Caterpillar 3116, 3126 8WL/1WM Engine Complete Service Manual

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Covers: Caterpillar 3116, 3126 Diesel Engines (8WL and 1WM serial number prefix)
Pages: 1,878
Format: PDF files (zipped)
File size: 47mb
Compatibility: Windows/Mac computers
Notes: Instant download only.

This 7 volume service manual set contains complete specifications, systems operation information, disassembly and assembly procedures, testing and adjusting instructions and troubleshooting steps for the Caterpillar 3116, 3126 8WL/1WM diesel engine. Additionally, the Cat 3116, 3126 8WL/1WM engine wiring diagrams are included in high resolution PDF format. This is a complete OEM reference for professional mechanics to service and repair the engine. View the manuals on your computer or print off pages as needed.

Topics in the Caterpillar 3116, 3126 8WL/1WM Engine Complete Service Manual:

  • Engine Design
  • Fuel Lines Group
  • Fuel Filter Lines Group
  • Fuel Heater And Water Separator (If Equipped)
  • Hydraulic Electronic Unit Injector (HEUI)
  • Hydraulic Oil Lines
  • Hydraulic Pump Group (Fuel Transfer And High Pressure Oil Pumps)
  • Injection Actuation Pressure Control Valve
  • Valve Rocker Arms And Lifters
  • Valves
  • Valve Cover
  • Cylinder Head
  • Camshaft
  • Turbocharger
  • Exhaust Manifold
  • Air Inlet Elbow
  • Oil Pump
  • Breather (Crankcase)
  • Oil Cooler Bypass Valve
  • Oil Filter Base
  • Engine Oil Pressure
  • Water Pump
  • Water Pump Belt Tightener
  • Water Temperature Regulator
  • Fan Drive
  • Cylinder Block
  • Piston Cooling Jet
  • Cylinder Block Cover Group
  • Crankshaft Seals
  • Crankshaft
  • Crankshaft Pulley Group
  • Connecting Rod
  • Pistons And Rings
  • Connecting Rod And Main Bearing Journals
  • Front Gear Group
  • Front Housing
  • Front Housing Cover
  • Flywheel
  • Flywheel Housing
  • Flywheel Runout
  • Flywheel Housing Runout
  • Flywheel Housing Bore
  • Electronic Control Group (Wiring And Sensors)
  • Adapter Group (Engine To Transmission)
  • Electric Starting Motor
  • Alternator
  • Regulator
  • Inlet Air Heater
  • Ether Starting Aid
  • Wiring Group (Inlet Air Heater)
  • Air Compressor

Caterpillar 3116, 3126 8WL/1WM Diesel Engine Disassembly & Assembly Manual:

