Valves....678
Compression Release Valve....681
Manual Valve Group (Cylinder Pressure)....683
Turbocharger....684
Exhaust Manifold....686
Air Cleaner Adapter....688
Air Inlet Elbow....689
Air Inlet Shutoff....690
Prelube Pump....692
Engine Oil Pump....694
Engine Centrifugal Oil Filter....698
Engine Oil Filter....699
Priority Valve....702
Engine Oil Cooler....704
Engine Oil Temperature Regulator....705
Inlet Valve Lubrication Metering Pump....706
Crankcase Breather....708
Water Temperature Regulator....709
Water Pump....716
Auxiliary Water Pump - Sea Water....725
Cylinder Block....735
Cylinder Liner....740
Piston and Rings - Four Ring Piston....742
Piston and Rings - Three Ring Piston....744
Connecting Rod....748
Connecting Rod and Main Bearing Journals....754
Crankshaft....755
Crankshaft Seals....758
Housing (Front)....760
Gear Group (Front)....762
Housing (Rear)....766
Gear Group (Rear)....768
Manual Barring Group - 501 Reduction....772
Manual Barring Group....774
Flywheel....776
Flexible Coupling....780
Flexible Drive....802
Vibration Damper - Single....804
Engine Lifting Bracket....806
Engine Support....807
Stub Shaft (Front)....812
Electric Starting Motor....816
Air Starting Motor....820
Pressure Regulating Valve....822
Temperature Sensor....827
Probe Adapter....828
Engine Speed Sensor....830
Prelube Pump Motors....832
Pressure Contactor....834
Pressure Transducer....842
Temperature Contactor - Coolant....846
Temperature Contactor....849
Pressure Switch....855
SENR3599 - Systems Operation (3606 and 3608 Engines)....857
Fuel System Operation....859
Fuel Injection Control Linkage....863
Fuel Injector....866
Fuel Injection Cycle....869
Air Inlet and Exhaust System Operation....873
Aftercooler....875
Turbocharger - Napier 297....877
Turbocharger....881
Lubrication System Operation....883
Engine Oil Pump....886
Engine Oil Coolers and Temperature Regulators....889
Engine Oil Filters....891
Centrifugal Oil Filters....893
Internal Lubrication....895
Piston Cooling Jets....898
Cooling System Operation....899
Combined Circuit Cooling System....900
Separate Circuit Cooling System....903
Cylinder Block; Liners and Heads....907
Pistons; Rings and Connecting Rods....909
Crankshaft....910
Camshaft....911
Front Gear Group....912
Rear Gear Group....913
Crankcase Explosion Relief Valves....914
Engine Barring Group....915
Air Starting System Operation....918
Electrical System Operation....919
Grounding Practices....920
Starting Motor - Protection....921
Magnetic Pickup....922
Circuit Breaker....924
SENR3599 - Testing and Adjusting (3606 and 3608 Engines)....925
Troubleshooting....927
General Information (Fuel System)....958
Fuel System Inspection....959
Fuel Injector Testing....960
Fuel Pressure....961
Engine Prelube....966
Engine Rotation....967
Finding the Top Center Position for the No. 1 Piston....968
Camshaft Timing....972
Crankshaft Position for Fuel Timing and Valve Lash Adjustment....979
Fuel Timing....985
Fuel Injector Synchronization....992
Heinzmann Governor....997
Woodward PGEV Governor....1001
Woodward EGB29P Governor....1007
Woodward 3161 Governor....1011
Fuel Setting....1017
Restriction of Air Inlet and Exhaust....1022
Measuring Inlet Manifold Pressure....1023
Measuring Exhaust Temperature....1025
Crankcase Pressure....1026
Compression....1027
Valve Lash and Valve Bridge Adjustment....1028
General Information (Lubrication System)....1033
Excessive Engine Oil Consumption - Inspect....1034
Lubrication Metering Pump for the Inlet Valve....1035
Measuring Engine Oil Pressure....1037
Engine Oil Pressure is Low....1038
