Caterpillar G3500 Engines Repair Service Manual

Catalog: 
Construction Heavy Machinery
Make: 
Caterpillar
Model: 
G3500
Price: US$ 55.00

Complete service repair manual with Electrical Wiring Diagrams for Caterpillar G3500 Engines, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Caterpillar G3500-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.

SENR1186 - Schematic (G3500 Generator Set Electrical System).pdf
SENR6419 - Disassembly and Assembly (G3500 Engines).pdf
SENR6413 - Troubleshooting (G3500 Engines).pdf
SENR6412 - Testing and Adjusting (G3500 Engines).pdf
SENR6412 - Systems Operation (G3500 Engines).pdf
SENR6411 - Specifications (G3500 Engines).pdf
RENR5924 - Schematic (G3500 Engine Electrical System 114-8162-10).pdf

PRODUCT DETAILS:
Total Pages: 1,482 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English

TABLE OF CONTENTS
RENR5924 - Schematic (G3500 Engine Electrical System 114-8162-10)...1
SENR 1186 - Schematic (G3500 Generator Set Electrical System)...3
  Main...4
  Collage...6
SENR6411 - Specifications (G3500 Engines)...38
  Engine Design...40
  Gas Engine Ignition...42
  Ignition Transformer...44
  Gas Pressure Regulator...47
  Camshaft...50
  Valve Mechanism...53
  Cylinder Head...57
  Cylinder Head Valves...61
  Turbocharger...63
  Exhaust Manifold - Dry...66
  Exhaust Flange...68
  Exhaust Bypass Valve...70
  Engine Oil Pump...75
  Engine Oil Filter...80
  Engine Oil Cooler Bypass and Cooling Jet Sequence Valves...83
  Engine Oil Pan...87
  Engine Oil Temperature Regulator...90
  Water Pump...92
  Auxiliary Water Pump...100
  Water Connection Group...108
  Thermostatic Valve...110
  Water Temperature Regulator...112
  Cylinder Block...121
  Crankshaft...125
  Crankshaft Wear Sleeves and Seals...129
  Connecting Rod...132
  Connecting Rod and Main Bearing Journals...140
  Piston and Rings...143
  Cylinder Liner...147
  Camshaft Bearing Position...148
  Gear Group (Front)...151
  Gear Group (Rear)...158
  Balancer Group (Front)...162
  Accessory Drive (Lower Left Hand)...164
  Vibration Damper Guard...168
  Vibration Damper...172
  Stub Shaft (Front)...186
  Flywheel...188
  Flywheel Housing...191
  Belt Tension Chart...194
  Pressure Sensor...197
  Pressure Sensor - Oil Pressure...201
  Detonation Sensor...203
  Manifold Air Pressure Sensor...208
  Engine Speed_Timing Sensor...211
  Speed Sensor...216
SENR6412 - Systems Operation (G3500 Engines)...221
  Electronic Control System Operation...223
  Electronic Control Module (ECM)...233
  Electronic Control System Parameters...234
  Engine Monitoring System...241
  Ignition System...256
  Air_Fuel Ratio Control...266
  Governor...269
  Gas Pressure Regulator...276
  Carburetor...278
  Air Inlet and Exhaust System Components...282
  Aftercooler...287
  Exhaust Manifold...290
  Turbocharger...293
  Exhaust Bypass Valve...295
  Valve System Components...297
  Lubrication System...299
  Duplex Oil Filter...303
  Prelube Pump - Electric...305
  Prelube Pump - Air...307
  Accumulator...311
  Engine Oil Level Regulator...313
  Crankcase Breather...315
  Fumes Disposal System...317
  Cooling System...319
  Cylinder Block; Liners and Heads...331
  Pistons; Rings and Connecting Rods...334
  Crankshaft...336
  Camshaft...339
  Air Starting System - Starting with an Air Prelube Pump...340
  Air Starting System...343
  Grounding Practices...347
  Charging System...348
  Starting System...350
SENR6412 - Testing and Adjusting (G3500 Engines)...352
  General Information (Electronic Control System)...354
  Electronic Control Module (ECM)...355
  Manifold Air Pressure Sensor...360
  Engine Speed Sensor - Adjust...362
