Caterpillar Engine

Engine Fundamentals
Fundamentals
Course Overview

This course introduces the student to basic diesel engine theory and
service procedures. Caterpillar engine systems and applications will
be studied. Several Caterpillar Engines will be presented with
emphasis on the 3406 due to its high field population.

The following course curriculum has been developed using the

reference materials and tooling listed on the following pages.
Substitute materials and tooling may be used at the discretion of the
instructor.

Course Exercises and lab assignments may require modification if

substitute materials and tooling are used.

2000 Caterpillar Inc. Property of Caterpillar Inc.

Revision: November 1, 2001
NOTES
 Table of Contents
Table Of Contents
UNIT 1: Introduction to Caterpillar Diesel Engines
Lesson 1: Caterpillar Engine Product Line, Applications
Lesson 2: Diesel Engine Components and Operation
Lesson 3: Engine Performance Terminology

UNIT 2: Air Intake and Exhaust Systems

Lesson 1: Intake and Exhaust System Components, Operation,
and Maintenance
Lesson 2: Remove, Inspect, and Install Air and Exhaust System
Components

UNIT 3 Lubrication Systems and Oil

Lesson 1: Lube System Components and Operation
Lesson 2: Remove, Inspect, and Install Lube System
Components

UNIT 4: Cooling Systems

Lesson 1: Cooling System Components and Operation
Lesson 2: Remove, Inspect, and Install Cooling System
Components

UNIT 5: Diesel Fuel and Mechanically Controlled Fuel Systems

Lesson 1: Diesel Fuel
Lesson 2: Caterpillar 3406 New Scroll Fuel System
Lesson 3: Remove, Inspect, and Install Fuel System
Components
Lesson 4: Caterpillar Sleeve Metering Fuel Systems
Lesson 5: 3116/26 Mechanical Unit Injector Fuel Systems

UNIT 6: Engine Disassembly, Inspection, and Assembly

Lesson 1: 3406 Disassembly and Inspection
Lesson 2: Caterpillar 3406 Engine maintenance

UNIT 7: Electronically Controlled Fuel Systems

Lesson 1: Caterpillar Electronic Fuel Systems
Lesson 2: Remove, Inspect, and Install 3406E Components
NOTES
Caterpillar Engine

Course Description
Fundamentals
Course Description

Description

1. Caterpillar Engine Fundamentals

2. Course Number
3. Prerequisite: None
4. Four lecture and twelve laboratory hours per week.
5. Credit: Four semester hours

Methods of Presentation

1. Lecture and discussion

2. Demonstrations
3. Supporting laboratory exercises and lab worksheets

Suggested Evaluation of Student Achievement

1. Unit test--__________%
2. Laboratory worksheets--________%
3. Final Exam--______________%
4. Classroom and laboratory participation--_________%
NOTES
Caterpillar Engine
Fundamentals

Objectives
Objectives

This course prepares Caterpillar dealer entry-level service technicians

for more advanced training on specific engines and systems. After
successfully completing this course, a student will be able to:

- Identify the wide range of engines in the Caterpillar Product Line.

- Identify various diesel engine applications.
- Explain basic diesel engine theory.
- Define engine performance terms.
- Identify basic diesel engine components and their function.
- Describe the following engine systems:
Air intake and exhaust systems
Lubrication system
Cooling system
Fuel system and governor
- Demonstrate the ability to disassemble and inspect Caterpillar
3406 diesel engine with a mechanical governor.
- Demonstrate the ability to reassemble and perform necessary
adjustments on a Caterpillar 3406 diesel engine with a mechanical
governor.
- Explain the operation of the Caterpillar Sleeve Metering Fuel
System.
- Explain the operation of the Caterpillar 3116/26 Mechanical Unit
Injector Fuel System.
- Explain the operation of and identify components used in
Caterpillar electronically controlled engines using EUI and HEUI
fuel systems.
NOTES
Caterpillar Engine

Reference Materials
Fundamentals
Reference Materials

Student Materials
Industrial Engine Selection Guide LECH9163
Harness the Power (Cat Truck Engines for 1998) LEXT9136
Marine Propulsion Engines Selection Guide LECM0038
The Engine Book LEBQ9801
Introduction to Engines TECB6005
Glossary of Terms LEXQ9297
3400 Engine Major Component Performance Guide SEBD0794
CG-4, The Preferred Oil LEDQ7315
Oil and your Engine SEBD0640
3406E Operation and Maintenance Manual SEBU6758
Cooling System Design Fundamentals LEKQ7353
Coolant and Your Engine SEBD0970
A Close Look at Cat Extended Life Coolant LEDQ7330
Diesel Fuel and Your Engine SEBD0717
Fuel Contamination Control PEHP7046
Using 5P4150 Nozzle Tester Group SEHS7292
Testing 7000 Series Nozzles SEHS9083
How Diesel Engines Work and Wear TECB6006

Component Analysis Publications (to be put in a separate binder)

Engine Bearings and Crankshafts SEBD0531

Electrical Discharge Damage to Bearings SEBD0610
Analyzing Fuel Nozzle and Fuel Line Failures SEBD0639
Analyzing Diesel and Natural Gas Engine Valve Failures SEBD0668
Turbochargers SEBV0550
Engine Valves SEBV0551
Pistons, Rings, and Liners SEBV0553
Connecting Rods SEBV0546
Reference Materials (continued)
Classroom and Lab Materials

