Caterpillar 3406 3406B G3406 G3412 Engine Workshop Repair Service Manual PDF - MCAT3406EN.zip

A full workshop and repair guide, complete with electrical wiring schematics, covering the Caterpillar 3406 engine. It delivers every technical detail needed to service, troubleshoot, fix, and overhaul the engine the way trained technicians do.

Inside the Caterpillar 3406 Engines workshop service 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.

REG01438 - Systems Operation (3406 VEHICULAR ENGINE).pdf

REG01438 - Testing And Adjusting (3406 VEHICULAR ENGINE).pdf

REG01439 - Specifications (3406 ENGINE FOR CATERPILLAR BUILT MACHINES).pdf

RENR5952 - Specifications (G3406 and G3412 Generator Set Engines).pdf

RENR5953 - Systems Operation (G3406 and G3412 Generator Set Engines).pdf

RENR5953 - Testing and Adjusting (G3406 and G3412 Generator Set Engines).pdf

RENR5956 - Schematic (G3406 & G3412 Generator Set Electrical System).pdf

RENR8112 - Schematic (G3406 and G3412 Generator Set Electrical System R7A102-UP; R7E103-UP; KAP232-UP; KAR280-UP).pdf

SEBR0510 - Attachment Specifications (3406 INDUSTRIAL & MARINE ENGINES).pdf

SEBR0510 - Attachment Systems Operation (3406 INDUSTRIAL & MARINE ENGINES).pdf

SEBR0510 - Disassembly & Assembly (3406 INDUSTRIAL & MARINE ENGINES).pdf

SEBR0510 - General Service Information (3406 INDUSTRIAL & MARINE ENGINES).pdf

SEBR0510 - Testing And Adjusting (3406 INDUSTRIAL & MARINE ENGINES).pdf

SEBR0512 - Disassembly and Assembly (3406 DIESEL TRUCK ENGINE).pdf

SEBR0512 - Specifications (3406 DIESEL TRUCK ENGINE).pdf

SEBR0512 - Systems Operation (3406 DIESEL TRUCK ENGINE).pdf

SEBR0512 - Testing And Adjusting (3406 DIESEL TRUCK ENGINE).pdf

SEBR0512 - Troubleshooting (3406 DIESEL TRUCK ENGINE).pdf

SEBU5791 - Operation and Maintenance Manual (3406 INDUSTRIAL AND GENERATOR SET ENGINES).pdf

SENR2537 - Systems Operations (3406 & 3406B GENERATOR SET ENGINES).pdf

SENR2537 - Testing and Adjusting (3406 & 3406B GENERATOR SET ENGINES).pdf

SENR2539 - Systems Operation (3400 GENERATOR SET ENGINE ATTACHMENTS).pdf

SENR2539 - Testing and Adjusting (3400 GENERATOR SET ENGINE ATTACHMENTS).pdf

SENR2540 - Disassembly and Assembly (3406 ENGINE FOR GENERATOR SET).pdf

SENR3867 - Disassembly and Assembly (3406 SPARK IGNITED ENGINE).pdf

UENR8300 - Schematic (G3406 Generator Set with EMCP4.2 for Gas Electrical System).pdf

PRODUCT DETAILS:

