Caterpillar CG137-8 and CG137-12 Engines Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Caterpillar CG137-08 and CG137-12 Engines, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Caterpillar CG137-8 and CG137-12 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.
KENR9787 - Specifications (CG137-08 and CG137-12 Generator Sets).pdf
KENR9788 - Systems Operation (CG137-08 and CG137-12 Industrial Engines).pdf
KENR9788 - Testing and Adjusting (CG137-08 and CG137-12 Industrial Engines).pdf
KENR9788 - Troubleshooting (CG137-08 and CG137-12 Industrial Engines).pdf
M0090979 - Systems Operation (CG137-8 Gas Engine).pdf
M0090979 - Testing and Adjusting (CG137-8 Gas Engine).pdf
M0090983 - Troubleshooting (CG137-8 Gas Engine).pdf
M0092679 - Disassembly and Assembly (CG137-08 Engines).pdf
M0109962 - Schematic (CG137-8 Engine HMI Display Electrical System).pdf
M0115971 - Schematic (CG137-8 Engine Control Panel Electrical System).pdf
UENR0103 - Disassembly and Assembly (CG137-08 and CG137-12 Engines).pdf
UENR3682 - Schematic (CG137-8 Engine Electrical System).pdf
UENR8336 - Schematic (CG137-8 Engine HMI Display Electrical System).pdf
UENR8340 - Schematic (CG137-8 Engine Electrical System).pdf
PRODUCT DETAILS:
Total Pages: 1,708 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
KENR9787 - Specifications (CG137-08 and CG137-12 Generator Sets)....1
Gas Engine Ignition....3
Ignition Transformer....8
Gas Pressure Regulator....10
Governor Drive....12
Engine Oil Lines....17
Camshaft....23
Valve Cover....29
Valve Mechanism....35
Cylinder Head....42
Cylinder Head Valves....49
Turbocharger....53
Accumulator....57
Exhaust Manifold - Water Cooled....58
Exhaust Manifold....64
Exhaust Bypass Valve....70
Air Cleaner....77
Air Cleaner Adapter....79
Engine Oil Pump....81
Engine Oil Filter Base....87
Crankcase Breather....92
Water Pump....94
Auxiliary Water Pump....100
Water Temperature Regulator....102
Cylinder Block....105
Crankshaft....114
Connecting Rod....119
Connecting Rod and Main Bearing Journals....122
Piston and Rings....123
Cylinder Liner....127
Camshaft Bearings....128
Camshaft Bearing Position....131
Crankshaft Pulley....135
Gear Group (Front)....136
Cover Group (Front Housing)....143
Gear Group (Rear)....144
Vibration Damper and Pulley....146
Stub Shaft (Rear)....148
Flywheel Housing Cover....150
Flywheel....153
Flywheel Housing....155
Alternator and Regulator....157
Electric Starting Motor....161
Air Starting Motor....163
Gas Solenoid Valve....167
Engine Speed Sensor....168
Coolant Temperature Sensor....169
Pressure Sensor....170
Fuel Pressure Sensor....171
Inlet Air Temperature Sensor....172
Engine Oil Temperature Sensor....173
Engine Oil Pressure Sensor....174
Exhaust Temperature Sensor....175
Engine Speed_Timing Sensor....177
Magnetic Switch....178
KENR9788 - Systems Operation (CG137-08 and CG137-12 Industrial Engines)....180
Engine Control Panel....181
Electronic Control System Components....191
Electronic Control Module (ECM)....200
Electrical Connectors....203
System Configuration Parameters....220
Engine Monitoring Parameters....228
Engine Monitoring System....233
Ignition Transformer....234
Spark Plug....237
Carburetor....239
Gas Pressure Regulator....242
Aftercooler....244
Catalytic Converter....246
Exhaust Manifold....248
Exhaust Bypass Valve....249
Turbocharger....251
Lubrication System....253
Accumulator....257
Cooling System....260
Cylinder Block; Liners and Heads....265
Pistons; Rings and Connecting Rods....270
Crankshaft....271
Camshaft....273
Vibration Damper....274
Air Starting System....276
Charging System....279
Starting System....281
KENR9788 - Testing and Adjusting (CG137-08 and CG137-12 Industrial Engines)....284
Spark Plug - Test....286
Carburetor (Low Pressure Gas) - Adjust....287
Engine Governing - Adjust....288
Finding Top Center Position for No. 1 Piston....289
Gas Pressure - Check and Adjust....292
