Caterpillar 3612, 3616 Series Engines Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Caterpillar 3612, 3616 Series Engines, with all the technical information to maintain, diagnose, repair, rebuild like professional mechanics.
Caterpillar 3612, 3616 Series Engines workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
RELP0834 - Parts Manual (3616 Industrial Engine).pdf
SENR3594 - Disassembly & Assembly (3612 & 3616 Engines).pdf
SENR3593 - Testing & Adjusting (3612 & 3616 Engines).pdf
SENR3593 - Systems Operation (3612 & 3616 Engines).pdf
SENR3592 - Specifications (3612 & 3616 Engines).pdf
RENR5970 - Systems Operation (Jacket Water Heaters, Lube Oil Heaters & Combination Heaters for G3600, 3600 & C280 Engines).pdf
RENR5901 - Troubleshooting (Engine Oil Cooler).pdf
RENR5901 - Systems Operation (Engine Oil Cooler).pdf
RENR5901 - Disassembly & Assembly (Engine Oil Cooler).pdf
RENR2459 - Schematic (3606, 3608, 3612, 3616 Diesel Marine Monitoring System II Generator Monitoring System).pdf
RENR2458 - Schematic (3600 Diesel Marine Monitoring System Electrical System).pdf
ENGINE - GENERATOR SET
Model Prefix
3612 GEN SET ENGINE 9RC
ENGINE - INDUSTRIAL
Model Prefix
3612 INDUSTRIAL ENGINE 9RC
3612 LOCOMOTIVE ENGINE 9RC
3612 LOCOMOTIVE ENGINE ZYC
MARINE PRODUCTS
Model Prefix
3612 MARINE ENGINE 9FR
3612 MARINE ENGINE 9RC
3612 MARINE ENGINE NZA
ENGINE - GENERATOR SET
Model Prefix
3616 GEN SET ENGINE 1PD
ENGINE - INDUSTRIAL
Model Prefix
3616 INDUSTRIAL ENGINE 1PD
3616 LOCOMOTIVE ENGINE 1PD
MARINE PRODUCTS
Model Prefix
3616 MARINE ENGINE 1FN
3616 MARINE ENGINE 1PD
3616 MARINE ENGINE RMN
PRODUCT DETAILS:
Total Pages: 1,594 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
RELP0834 - Parts Manual (3616 Industrial Engine).......2
RENR2458 - Schematic (3600 Diesel Marine Monitoring System Electrical System).......281
Collage.......282
Main.......297
RENR2459 - Schematic (3606, 3608, 3612, 3616 Diesel Marine Monitoring System II Generator Monitoring System).......299
Collage.......300
Main.......326
RENR5901 - Disassembly & Assembly (Engine Oil Cooler).......328
Engine Oil Cooler - Assemble.......329
Engine Oil Cooler - Disassemble.......335
RENR5901 - Systems Operation (Engine Oil Cooler).......339
Component Description.......340
Engine Oil Cooler.......345
RENR5901 - Troubleshooting (Engine Oil Cooler).......348
Buildup - Clean.......349
Channel Plate - Clean.......350
Dirty Channel Plate.......351
Engine Coolant Temperature (High) - High Inlet Temperature of the Coolant.......353
Engine Oil Temperature (High) - High Lube Oil Temperature to the Engine.......354
Faulty Regulator - Faulty Regulators.......355
Fouled Channel Plate.......356
RENR5970 - Systems Operation (Jacket Water Heaters, Lube Oil Heaters & Combination Heaters for G3600, 3600 & C280 Engines).......357
Electrical System Schematic.......358
Installation and System Start-Up.......362
Introduction.......377
Maintenance.......383
System Components.......416
Troubleshooting.......433
SENR3592 - Specifications (3612 & 3616 Engines).......440
Accessory Drive.......443
Aftercooler.......449
Air Cleaner Adapter.......451
Air Inlet Elbow.......452
Air Inlet Shutoff.......453
Air Shutoff.......455
Air Starting Motor.......459
Auxiliary Water Pump - Sea Water.......461
Camshaft - Earlier.......471
Camshaft - Later.......476
Camshaft Bearing Position.......481
Camshaft Bearings.......484
Compression Release Valve.......485
Connecting Rod and Main Bearing Journals.......487
Connecting Rod.......488
Crankcase Breather.......494
Crankshaft Seals.......495
Crankshaft.......497
Cylinder Block.......503
Cylinder Head Valves.......515
Cylinder Head.......518
Cylinder Liner.......522
Engine Centrifugal Oil Filter.......524
Engine Design.......525
Engine Lifting Bracket.......527
Engine Oil Cooler.......529
Engine Oil Filter.......531
Engine Oil Pump.......532
Engine Oil Temperature Regulator.......541
Engine Speed Sensor.......542