  Detonation Sensor...363
  Ignition Transformer...365
  Ignition System...370
  General Information (Fuel System)...372
  Air_Fuel Ratio Control - Adjust...374
  Carburetor - Adjust...375
  Gas Pressure...376
  Finding the Top Center Position for the No. 1 Piston...378
  Camshaft Timing...380
  Restriction of Air Inlet and Exhaust...387
  Measuring Inlet Manifold Temperature...390
  Measuring Exhaust Temperature...392
  Exhaust Bypass Valve...393
  Engine Crankcase Pressure (Blowby) - Test...395
  Compression...396
  Crankshaft Position for Valve Lash Setting...398
  Valve Lash and Valve Bridge Adjustment...400
  General Information (Lubrication System)...404
  Accumulator Pressure - Test...405
  Duplex Oil Filter - Adjust...409
  Measuring Engine Oil Pressure...412
  General Information (Cooling System)...414
  Visual Inspection...416
  Testing the Cooling System...418
  Cylinder Block...422
  Cylinder Liner Projection...424
  Flywheel - Inspect...429
  Flywheel Housing - Inspect...432
  Vibration Damper - Check...437
  Pressure Regulating Valve...439
  Lubrication...441
  General Information (Air_Electric Starting System)...442
  Test Tools for the Electrical System...445
  Charging System...450
  Battery...451
  Electric Starting Motor - Test...452
SENR6413 - Troubleshooting (G3500 Engines)...453
  System Overview...464
  Self-Diagnostics...469
  Location of Components...471
  Electrical Connectors and Functions...479
  Electronic Service Tools...486
  Engine Monitoring System...493
  Programming Parameters...495
  Customer Parameters Worksheet...497
  Replacing the ECM...499
  Replacing the EIS Control Module...502
  Troubleshooting Data Sheet...505
  Air Starting Motor - Malfunction...507
  Alternator - Malfunction...511
  Coolant in Engine Oil...513
  Detonation...515
  Diagnostic Code Will Not Clear...517
  Electronic Service Tool Displays UNDETERMINED...518
  Electronic Service Tool Will Not Communicate with ECM...519
  Engine Coolant Temperature (High)...520
  Engine Coolant Temperature (Low)...523
  Engine Cranks but Will Not Start...524
  Engine Has Early Wear...526
  Engine Misfires; Runs Rough or Is Unstable...528
  Engine Oil in Cooling System...531
  Engine Oil Pressure (Low)...532
  Engine Shutdown without a Diagnostic Code...534
  Engine Starts but Stalls Immediately...536
  Engine Timing Does Not Match Programmed Timing...538
  Engine Will Not Crank...539
  Excessive Engine Oil Consumption...541
  Exhaust Port Temperature (High)...543
  Fuel Metering Valve...545
  Inlet Air Temperature (High)...546
  Intermittent Engine Shutdown...548
  Low Power_Poor or No Response to Throttle...550
  Mechanical Noise (Knock) in Engine...553
  Noise Coming from Cylinder...556
  Poor Fuel Consumption...557
  Short Spark Plug Life...558
  Too Much Vibration...560
  Diagnostic Codes...561
  MID 014 - CID 0168 - FMI 02 System Voltage intermittent_erratic...563
  MID 014 - CID 0300 - FMI 03 Primary Return short to +batt...564
  MID 014 - CID 0300 - FMI 04 Primary Return short to ground...565
  MID 014 - CID 0301 - FMI 05 Ignition Transformer Primary #1 open circuit...566
  MID 014 - CID 0301 - FMI 06 Ignition Transformer Primary #1 short...567
  MID 014 - CID 0301 - FMI 12 Ignition Transformer Primary #1 short to return...568
  MID 014 - CID 0302 - FMI 05 Ignition Transformer Primary #2 open circuit...569
  MID 014 - CID 0302 - FMI 06 Ignition Transformer Primary #2 short...570
  MID 014 - CID 0302 - FMI 12 Ignition Transformer Primary #2 short to return...571
  MID 014 - CID 0303 - FMI 05 Ignition Transformer Primary #3 open circuit...572
  MID 014 - CID 0303 - FMI 06 Ignition Transformer Primary #3 short...573
