Cat 3406E & 3465 Engine Service Repair Manual Caterpillar
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Cat 3406E & 3465 Engine Service Repair Manual Caterpillar
LANGUAGE:ENGLISH
PAGES:420+
DOWNLOADABLE:YES
FILE TYPE:PDF
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Cat 3406E & 3465 Engine Service Repair Manual Caterpillar
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.
TABLE OF CONTENTS:
Cat 3406E & 3465 Engine Service Repair Manual Caterpillar
Electronic Troubleshooting
System Overview
Electronic Service Tools
Electronic Display Module (If Equipped)
Replacing the ECM
Self—Diagnostics
Sensors and Electrical Connectors
Engine VWring Information
Programming Parameters
Programming Parameters
Factory Passwords
Flash Programming
System Configuration Parameters
System Configuration Parameters
Troubleshooting without a Diagnostic Code
Altemator (Charging Problem) I
Altemator (Noisy Operation)
Can Not Reach Top Engine RPM
Coolant in Engine Oil
Coolant Temperature Is Too High
ECM VWII Not Accept Factory Passwords
ECM Vlfill Not Communicate with Other Systems or
Display Modules
Electronic Service Tool \MII Not Communicate with
Engine Cranks but Vlfill Not Start 2
Engine Has Early Wear
Engine Misfires, Runs Rough or Is Unstable
Engine Oil in Cooling System
Engine Oil Temperature Is Too High
Engine Overspeeds on Start up
Engine Stalls at Low RPM
Engine Wbration
Engine Will Not Crank
Excessive Black Smoke
Excessive Engine Oil Consumption
Excessive Fuel Consumption
Excessive Valve Lash
Excessive White Smoke
Exhaust Temperature Is Too High
Fuel in Cooling System
Fuel Dilution of Engine Oil
Intermittent Engine Shutdown
Intermittent Low Power or Power Cutout
Low Engine Oil Pressure
Low Power/Poor or No Response to Throttle
Mechanical Noise (Knock) in Engine
Noise Coming from Cylinder
Poor Acceleration or Response
Valve Rotator or Spring Lock Is Free
Troubleshooting with a Diagnostic Code
Diagnostic Codes
CID 000 FMI Cylinder#‘l Injector fault
CID 0004 FMI CyIinder#4 Injector fault 49
CID 0005 FMI CyIinder #5 Injector fault 49
CID 0006 FMI Cylinder#6 Injector fault 49
CID 004 FMI 03 8 Volt DC Supply shortto +batt 50
CID 004 FMI 04 8 Volt DC Supply Short to
round 50
CID 009 FMI 08 Throttle Position signal
abnomtal 50
CID 0094 FMI 03 Fuel Pressure open/short to
+batt 50
CID 0094 FMI 04 Fuel Pressure short to ground 5
CID 0 00 FMI 03 Engine Oil Pressure openlshort to
+batt 5
CID 0 00 FMI 04 Engine Oil Pressure short to
ground 5
CID 0 0 FMI 03 Engine Coolant Temperature
open/short to +batt 5
CID 0 0 FMI 04 Engine Coolant Temperature short
to ground 52
CID 0 68 FMI 00 System Voltage High 52
CID 0 68 FMI 0 System Voltage Low 52
CID 0 68 FMI 02 System Voltage intennittentl
erratic 52
CID 0 72 FMI 03 Intake Manifold Air Temp open/short
to +batt 53
CID 0 72 FMI 04 Intake Manifold Air Temp short to
ground 53
C D 0 74 FMI 03 Fuel Temperature open/short to
+batt 53
CID 0 74 FMI 04 Fuel Temperature short to
ground 54
CID 0 90 FMI 02 Loss of Engine Speed Signal 54
CID 0 90 FMI Engine Speed Sensor mechanical
failure 54
CID 0248 FMI 09 Cat Data Link not
communicating 55
CID 0253 FMI 02 Personality Module mismatch 55
CID 0254 FMI 2 Electronic Control Module
CID 026 FMI 3 Engine Timing Calibration
required 56
CID 0262 FMI 03 5 Volt Sensor DC Power Supply
short to +batt 56
CID 0262 FMI 04 5 Volt Sensor DC Power Supply
short to ground 56
