Caterpillar 3406C Engines Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Caterpillar 3406C Engines, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Caterpillar 3406C 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.
SEBR0560 - Disassembly and Assembly (3406C DIESEL TRUCK ENGINE).pdf
SEBR0560 - Specifications (3406C DIESEL TRUCK ENGINE).pdf
SEBR0560 - Systems Operation (3406C DIESEL TRUCK ENGINE).pdf
SEBR0560 - Testing and Adjusting (3406C DIESEL TRUCK ENGINE).pdf
SEBR0560 - Troubleshooting (3406C DIESEL TRUCK ENGINE).pdf
SENR1027 - Specifications (3406C Engines for Caterpillar Built Machines).pdf
SENR1028 - Systems Operation (3406C ENGINE FOR CATERPILLAR BUILT MACHINES).pdf
SENR1028 - Testing and Adjusting (3406C ENGINE FOR CATERPILLAR BUILT MACHINES).pdf
SENR1029 - Disassembly and Assembly (3406C ENGINE FOR CATERPILLAR BUILT MACHINES).pdf
SENR1096 - Specifications (3406C GENERATOR SET ENGINE ATTACHMENTS).pdf
SENR1097 - Systems Operation (3406C GENERATOR SET ENGINE ATTACHMENTS).pdf
SENR1097 - Testing & Adjusting (3406C GENERATOR SET ENGINE ATTACHMENTS).pdf
SENR1098 - Disassembly and Assembly (3406C GENERATOR SET ENGINE).pdf
SENR1102 - Specifications (3406C GENERATOR SET ENGINE).pdf
SENR1103 - Systems Operation (3406C GENERATOR SET ENGINE).pdf
SENR1103 - Testing & Adjusting (3406C GENERATOR SET ENGINE).pdf
SENR6409 - Disassembly and Assembly (3406C DIESEL ENGINES FOR CATERPILLAR BUILT MACHINES).pdf
SENR6470 - Specifications (3406C ENGINE FOR CATERPILLAR BUILT MACHINES).pdf
SENR6471 - Systems Operation (3406C ENGINE FOR CATERPILLAR BUILT MACHINES).pdf
SENR6471 - Testing and Adjusting (3406C ENGINE FOR CATERPILLAR BUILT MACHINES).pdf
SENR6521 - Troubleshooting (3406C Diesel Truck Engine).pdf
SENR6523 - Specifications (3406C Industrial & Marine Engines).pdf
SENR6524 - Systems Operation (3406C Industrial & Marine Engines).pdf
SENR6524 - Testing & Adjusting (3406C Industrial & Marine Engines).pdf
SENR6525 - Disassembly & Assembly (3406C Industrial & Marine Engines).pdf
SENR6526 - Disassembly and Assembly (3406C Industrial & Marine Engines).pdf
SENR6527 - Specifications (3406C Industrial & Marine Engine Attachments).pdf
SENR6528 - Systems Operation (3406C Industrial & Marine Engine Attachments).pdf
SENR6528 - Testing & Adjusting (3406C Industrial & Marine Engine Attachments).pdf
SENR6546 - Specifications (3406C Diesel Truck Engine).pdf
SENR6547 - Systems Operation (3406C Diesel Truck Engine).pdf
SENR6547 - Testing & Adjusting (3406C Diesel Truck Engine).pdf
SENR6548 - Disassembly & Assembly (3406C Diesel Truck Engine).pdf
PRODUCT DETAILS:
Total Pages: 4,012 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
SEBR0560 - Disassembly and Assembly (3406C DIESEL TRUCK ENGINE)....3
General Instructions (D & A)....6
Air Compressor....19
Fuel Injection Lines....21
Fuel Injection Line Adapters....23
Electric Starting Motor....26
Tachometer Drive....27
Fuel Priming Pump....29
Fuel Filter And Base....30
Fuel Transfer Pump....33
Fuel Ratio Control....42
Automatic Timing Advance....48
Fuel Injection Pump Housing And Governor....57
Governor....60
Fuel Injection Pumps....78
Fuel Injection Pump Housing....86
Turbocharger (Earlier)....92
Turbocharger (Later)....103
Water Temperature Regulator And Manifold....113
Water Temperature Regulator (Ford)....115
Oil Filter And Base....117
Oil Filter Base....119
Exhaust Manifold....121
Alternator And Mounting Group....123
Water Pump....125
Valve Covers....130
Rocker Shaft Assemblies And Push Rods....131
Rocker Shaft Assemblies....136
Valve Lifters....138
Fuel Injection Nozzles And Adapters....145
Cylinder Head Assembly....148
Spacer Plate....152
Valves....154
Valve Seat Inserts....156
Bridge Dowels....158
Valve Guides....160
Oil Pan....162
Flywheel....164
Flywheel Housing....166
Oil Pump....168
Piston Cooling Tubes....172
Connecting Rod Bearings....174
Crankshaft Main Bearings....177
Pistons And Connecting Rod Assemblies....181
Crankshaft....186
Camshaft....192
Camshaft Bearings....195
Crankshaft Front Seal And Wear Sleeve....197
Crankshaft Rear Seal And Wear Sleeve....201
Vibration Damper And Pulley....205
Cylinder Liners....207
Fan Drive....209
Engine Front Support....213
Timing Gears And Plate....214
Air Compressor And Accessory Drive....217
Timing Gear Cover....223
Oil Cooler (BrakeSaver) [If So Equipped]....225
Flywheel (BrakeSaver) [If So Equipped]....227
BrakeSaver Control Valve [If So Equipped]....229
BrakeSaver [If So Equipped]....233
Oil Pan (BrakeSaver) [If So Equipped]....244
Oil Pump (BrakeSaver) [If So Equipped]....246
Jacobs Engine Brake [If So Equipped]....252
Engine Oil Cooler....261
SEBR0560 - Specifications (3406C DIESEL TRUCK ENGINE)....263
Introduction....266
Engine Design....267
Fuel System Identification....268
