Complete service repair manual contains service, maintenance, and troubleshooting information for the Caterpillar 3406, 3406B, 3406C, 3406E Engine. Diagnostic and repair procedures are covered in great detail to repair, maintain, rebuild, refurbish or restore your engine like a professional mechanic in local service/repair workshop. This cost-effective quality manual is 100% complete and intact as should be without any missing pages. It is the same factory shop manual used by dealers that guaranteed to be fully functional to save your precious time.

This manual for Caterpillar 3406, 3406B, 3406C, 3406E Engine is divided into different sections. Each section covers a specific component or system and, in addition to the standard service procedures, includes disassembling, inspecting, and assembling instructions. A table of contents is placed at the beginning of each section. Pages are easily found by category, and each page is expandable for great detail. It is in the cross-platform PDF document format so that it works like a charm on all kinds of devices. You do not need to be skilled with a computer to use the manual.

2,394 pages, bookmarked, Searchable, Printable, high quality PDF

ENGINE - GENERATOR SET
Model Prefix
3406 GEN SET ENGINE 75Z
3406B GEN SET ENGINE 2RJ
3406B GEN SET ENGINE 2WB
3406B GEN SET ENGINE 4JK
3406B GEN SET ENGINE 4PM
3406B GEN SET ENGINE 4RG
3406B GEN SET ENGINE 6TG
3406B GEN SET ENGINE 9PL
3406C GEN SET ENGINE 1LS
3406C GEN SET ENGINE 4JK
3406C GEN SET ENGINE 4RG
3406C GEN SET ENGINE 4ZR
3406C GEN SET ENGINE 8FS
3406C GENERATOR SET 9ES
3406C GENERATOR SET C2G
3406C GENERATOR SET C2Y
3406C GENERATOR SET C5G
3406C GENERATOR SET C8G
3406C GENERATOR SET KPS
3406C GENERATOR SET LRX
3406C GENERATOR SET NKM
3406C GENERATOR SET ZKC
3406E GEN SET ENGINE 9NN
3406E GENERATOR SET 8AZ

ENGINE - INDUSTRIAL
Model Prefix
3406 INDUSTRIAL ENGINE 90U
3406 INDUSTRIAL ENGINE 9HB
3406B INDUSTRIAL ENGINE 6TB
3406B INDUSTRIAL ENGINE WJA
3406C INDUSTRIAL ENGINE 3ER
3406C INDUSTRIAL ENGINE 4GW
3406C INDUSTRIAL ENGINE 5H9
3406C INDUSTRIAL ENGINE 7T2
3406C REMAN ENGINE 2MZ
3406E INDUSTRIAL ENGINE 6BR

ENGINE - MACHINE
Model Prefix
3406 ENGINE - MACHINE 11N
3406 ENGINE - MACHINE 41Z
3406 ENGINE - MACHINE 70V
3406 ENGINE - MACHINE 81Y
3406 ENGINE - MACHINE 9AP
3406 ENGINE - MACHINE A5Y
3406 ENGINE - MACHINE BMS
3406B ENGINE - MACHINE 11N
3406B ENGINE - MACHINE 6TB
3406C ENGINE - MACHINE 11N
3406C ENGINE - MACHINE 41Z
3406C ENGINE - MACHINE A5N
3406C ENGINE - MACHINE A5Y
3406C ENGINE - MACHINE TXC
3406E ENGINE - MACHINE 9AP
3406E ENGINE - MACHINE BET
3406E ENGINE - MACHINE BKN

ENGINE - TRUCK
Model Prefix
3406 REMAN ENGINE 8SB
3406 TRUCK ENGINE 8SB
3406 TRUCK ENGINE 92U
3406B REMAN ENGINE 7XC
3406B TRUCK ENGINE 2EK
3406B TRUCK ENGINE 3ZJ
3406B TRUCK ENGINE 4CK
3406B TRUCK ENGINE 4MG
3406B TRUCK ENGINE 5KJ
3406B TRUCK ENGINE 5YG
3406B TRUCK ENGINE 7FB
3406B TRUCK ENGINE 8TC
3406C TRUCK ENGINE 3ZJ
3406C TRUCK ENGINE 4CK
3406C TRUCK ENGINE 5KJ
3406C TRUCK ENGINE 8PN
3406E REMAN ENGINE 4AS
3406E TRUCK ENGINE 1LW
3406E TRUCK ENGINE 1MM
3406E TRUCK ENGINE 2WS
3406E TRUCK ENGINE 5DS
3406E TRUCK ENGINE 5EK
3406E TRUCK ENGINE 6TS

MARINE PRODUCTS
Model Prefix
3406 MARINE ENGINE 91U
3406B MARINE ENGINE 4TB
3406C GEN SET ENGINE 2AM
3406C GEN SET ENGINE 4BM
3406C GENERATOR SET PFH
3406C MARINE ENGINE 1SS
3406C MARINE ENGINE 4T7
3406E MARINE ENGINE 9WR

SENR1072 - Schematic (Caterpillar 3176C; 3196; 3406E & 3456 Industrial Engines)
RENR1272 - Specifications (3406E Truck Engine).pdf
RENR1272 - Systems Operation (3406E Truck Engine).pdf
RENR1272 - Testing and Adjusting (3406E Truck Engine).pdf
RENR1273 - Systems Operation (3406E Truck Engine).pdf
RENR1273 - Testing & Adjusting (3406E Truck Engine).pdf
RENR1277 - Disassembly and Assembly (3406E TRUCK ENGINE).pdf
RENR1327 - Schematic (C-10, C-12 & 3406E TRUCK ENGINE).pdf
RENR1328 - Troubleshooting (3406E; C-10 and C-12 On-highway Engines).pdf
RENR1362 - Specifications (3406E and 3456 Engines for Caterpillar Built Machines).pdf
RENR1363 - Systems Operation (3406E and 3456 Engines for Caterpillar Built Machines).pdf
RENR1363 - Testing and Adjusting (3406E and 3456 Engines for Caterpillar Built Machines).pdf
RENR1364 - Disassembly and Assembly (3406E and 3456 Engines for Caterpillar Built Machines).pdf
RENR1364 - Specifications (3406E and 3456 Engines for Caterpillar Built Machines).pdf
RENR2227 - Troubleshooting (3406E and 3456 Generator Set Engines).pdf
RENR2237 - Schematic (C-10; C-12; 3406E; C-15; and C-16 Truck Engine Electrical System).pdf
RENR2237 - Schematic (C-10; C-12; 3406E; C-15; C-16 On-highway Engines Electrical System).pdf
RENR2237 - Schematic (C-10_C-12_3406E_C-15_C-16 On-Highway Engine Electrical System).pdf
RENR2238 - Toubleshooting (3406E_C-10_C-12_C-15_C-16_C-18 Truck Engine).pdf
RENR2302 - Specifications (3406E and 3456 Generator Set Engines).pdf
RENR2303 - Systems Operation (3406E and 3456 Generator Set Engines).pdf
RENR2303 - Testing and Adjusting (3406E and 3456 Generator Set Engines).pdf
RENR2304 - Disassembly and Assembly (3406E and 3456 Generator Set Engines).pdf
RENR2339 - Troubleshooting (3456 Engines for Caterpillar Built Machines).pdf
SEBU5595 - Maintenance Intervals Operation and Maintenance Manual Excerpt (3406E Truck Engines).pdf
SENR1066 - Specifications (3406E and 3456 Industrial Engines).pdf
SENR1067 - Systems Operation (3406E and 3456 Industrial Engines).pdf
SENR1067 - Testing and Adjusting (3406E and 3456 Industrial Engines).pdf
SENR1068 - Disassembly and Assembly (3406E & 3456 INDUSTRIAL ENGINE).pdf
SENR1072 - Schematic (Caterpillar 3176C; 3196; 3406E & 3456 Industrial Engines).pdf
SENR1073 - Troubleshooting (3176C; 3406E and 3456 Industrial Engines).pdf
SENR5016 - Disassembly and Assembly (3406E On-Highway Engine).pdf
SENR5017 - Systems Operation (3406E Truck Engine).pdf
SENR5017 - Testing & Adjusting (3406E Truck Engine).pdf
SENR5577 - Specifications (3406E Truck Engine).pdf
...

EXCERPT:

Disassembly and Assembly
3406E & 3056 INDUSTRIAL ENGINE Media Number -SENR1068-03  Publication Date -01/11/2004  Date Updated -20/12/2004  

Fuel Manifold
SMCS - 1702-010
 
Remove & Install Fuel Manifold
Fluid Spillage Containment

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to "Tools And Shop Products Guide", NENG2500 for tools and supplies suitable to collect and contain fluids in Caterpillar machines. Dispose of fluids according to local regulations and mandates.

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1. Put marks on the fuel lines connected to fuel manifold (1) for purposes of identification. Disconnect the fuel lines to fuel manifold (1).