  MID 014 - CID 0303 - FMI 12 Ignition Transformer Primary #3 short to return...574
  MID 014 - CID 0304 - FMI 05 Ignition Transformer Primary #4 open circuit...575
  MID 014 - CID 0304 - FMI 06 Ignition Transformer Primary #4 short...576
  MID 014 - CID 0304 - FMI 12 Ignition Transformer Primary #4 short to return...577
  MID 014 - CID 0305 - FMI 05 Ignition Transformer Primary #5 open circuit...578
  MID 014 - CID 0305 - FMI 06 Ignition Transformer Primary #5 short...579
  MID 014 - CID 0305 - FMI 12 Ignition Transformer Primary #5 short to return...580
  MID 014 - CID 0306 - FMI 05 Ignition Transformer Primary #6 open circuit...581
  MID 014 - CID 0306 - FMI 06 Ignition Transformer Primary #6 short...582
  MID 014 - CID 0306 - FMI 12 Ignition Transformer Primary #6 short to return...583
  MID 014 - CID 0307 - FMI 05 Ignition Transformer Primary #7 open circuit...584
  MID 014 - CID 0307 - FMI 06 Ignition Transformer Primary #7 short...585
  MID 014 - CID 0307 - FMI 12 Ignition Transformer Primary #7 short to return...586
  MID 014 - CID 0308 - FMI 05 Ignition Transformer Primary #8 open circuit...587
  MID 014 - CID 0308 - FMI 06 Ignition Transformer Primary #8 short...588
  MID 014 - CID 0308 - FMI 12 Ignition Transformer Primary #8 short to return...589
  MID 014 - CID 0309 - FMI 05 Ignition Transformer Primary #9 open circuit...590
  MID 014 - CID 0309 - FMI 06 Ignition Transformer Primary #9 short...591
  MID 014 - CID 0309 - FMI 12 Ignition Transformer Primary #9 short to return...592
  MID 014 - CID 0310 - FMI 05 Ignition Transformer Primary #10 open circuit...593
  MID 014 - CID 0310 - FMI 06 Ignition Transformer Primary #10 short...594
  MID 014 - CID 0310 - FMI 12 Ignition Transformer Primary #10 short to return...595
  MID 014 - CID 0311 - FMI 05 Ignition Transformer Primary #11 open circuit...596
  MID 014 - CID 0311 - FMI 06 Ignition Transformer Primary #11 short...597
  MID 014 - CID 0311 - FMI 12 Ignition Transformer Primary #11 short to return...598
  MID 014 - CID 0312 - FMI 05 Ignition Transformer Primary #12 open circuit...599
  MID 014 - CID 0312 - FMI 06 Ignition Transformer Primary #12 short...600
  MID 014 - CID 0312 - FMI 12 Ignition Transformer Primary #12 short to return...601
  MID 014 - CID 0313 - FMI 05 Ignition Transformer Primary #13 open circuit...602
  MID 014 - CID 0313 - FMI 06 Ignition Transformer Primary #13 short...603
  MID 014 - CID 0313 - FMI 12 Ignition Transformer Primary #13 short to return...604
  MID 014 - CID 0314 - FMI 05 Ignition Transformer Primary #14 open circuit...605
  MID 014 - CID 0314 - FMI 06 Ignition Transformer Primary #14 short...606
  MID 014 - CID 0314 - FMI 12 Ignition Transformer Primary #14 short to return...607
  MID 014 - CID 0315 - FMI 05 Ignition Transformer Primary #15 open circuit...608
  MID 014 - CID 0315 - FMI 06 Ignition Transformer Primary #15 short...609
  MID 014 - CID 0315 - FMI 12 Ignition Transformer Primary #15 short to return...610
  MID 014 - CID 0316 - FMI 05 Ignition Transformer Primary #16 open circuit...611
  MID 014 - CID 0316 - FMI 06 Ignition Transformer Primary #16 short...612
  MID 014 - CID 0316 - FMI 12 Ignition Transformer Primary #16 short to return...613
  MID 014 - CID 0317 - FMI 08 Load Sensor (MAPS) signal abnormal...614
  MID 014 - CID 0317 - FMI 11 No Inlet Manifold Pressure signal...615
  MID 014 - CID 0318 - FMI 01 Loss of Right Bank Detonation Sensor Signal...616
  MID 014 - CID 0318 - FMI 03 Right Bank Detonation Sensor short to +batt...617
  MID 014 - CID 0318 - FMI 05 Right Bank Detonation Sensor open or short to ground...618