Engine Support.......544
Exhaust Manifold.......547
Flexible Coupling.......551
Flywheel.......568
Fuel Filter Housing.......572
Fuel Injection Control Linkage.......574
Fuel Injection Lines Group - Diesel Fuel.......580
Fuel Injection Lines Group - Front Mounted Turbocharger.......583
Fuel Injection Lines Group - Heavy Fuel Oil.......586
Fuel Injection Lines Group.......589
Fuel Injector - Distillate Fuel.......593
Fuel Injector - Heavy Fuel Oil.......595
Fuel Injector Mechanism.......597
Fuel Pressure Control Valve - Diesel Fuel.......599
Fuel Pressure Control Valve - Front Mounted Turbocharger.......601
Fuel Pressure Control Valve - Heavy Fuel Oil.......603
Fuel Transfer Pump.......605
Gear Group (Front).......607
Gear Group (Rear).......610
Governor Drive.......616
Housing (Front).......621
Housing (Rear).......623
Inlet Valve Lubrication Metering Pump.......627
Manual Barring Group - 501 Reduction.......629
Manual Barring Group.......631
Manual Valve Group (Cylinder Pressure).......632
Piston and Rings - Four Ring Piston.......633
Piston and Rings - Three Ring Piston.......635
Prelube Pump Motors.......639
Prelube Pump.......641
Pressure Contactor.......647
Pressure Regulating Valve.......649
Priority Valve.......654
Probe Adapter.......656
Shutoff (Energize to Run).......658
Shutoff (Energize to Shutdown).......660
Stub Shaft (Front).......663
Temperature Contactor.......669
Temperature Sensor.......671
Turbocharger.......672
Valve Mechanism.......676
Vibration Damper - Dual.......678
Vibration Damper - Single.......682
Water Pump - Sea Water.......686
Water Pump.......688
Water Temperature Regulator.......694
SENR3593 - Systems Operation (3612 & 3616 Engines).......700
Aftercooler.......701
Air Inlet and Exhaust System Operation.......703
Air Starting System Operation.......705
Camshaft.......714
Centrifugal Oil Filters.......715
Combined Circuit Cooling System.......717
Cooling System Operation.......721
Crankcase Explosion Relief Valves.......722
Crankshaft.......723
Cylinder Block, Liners and Heads.......724
Engine Barring Group.......726
Engine Design.......733
Engine Oil Coolers and Temperature Regulators.......735
Engine Oil Filters.......737
Engine Oil Pump.......739
Front Gear Group.......741
Fuel Injection Control Linkage.......742
Fuel Injection Cycle.......746
Fuel Injector.......750
Fuel System Operation.......753
Internal Lubrication.......756
Lubrication System Operation.......759
Piston Cooling Jets.......763
Pistons, Rings and Connecting Rods.......764
Rear Gear Group.......765
Separate Circuit Cooling System.......766
Turbocharger - Napier 297.......770
Turbocharger.......774
SENR3593 - Testing & Adjusting (3612 & 3616 Engines).......776
Battery.......778
Camshaft Timing.......779
Compression.......785
Connecting Rod Bearings.......786
Crankcase Pressure.......787
Crankshaft Deflection (Bend).......788
Crankshaft Position for Fuel Timing and Valve Lash Adjustment.......790
Cylinder Block.......793
Cylinder Head.......794
Engine Oil Pressure is High.......797
Engine Oil Pressure is Low.......798
Engine Rotation.......800
Excessive Bearing Wear - Inspect.......801
Excessive Engine Oil Consumption - Inspect.......802
Finding the Top Center Position for the No. 1 Piston.......803
Flywheel and Flywheel Housing.......805
Fuel Injector Synchronization.......813
Fuel Injector Testing.......821
Fuel Pressure.......822
Fuel Setting.......827
Fuel System Inspection.......833
Fuel Timing.......834
General Information (Cooling System).......841
General Information (Fuel System) - Diesel.......843
General Information (Lubrication System).......844
Heinzmann Governor.......845
Increased Engine Oil Temperature - Inspect.......850
Indicators for Engine Oil Pressure.......851
Lubricator and Strainer.......852
Main Bearings.......854
Measuring Engine Oil Pressure.......855
Measuring Exhaust Temperature.......856
Measuring Inlet Manifold Pressure.......857
Pressure Regulating Valve.......859