2. Remove the support clip holding wire (2) to the cylinder block. Disconnect wire (2) at the connector.

NOTICE

Upon installation, the connector must pull into the receptacle using the Allen screws. A clip holds the Allen screws into the connector. Removing the screws will damage the seals.

3. Remove bolts (3) holding fuel manifold (1) to the cylinder block. Remove fuel manifold (1).
4. Install fuel manifold (1) in the reverse order of removal.

RENR1272 - Specifications (3406E Truck Engine)..3
  Engine Design..5
  Fuel Transfer Pump..8
  Fuel Filter Base..14
  Fuel Filter (Primary)..15
  Electronic Unit Injector Mechanism..16
  Electronic Unit Injector Rocker Arm..18
  Valve Mechanism..19
  Valve Mechanism Cover..21
  Cylinder Head Valves..23
  Compression Brake - If Equipped..30
  Turbocharger..39
  Exhaust Manifold..41
  Exhaust Manifold Shield..44
  Camshaft..45
  Engine Oil Filter Base..49
  BrakeSaver..51
  BrakeSaver Control Valve..54
  BrakeSaver Engine Oil Filter Base..55
  BrakeSaver Engine Oil Pump..57
  Engine Oil Pump..63
  Engine Oil Pan..66
  Crankcase Breather..69
  Coolant Conditioner Base..70
  Water Lines..72
  Water Temperature Regulator..73
  Water Pump..75
  Cylinder Block..77
  Cylinder Liner..84
  Crankshaft..86
  Vibration Damper..89
  Connecting Rod Bearing Journal..92
  Main Bearing Journal..93
  Connecting Rod..95
  Piston and Rings..98
  Accessory Drive (Air Compressor)..102
  Housing (Front)..104
  Gear Group (Front)..106
  Flywheel..111
  Flywheel Housing..114
  Engine to Transmission Adapter..117
  Belt Tension Chart..119
  Belt Tensioner..121
  Fan Drive..123
  Engine Support (Front)..124
  Alternator and Regulator..126
  Alternator Mounting..133
  Electric Starting Motor..134
  Electrical Ground Stud..141
  Coolant Temperature Sensor..142
  Fuel Temperature Sensor..143
  Engine Oil Pressure Sensor..144
  Boost Pressure Sensor..145
  Atmospheric Pressure Sensor..146
  Inlet Air Temperature Sensor..147
  Speed_Timing Sensor..148
RENR1272 - Systems Operation (3406E Truck Engine)..149
  General Information..150
  Electronic Control System Components..157
  Fuel System..166
  Air Inlet and Exhaust System..176
  Lubrication System..184
  Cooling System..194
  BrakeSaver..199
  Compression Brake..213
  Electrical System..217
RENR1272 - Testing and Adjusting (3406E Truck Engine)..224
  Troubleshooting..225
  BrakeSaver Troubleshooting..231
  Engine Vibration Troubleshooting..232
  Fuel System..236
  Electronic Control System..253
  Air Inlet And Exhaust System..259
  Lubrication System..275
  Cooling System..281
  Basic Block..292
  Compression Brake..306
  Electrical System..317
RENR1273 - Systems Operation (3406E Truck Engine)..327
  Air Inlet and Exhaust System..327
  BrakeSaver..335
  Compression Brake..352
  Cooling System..357
  Electrical System..363
  Electronic Control System Components..370
  Fuel System..380
  General Information..391
  Lubrication System..399
RENR1273 - Testing & Adjusting (3406E Truck Engine)..410
  Air Inlet And Exhaust System..410
  Basic Block..426
  BrakeSaver Klunk Check (Free Movement of the Valve Spool)..442
  BrakeSaver Pull-Down RPM Check..444
  BrakeSaver Troubleshooting..445
  Compression Brake..446
  Cooling System..458
  Electrical System..470
  Electronic Control System..480
  Engine Vibration Troubleshooting..487
  Fuel System..491
  Lubrication System..508
  Troubleshooting..514
RENR1277 - Disassembly and Assembly (3406E TRUCK ENGINE)..521
  Air Compressor - Remove and Install..523
  Fuel Priming Pump..527
  Fuel Filter and Base..528
  Fuel Transfer Pump..530
  Electronic Control Module..532
  Electronic Unit Injectors..534
  Injector Sleeves..536
  Electric Starting Motor..540
  Turbocharger..541
  Water Temperature Regulators..546
  Engine Oil Cooler..550
  Oil Filter and Base..554
  Exhaust Manifold..556
  Water Pump..558
  Fan Drive..562
  Engine Front Support..566
  Vibration Damper and Pulley..567
  Timing Gear Cover..569
  Timing Gears and Plate..574
  Pump Drive..579
  Valve Covers..581
  Valve Cover Base..582
  Rocker Arm and Shaft Assemblies..584
  Cylinder Head Assembly..587
  Spacer Plate..593
  Valve Springs..596
  Inlet and Exhaust Valves..600
  Valve Seals..602
  Valve Seat Inserts..604
  Valve Guides..606
  Oil Pan..608
  Flywheel..610
  Flywheel Housing..612
  Oil Pump..622
  Piston Cooling Jets..626
  Camshaft..628
  Camshaft Bearings..636
  Connecting Rod Bearings..645
  Crankshaft Main Bearings..648
  Crankshaft..652
  Crankshaft Front Seal and Wear Sleeve..658
  Crankshaft Rear Seal and Wear Sleeve..662
  Cylinder Liners..666
  Pistons and Connecting Rod Assemblies..668
  Oil Cooler (BrakeSaver) [If Equipped]..673
  Flywheel (BrakeSaver) [If Equipped]..676
  BrakeSaver Control Valve [If Equipped]..677
  BrakeSaver [If Equipped]..681
  Oil Pan (BrakeSaver) [If Equipped]..691
  Oil Pump (BrakeSaver) [If Equipped]..693
  Compression Brake..699
RENR1327 - Schematic (C-10, C-12 & 3406E TRUCK ENGINE)..709
RENR1328 - Troubleshooting (3406E; C-10 and C-12 On-highway Engines)..715
  System Overview..720
  Electronic Service Tools..740
  Replacing the ECM..745
  Sensors and Electrical Connectors..748
  Engine Wiring Harness Diagram..752
  Vehicle Wiring Harness Diagram..754
  Programming Parameters..756
  Test ECM Mode..757
  Customer Passwords..759
  ECM Date_Time Stamped Information..760
  ECM Snapshot..762
  Factory Passwords..765
  Factory Passwords Worksheet..766
  Flash Programming..768
  Service Information Report..770
  Customer Specified Parameters..772
  Customer Specified Parameters Table..802
  Customer Specified Parameters Worksheet..808
  System Configuration Parameters..813
  Can Not Reach Top Engine RPM..815
  Can Not Reach Vehicle Speed Limit..818
  Check Engine Lamp or Warning Lamp Is Malfunctioning..822
  Cooling Fan Is Always ON..824
  Cruise Control; Idle; or PTO Can Not Be Set..827
  Driver Questionnaire..829
  Driver Questionnaire Response..831
  ECM Will Not Accept Factory Passwords..833
  Electronic Service Tool Will Not Communicate with ECM..834
  Engine Cranks but Will Not Start..837
  Engine Misfires; Runs Rough or Is Unstable..841
  Engine Retarder (Compression Brake) Will Not Turn ON..844
  Engine Vibration..846
  Engine Will Not Crank..848
  Excessive Black Smoke..850
  Excessive Fuel Consumption..853
  Excessive White Smoke..855
  Intermittent Cruise Control; Idle; or PTO Kickout..858
  Intermittent Engine Shutdown..860
  Intermittent Low Power or Power Cutout..862
  Low Power_Poor or No Response to Throttle..866
  Poor Acceleration or Response..870
  Diagnostic Codes..873
  No Diagnostic Code Detected (55)..876
  0001-11 Cylinder #1 Injector current fault (72)..877
  0002-11 Cylinder #2 Injector current fault (72)..878
  0003-11 Cylinder #3 Injector current fault (73)..879
  0004-11 Cylinder #4 Injector current fault (73)..880
  0005-11 Cylinder #5 Injector current fault (74)..881
  0006-11 Cylinder #6 Injector current fault (74)..882
  0022-13 Engine Speed Signal Calibration Not Performed (42)..883
  0026-05 Auxiliary Output #01 current low (69)..884
  0026-06 Auxiliary Output #01 current high (69)..885
  0030-08 PTO Throttle signal invalid (29)..886
  0030-13 PTO Throttle out of calibration (29)..887
  0040-05 Auxiliary Output #02 current low (66)..888
  0040-06 Auxiliary Output #02 current high (66)..889