  MID 014 - CID 0319 - FMI 01 Loss of Left Bank Detonation Sensor Signal...619
  MID 014 - CID 0319 - FMI 03 Left Bank Detonation Sensor short to +batt...620
  MID 014 - CID 0319 - FMI 05 Left Bank Detonation Sensor open or short to ground...621
  MID 014 - CID 0320 - FMI 05 Timing Control Speed Sensor open_short to +batt...622
  MID 014 - CID 0320 - FMI 07 Speed_Timing Sensor improper response...623
  MID 014 - CID 0320 - FMI 08 Engine Speed_Timing signal abnormal...624
  MID 014 - CID 0321 - FMI 04 Diagnostic Reset Switch short to ground...625
  MID 014 - CID 0322 - FMI 03 Shutdown Relay short to +batt...626
  MID 014 - CID 0322 - FMI 05 Shutdown Relay open_short to ground...627
  MID 014 - CID 0323 - FMI 03 Shutdown Lamp short to +batt...628
  MID 014 - CID 0323 - FMI 05 Shutdown Lamp open_short to ground...629
  MID 014 - CID 0324 - FMI 03 Warning Lamp short to +batt...630
  MID 014 - CID 0324 - FMI 05 Warning Lamp open_short to ground...631
  MID 014 - CID 0325 - FMI 00 Excessive Detonation...632
  MID 014 - CID 0326 - FMI 01 Detonation Retarded Timing...633
  MID 014 - CID 0327 - FMI 02 Number of Detonation Sensors mismatch...634
  MID 014 - CID 0328 - FMI 02 Number of Cylinders mismatch...635
  MID 014 - CID 0329 - FMI 11 Communication Fault with CAT A_F Ratio Control...636
  MID 014 - CID 0330 - FMI 11 Propane Timing Mode requested...637
  MID 014 - CID 0331 - FMI 11 Ignition Shutdown requested...638
  MID 014 - CID 0401 - FMI 00 Ignition Transformer Secondary #1 maintenance needed...639
  MID 014 - CID 0401 - FMI 05 Ignition Transformer Secondary #1 open circuit...640
  MID 014 - CID 0401 - FMI 06 Ignition Transformer Secondary #1 short to ground...641
  MID 014 - CID 0401 - FMI 12 Ignition Transformer Secondary #1 noisy component...642
  MID 014 - CID 0402 - FMI 00 Ignition Transformer Secondary #2 maintenance needed...643
  MID 014 - CID 0402 - FMI 05 Ignition Transformer Secondary #2 open circuit...644
  MID 014 - CID 0402 - FMI 06 Ignition Transformer Secondary #2 short to ground...645
  MID 014 - CID 0402 - FMI 12 Ignition Transformer Secondary #2 noisy component...646
  MID 014 - CID 0403 - FMI 00 Ignition Transformer Secondary #3 maintenance needed...647
  MID 014 - CID 0403 - FMI 05 Ignition Transformer Secondary #3 open circuit...648
  MID 014 - CID 0403 - FMI 06 Ignition Transformer Secondary #3 short to ground...649
  MID 014 - CID 0403 - FMI 12 Ignition Transformer Secondary #3 noisy component...650
  MID 014 - CID 0404 - FMI 00 Ignition Transformer Secondary #4 maintenance needed...651
  MID 014 - CID 0404 - FMI 05 Ignition Transformer Secondary #4 open circuit...652
  MID 014 - CID 0404 - FMI 06 Ignition Transformer Secondary #4 short to ground...653
  MID 014 - CID 0404 - FMI 12 Ignition Transformer Secondary #4 noisy component...654
  MID 014 - CID 0405 - FMI 00 Ignition Transformer Secondary #5 maintenance needed...655
  MID 014 - CID 0405 - FMI 05 Ignition Transformer Secondary #5 open circuit...656
  MID 014 - CID 0405 - FMI 06 Ignition Transformer Secondary #5 short to ground...657
  MID 014 - CID 0405 - FMI 12 Ignition Transformer Secondary #5 noisy component...658
  MID 014 - CID 0406 - FMI 00 Ignition Transformer Secondary #6 maintenance needed...659
  MID 014 - CID 0406 - FMI 05 Ignition Transformer Secondary #6 open circuit...660
  MID 014 - CID 0406 - FMI 06 Ignition Transformer Secondary #6 short to ground...661
  MID 014 - CID 0406 - FMI 12 Ignition Transformer Secondary #6 noisy component...662
  MID 014 - CID 0407 - FMI 00 Ignition Transformer Secondary #7 maintenance needed...663
  MID 014 - CID 0407 - FMI 05 Ignition Transformer Secondary #7 open circuit...664