Restriction of Air Inlet and Exhaust.......861
Start Up Procedure.......862
Test Tools for the Cooling System.......863
Test Tools for the Electrical System.......866
Test for the Water Temperature Regulator.......870
Testing the Cooling System.......871
Timing Adjustments for Fuel System.......875
Troubleshooting.......876
Valve Lash and Valve Bridge Adjustment.......907
Vibration Damper.......913
Visual Inspection.......914
Water Temperature Gauge.......916
Woodward 3161 Governor.......918
Woodward EGB29P Governor.......925
SENR3594 - Disassembly & Assembly (3612 & 3616 Engines).......930
3612 GENERATOR,INDUSTRIAL,LOCOMOTIVE AND MARINE JANUARY 1998 TO CURRENT 9RC00001-UP(SEBP3781 - 117) - Documentation.......936
Accessory Drive - Assemble.......955
Accessory Drive - Disassemble.......961
Accessory Drive - Install.......966
Accessory Drive - Remove.......968
Aftercooler - Assemble.......970
Aftercooler - Disassemble.......973
Aftercooler - Install - High Performance Aftercooler.......976
Aftercooler - Install - Standard Aftercooler.......988
Aftercooler - Remove - High Performance Aftercooler.......992
Aftercooler - Remove - Standard Aftercooler.......1003
Air Inlet Shutoff - Remove and Install.......1007
Air Lubricator - Remove and Install.......1009
Air Regulator - Remove and Install - Air Starting.......1012
Air Starting Motor - Assemble.......1016
Air Starting Motor - Disassemble.......1030
Air Starting Motor - Install.......1041
Air Starting Motor - Remove.......1043
Air Starting Motor Silencer - Remove and Install.......1045
Auxiliary Water Pump - Assemble.......1048
Auxiliary Water Pump - Disassemble.......1052
Auxiliary Water Pump - Install.......1055
Auxiliary Water Pump - Remove.......1057
Camshaft - Install.......1059
Camshaft - Remove.......1068
Camshaft Bearings - Install.......1074
Camshaft Bearings - Remove.......1077
Camshaft Drive Gear - Install.......1079
Camshaft Drive Gear - Remove.......1083
Centrifugal Oil Filter - Assemble.......1086
Centrifugal Oil Filter - Disassemble.......1089
Centrifugal Oil Filter - Install.......1092
Centrifugal Oil Filter - Remove.......1094
Crankcase Explosion Relief Valve - Remove and Install.......1096
Crankshaft - Install.......1099
Crankshaft - Remove.......1106
Crankshaft Front Gear - Remove and Install.......1111
Crankshaft Front Seal - Install.......1114
Crankshaft Front Seal - Remove.......1116
Crankshaft Main Bearings - Install.......1118
Crankshaft Main Bearings - Remove.......1132
Crankshaft Rear Gear - Remove and Install.......1141
Crankshaft Rear Seal - Install.......1144
Crankshaft Rear Seal - Remove.......1146
Cylinder Head - Assemble.......1148
Cylinder Head - Disassemble.......1160
Cylinder Head - Install.......1169
Cylinder Head - Remove.......1176
Cylinder Liner - Install.......1184
Cylinder Liner - Remove.......1187
Electric Starting Motor - Remove and Install.......1190
Engine Lifting Bracket - Remove and Install.......1193
Engine Oil Coolers - Assemble.......1196
Engine Oil Coolers - Disassemble.......1199
Engine Oil Coolers - Install.......1201
Engine Oil Coolers - Remove.......1203
Engine Oil Filler and Oil Level Gauge - Remove and Install.......1205
Engine Oil Filter Elements - Remove and Install.......1213
Engine Oil Filter Housings - Assemble.......1217
Engine Oil Filter Housings - Disassemble.......1224
Engine Oil Filter Housings - Install.......1231
Engine Oil Filter Housings - Remove.......1233
Engine Oil Pan - Assemble.......1235
Engine Oil Pan - Disassemble.......1240
Engine Oil Pan - Install.......1244
Engine Oil Pan - Remove.......1247
Engine Oil Pump - Assemble.......1250
Engine Oil Pump - Disassemble.......1254
Engine Oil Pump - Install.......1257
Engine Oil Pump - Remove.......1259
Engine Support - Remove and Install.......1261
Exhaust Manifold - Remove and Install - 3612.......1264
Exhaust Manifold Shield - Remove and Install.......1267
Expansion Tank - Remove and Install.......1270