  0041-03 8 Volt Supply voltage high (21)..890
  0041-04 8 Volt Supply voltage low (21)..891
  0051-05 Auxiliary Output #03 current low (67)..892
  0051-06 Auxiliary Output #03 Current High (67)..893
  0071-00 Idle Shutdown Override (01)..894
  0071-01 Idle Shutdown (47)..896
  0071-14 PTO Shutdown (47)..897
  0084-00 Vehicle Overspeed Warning (41)..898
  0084-01 Vehicle Speed loss of signal (31)..899
  0084-02 Vehicle Speed signal invalid (36)..900
  0084-08 Vehicle Speed signal out of range (36)..901
  0084-10 Vehicle Speed signal rate of change (36)..902
  0084-14 Quick Stop Occurrence..903
  0091-08 Throttle Position Invalid (32)..904
  0091-13 Throttle Position out of calibration (28)..905
  0100-01 Low Oil Pressure Warning (46)..906
  0100-03 Oil Pressure voltage high (24)..913
  0100-04 Oil Pressure voltage low (24)..915
  0100-11 Very Low Oil Pressure (46)..917
  0102-00 Excessive Boost Pressure..924
  0102-03 Boost Pressure voltage high (25)..925
  0102-04 Boost Pressure voltage low (25)..926
  0105-00 High Intake Manifold Air Temperature Warning (64)..927
  0105-03 Intake Manifold Air Temperature voltage high (38)..929
  0105-04 Intake Manifold Air Temperature voltage low (38)..930
  0105-11 Very High Intake Manifold Air Temperature (64)..931
  0108-03 Barometric Pressure voltage high (26)..933
  0108-04 Barometric Pressure voltage low (26)..934
  0110-00 High Coolant Temperature Warning (61)..935
  0110-03 Coolant Temperature voltage high (27)..936
  0110-04 Coolant Temperature voltage low (27)..937
  0110-11 Very High Coolant Temperature (61)..938
  0111-01 Low Coolant Level Warning (62)..939
  0111-02 Coolant Level signal invalid (12)..941
  0111-11 Very Low Coolant Level (62)..942
  0121-05 Low_High Retarder current low (14)..944
  0121-06 Low_High Retarder current high (14)..945
  0122-05 Med_High Retarder current low (14)..946
  0122-06 Med_High Retarder current high (14)..947
  0168-02 ECM Battery Power Intermittent (51)..948
  0171-03 Ambient Air Temperature voltage high..950
  0171-04 Ambient Air Temperature voltage low..951
  0171-11 Ambient Air Temperature Data Lost..952
  0174-00 High Fuel Temperature Warning (65)..953
  0174-03 Fuel Temperature voltage high (13)..954
  0174-04 Fuel Temperature voltage low (13)..955
  0190-00 Engine Overspeed Warning (35)..956
  0190-02 Primary Engine Speed Loss of Signal (34)..957
  0191-07 Transmission Not Responding (68)..958
  0231-11 J1939 Data Link Fault (58)..959
  0232-03 5 Volt Supply voltage high (21)..960
  0232-04 5 Volt Supply voltage low (21)..961
  0244-02 Event Recorder Data Lost (02)..962
  0249-11 J1922 Data Link Fault (58)..963
  0252-11 Engine Software Incorrect (59)..964
  0253-02 Check Customer or System Parameters (56)..965
  0253-11 Check Transmission Customer Parameters (56)..966
  0254-12 ECM Fault (53)..967
  5 Volt Engine Pressure Sensor Supply Circuit - Test..968
  Accelerator Pedal (Throttle) Position Sensor Circuit - Test..977
  ATA (SAE J1587 _ J1708) Data Link Circuit - Test..989
  Auxiliary Brake Circuit - Test..998
  Check Engine Lamp Circuit - Test..1006
  Coolant Level Sensor Circuit - Test..1013
  Cooling Fan Circuit and A_C High Pressure Switch Circuit - Test..1021
  Cruise Control Switch Circuit - Test..1039
  Eaton Top 2 Transmission Circuit - Test..1048
  ECM Memory - Test..1060
  Electrical Connectors - Inspect..1065
  Engine Pressure Sensor Open or Short Circuit - Test..1073
  Engine Running Output Circuit - Test..1082
  Engine Shutdown Output Circuit - Test..1087
  Engine Speed_Timing Sensor Circuit - Test..1092
  Engine Temperature Sensor Open or Short Circuit - Test..1101
  Idle Shutdown Timer - Test..1110
  Ignition Key Switch Circuit and Battery Supply Circuit - Test..1115
  Injector Solenoid Circuit - Test..1122
  Multi-Torque - Test..1137
  Powertrain Data Link Circuit - Test..1139
  PTO Shutdown Timer - Test..1148
  PTO Switch Circuit - Test..1152
  Remote PTO Accelerator Position Sensor Circuit - Test..1166
  Retarder (Compression Brake) Solenoid Circuit - Test..1174
  Tachometer Circuit - Test..1189
  Torque Limit Switch Circuit - Test..1197
  Vehicle Speed and Speedometer Circuit - Test..1203
  Warning Lamp Circuit - Test..1215
  Engine Speed_Timing Sensor - Calibrate..1221
  Injector Code - Calibrate..1226
  Vehicle Speed Circuit - Calibrate..1228
RENR1362 - Specifications (3406E and 3456 Engines for Caterpillar Built Machines)..1230
  Engine Design..1232
  Fuel Transfer Pump..1234
  Fuel Filter Base..1238
  Electronic Unit Injector Mechanism..1239
  Electronic Unit Injector Rocker Arm..1241
  Valve Mechanism..1242
  Valve Mechanism Cover..1244
  Cylinder Head Valves..1246
  Cylinder Head..1250
  Compression Brake - If Equipped..1254
  Turbocharger..1257
  Air Inlet Elbow..1267
  Exhaust Manifold..1268
  Exhaust Manifold Shield..1271
  Camshaft..1272
  Engine Oil Filter Base..1277
  Engine Oil Cooler Bypass Valve..1280
  Engine Oil Pump..1282
  Engine Oil Pan..1288
  Crankcase Breather..1291
  Water Lines..1292
  Water Temperature Regulator..1293
  Water Pump..1294
  Cylinder Block..1296
  Cylinder Liner..1303
  Crankshaft..1306
  Vibration Damper..1309
  Connecting Rod Bearing Journal..1311
  Main Bearing Journal..1312
  Connecting Rod..1314
  Piston and Rings..1317
  Housing (Front)..1322
  Front Housing and Covers..1324
  Gear Group (Front)..1326
  Flywheel..1331
  Flywheel Housing..1333
  Belt Tension Chart..1341
  Mounting Gp-Fan Drive..1343
  Engine Support (Front)..1344
  Alternator and Regulator..1345
  Electric Starting Motor..1349
  Electrical Ground Stud..1355
  Coolant Temperature Sensor..1356
  Fuel Temperature Sensor..1357
  Fuel Pressure Sensor..1358
  Engine Oil Pressure Sensor..1359
  Atmospheric Pressure Sensor..1360
  Inlet Air Temperature Sensor..1361
  Speed and Timing Sensor..1363
RENR1363 - Systems Operation (3406E and 3456 Engines for Caterpillar Built Machines)..1364
  General Information..1365
  Glossary of Electronic Control Terms..1371
  Electronic Control System Components..1376
  Fuel System..1382
  Air Inlet and Exhaust System..1392
  Lubrication System..1398
  Cooling System..1403
  Basic Engine..1406
  Compression Brake..1408
  Electrical System..1412
RENR1363 - Testing and Adjusting (3406E and 3456 Engines for Caterpillar Built Machines)..1420
  Troubleshooting..1422
  Fuel System - Inspect..1428
  Air in Fuel - Test..1430
  Electronic Unit Injector - Adjust..1433
  Electronic Unit Injector - Test..1437
  Finding Top Center Position for No. 1 Piston..1439
  Fuel Quality - Test..1443
  Fuel System - Prime..1445
  Fuel System Pressure - Test..1451
  Gear Group (Front) - Time..1454
  Air Inlet and Exhaust System - Inspect..1463
  Turbocharger - Inspect..1468
  Inlet Manifold Pressure - Test..1473
  Exhaust Temperature - Test..1476
  Aftercooler - Test..1477
  Engine Crankcase Pressure (Blowby) - Test..1484
  Compression - Test..1486
  Engine Valve Lash - Inspect_Adjust..1487
  Engine Oil Pressure - Test..1491
  Excessive Bearing Wear - Inspect..1500
  Excessive Engine Oil Consumption - Inspect..1501
  Increased Engine Oil Temperature - Inspect..1502
  Cooling System - Check - Overheating..1503
  Cooling System - Inspect..1506
  Cooling System - Test..1508
  Water Temperature Regulator - Test..1516
  Water Pump - Test..1518
  Piston Ring Groove - Inspect..1520
