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    ENGINE - 3406

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    SENR6471-00-00-ALL

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    ENGINE - 3406

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    17 views108 pages

    Senr6471 00 00 All

    Uploaded by

    Jaime castro
    ENGINE - 3406

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 108
    CATERPILLAR ra Systems Operation Testing & Adjusting 3406C Eng For Caternillar Built Machines 11N3780-UP Important Safety Information Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident ocours. A person must be alert to potential hazards, This person should also have the necessary training, skils and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or other persons. The hazards are identified by the "Safety Alert Symbot” and followed by a “Signal Word" such as "WARNING’ as shown below. The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. ‘The message that appears under the warning, explaining the hazard, can be either written or pictorally presented. Operations that may cause product damage are identified by NOTICE labels on the product and in this publication, Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are therefore not all inclusive. Ifa tool, procedure, work ‘method or operating technique not specifically recommended by Caterpilar is used, you must satisfy yourself that itis safe for you and others. You should also ensure that the product will not be damaged (or made unsafe by the operation, lubrication, maintenance or repair procedures you choose. The information, specifications, and illustrations in this publication are on the basis of information available at the time it was written. The specifications, torques, pressures, measurements, adjustments, ilustrations, and other items can change at any time. These changes can affect the service given 10, the product. Obtain the complete and most current information before starting any job. Caterpillar dealers have the most current information available. For a list of the most current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F. Index Basic Block 6 ‘Connecting Rod And Main Bearings 6 Connecting Rods And Pistons 96 i Cylinder Block 96 Systems Operation Cylinder Liner Projection 97 Ar inlet And Exhaust System 25 Flywheel And Flywheel Housing 98 Attercooler 26 Piston Rings 96 Turbocharger or Vibration Damper 101 Valves And Vaive System Components 28 Conon a Basic Block 35 Belt Tightening Chart 95 Camshaft 36 Testing The Cooling System 3 Grankshatt 38 Visual Inspection OF The Cooling System... 90 Cylinder Block and Liners 35 Pistons, Rings And Connecting Rods 35 ee canes ae nal Vibration Damper 5 36 ee a Cooling System 31 Rack Shutoff Solenoid 106 Coolant Conditioner (An Attachment) 34 Starting System 108 Coolant For alr Compressor 3 Test Tools For Electrical System 102 Electrical System 36 Fue! System 49 ‘Charging System Components 7 Check And Adjustment Of The Fuel Ratio Control Engine Electrical System 36 Linkage 74 Grounding Practices 36 Checking Engine Cylinders Separately 49 Other Components 0 Checking Engine Timing By Timing Pin Starting System Components 39 Method 62 Checking Engine Timing With 878300 Timing Fuel System 5 Indicator Group And 875301 Diesel Timing Adapter ‘Automatic Timing Advance Unit 7 Group 59 Dual Horsepower Solenoid (if Equipped) 14 Checking The Plunger And Lifter Of An Injection Fuel Flow 5 Pump 82 Fue! Injection Pump é Dual Horsepower Solenoid Adjustment (if Fuel Injection Nozzie 8 Equipped) cA Fuel Ratio Control 15 Engine Speed Measurement 78 Fuel Transfer Pump 8 Finding Top Center Compression Position For No. Governor "1 1 Piston 58 il Flow For Fuel injection Pump and Fue! Injection Lines. 51 Governor 10 Fuel Ratio Control Adjustment 2 Fuel Ratio Control And Governor Check 7 Lubrication System 28 Fuel Setting Procedure 65 i Flow In The Engine 30 Fuel System Inspection 49 il Flow Thru The Oil Filter And Oil Cooler a Fuel Transfer Pump 49 Governor Adjustments 73 . oe Flemoval And installation Of Fuel Injection Testing And Adjusting Pumps 52 Testing Fue! injection Nozzles 50 Air inlet And Exhaust System 83 Bridge Adjustment 5 Lubrication System 87 Compression 85 Increased Oil Temperature 0 Grankease (Crankshaft Compartment) Measuring Engine Oil Pressure 88 Pressure a Oil Pressure Is High 90 Cylinder Head 85 Oil Pressure Is Low 89 Exhaust Temperature 86 Too Much Bearing Wear 90 Measurement Of Pressure in Inlet Manifold... 83 ‘Too Much Oil Consumption ar Restriction Of Air inlet And Exhaust 83 Turbocharger 84 ‘Troubleshooting 4a Valve Lash Setting 86 ‘Troubleshooting index a 3406C Engine index Specifications NOTE: For Spectications with ilustratons, make reference to Spectication For 3406C Engine For Caterpilar Bult Machines, SENRGA7O. tthe ‘Specifications in SENR6470 are not the same as the Systems Operation and the Testing And Adjusting, look atthe printing date onthe front cover of each book Use the Spectications given in the book with the latest cate 3406C Eng Index Systems Operation Fuel System Fuel Flow — )e | 9 CE z ZA 4 _ yee LY fh. ic Va | | \ : i Fuel System Schematic (1) Fuel injection nozzte. 