Caterpillar G3512E Generator Set Engine Repair Service Manual
Complete service repair manual with Electrical Wiring Diagrams for Caterpillar G3512E Generator Set Engine, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Caterpillar G3512E Generator Set Engine 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.
KENR5271 - Disassembly and Assembly (G3512E; G3516C and G3516E Generator Set Engines).pdf
KENR8688 - Schematic (G3512E Generator Set Engine Electrical System).pdf
KENR9736 - Specifications (G3512E Generator Set Engines).pdf
KENR9737 - Systems Operation (G3512E and G3520E Generator Set Engines).pdf
KENR9737 - Testing and Adjusting (G3512E and G3520E Generator Set Engines).pdf
KENR9738 - Troubleshooting (G3512E Generator Set Engine).pdf
RENR8103 - Schematic (G3500C and G3500E Generator Electrical System) (B9P201-UP; CWW207-UP, CWY207-UP All other SN 1-UP).pdf
PRODUCT DETAILS:
Total Pages: 1,291 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
KENR5271 - Disassembly and Assembly (G3512E; G3516C and G3516E Generator Set Engines)....1
Electronic Control Module - Remove and Install....4
Fuel Control Valve - Remove and Install....8
Throttle Control Valve - Remove....17
Throttle Control Valve - Install....23
Spark Plug - Remove and Install....29
Exhaust Elbow - Remove and Install....37
Exhaust Manifold - Remove....44
Exhaust Manifold - Install....47
Aftercooler - Remove....51
Aftercooler - Install....57
Air Inlet Manifold - Remove and Install....62
Turbocharger - Remove....76
Turbocharger - Disassemble - Single Turbocharger....86
Turbocharger - Assemble - Single Turbocharger....88
Turbocharger - Install....90
Actuator Bypass Valve (Variable) - Remove....100
Actuator Bypass Valve (Variable) - Install....103
Water Temperature Regulators - Remove....110
Water Temperature Regulators - Install....116
Thermostatic Valve - Remove....124
Thermostatic Valve - Disassemble....126
Thermostatic Valve - Assemble....128
Thermostatic Valve - Install....130
Water Pump - Remove....132
Water Pump - Disassemble....135
Water Pump - Assemble....142
Water Pump - Install....149
Auxiliary Water Pump - Remove....151
Auxiliary Water Pump - Disassemble....153
Auxiliary Water Pump - Assemble....159
Auxiliary Water Pump - Install....167
Engine Oil Pump - Remove....169
Engine Oil Pump - Disassemble....175
Engine Oil Pump - Assemble....182
Engine Oil Pump - Install....189
Engine Oil Cooler - Remove....194
Engine Oil Cooler - Install....205
Engine Oil Filter Base - Remove....214
Engine Oil Filter Base - Disassemble....220
Engine Oil Filter Base - Assemble....222
Engine Oil Filter Base - Install....224
Engine Oil and Water Pump Drive - Remove....230
Engine Oil and Water Pump Drive - Disassemble....232
Engine Oil and Water Pump Drive - Assemble....237
Engine Oil and Water Pump Drive - Install....241
Engine Oil Pan - Remove....243
Engine Oil Pan - Disassemble....247
Engine Oil Pan - Assemble....249
Engine Oil Pan - Install....252
Engine Oil Sequence Valves - Remove and Install....257
Drive Housing (Front) - Remove and Install....262
Vibration Damper - Remove and Install....273
Flywheel - Remove and Install....277
Flywheel Housing - Remove....291
Flywheel Housing - Install....301
Crankshaft Front Seal and Wear Sleeve - Remove....316
Crankshaft Front Seal and Wear Sleeve - Install....318
Crankshaft Rear Seal and Wear Sleeve - Remove....325
Crankshaft Rear Seal and Wear Sleeve - Install....327
Accessory Drive (Front) - Remove....333
Accessory Drive (Front) - Disassemble....341
Accessory Drive (Front) - Assemble....348
Accessory Drive (Front) - Install....354
Gear Group (Rear) - Remove....361
Gear Group (Rear) - Install....364
Crankcase Breather - Remove and Install....370
Valve Cover - Remove and Install....372
Rocker Shaft and Push Rod - Remove....376
Rocker Shaft - Disassemble....378
Rocker Shaft - Assemble....380
Rocker Shaft and Push Rod - Install....382
Cylinder Head - Remove....384
Cylinder Head - Disassemble....395
Cylinder Head - Assemble....407
Cylinder Head - Install....419
Piston Cooling Jets - Remove and Install....431