Fuel Injecion Lines....269
Fuel Injection Nozzle And Adapter....273
Fuel Transfer Pump....275
Fuel Injection Pump....277
Fuel Injection Pump Housing....280
Governor....283
Switch Group (Used On Engines With BrakeSaver)....287
Governor Control Linkage....289
Ether Starting Aid....290
Fuel Ratio Control....292
Primary Fuel Filter....294
Fuel Filter Base....295
Governor And Fuel Pump Drive Group (4W4619 Only)(Automatic Timing Advance Unit)....297
Governor And Fuel Pump Drive Group (Automatic Timing Advance Unit)....299
Auxiliary Drive Group....301
Idler Gear Shaft Pilot Bore....303
Idler Gear Assembly (For Front Gear Group)....305
Front Housing And Covers....307
Engine Front Support....309
Front (Timing) Gear Group....310
Camshaft....312
Camshaft Bearings....315
Valve Covers....316
Breather Cap....317
Valves....318
Valve Rocker Arms; Lifters And Bridges....323
Cylinder Head....327
Turbochargers....329
Exhaust Manifold....336
Exhaust Manifold Shield....337
Exhaust Adapter Group....338
Jake Brake....339
Oil Pressure....342
Oil Pump....344
Oil Pan....352
Oil Filters....354
Water Pump....357
Coolant Conditioner Base....359
Aftercooler....360
Belt Tension Chart....362
Water Temperature Regulators....363
Cylinder Block....365
Cylinder Liners....369
Cylinder Liner Projection....371
Pistons And Rings....373
Connecting Rods....376
Connecting Rod And Main Bearing Journals....379
Crankshaft....381
Accessory Drive Groups....383
Pulley Tightener Group....385
Pulley And Damper Groups....386
Flywheel Housing....388
Flywheels....390
Flywheel Adapter Group....398
BrakeSaver Group....400
BrakeSaver Control Valve....402
BrakeSaver Fastener Group....403
Oil Cooler Bypass Valve....404
Flywheel Housing Bore....406
Flywheel Housing Runout....410
Flywheel Runout....412
Alternators And Regulators....415
Electric Starting Motors....419
Starter Solenoids....422
Shutoff Solenoids....424
SEBR0560 - Systems Operation (3406C DIESEL TRUCK ENGINE)....427
SEBR0560 - Testing and Adjusting (3406C DIESEL TRUCK ENGINE)....499
SEBR0560 - Troubleshooting (3406C DIESEL TRUCK ENGINE)....601
Introduction....602
High Fuel Consumption....603
High Fuel Consumption Complaints....607
Low Power And Engine Response Complaints....610
Low Power Complaints....612
Engine Response Complaints....614
Primary Engine Checks....616
Road Test....619
Non-Engine Related Problems....621
Misfiring And Running Rough....624
Excessive Black Or Gray Exhaust Smoke....627
Excessive White Or Blue Exhaust Smoke....630
Hard Starting (Engine Crankshaft Turns Freely)....633
Engine Does Not Start....636
Cooling System....638
Loss Of Coolant....642
Fuel In Crankcase Oil....644
Engine Vibration Troubleshooting....645
SENR1027 - Specifications (3406C Engines for Caterpillar Built Machines)....649
Engine Design....652
Fuel Injection Lines....654
Fuel Injection Pump....657
Fuel Injection Pump Housing....659
Fuel Injection Nozzles and Adapters....662
Fuel Ratio Control....664
Governor....666
Governor and Fuel Pump Drive....677
Fuel Transfer Pump....683
Fuel Filter Base....685
Fuel Filter (Primary)....687
Ether Starting Aid....688
Valve Rocker Arms; Lifters; and Bridges....691
Valve Mechanism Cover....695
Cylinder Head Valves....696
Cylinder Head....699
Compression Brake - If Equipped....702
Turbocharger....706
Aftercooler....707
Exhaust Manifold....709
Exhaust Manifold Shield....712
Camshaft....713
Camshaft Bearings....715
Engine Oil Filter Base....717
Engine Oil Cooler Bypass Valve....723
Engine Oil Pump....725
Engine Oil Pan....739
Crankcase Breather....749
Coolant Conditioner Base....750
Water Temperature Regulator....751
Water Pump....753
Cylinder Block Cover Group - If Equipped....757
Cylinder Block....758
Cylinder Liner....763
Cylinder Liner Projection....765
Crankshaft....766
Vibration Damper....769
Connecting Rod Bearing Journal....774
Main Bearing Journal....775
Connecting Rod - Connecting Rod For One-Piece Aluminum Piston....777
Connecting Rod - Connecting Rod For Steel Articulated Piston....780
Piston and Rings - Two-Piece Articulated Piston....783
Piston and Rings - One-Piece Piston....785
Accessory Drive....787
Front Housing and Covers....791
Gear Group (Front)....798
Flywheel....800
Flywheel Housing....811
Crankshaft Pulley....825
Belt Tension Chart....826
Belt Tensioner - Belt Tensioner With Spring Tensioner....828
Belt Tensioner - Belt Tensioner Without Spring Tensioner....830
Fan Drive....832
Engine Trunnion....837
Engine Support (Front)....839
Engine Support (Rear)....841
Alternator and Regulator....842
Electric Starting Motor....856
Magnetic Pickup....874
Engine Oil Pressure Switch....876
Service Meter....877
Fuel Pressure Indicator....878
SENR1028 - Systems Operation (3406C ENGINE FOR CATERPILLAR BUILT MACHINES)....879