  Connecting Rod Bearings - Inspect..1521
  Main Bearings - Inspect..1522
  Cylinder Block - Inspect..1523
  Cylinder Liner Projection - Inspect..1525
  Flywheel - Inspect..1532
  Flywheel Housing - Inspect..1535
  Vibration Damper - Check..1541
  Slave Piston Lash - Adjust..1544
  Control Valve (Compression Brake) - Test..1548
  Solenoid Valve (Compression Brake) - Test..1552
  Battery - Test..1556
  Charging System - Test..1557
  Electric Starting System - Test..1558
  Pinion Clearance - Adjust..1559
RENR1364 - Disassembly and Assembly (3406E and 3456 Engines for Caterpillar Built Machines)..1562
  Water Pump - Assemble ..1565
  Fuel Priming Pump - Remove and Install..1570
  Fuel Filter Base - Remove and Install..1573
  Fuel Transfer Pump - Remove..1576
  Fuel Transfer Pump - Install..1578
  Electronic Unit Injector - Remove..1580
  Electronic Unit Injector - Install..1584
  Electronic Unit Injector Sleeve - Remove..1590
  Electronic Unit Injector Sleeve - Install..1592
  Turbocharger - Remove..1595
  Turbocharger - Disassemble..1597
  Turbocharger - Assemble..1599
  Turbocharger - Install..1601
  Exhaust Manifold - Remove and Install..1604
  Inlet and Exhaust Valve Springs - Remove and Install..1608
  Inlet and Exhaust Valves - Remove and Install..1613
  Inlet and Exhaust Valve Guides - Remove and Install..1618
  Inlet and Exhaust Valve Seat Inserts - Remove and Install..1621
  Engine Oil Filter Base - Remove..1624
  Engine Oil Filter Base - Disassemble..1626
  Engine Oil Filter Base - Assemble..1630
  Engine Oil Filter Base - Install..1633
  Engine Oil Cooler - Remove..1635
  Engine Oil Cooler - Disassemble..1637
  Engine Oil Cooler - Assemble..1640
  Engine Oil Cooler - Install..1642
  Engine Oil Pump - Remove..1644
  Engine Oil Pump - Disassemble..1646
  Engine Oil Pump - Assemble..1649
  Engine Oil Pump - Install..1652
  Water Pump - Remove..1654
  Water Pump - Disassemble..1659
  Water Pump - Assemble..1664
  Water Pump - Install..1672
  Water Temperature Regulator - Remove and Install..1676
  Flywheel - Remove..1686
  Flywheel - Install..1688
  Crankshaft Rear Seal - Remove..1690
  Crankshaft Rear Seal - Install..1692
  Flywheel Housing - Remove and Install..1695
  Vibration Damper and Pulley - Remove and Install..1700
  Crankshaft Front Seal - Remove..1703
  Crankshaft Front Seal - Install..1705
  Front Cover - Remove..1707
  Front Cover - Install..1709
  Gear Group (Front) - Remove..1712
  Gear Group (Front) - Install..1719
  Housing (Front) - Remove..1724
  Housing (Front) - Install..1728
  Valve Mechanism Cover - Remove and Install..1732
  Valve Mechanism Cover Base - Remove and Install..1735
  Compression Brake - Remove - If Equipped..1739
  Compression Brake - Disassemble - If Equipped..1741
  Compression Brake - Assemble - If Equipped..1747
  Compression Brake - Install - If Equipped..1753
  Rocker Arm and Shaft - Remove..1756
  Rocker Arm - Disassemble..1759
  Rocker Arm - Assemble..1761
  Rocker Arm and Shaft - Install..1763
  Cylinder Head - Remove..1766
  Cylinder Head - Install..1773
  Camshaft - Remove..1779
  Camshaft - Install..1788
  Camshaft Gear - Remove and Install..1795
  Camshaft Bearings - Remove..1799
  Camshaft Bearings - Install..1802
  Engine Oil Pan - Remove and Install..1807
  Cylinder Liner - Remove..1811
  Cylinder Liner - Install..1813
  Piston Cooling Jets - Remove and Install..1816
  Pistons and Connecting Rods - Remove..1819
  Pistons and Connecting Rods - Disassemble..1821
  Pistons and Connecting Rods - Assemble..1824
  Pistons and Connecting Rods - Install..1830
  Connecting Rod Bearings - Remove..1834
  Connecting Rod Bearings - Install..1836
  Crankshaft Main Bearings - Remove..1838
  Crankshaft Main Bearings - Install..1840
  Crankshaft - Remove..1843
  Crankshaft - Install..1846
  Bearing Clearance - Check..1849
  Coolant Temperature Sensor - Remove and Install..1852
  Engine Oil Pressure Sensor - Remove and Install..1855
  Speed_Timing Sensor - Remove and Install..1857
  Fan Drive - Remove..1861
  Fan Drive - Disassemble..1862
  Fan Drive - Assemble..1864
  Fan Drive - Install..1866
  Electronic Control Module - Remove and Install..1868
  Electric Starting Motor - Remove and Install..1871
RENR1364 - Specifications (3406E and 3456 Engines for Caterpillar Built Machines)..1874
  Engine Design..1876
  Fuel Transfer Pump..1878
  Fuel Filter Base..1882
  Electronic Unit Injector Mechanism..1883
  Electronic Unit Injector Rocker Arm..1885
  Valve Mechanism..1886
  Valve Mechanism Cover..1888
  Cylinder Head Valves..1890
  Cylinder Head..1894
  Compression Brake - If Equipped..1898
  Turbocharger..1901
  Air Inlet Elbow..1911
  Exhaust Manifold..1912
  Exhaust Manifold Shield..1915
  Camshaft..1916
  Engine Oil Filter Base..1921
  Engine Oil Cooler Bypass Valve..1924
  Engine Oil Pump..1926
  Engine Oil Pan..1932
  Crankcase Breather..1935
  Water Lines..1936
  Water Temperature Regulator..1937
  Water Pump..1938
  Cylinder Block..1940
  Cylinder Liner..1947
  Crankshaft..1950
  Vibration Damper..1953
  Connecting Rod Bearing Journal..1955
  Main Bearing Journal..1956
  Connecting Rod..1958
  Piston and Rings..1961
  Housing (Front)..1966
  Front Housing and Covers..1968
  Gear Group (Front)..1970
  Flywheel..1975
  Flywheel Housing..1977
  Belt Tension Chart..1985
  Mounting Gp-Fan Drive..1987
  Engine Support (Front)..1988
  Alternator and Regulator..1989
  Electric Starting Motor..1993
  Electrical Ground Stud..1999
  Coolant Temperature Sensor..2000
  Fuel Temperature Sensor..2001
  Fuel Pressure Sensor..2002
  Engine Oil Pressure Sensor..2003
  Atmospheric Pressure Sensor..2004
  Inlet Air Temperature Sensor..2005
  Speed and Timing Sensor..2007
RENR2227 - Troubleshooting (3406E and 3456 Generator Set Engines)..2008
  System Overview..2013
  Electronic Service Tools..2015
  Replacing the ECM..2025
  Self-Diagnostics..2029
  Sensors and Electrical Connectors..2030
  Engine Wiring Information..2034
  Programming Parameters..2037
  Factory Passwords..2038
  Factory Passwords Worksheet..2039
  Flash Programming..2041
  System Configuration Parameters..2043
  Can Not Reach Top Engine RPM..2053
  Coolant in Engine Oil..2057
  ECM Will Not Accept Factory Passwords..2061
  ECM Will Not Communicate with Other Systems or Display Modules..2063
  Electronic Service Tool Will Not Communicate with ECM..2065
  Engine Cranks but Will Not Start..2069
  Engine Has Early Wear..2072
  Engine Misfires; Runs Rough or Is Unstable..2075
  Engine Stalls at Low RPM..2079
  Engine Vibration..2082
  Engine Will Not Crank..2084
  Excessive Black Smoke..2087
  Excessive Engine Oil Consumption..2091
  Excessive Fuel Consumption..2093
  Excessive Valve Lash..2096
  Excessive White Smoke..2098
  Fuel in Cooling System..2101
  Fuel Dilution of Engine Oil..2102
  Intermittent Engine Shutdown..2104
  Intermittent Low Power or Power Cutout..2106
  Low Engine Oil Pressure..2109
  Low Power_Poor or No Response to Throttle..2112
  Mechanical Noise (Knock) in Engine..2115
  Noise Coming from Cylinder..2118
  Poor Acceleration or Response..2121
  Valve Rotator or Spring Lock Is Free..2124
  Diagnostic Codes..2125
  CID 0001 FMI 05 Cylinder #1 Injector open circuit..2128
  CID 0001 FMI 06 Cylinder #1 Injector short..2129
  CID 0002 FMI 05 Cylinder #2 Injector open circuit..2130