Total Pages: 3,100 pages

File Format: PDF

Language: English

TABLE OF CONTENTS

REG01438 - Systems Operation (3406 VEHICULAR ENGINE)....3

REG01438 - Testing And Adjusting (3406 VEHICULAR ENGINE)....61

REG01439 - Specifications (3406 ENGINE FOR CATERPILLAR BUILT MACHINES)....206

Introduction....210

Engine Design....211

New Scroll Fuel System....212

Fuel Injection Lines (Later Engines)....213

Fuel Injection Lines (Earlier Engines)....216

Fuel Injection Nozzle And Adapter (Later Engines)....219

Fuel Injection Nozzle And Adapter (Earlier Engines)....221

Governor and Fuel Pump Drive Group (Automatic Timing Advance Unit)....224

Fuel System Identification....226

Fuel Injection Pump....227

Governor....238

Fuel Injection Pump Housing....245

Automatic Timing Advance Unit....250

Fuel Ratio Control....252

Fuel Injection Lines....255

Fuel Transfer Pump....256

Drive For Fuel Transfer Pump And Tachometer....262

Secondary Fuel Filter Base - 16G Motor Grader Only....264

Primary Fuel Filter....265

Fuel Filter Base....266

Front (Timing) Gear Group....268

Front (Timing) Gear Group (621B; 623B)....270

Rear Gear Group (D8N)....272

Valve Covers....273

Camshaft....274

Valves....276

Intake Valve Timing....280

Valve Rocker Arms; Lifters And Bridges....281

Cylinder Head....284

Turbocharger Impeller Installation (AiResearch Only)....286

Turbocharger TV61....288

Turbocharger TV81....290

Turbocharger TW81....292

Turbocharger T12....294

Turbocharger TL81....296

Exhaust Manifold....298

Exhaust Manifold Shield....299

Muffler and Ejector Group....300

Air Cleaner....302

Oil Filter (245 Excavator; 621B and 623B Tractors)....303

Oil Filter (16G Motor Grader; 824C Tractor; 825C & 826C Compactors; 980C Wheel Loader; 983B Track-Type Loader; 621E and 623E Tractors)....305

Engine Oil Lines....307

Oil Pump....308

Oil Cooler Bypass Valve....312

Oil Pump (One Section Gear)....314

Breather Cap....317

Oil Pan (Typical Example)....318

Oil Cooler (621B and 623B - Torque Converter Oil; 980C - Hydraulic Oil)....320

Hydraulic Oil Cooler....321

Fan Drive....322

Alternator and Fan Support....323

Water Temperature Regulators....324

Belt Tension Chart....326

Water Pump....327

Belt Tighteners....329

Radiator....331

Radiator(Folded Core)....335

Aftercooler....338

Coolant Conditioner Base....339

Cylinder Block....341

Idler Gear Shaft Pilot Bore....345

Idler Gear Assembly(For Front Gear Group)....347

Cylinder Liners....349

Cylinder Liner Projection....351

Pistons And Rings....354

Connecting Rods....356

Bearings For Connecting Rods And Mains....359

Crankshaft (Earlier)....360

Crankshaft (Later)....362

Flywheel Housing....364

Flywheel Housing Bore....369

Flywheel Housing Runout....372

Flywheel Runout....374

Flywheel....376

Trunnion Group....378

Front Housing And Covers....379

Engine And Drive Support (245 Excavator)....383

Engine Support....384

Engine And Transmission Support (980C Wheel Loader)....387

Alternator Mounting Group (980C Wheel Loader; 824C Tractor; 825C & 826C Compactors)....388

Accessory Drive Group (245 & 245B Excavators; 16G Motor Grader; 824C Tractor; 825C & 826C Compactors; 980C Wheel Loader)....389