SENR1028 - Testing and Adjusting (3406C ENGINE FOR CATERPILLAR BUILT MACHINES)....934
SENR1029 - Disassembly and Assembly (3406C ENGINE FOR CATERPILLAR BUILT MACHINES)....936
Crankshaft Front Seal & Wear Sleeve....938
Crankshaft Rear Seal & Wear Sleeve....941
Flywheel....945
Flywheel Housing....947
Fuel Filter & Base....952
Automatic Timing Advance....953
Automatic Timing Advance ....962
Fuel Injection Pump Housing & Governor....972
Governor....974
Fuel Injection Pumps....990
Fuel Injection Pump Housing....997
Fuel Ratio Control....1001
Fuel Injection Lines....1004
Fuel Transfer Pump....1006
Oil Filter & Base Assembly....1011
Shutoff Solenoid....1013
Exhaust Manifold....1014
Vibration Damper....1016
Water Temperature Regulator....1017
Water Pump....1019
Valve Covers....1026
Valve Cover Bases....1028
Rocker Shaft Assemblies & Push Rods....1030
Rocker Shaft Assemblies....1036
Valve Lifters....1038
Fuel Injection Nozzles & Adapters....1044
Cylinder Head Assembly....1047
Spacer Plate....1051
Valves....1053
Valve Seat Inserts....1055
Bridge Dowels....1057
Valve Guides....1059
Oil Pan & Plate....1061
Oil Pump....1063
Piston Cooling Tubes....1067
Pistons & Connecting Rod Assemblies....1069
Cylinder Liners....1073
Timing Gear Cover....1075
Timing Gears & Plate....1077
Camshaft....1080
Camshaft Bearings....1083
Connecting Rod Bearings....1085
Crankshaft Main Bearings....1088
Crankshaft....1092
SENR1096 - Specifications (3406C GENERATOR SET ENGINE ATTACHMENTS)....1098
Introduction....1099
Governor Controls....1100
Accessory Drive Group....1102
Exhaust Elbow....1104
Ether Starting Aids....1105
Radiator....1108
Air Cleaners....1110
Air Cleaner Adapter....1112
Auxiliary Drive Group....1113
Magnetic Pickup....1115
Starter Magnetic Switches....1116
Sensors....1117
Coolant Conditioner Base....1120
Sending Units....1121
Switches....1124
Tachometer....1129
Indicators....1131
Alternators And Regulators....1137
Shutoff Solenoids....1145
Air Shutoff Group And Solenoid....1147
Starting Motors....1150
Alternator Mounting Group....1155
Hydraulic Pump Drive Mounting....1157
Muffler Group....1158
Fuel Ratio Control....1159
Primary Fuel Filter....1161
Oil Pan....1162
SENR1097 - Systems Operation (3406C GENERATOR SET ENGINE ATTACHMENTS)....1163
SENR1097 - Testing & Adjusting (3406C GENERATOR SET ENGINE ATTACHMENTS)....1235
SENR1098 - Disassembly and Assembly (3406C GENERATOR SET ENGINE)....1293
Introduction....1295
Engine Design....1296
Radiator....1297
Radiator & Radiator Guard....1299
Fuel Injection Lines....1305
Fuel Filter & Base....1307
Fuel Transfer Pump....1309
Fuel Injection Pump Housing & Governor....1317
Governor....1322
Fuel Injection Pumps....1338
Fuel Injection Pump Housing....1345
Valve Covers....1352
Fuel Injection Line Adapters....1353
Electric Starting Motor....1355
Turbocharger....1356
Water Temperature Regulator....1366
Engine Oil Cooler....1368
Oil Filter & Base....1370
Oil Filter Base....1372
Exhaust Manifold....1374
Water Pump....1376
Fan Drive....1382
Vibration Damper & Pulley....1386
Engine Front Support....1388
Timing Gear Cover....1389
Timing Gears & Plate....1391
Accessory Drive....1394
Rocker Shaft Assemblies & Push Rods....1397
Rocker Shaft Assemblies....1402
Valve Lifters....1404
Fuel Injection Nozzles & Adapters....1411
Aftercooler Core....1414
Aftercooler Housing....1417
Cylinder Head Assembly....1419
Spacer Plate....1423
Valves....1425
Valve Seat Inserts....1427
Bridge Dowels....1429
Valve Guides....1431
Oil Pan....1433
Flywheel....1435
Flywheel Housing....1437
Oil Pump....1439
Piston Cooling Tubes....1444
Camshaft....1446
Camshaft Bearings....1449
Connecting Rod Bearings....1451
Crankshaft Main Bearings....1454
Crankshaft....1458
Crankshaft Front Seal & Wear Sleeve....1464
Crankshaft Rear Seal & Wear Sleeve....1468
Cylinder Liners....1472
Pistons & Connecting Rod Assemblies....1474
Control Panel....1479
Control Panels....1481
Control Panel Enclosure....1483
Battery Charger (Standby)....1490
Engine & Generator....1492
SENR1102 - Specifications (3406C GENERATOR SET ENGINE)....1496
Introduction....1498
Engine Design....1499
Fuel Injection Lines....1500
Fuel Injection Nozzle And Adapter....1502
Fuel Transfer Pump....1504
Fuel Injection Pump....1506
Fuel Injection Pump Housing....1508
Governor....1511
Governor And Fuel Pump Drive Group....1515
Primary Fuel Filter....1517
Fuel Filter Base....1518
Idler Gear Shaft Pilot Bore....1519
Idler Gear Assembly (For Front Gear Group)....1521
Front Housing And Covers....1523
Front (Timing) Gear Group....1525
Accessory Drive Groups....1527
Camshaft....1530
Camshaft Bearings....1533
Breather Cap....1535
Valve Covers....1536
Valves....1537
Valve Rocker Arms; Lifters And Bridges....1541
Cylinder Head....1545
Turbochargers....1547
Exhaust Manifold....1551