  CID 0002 FMI 06 Cylinder #2 Injector short..2131
  CID 0003 FMI 05 Cylinder #3 Injector open circuit..2132
  CID 0003 FMI 06 Cylinder #3 Injector short..2133
  CID 0004 FMI 05 Cylinder #4 Injector open circuit..2134
  CID 0004 FMI 06 Cylinder #4 Injector short..2135
  CID 0005 FMI 05 Cylinder #5 Injector open circuit..2136
  CID 0005 FMI 06 Cylinder #5 Injector short..2137
  CID 0006 FMI 05 Cylinder #6 Injector open circuit..2138
  CID 0006 FMI 06 Cylinder #6 Injector short..2139
  CID 0091 FMI 08 Throttle Position signal abnormal..2140
  CID 0100 FMI 03 Engine Oil Pressure open_short to +batt..2141
  CID 0100 FMI 04 Engine Oil Pressure short to ground..2142
  CID 0100 FMI 13 Engine Oil Pressure calibration required..2143
  CID 0110 FMI 03 Engine Coolant Temperature open_short to +batt..2144
  CID 0110 FMI 04 Engine Coolant Temperature short to ground..2145
  CID 0168 FMI 00 System Voltage High..2146
  CID 0168 FMI 01 System Voltage Low..2147
  CID 0168 FMI 02 System Voltage intermittent_erratic..2148
  CID 0172 FMI 03 Intake Manifold Air Temp open_short to +batt..2149
  CID 0172 FMI 04 Intake Manifold Air Temp short to ground..2150
  CID 0174 FMI 03 Fuel Temperature open_short to +batt..2151
  CID 0174 FMI 04 Fuel Temperature short to ground..2152
  CID 0175 FMI 03 Engine Oil Temperature open_short to +batt..2153
  CID 0175 FMI 04 Engine Oil Temperature short to ground..2154
  CID 0190 FMI 02 Loss of Engine Speed Signal..2155
  CID 0190 FMI 08 Engine Speed abnormal..2157
  CID 0248 FMI 09 CAT Data Link communications..2159
  CID 0253 FMI 02 Personality Module mismatch..2160
  CID 0254 FMI 12 Electronic Control Module Error..2162
  CID 0261 FMI 13 Engine Timing Calibration required..2163
  CID 0262 FMI 03 5 Volt Sensor DC Power Supply short to +batt..2164
  CID 0262 FMI 04 5 Volt Sensor DC Power Supply short to ground..2165
  CID 0263 FMI 03 Digital Sensor Supply short to +batt..2166
  CID 0263 FMI 04 Digital Sensor Supply short to ground..2167
  CID 0268 FMI 02 Check Programmable Parameters..2168
  CID 0273 FMI 00 Turbo Outlet Pressure above normal..2169
  CID 0273 FMI 03 Turbo Outlet Pressure open_short to +batt..2170
  CID 0273 FMI 04 Turbo Outlet Pressure short to ground..2171
  CID 0273 FMI 13 Turbo Outlet Pressure calibration required..2172
  CID 0274 FMI 03 Atmospheric Pressure open_short to +batt..2173
  CID 0274 FMI 04 Atmospheric Pressure short to ground..2174
  CID 0274 FMI 13 Atmospheric Pressure calibration required..2175
  CID 0336 FMI 02 Incorrect ECS Switch inputs..2176
  CID 0337 FMI 02 Incorrect Remote E-Stop Switch inputs..2177
  CID 0342 FMI 02 Loss of Secondary Engine Speed signal..2178
  CID 0342 FMI 08 Secondary Engine Speed signal abnormal..2179
  CID 0444 FMI 05 Start Relay open circuit..2181
  CID 0444 FMI 06 Start Relay short to ground..2182
  CID 0446 FMI 05 Air Shutoff Relay open..2183
  CID 0446 FMI 06 Air Shutoff Relay short..2184
  CID 0460 FMI 02 Filtered Fuel Pressure misinstalled..2185
  CID 0460 FMI 03 Filtered Fuel Pressure open_short to +batt..2186
  CID 0460 FMI 04 Filtered Fuel Pressure short to ground..2187
  CID 0460 FMI 13 Filtered Fuel Pressure calibration required..2188
  CID 0535 FMI 08 Exhaust Temperature Sensor noisy signal..2189
  CID 0545 FMI 05 Ether Start Relay open_short to +batt..2190
  CID 0545 FMI 06 Ether Start Relay short to ground..2191
  Event Codes..2192
  E004 Engine Overspeed Shutdown..2195
  E009 High Altitude Derate..2196
  E015 High Engine Coolant Temperature Derate..2198
  E016 High Engine Coolant Temperature Shutdown..2200
  E017 High Engine Coolant Temperature Warning..2202
  E019 High Engine Oil Temperature Shutdown..2203
  E020 High Engine Oil Temperature Warning..2204
  E027 High Inlet Air Temperature Warning..2205
  E038 Low Engine Coolant Temperature Warning..2207
  E040 Low Engine Oil Pressure Shutdown..2209
  E043 Low System Voltage Warning..2212
  E056 High Fuel Temperature Warning..2214
  E058 Low Engine Coolant Level Shutdown..2216
  E059 Low Engine Coolant Level Warning..2218
  E100 Low Engine Oil Pressure Warning..2220
  E173 High Exhaust Temperature Warning..2223
  E190 Engine Overspeed Warning..2225
  E271 User Defined Switch Active..2226
  Air Shutoff System - Test..2227
  Analog Sensor Supply Circuit - Test..2232
  ATA (SAE J1587 _ J1708) Data Link Circuit - Test..2238
  CAT Data Link Circuit - Test..2243
  Digital Sensor Supply Circuit - Test..2249
  Electrical Connectors - Inspect..2256
  Electrical Power Supply Circuit - Test..2263
  Emergency Stop Switch Circuit - Test..2269
  Engine Control Switch (ECS)..2274
  Engine Control Switch (ECS) (EMCP II)..2281
  Engine Sensor Open_Short Circuit - Test..2286
  Engine Speed_Timing Sensor Circuit - Test..2292
  Ether Injection System - Test..2298
  Injector Solenoid Circuit - Test..2310
  Overspeed Verify Switch Circuit - Test..2324
  Speed Control (Switch) - Test..2330
  Start Relay Circuit - Test..2337
  User Defined Shutdown Input Circuit - Test..2342
  Engine Pressure Sensor - Calibrate..2348
  Engine Speed_Timing Sensor - Calibrate..2351
  Injector Code - Calibrate..2356
RENR2237 - Schematic (C-10; C-12; 3406E; C-15; C-16 On-highway Engines Electrical System)..2358
  Collage..2358
  Main..2367
RENR2237 - Schematic (C-10; C-12; 3406E; C-15; and C-16 Truck Engine Electrical System)..2369
RENR2237 - Schematic (C-10_C-12_3406E_C-15_C-16 On-Highway Engine Electrical System)..2371
  Collage..2371
  Main..2380
RENR2238 - Toubleshooting (3406E_C-10_C-12_C-15_C-16_C-18 Truck Engine)..2382
RENR2302 - Specifications (3406E and 3456 Generator Set Engines)..2802
  Engine Design..2804
  Fuel Transfer Pump..2807
  Fuel Filter Base..2809
  Electronic Unit Injector Mechanism..2810
  Valve Mechanism..2812
  Valve Mechanism Cover..2814
  Cylinder Head Valves..2816
  Cylinder Head..2820
  Turbocharger..2824
  Exhaust Manifold..2825
  Camshaft..2828
  Engine Oil Filter Base..2833
  Engine Oil Pump..2835
  Engine Oil Pan..2838
  Water Temperature Regulator..2839
  Water Pump..2841
  Cylinder Block..2843
  Cylinder Liner..2850
  Crankshaft..2853
  Vibration Damper..2856
  Connecting Rod Bearing Journal..2858
  Main Bearing Journal..2859
  Connecting Rod..2860
  Piston and Rings..2863
  Housing (Front)..2867
  Gear Group (Front)..2869
  Flywheel..2874
  Flywheel Housing..2878
  Belt Tension Chart..2883
  Alternator and Regulator..2885
  Alternator Mounting..2888
  Electric Starting Motor..2889
  Electrical Ground Stud..2897
  Magnetic Pickup..2898
  Coolant Temperature Sensor..2899
  Coolant Level Sensor..2900
  Fuel Temperature Sensor..2902
  Fuel Pressure Sensor..2903
  Engine Oil Pressure Sensor..2904
  Atmospheric Pressure Sensor..2905
  Inlet Air Temperature Sensor..2906
  Turbocharger Outlet Pressure Sensor..2907
  Speed_Timing Sensor..2908
RENR2303 - Systems Operation (3406E and 3456 Generator Set Engines)..2910
  General Information..2911
  Electronic Control System Components..2918
  Fuel System..2924
  Air Inlet and Exhaust System..2930
  Lubrication System..2937
  Cooling System..2942
  Basic Engine..2945
  Air Starting System..2947
  Electrical System..2950
RENR2303 - Testing and Adjusting (3406E and 3456 Generator Set Engines)..2957
  Fuel System - Inspect..2959
  Air in Fuel - Test..2961
  Electronic Unit Injector - Adjust..2964
  Electronic Unit Injector - Test..2968
