Caterpillar 3406B Truck Diesel Engine Service Manual

Covers: Caterpillar 3406B diesel engine with serial prefixes

• 7FB
• 4MG
• 5KJ

Pages: 1,278
Format: PDF files (zipped)
File size: 55mb
Compatibility: Windows/Mac computers
Notes: Bookmarked, searchable, printable, instant download

This 9-volume service manual set contains complete specifications, systems operation information, disassembly and assembly procedures, testing and adjusting instructions and troubleshooting steps for Cat 3406B 4MG, 7FB and 5KJ diesel engines. This is a complete OEM reference for professional mechanics to service and overhaul the engine. View the manuals on your computer or print off pages as needed.

Please contact us with your engine serial number if you have compatibility questions.

Topics:

Engine Specifications

Operation & Maintenance

• Schedule
• Procedures

Engine Systems Operation

• Fuel System
• Air Inlet And Exhaust System
• Jake Brake
• Lubrication System
• BrakeSaver
• Cooling System
• Electrical System

Disassembly and Assembly

• Air Compressor
• Fuel Injection Lines
• Fuel Injection Line Adapters
• Electric Starting Motor
• Tachometer Drive
• Fuel Priming Pump
• Fuel Filter And Base
• Fuel Transfer Pump
• Fuel Ratio Control For Use With Earlier Engines
• Fuel Ratio Control For Use With Later Engines
• Automatic Timing Advance 7FB1-Up, 4MG1-4MG3599
• Fuel Injection Pump Housing And Governor
• Governor
• Fuel Injection Pumps
• Fuel Injection Pump Housing
• Turbocharger (TV72 & TV78)
• Turbocharger (S4A)
• Water Temperature Regulator And Manifold
• Water Temperature Regulator (Ford)
• Engine Oil Cooler
• Oil Filter And Base
• Oil Filter Base
• Exhaust Manifold
• Alternator And Mounting Group
• Water Pump
• Valve Covers
• Rocker Shaft Assemblies And Push Rods
• Rocker Shaft Assemblies
• Valve Lifters
• Fuel Injection Nozzles (Earlier)
• Fuel Injection Nozzle Adapters (Earlier)
• Fuel Injection Nozzles And Adapters (Later)
• Aftercooler Core
• Aftercooler Housing
• Cylinder Head Assembly
• Spacer Plate
• Valves
• Valve Seat Inserts
• Bridge Dowels
• Valve Guides
• Oil Pan
• Flywheel
• Oil Pump
• Piston Cooling Tubes
• Connecting Rod Bearings
• Crankshaft Main Bearings
• Pistons And Connecting Rod Assemblies
• Crankshaft
• Camshaft Bearings
• Crankshaft Front Seal And Wear Sleeve
• Crankshaft Rear Seal And Wear Sleeve
• Vibration Damper And Pulley
• Cylinder Liners
• Fan Drive
• Flywheel Housing
• Engine Front Support
• Camshaft
• Timing Gears And Plate
• Air Compressor And Accessory Drive
• Timing Gear Cover
• Oil Cooler (BrakeSaver)
• Flywheel (BrakeSaver)
• BrakeSaver Control Valve
• BrakeSaver
• Oil Pan (BrakeSaver)
• Oil Pump (BrakeSaver)
• Jacobs Engine Brake