CID 0267 FMI 02 Incorrect Engine Shutdown Switch
CID 0268 FMI 02 Check Programmable
Parameters 57
CID 0273 FMI 03 Turbo Outiet Pressure open/short
to +batt 57
CID 0273 FMI 04 Turbo Outiet Pressure short to
ground 58
CID 0274 FMI 03 Atmospheric Pressure open/short
to +batt 58
CID 0274 FMI 04 Atmospheric Pressure short to
ground 58
CID 0275 FMI 03 Right Turbo InIet Pressure
open/short to +batt 58
CID 0275 FMI 04 Right Turbo Inlet Pressure short to
ground 59
CID 029 FMI 05 Engine Cooling Fan Solenoid or
CID 029 FMI 06 Engine Cooling Fan Solenoid SI
to ground
CID 0296 FMI 09 Unable to communicate with
Transmission ECM
CID 0342 FMI 02 Loss of Secondary Engine Spee
signal
CID 0342 FMI Secondary Engine Speed Sens:
mechanical failure
CID 0545 FMI 05 Ether Start Relay open/short to
+batt
CID 0545 FMI 06 Ether Start Relay short to
ground
CID 0788 FMI 02 Loss of Engine Retarder Select
CID 079 FMI 05 Compression Brake Low/High
Solenoid current low
CID 079 FMI 06 Compression Brake Low/High
Solenoid current high
CID 0792 FMI 05 Compression Brake Medium/His
Solenoid current low
CID 0792 FMI 06 Compression Brake Medium/His
Solenoid current high
CID 076 FMI 05 Engine Cooling Fan Bypass
Solenoid open crrcurt
CID 076 FMI 06 Engine Cooling Fan Bypass
Solenoid short to ground
CID 586 FMI 05 Retarder Indicator Lamp open
CID 586 FMI 06 Retarder Indicator Lamp shortt
ground
Troubleshooting with an Event Code
Event Codes
E0 5 High Engine Coolant Temperature Derate
E0 7 High Engine Coolant Temperature
Waming
E025 High Inlet Air Temperature Derate
E027 High Inlet Air Temperature Warning
E039 Low Engine Oil Pressure Derate
E056 High Fuel Temperature Waming
E094 Axle Protection Derate
E 00 Low Engine Oil Pressure Warning
E 90 Engine Overspeed Warning
E272 Inlet Air Restnction Waming
Diagnostic Functional Tests
5 Volt Engine Pressure Sensor Supply Circuit
Air Filter Restriction Lamp Test
Cat Data Link Circuit — Test
Compression Brake Lamp Circuit — Test
Compression Brake Solenoid Circuit Test
Digital Sensor Supply Circuit — Test
Electrical Connectors Inspect
Electrical Power Supply Circuit — Test
Engine Cooling Fan Bypass Solenoid Circuit
Engine Pressure Sensor Open or Short Circuit —
Engine Shutdovm Switch Circuit Test
Engine Speed/Timing Sensor Circuit Test
Engine Temperature Sensor Open or Short Circuit
Ether Injection System Test
Injector Solenoid Circuit Test
Throttle Position Sensor Circuit Test
Calibration Procedures
Engine Speed/Timing Sensor Calibrate
Index Section
Index
Engine Design
Fuel Transfer Pump
Fuel Filter Base
Electronic Unit Injector Mechanism
Electronic Unit Injector Rocker Arm
Valve Mechanism
Valve Mechanism Cover
Cylinder Head Valves
Cylinder Head
Compression Brake (If Equipped)
Turbocharger
Air Inlet Elbow
Exhaust Manifold L
Exhaust Manifold Shield
Camshaft
Engine Oil Filter Base
Engine Oil Cooler Bypass Valve
Engine Oil Pump
Engine Oil Pan
Crankcase Breather
Water Lines
Water Temperature Regulator
Water Pump
Cylinder Block
Cylinder Liner
Crankshaft
Vibration Damper
Connecting Rod Bearing Joumal
Main Bearing Journal
Connecting Rod
Piston and Rings
Housing (Front)
Front Housing and Covers
Gear Group (Front)
Flmeel Housing
Belt Tension Chart
Mounting Gp—Fan Drive
Engine Support (Front)
Alternator and Regulator
Electric Starting Motor
Electrical Ground Stud
Coolant Temperature Sensor
Fuel Temperature Sensor
Fuel Pressure Sensor
Engine Oil Pressure Sensor