Exhaust Manifold Shield....1552
Engine Oil Filter....1553
Engine Oil Pump....1554
Oil Pan....1557
Water Pump....1559
Belt Tension Chart....1561
Water Temperature Regulator....1562
Aftercooler....1563
Cylinder Block....1564
Cylinder Liners....1568
Cylinder Liner Projection....1570
Pistons And Rings....1574
Connecting Rods....1578
Connecting Rod And Main Bearing Journals....1583
Crankshaft....1585
Flywheel Housing Cover....1587
Flywheel Housing....1588
Flywheel....1590
Service Meters....1592
SENR1103 - Systems Operation (3406C GENERATOR SET ENGINE)....1593
SENR1103 - Testing & Adjusting (3406C GENERATOR SET ENGINE)....1625
SENR6409 - Disassembly and Assembly (3406C DIESEL ENGINES FOR CATERPILLAR BUILT MACHINES)....1705
Crankshaft Front Seal & Wear Sleeve....1707
Crankshaft Rear Seal & Wear Sleeve....1711
Flywheel....1715
Flywheel Housing....1717
Fuel Filter & Base....1721
Automatic Timing Advance....1722
Fuel Injection Pump Housing & Governor....1730
Governor....1732
Fuel Injection Pumps....1749
Fuel Injection Pump Housing....1755
Fuel Ratio Control....1759
Fuel Injection Lines....1762
Fuel Transfer Pump....1764
Oil Filter & Base Assembly....1769
Shutoff Solenoid....1771
Exhaust Manifold....1772
Vibration Damper....1774
Water Temperature Regulator....1775
Water Pump....1777
Valve Covers....1784
Valve Cover Bases....1786
Rocker Shaft Assemblies & Push Rods....1788
Rocker Shaft Assemblies....1794
Valve Lifters....1796
Fuel Injection Nozzles & Adapters....1803
Cylinder Head Assembly....1806
Spacer Plate....1810
Valves....1812
Valve Seat Inserts....1815
Bridge Dowels....1817
Valve Guides....1819
Oil Pan & Plate....1821
Oil Pump....1823
Piston Cooling Tubes....1827
Pistons & Connecting Rod Assemblies....1829
Cylinder Liners....1834
Timing Gear Cover....1836
Timing Gears & Plate....1838
Camshaft....1841
Camshaft Bearings....1844
Connecting Rod Bearings....1846
Crankshaft Main Bearings....1849
Crankshaft....1853
SENR6470 - Specifications (3406C ENGINE FOR CATERPILLAR BUILT MACHINES)....1860
Introduction....1863
Engine Design....1864
Fuel Injection Lines....1866
Fuel Injection Nozzle And Adapter....1868
Fuel Transfer Pump....1870
Fuel Injection Pump....1872
Fuel Injection Pump Housing....1875
Governor....1878
Fuel Ratio Control....1883
Governor And Fuel Pump Drive Group....1885
Dual Horsepower Solenoid (If Equipped)....1888
Primary Fuel Filter....1889
Fuel Filter Base....1890
Idler Gear Shaft Pilot Bore....1891
Idler Gear Assembly (For Front Gear Group)....1893
Front Housing And Covers....1895
Front (Timing) Gear Group....1898
Accessory Drive Group....1900
Camshaft....1903
Camshaft Bearings....1906
Breather Cap....1907
Valve Covers....1908
Valves....1909
Valve Rocker Arms; Lifters And Bridges....1913
Cylinder Head....1917
Turbocharger....1919
Exhaust Manifold....1924
Exhaust Manifold Shield....1925
Exhaust Elbow Adapter Group....1926
Exhaust Extension Group....1927
Dust Ejector Group....1928
Muffler and Ejector Group....1929
Air Cleaner....1931
Oil Filter....1933
Oil Cooler Bypass Valve....1936
Oil Pump....1937
Oil Pan....1943
Water Pump....1945
Belt Tension Chart....1947
Fan Drive....1948
Fan Group....1950
Belt Tightener....1951
Radiator....1953
Coolant Flow Switches....1960
Water Temperature Regulator....1962
Aftercooler....1963
Coolant Conditioner Base....1964
Cylinder Block....1965
Cylinder Liners....1968
Cylinder Liner Projection....1970
Pistons And Rings....1974
Connecting Rods....1978
Connecting Rod And Main Bearing Journals....1983
Crankshaft....1985
Engine Support....1987
Flywheel Housing Cover....1990
Flywheel Housing....1991
Flywheel Group....1996
Flywheel Housing Bore....2004
Flywheel Housing Runout....2007
Flywheel Runout....2009
Magnetic Pickup Group....2012
Rear Gear Group....2013
Alternator and Fan Support....2014
Alternator Mounting Group....2015
Alternator And Regulator....2018
Starting Motor....2029
Shutoff Solenoid....2033
Coolant Temperature Sensor....2035
Fuel Pressure Gauge....2036
Service Meter....2037
SENR6471 - Systems Operation (3406C ENGINE FOR CATERPILLAR BUILT MACHINES)....2038
SENR6471 - Testing and Adjusting (3406C ENGINE FOR CATERPILLAR BUILT MACHINES)....2083
SENR6521 - Troubleshooting (3406C Diesel Truck Engine)....2187
Air Inlet Heater - If Equipped....2189
Air in Fuel....2195
Alternator Charge Rate Is High....2198
Alternator Charge Rate Is Low....2199
Alternator Noise....2201
Alternator Will Not Charge....2203
Coolant Temperature Above Normal....2205
Coolant Temperature Below Normal....2210
Coolant in Engine Oil....2212
Engine Cranks but Will Not Start....2214
Engine Has Early Wear....2219
Engine Misfires, Knocks, or Is Unstable (at Idle Only)....2222
Engine Misfires, Runs Rough or Is Unstable....2224
Engine Oil in Cooling System....2227