Engine Oil Pressure is High....1039
Excessive Bearing Wear - Inspect....1040
Increased Engine Oil Temperature - Inspect....1041
Indicators for Engine Oil Pressure....1042
General Information (Cooling System)....1043
Visual Inspection....1046
Test Tools for the Cooling System....1047
Water Temperature Gauge....1049
Test for the Water Temperature Regulator....1051
Connecting Rod Bearings....1052
Main Bearings....1053
Cylinder Block....1054
Flywheel and Flywheel Housing....1055
Crankshaft Deflection (Bend)....1063
Vibration Damper....1065
Pressure Regulating Valve....1066
Lubricator and Strainer....1068
Test Tools for the Electrical System....1070
Battery....1074
SENR3600 - Disassembly and Assembly (3606 and 3608 Engines)....1076
Engine Lifting Bracket - Remove and Install....1082
Engine Support - Remove and Install....1085
Mounting Isolator - Remove and Install....1089
Air Lubricator - Remove and Install....1091
Air Regulator - Remove and Install - Air Starting....1094
Air Starting Motor Silencer - Remove and Install....1098
Air Starting Motor - Remove....1101
Air Starting Motor - Disassemble....1103
Air Starting Motor - Assemble....1114
Air Starting Motor - Install....1128
Electric Starting Motor - Remove and Install....1130
Exhaust Manifold Shield - Remove and Install....1133
Exhaust Manifold - Remove and Install - 3606....1142
Aftercooler - Remove....1145
Aftercooler - Disassemble....1148
Aftercooler - Assemble....1149
Aftercooler - Install....1150
Air Inlet Shutoff - Remove and Install....1152
Turbocharger - Remove....1155
Turbocharger - Disassemble....1160
Turbocharger - Assemble....1179
Turbocharger - Install....1193
Engine Oil Filler and Oil Level Gauge - Remove and Install....1197
Crankcase Explosion Relief Valve - Remove and Install....1205
Water Temperature Regulator - Remove and Install....1208
Remote Water Temperature Regulator Housing - Remove....1212
Remote Water Temperature Regulator Housing - Disassemble....1214
Remote Water Temperature Regulator Housing - Assemble....1216
Remote Water Temperature Regulator Housing - Install....1218
Expansion Tank - Remove and Install....1220
Water Pump - Remove - Jacket Water Pump....1222
Water Pump - Disassemble....1224
Water Pump - Assemble....1229
Water Pump - Install - Jacket Water Pump....1234
Auxiliary Water Pump - Remove....1236
Auxiliary Water Pump - Disassemble....1238
Auxiliary Water Pump - Assemble....1241
Auxiliary Water Pump - Install....1245
Water Pump Seal - Remove....1247
Water Pump Seal - Install....1250
Fuel Filters - Remove and Install....1254
Fuel Filter Housings - Remove....1257
Fuel Filter Housings - Disassemble....1260
Fuel Filter Housings - Assemble....1263
Fuel Filter Housings - Install....1266
Fuel Priming Pump - Remove....1269
Fuel Priming Pump - Disassemble....1270
Fuel Priming Pump - Assemble....1273
Fuel Priming Pump - Install....1277
Fuel Transfer Pump - Remove....1278
Fuel Transfer Pump - Disassemble....1280
Fuel Transfer Pump - Assemble....1287
Fuel Transfer Pump - Install....1295
Fuel Pressure Control Valve - Remove....1296
Fuel Pressure Control Valve - Disassemble....1298
Fuel Pressure Control Valve - Assemble....1300
Fuel Pressure Control Valve - Install....1302
Fuel Injection Control Linkage - Remove....1303
Fuel Injection Control Linkage - Install....1307
Governor - Remove....1311
Governor - Install....1313
Governor Actuator - Remove and Install....1315
Governor Drive - Remove - Later....1320
Governor Drive - Remove - Earlier....1322
Governor Drive - Disassemble - Earlier....1324
Governor Drive - Disassemble - Later....1326