Bearing Clearance - Check....434
Connecting Rod Bearings - Remove and Install....436
Piston and Connecting Rods - Remove....441
Piston and Connecting Rods - Install....445
Cylinder Liner - Remove....450
Cylinder Liner - Install....452
Camshaft - Remove....456
Camshaft - Install....463
Camshaft Bearings - Remove....472
Camshaft Bearings - Install....474
Crankshaft Main Bearings - Remove....476
Crankshaft Main Bearings - Install....480
Crankshaft - Remove....485
Crankshaft - Install....488
KENR8688 - Schematic (G3512E Generator Set Engine Electrical System)....493
Collage....494
Main....518
Features....518
Cover Page....519
Information....0
Electrical Symbols....520
Event Codes....521
Component Identifiers....522
Schematic....523
Engine Views....0
Left Side View....524
Right Side View....525
Junction Box....526
Power Distribution Box (Outside)....527
Power Distribution Box (Inside) Untitled....528
KENR9736 - Specifications (G3512E Generator Set Engines)....529
Air Lines....532
Gas Engine Ignition....535
Ignition Transformer....536
Fuel Filter....538
Gas Pressure Regulator....540
Actuator Linkage....541
Engine Oil Lines....543
Camshaft....545
Valve Mechanism....547
Cylinder Head....549
Cylinder Head Valves....552
Turbocharger....555
Turbocharger Oil Lines....557
Exhaust Fitting....558
Exhaust Manifold....560
Exhaust Flange....563
Air Cleaner....564
Engine Oil Pump....565
Engine Oil Filter....568
Engine Oil Cooler Bypass and Cooling Jet Sequence Valves....572
Engine Oil Pan....575
Crankcase Breather....577
Water Lines....578
Water Pump....585
Auxiliary Water Pump....587
Water Temperature Regulator....589
Cylinder Block....593
Crankshaft....597
Crankshaft Wear Sleeves and Seals....599
Connecting Rod....601
Connecting Rod and Main Bearing Journals....604
Piston and Rings....606
Cylinder Liner....608
Camshaft Bearing Position....609
Gear Group (Front)....611
Cover Group (Front Housing)....613
Gear Group (Rear)....618
Accessory Drive (Lower Left Hand)....621
Auxiliary Drive (Lower Left Hand)....623
Vibration Damper Guard....625
Vibration Damper....628
Flywheel Housing Cover....629
Flywheel....631
Flywheel Housing....633
Belt Tension Chart....635
Accessory Drive....636
Alternator and Regulator....638
Alternator Mounting....640
Electric Starting Motor....642
Gas Shutoff Valve....644
Engine Speed Sensor....646
Temperature Sensor....647
Coolant Temperature Sensor....649
Pressure Sensor....650
Detonation Sensor....652
Jacket Water Inlet Pressure Switch....653
Jacket Water Temperature Sensor....654
Thermocouple....655
Boost Pressure Sensor....656
Prelube Pressure Switch....657
Engine Oil Temperature Sensor....658
Engine Oil Pressure Sensor....659
Engine Speed_Timing Sensor....660
Magnetic Switch....661
KENR9737 - Systems Operation (G3512E and G3520E Generator Set Engines)....663
Electronic Control System Operation....665
Electronic Control Module (ECM)....668
Start_Stop Control....670
Engine Governing....672
Integrated Temperature Sensing Module....674
Electronic Control System Parameters....677
Engine Sensors....694
Electronic Service Tools....698
Engine Monitoring System....700
Ignition System....707
Fuel System Operation....710
Air_Fuel Ratio Control....717
Aftercooler....723
Compressor Bypass....725
Exhaust Manifold....727
Turbocharger....729
Valve System Components....731
Lubrication System....733
Cooling System....737
Cylinder Block; Liners and Heads....741
Pistons; Rings and Connecting Rods....744
Crankshaft....746
Camshaft....749
Air Starting System....750
Electric Starting System....753
Power Supply....755
Grounding Practices....756
Alternator....757
Starting Solenoid....759
Starting Motor....761
Circuit Breaker....763
KENR9737 - Testing and Adjusting (G3512E and G3520E Generator Set Engines)....765
General Information (Electronic Control System)....767
Engine Governing - Adjust....771
Manifold Air Pressure Sensor....774
Detonation Sensor....776
Engine Speed_Timing Sensor....777
Ignition Transformer....780
Ignition Timing - Adjust....786
General Information (Fuel System) - Gas....787
Air_Fuel Ratio Control - Adjust....788