Engine Oil in Exhaust System....2228
Engine Overspeeds on Start....2230
Engine Stalls at Low RPM....2231
Engine Vibration....2234
Engine Will Not Crank....2236
Excessive Black Smoke....2239
Excessive Blue Smoke....2241
Excessive Engine Oil Consumption....2243
Excessive Fuel Consumption....2245
Excessive Valve Lash....2248
Excessive White Smoke....2250
Exhaust Temperature Is Too High....2253
Fuel Quality....2255
Fuel Ratio Control....2256
Fuel Transfer Pump....2257
Fuel in Cooling System....2258
Fuel in Engine Oil....2259
Governor Instability....2261
Little or No Valve Lash....2262
Loss of Coolant....2263
Low Engine Oil Pressure....2267
Low Power....2269
Mechanical Noise (Knock) in Engine....2273
Noise Coming from Cylinder....2276
Soot in Inlet Manifold....2278
Valve Train Noise....2279
SENR6523 - Specifications (3406C Industrial & Marine Engines)....2281
Accessory Drive Group....2283
Aftercooler....2286
Air Starting Motor Pressure Regulating Valve....2288
Alternator And Regulator....2290
Alternator Mounting Group....2301
Breather Cap....2304
Camshaft Bearings....2306
Camshaft....2308
Connecting Rod And Main Bearing Journals....2311
Connecting Rods....2313
Crankshaft....2316
Cylinder Block....2318
Cylinder Head....2322
Cylinder Liner Projection....2324
Cylinder Liners....2328
Electric Starting Motor....2330
Engine Design....2336
Engine Front Support....2338
Engine Oil Filters And Bypass Valves....2340
Engine Oil Pump....2344
Exhaust Elbow Adapter Group....2347
Exhaust Manifold Shield....2349
Exhaust Manifold....2351
Flywheel Adapter Group....2353
Flywheel Housing Bore....2355
Flywheel Housing Cover....2358
Flywheel Housing Runout....2359
Flywheel Housing....2361
Flywheel Runout....2363
Flywheel....2366
Front Gear Group (Timing)....2371
Front Housing And Covers....2373
Fuel Filter Base....2376
Fuel Injection Lines....2378
Fuel Injection Nozzle And Adapter....2381
Fuel Injection Pump Housing....2383
Fuel Injection Pump....2386
Fuel Ratio Control....2390
Fuel Transfer Pump....2392
Governor and Fuel Pump Drive Group....2394
Governor....2398
Idler Gear Assembly (For Front Gear Group)....2403
Idler Gear Shaft Pilot Bore....2405
Magnetic Pickup Group....2407
Oil Pan....2408
Pistons And Rings....2410
Primary Fuel Filter....2412
Service Meter....2414
Shutoff Solenoids....2415
Starting Motor Solenoids....2417
Temperature Sensor....2419
Turbochargers....2420
Valve Covers....2428
Valve Rocker Arms, Lifters And Bridges....2429
Valves....2433
Water Pump....2437
Water Temperature Regulator....2439
SENR6524 - Systems Operation (3406C Industrial & Marine Engines)....2441
SENR6524 - Testing & Adjusting (3406C Industrial & Marine Engines)....2491
SENR6525 - Disassembly & Assembly (3406C Industrial & Marine Engines)....2597
Accessory Drive....2600
Aftercooler Core....2603
Aftercooler Housing (Industrial Engine)....2608
Aftercooler Housing (Marine Engine)....2610
Air Cleaner (Compact Marine Engine)....2613
Air Cleaner....2614
Automatic Timing Advance....2616
Bridge Dowels....2626
Camshaft Bearings....2628
Camshaft....2631
Connecting Rod Bearings....2634
Crankshaft Front Seal & Wear Sleeve....2637
Crankshaft Main Bearings....2641
Crankshaft Rear Seal & Wear Sleeve....2645
Crankshaft Vibration Damper & Pulley....2649
Crankshaft....2652
Cylinder Head Assembly....2658
Cylinder Liners....2662
Dipstick Assembly (Industrial Engine)....2666
Dispstick Assembly (Marine Engine)....2667
Electric Starting Motor....2668
Engine Front Support....2669
Engine Lifting Brackets (Industrial Engine)....2671
Engine Lifting Brackets (Marine Engine)....2672
Engine Rear Support....2673
Exhaust Manifold (Industrial Engine)....2675
Exhaust Manifold (Marine Engine)....2677
Expansion Tank....2683
Flywheel Housing....2686
Flywheel....2690
Fuel Filter Base....2692
Fuel Injection Line Adapters....2694
Fuel Injection Lines....2697
Fuel Injection Nozzle Adapters (Earlier)....2699
Fuel Injection Nozzles (Earlier)....2703
Fuel Injection Pump & Governor Drive....2708
Fuel Injection Pump & Governor....2712
Fuel Injection Pump Housing....2715
Fuel Injection Pumps....2721
Fuel Priming Pump....2729
Fuel Ratio Control....2730
Fuel Transfer Pump....2738
Governor (Industrial Engine)....2746
Governor (Marine Engine)....2748
Governor....2750
Instrument Panel....2768
Marine Gear Oil Cooler Core (Marine Engine)....2771
Oil Cooler (Industrial Engine)....2774
Oil Cooler (Marine Engine)....2776
Oil Filler Pipe (Industrial Engine)....2780
Oil Filter Base (Industrial Engine)....2781
Oil Filter Base (Marine Engine)....2785
Oil Pan....2788
Oil Pump....2790
Piston Cooling Tubes....2795
Pistons & Connecting Rod Assemblies....2797
Raw Water Pump (Compact Marine Engine)....2802
Raw Water Pump....2810
Rocker Shaft Assemblies & Push Rods....2820