Air Inlet Restriction and Exhaust Restriction - Test....297
Inlet Manifold Pressure - Test....301
Aftercooler - Test....304
Catalytic Converter Substrate - Inspect....310
Catalytic Converter Performance - Test....313
Catalytic Converter Pressure - Test....316
Engine Crankcase Pressure (Blowby) - Test....317
Compression - Test....319
Engine Valve Lash - Inspect_Adjust....321
Accumulator Pressure - Test....327
Engine Oil Pressure - Test....335
Excessive Bearing Wear - Inspect....342
Excessive Engine Oil Consumption - Inspect....343
Increased Engine Oil Temperature - Inspect....344
Cooling System - Check....345
Cooling System - Inspect....352
Cooling System - Test....354
Water Temperature Regulator - Test....362
Water Pump - Test....364
Connecting Rod - Inspect....368
Connecting Rod Bearings - Inspect....369
Main Bearings - Inspect....370
Cylinder Block - Inspect....372
Cylinder Liner Projection - Inspect....373
Flywheel - Inspect....385
Flywheel Housing - Inspect....388
Vibration Damper - Check....393
Starting Air Pressure - Adjust....395
Air Starting Motor - Lubricate....397
Battery - Test....398
Charging System - Test....401
Electric Starting System - Test....404
Factory Password - Obtain....407
ECM Will Not Accept Factory Passwords....409
Electronic Service Tool Does Not Communicate....410
ECM Software - Install....414
ECM - Replace....416
Electrical Connector - Inspect....419
Unburned Gas - Purge....425
KENR9788 - Troubleshooting (CG137-08 and CG137-12 Industrial Engines)....427
General Information....429
Welding Precaution....430
Electronic Service Tools....432
Diagnostic Capabilities....442
Troubleshooting Data Sheet....443
Diagnostic Trouble Codes....446
Symptom Troubleshooting....473
Air_Fuel Ratio Problem....474
Alternator Problem - Charging Problem and_or Noisy Operation....475
Catalytic Converter Has High Differential Temperature....477
Catalytic Converter Has High Inlet Temperature....479
Catalytic Converter Has High Outlet Temperature....482
Catalytic Converter Has Low Inlet Temperature....484
Coolant Temperature Is High....486
Coolant Temperature Is Low....490
Engine Cranks but Does Not Start....492
Engine Does Not Crank....495
Engine Misfires; Runs Rough or Is Unstable....498
Engine Overspeeds....502
Engine Shutdown Is Intermittent....504
Engine Shutdown Occurrence....506
Engine Shutdown or Start Inhibit Initiated by Driven Equipment....510
Engine Stalls Immediately After Starting....512
Engine Timing Does Not Match Programmed Timing....515
Exhaust Temperature Is High....516
Exhaust Temperature Is Low....522
Fuel Energy Content Problem....526
Fuel Flow Rate Is Low....527
Fuel Pressure Problem....529
Inlet Air Is Restricted....530
Inlet Air Temperature Is High....532
Intake Manifold Air Pressure Is High....535
Intake Manifold Air Temperature Is High....537
Oil Filter Differential Pressure Problem....539
Oil Pressure Is Low....541
Oil Temperature Is High....544
Power Is Low....546
Turbocharger Turbine Temperature Is High....548
Valve Lash Is Excessive....550
CAN Data Link - Test....552
Electrical Power Supply - Test....568
Engine Control Switch - Test....587
Exhaust Temperature Module - Test....592
Fuel Actuator - Test....602
Fuel Shutoff - Test....612
Ignition Primary - Test....625
Ignition Secondary - Test....648
Oxygen Level - Test....657
Sensor Signal (Analog; Active) - Test....687
Sensor Signal (Analog; Passive) - Test....706
Sensor Supply - Test....716
Shutdown - Test....732
Speed_Timing (Primary) - Test....741
Speed_Timing (Secondary) - Test....752
Starting - Test....761
Throttle Actuator - Test....774
M0090979 - Systems Operation (CG137-8 Gas Engine)....784
Electronic Control System Operation....785
Engine Control Panel....789
Electronic Control System Parameters - Configuration Parameters....790
Electronic Service Tools....798
Engine Monitoring System....799