2) Fue injection tines. (3) Fue return ne. (4) Constant bleed orice (part of the elbow), (5) Fue injection pump housing. (6) Fue priming pump (7) Check valves. (8) Fuel transter pump. (9) Fuel tank. (10) Primary fue fier. (11) Secondary fue iter 3406C Engine 5 Systems Operation Fuel is pulled from fuel tank (9) through primary fuel filter (10) by fuel transfer pump (8). From the fuel transfer pump the fuel is pushed through secondary {uel fer (11) and to the fue! manifold in fue injection pump housing (5). Fuel pressure in the fuel manifold is determined by the fuel transfer pump spring. A Cconstant bleed orifice isin the fuel return line elbow. Constant bleed orifice (4) lets a constant flow of fuel {90 through fuel return line (8) back to fuel tank (9). This helps keep the fuel cool and free of air. The individual fuel injection pumps get fuel from the fuel manifold and push fuel ata very high pressure through fuel ines (2) to fuel injection nozzles (1). Each fue! injection nozzle has very small hoes in the tip that change the flow of fuel to a very fine spray that gives good fuel combustion in the cylinder Fuel Injection Pump ‘The fue! injection pump increases the pressure of the fuel and sends an exact amount of fuel to the fuel injection nozzle. There is one fuel injection pump for each cylinder in the engine. Fuel Injection Pump (1) Spl port. (2) Check valve. (@) Pump barrel. (8) Bypass port (5, Purophnger-() Spin, (7 Fel ack (8) Gam) Liter ) Cam The fuel injection pump is moved by cam (10) of the {uel pump camshaft. When the camshaft turns, the cam raises lifter (8) and pump plunger (5). The pump plunger always makes a ful stroke, As the camshatt {urns farther, spring (6) returns the pump plunger and lifter to the bottom of the stroke. " 12 13 2 £7. 3 1 = “ 4 a FS 8 a 1m ql P q ID ON) Po 5 Ql) |=p aS 850090-1P1 Pump Barrel And Plunger Assembly (1) Spl por. (2) Check valve. (8} Pump barre. (4) Bypass port (6) Pump plunger. (11) Onticed reverse ow check valve. (42) Spring. (18) Spring, (14) Serol (15) Slo When the pump plunger is at the bottom of the stroke, fue! at transfer pump pressure flows through spill port (1) and bypass port (4). Fue! fils pump barrel (3) in the area above pump plunger (5). 3406C Engine Systems Operation — 50086-1P1 Pump Barrel And Plunger Assembly (1) Spl port. (2) Check valve, (3) Pump barrel. (4) Bypass port, (6, Pump plunger. (11) Orifice reverse flow check valve. (12) Spring, (19) Spring, (14) Sera. (15) Sit After pump plunger (5) begins the up stroke, fuel will bbe pushed out bypass port (4) unt the top of the pump plunger closes the port. As the pump plunger travels farther up, the pressure of the fuel increases. At approximately 690 kPa (100 psi), check valve (2) opens and lets fuel low into the fuel injection line to the fuel injection nozzle. E '50096-1°1 Pump Barrel And Plunger Assembly (1) Spi port. (2) Check valve. (3) Pump barre. (4) Bypass por. {6)Pump plunger. (11) Oriced reverse flow check vave. (12) Spring, (13) Spring, (14) Seal (15) Sot. ‘When the pump plunger travels farther up, scroll (14) Uncovers spill port (1). The fuel above the pump plunger goes through slot (15), along the edge of scroll (14) and out spill port (1) back to the fuel manifold This is the end of the injection stroke. The pump plunger can have more travel up, but no more fuel wil be sent to the fuel injection nozzle. 3406C Engine Systems Operation Pump Barrel And Plunger Assembly (1) Spit port. (2) Check valve. (4) Bypass port. (5) Pump plunger. (11) Oriiced reverse tow check valve. (12) Spring. (13) Spring (14) Sero. (18) Sot. When spill port (1) is opened by plunger (6) the fuel nozzle closes and spring (13) closes check valve (2) as the pressure above plunger (5) drops below 690 kPa (100 ps). At the same time the orficed reverse flow check vaive (11) opens. Orificed reverse flow check valve (11) closes when the fuel pressure in the fuel injection lines is 6900 kPa (1000 psi). This keeps the fuel in the injection line and above the reverse flow check valve at 6900 kPa (1000 si) NOTE: Oriticed reverse flow check valve (11) prevents rough idle by stopping any secondary injection of fuel between injection strokes. This valve is only effective below 8250 kPa (1200 psi) and has no effect above that pressure. When the engine is shutdown, the pressure is gradually released through a small groove ‘on the bottom face of orificed reverse flow check valve (11), \When the pump plunger travels down and uncovers bypass port (4), fue begins to fil the area above the pump plunger again, and the pump is ready to begin another stroke. ‘The amount of fuel the injection pump sends to the injection nozzle on each pump stroke can be changed by the rotation of the pump plunger. Gear (8) is attached to the pump plunger and is in mesh with fuel rack (7). The governor moves the fuel rack which turns the fuel pump plungers according to the fuel needs of the engine. When the governor turns the pump plunger, scroll (14) on the plunger changes the distance between the top of pump plunger and the point where scroll (14) uncovers spill port (1). The longer the distance from the top of