Service Meter....2829
Spacer Plate....2831
Sump Pump....2833
Tachometer Drive....2836
Timing Gear Cover....2838
Timing Gears & Plate....2843
Turbocharger (Industrial Engine)....2847
Turbocharger (Marine Engine)....2859
Valve Covers....2871
Valve Guides....2873
Valve Lifters....2875
Valve Seat Inserts....2882
Valves....2884
Water Pump (Compact Marine Engine)....2887
Water Pump (Industrial Engine)....2898
Water Pump (Marine Engine)....2901
Water Temperature Regulator (Compact Marine Engine)....2904
Water Temperature Regulator (Industrial Engine)....2907
Water Temperature Regulator (Marine Engine)....2910
SENR6526 - Disassembly and Assembly (3406C Industrial & Marine Engines)....2914
Accessory Drive....2917
Aftercooler Core....2921
Aftercooler Housing (Industrial Engine)....2927
Aftercooler Housing (Marine Engine)....2930
Air Cleaner (Compact Marine Engine)....2933
Air Cleaner....2934
Automatic Timing Advance....2936
Bridge Dowels....2947
Camshaft Bearings....2949
Camshaft....2953
Connecting Rod Bearings....2957
Crankshaft Front Seal & Wear Sleeve....2961
Crankshaft Main Bearings....2965
Crankshaft Rear Seal & Wear Sleeve....2969
Crankshaft Vibration Damper & Pulley....2973
Crankshaft....2976
Cylinder Head Assembly....2982
Cylinder Liners....2986
Dipstick Assembly (Industrial Engine)....2990
Dispstick Assembly (Marine Engine)....2992
Electric Starting Motor....2994
Engine Front Support....2995
Engine Lifting Brackets (Industrial Engine)....2997
Engine Lifting Brackets (Marine Engine)....2999
Engine Rear Support....3001
Exhaust Manifold (Industrial Engine)....3003
Exhaust Manifold (Marine Engine)....3005
Expansion Tank....3011
Flywheel Housing....3015
Flywheel....3019
Fuel Filter Base....3021
Fuel Injection Line Adapters....3023
Fuel Injection Lines....3026
Fuel Injection Nozzle Adapters (Earlier)....3028
Fuel Injection Nozzles (Earlier)....3032
Fuel Injection Pump & Governor Drive....3037
Fuel Injection Pump & Governor....3042
Fuel Injection Pump Housing....3045
Fuel Injection Pumps....3052
Fuel Priming Pump....3060
Fuel Ratio Control....3061
Fuel Transfer Pump....3069
Governor (Industrial Engine)....3078
Governor (Marine Engine)....3080
Governor....3082
Instrument Panel....3101
Marine Gear Oil Cooler Core (Marine Engine)....3104
Oil Cooler (Industrial Engine)....3107
Oil Cooler (Marine Engine)....3109
Oil Filler Pipe (Industrial Engine)....3114
Oil Filter Base (Industrial Engine)....3115
Oil Filter Base (Marine Engine)....3119
Oil Pan....3123
Oil Pump....3125
Piston Cooling Tubes....3130
Pistons & Connecting Rod Assemblies....3132
Raw Water Pump (Compact Marine Engine)....3138
Raw Water Pump....3146
Rocker Shaft Assemblies & Push Rods....3157
Service Meter....3167
Spacer Plate....3169
Sump Pump....3171
Tachometer Drive....3174
Timing Gear Cover....3176
Timing Gears & Plate....3181
Turbocharger (Industrial Engine)....3185
Turbocharger (Marine Engine)....3198
Valve Covers....3211
Valve Guides....3213
Valve Lifters....3215
Valve Seat Inserts....3222
Valves....3224
Water Pump (Compact Marine Engine)....3227
Water Pump (Industrial Engine)....3238
Water Pump (Marine Engine)....3241
Water Temperature Regulator (Compact Marine Engine)....3244
Water Temperature Regulator (Industrial Engine)....3247
Water Temperature Regulator (Marine Engine)....3250
SENR6527 - Specifications (3406C Industrial & Marine Engine Attachments)....3255
Accessory Drive Group....3257
Air Cleaner Adapter....3258
Air Cleaner....3259
Air Shutoff Group And Solenoid....3263
Air Starting Motor....3266
Ammeter....3267
Auxiliary Drive Group....3268
Auxiliary Water Pump....3271
Belt Tension Chart....3272
Electric Starting Motor....3273
Engine Oil Filter Group....3275
Ether Starting Aid....3276
Exhaust Pipes (With Dust Ejector)....3279
Fuel Filter And Lines....3280
Fuel Injection Lines....3282
Fuel Pressure Indicator....3285
Governor Control....3287
Hydraulic Pump Drive Mounting....3291
Introduction....3292
Jacket Water Heater....3293
Muffler Group (With Dust Ejector)....3294
Oil Pan....3296
Oil Pressure Indicator....3297
Power Take-Off Clutch....3300
Pressure Cap....3304
Pressure Switches....3305
Pulley Tightener Group....3308
Radiator....3310
Rear Stub Shaft....3311
Sending Units For Oil Pressure Indicator....3312
Sending Units For Water Temperature Indicator....3313
Shutoff Solenoid....3314
Tachometer (Digital)....3318
Temperature Indicator....3320
Temperature Switches....3321
Transformer Group....3323
Water Temperature Indicator....3324
SENR6528 - Systems Operation (3406C Industrial & Marine Engine Attachments)....3327
SENR6528 - Testing & Adjusting (3406C Industrial & Marine Engine Attachments)....3390
SENR6546 - Specifications (3406C Diesel Truck Engine)....3442
Accessory Drive Groups....3444
Alternators And Regulators....3446
