Caterpillar C3.6 and C2.8 Diesel Engine Workshop Repair Service Manual PDF - MCATC3.6OPEK.zip
This is a full factory-style repair guide for the Caterpillar C3.6 and C2.8 diesel engines, containing everything required to service, troubleshoot, fix, and overhaul them at a professional mechanic's level.
Inside the Caterpillar C3.6 and C2.8 diesel workshop service and repair manual, you'll find:
* 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