Atmospheric Pressure Sensor
Inlet Air Temperature Sensor
Speed and Timing Sensor
Index Section
Index
General Infomiation
Glossary of Electronic Control Terms
Electronic Control System Components
Fuel System
Air Inlet and Exhaust System
Lubrication System
Cooling System
Basic Engine
Compression Brake
Electrical System
Testing and Adjusting Section
Troubleshooting
Troubleshooting
Air in Fuel Test
Electronic Unit Injector Adjust
Electronic Unit Injector Test
Finding Top Center Position for No Piston
Fuel Quality Test
Fuel System — Prime
Fuel System Pressure Test
Gear Group (Frontj Tlme
Air Inlet and Exhaust System
Air Inlet and Exhaust System — Inspect
Turbocharger Inspect
Inlet Manifold Pressure Test
Exhaust Temperature Test
Aftercooler Test
Engine Crankcase Pressure (Blowby) Test
Compression Test
Engine Valve Lash Inspect/Adjust
Excessive Bearing Wear— Inspect
Excessive Engine Oil Consumption Inspect
Increased Engine Oil Temperature Inspect
Cooling System lnspect
Disassembly and Assembly Section
Fuel Priming Pump Remove and Install
Fuel Filter Base Remove and Install
Fuel Transfer Pump Remove
Fuel Transfer Pump Install
Electronic Unit Injector Remove
Electronic Unit Injector Install
Electronic Unit Injector Sleeve Remove
Electronic Unit Injector Sleeve Install
Turbocharger Remove
Turbocharger Disassemble
Turbocharger Assemble
Turbocharger Install
Exhaust Manifold Remove and Install
Inlettalrlid Exhaust Valve Springs Remove and
ns a
Inlet and Exhaust Valves Remove and Install
Inlet and Exhaust Valve Guides Remove and
Install
Inlet and Exhaust Valve Seat Inserts Remove ani
Install
Engine Oil Filter Base Remove
Engine Oil Filter Base Disassemble
Engine Oil Filter Base Assemble
Engine Oil Filter Base Install
Engine Oil Cooler Remove
Engine Oil Cooler Disassemble
Engine Oil Cooler Assemble
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 Disassemble
Water Pump Assemble
Water Pump Assemble
Water Pump Install
Water Temperature Regulator Remove and Instal
Flywheel Remove
Flywheel Install
Crankshaft Rear Seal Remove
Crankshaft Rear Seal 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
Valve Mechanism Cover — Remove and Install
Valve Mechanism Cover Base Remove and
Install
Compression Brake Remove (If Equipped)
Compression Brake Disassemble (If Equipped)
Compression Brake Assemble (If Equipped)
Compression Brake Install (If Equipped)
Rocker Am and Shaft Remove
Rocker Arm Disassemble
Rocker Aim Assemble
Rocker Aim and Shaft Install
Cylinder Head Remove
Cylinder Head Install
Camshaft Remove
Camshaft Install
Camshaft Gear Remove and Install
Camshaft Bearings Remove
Camshaft Bearings Install
Engine Oil Pan Remove and Install
Cylinder Liner Remove
Cylinder Liner 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
Connecting Rod Bearings Remove
Connecting Rod Bearings Install
Crankshaft Main Bearings Remove
Crankshaft Main Bearings Install
Crankshaft Remove
Crankshaft Install
Bearing Clearance Check
Coolant Temperature Sensor Remove and
Install
Engine Oil Pressure Sensor Remove and Install
Speed/Timing Sensor Remove and Install
Fan Drive Remove
Fan Drive Disassemble
Fan Drive Assemble
Fan Drive Install
Electronic Control Module — Remove and Install
Electric Starting Motor — Remove and Install
Index Section
Index
PLEASE NOTE:
⦁ This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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