Belt Tension Chart....3450
BrakeSaver Group (If Equipped)....3451
Breather Cap....3454
Camshaft Bearings....3455
Camshaft....3457
Connecting Rod And Main Bearing Journals....3460
Connecting Rods....3462
Coolant Conditioner Base....3465
Crankshaft....3467
Cylinder Block....3469
Cylinder Head....3473
Cylinder Liner Projection....3475
Cylinder Liners....3478
Engine Design....3480
Engine Front Support....3482
Engine Oil Cooler Bypass Valve Engines With BrakeSaver....3483
Engine Oil Filters....3485
Engine Oil Pan....3489
Engine Oil Pressure....3491
Engine Oil Pump....3493
Exhaust Adapter Group....3501
Exhaust Manifold Shield....3502
Exhaust Manifold....3503
Flywheel Adapter Group 6N9829 Flywheel Adapter Group....3504
Flywheel Housing....3506
Flywheels....3508
Front (Timing) Gear Group....3511
Front Housing And Covers....3513
Fuel Filter Base....3515
Fuel Injection Lines....3517
Fuel Injection Nozzle And Adapter....3520
Fuel Injection Pump Housing....3522
Fuel Injection Pump....3525
Fuel Ratio Control....3527
Fuel System Identification....3529
Fuel Transfer Pump....3530
Governor And Fuel Pump Drive Group (Automatic Timing Advance Unit)....3532
Governor Control Linkage....3534
Governor....3536
Idler Gear Assembly (For Front Gear Group)....3540
Idler Gear Shaft Pilot Bore....3542
Introduction....3544
Jake Brake (If Equipped)....3545
Pistons And Rings....3548
Primary Fuel Filter....3550
Pulley And Damper Groups....3551
Pulley Tightener Group....3553
Shutoff Solenoid....3555
Switch Group (Used On Engines With BrakeSaver)....3558
Turbocharger....3560
Valve Covers....3564
Valve Rocker Arms, Lifters And Bridges....3565
Valves....3569
Water Pump....3573
Water Temperature Regulators....3577
SENR6547 - Systems Operation (3406C Diesel Truck Engine)....3578
SENR6547 - Testing & Adjusting (3406C Diesel Truck Engine)....3647
SENR6548 - Disassembly & Assembly (3406C Diesel Truck Engine)....3751
Air Compressor & Accessory Drive....3754
Air Compressor....3760
Alternator & Mounting Group....3763
Automatic Timing Advance....3765
BrakeSaver Control Valve [If So Equipped]....3774
BrakeSaver [If So Equipped]....3779
Bridge Dowels....3790
Camshaft Bearings....3792
Camshaft....3795
Connecting Rod Bearings....3798
Crankshaft Front Seal & Wear Sleeve....3802
Crankshaft Main Bearings....3806
Crankshaft Rear Seal & Wear Sleeve....3811
Crankshaft....3815
Cylinder Head Assembly....3821
Cylinder Liners....3825
Dipstick Assembly....3828
Electric Starting Motor....3830
Engine Front Support....3832
Engine Lifting Brackets....3833
Exhaust Manifold....3835
Fan Drive....3838
Flywheel (BrakeSaver) [If So Equipped]....3842
Flywheel Housing....3844
Flywheel....3847
Fuel Filter & Base....3849
Fuel Injection Line Adapters....3852
Fuel Injection Lines....3855
Fuel Injection Nozzles & Adapters....3858
Fuel Injection Pump Housing & Governor....3862
Fuel Injection Pump Housing....3866
Fuel Injection Pump....3873
Fuel Priming Pump....3881
Fuel Ratio Control....3883
Fuel Transfer Pump....3892
Governor....3901
Inlet & Exhaust Valves....3919
Introduction....3922
Jacobs Engine Brake [If So Equipped]....3923
Oil Cooler (BrakeSaver) [If So Equipped]....3933
Oil Cooler (Engine)....3936
Oil Filter & Base....3938
Oil Filter Base....3941
Oil Pan (BrakeSaver) [If So Equipped]....3943
Oil Pan....3945
Oil Pump (BrakeSaver) [If So Equipped]....3947
Oil Pump....3953
Piston Cooling Tubes....3958
Pistons & Connecting Rod Assemblies....3960
Rocker Shaft Assemblies & Push Rods....3966
Rocker Shaft Assemblies....3971
Spacer Plate....3973
Tachometer Drive....3975
Timing Gear Cover....3977
Timing Gears & Housing Plate....3980
Turbocharger....3984
Valve Covers....3987
Valve Guides....3988
Valve Lifters....3990
Valve Seat Inserts....3997
Vibration Damper & Pulley....4000
Water Pump....4003
Water Temperature Regulators....4008
bonus material....4012
RENR1377 - Systems Operation (Electric Protection System Energize-To-Run for Generator Set; Industrial & Marine Diesel Engines)....4014
Abbreviations and Symbols....4015
ETR Component Descriptions....4024
ETR Introduction....4037
ETR Junction Box-Switchgear Not Required (OP,WT)....4039
ETR Junction Box-Switchgear Not Required (OP,WT,OS)....4056
ETR Junction Box-Switchgear Required (OP,WT,OS)....4081
Junction Box and Enclosure Group....4105
RENR1377 - Testing & Adjusting (Electric Protection System Energize-To-Run for Generator Set; Industrial & Marine Diesel Engines)....4110
Crank Terminate Speed Calibration....4111
Diode Test....4113
Electric Protection System Functional Test....4114
Engine Oil Pressure Switch Test....4117
General Testing and Adjusting Information....4119
General Troubleshooting Information....4122
Magnetic Pickup Test....4123
Oil Step Speed Calibration....4126