Flywheel and Ring Gear - Remove and Install.......1272
Fuel Filter Housings - Assemble.......1277
Fuel Filter Housings - Disassemble.......1280
Fuel Filter Housings - Install.......1283
Fuel Filter Housings - Remove.......1286
Fuel Filters - Remove and Install.......1289
Fuel Injection Control Linkage - Install.......1292
Fuel Injection Control Linkage - Remove.......1296
Fuel Injector - Install.......1300
Fuel Injector - Remove.......1305
Fuel Pressure Control Valve - Assemble.......1309
Fuel Pressure Control Valve - Disassemble.......1311
Fuel Pressure Control Valve - Install.......1313
Fuel Pressure Control Valve - Remove.......1314
Fuel Priming Pump - Assemble.......1316
Fuel Priming Pump - Disassemble.......1320
Fuel Priming Pump - Install.......1323
Fuel Priming Pump - Remove.......1324
Fuel Transfer Pump - Assemble.......1325
Fuel Transfer Pump - Disassemble.......1333
Fuel Transfer Pump - Install.......1340
Fuel Transfer Pump - Remove.......1341
Governor - Install.......1343
Governor - Remove.......1345
Governor Actuator - Remove and Install.......1347
Governor Drive - Assemble - Earlier.......1352
Governor Drive - Assemble - Later.......1354
Governor Drive - Disassemble - Earlier.......1356
Governor Drive - Disassemble - Later.......1358
Governor Drive - Install - Earlier.......1360
Governor Drive - Install - Later.......1363
Governor Drive - Remove - Earlier.......1365
Governor Drive - Remove - Later.......1367
Housing (Front) - Install.......1369
Housing (Front) - Remove.......1373
Housing (Rear) - Install.......1377
Housing (Rear) - Remove.......1379
Idler Gears (Front) - Install.......1381
Idler Gears (Front) - Remove.......1386
Idler Gears (Rear) - Install.......1389
Idler Gears (Rear) - Remove.......1397
Lubrication Metering Pump - Remove and Install.......1406
Manual Barring Group - Assemble.......1409
Manual Barring Group - Disassemble.......1411
Manual Barring Group - Install.......1413
Manual Barring Group - Remove.......1415
Mounting Isolator - Remove and Install.......1417
Oil Temperature Regulators - Remove and Install.......1419
Piston Cooling Jets - Remove and Install.......1423
Piston and Connecting Rods - Install - Hydraulic Tensioned Rod Bolts.......1426
Piston and Connecting Rods - Install.......1437
Piston and Connecting Rods - Remove - Hydraulic Tensioned Rod Bolts.......1446
Piston and Connecting Rods - Remove.......1454
Prelube Valve (Continuous) - Remove and Install.......1461
Prelubrication Oil Pump - Assemble.......1463
Prelubrication Oil Pump - Disassemble.......1466
Prelubrication Oil Pump - Install.......1469
Prelubrication Oil Pump - Remove.......1474
Priority Valve - Assemble.......1479
Priority Valve - Disassemble.......1481
Priority Valve - Install.......1483
Priority Valve - Remove.......1485
Remote Water Temperature Regulator Housing - Assemble.......1488
Remote Water Temperature Regulator Housing - Disassemble.......1490
Remote Water Temperature Regulator Housing - Install.......1492
Remote Water Temperature Regulator Housing - Remove.......1494
Rocker Arm - Assemble.......1496
Rocker Arm - Disassemble.......1501
Turbocharger - Assemble.......1503
Turbocharger - Disassemble.......1517
Turbocharger - Install.......1536
Turbocharger - Remove.......1539
Valve Cover Base - Remove and Install.......1542
Valve Lifter - Assemble.......1544
Valve Lifter - Disassemble.......1547
Valve Lifter - Install.......1550
Valve Lifter - Remove.......1552
Valve Mechanism - Install.......1554
Valve Mechanism - Remove.......1558
Vibration Damper - Install.......1560
Vibration Damper - Remove.......1563
Water Pump - Assemble.......1566
Water Pump - Disassemble.......1571
Water Pump - Install - Jacket Water Pump.......1576
Water Pump - Remove - Jacket Water Pump.......1578
Water Pump Seal - Install.......1580
Water Pump Seal - Remove.......1584
Water Temperature Regulator - Remove and Install.......1587
Caterpillar 3612, 3616 Series Engines Repair Service Manual