Testing and Adjusting

• Brakesaver Troubleshooting
• Pull-Down RPM Check
• Klunk Check (Check For Free Movement Of The Valve Spool)
• BrakeSaver Troubleshooting Problem List
• Fuel System
• Fuel System Inspection
• Fuel Transfer Pump
• Checking Engine Cylinders Separately
• Fuel Injection Lines
• Fuel Injector Testing
• Checking the Plunger and Lifter of an Injection Pump
• Removal and Installation of Fuel Injection Pumps
• Removal of Fuel Injection Pumps
• Installation of Fuel Injection Pump
• Finding Top Center Compression Position for No. 1 Piston
• Checking Engine Timing With 8T53
• Checking Engine Timing By Timing Pin Method 7FB1-Up, 4MG1-4MG3599
• Engine Timing By Timing Pin Method 4MG36
• Fuel Setting Procedure
• Fuel Ratio Control And Governor Check (Earlier Engines)
• Fuel Ratio Control Adjustment (All Engines Except CARB Approved) For Use With Earlier Engines
• Fuel Ratio Control Adjustment (CARB Approved Engines) For Use With Earlier Engines
• Check And Adjustment Of The Fuel Ratio Control Linkage For Use With Earlier Engines
• Fuel Ratio Control And Governor Check (Later Engines)
• Fuel Ratio Control Adjustment (Later Engines)
• Engine Speed Measurement
• Governor Adjustments
• Air Inlet And Exhaust System
• Restriction Of Air Inlet And Exhaust
• Measurement Of Pressure In Inlet Manifold
• Exhaust Temperature
• Air To Air Aftercooled Systems
• Visual Inspection
• Air System Restriction
• Turbocharger Failure
• Inlet Manifold Pressure
• Aftercooler Core Leakage
• Dynamometer Test
• Crankcase (Crankshaft Compartment) Pressure
• Compression
• Cylinder Head
• Valves
• Valve Seat Inserts
• Valve Guides
• Checking Valve Guide Bores
• Bridge Dowel
• Bridge Adjustment
• Valve Clearance Setting
• Jake Brake Adjustment
• Lubrication System
• Too Much Oil Consumption
• Oil Leakage On Outside Of Engine
• Oil Leakage Into Combustion Area Of Cylinders
• Measuring Engine Oil Pressure
• Oil Pressure Is Low
• Crankcase Oil Level
• Oil Pump Does Not Work Correctly
• Oil Filter Bypass Valves
• Too Much Clearance At Engine Bearings Or Open Lubrication System (Broken Or Disconnected Oil Line Or Passage)
• Piston Cooling Tubes (Jets)
• Oil Pressure Is High
• Too Much Bearing Wear
• Increased Oil Temperature
• Cooling System
• Visual Inspection Of The Cooling System
• Testing The Cooling System
• Test Tools For Cooling System
• Checking Pressure Cap
• Testing Radiator And Cooling System For Leaks
• Gauge For Water Temperature
• Water Temperature Regulators
• Belt Tension Chart
• Basic Block
• Piston Rings
• Connecting Rods And Pistons
• Connecting Rod And Main Bearings
• Cylinder Block
• Projection Of Cylinder Liner
• Flywheel And Flywheel Housing
• Face Run Out (Axial Eccentricity) Of The Flywheel Housing
• Bore Runout (Radial Eccentricity) Of The Flywheel Housing
• Face Runout (Axial Eccentricity) Of The Flywheel
• Bore Runout (Radial Eccentricity) Of The Flywheel
• Vibration Damper
• Electrical System
• Test Tools For Electrical System
• Battery
• Charging System
• Alternator Regulator Adjustment (Delco-Remy)
• Alternator Pulley Nut Tightening (Delco-Remy)
• Starting System
• Pinion Clearance Adjustment

Troubleshooting

• Introduction
• High Fuel Consumption
• High Fuel Consumption Complaints
• Low Power And Engine Response Complaints
• Low Power Complaints
• Engine Response Complaints
• Primary Engine Checks
• Road Test
• Non-Engine Related Problems
• Misfiring And Running Rough
• Excessive Black Or Gray Exhaust Smoke
• Excessive White Or Blue Exhaust Smoke
• Hard Starting (Engine Crankshaft Turns Freely)
• Engine Does Not Start
• Cooling System
• Loss Of Coolant
• Fuel In Crankcase Oil
• Engine Vibration Troubleshooting

General Torque Specifications for All Caterpillar Products

Cat Shop Supplies and Tools