Overspeed Calibration....4128
Overspeed Verification Test....4130
Slave Relay Test....4132
Troubleshooting the ETR Full Protective System (OP, WT, OS)....4134
Troubleshooting the ETR Partial Protection System (OP, WT)....4148
Water Temperature Contactor Switch Test....4157
SEBF9050 - Applied Failure Analysis - Engine Valve Failure Modes{1100; 1105}....4159
SEBU6875 - Owner's Manual (Caterpillar Driver Information Display)....4174
SEGV3008 - Systems Operation (Fundamentals Electrical System for All Caterpillar Products)....4258
Basic Circuit Theory....4259
Basic Electrical Components....4270
Battery....4299
Charging System....4318
Circuit Voltage....4345
Electrical Measurement....4353
Electrical Schematic....4366
Electricity - How It Works....4373
Magnetism....4387
Ohms Law....4396
Solid State Electrical Components....4404
Starting System....4420
SENR2995 - Product Safety....4439
SENR3130 - Specifications (Torque Specifications for All Caterpillar Products)....4447
SENR3130 - Torque Specifications....4467
Air Brake Fittings....4468
Air Conditioning Fittings....4470
Bulkhead Nuts....4472
English (SAE) Fasteners....4475
Flare Fittings....4480
General Information....4484
Ground Engaging Tool (G.E.T.) Fasteners....4487
Hose Clamps....4489
Installation of Fittings....4492
Metric (ISO) Fasteners....4496
Miscellaneous Fittings....4502
O-Ring Face Seal Fittings....4504
Plugs....4506
Straight Thread O-Ring Fittings....4510
Tapered Pipe Thread Fittings....4515
SENR3981 - Schematic - Fluid Power & Electrical Graphic Symbols....4517
Electrical Power Graphic Symbols....4518
Fluid Power Graphic Symbols....4526
SENR4024 - Specifications (Industrial & Marine Engine Attachments)....4547
Air Cleaners Panel Type - Single Stage Air Cleaners....4549
Air Shut-Off Groups....4551
Ammeters....4554
Auxiliary Drive Groups....4556
Belt Tightener (3N9582)....4559
Circuit Breakers....4561
Ether Starting Aid....4562
Exhaust Pipes (With Dust Ejector)....4565
Front Stub Shaft....4566
Fuel Injection Lines (Double Walled)....4567
Fuel Pressure Gauges....4569
Gauge For Transmission Oil Pressure (1W4126)....4571
Gauges For Engine Oil Pressure, 5L7455, 5L7456 (Electric)....4572
Gauges For Water Temperature (Electric)....4574
Gauges for Engine Oil Pressure 7W2936, 7W2937 (Electric)....4576
Gauges for Water Temperature 7W2061, 7W2060 (Electric)....4578
Governor Controls....4580
Governor Linkage....4583
Hydraulic Pump Drive Mounting....4586
Introduction....4588
Jacket Water Heater 5N5739 120 VAC, 3000 Watts; 5N5740 240 VAC, 3000 Watts....4589
Magnetic Pick-up....4590
Magnetic Switch (Used with electric starting and air shut-off systems)....4592
Muffler Groups (With Dust Ejector)....4593
Oil Filter Group - L.H....4595
Power Take-Off Clutch (3N7841)....4597
Pressure Cap Of Cooling System....4601
Pressure Switch Terminal No. 2 Is Normally Open;Terminal No. 3 is Normally Closed....4603
Pressure Switches....4604
Primary Fuel Filter....4606
Radiator....4607
Sending Unit For Engine Oil Pressure Gauge (1W4687)....4609
Sending Unit For Oil Pressure....4610
Sending Units For Water Temperature....4612
Shut-Off Solenoids 6T8021, 6T8022, 6T8023, 9G8180....4613
Shut-Off Solenoids....4617
Temperature Switches - 3N7442, 6N5899 & 8N1693....4619
Temperature Switches - 5N8597 & 5N8598 ....4620
Time Delay Relay 5N2124 (Dynalco Corp. Number DSC-9)....4621
V-Belt Tension Chart....4622
Woodward PSG Governor....4623
SENR7508 - Disassembly & Assembly (30SI Series and 34SI Series Alternator)....4626
Alternator - Assemble....4627
Alternator - Disassemble....4640
SENR7508 - Specifications (30SI Series and 34SI Series Alternator)....4653
SENR7508 - Systems Operation (30SI Series and 34SI Series Alternator)....4667
Component Description....4668
General Information....4671
Normal Operation....4673
SENR7508 - Testing & Adjusting (30SI Series and 34SI Series Alternator)....4676
Component - Test....4677
General Information....4681
Initial Troubleshooting Procedure....4682
T1 Alternator Output - Test....4684
T2 Electrical System Current - Test....4686
T3 Charging System - Test....4688
T4 Alternator Drive System - Check....4690
T5 Alternator Current - Test....4691
T6 Residual Magnetism Restoration....4693
T7 Identifying Source of Current Draw - Test....4695
T8 Alternator Overcharging - Test....4696
SENR7594 - General Service Information (Midland Air Compressors)....4698
EL-740 Air Compressor....4699
UENR3262 - Disassembly & Assembly - Seal Installation....4723
Duo-Cone Seals - Install....4724
Lip Type Seals - Install....4753
O-Ring Seals - Install - RADIAL, FITTING ASSEMBLY O-RINGS & OTHER O-RING APPLICATIONS....4763
O-Ring Seals - Install - RADIAL, FITTING ASSEMBLY ORINGS & OTHER O-RING APPLICATIONS....4789
Caterpillar 3406C Engines Repair Service Manual