  MID 014 - CID 0407 - FMI 06 Ignition Transformer Secondary #7 short to ground...665
  MID 014 - CID 0407 - FMI 12 Ignition Transformer Secondary #7 noisy component...666
  MID 014 - CID 0408 - FMI 00 Ignition Transformer Secondary #8 maintenance needed...667
  MID 014 - CID 0408 - FMI 05 Ignition Transformer Secondary #8 open circuit...668
  MID 014 - CID 0408 - FMI 06 Ignition Transformer Secondary #8 short to ground...669
  MID 014 - CID 0408 - FMI 12 Ignition Transformer Secondary #8 noisy component...670
  MID 014 - CID 0409 - FMI 00 Ignition Transformer Secondary #9 maintenance needed...671
  MID 014 - CID 0409 - FMI 05 Ignition Transformer Secondary #9 open circuit...672
  MID 014 - CID 0409 - FMI 06 Ignition Transformer Secondary #9 short to ground...673
  MID 014 - CID 0409 - FMI 12 Ignition Transformer Secondary #9 noisy component...674
  MID 014 - CID 0410 - FMI 00 Ignition Transformer Secondary #10 maintenance needed...675
  MID 014 - CID 0410 - FMI 05 Ignition Transformer Secondary #10 open circuit...676
  MID 014 - CID 0410 - FMI 06 Ignition Transformer Secondary #10 short to ground...677
  MID 014 - CID 0410 - FMI 12 Ignition Transformer Secondary #10 noisy component...678
  MID 014 - CID 0411 - FMI 00 Ignition Transformer Secondary #11 maintenance needed...679
  MID 014 - CID 0411 - FMI 05 Ignition Transformer Secondary #11 open circuit...680
  MID 014 - CID 0411 - FMI 06 Ignition Transformer Secondary #11 short to ground...681
  MID 014 - CID 0411 - FMI 12 Ignition Transformer Secondary #11 noisy component...682
  MID 014 - CID 0412 - FMI 00 Ignition Transformer Secondary #12 maintenance needed...683
  MID 014 - CID 0412 - FMI 05 Ignition Transformer Secondary #12 open circuit...684
  MID 014 - CID 0412 - FMI 06 Ignition Transformer Secondary #12 short to ground...685
  MID 014 - CID 0412 - FMI 12 Ignition Transformer Secondary #12 noisy component...686
  MID 014 - CID 0413 - FMI 00 Ignition Transformer Secondary #13 maintenance needed...687
  MID 014 - CID 0413 - FMI 05 Ignition Transformer Secondary #13 open circuit...688
  MID 014 - CID 0413 - FMI 06 Ignition Transformer Secondary #13 short to ground...689
  MID 014 - CID 0413 - FMI 12 Ignition Transformer Secondary #13 noisy component...690
  MID 014 - CID 0414 - FMI 00 Ignition Transformer Secondary #14 maintenance needed...691
  MID 014 - CID 0414 - FMI 05 Ignition Transformer Secondary #14 open circuit...692
  MID 014 - CID 0414 - FMI 06 Ignition Transformer Secondary #14 short to ground...693
  MID 014 - CID 0414 - FMI 12 Ignition Transformer Secondary #14 noisy component...694
  MID 014 - CID 0415 - FMI 00 Ignition Transformer Secondary #15 maintenance needed...695
  MID 014 - CID 0415 - FMI 05 Ignition Transformer Secondary #15 open circuit...696
  MID 014 - CID 0415 - FMI 06 Ignition Transformer Secondary #15 short to ground...697
  MID 014 - CID 0415 - FMI 12 Ignition Transformer Secondary #15 noisy component...698
  MID 014 - CID 0416 - FMI 00 Ignition Transformer Secondary #16 maintenance needed...699
  MID 014 - CID 0416 - FMI 05 Ignition Transformer Secondary #16 open circuit...700
  MID 014 - CID 0416 - FMI 06 Ignition Transformer Secondary #16 short to ground...701
  MID 014 - CID 0416 - FMI 12 Ignition Transformer Secondary #16 noisy component...702
  MID 014 - CID 0591 - FMI 12 EEPROM checksum fault or ECM not programmed...703
  MID 018 - CID 0317 - FMI 11 No Inlet Manifold Pressure signal...704
  MID 018 - CID 0321 - FMI 04 Diagnostic Reset Switch short to ground...705
  MID 018 - CID 0523 - FMI 00 Engine Overspeed Shutdown...706
  MID 018 - CID 0523 - FMI 02 Noisy Engine Speed signal...707
