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