  Finding Top Center Position for No. 1 Piston..2970
  Fuel Quality - Test..2974
  Fuel System - Prime..2976
  Fuel System Pressure - Test..2982
  Gear Group (Front) - Time..2985
  Air Inlet and Exhaust System - Inspect..2994
  Turbocharger - Inspect..2999
  Inlet Manifold Pressure - Test..3003
  Exhaust Temperature - Test..3006
  Aftercooler - Test..3007
  Engine Crankcase Pressure (Blowby) - Test..3013
  Compression - Test..3015
  Engine Valve Lash - Inspect_Adjust..3016
  Engine Oil Pressure - Test..3020
  Excessive Bearing Wear - Inspect..3029
  Excessive Engine Oil Consumption - Inspect..3030
  Increased Engine Oil Temperature - Inspect..3031
  Cooling System - Check - Overheating..3032
  Cooling System - Inspect..3035
  Cooling System - Test..3037
  Water Temperature Regulator - Test..3045
  Water Pump - Test..3047
  Piston Ring Groove - Inspect..3049
  Connecting Rod Bearings - Inspect..3050
  Main Bearings - Inspect..3051
  Cylinder Block - Inspect..3052
  Cylinder Liner Projection - Inspect..3054
  Flywheel - Inspect..3061
  Flywheel Housing - Inspect..3064
  Vibration Damper - Check..3070
  Battery - Test..3073
  Charging System - Test..3076
  Electric Starting System - Test..3084
  Pinion Clearance - Adjust..3085
RENR2304 - Disassembly and Assembly (3406E and 3456 Generator Set Engines)..3090
  Fuel Filter Base - Remove..3094
  Fuel Filter Base - Disassemble..3096
  Fuel Filter Base - Assemble..3098
  Fuel Filter Base - Install..3100
  Fuel Transfer Pump - Remove..3102
  Fuel Transfer Pump - Install..3104
  Electronic Unit Injector - Remove..3106
  Electronic Unit Injector - Install..3110
  Electronic Unit Injector Sleeve - Remove..3116
  Electronic Unit Injector Sleeve - Install..3118
  Turbocharger - Remove..3121
  Turbocharger - Disassemble..3123
  Turbocharger - Assemble..3125
  Turbocharger - Install..3127
  Exhaust Manifold - Remove and Install..3130
  Inlet and Exhaust Valve Springs - Remove and Install..3134
  Inlet and Exhaust Valves - Remove and Install..3139
  Inlet and Exhaust Valve Guides - Remove and Install..3144
  Inlet and Exhaust Valve Seat Inserts - Remove and Install..3147
  Inlet and Exhaust Valve Seals - Remove and Install..3150
  Engine Oil Filter Base - Remove..3153
  Engine Oil Filter Base - Disassemble..3155
  Engine Oil Filter Base - Assemble..3157
  Engine Oil Filter Base - Install..3159
  Engine Oil Cooler - Remove..3161
  Engine Oil Cooler - Disassemble..3163
  Engine Oil Cooler - Assemble..3166
  Engine Oil Cooler - Install..3168
  Engine Oil Pump - Remove..3169
  Engine Oil Pump - Disassemble..3171
  Engine Oil Pump - Assemble..3174
  Engine Oil Pump - Install..3177
  Water Pump - Remove..3179
  Water Pump - Disassemble..3182
  Water Pump - Assemble..3184
  Water Pump - Install..3187
  Water Temperature Regulator - Remove and Install..3190
  Flywheel - Remove..3200
  Flywheel - Install..3202
  Crankshaft Rear Seal - Remove..3204
  Crankshaft Rear Seal - Install..3206
  Flywheel Housing - Remove and Install..3208
  Vibration Damper and Pulley - Remove and Install..3213
  Crankshaft Front Seal - Remove..3216
  Crankshaft Front Seal - Install..3218
  Front Cover - Remove..3220
  Front Cover - Install..3222
  Gear Group (Front) - Remove..3225
  Gear Group (Front) - Install..3231
  Housing (Front) - Remove..3236
  Housing (Front) - Install..3240
  Valve Mechanism Cover - Remove and Install..3243
  Valve Mechanism Cover Base - Remove and Install..3246
  Rocker Arm and Shaft - Remove..3250
  Rocker Arm - Disassemble..3253
  Rocker Arm - Assemble..3255
  Rocker Arm and Shaft - Install..3257
  Cylinder Head - Remove..3260
  Cylinder Head - Install..3267
  Camshaft - Remove..3273
  Camshaft - Install..3282
  Camshaft Gear - Remove and Install..3289
  Camshaft Bearings - Remove..3293
  Camshaft Bearings - Install..3296
  Engine Oil Pan - Remove and Install..3301
  Cylinder Liner - Remove..3305
  Cylinder Liner - Install..3307
  Piston Cooling Jets - Remove and Install..3310
  Pistons and Connecting Rods - Remove..3313
  Pistons and Connecting Rods - Disassemble..3315
  Pistons and Connecting Rods - Assemble..3318
  Pistons and Connecting Rods - Install..3324
  Connecting Rod Bearings - Remove..3326
  Connecting Rod Bearings - Install..3328
  Crankshaft Main Bearings - Remove..3330
  Crankshaft Main Bearings - Install..3332
  Crankshaft - Remove..3335
  Crankshaft - Install..3338
  Bearing Clearance - Check..3341
  Atmospheric Pressure Sensor - Remove and Install..3344
  Coolant Temperature Sensor - Remove and Install..3346
  Engine Oil Pressure Sensor - Remove and Install..3349
  Fuel Temperature Sensor - Remove and Install..3351
  Speed_Timing Sensor - Remove and Install..3354
  Turbocharger Outlet Pressure Sensor - Remove and Install..3358
  Inlet Air Temperature Sensor - Remove and Install..3360
  Fan Drive - Remove..3362
  Fan Drive - Disassemble..3363
  Fan Drive - Assemble..3365
  Electronic Control Module - Remove and Install..3367
  Alternator - Remove and Install..3370
  Electric Starting Motor - Remove and Install..3373
RENR2339 - Troubleshooting (3456 Engines for Caterpillar Built Machines)..3375
  System Overview..3379
  Glossary..3381
  Electronic Service Tools..3387
  Electronic Display Module - If Equipped..3391
  Replacing the ECM..3392
  Self-Diagnostics..3395
  Sensors and Electrical Connectors..3396
  Engine Wiring Information..3400
  Programming Parameters..3401
  Factory Passwords..3402
  Factory Passwords Worksheet..3403
  Flash Programming..3404
  System Configuration Parameters..3406
  Alternator - Charging Problem..3410
  Alternator - Noisy Operation..3411
  Can Not Reach Top Engine RPM..3412
  Coolant in Engine Oil..3415
  Coolant Temperature Is Too High..3418
  ECM Will Not Accept Factory Passwords..3419
  ECM Will Not Communicate with Other Systems or Display Modules..3421
  Electronic Service Tool Will Not Communicate with ECM..3422
  Elevated Idle..3426
  Engine Cranks but Will Not Start..3427
  Engine Has Early Wear..3430
  Engine Misfires; Runs Rough or Is Unstable..3433
  Engine Oil in Cooling System..3436
  Engine Oil Temperature Is Too High..3437
  Engine Stalls at Low RPM..3439
  Engine Vibration..3442
  Engine Will Not Crank..3444
  Excessive Black Smoke..3446
  Excessive Engine Oil Consumption..3450
  Excessive Fuel Consumption..3452
  Excessive Valve Lash..3455
  Excessive White Smoke..3457
  Exhaust Temperature Is Too High..3461
  Fuel in Cooling System..3462
  Fuel Dilution of Engine Oil..3464
  Intermittent Engine Shutdown..3466
  Intermittent Low Power or Power Cutout..3469
  Low Engine Oil Pressure..3471
  Low Power_Poor or No Response to Throttle..3474
  Mechanical Noise (Knock) in Engine..3477
  Noise Coming from Cylinder..3478
  Poor Acceleration or Response..3481
  Valve Rotator or Spring Lock Is Free..3485
  Diagnostic Codes..3486
  CID 0001 FMI 05 Cylinder #1 Injector open circuit..3489
  CID 0001 FMI 06 Cylinder #1 Injector short..3490
  CID 0002 FMI 05 Cylinder #2 Injector open circuit..3491
  CID 0002 FMI 06 Cylinder #2 Injector short..3492
  CID 0003 FMI 05 Cylinder #3 Injector open circuit..3493
  CID 0003 FMI 06 Cylinder #3 Injector short..3494
  CID 0004 FMI 05 Cylinder #4 Injector open circuit..3495
  CID 0004 FMI 06 Cylinder #4 Injector short..3496
  CID 0005 FMI 05 Cylinder #5 Injector open circuit..3497
  CID 0005 FMI 06 Cylinder #5 Injector short..3498