Governor Drive - Assemble - Later....1328
Governor Drive - Assemble - Earlier....1330
Governor Drive - Install - Earlier....1332
Governor Drive - Install - Later....1335
Prelubrication Oil Pump - Remove....1337
Prelubrication Oil Pump - Disassemble....1342
Prelubrication Oil Pump - Assemble....1345
Prelubrication Oil Pump - Install....1348
Prelube Valve (Continuous) - Remove and Install....1353
Lubrication Metering Pump - Remove and Install....1355
Engine Oil Pump - Remove....1358
Engine Oil Pump - Disassemble....1360
Engine Oil Pump - Assemble....1363
Engine Oil Pump - Install....1367
Engine Oil Coolers - Remove....1369
Engine Oil Coolers - Disassemble....1371
Engine Oil Coolers - Assemble....1373
Engine Oil Coolers - Install....1376
Engine Oil Filter Elements - Remove and Install....1378
Engine Oil Filter Housings - Remove....1382
Engine Oil Filter Housings - Disassemble....1384
Engine Oil Filter Housings - Assemble....1391
Engine Oil Filter Housings - Install....1398
Centrifugal Oil Filter - Remove....1400
Centrifugal Oil Filter - Disassemble....1402
Centrifugal Oil Filter - Assemble....1405
Centrifugal Oil Filter - Install....1408
Engine Oil Pan - Remove....1410
Engine Oil Pan - Disassemble....1413
Engine Oil Pan - Assemble....1417
Engine Oil Pan - Install....1422
Oil Temperature Regulators - Remove and Install....1425
Priority Valve - Remove....1429
Priority Valve - Disassemble....1432
Priority Valve - Assemble....1434
Priority Valve - Install....1436
Vibration Damper - Remove....1438
Vibration Damper - Install....1441
Flywheel and Ring Gear - Remove and Install....1444
Crankshaft Front Seal - Remove....1449
Crankshaft Front Seal - Install....1451
Crankshaft Rear Seal - Remove....1453
Crankshaft Rear Seal - Install....1455
Crankshaft Front Gear - Remove and Install....1457
Crankshaft Rear Gear - Remove and Install....1460
Camshaft Drive Gear - Remove....1463
Camshaft Drive Gear - Install....1466
Idler Gears (Rear) - Remove....1470
Idler Gears (Rear) - Install....1472
Idler Gears (Front) - Remove....1474
Idler Gears (Front) - Install....1477
Housing (Front) - Remove....1482
Housing (Front) - Install....1486
Housing (Rear) - Remove....1490
Housing (Rear) - Install....1492
Manual Barring Group - Remove....1494
Manual Barring Group - Disassemble....1496
Manual Barring Group - Assemble....1498
Manual Barring Group - Install....1500
Valve Cover Base - Remove and Install....1502
Valve Mechanism - Remove....1504
Valve Mechanism - Install....1506
Rocker Arm - Disassemble....1510
Rocker Arm - Assemble....1512
Valve Lifter - Remove....1517
Valve Lifter - Disassemble....1519
Valve Lifter - Assemble....1522
Valve Lifter - Install....1525
Fuel Injector - Remove....1527
Fuel Injector - Install....1531
Cylinder Head - Remove....1536
Cylinder Head - Disassemble....1544
Cylinder Head - Assemble....1553
Cylinder Head - Install....1565
Piston Cooling Jets - Remove and Install....1572
Piston and Connecting Rods - Remove - Hydraulic Tensioned Rod Bolts....1575
Piston and Connecting Rods - Remove....1583
Piston and Connecting Rods - Install - Hydraulic Tensioned Rod Bolts....1590
Piston and Connecting Rods - Install....1601
Cylinder Liner - Remove....1610
Cylinder Liner - Install....1613
Camshaft - Remove....1616
Camshaft - Install....1622
Camshaft Bearings - Remove....1631
Camshaft Bearings - Install....1633
Crankshaft Main Bearings - Remove....1636
Crankshaft Main Bearings - Install....1645
Crankshaft - Remove....1651
Crankshaft - Install....1656
Caterpillar 3606 and 3608 Engines Repair Service Manual