  MID 018 - CID 0523 - FMI 11 No A_F Ratio Engine Speed Sensor Shutdown...708
  MID 018 - CID 0550 - FMI 02 Noisy or Loss of Oxygen Signal...709
  MID 018 - CID 0551 - FMI 01 Oxygen Sensor not connected to buffer...710
  MID 018 - CID 0552 - FMI 11 Engine Speed present during an O2 calibration...711
  MID 018 - CID 0553 - FMI 11 Oxygen Signal present when it should not have been...712
  MID 018 - CID 0554 - FMI 11 Oxygen Signal missing during O2 calibration step...713
  MID 018 - CID 0555 - FMI 02 Noisy Oxygen signal...714
  MID 018 - CID 0556 - FMI 11 Oxygen Sensor Calculated Gain out of range...715
  MID 018 - CID 0557 - FMI 11 Oxygen Sensor Calculated Offset out of range...716
  MID 018 - CID 0560 - FMI 02 Cat Data Link fault...717
  MID 018 - CID 0563 - FMI 11 Loss of Desired Speed Signal...718
  MID 018 - CID 0564 - FMI 02 Noisy Desired Speed Signal...719
  MID 018 - CID 0565 - FMI 11 Shutdown Imminent Due To Missing Desired Speed Signal...720
  MID 018 - CID 0570 - FMI 11 Temperature Sensor Reading out of range...721
  MID 018 - CID 0576 - FMI 02 Heinzmann Actuator not controlling position...722
  MID 018 - CID 0577 - FMI 11 Heinzmann Actuator Calculated Gain out of range...723
  MID 018 - CID 0578 - FMI 11 Heinzmann Actuator Calculated Offset out of range...724
  MID 018 - CID 0590 - FMI 12 Engine Control Module malfunction...725
  MID 018 - CID 0591 - FMI 12 EEPROM checksum fault or ECM not programmed...726
  MID 018 - CID 0770 - FMI 09 Cat Data Link #2 communications...729
  Cat Data Link...730
  Control Module Self Test...750
  Desired Engine Speed Signal...758
  Detonation Retard and Detonation Shutdown...777
  Detonation Sensors...815
  Diagnostic Reset Switch...829
  Electrical Power Supply...839
  Engine Speed Sensor...849
  Engine Speed_Timing Sensor...857
  Engine Speed Switch...866
  Fuel Actuator...871
  Ignition Shutdown Circuit...879
  Ignition Transformers Primary Circuit...885
  Ignition Transformers Secondary Circuit and Spark Plugs...908
  Inlet Manifold Pressure Sensor...916
  Inlet Manifold Temperature Sensor...928
  Inspecting Electrical Connectors...935
  Oxygen Sensor Calibration Switch...944
  Oxygen Sensor Signal...950
  Propane Switch...967
  Shutdown Lamp...972
  Shutdown Relay...978
  Warning Lamp Circuit - Test...983
  Engine Speed_Timing Sensor - Calibrate...989
  Oxygen Sensor - Calibrate...995
SENR6419 - Disassembly and Assembly (G3500 Engines)...1001
  Air Starting Motor - Remove...1005
  Air Starting Motor - Disassemble...1008
  Air Starting Motor - Assemble...1038
  Air Starting Motor - Install...1069
  Electric Starting Motor - Remove and Install...1072
  Service Meter - Remove and Install...1074
  Gas Pressure Regulator Solenoid - Remove and Install...1077
  Gas Pressure Regulator - Remove - Low Pressure...1079
  Gas Pressure Regulator - Remove...1080
  Gas Pressure Regulator - Remove - High Pressure...1081
  Gas Pressure Regulator - Disassemble...1082
  Gas Pressure Regulator - Assemble...1086
  Gas Pressure Regulator - Install - Low Pressure...1089
  Gas Pressure Regulator - Install - High Pressure...1090
  Fuel Control Actuator - Remove and Install...1091
  Fuel Control Valve - Remove and Install...1097
  Electronic Sensor - Remove and Install...1102
  Carburetor - Remove - Low Pressure...1105
  Carburetor - Remove - High Pressure...1109
  Carburetor - Disassemble - High Pressure...1110
  Carburetor - Assemble - High Pressure...1115
  Carburetor - Install - Low Pressure...1120
  Carburetor - Install - High Pressure...1122
  Air Cleaner - Remove and Install...1124
  Turbocharger - Remove...1126
  Turbocharger - Disassemble...1132