Ignition System....801
Fuel System Operation....804
Air Inlet and Exhaust System Components....806
Aftercooler....808
Turbocharger....810
Exhaust Bypass Valve....812
Lubrication System....814
Accumulator....818
Cylinder Block; Liners and Heads....821
Pistons; Rings and Connecting Rods....825
Crankshaft....826
Camshaft....828
Air Starting System....829
Charging System....832
Starting System....834
M0090979 - Testing and Adjusting (CG137-8 Gas Engine)....837
Engine Governing - Adjust....839
Spark Plug - Test....840
Air_Fuel Ratio Control - Adjust....841
Finding the Top Center Position for the No. 1 Piston....842
Air Inlet Restriction and Exhaust Restriction - Test....845
Inlet Manifold Pressure - Test....849
Aftercooler - Test....852
Engine Crankcase Pressure (Blowby) - Test....858
Compression - Test....860
Engine Valve Lash - Inspect_Adjust....862
Catalytic Converter Pressure - Test....868
Accumulator Pressure - Test....869
Engine Oil Pressure - Test....877
Excessive Bearing Wear - Inspect....884
Excessive Engine Oil Consumption - Inspect....885
Increased Engine Oil Temperature - Inspect....886
Cooling System - Check....887
Cooling System - Inspect....894
Cooling System - Test....896
Water Temperature Regulator - Test....904
Water Pump - Test....906
Connecting Rod - Inspect....910
Connecting Rod Bearings - Inspect....911
Main Bearings - Inspect....912
Cylinder Block - Inspect....914
Cylinder Liner Projection - Inspect....915
Flywheel - Inspect....927
Flywheel Housing - Inspect....930
Vibration Damper - Check....935
Starting Air Pressure - Adjust....937
Air Starting Motor - Lubricate....939
Charging System - Test....940
Battery - Test....943
Electric Starting System - Test....946
M0090983 - Troubleshooting (CG137-8 Gas Engine)....948
General Information....951
Welding Precaution....952
Electronic Service Tools....954
Component Location....963
Engine Monitoring System....964
Diagnostic Capabilities....974
Programmable Parameters....976
Electrical Connectors....977
Configuration Parameters....978
Diagnostic Trouble Codes....979
Event Codes....992
Symptom Troubleshooting....1008
Alternator Problem - Charging Problem and_or Noisy Operation....1010
Catalytic Converter Has High Differential Temperature....1013
Catalytic Converter Has High Inlet Temperature....1015
Catalytic Converter Has High Outlet Temperature....1018
Catalytic Converter Has Low Inlet Temperature....1020
Clean Emissions Module Has High Oxygen Level....1022
Coolant Temperature Is High....1024
Coolant Temperature Is Low....1030
Engine Cranks but Does Not Start....1034
Engine Does Not Crank....1037
Engine Misfires; Runs Rough or Is Unstable....1040
Engine Overspeeds....1045
Engine Shutdown Occurrence....1048
Engine Shutdown Occurs Intermittently....1052
Engine Shutdown or Start Inhibit Initiated by Driven Equipment....1055
Engine Stalls Immediately After Starting....1057
Exhaust Temperature Is High....1060
Exhaust Temperature Is Low....1072
Fuel Energy Content Problem....1078
Inlet Air Is Restricted....1080
Intake Manifold Air Pressure Is High....1083
Intake Manifold Air Temperature Is High....1084
Oil Filter Differential Pressure Problem....1090
Oil Pressure Is Low....1093
Oil Temperature Is High....1098
Temperature Ratio of Coolant to Oil Is Low....1101
Data Link - Test....1104
Electrical Power Supply - Test....1110
Engine Control Switch - Test....1113
Exhaust Temperature - Test....1116
Fuel Actuator - Test....1121
Fuel Shutoff - Test....1126
Ignition Primary - Test....1129
Ignition Secondary - Test....1137
Nitrogen Oxide Level - Test....1148
Oxygen Level - Test....1154
Sensor Calibration Required - Test....1160
Sensor Signal (Analog; Active) - Test....1163
Sensor Signal (Analog; Passive) - Test....1168
Sensor Supply - Test....1172
Solenoid Valve - Test....1175
Speed Control - Test....1178
Speed_Timing - Test - Camshaft Sensor....1185
