Download Caterpillar 3406B 4MG, 7FB, 5KJ Diesel Engine Service Manual

It is Original 8-volume service manual set contains complete specifications, systems operation information, disassembly and assembly procedures, testing and adjusting instructions and troubleshooting steps for Caterpillar 3406B 4MG, 7FB, 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 in the Caterpillar 3406B 4MG, 7FB, 5KJ Diesel Engine Service Manual:

Engine Specifications

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 (Delco-Remy)
Pinion Clearance Adjustment (Bosch)
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

Covers: Caterpillar 3406B diesel engine with serial prefixes
7FB
4MG
5KJ
Pages: 1,139
Format: PDF files (zipped)
File size: 52mb
Compatibility: Windows/Mac computers
Notes: Instant download only.