  • Fuel Transfer Pump – Remove
  • Fuel Transfer Pump – Install
  • Fuel Pressure Regulator – Remove and Install
  • Unit Injector – Remove
  • Unit Injector – Install
  •  Unit Injector Sleeve – Remove
  • Unit Injector Sleeve – Install
  • Injection Actuation Pressure Control Valve – Remove
  • Injection Actuation Pressure Control Valve – Disassemble
  • Injection Actuation Pressure Control Valve – Assemble
  • Injection Actuation Pressure Control Valve – Install
  • Unit Injector Hydraulic Pump – Remove
  • Unit Injector Hydraulic Pump – Install
  • Turbocharger – Remove
  • Turbocharger – Disassemble
  • Turbocharger – Assemble
  • Turbocharger – Install
  • Exhaust Manifold – Remove and Install
  • Air Inlet Heater – Remove and Install
  • Air Inlet Heater Solenoid – Remove and Install
  • Air Inlet Cover – Remove and Install
  • Inlet Manifold – Remove
  • Inlet Manifold – Install
  • Inlet and Exhaust Valves – Remove and Install
  • Inlet and Exhaust Valve Guides – Remove and Install
  • Inlet and Exhaust Valve Seat Inserts – Remove and Install
  • Engine Oil Filter Base – Remove
  • Engine Oil Filter Base – Disassemble
  • Engine Oil Filter Base – Assemble
  • Engine Oil Filter Base – Install
  • Engine Oil Filter Bypass Valve – Remove and Install
  • Engine Oil Cooler Bypass Valve – Remove and Install
  • Engine Oil Cooler – Remove
  • Engine Oil Cooler – Install
  • Engine Oil Pump – Remove
  • Engine Oil Pump – Disassemble
  • Engine Oil Pump – Assemble
  • Engine Oil Pump – Install
  • Water Pump – Remove
  • Water Pump – Disassemble
  • Water Pump – Assemble
  • Water Pump – Install
  • Water Temperature Regulator Housing – Remove and Install
  • Water Temperature Regulator – Remove and Install
  • Engine Lifting Bracket – Remove and Install
  • Engine Support (Front) – Remove and Install
  • Flywheel – Remove
  • Flywheel – Install
  • Crankshaft Rear Seal – Remove
  • Crankshaft Rear Seal – Install
  • Crankshaft Wear Sleeve (Rear) – Remove – If Equipped
  • Crankshaft Wear Sleeve (Rear) – Install
  • Crankshaft Rear Seal Carrier – Remove and Install
  • Flywheel Housing – Remove and Install
  • Vibration Damper and Pulley – Remove and Install
  • Crankshaft Front Seal – Remove
  • Crankshaft Front Seal – Install
  • Front Cover – Remove
  • Front Cover – Install
  • Gear Group (Front) – Remove
  • Gear Group (Front) – Install
  • Housing (Front) – Remove
  • Housing (Front) – Install
  • Camshaft Idler Gear – Remove and Install
  • Valve Mechanism Cover – Remove and Install
  • Rocker Shaft and Pushrod – Remove
  • Rocker Shaft – Disassemble
  • Rocker Shaft – Assemble
  • Rocker Shaft and Pushrod – Install
  • Cylinder Head – Remove
  • Cylinder Head – Install
  • Lifter Group – Remove and Install
  • Camshaft – Remove
  • Camshaft – Install
  • Camshaft Gear – Remove and Install
  • Camshaft Bearings – Remove and Install
  • Engine Oil Pan – Remove and Install
  • Piston Cooling Jets – Remove and Install
  • Pistons and Connecting Rods – Remove
  • Pistons and Connecting Rods – Disassemble
  • Pistons and Connecting Rods – Assemble
  • Pistons and Connecting Rods – Install
  • Crankshaft Main Bearings – Remove
  • Crankshaft Main Bearings – Install
  • Crankshaft – Remove
  • Crankshaft – Install
  • Crankshaft Gear – Remove and Install
  • Bearing Clearance – Check
  • Ether Atomizer – Remove and Install
  • Idler Pulley – Remove
  • Idler Pulley – Disassemble
  • Idler Pulley – Assemble
  • Idler Pulley – Install
  • Belt Tensioner – Remove and Install
  • Belt Tightener – Remove
  • Belt Tightener – Disassemble
  • Belt Tightener – Assemble
  • Belt Tightener – Install
  • Fan Drive – Remove
  • Fan Drive – Disassemble
  • Fan Drive – Assemble
  • Fan Drive – Install
  • Engine Control Module – Remove and Install
  • Alternator – Remove and Install
  • Electric Starting Motor – Remove and Install
  • Air Compressor – Remove and Install
  • Air Compressor Drive Gear – Remove and Install

Caterpillar 3116, 3126 8WL/1WM Diesel Engine Systems Operation Manual:

  • General Information
  • Air Inlet And Exhaust System
  • Lubrication System
  • Cooling System
  • Basic Block
  • Electrical System

Caterpillar 3116, 3126 8WL/1WM Diesel Engine Testing & Adjusting Manual:

  • Introduction
  • Troubleshooting
  • Electronic Control System
  • Fuel System
  • Fuel Priming Procedure (If Equipped With Priming Pump Attachment)
  • Air Inlet And Exhaust System
  • Lubrication System
  • Cooling System
  • Belt Tension Chart
  • Basic Block
  • Electrical System

Caterpillar 3116, 3126 8WL/1WM Diesel Engine Troubleshooting Manual:

  • Introduction
  • P-1.0 3100 HEUI Electronic System Overview
  • P-2.0 Programming Parameters
  • Troubleshooting Without a Diagnostic Code
  • Troubleshooting With A Diagnostic Code
  • Glossary Of Terms

Caterpillar 3116, 3126 8WL/1WM Diesel Engine Wiring Schematic

PLUS Caterpillar 3116, 3126 8WL/1WM Diesel Engine Special Instructions and General Torque Specifications for Caterpillar Products Manual

 

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Bore … 110.0 mm (4.33 inch)
Stroke … 127.0 mm (5.00 inch)
Displacement … 7.2 L (439 cu in)
Number of cylinders … 6
Cylinder arrangement … In-line
Valves per cylinder … 3
Type of combustion … Direct injection
Note: The front end of the engine is opposite of the flywheel end of the engine. The left side of the
engine and the right side of the engine are viewed from the flywheel end of the engine. The no. 1
cylinder is the front cylinder.
Crankshaft rotation (view from the flywheel end) … Counterclockwise
Valve lash with engine stopped (cold)
Inlet … 0.38 ± 0.08 mm (0.015 ± 0.003 inch)
Exhaust … 0.64 ± 0.08 mm (0.025 ± 0.003 inch)
Firing order … 1, 5, 3, 6, 2, 4