Speed_Timing - Test - Crankshaft Sensor....1192
Throttle Actuator - Test....1199
Customer Passwords....1201
Factory Passwords....1203
ECM Will Not Accept Factory Passwords....1205
Electronic Service Tool Does Not Communicate....1207
Test ECM Mode....1214
ECM Software - Install....1216
ECM - Replace....1218
Electrical Connectors - Inspect....1220
Unburned Gas - Purge....1229
Timing - Calibrate....1230
M0092679 - Disassembly and Assembly (CG137-08 Engines)....1231
Engine Support - Remove and Install....1234
Electronic Control Module (Engine) - Remove and Install....1235
Electric Starting Motor - Remove and Install....1237
Air Starting Motor - Remove and Install....1239
Gas Pressure Regulator - Remove and Install....1241
Rotary Actuator (Carburetor) - Remove and Install....1243
Carburetor - Remove and Install....1245
Transformer - Remove and Install....1247
Spark Plugs - Remove and Install....1248
Spark Plug Adapter - Remove and Install....1250
Exhaust Bypass - Remove and Install....1253
Exhaust Bypass - Disassemble....1255
Exhaust Bypass - Assemble....1259
Exhaust Manifold - Remove and Install....1263
Aftercooler - Remove and Install....1267
Air Cleaner Housing - Remove and Install....1269
Turbocharger - Remove and Install....1270
Turbocharger - Disassemble....1273
Turbocharger - Assemble....1275
Water Temperature Regulator - Remove and Install....1277
Water Pump - Remove and Install....1279
Water Pump - Disassemble....1281
Water Pump - Assemble....1283
Auxiliary Water Pump - Remove and Install....1285
Auxiliary Water Pump - Disassemble....1286
Auxiliary Water Pump - Assemble....1293
Engine Oil Pump - Remove and Install....1301
Engine Oil Pump - Disassemble....1303
Engine Oil Pump - Assemble....1307
Engine Oil Cooler - Remove and Install....1311
Engine Oil Filter Base - Remove and Install....1313
Engine Oil Pan - Remove and Install....1316
Vibration Damper and Pulley - Remove and Install....1319
Flywheel - Remove and Install....1321
Flywheel Housing - Remove and Install....1324
Crankshaft Front Seal and Wear Sleeve - Remove and Install....1328
Crankshaft Rear Seal and Wear Sleeve - Remove and Install....1332
Timing Gear Cover - Remove and Install....1336
Timing Gears - Remove and Install....1338
Engine Balancer - Remove and Install....1343
Valve Cover - Remove and Install....1348
Valve Cover Base - Remove and Install....1350
Rocker Shaft and Push Rod - Remove and Install....1352
Rocker Shaft - Disassemble....1356
Rocker Shaft - Assemble....1359
Valve Lifter - Remove and Install....1363
Inlet and Exhaust Valves - Remove and Install....1367
Inlet and Exhaust Valve Guides - Remove and Install....1371
Bridge Dowels - Remove and Install....1374
Inlet and Exhaust Valve Seat Inserts - Remove and Install....1377
Cylinder Head - Remove and Install....1380
Piston Cooling Jets - Remove and Install....1385
Connecting Rod Bearings - Remove and Install....1388
Pistons and Connecting Rods - Remove and Install....1392
Pistons and Connecting Rods - Disassemble - One-Piece Piston....1396
Pistons and Connecting Rods - Assemble - One-Piece Piston....1398
Cylinder Liner - Remove and Install....1402
Camshaft - Remove and Install....1407
Camshaft Bearings - Remove and Install....1414
Crankshaft Main Bearings - Remove and Install....1419
Crankshaft - Remove and Install....1425
M0109962 - Schematic (CG137-8 Engine HMI Display Electrical System)....1431
Features....1431
Cover Page....1433
Schematic....1434
Machine Views....0
HMI Display Panel....1435
M0115971 - Schematic (CG137-8 Engine Control Panel Electrical System)....1436
Features....1436
Cover Page....1438
Schematic....1439
Machine Views....0
Control Panel....1440
UENR0103 - Disassembly and Assembly (CG137-08 and CG137-12 Engines)....1441
Engine Support - Remove and Install....1444
Electronic Control Module (Engine) - Remove and Install....1445
Electric Starting Motor - Remove and Install....1447
