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. Revision: August 1, 2000
Property of Caterpillar Inc.
Engine Fundamentals
Caterpillar Engine Fundamentals
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
Table of Contents
Table Of Contents
Course Description Description 1. 2. 3. 4. 5.
Caterpillar Engine Fundamentals Course Number Prerequisite: None Four lecture and twelve laboratory hours per week. 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. 2. 3. 4.
Unit test--__________% Laboratory worksheets--________% Final Exam--______________% Classroom and laboratory participation--_________%
Course Description
Caterpillar Engine Fundamentals
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.
Objectives
Caterpillar Engine Fundamentals
Reference Materials Student Materials Industrial Engine Selection Guide Harness the Power (Cat Truck Engines for 1998) Marine Propulsion Engines Selection Guide The Engine Book Introduction to Engines Glossary of Terms 3400 Engine Major Component Performance Guide CG-4, The Preferred Oil Oil and your Engine 3406E Operation and Maintenance Manual Cooling System Design Fundamentals Coolant and Your Engine A Close Look at Cat Extended Life Coolant Diesel Fuel and Your Engine Fuel Contamination Control Using 5P4150 Nozzle Tester Group Testing 7000 Series Nozzles How Diesel Engines Work and Wear
LECH9163 LEXT9136 LECM0038 LEBQ9801 TECB6005 LEXQ9297 SEBD0794 LEDQ7315 SEBD0640 SEBU6758 LEKQ7353 SEBD0970 LEDQ7330 SEBD0717 PEHP7046 SEHS7292 SEHS9083 TECB6006
Component Analysis Publications (to be put in a separate binder) Engine Bearings and Crankshafts Electrical Discharge Damage to Bearings Analyzing Fuel Nozzle and Fuel Line Failures Analyzing Diesel and Natural Gas Engine Valve Failures Turbochargers Engine Valves Pistons, Rings, and Liners Connecting Rods
SEBD0531 SEBD0610 SEBD0639 SEBD0668 SEBV0550 SEBV0551 SEBV0553 SEBV0546
Reference Materials
Caterpillar Engine Fundamentals
Reference Materials (continued) Classroom and Lab Materials The Sleeve Metering Fuel System CD-ROM Caterpillar EUI Fuel System CD-ROM Caterpillar 3126B Engine CD-ROM 3406B Service Manual 3406C Service Manual 3406E Service Manual 3406E Service Manual
LERV9802 RENR1391 RENR1390 SEBR0544 SEBR0560 SENR5580 RENR1275
Video Tapes Oil in Your Engine Cat 3406E Operation and Maintenance Video Are You Listening To Your Oil? 3406 Maintenance Systems Overview 3406 Maintenance Daily Maintenance 3406 Maintenance PM Level 1 3406 Maintenance PM Level 2 and 3 Fuel Nozzle Testing
LEVP9001 LEVP3828 PEVP2028 LEVP2125 LEVP2126 LEVP2127 LEVP2128 LEVP9167
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.
Tooling Requirements NOTE: Except where noted, the tools on this list are needed per engine work station. 8T0461 Serviceman’s Tool Set or Equal 1U5750 Diesel Engine Repair Stand 1U5749 Engine Adapter Plate 6V6981 Nozzle Puller Group 6V4186 Pin 9S9082 Turning Tool 7M3978 Piston Ring Expander 5P0961 Nozzle Adapter Wrench 5P0144 Fuel Line Socket 8T3139 Spanner Wrench 6V9448 Cylinder Pack Puller 4C5084 Filter Cutter 8T0455 Liner Projection Tool Group 5P0144 Fuel Line Socket 9S7354 Torque Wrench 9U5006 Torque Wrench 9U5007 Torque Wrench 9U5018 Torque Wrench 9U5019 Torque Wrench 1P7408 Thermo-hydrometer 8S2244 Extractor 8T5287 Wrench 5P4150 Nozzle Test Group 5P7314 Wear Sleeve Ring 8T3198 Nozzle Tube 8T3199 Nozzle Screw 9S8140 Pressurizing Gp 6V6142 Crank Seal Installer 6V6143 Crank Seal Installer 1B4206 Nut 6V7025 Nozzle Seal Guide 4C3601 Piston Ring Expander 5P5195 Fuel Line Wrench 6V2171 Tube Assembly
5P3526 Ring Compressor 5P7433 Valve Lifter Tool Group 8T0455 Liner Projection Tool Gp 8T3222 Gov Adjusting Tool Group 6V7050 Compressor Gp 5P5195 Fuel Line Wrench 6V7898 Dial Bore Gauge 6V7899 Size Setting Fixture 2F2990 Plug (qty 50) 5F2807 Cap (qty 50) 2P8250 Filter Strap Wrench 5P0957 Battery/Coolant Tester 5P7312 Wear Sleeve Distorter 8S2270 Collecter Assembly 8T5296 Coolant Test Kit 1U7600 Lip Seal Puller 5P6521 Screw Tip 6V4089 Nozzle Reamer 6V6983 Adapter 6V6068 Calibration Fluid 6V6070 Fuel Setting Tool Gp 1P7408 Thermo-Hydrometer 2P5518 Bearing Removal Tool 5S1330 Valve Spring Compressor 8S2241 Cam Bearing Tool Gp 1U9725 Nozzle Adapter Wrench 2P8260 Liner Installer Group 1U6319 Socket 1U9897 Bridge Group 1P7438 Beaker 9U7530 3406E Service Tools 5P1733 Crank Seal Locator 6V2170 Tube Assembly 5P7448 Adapter
Tooling Requirements
Caterpillar Engine Fundamentals
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 Harness the Power (Cat Truck Engines for 1998) Caterpillar Marine Engine Selection Guide The Engine Book Introduction to Diesel Engines How Diesel Engines Work and Wear Glossary of Terms 3400 Engine Major Component Performance Guide Unit 1 Quiz Tooling: None required
LECH9163 LEXT8138 LECM8477 LEBQ9801 TECB6005 TECB6006 LEXQ8150 SEBD0794 Copy
Unit 1: Caterpillar Engine Applications
UNIT 1
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 Harness the Power (Cat Truck Engines for 1998) Caterpillar Marine Engine Selection Guide
LECH9163 LEXT8138 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.
Lesson 1: Engine Product Line and Applications
Lesson 1: Caterpillar Engine Product Line and Applications