Finding the Top Center Position for the No. 1 Piston....790
Camshaft Timing....792
Restriction of Air Inlet and Exhaust....798
Measuring Inlet Manifold Temperature....801
Measuring Exhaust Temperature....803
Compression....804
Crankshaft Position for Valve Lash Setting....806
Valve Lash and Valve Bridge Adjustment....808
General Information (Lubrication System)....814
Excessive Bearing Wear - Inspect....815
Excessive Engine Oil Consumption - Inspect....816
Increased Engine Oil Temperature - Inspect....817
Measuring Engine Oil Pressure....818
General Information (Cooling System)....820
Visual Inspection....822
Test Tools for the Cooling System....824
Testing the Cooling System....828
Cylinder Block....832
Cylinder Liner Projection....834
Flywheel - Inspect....839
Flywheel Housing - Inspect....843
Vibration Damper - Check....848
General Information (Air_Electric Starting System)....850
Test Tools for the Electrical System....853
Battery....858
KENR9738 - Troubleshooting (G3512E Generator Set Engine)....859
General Information....862
Welding Precaution....863
Electronic Service Tools....865
Troubleshooting Data Sheet....875
System Overview....877
Component Location....880
Engine Monitoring System....883
Diagnostic Capabilities....892
Programmable Parameters....893
Electrical Connectors....894
Configuration Parameters....899
Diagnostic Trouble Codes....902
Event Codes....913
Symptom Troubleshooting....926
Coolant Pressure Is High....927
Coolant Pressure Is Low....929
Coolant Temperature Is High....931
Coolant Temperature Is Low....935
Detonation Occurrence....937
Engine Cranks but Does Not Start....944
Engine Does Not Crank....947
Engine Misfires; Runs Rough or Is Unstable....950
Engine Overcrank Occurrence....954
Engine Overloads....957
Engine Overspeeds....959
Engine Shutdown Occurrence....962
Engine Shutdown Occurs Intermittently....966
Engine Shutdown or Start Inhibit Initiated by Driven Equipment....969
Engine Stalls Immediately After Starting....971
Engine Timing Does Not Match Programmed Timing....974
Exhaust Temperature Is High....975
Exhaust Temperature Is Low....982
Fuel Differential Pressure Is High....986
Fuel Differential Pressure Is Low....988
Fuel Energy Content Problem....990
Fuel Flow Rate Is Low....992
Fuel Metering Valve Problem....994
Fuel Pressure Problem....996
Fuel Temperature Is High....998
Generator Output Power Readings Do Not Match....999
Inlet Air Temperature Is High....1002
Oil Filter Differential Pressure Problem....1005
Oil Pressure Is High....1008
Oil Pressure Is Low....1009
Oil Temperature Is High....1012
System Voltage Problem....1014
Temperature Ratio of Coolant to Oil Is Low....1015
Turbocharger Turbine Temperature Is High....1017
Turbocharger Turbine Temperature Is Low....1020
Cat Data Link - Test....1022
Detonation - Test....1029
Electrical Power Supply - Test....1039
EPG Circuit Breaker - Test....1046
Fuel Control - Test....1049
Fuel Metering Valve - Test....1064
Generator Output Power - Test....1076
Ignition Primary - Test....1086
Ignition Secondary - Test....1106
Indicator Lamp - Test....1115
Integrated Temperature Sensing Module - Test....1124
Sensor Signal (Analog; Active) - Test....1141
Sensor Signal (Analog; Passive) - Test....1153
Sensor Signal (PWM) - Test....1159
Sensor Supply - Test....1172
Speed Control (Switch) - Test....1178
Speed_Timing - Test....1184
Starting - Test....1194
Throttle Actuator - Test....1211
Turbocharger Compressor Bypass - Test....1220
Customer Passwords....1230
Factory Passwords....1232
ECM Will Not Accept Factory Passwords....1234
Electronic Service Tool Does Not Communicate....1236
ECM Software - Install....1240
ECM - Replace....1242
Control Module - Replace....1246
Electrical Connectors - Inspect....1251
Unburned Gas - Purge....1258
Generator Output Power Sensor - Set....1259
Timing - Calibrate....1262
RENR8103 - Schematic (G3500C and G3500E Generator Electrical System) (B9P201-UP; CWW207-UP, CWY207-UP All other SN 1-UP)....1265
Collage....1266
Main....1295
Caterpillar G3512E Generator Set Engine Repair Service Manual