Air Starting Motor - Remove and Install....1449
Air Starting Motor - Remove and Install - Alternate Air Starting Motor - TDI....1451
Gas Pressure Regulator - Remove and Install....1453
Gas Pressure Regulator - Disassemble....1456
Gas Pressure Regulator - Assemble....1464
Rotary Actuator (Carburetor) - Remove and Install - G3408B....1471
Rotary Actuator (Gas Pressure Regulator) - Remove and Install....1472
Carburetor - Remove and Install....1473
Carburetor - Disassemble....1476
Carburetor - Assemble....1481
Transformer - Remove and Install....1485
Spark Plugs - Remove and Install....1486
Spark Plug Adapter - Remove and Install....1488
Exhaust Bypass - Remove and Install....1491
Exhaust Bypass - Disassemble....1493
Exhaust Bypass - Assemble....1497
Exhaust Manifold - Remove and Install....1501
Catalytic Converter - Remove and Install....1505
Aftercooler - Remove and Install - G3408B....1507
Air Cleaner Housing - Remove and Install....1510
Turbocharger - Remove and Install - G3408B....1512
Turbocharger - Disassemble....1516
Turbocharger - Assemble....1522
Water Temperature Regulator - Remove and Install....1528
Water Pump - Remove and Install....1530
Water Pump - Disassemble....1532
Water Pump - Assemble....1534
Auxiliary Water Pump - Remove and Install....1536
Auxiliary Water Pump - Disassemble....1537
Auxiliary Water Pump - Assemble....1544
Engine Oil Pump - Remove and Install....1552
Engine Oil Pump - Disassemble....1554
Engine Oil Pump - Assemble....1558
Engine Oil Cooler - Remove and Install - G3408B....1562
Engine Oil Filter Base - Remove and Install - G3408B....1564
Engine Oil Pan - Remove and Install - G3408B....1567
Vibration Damper and Pulley - Remove and Install....1570
Flywheel - Remove and Install....1572
Flywheel Housing - Remove and Install....1575
Crankshaft Front Seal and Wear Sleeve - Remove and Install....1579
Crankshaft Rear Seal and Wear Sleeve - Remove and Install....1583
Timing Gear Cover - Remove and Install....1587
Timing Gears - Remove and Install....1589
Engine Balancer - Remove and Install....1594
Valve Cover - Remove and Install - G3408B....1599
Valve Cover Base - Remove and Install - G3408B....1601
Rocker Shaft and Push Rod - Remove and Install - G3408B....1603
Rocker Shaft - Disassemble....1607
Rocker Shaft - Assemble....1610
Valve Lifter - Remove and Install....1614
Inlet and Exhaust Valves - Remove and Install....1618
Inlet and Exhaust Valve Guides - Remove and Install....1622
Bridge Dowels - Remove and Install....1625
Inlet and Exhaust Valve Seat Inserts - Remove and Install....1628
Cylinder Head - Remove and Install - G3408B....1631
Piston Cooling Jets - Remove and Install....1636
Connecting Rod Bearings - Remove and Install....1639
Pistons and Connecting Rods - Remove and Install....1647
Pistons and Connecting Rods - Disassemble - One-Piece Piston....1651
Pistons and Connecting Rods - Assemble - One-Piece Piston....1653
Cylinder Liner - Remove and Install....1657
Camshaft - Remove and Install....1662
Camshaft Bearings - Remove and Install....1669
Crankshaft Main Bearings - Remove and Install....1674
Crankshaft - Remove and Install....1680
UENR3682 - Schematic (CG137-8 Engine Electrical System)....1686
Features....1686
Cover Page....1687
Schematic....1689
Machine Views....0
ECM Panel....1690
Electric Starter....1691
Left Side View....1692
Operator Control Panel....1693
Right Side View....1694
UENR8336 - Schematic (CG137-8 Engine HMI Display Electrical System)....1695
Features....1695
Cover Page....1697
Schematic....1698
Machine Views....0
HMI Display Panel....1699
UENR8340 - Schematic (CG137-8 Engine Electrical System)....1700
Features....1700
Cover Page....1702
Schematic....1703
Machine Views....0
Catalyst Wiring....1704
Engine ECM Panel Box....1705
Left Side View....1706
Right Side View....1707
Top VIew....1708
Caterpillar CG137-8 and CG137-12 Engines Repair Service Manual