Connections For Glow Plug Wiring....393

Tachometer Drive....394

Air Compressor Drive....395

Pressure Switch....397

Differential Pressure Switch....398

Vacuum Switch....399

Coolant Flow Switches....400

Temperature Switch....402

Starter Motors....404

Starter Solenoids....409

Control Solenoid....412

Shut-off Solenoids....413

Alternators....416

Regulators....425

RENR5952 - Specifications (G3406 and G3412 Generator Set Engines)....428

Engine Design....430

Spark Plug Adapter....432

Spark Plug and Transformer....436

Gas Engine Ignition....438

Ignition Transformer....439

Gas Pressure Regulator....441

Governor Drive....446

Camshaft....451

Valve Cover....453

Valve Mechanism....455

Cylinder Head....459

Cylinder Head Valves....465

Turbocharger....471

Exhaust Manifold - Water Cooled....473

Exhaust Bypass Valve....475

Air Cleaner....476

Engine Oil Pump....478

Engine Oil Filter Base....482

Engine Oil Pan....484

Crankcase Breather....485

Water Pump....487

Fan Drive....490

Water Temperature Regulator....495

Cylinder Block....497

Crankshaft....503

Connecting Rod - Connecting Rod For One-Piece Aluminum Piston....507

Connecting Rod and Main Bearing Journals....511

Piston and Rings....513

Cylinder Liner....515

Camshaft Bearings....517

Camshaft Bearing Position....519

Gear Group (Front)....520

Housing (Front)....522

Cover Group (Front Housing)....525

Idler Gear Assembly....526

Cover Group (Rear Housing)....528

Vibration Damper and Pulley....530

Flywheel....532

Flywheel Housing....534

Belt Tension Chart....536

Accessory Drive....538

Alternator and Regulator....542

Electric Starting Motor....548

Air Starting Motor....550

Gas Solenoid Valve....552

Engine Speed Sensor....554

Coolant Level Sensor....555

Engine Oil Pressure Sensor....558

Engine Speed_Timing Sensor....559

RENR5953 - Systems Operation (G3406 and G3412 Generator Set Engines)....561

Electronic Control System Operation....562

Electronic Control System Parameters - Electronic Ignition System (EIS)....563

Engine Monitoring System....566

Engine Monitoring System - Electronic Ignition System (EIS)....570

Ignition System....573

Ignition System - Electronic Ignition System (EIS)....579

Governor....588

Gas Pressure Regulator....590

Carburetor....593

Air Inlet and Exhaust System Components....597

Aftercooler....599

Exhaust Manifold....600

Turbocharger....601

Exhaust Bypass Valve....603

Valve System Components....606

Lubrication System....608

Cooling System....616

Cylinder Block; Liners and Heads....625

Pistons; Rings and Connecting Rods....629

Crankshaft....631

Camshaft....633

Air Starting System Operation....634

Grounding Practices....636

Charging System....637

Starting System....639

Related Components....641

RENR5953 - Testing and Adjusting (G3406 and G3412 Generator Set Engines)....644

Troubleshooting....646

General Information (Electronic Control System)....677

Manifold Air Pressure Sensor....678

Detonation Sensor....680

Engine Speed_Timing Sensor....682

Ignition Transformer....688

Ignition System....697

General Information (Fuel System)....709

Carburetor - Adjust....711

Gas Pressure....714

Finding the Top Center Position for the No. 1 Piston....718

Governor - Adjust....720

Restriction of Air Inlet and Exhaust....725

Measuring Inlet Manifold Temperature....727

Turbocharger - Inspect....730

Measuring Inlet Manifold Pressure....732

Measuring Exhaust Temperature....733

Exhaust Bypass Valve....734

Compression....736

Crankshaft Position for Valve Lash Setting....738

Valve Lash and Valve Bridge Adjustment....742

General Information (Lubrication System)....750

Measuring Engine Oil Pressure....751

General Information (Cooling System)....754

Testing the Cooling System....756

Cylinder Block....760

Cylinder Liner Projection....761

Flywheel - Inspect....768

Flywheel Housing - Inspect....771

Vibration Damper - Check....776

Pressure Regulating Valve....777

Lubrication....779

General Information (Air_Electric Starting System)....780

Test Tools for the Electrical System....783

Charging System....788

Battery....789

RENR5956 - Schematic (G3406 & G3412 Generator Set Electrical System)....790

Collage....791

Main....806

RENR8112 - Schematic (G3406 and G3412 Generator Set Electrical System R7A102-UP; R7E103-UP; KAP232-UP; KAR280-UP)....808

Collage....809

Main....833

SEBR0510 - Attachment Specifications (3406 INDUSTRIAL & MARINE ENGINES)....835

Air Fuel Ratio Controls....837

Air Shut-Offs....839

Ammeter....842

Auxiliary Drive Groups....843

Belt Tightener....846

Circuit Breaker....848

Flywheels....849

Fuel Pressure Gauges....851

Gauges For Engine Oil Pressure....853

Gauges For Gear Oil Pressure....855

Gauges For Water Temperature....857

Governor Air Actuator....859

Governor Controls....860

Governor Linkage....861

Introduction....863

Magnetic Pick-Up....864

Oil Pressure Shut-Off....865

Oil Pressure Switch ....866

Oil Pressure Switch....868

Overspeed Contactor Group....872

Power Take-Off Clutch Groups....873

Pressure Switch....878

Primary Fuel Filter....879

Radiators....880

Sending Unit For Gear Oil Pressure....882

Sending Units For Oil Pressure....883

Sending Units For Water Temperature....884

Shut-Off Solenoids....885

Starter Magnetic Switch....887

Starter Motors....888

Starter Solenoid....889

Tachometers....891

V-Belt Tension Chart....893

Water Temperature Shut-Off Valve....894

Water Temperature Switches....895

Woodward PSG Governor....897

SEBR0510 - Attachment Systems Operation (3406 INDUSTRIAL & MARINE ENGINES)....903

SEBR0510 - Disassembly & Assembly (3406 INDUSTRIAL & MARINE ENGINES)....951

Accessory Drive....954

Aftercooler Core....957