the pump plunger to the point where scroll (14) uncovers spill port (1), the more fuel wil be injected. To stop the engine, the pump plunger is rotated so that siot (15) on the pump plunger is in line with spil pot (1), The fuel will now go out the spill port and not to the injection nozzle. Fuel Injection Nozzle The fue! injection nozzie is installed in an adapter in the cylinder head and extended into the combustion chamber. The fuel injection pump sends fuel with high pressure to the fue! injection nozzle where the fuel is, made into a fine spray for good combustion, Fuel injection Nozzle (1) Carbon dam. (2) Seal (9) Passage. (4 Fitr screen. (5) net passage. (6) Orites, (7) Vale, (6) Orameter. (8) Spring, Seal (2) goes against the nozzle adapter and prevents leakage of compression from the cylinder. Carbon dam (1) keeps cartoon out of the bore of the nozzle adapter. Fuel with high pressure from the fuel injection pump goes into inlet passage (5). Fuel then goes through soreen (4) and into passage (3) to the area below diameter (8) of valve (7). When the pressure of the fuel that pushes against diameter (8) becomes greater than the force of spring (9), valve (7) lifts up. This occurs when the fuel pressure goes above the Valve Opening Pressure of the fuel injection nozzle. When valve (7) lifts, the tip of the valve comes off of the nozzle seat and the fuel will go through the six small orfices (6) into the combustion chamber. 3406C Engine ‘Systems Operation ‘The injection of fuel continues until the pressure of fuel against diameter (8) becomes less than the force of spring (9). With less pressure against diameter (8), spring (8) pushes valve (7) against the nozzle seat and stops the flow of fuel tothe combustion chamber. The fue! injection nozzle can not be disassembled and no adjustments can be made, Fuel Transfer Pump ‘The fuel transfer pump is a piston pump that is moved by a cam (eccentric) on the camshatt for the fuel injection pump. The transfer pump is located on the bottom side ofthe fuel injection pump housing Fuel Transfer Pump (Start Of Down Stroke) (Arows Indicate Fuel Flow Drecton) (1) Push roa 2) isto. (8) Outlet check valve. 4) Pumping check valve. (5) Pumping spring. (6) Pump inlet port. (7) Inet check valve. (8) Pump outlet por. When the fuel injection pump camshaft turns, the cam ‘moves push rod (1) and piston (2) down. As the piston ‘moves down, inlet check valve (7) and outlet check valve (3) close. Pumping check valve (4) opens and allows the fuel below the piston to move into the area above the piston. Pumping spring (5) is compressed as the piston is pushed down by push rod (1). Fuel Transfer Pump (Start Of Up Stroke) (Arrows indicate Fuel Flow Direction) (1) Push rod. (2) Piston, (3} Outlet check valve. (4) Pumping check. valve. (5) Pumping spring. (6) Pump inet por. (7) Inet check valve. (8) ump outlet port ‘As the fue injection pump camshatt continues to turn, the cam no longer puts force on push rod (1). Pumping spring (6) now moves piston (2) up. This causes pumping check valve (4) to close. Inlet check valve (7) ‘and outlet check valve (3) will open, As the piston moves up, the fuel in the area above the piston is pushed through the outlet check valve (3) and out pump outiet port (8). Fuel also moves through pump inlet port (6) and inlet check valve (7) to fill the area below piston (2). The pump is now ready to start a new cycle. ‘3406C Engine ‘Systems Operation Oil Flow For Fuel Injection Pump And Governor 6 1 8 87536511 uel Injection Pump And Governor (1) Servo. 2) Fu injection pump housing. (3) Cover. (4) supply from cylinder block. (5) Oi crn into cyinder block. (6) Dashpo. (7) Governor rear housing. (8) Governor center housing, 3406C Engine 10 Systems Operation Lubrication oll from the side of the cylinder block goes into the side of the fuel injection pump housing at location (4). The oil then goes fo a passage between fuel injection pump housing (2) and governor center, housing (8) where it flows to three different locations. ‘A part ofthe oll goes back into the main oll passage in {ua injection pump housing (2) This ol gives a supply Cf lubrication for the three fuel injection pump camshaft bearings. At the camshaft bearing next to the ‘governor, oll flows into dled passages in the CCamshatt to give lubrication tothe fiyweight carrier thrust bearing. Oil drains from the camshaft bearings into the fuel injection pump housing, A drain hole inthe housing keeps the level of ol in the housing even with the center of the camshaft. Oil drains from the housing, through drain port (5), back to the engine block. Oil also flows through a different passage back to the fuel injection pump housing. Tris passage is connected to governor servo (1). The governor servo gives hydraulic assistance to move the fuel rack The remainder of the oil goes through a passage in the {governor center housing (8) and governor rear housing (7) to cover (3) or the fuel ratio control. From the cover (r the fue! ratio control, oll drains back into the {governor housing. This oil lubricates the governor Control components and supplzs the cil for the

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