 00
71-11 Engine Shutdown Override Switch Occurrence
84-14 Quick Stop Occurrence
96-03 96-03 Fuel Level Voltage High
96-04 96-04 Fuel Level Voltage Low
186-04 PTO Engine Shutdown Switch Voltage Low
224-11 Theft Deterent Active
224-14 Theft Deterent Active with Engine Cranking
231-12 J1939 Device Not Responding
246-11 Brake Pedal Switch #1 Fault
247-11 Brake Pedal Switch #2 Fault
01 71-00 Idle Shutdown Override
12
111-02
Coolant Level signal invalid
111-03 Coolant Level voltage high
111-04 111-04 Coolant Level voltage low
15
164-02
164-02 Injection Actuation Pressure Signal Erratic
164-03 164-03 Injection Actuation Pressure Voltage High
164-04 164-04 InjectionActuation Pressure Voltage Low
16
173-00
High Exhaust Gas Temperature Derate
173-11 Very High Exhaust Gas Temperature Derate
17 164-00
164-00 Excessive Injection Actuation Pressure
18 42-11 Injection Actuation Pressure output fault
21
41-03 678-03 8 Volt Supply voltage high
41-04 678-04 8 Volt Supply voltage low
232-03 620-03 5 Volt Supply voltage high
232-04 620-04 5 Volt Supply voltage low
24
100-03
100-03 Oil Pressure voltage high
100-04 100-04 Oil Pressure voltage low
25
102-01
102-01 Low Boost Pressure
102-02 102-02 Boost Pressure signal erratic
102-03 102-03 Boost Pressure voltage high
102-04 102-04 Boost Pressure voltage low
102-07 102-07 Boost Pressure not responding
26
108-03
108-03 Barometric Pressure voltage high
108-04 108-04 Barometric Pressure voltage low
27
110-03
110-03 Coolant Temperature voltage high
110-04 110-04 Coolant Temperature voltage low
28 91-13 Throttle Position out of Calibration
29 30-08 PTO Throttle signal invalid
30-13 PTO Throttle out of calibration
31 84-01 Vehicle Speed loss of signal
32 91-08 Throttle Position Invalid
33
32-05 646-05 Turbo Wastegate Solenoid current low
32-06 646-06 Turbo Wastegate Solenoid current hig
32-11 646-11 Turbo Wastegate Solenoid current mismatch
34
64-02 Secondary Engine Speed loss of signal
64-11 Secondary Engine Speed no pattern
190-02 Primary Engine Speed loss of signal
190-11 Primary Engine Speed no pattern
35 190-00
190-15 Engine Overspeed Warning
36
84-02 Vehicle Speed signal invalid
84-08 Vehicle Speed signal out of range
84-10 Vehicle Speed signal rate of change
37
94-03 94-03 Fuel Pressure voltage high
94-04 94-04 Fuel Pressure voltage low
38
105-03
105-03 Intake Manifold Air Temperature voltage high
105-04 105-04 Intake Manifold Air Temperature voltage low
39 164-11
164-11 Injection Actuation Pressure system fault
41 84-00 Vehicle Overspeed Warning
42
22-11 637-11 Primary to Secondary Engine Speed Signal
Calibration
22-13 637-13 Engine Speed Signal Calibration Not Performed
44
128-03
Secondary Fuel Level voltage high
128-04 Secondary Fuel level voltage low
46 100-01
100-17 Low Oil Pressure Warning
100-11 100-18 Very Low Oil Pressure
47
71-01 Idle Shutdown
71-14 PTO Shutdown
186-14 PTO Engine Shutdown Switch Occurrence
49
70-05 729-05 Inlet Air Heater current low
70-06 729-06 Inlet Air Heater current high
51
168-00
168-00 Excessive ECM Battery Power
168-01 168-01 Low ECM Battery Power
168-02 168-02 ECM Battery Power Intermittent
55 N/A N/A No Diagnostic Code Detected
56
253-02
630-02 Check Customer or System Parameters
253-14 Truck Manufacturer Paremater Not Programmed
57 231-14
Transmission Data Link Derate
58
231-02
639-02 J1939 Data Incorrect
231-11 639-12 J1939 Data Link Fault
59 252-11
631-11 Engine Software Incorrect
61
110-00
110-15 High Coolant Temperature Warning
110-11 110-16 Very High Coolant Temperature
62
111-01
111-17 Low Coolant Level Warning
111-11 111-18 Very Low Coolant Level
111-14 Low Coolant Level Warning
63
94-01 Low Fuel Pressure Warning
94-11 Low Cranking Fuel Pressure
64 105-00
1636-15 High Intake Manifold Air Temperature Warning
105-11 1636-16 Very High Intake Manifold Air Temperature
71 43-02 Key Switch Fault
72
1-11 651-11 Cylinder #1 Injector current fault
2-11 652-11 Cylinder #2 Injector current fault
73
3-11 653-11 Cylinder #3 Injector current fault
4-11 654-11 Cylinder #4 Injector current fault
74
5-11 655-11 Cylinder #5 Injector current fault
6-11 656-11 Cylinder #6 Injector current fault

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