  Turbocharger - Assemble...1139
  Turbocharger - Install...1148
  Aftercooler - Remove and Install...1153
  Air Inlet Manifold - Remove and Install...1166
  Exhaust Elbow - Remove and Install...1168
  Exhaust Bypass Valve - Remove and Install...1176
  Exhaust Manifold - Remove - Dry...1179
  Exhaust Manifold - Remove - Water Cooled...1182
  Exhaust Manifold - Install - Dry...1186
  Exhaust Manifold - Install - Water Cooled...1189
  Water Temperature Regulators - Remove...1193
  Water Temperature Regulators - Install...1196
  Water Pump - Remove...1199
  Water Pump - Disassemble...1202
  Water Pump - Assemble...1208
  Water Pump - Install...1215
  Thermostatic Valve - Remove...1217
  Thermostatic Valve - Disassemble...1219
  Thermostatic Valve - Assemble...1221
  Thermostatic Valve - Install...1223
  Auxiliary Water Pump - Remove...1225
  Auxiliary Water Pump - Disassemble...1229
  Auxiliary Water Pump - Assemble...1234
  Auxiliary Water Pump - Install...1240
  Engine Oil Cooler - Remove...1244
  Engine Oil Cooler - Disassemble...1247
  Engine Oil Cooler - Assemble...1251
  Engine Oil Cooler - Install...1256
  Engine Oil Pump - Remove...1258
  Engine Oil Pump - Disassemble...1261
  Engine Oil Pump - Assemble...1265
  Engine Oil Pump - Install...1270
  Engine Oil Filter Housing - Remove...1272
  Engine Oil Filter Housing - Disassemble...1275
  Engine Oil Filter Housing - Assemble...1280
  Engine Oil Filter Housing - Install...1285
  Engine Oil and Water Pump Drive - Remove...1287
  Engine Oil and Water Pump Drive - Disassemble...1289
  Engine Oil and Water Pump Drive - Assemble...1292
  Engine Oil and Water Pump Drive - Install...1295
  Engine Oil Pan - Remove...1297
  Engine Oil Pan - Disassemble...1299
  Engine Oil Pan - Assemble...1302
  Engine Oil Pan - Install...1305
  Crankcase Breather - Remove and Install...1307
  Valve Cover and Spark Plug - Remove and Install...1310
  Rocker Shaft and Push Rod - Remove...1315
  Rocker Shaft - Disassemble...1317
  Rocker Shaft - Assemble...1320
  Rocker Shaft and Push Rod - Install...1323
  Cylinder Head - Remove...1326
  Cylinder Head - Disassemble...1329
  Cylinder Head - Assemble...1336
  Cylinder Head - Install...1343
  Spacer Plate - Remove and Install...1349
  Accessory Drive (Front) - Remove...1353
  Accessory Drive (Front) - Disassemble...1355
  Accessory Drive (Front) - Assemble...1358
  Accessory Drive (Front) - Install...1362
  Drive Housing (Front) - Remove and Install...1364
  Vibration Damper - Remove and Install...1372
  Crankshaft Front Seal and Wear Sleeve - Remove...1375
  Crankshaft Front Seal and Wear Sleeve - Install...1378
  Flywheel - Remove and Install...1385
  Crankshaft Rear Seal and Wear Sleeve - Remove...1388
  Crankshaft Rear Seal and Wear Sleeve - Install...1391
  Flywheel Housing - Remove...1396
  Flywheel Housing - Install...1400
  Engine Oil Sequence Valves - Remove and Install...1405
  Gear Group (Rear) - Remove...1410
  Gear Group (Rear) - Install...1413
  Piston Cooling Jets - Remove and Install...1419
  Bearing Clearance - Check...1422
  Connecting Rod Bearings - Remove and Install...1425
  Crankshaft Main Bearings - Remove...1430
  Crankshaft Main Bearings - Install...1434
  Piston and Connecting Rods - Remove...1439
  Piston and Connecting Rods - Install...1444
  Cylinder Liner - Remove...1448
  Cylinder Liner - Install...1450
  Camshaft - Remove...1454
  Camshaft - Install...1461
  Camshaft Bearings - Remove...1470
  Camshaft Bearings - Install...1473
  Crankshaft - Remove...1476
  Crankshaft - Install...1480
 
Caterpillar G3500 Engines Repair Service Manual

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