The Sleeve Metering Fuel System CD ROM LERV9802

Caterpillar EUI Fuel System CD ROM RENR1391
Caterpillar 3126B Engine CD ROM RENR1390
Caterpillar HEUI HI300B Fuel System CD ROM RENR1392
3406B Service Manual SEBR0544
3406C Service Manual SEBR0560
3406E Service Manual SENR5580
3406E Service Manual RENR1275

Video Tapes

Oil in Your Engine LEVN9001

Cat 3406E Operation and Maintenance Video LEVN3828
Are You Listening To Your Oil? PEVN2028
3406 Maintenance Systems Overview LEVN2125
3406 Maintenance Daily Maintenance LEVN2126
3406 Maintenance PM Level 1 LEVN2127
3406 Maintenance PM Level 2 and 3 LEVN2128
Fuel Nozzle Testing LEVN9167

Laboratory Requirements

Engines for disassembly (quantity depends on class size)

3406B or 3406C engine(s) with mechanical governor

3406E engine(s)

Overhead crane/hoist (4000 lb capacity)

Access to runable engine training aid or vehicle (to show systems in an engine installation).
Workshop accessories such as solvent wash tank, parts carts, work benches, etc.
Caterpillar Engine

Tooling Requirements
Fundamentals
Tooling Requirements
NOTE: Except where noted, the tools on this list are needed per engine work station.

8T0461 Servicemans Tool Set or Equal 5P3526 Ring Compressor

1U5750 Diesel Engine Repair Stand 5P7433 Valve Lifter Tool Group
1U5749 Engine Adapter Plate 8T0455 Liner Projection Tool Gp
6V6981 Nozzle Puller Group 8T3222 Gov Adjusting Tool Group
6V4186 Pin 6V7050 Compressor Gp
9S9082 Turning Tool 5P5195 Fuel Line Wrench
7M3978 Piston Ring Expander 6V7898 Dial Bore Gauge
5P0961 Nozzle Adapter Wrench 6V7899 Size Setting Fixture
5P0144 Fuel Line Socket 2F2990 Plug (qty 50)
8T3139 Spanner Wrench 5F2807 Cap (qty 50)
6V9448 Cylinder Pack Puller 2P8250 Filter Strap Wrench
4C5084 Filter Cutter 5P0957 Battery/Coolant Tester
8T0455 Liner Projection Tool Group 5P7312 Wear Sleeve Distorter
5P0144 Fuel Line Socket 8S2270 Collecter Assembly
9S7354 Torque Wrench 8T5296 Coolant Test Kit
9U5006 Torque Wrench 1U7600 Lip Seal Puller
9U5007 Torque Wrench 5P6521 Screw Tip
9U5018 Torque Wrench 6V4089 Nozzle Reamer
9U5019 Torque Wrench 6V6983 Adapter
1P7408 Thermo-hydrometer 6V6068 Calibration Fluid
8S2244 Extractor 6V6070 Fuel Setting Tool Gp
8T5287 Wrench 1P7408 Thermo-Hydrometer
5P4150 Nozzle Test Group 2P5518 Bearing Removal Tool
5P7314 Wear Sleeve Ring 5S1330 Valve Spring Compressor
8T3198 Nozzle Tube 8S2241 Cam Bearing Tool Gp
8T3199 Nozzle Screw 1U9725 Nozzle Adapter Wrench
9S8140 Pressurizing Gp 2P8260 Liner Installer Group
6V6142 Crank Seal Installer 1U6319 Socket
6V6143 Crank Seal Installer 1U9897 Bridge Group
1B4206 Nut 1P7438 Beaker
6V7025 Nozzle Seal Guide 9U7530 3406E Service Tools
4C3601 Piston Ring Expander 5P1733 Crank Seal Locator
5P5195 Fuel Line Wrench 6V2170 Tube Assembly
6V2171 Tube Assembly 5P7448 Adapter
NOTES
 Unit 1: Caterpillar Engine Applications
UNIT 1
Caterpillar Engine Applications and Principles
of Operation

Unit Objectives:

The student will be able to:

1. Identify a wide range of Caterpillar engines and their

applications.
2. Identify basic engine components and explain principles of
diesel engine operation.
3. Define essential engine performance terminology.

Unit References:

Industrial Engine Selection Guide LECH9163

Harness the Power (Cat Truck Engines for 1998) LEXT8138
Caterpillar Marine Engine Selection Guide LECM8477
The Engine Book LEBQ9801
Introduction to Diesel Engines TECB6005
How Diesel Engines Work and Wear TECB6006
Glossary of Terms LEXQ8150
3400 Engine Major Component Performance Guide SEBD0794
Unit 1 Quiz Copy

Tooling:

None required
NOTES
 Lesson 1: Engine Product Line and Applications
Lesson 1: Caterpillar Engine Product Line and
Applications

Objective:

At the completion of this lesson the student will be able to identify a

wide range of Caterpillar engines and their applications.

References:

Industrial Engine Selection Guide LECH9163

Harness the Power (Cat Truck Engines for 1998) LEXT8138
Caterpillar Marine Engine Selection Guide LECM8477

Introduction:

Caterpillar engines are known around the world for their durability,
performance, and efficiency. Whether they are used in earthmoving
equipment, on-road or off-road vehicles, industrial power situations,
marine installations, or electric power generation, Caterpillar engines
have set new standards for decades. To give customers a competitive
advantage, Caterpillar is constantly working to push performance to
higher levels.

Today's line of Caterpillar engines offers some of the most advanced

engineering features available. These include electronic controls,
hydraulically actuated electronically controlled unit injectors (HEUI),
and other exclusive technologies that dramatically reduce engine
emissions.
NOTES