  CID 0006 FMI 05 Cylinder #6 Injector open circuit..3499
  CID 0006 FMI 06 Cylinder #6 Injector short..3500
  CID 0091 FMI 08 Throttle Position signal abnormal..3501
  CID 0100 FMI 03 Engine Oil Pressure open_short to +batt..3502
  CID 0100 FMI 04 Engine Oil Pressure short to ground..3503
  CID 0100 FMI 13 Engine Oil Pressure calibration required..3504
  CID 0110 FMI 03 Engine Coolant Temperature open_short to +batt..3505
  CID 0110 FMI 04 Engine Coolant Temperature short to ground..3506
  CID 0168 FMI 00 System Voltage High..3507
  CID 0168 FMI 01 System Voltage Low..3508
  CID 0168 FMI 02 System Voltage intermittent_erratic..3509
  CID 0172 FMI 03 Intake Manifold Air Temp open_short to +batt..3510
  CID 0172 FMI 04 Intake Manifold Air Temp short to ground..3511
  CID 0174 FMI 03 Fuel Temperature open_short to +batt..3512
  CID 0174 FMI 04 Fuel Temperature short to ground..3513
  CID 0190 FMI 02 Loss of Engine Speed Signal..3514
  CID 0190 FMI 08 Engine Speed signal abnormal..3516
  CID 0253 FMI 02 Personality Module mismatch..3517
  CID 0254 FMI 12 Electronic Control Module Error..3518
  CID 0261 FMI 13 Engine Timing Calibration required..3519
  CID 0262 FMI 03 5 Volt Sensor DC Power Supply short to +batt..3520
  CID 0262 FMI 04 5 Volt Sensor DC Power Supply short to ground..3521
  CID 0268 FMI 02 Check Programmable Parameters..3522
  CID 0273 FMI 03 Turbo Outlet Pressure open_short to +batt..3523
  CID 0273 FMI 04 Turbo Outlet Pressure short to ground..3524
  CID 0273 FMI 13 Turbo Outlet Pressure calibration required..3525
  CID 0274 FMI 03 Atmospheric Pressure open_short to +batt..3526
  CID 0274 FMI 04 Atmospheric Pressure short to ground..3527
  CID 0274 FMI 13 Atmospheric Pressure calibration required..3528
  CID 0342 FMI 02 Loss of Secondary Engine Speed signal..3529
  CID 0342 FMI 08 Secondary Engine Speed signal abnormal..3531
  CID 0545 FMI 05 Ether Start Relay open_short to +batt..3532
  CID 0545 FMI 06 Ether Start Relay short to ground..3533
  CID 0799 FMI 12 Need Service Tool update..3534
  Event Codes..3535
  E009 High Altitude Derate..3538
  E015 High Engine Coolant Temperature Derate..3540
  E017 High Engine Coolant Temperature Warning..3543
  E025 High Inlet Air Temperature Derate..3546
  E027 High Inlet Air Temperature Warning..3548
  E039 Low Engine Oil Pressure Derate..3550
  E056 High Fuel Temperature Warning..3553
  E100 Low Engine Oil Pressure Warning..3555
  E190 Engine Overspeed Warning..3558
  E265 User Defined Shutdown..3559
  Analog Sensor Supply Circuit - Test..3560
  ATA (SAE J1587 _ J1708) Data Link Circuit - Test..3567
  CAT Data Link Circuit - Test..3572
  Electrical Connectors - Inspect..3576
  Electrical Power Supply Circuit - Test..3583
  Engine Sensor Open_Short Circuit - Test..3589
  Engine Speed_Timing Sensor Circuit - Test..3597
  Ether Injection System - Test..3604
  Injector Solenoid Circuit - Test..3615
  Throttle Switch Circuit - Test..3631
  User Defined Shutdown Input Circuit - Test..3637
  Engine Pressure Sensor - Calibrate..3641
  Engine Speed_Timing Sensor - Calibrate..3644
  Injector Code - Calibrate..3649
SEBU5595 - Maintenance Intervals Operation and Maintenance Manual Excerpt (3406E Truck Engines)..3651
SENR1066 - Specifications (3406E and 3456 Industrial Engines)..3679
  Engine Design..3681
  Fuel Transfer Pump..3684
  Fuel Filter Base..3686
  Fuel Filter (Primary)..3688
  Electronic Unit Injector Mechanism..3689
  Electronic Unit Injector Rocker Arm..3691
  Rocker Shaft..3692
  Valve Mechanism..3693
  Valve Mechanism Cover..3695
  Cylinder Head Valves..3697
  Cylinder Head..3700
  Turbocharger..3704
  Exhaust Manifold..3706
  Exhaust Manifold Shield..3709
  Camshaft..3710
  Engine Oil Filter Base..3715
  Engine Oil Pump..3717
  Engine Oil Pan..3720
  Engine Oil Filler..3722
  Crankcase Breather..3724
  Coolant Conditioner Base..3725
  Water Lines..3727
  Water Temperature Regulator..3728
  Water Pump..3730
  Cylinder Block..3732
  Cylinder Liner..3739
  Crankshaft..3741
  Vibration Damper..3744
  Connecting Rod Bearing Journal..3747
  Main Bearing Journal..3748
  Connecting Rod..3750
  Piston and Rings..3753
  Accessory Drive..3755
  Housing (Front)..3756
  Gear Group (Front)..3758
  Gear Group (Rear)..3763
  Flywheel..3765
  Flywheel Housing..3772
  Belt Tension Chart..3778
  Fan Drive..3780
  Engine Support (Front)..3782
  Engine Support (Rear)..3785
  Alternator..3786
  Alternator Mounting..3793
  Electric Starting Motor..3794
  Air Starting Motor..3800
  Air Starting Motor Pressure Regulating Valve..3801
  Coolant Level Sensor..3803
  Jacket Water Heater..3804
  Engine Oil Pressure Sensor..3806
  Atmospheric Pressure Sensor..3807
  Inlet Air Temperature Sensor..3808
  Speed_Timing Sensor..3809
  Air Shutoff Solenoid..3810
SENR1067 - Systems Operation (3406E and 3456 Industrial Engines)..3812
  General Information..3813
  Glossary of Electronic Control Terms..3825
  Fuel System..3830
  Air Inlet and Exhaust System..3840
  Lubrication System..3848
  Cooling System..3853
  Electrical System..3858
SENR1067 - Testing and Adjusting (3406E and 3456 Industrial Engines)..3865
  Fuel System - Inspect..3867
  Air in Fuel - Test..3869
  Electronic Unit Injector - Adjust..3872
  Electronic Unit Injector - Test..3876
  Finding Top Center Position for No. 1 Piston..3878
  Fuel Quality - Test..3882
  Fuel System - Prime..3884
  Fuel System Pressure - Test..3890
  Gear Group (Front) - Time..3893
  Air Inlet and Exhaust System - Inspect..3902
  Turbocharger - Inspect..3907
  Inlet Manifold Pressure - Test..3912
  Exhaust Temperature - Test..3915
  Aftercooler - Test..3916
  Engine Crankcase Pressure (Blowby) - Test..3923
  Engine Valve Lash - Inspect_Adjust..3925
  Engine Oil Pressure - Test..3929
  Engine Oil Pump - Inspect..3938
  Excessive Bearing Wear - Inspect..3939
  Excessive Engine Oil Consumption - Inspect..3940
  Increased Engine Oil Temperature - Inspect..3941
  Cooling System - Check - Overheating..3942
  Cooling System - Inspect..3945
  Cooling System - Test..3947
  Water Temperature Regulator - Test..3955
  Water Pump - Test..3957
  Piston Ring Groove - Inspect..3959
  Connecting Rod Bearings - Inspect..3960
  Main Bearings - Inspect..3961
  Cylinder Block - Inspect..3962
  Cylinder Liner Projection - Inspect..3964
  Flywheel - Inspect..3971
  Flywheel Housing - Inspect..3974
  Vibration Damper - Check..3980
  Battery - Test..3983
  Charging System - Test..3984
  Electric Starting System - Test..3985
  Pinion Clearance - Adjust..3986
SENR1068 - Disassembly and Assembly (3406E & 3456 INDUSTRIAL ENGINE)..3992
  Air Compressor..3994
  Fuel Priming Pump..3996
  Fuel Filter & Base..3998
  Fuel Transfer Pump..4001
  Fuel Manifold..4003
  Electronic Control Module..4005
  Personality Ratings Module..4007
  Electronic Unit Injectors..4008
  Injector Sleeves..4010
  Electric Starting Motor..4014
  Turbocharger..4015
  Water Temperature Regulator & Manifold..4018
  Engine Oil Cooler..4021
  Oil Filter & Base..4023
  Oil Filter Base..4025
  Exhaust Manifold..4027
  Water Pump..4029
  Fan Drive Assembly..4034
  Engine Front Support..4040
  Vibration Damper..4041
  Timing Gear Cover..4044
  Timing Gears & Plate..4049
  Pump Drive..4054
  Valve Covers..4056
  Valve Cover Base..4058
  Rocker Arm & Shaft Assemblies..4060
  Cylinder Head Assembly..4063
  Spacer Plate..4069
  Valve Springs..4072
  Valves..4076
  Valve Seals..4078
  Valve Seat Inserts..4080
  Valve Guides..4082
  Oil Pan..4084
  Flywheel..4086
  Flywheel Housing..4088
  Oil Pump..4091
  Piston Cooling Jets..4095
  Camshaft..4097
  Camshaft Bearings..4104
  Connecting Rod Bearings..4112
  Crankshaft Main Bearings..4115
  Crankshaft..4119
  Crankshaft Front Seal & Wear Sleeve..4125
  Crankshaft Rear Seal & Wear Sleeve..4129
  Cylinder Liners..4133
  Pistons & Connecting Rod Assemblies..4135
SENR1072 - Schematic (Caterpillar 3176C; 3196; 3406E & 3456 Industrial Engines)..4141
  Collage..4142
  Main..4150
SENR1073 - Troubleshooting (3176C; 3406E and 3456 Industrial Engines)..4152
  General Information..4155
  Welding Precaution..4156
  Electronic Service Tools..4158
  System Overview..4164
  Component Location..4166
  Electronic Display Module..4173
  Indicator Lamps..4175
  Engine Monitoring System..4176
  Diagnostic Capabilities..4179
  Programmable Parameters..4181
  Electrical Connectors..4182
  Wiring Information..4186
  Configuration Parameters..4187
  Diagnostic Trouble Codes..4194
  Diagnostic Code Cross Reference..4201
  Event Codes..4205
  Acceleration Is Poor or Throttle Response Is Poor..4215
  Coolant Contains Fuel..4219
  Coolant Contains Oil..4221
  Coolant Level Is Low..4223
  Coolant Temperature Is High..4225
  Cylinder Is Noisy..4229
  ECM Does Not Communicate with Other Modules..4231
  Engine Cranks but Does Not Start..4232
  Engine Does Not Crank..4235
  Engine Has Early Wear..4237
  Engine Has Mechanical Noise (Knock)..4240
  Engine Misfires; Runs Rough or Is Unstable..4242
  Engine Overspeeds..4245
  Engine Shutdown Is Intermittent..4246
  Engine Stalls at Low RPM..4249
  Engine Top Speed Is Not Obtained..4251
  Engine Vibration Is Excessive..4255
  Exhaust Has Excessive Black Smoke..4257
  Exhaust Has Excessive White Smoke..4259
  Exhaust System Contains Oil..4263
  Exhaust Temperature Is High..4265
  Fuel Consumption Is Excessive..4267
  Fuel Pressure Problem..4270
  Fuel Temperature Is High..4272
  Intake Manifold Air Pressure Is High..4274
  Intake Manifold Air Temperature Is High..4276
  Oil Consumption Is Excessive..4278
  Oil Contains Coolant..4280
  Oil Contains Fuel..4282
  Oil Pressure Is Low..4284
  Power Is Intermittently Low or Power Cutout Is Intermittent..4287
  Valve Lash Is Excessive..4289
  Valve Rotator or Spring Lock Is Free..4291
  Air Shutoff - Test..4292
  Coolant Level - Test..4304
  Data Link - Test..4312
  ECM_Personality Module - Test..4319
  Electrical Power Supply - Test..4323
  Ether Starting Aid - Test..4330
  Indicator Lamp - Test..4341
  Injector Solenoid - Test..4347
  Sensor Signal (Analog; Active) - Test..4363
  Sensor Signal (PWM) - Test..4376
  Sensor Supply - Test..4384
  Speed Control - Test..4395
  Speed_Timing - Test..4402
  Switch Circuits - Test..4412
  Customer Passwords..4418
  Factory Passwords..4419
  ECM Will Not Accept Factory Passwords..4421
  Electronic Service Tool Does Not Communicate..4423
  ECM Software - Install..4427
  ECM - Replace..4429
  Electrical Connectors - Inspect..4434
  Throttle Position Sensor - Calibrate..4442
  Timing - Calibrate..4444
SENR5016 - Disassembly and Assembly (3406E On-Highway Engine)..4448
SENR5017 - Systems Operation (3406E Truck Engine)..4585
  Air Inlet and Exhaust System ..4585
  Basic Engine ..4594
  BrakeSaver ..4597
  Compression Brake ..4615
  Cooling System ..4620
  Electrical System ..4626
  Electronic Control System Components ..4634
  Fuel System ..4644
  General Information ..4656
  Glossary of Electronic Control Terms ..4658
  Lubrication System ..4665
SENR5017 - Testing & Adjusting (3406E Truck Engine)..4676
  Aftercooler - Test..4676
  Air Inlet and Exhaust System - Inspect..4684
  Air in Fuel - Test..4690
  Battery - Test..4693
  BrakeSaver Klunk Check (Free Movement of the Valve Spool)..4695
  BrakeSaver Pull-Down RPM Check..4697
  BrakeSaver Troubleshooting Problem List..4698
  BrakeSaver Troubleshooting..4706
  Charging System - Test..4707
  Compression - Test..4708
  Connecting Rod Bearings - Inspect..4709
  Control Valve (Compression Brake) - Test..4710
  Cooling System - Check - Overheating..4714
  Cooling System - Inspect..4718
  Cooling System - Test..4720
  Cylinder Block - Inspect..4730
  Cylinder Liner Projection - Inspect..4732
  Electric Starting System - Test..4736
  Electronic Unit Injector - Adjust..4737
  Electronic Unit Injector - Test..4739
  Engine Crankcase Pressure (Blowby) - Test..4741
  Engine Oil Pressure - Test..4743
  Engine Valve Lash - InspectAdjust..4752
  Engine Vibration Troubleshooting..4757
  Excessive Bearing Wear - Inspect..4761
  Excessive Engine Oil Consumption - Inspect..4762
  Exhaust Temperature - Test..4764
  Finding Top Center Position for No. 1 Piston..4765
  Flywheel - Inspect..4769
  Flywheel Housing - Inspect..4773
  Fuel Quality - Test..4778
  Fuel System - Inspect..4780
  Fuel System - Prime..4781
  Fuel System Pressure - Test..4787
  Gear Group (Front) - Time..4791
  Increased Engine Oil Temperature - Inspect..4801
  Inlet Manifold Pressure - Test..4802
  Main Bearings - Inspect..4805
  Pinion Clearance - Adjust..4806
  Pinion Clearance - Adjust..4809
  Piston Ring Groove - Inspect..4813
  Slave Piston Lash - Adjust..4814
  Solenoid Valve (Compression Brake) - Test..4821
  Troubleshooting..4826
  Turbocharger - Inspect..4834
  Vibration Damper - Check..4839
  Water Pump - Test..4842
  Water Temperature Regulator - Test..4845
SENR5577 - Specifications (3406E Truck Engine)..4847
  Accessory Drive (Air Compressor)..4849
  Alternator Mounting..4851
  Alternator and Regulator 1..4853
  Alternator and Regulator 2..4855
  Atmospheric Pressure Sensor..4858
  Belt Tension Chart..4859
  Belt Tensioner..4861
  Boost Pressure Sensor..4863
  BrakeSaver Control Valve..4864
  BrakeSaver Engine Oil Filter Base..4866
  BrakeSaver Engine Oil Pump..4868
  BrakeSaver..4874
  Camshaft..4877
  Compression Brake - If Equipped..4881
  Connecting Rod ..4890
  Connecting Rod Bearing Journal..4893
  Coolant Conditioner Base..4894
  Coolant Temperature Sensor..4896
  Crankcase Breather ..4897
  Crankshaft..4899
  Cylinder Block..4903
  Cylinder Head ..4910
  Cylinder Head Valves..4915
  Cylinder Liner..4918
  Electric Starting Motor..4920
  Electrical Ground Stud..4926
  Electronic Unit Injector Mechanism..4927
  Electronic Unit Injector Rocker Arm..4929
  Engine Design..4930
  Engine Oil Cooler Bypass Valve..4932
  Engine Oil Filler..4934
  Engine Oil Filter Base..4935
  Engine Oil Pan..4937
  Engine Oil Pressure Sensor..4940
  Engine Oil Pump..4941
  Engine Support (Front)..4945
  Engine to Transmission Adapter..4947
  Exhaust Manifold Shield..4949
  Exhaust Manifold..4950
  Fan Drive..4953
  Flywheel Housing..4955
  Flywheel..4958
  Fuel Filter (Primary)..4961
  Fuel Filter Base..4963
  Fuel Temperature Sensor..4965
  Fuel Transfer Pump..4966
  Gear Group (Front)..4968
  Housing (Front)..4973
  Inlet Air Temperature Sensor..4975
  Main Bearing Journal..4976
  Piston and Rings..4977
  Rocker Shaft..4979
  SpeedTiming Sensor..4980
  Turbocharger..4981
  Valve Mechanism Cover..4983
  Valve Mechanism..4985
  Vibration Damper..4987
  Water Pump..4989
  Water Temperature Regulator..4991

Caterpillar 3406E & 3456 Engine Workshop Repair & Service Manual